5500 CentriSmart Operations Manual PDF
5500 CentriSmart Operations Manual PDF
5500 CentriSmart Operations Manual PDF
OPERATIONS MANUAL
Revised April 2004
Hutchison Hayes, L. P.
NOTICE OF CONFIDENTIALITY
This information is highly confidential
and is solely for the benefit of
Recipient
TABLE OF CONTENTS
5500 CENTRISMART OPERATIONS MANUAL
SECTION 1 - INTRODUCTION
Overview
Data
Page
5
SECTION 2 -START-UP
Safety
Installation
Pre Start Safety Precautions
Belt Tension Procedure
Variable Main/Back DriveSee Section 13
Hydraulic Back Drive
SECTION 3 - OPERATION
A. Variable Main & Back Drive
Hydraulic Back Drive
Standard
Warning
Torque Lever & Setting
22
B. Cleaning
C. Dam Plate Adjustment
Pond Depth Chart
SECTION 4 - LUBRICATION
A. Grease & Oil Data
Lubrication Schedule
27
33
Page
SECTION 6 - PLANETARY GEARBOX & BACK DRIVE ASSEMBLY
58
67
78
97
100
SECTION 11 - MISCELLANEOUS
Recommended spare parts list
Electric Variable Main & Back Drive
Hydraulic Back Drive
Standard
Charts
Storage
106
113
145
SECTION I
INTRODUCTION
OVERVIEW
HUTCHISON HAYES HIGH G CENTRIFUGE MODEL 5500
This Service Manual describes the centrifuge, and lists instructions for the installation,
operation, and maintenance requirements.
The basic purpose of this centrifuge is to separate the liquid and solids from the fluid feed
(slurry.)
A stainless steel rotating bowl, driven by a 60 H.P. electric motor is used to centrifuge the
slurry; that is to sling the solids against its inside wall surface while a stainless steel
screw conveyor (faced with hard tiles) gathers and conveys these solids to a central
discharge area.
The conveyor is driven at a slightly slower RPM through a planetary gear reducer.
The liquids migrate to the front end of the machine and are dispelled through four (4)
adjustable plate dam openings, to a central discharge area.
For a more comprehensive description of how the centrifuge operates, see the Operation
Section of this manual.
2118 Gs
3053 RPM
3022 RPM
3110 Gs
3700 RPM
3663 RPM
12,000 LBS./HR.
35.500 (MAX.)
16 IN.
55.56 IN.
7,365 LBS.
2118 Gs
3053 RPM
2996 RPM
3110 Gs
3700 RPM
3630 RPM
(Approx.)
SECTION 2
START-UP
SAFETY
Because the 5500 High G Centrifuge is a high-speed, high-torque piece of rotating
machinery, caution should be exercised by operating personnel.
HH recommends operating personnel review the centrifuge manual before working with
the equipment.
Periodic safety meetings to familiarize new operating personnel with the centrifuges
characteristics are also recommended.
This manual is intended for use by qualified operators familiar with processing
equipment and trained for this particular centrifuge.
Maintenance personnel should be experienced mechanics.
Electricians should be licensed, qualified personnel familiar with electrical safety
procedures.
CAUTION
Persons without recommended experience may not understand the instructions listed in
this manual
A. GENERAL
1. Read all manuals and instructions before attempting to install or operate
equipment, and follow all recommendations.
2. Follow all lubricating and/or greasing procedures and schedules recommended
in the equipment instructions.
3. If nameplates are lost, damaged, or removed, replace them. They have been
affixed to the equipment to provide warnings, instructions, etc., for the
maintenance and operating personnel.
4. Do not operate belt driven or chain driven equipment without guards. If
equipment was purchased without guards, user is responsible for providing
proper guards that meet all applicable codes.
5. Make periodic checks for loose bolts on rotating assemblies, the supporting
structure, covers, hatches, guards, and piping connections.
6. Do not operate equipment if excessive vibration or abnormal noise develops.
7. If the equipment is supplied with covers or guards, do not remove these until
the equipment has come to a complete stop.
8. Never operate equipment with parts that have not been manufactured or
approved by the original equipment manufacturer.
B. HANDLING
1. Safe practices for lifting and handling equipment should be followed. Hoists
and slings should be of adequate capacity, inspected regularly, and in good
repair.
10
2. Always use extra caution when lifting, moving, or holding worn parts, since
these may be sharp, slippery, or weakened. Never place hands, feet or head at
possible pinch points.
3. Always provide a sufficiently large cleared area around the equipment during
maintenance.
C. ROTATING EQUIPMENT
1. Do not exceed the maximum speed, process material specific gravity, process
pressure or temperature, or maximum design feed rate as specified on the
equipment nameplate or within the operating manual.
2. Do not use a pipe wrench on any part of the rotating equipment.
3. Do not interchange parts that have been balanced as an assembly.
4. Do not attempt to utilize the rotating equipment in an application for which it
was not originally selected.
5. When taking samples or removing any material from equipment like grinders,
screw conveyors, open throat pumps, etc., make sure all machine components
are at rest and the power is shut off with the disconnect switch locked in the
off position.
6. Do not get rags, loose clothing, sticks, etc., near rotating or moving parts.
7. The equipment must coast to a complete stop. Do not brake it by hand or in
any other way force it to stop, unless it is equipped with a braking mechanism
supplied by the original equipment manufacturer.
8. Do not operate the rotating equipment unless the direction of the rotating part
or assembly conforms to that of the Instruction and/or Operation Manual.
9. If a rotating assembly must be turned by hand, use caution: Avoid sharp
edges and close areas where fingers may be cut or trapped (example: pulleys).
D. PUMP
1. If positive displacement pumps are used in the process be sure the discharge
line is unobstructed before starting the pump.
2. In plants using any type of grinder with the discharge directly connected to a
pump, be sure that the pump is in operation before putting any product into
the grinder.
3. Do not run a positive displacement pump dry.
E. EXPLOSION PROOF EQUIPMENT
1. Do not operate equipment driven by an explosion-proof motor and control
until all seal fittings are properly sealed with recommended fiber or
compound, and tagged.
2. Never use abrasive material or a file to remove corrosion from explosionproof equipment.
3. Cover screws and bolts used to hold explosion-proof joints together must
always be tight, and only of the type and material recommended by the
manufacturer.
11
F. MOTOR
1. Do not neglect to check that the line voltage applied to the motor controller is
the same voltage for which the motor is wired.
2. Always follow motor manufacturers specifications on bearing lubrication.
3. Do not attempt to operate a motor that is overheated due to frequent starts and
stops. Allow the motor to cool to ambient temperature (as designated on the
motor nameplate) before each restart.
G. ELECTRICAL (General)
1. Install and ground all equipment (permanent and portable) in accordance with
requirements of the National Electric Code and local electric codes.
2. Use circuit breakers or fused disconnects between equipment and power
source.
3. Never touch electrical components with wet hands or when standing on a wet
surface. Insulate yourself from ground and use insulated tools.
4. When handling electrical equipment, take care to avoid contacting live parts.
Assume all circuits are live. Check with a voltmeter.
5. Label all control circuits clearly.
6. Keep electrical controls and motors clean and free of dust dust prevents
thorough air circulation, generating heat; heat in turn can ignite the dust or
flammable vapors if present in the atmosphere.
7. Never wash electrical equipment unless it is constructed for that purpose.
Never wash live electrical equipment.
H. ELECTRICAL (Repairs)
1. Only qualified personnel, familiar with electrical safety procedures and the
construction and operation of the equipment, should work on electrical
equipment.
2. De-energize all power before opening any electrical enclosure, or before
connecting and disconnecting test equipment and components. Provide a
safety lockout at the power source.
3. Use only approved safety rubber gloves and mats, insulated tools, and eye
shields when doing electrical work.
4. Periodically inspect and operate all of the automatic shut-off devices and
monitoring systems provided.
5. On DC powered equipment, do not perform any inspection (mechanical or
electrical) until the power has been turned off and disconnected, and all
rotating assemblies have come to a complete stop. The moving motor may
generate DC voltage feed back.
I. CHEMICALS
1. If corrosive and/or toxic chemicals or solvents are used as part of the process
or as cleaning materials: become thoroughly familiar with the properties of
the products and their hazards, the precautions necessary to handle the product
12
safely, and follow all manufacturer recommendations for the type of product
being handled.
a. Use in well ventilated area and keep employee exposure below
permissible limits.
b. If flammable, take care to prevent fire or explosion.
c. Avoid contact with the skin and eyes wear goggles, gloves, shields,
etc., as required by the nature of the solvent or chemical.
2. If in doubt whether a product is dangerous or not Assume It Is. Take all
necessary precautions to avoid personal injury.
J. VENTILATION
1. Toxic fumes, if present in the system, must not be permitted to escape to the
operating area. They should be adequately vented away form the worker in
accordance with applicable environmental regulations.
2. If in doubt whether any vapor is toxic or not Assume It Is. Take all
necessary precautions to avoid personal injury or adverse health effects.
Worker exposure should be maintained below the permissible limit and at the
lowest feasible level.
3. If it is necessary to enter an area where toxic vapors are present, consult with
responsible authorities for recommendations concerning safety.
4. Use NIOSH approved breathing apparatus when working with toxic or
hazardous materials, or with materials that reduce the oxygen concentration in
the air, such as carbon dioxide.
K. COMBUSTIBLE PRODUCTS
1. If combustible products are used as part of the process or as cleaning products,
become thoroughly familiar with the safety precautions necessary to handle
the product. Follow all recommendations to avoid personal injury or property
damage that could be caused by fire or explosion.
L. PRESSURE VESSELS
1. Vessels operating under internal pressure should be maintained and inspected
in accordance with the manufacturer instructions and/or applicable local or
state codes. If corrosion or erosion is expected, frequency of inspection
should be increased. Qualified personnel should make all necessary repairs.
2. Vessels operating under internal pressure should be provided with a safety
device to relieve excess pressure in accordance with the Unfired Pressure
Vessels Code.
3. Safety devices should be in good operating condition at all times. It is
recommended that they be inspected and tested frequently and maintained in
accordance with manufacturer instructions and/or applicable local and state
codes.
13
2. Do not make any repairs until dangerous vapors and gases are replaced with
clean air.
3. Hutchison Hayes, L. P. should be consulted before attempting to make major
repairs to any of the rotating equipment we manufacture. Under no
circumstances should weld repair or other alterations be made to major
rotating components without the full knowledge and assistance of qualified
Manufacturer personnel. Failure to obtain this assistance may result in rupture
of parts involved with possible injury to personnel or damage to equipment.
4. Repairs to hard-surfaced parts must be performed with strict quality control of
materials and methods. Hard-surfacing materials are brittle, and can break off
if improperly applied. After startup, periodic inspection of these parts is
necessary to anticipate separation of materials.
5. During repairs, when equipment may be physically or electronically unstable,
post barriers or signs announcing hazardous conditions.
6. After repairs and before restarting, reinstall all guards and reconnect all
mechanical and electrical safety devices.
Q. CORROSION, EROSION, AND PITTING OF ROTATING EQUIPMENT
1. To insure a high factor of safety under severe operating conditions, high speed
rotating equipment manufactured by Hutchison Hayes, L. P. is designed after
a careful stress analysis has been made of highly stressed parts. A thorough
control of metallurgical properties is maintained throughout manufacture, and
all material is warranted as free of defects at time of shipment.
2. It should be noted that equipment subjected to severe erosive or corrosive
environment could deteriorate over a period of time, depending on the severity
of the exposure and/or possible misuse. Users of high speed rotating
equipment should be aware of the fact that extremely high forces are brought
into play when their equipment is in operation. Any weakening of highly
stressed members by misuse, erosion, corrosion, chemical pitting, or stress
cracking must be guarded against to prevent possible metal failure.
3. In the interest of longer and safer operation of the equipment, Hutchison
Hayes. L. P. recommends that the equipment owner maintain a periodic (at
least monthly) inspection on highly stressed rotating and/or moving parts
which are subjected to erosive or corrosive wear.
4. The following points should be noted and the recommended action taken:
a. Do not operate equipment when:
1. Holes are wearing through rotating and/or moving parts.
2. Grooves greater than 1/16 deep are worn in rotating and/or moving
parts.
3. Evidence of cracks is present, especially in rotating and/or moving
parts.
4. Chemical pitting of 1/16 depth or greater on rotating and/or moving
parts.
5. Component surfaces are covered with a light corrosion or etching.
b. Chemical pitting is observed:
15
All cases of chemical pitting, even less than 1/16 depth, should be
watched carefully. This pitting action is almost always due to the
breakdown of the passive film on stainless surfaces in the presence of
chlorides. This often occurs under product cake that has not been
sufficiently cleaned from the surface. High temperature, low pH, and
high acidity accelerate the pitting action.
5. Contact Hutchison Hayes,L. P. regarding the repair or replacement of rotating
and/or moving parts whose surface is noticeably pitted.
16
INSTALLATION
Location
a.
b.
c.
d.
e.
f.
g.
Install the centrifuge unit in a location where sufficient headroom is allowed for
lifting the bowl out of its frame enclosure.
A 2-ton overhead hoist should be installed to facilitate inspection or repair work.
A clear area in the vicinity of the centrifuge should be provided to set the bowl
during inspection or repair.
Room should be allowed at the front end of the machine for withdrawing the
planetary gearbox. A zone approximately 20 wide x 2 6 long from the front
end of the gearbox should be kept clear.
Room should be allowed at the rear end of the machine for withdrawing the feed
tube. A zone approximately 6 wide x 3 0 long from the end of the feed tube
support clamp should be kept clear.
Clear access space should be provided around the centrifuge.
The centrifuge isolators should set on a smooth level surface on structural
members of sufficient strength.
IMPORTANT CAUTION
Since this centrifuge operates at high speed and is subjected to severe wear conditions, it
is important that any indications of weakening of highly stressed components be
recognized before a failure can occur.
To facilitate this HH recommends a monthly visual inspection on highly stressed
components, such as:
The bowl
Shafts wear plates
Wear tiles
Conveyor, etc.
If inspection reveals:
1. Holes worn through moving parts
2. Wear grooves greater than 1/16 thick in moving parts
3. Cracks present is moving parts
4. Chemical pitting to a depth of 1/16 or greater in moving parts
DO NOT OPERATE THE EQUIPMENT UNTIL REPAIRS ARE MADE
FAILURE TO FOLLOW THE ABOVE RECOMMENDATIONS MAY RESULT
IN SEVERE PERSONAL INJURY OR PROPERTY DAMAGE
17
PIPING
1. Customer piping tie-ins to the centrifuge should be made with flexible connections.
2. Customer tie-in at feed tube should have a suitable pipe support so that no weight is
imposed on the centrifuge feed tube.
A flexible connection is required here.
3. A flush line should be provided at the feed tube tie-in. HH recommends hot water.
A ball valve should be located as close as possible to the feed line to prevent plugging
the flush branch with solids.
4. Use a screen at the pump suction to protect the pump and centrifuge from oversize
solids.
5. Liquid discharge lines should have a minimum of " per ft. slope.
6. HH recommends installation of a pressure indicator in the feed line upstream of the
customer tie-in to regulate the feed supply to the centrifuge.
For HH 5500 centrifuges with Hydraulic Main Drive or Hydraulic Back Drive, the
following hydraulic oil is recommended: MOBIL DTE 26.
(See the Product Data Sheets on the following pages.)
Caution: Other hydraulic oils should only be used with written confirmation that the oil
conforms to the specifications on the MOBIL DTR 26 product.
18
19
16. Do not replace any damaged or worn out Machine Parts with other than HH
replacements.
17. The customer may replace ordinary wear parts such as oil seals, o-ring and gaskets.
A replacement list is in the Parts List Section.
18. Do not open the cover or attempt removal of a shroud or belt guard until the
centrifuge is motionless.
19. Use the correct tools for any assembly or disassembly work.
20. Do not supply slurry into the centrifuge until the unit is fully up to normal operating
speed.
21. If more than one (1) centrifuge is in operation, never attempt to exchange any
machined parts.
22. Never use a pipe wrench on any part of the centrifuge.
23. There is a slow down period as the machine decelerates towards shut-down. Leave
the cover shut until the centrifuge is motionless. Do not attempt any disassembly
before the machine is static.
24. Never prop the centrifuge cover partially open by using blocks of wood or any other
foreign object.
IMPORTANT CAUTION
25. Whenever the centrifuge cover is opened for cleaning, inspection, etc., the one (1)
hinge safety pins must be engaged to prevent accidental closing of the cover, this
procedure should always be followed.
26. Flexible connections should be used at all customer piping tie-ins.
27. Do not attempt any repairs to the gearbox at the front of the machine beyond
replacement of the pinion shaft oil seal.
20
21
SECTION 3
OPERATION
22
OPERATION
The slurry to be separated is pumped into the feed tube, axially located at the rear of the
machine.
The slurry is directed into a feed chamber where it is dispersed by four (4) externally
mounted feed nozzles and directed by centrifugal force along and against the inside wall
of the bowl.
This ring of slurry or pond will contain solids against the bowl wall. These solids are
scrolled forward over a beach area by the screw conveyor and discharged through four
(4) ports at the solids end of the centrifuge located in the rear.
The lighter liquids migrate forward and are discharged through four (4) adjustable plate
dam nozzles at the liquids discharge area located at the front end of the centrifuge; i.e. the
gearbox end.
OVER-TORQUE PROTECTION
A TORQUE CONTROL DEVICE is located at the front of the gearbox. If a
predetermined torque limit on the screw conveyor is reached during operation, the device
will trip and close a microswitch sending a signal to cut off the feed supply
This protects the screw conveyor and the gearbox from over-torque damage.
A torque arm, contacting a rub pad on a trip lever is held in balance by means of a spring
loaded cylinder linkage.
If the pre-set torque limit is exceeded, this torque arm will rotate the trip lever out of the
way and the torque arm will rotate at the same RPM as the bowl.
When this happens, no solids can be conveyed to the solids discharge ports. The spring
loaded cylinder linkage will have tripped, and caused the feed to stop so no further
accumulation of slurry can occur.
When the torque-control device trips:
a. Stop the centrifuge.
b. Remove the gearbox shroud.
c. Rotate the torque-arm clockwise by hand to determine if the screw conveyor is
stopped by an accumulation of solids or debris.
d. Replace the gearbox shroud and restart the centrifuge.
e. If the gearbox rotates, the conveyor is blocked and will need cleaning. If the gearbox
does not rotate but the centrifuge trips out immediately after restart, the bowl must be
cleared by cleaning. Diagram to be inserted
23
WARNING
SUDDEN HIGH SPEED ROTATION OF THE TORQUE ARM
An aluminum torque arm is externally mounted on the planetary gearbox first stage
pinion shaft. This part faces against the pivot arm (lever) which when tripped through a
spring-loaded compression link, mechanically operates a microswitch causing motor
shutdown. This happens if the centrifuge conveyor becomes jammed or locked-up and
rotates the bowl.
This aluminum torque arm, item 950 normally is stationary. However, it can come up to
the bowl/gearbox rotating speed instantaneously without warning in the event of a
conveyor jam.
It is important that all operating personnel understand this hazard and at all times keep
clear from this torque arm while the centrifuge is running.
24
CLEANING BOWL
1. Flush the bowl with water before shutting down
2. When the bowl is flushed, stop the machine but continue flushing.
3. Rotate the bowl by jogging the motor.
4. Reverse rotate bowl by pulling on V-belts.
CAUTION: Keep Hands Clear of Pulleys
NOTE: Rotating each way while flushing will move some solids to the liquids discharge
and some flushing liquid to the solids discharge.
If this is a problem, arrange to divert the liquids and solids discharge before cleaning.
If cleaning does not remove solids deposits, the bowl will have to be pulled for inspection
and further cleaning. Go to Disassembly Section.
PLATE DAMS ADJUSTMENT
1. The four (4) plate dams are used to set the Pond depth.
2. The plate dams are located in the front hub. Access to the plate dams is allowed by
raising the centrifuge cover with the machine shut down.
3. The plate dams are adjusted by loosening three (3) capscrews and rotating the plate
clockwise.
4. A Maximum Setting, (i.e., the highest number engraved on the plate aligned with the
arrow mark on the front hub) will cause a maximum pond depth giving maximum
clarification of the liquid.
5. A Minimum Setting (i.e., the lowest number engraved on the plate aligned with the
arrow mark on the front hub) will cause a minimum pond depth and will result in the
Maximum dryness of the discharged solids.
IMPORTANT
6. When plate dams are indexed by rotation, all four (4) dams must be indexed to the
same number.
7. After adjusting, always recheck all twelve (12) capscrews for correct tightness.
25
26
SECTION 4
LUBRICATION
27
28
Royal Purple
NEW IMPROVED
SYNERGY
HIGH PERFORMANCE GEAR OIL
29
30
31
Lubricant
Chevron SRI-2
Mobil SHC-220
**Conveyor Bearings:
15 Days
Purge till relief
Chevron SRI-2
Mobil SHC-220
Gearbox:
Royal Purple
Synergy Gear Oil
ISO Grade 150
SAE 90
AGMA Grade 4EP
6 months
NEVER-SEEZ Compound
Fluid Coupling:
SAE 10W
Fyrquel 550
Houghto Safe 1010
SAE 5W
Fyrquel 90
Houghto safe 1010
Pydraul 29E LT
32
SECTIO N 5
ASSEMBLY AND DISASSEMBLY
33
34
35
CONVEYOR REMOVAL
Positioning bowl for conveyor removal
(After the gearbox has been removed)
1. With bowl assembly now sitting horizontally in a clear, clean work area, remove the
bowl spreader bar.
2. Attach the conveyor lifter to the adaptor hub (at gearbox end of centrifuge) using four
(4) 7/16 14 UNC X 2 3/ 4 long bolt with heavy hex head nuts.
3. Place the bowl assembly on a support stand as shown in Figure 1.
4. Height H in diagram must be tall enough so the drive sheave (pulley) clears the
floor by at least two (2) inches.
CAUTION: Never allow the drive shaft to contact any surface during this lifting
procedure. It is not designed to carry any load and can easily be damaged.
5. The weight must be carried through the rear hub resting on the stand.
With the bowl assembly now resting securely in an upright position:
6. Remove the twelve (12) 3/8 / capscrews from the front hub at top end of the bowl
assembly.
7. Using four (4) bolts just removed, screw them into the four (4) jackscrew holes and
remove the hub.
8. Once the front hub is jacked free, it can be lifted out with the overhead hoist.
36
9. Set this front hub, pillow block, and gearbox adaptor hub assembly in a clean, clear
space.
10. Unbolt the Conveyor Lifter Plate from the gearbox adaptor hub just removed.
11. Remove four (4) capscrews from the seal housing at the end of the conveyor and
attach the Conveyor Lifter Plate.
12. Slowly hoist out the conveyor.
13. Set the conveyor upright on a smooth, clean and clear work area.
14. With the hoist still attached to the conveyor, secure the conveyor assembly with ropes
so it cannot topple over.
15. Once secured, disconnect the hoist connection and remove the Conveyor Lifter Plate.
CONVEYOR DISASSEMBLY
FRONT CONVEYOR BEARING REMOVAL
1. If the front conveyor bearings are in good condition, they do not need to be pulled.
Disregard Steps 2, 3 and 4 and go to Step 5.
2.
If the Front Conveyor Bearings are worn out or damaged, remove the six (6)
capscrews from the liquids and seal housing.
3.
Jack out the liquids end seal housing using two (2) capscrews just removed.
4. Using a slide hammer type bearing puller, remove the two (2) bearings.
5. Remove the Conveyor Bearing Housing by removing the eight (8) capscrews and
jacking it out using two (2) of the removed capscrews.
This opens the end of the Conveyor Tube and allows access to the Accelerator Plate
and Feed Chamber Liner.
ACCELERATOR PLATE AND FEED NOZZLES
1. The accelerator plate is removed by inserting the long T-handle wrench into the
conveyor tube and screwing it tightly into the threaded hub on the centerline of
the accelerator plate.
2. With the T-handle wrench * attached firmly, loosen the two (2) 3/8setscrews and
the two (2) 3/8 lockscrews from the conveyor tube. They are located just
forward from the feed nozzle located on the outside of the conveyor tube.
3. With the setscrews and lockscrews backed-off enough to allow the plate to be
pulled out, slowly withdraw the accelerator plate.
37
4. Remove the four (4) externally mounted feed nozzles by unscrewing two (2)
capscrews at each nozzle and withdrawing each nozzle by gripping its flange and
pulling it out.
5. Note the condition of the O-Ring on each feed nozzle.
* T-handle wrench (available from HH)
CONVEYOR REAR BEARING HOUSING REMOVAL
1. Remove the conveyor as per the previous Conveyor Removal Section, but set the
conveyor in a horizontal position on a clean, clear work surface.
2. Remove the conveyor lifter plate from the front of the conveyor.
3. Carefully raise the conveyor to a vertical position with the front end (gearbox
end) resting on a very clean surface.
4. Remove the rear bearing housing by unscrewing the six (6) 1/ 4 capscrews.
5. Using two (2) of the screws just removed, place them in the two (2) jackscrew
locations and evenly jack the solids-end bearing seal housing (Item 11) out.
6. Inspect the two (2) oil seals, and the O-Ring for any damage. If damaged or
worn, remove them.
7. Inspect the ball bearing. If it is in good condition, go to Step 10.
8. If the bearing must be replaced due to wear or damage, reinsert the six (6)
capscrews in the rear bearing housing to stabilize it for pulling the ball bearing.
9. Use a slide hammer type bearing puller to extract the bearing.
10. Remove the six (6) capscrews from the rear bearing housing and using two (2) of
them, jack-out the bearing housing, the retainer tube assembly will come out with
the rear bearing housing.
11. Remove the six (6) capscrews from the retainer tube flange.
12. Pull the retainer tube assembly out.
13. Inspect the front oil seals for wear or damage.
If the front oil seals are worn or damaged, they will have to be replaced.
14. To replace the two (2) front oil seals, the bearing must be pulled.
Replace the rear bearing housing into the conveyor and replace the six (6)
capscrews.
38
15. Remove the ball bearing using a slide hammer type bearing puller.
16. Remove the oil seal retaining ring.
17. Pull the two (2) oil seals and replace them.
18. Remove the rear bearing housing.
Now access is clear for removal and inspection of the retainer tube seal.
RETAINER TUBE SEAL REMOVAL
1. Reach into the conveyor and remove the four (4) 1/ 4 capscrews on the seal
retainer plate.
2. Pull the seal retainer plate out.
3. Inspect the oil seal and replace if worn or damaged.
39
Item
No.
1
1A
2
3
6
9
10
11
Part Numbers
Hutchison Hayes 5500 High G Centrifuge
HH Machined Components
Description
HH Part
12
13
15
16
17
18
19
19A
20
21
22
Bowl
Bowl Liner
Bowl Extension
Conveyor
Flinger
Rear Hub
Conveyor Bearing Housing (Solids End)
Conveyor Bearing Seal Housing (Solids
End)
Retainer Ring
Retainer Tube
Pillow Block Housing
Pillow Block Housing
Bearing End Plate
Spacer Ring
Flinger Cover
Flinger Cover (nearest gearbox)
Flinger
Case Flinger
Feed Tube Assembly
24
27
28
29
35
36
37
38
39
40
41
42
04065
04052
04053
04073
04050
04054
04083
04071
04010
04058
04058
04059
04081
04060
04072
04073
04084
04009/
13994
04056
04057
04046
04062
04061/
04001
04087
04055
04078
04051
04063
04067
04064
40
Item No.
12
43
Item No.
100
101
102
103
Item No.
200
201
202
203
204
Item No.
205
207
Item No.
24d
300
304
302
305
306
Item No.
400
401
Oil Seals
Customer Replaceable Items
Description
Seal for the Rear Seal Housing
Seal for the Rear Bearing Housing
Sheave Seal
Retainer Tube Seal
Front Seal Housing Seal
All seals good for 300F
Gaskets
Customer Replaceable Items
Description
Drive Sheave Gasket
Dam Plate Gasket
O-Rings
Customer Replaceable Items
Description
O-ring accelerator plate
O-ring solid end seal housing
O-ring Liquid hub & conical section
O-ring feed nozzle
O-ring liquid end Seal Housing Inner
O-ring liquid end seal Housing Inner
Grease Fittings
Customer Replaceable Items
Description
Grease Fitting, Non-Corroding 1/8 PTF
Straight Type
Grease Pressure Relief Fitting
HH Part
04036
04037
HH Part
04042
04043
04040
04041
HH Part
04032
04031
04033
04030
04032
HH Part
04069
04068
HH Part
04022
04023
04025
04020
04024
04021
HH No.
03089
03088
41
42
43
1. Stamp the top of the pillow block assemblies with an S for solid and an L for
liquid, also stamp the top with a V with the point directed toward the bowl assembly.
Be sure to stamp the horseshoe covers and pillow block covers on both sides of the pillow
also.
2. Remove the three (3) bolts that retain the two (2) horseshoe covers and remove the
horseshoe covers.
3. Remove eight (8) bolts from the sheave and using jack bolts remove the sheave from
the bowl hub.
4. For liquid hub, remove the gear flange.
5. Using a two (2) or three (3) jaw puller, remove the pillow block as an assembly. Put a
plate across the top of the hub for the stud to push on.
6. Remove the two pillow block covers and remove the bearing from the housing.
7. Loosen the two (2) setscrews in the pillow block flingers and the case flingers and
remove both from the hub.
8. Clean all parts thoroughly and assembly in reverse order.
44
45
46
47
48
ASSEMBLY TIPS
MAINTENANCE CAUTIONS FOR
THE 5500 HIGH G CENTRIFUGE
Bearings:
The inner and outer race must be replaced as a set.
Opened bearing, or cleaned parts should be kept covered until assembly.
Always use a thermometer to check the temperature of oil used to heat the
bearings.
If no heat is used to install bearings, use only an arbor press to insert bearings in
place.
Correctly lubricate all bearings before operating the centrifuge.
Do not wash new bearings with solvent before installing.
Keep new bearing wrapped and boxed until ready for use.
Seals:
Avoid touching the sealing surface. Keep seals wrapped in soft tissue until ready
for installation.
Threaded Connections:
All threaded connections and pilot diameters should be wiped clean and
lubricated with an anti-galling compound such as NEVER-SEEZ.
Torque all screws on the rotating assembly per the Recommended Capscrew
Seating Torque charts shown in the Start-Up Section of this Manual. To help
prevent capscrew failure if excessive torque is required to seat mating parts
during assembly, the over torqued screws should be removed, discarded and
replaced with new screws installed at the correct torque.
O-Rings:
Inspect for nicks and cuts before installing, if damaged, do not install. Lubricate
O-Rings for easier installation.
49
Machined Parts:
Clean with degreasing solvent before reassembly.
Set parts on clean work area and protect finished surfaces and openings on the
part.
Be sure to align any balanced parts on the rotating assembly by matching the VMarks stamped on the parts.
If more than one (1) centrifuge is owned, do not interchange any parts which
comprise a balanced rotating assembly.
50
Conveyors equipped with carbide tiles should never be set down directly on a
concrete floor. The carbide is very brittle and tile damage could result.
7. Monitor items such as drive belts, O-Rings, seals, and vibration isolators.
These items will become brittle with age and deterioration will adversely affect
centrifuge performance.
Replace these items when indicated by inspection.
51
POSITION
QTY
ALLOY
TYPE
STYLE
SIZE
LOCK
TIGHT OR
NEVER
SEIZE
CONVEYOR
1
ACCELERATOR PLATE
SS
FEED NOZZLES
SS
BLACK
SET/CUP
SOCKET HEAD
3/8" X 1"
SOCKET HEAD
1/2" X 3/4"
SOCKET HEAD
3/8" X 1"
DOWEL
PIN
SPLINE ADAPTER
12
BLACK
SOCKET HEAD
3/8" X 1 3/4"
SS
SOCKET HEAD
3/8" X 1 1/4"
7
8
6
SS
(HELD BY ABOVE)
SOCKET HEAD
5/16" X 3 3/4"
242
LOCTITE
242
LOCTITE
NEVER
SEIZE
3/8" X 1"
NEVER
SEIZE
NEVER
SEISE
NEVER
SEIZE
BOWL
1
BOWL EXTENTION
12
SS
SOCKET HEAD
3/8" X 1 1/4"
SS
3/8"X 1 1/4"
SS
SOCKET HEAD
SOC.FLAT
HEAD
3/8" X 3/4
12
SS
SOCKET HEAD
3/8" X 2"
DAM PLATES
12
SS
SOCKET HEAD
5/16" X 7/8"
DISCHARGE PLOWS
28
SS
SOCKET HEAD
3/8" X 3/4"
NEVER
SEIZE
NEVER
SEIZE
242
LOCTITE
NEVER
SEIZE
NEVER
SEIZE
242
LOCTITE
52
BLACK
BLACK
HEX HEAD
SOC. FLAT
HEAD
END COVER
4
5
6
7
3/4 X 3"
3/8" X 1"
12
SS
SOCKET HEAD
3/8" X 1 1/4
CASE FLINGER
SS
SET/CUP
5/16 X 1/2"
GREASE FLINGER
GREASE ZERT
GREASE RELIEF
6
6
1
SS
PLATED
PLATED
SET/CUP
HEX
HEX
3/8" X 5/8"
1/8" NPT
1/8" NPT
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
N/A
N/A
GEAR END
1
GEAR FLANGE
BLACK
GEAR BOX
12
BLACK
BLACK
ROTODIFF
12
BLACK
3/8" X 1 1/4"
SOCKET HEAD
7/16" X 1 3/4"
DOWEL
PIN
SOCKET HEAD
BLACK
NEVER
SEIZE
NEVER
SEIZE
1"
SOCKET HEAD
1/2 X 1 1/4
SOCKET HEAD
16MM X 60
DOWEL
PIN
NEVER
SEIZE
NEVER
SEIZE
1/2 X 1 1/4
SHEAVE
1
SHEAVE
SHEAVE TO HEAD
BLACK
SOCKET HEAD
DOWEL
PIN
3/8" X 1 3/4
NEVER
SEIZE
1"
53
16
SS
HEX HEAD
12
SS
HEX HEAD
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
8
8
SS
SS
HEX HEAD
EXTRA HEAVY
SS
HEX HEAD
SS
HEX HEAD
SS
SOCKET HEAD
SS
HEX HEAD
3/8" X 1 3/4"
3/4" X 1 1/2" FLAT AND LOCK
WSHR
CASE TO BASE
1
SS
HEX HEAD
2
3
TEFLON IN CASE
COVER SAFETY PIN
6
1
SS
PLATED
HEX HEAD
HITCH PIN
NEVER
SEIZE
NEVER
SEIZE
GEAR GUARD
1
SS
HEX HEAD
SS
HEX HEAD
SS
NUT
3/8" NUT
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
54
BELT GUARD
1
SS
HEX HEAD
TORQUE BLOCK
BLACK
SOCKET HEAD
3/8" X 2"
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
SS
HEX HEAD
SS
HEX HEAD
SS
HEX HEAD
SS
HEX HEAD
GEAR GUARD
SS
HEX HEAD
SS
HEX HEAD
SS
HEX HEAD
AUTOGARD ON SHAFT
BLACK
SOCKET HEAD
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
NEVER
SEIZE
242
LOCTITE
NEVER
SEIZE
SET/CUP
MAIN DRIVE
1
BELT GUARD
SS
HEX HEAD
55
Nominal Size
1/ 4
5/16
3/ 8
1/ 2
3/ 4
Coarse Thread
Lubricated*
Plain
Plated
120/10
90/7.5
245/20.4
185/15.4
435/36
330/27.5
1040/87
775/65
3520/293
2640/220
CHART 2
(ALLOY STEEL)
IN. LBS./FT. LBS
56
57
SECTION 6
PLANETARY GEARBOX AND BACKDRIVE ASSEMBLY
58
Hutchison Hayes, L. P.
Model GB-53/GB-100 Planetary Gearbox
Instruction Manual
CONTENTS
1.
2.
3.
4.
5.
6.
7.
Construction
Installation
Operation
Lubrication
Maintenance
Dismantling
Assembly
59
1. Construction
(1) The reduction gear unit is a two (2) stage planetary system. The first stage
uses two (2) planetary gears and the second stage uses three (3) planets.
(2) All bearings are either ball or cylindrical roller type.
(3) Lip style oil seals are used at the gearbox cover plates where the output and
first stage pinion shafts pass through.
O-Rings are used to seal mating parts which are static with respect to each
other.
(4) Threaded plug openings are provided for oil fill, overflow, and drain.
2. Installation
(1) The gearbox is designed to operate in the horizontal plane, that is, axially in
line with the model 5500 centrifuge rotating assembly.
(2) The gearbox is driven by means of a gear flange which attaches at the
centrifuge end to the liquids end bowl hub assembly. The gearbox bolts
directly to the other end of the gear flange.
(3) The gear flange must be accurately aligned within .002 inches runout, and
secured correctly to the bowl hub before the gearbox is mounted.
(4) After mounting the gearbox, check runout on the first stage side. If runout
exceeds .005 inches, shims may be required.
3. Operation
(1) Before running the gearbox, be sure that the unit is filled to the proper level
with lubricating oil.
(2) For recommended lubricating product, see Table 1.
(3) With the fill opening at top dead center, remove the plug from the fill
connection and the uppermost level connection which is located on the cover
plate furthest away from the centrifuge.
Pour oil into the fill port located on top of the casing until it starts to overflow
from the side port.
Plug tightly after filling. Use Teflon tape. The required oil quantity is
approximately one (1) gallon.
(4) On initial operation, check the direction of rotation of the gearbox. It should
be counter-clockwise as you stand at the gearbox end facing the centrifuge.
60
(5) If excessive temperature on the casing (above 180 deg. F.) occurs, stop the
centrifuge and check for the cause.
(6) If excessive noise and/or vibration occur suddenly, stop the centrifuge and
check for the cause.
4. Lubrication
(1) Gears are lubricated by oil bath.
(2) Refer to Table 1 for recommended lubricating product.
(3) Never add a different brand of lubricating oil to the existing supply. Mixing
oil must be strictly avoided.
(4) When changing brands, flush gear unit thoroughly before filling.
5. Maintenance.
(1) Oil Change Intervals
First, change after 500 hours of operation, then every six (6) months or 2500
operating hours whichever comes first.
(2) Any unusually severe operating conditions such as rapid ambient temperature
fluctuations, or the presence of corrosive gases in the operating area could
affect the life and characteristics of the lubricating product. Contact the
manufacturing company for recommendations to follow.
(3) For extended storage of the GB-53 (30 days or longer) fill the unit with a
corrosion preventive oil and run for a short period after flushing.
(4) Restarting the Unit:
Empty and flush the gearbox. Refill with the correct type and quantity of oil.
(5) Wipe off any spilled oil. Run the unit briefly and check for leaks.
6. Dismantling
We recommend that the gearbox not be dismantled because special handling
procedures are required for maintenance of these units. A clean room
environment and a thorough knowledge of clearances and fits are required. With
the exception of replacement of the first stage pinion bearing and seal, the
gearbox should be returned to its manufacturer for inspection and damage and/or
wear assessment.
An incorrectly reassembled planetary gearbox could cause major damage to the
unit, the centrifuge, and could pose a potentially lethal danger to operating
personnel.
61
7. Assembly
(1) Use care to prevent any foreign debris from entering the gearbox.
(2) Secure capscrews using proper torque.
1/ 4-20 Capscrews = 150 in. lbs.
5/16-18 Capscrews = 305 in. lbs.
(2) Change O-Ring whenever the gearbox is opened up.
62
TABLE 1
RECOMMENDED OIL PRODUCT
ROYAL PURPLE SYNERGY GEAR OIL ISO GRADE 150
SAE 90
AGMA GR. 4EP
63
64
65
66
SECTION 7
PARTS LIST
67
PARTS LIST
To order parts contact:
Hutchison Hayes, L. P.
P. O. Box 2965
Houston, Texas 77252
3520 East Belt
Houston, Texas 77015
Tel: (713) 455-9600
Fax: (713) 455 7753
(800) 441 4850
Web site: www.hutch-hayes.com
Email: cbailey@hutch-hayes.com
The parts listed in this section are customer replaceable components, except for
the machined items, which should be ordered from HH.
68
Part #
Description
2879
2926
2989
16
3044
19
3044P
16
3047
16
3048
17
3049
3056
3057
3088
3089
Grease fitting
3123
3441
Dam plates
3710
Warning stickers
3994
4020
4021
4022
4023
4024
4025
4031
4032
4034
4036
Rtn. Ring
4037
Rtn. Ring
4040
Cotter pin
69
Part #
Description
4041
4042
4043
4050
4051
4052
Bowl extension
4053
4054
4055
4056
Accelerator plate
4057
4058
Pillow block
4059
4060
4061
4062
4063
4064
Gear flange
4065
4068
4072
4073
4078
Spline adapter
4080
4081
4083
4084
Case flinger
4091
Base assy.
4098
Nameplate
70
Part #
Description
4100
GB-53 gearbox
4779
71
Part #
Description
2860
MOTOR MOUNT 20 HP
4120
4122
TIMING SHEAVE
Q D BUSHING AUTOGARD
SHAFT
4123
4134
TIMING BELT
4135
4138
AUTOGARD COUPLING
4139
MOTOR 20 HP EX PROOF
4141
AUTOGARD SHAFT
4227
4732
4734
PROX SWITCH
PROX SWITCH MOUNTING
BRACKET
4748
4759
100
2653
72
Part #
Description
3083
60 HP SLIDE BASE
4755
60 HP MOTOR BALDOR
3990
4001
4013
SKID ISOLATORS
4136
4245
4246
4247
4248
100
2654
73
PART
#
2712
Description
3164
3986
4619
4631
4632
4633
4634
4635
4636
4638
4639
10
4640
4641
4642
4643
4645
4646
4647
4648
4650
4652
4653
4654
15 HP DRIVE - P/N
ATV58HD16N4ZU
25 HP DRIVE- P/N
ATV58HD28N4XZU
60 HP DRIVE - P/N
ATV58HD64N4XZU
25HP DRIVE OVERLOAD PRO. GV7RE40
60HP DRIVE OVERLOAD PRO. GV7RE80
AUX SWITCH - P/N LA1LB019
OVERLOAD PROTECTION LB1LB03P06
CONTACTOR - P/N LC1D15000G7
INTEGRAL STARTER - P/N
LD1LB030FC
AMPLYFIER CONTROLLER - MK15RPN-EXO/24
ISOLATION RELAY - P/N NY2B31
74
4659
4660
4661
4662
4663
4665
4666
4667
4668
4669
4670
4672
4673
4674
PRESSURAZATION BLOWER
1954K67
RELAY SOCKET - P/N 8501NR51
4675
4676
4677
4678
4679
4697
4712
4713
4714
Qty
1
2
ENCLOUSURE - P/N
A48H3616SS6LP
BACK PAN - P/N A48P36
2P/1A
75
4716
4719
ENCLOSURE- EXB181808
4720
4726
4727
4741
4742
4743
4744
4753
FILTER
4754
LINE REACTOR
4765
4766
4767
4769
4773
18 AMP DC CHOKE
4774
32 AMP DC CHOKE
4775
LINE REACTOR
Qty
76
4753
FILTER
4754
LINE REACTOR
4765
4766
4767
4769
4773
18 AMP DC CHOKE
4774
32 AMP DC CHOKE
4775
LINE REACTOR
77
SECTION 8
ELECTRICAL & WIRING
78
WIRING SPECS
Wire size and length for duster
Main drive motor 40HP
Back drive motor 20 HP
Feed hopper 2 HP
Vibration and 1 Prox.
Flush system with 3 way valve
Flush system with sol.
Level sensors
Level sensors
100'
100'
100'
100'
100'
100'
6' and 6'
50'
Duster side
753-C-1 1/4"
753-A-3/4"
753-A-1/2"
753-A-3/4"
753-A-3/4"
753-A-3/4"
753-O-1/2"
753-A-3/4"
Panel side
753-C-1 1/4"
753-A-3/4"
753-A-1/2"
753-A-3/4"
753-A-3/4"
753-A-3/4"
N/A
753-A-1/2"
Wire size and length for Variable Main and Back Drive 5500
Main drive motor 60 HP
Back drive motor 20HP
Vibration and prox.
Vibration and 2 prox.
100'
100'
100'
100'
Centrifuge side
753-C-1 1/4"
753-A-3/4"
753-A-3/4"
753-B-3/4"
Panel side
753-C-1 1/4"
753-A-3/4"
753-A-1/2"
753-B-3/4"
12'
6'
7'
Centrifuge side
753-C-1 1/4"
753-O-1/2"
753-O-1/2"
Panel side
753-C-1 1/4"
753-O-1/2"
753-O-1/2"
79
12'
6'
6'
Centrifuge side
753-C-1 1/4"
753-O-1/2"
753-O-1/2"
Panel side
753-C-1 1/4"
753-O-1/2"
753-O-1/2"
Note: The 5500 Centrifuge and Duster main drive that has 6/4 gexol armored and sheathed without the 16/4 conductors a 753-B-1" gland is
used.
Hutchison Hayes uses Hawke type 753 glands
80
81
Desiccant:
Humisorb Multiform Desiccant Products, Inc.
Product is reusable-reactive by heating at 245 Deg. F. to 260 Deg. F. for sixteen (16)
hours.
Complies with MIL-D-3464 Type 2, and MIL-P-116 method 2.
Product is dry, dustless, inert, odorless, tasteless, non-toxic, non-corrosive, and nondeliquescent.
82
83
85
TO
GAUGE
Distribution L1
Distribution L2
Distribution L3
CB 1 - L1
CB 1 - L2
CB 1 - L3
6 AWG Black
6 AWG Black
6 AWG Black
CB 1 - L1
CB 1 - L2
CB 1 - L3
VFD 1 - L1
VFD 1 - L2
VFD 1 - L3
6 AWG Black
6 AWG Black
6 AWG Black
VFD 1 - U
VFD 1 - V
VFD 1 - W
TB 1-1
TB 1-2
TB 1-3
6 AWG Black
6 AWG Black
6 AWG Black
VFD 1+
VFD 1--
Main Contact L1
Main Contact L2
6 AWG Black
6 AWG Black
Distribution L1
Distribution L2
Distribution L3
CB 2 - L1
CB 2 - L2
CB 2 - L3
8 AWG Black
8 AWG Black
8 AWG Black
CB 2 - L1
CB 2 - L2
CB 2 - L3
VFD 2 - L1
VFD 2 - L2
VFD 2 - L3
8 AWG Black
8 AWG Black
8 AWG Black
VFD 2 - U
VFD 2 - V
VFD 2 - W
TB 1-4
TB 1-5
TB 1-6
8 AWG Black
8 AWG Black
8 AWG Black
VFD 2 +
VFD 2 --
Main Contact L1
Main Contact L2
8 AWG Black
8 AWG Black
Distribution L1
Distribution L2
Distribution L3
CB 3 - L1
CB 3 - L2
CB 3 - L3
8 AWG Black
8 AWG Black
8 AWG Black
CB 3 - L1
CB 3 - L2
CB 3 - L3
VFD 3 - L1
VFD 3 - L2
VFD 3 - L3
8 AWG Black
8 AWG Black
8 AWG Black
VFD 3 - U
VFD 3 - V
VFD 3 - W
TB 1-7
TB 1-8
TB 1-9
8 AWG Black
8 AWG Black
8 AWG Black
VFD 3 -VFD 3 +
L2 - T4 Main Contact
PA - T3 Main Contact
10 AWG Black
10 AWG Black
NOTE
Main Drive
Main Drive
Main Drive
DC Buss
DC Buss
Back Drive
Back Drive
Back Drive
DC Buss
DC Buss
Feed Pump
Feed Pump
Feed Pump
DC Buss
DC Buss
86
Ground
Ground
Ground
Ground
Ground
VFD 2 - L1
VFD 2 - L2
VFD 2 - L3
M1 - L1
TB 1-10
10 AWG Black
M1 - L2
TB 1-11
10 AWG Black
M1 - L3
TB 1-12
10 AWG Black
Auxiliary
Contact
Auxiliary
Contact
Auxiliary
Contact
Distribution L1
Distribution L2
CB 4 - L1
CB 4 - L2
12 AWG Black
12 AWG Black
480 Volt
480 Volt
CB 4 - L1
CB 4 - L2
Transformer 1 - H1
Transformer 1 - H4
12 AWG Black
12 AWG Black
CB 5 - L1
TB 2-1
14 AWG Red
14 AWG Red
110 Volt
110 Volt
TB 2-2
14 AWG White
Neutral
TB 2-3
TB 2-4
TB 2-5
TB 2-6
TB 2-7
TB 2-8
PLC - L - PWR
PLC - N
24 VDC - L
24 VDC - N
Output 1-200
Receptacle - N
18 AWG Red
18 AWG White
18 AWG Red
18 AWG White
18 AWG Red
18 AWG White
PS 1
PS 1
PS 2
PS 2
110 VAC
TB 2-9
TB 2-10
Output 1-101
M1 - A2
18 AWG Red
18 AWG White
TB 2-11
Output 1-102
18 AWG Red
TB 2-13
Output 1-103
18 AWG Red
TB 2-15
TB 2-17
TB 2-19
Output 1-104
Output 1-105
ESD 1
18 AWG Red
18 AWG Red
18 AWG Blue
Transformer 1 X1
CB 5 - L1
Transformer 1 X2
Bypass 1
Close
Bypass 1
Open
Bypass 2
Close
Bypass 2
Open
Horn
E-Stop
87
TB 2-20
TB 2-21
Input 1-101
18 AWG Gray
TB 2-22
Input 1-201
18 AWG Gray
TB 2-23
Input 1-102
18 AWG Gray
TB 2-24
Input 1-202
18 AWG Gray
TB 2-25
Input 1-103
18 AWG Gray
TB 2-26
Input 1-203
18 AWG Gray
TB 2-27
Input 1-104
18 AWG Gray
TB 2-28
Input 1-204
18 AWG Gray
TB 2-29
Analog - 200
18 AWG Black
TB 2-30
TB 2-31
TB 2-32
Analog - 202
Analog - 100
Analog - 102
18 AWG White
18 AWG Black
18 AWG White
TB 2-33
Analog - 204
18 AWG Black
TB 2-34
Analog - 206
18 AWG White
TB 2-35
Analog - 104
18 AWG Black
TB 2-36
TB 2-37
TB 2-38
Analog - 106
24 VDC+
24 VDC --
18 AWG White
18 AWG Gray
18 AWG White
ISB1 -5
24 VDC + TB237
24 VDC -- TB238
Input 1-100
18 AWG Gray
ISB 1-7
18 AWG Gray
ISB 1-8
18 AWG White
M1 - 13
M1 - 14
MAG. N/0
Input 1-105
Input 1-205
Input 1-107
18 AWG Gray
18 AWG Gray
18 AWG Gray
E-Stop
Main Drive
Thermostat
Main Drive
Thermostat
Back Drive
Thermostat
Back Drive
Thermostat
Feed Pump
Thermostat
Feed Pump
Thermostat
Bypass 2
Open
Bypass 2
Open
Vibration
Switch - CH
1
Vibration
Switch - CH
1
Level Sensor
- CH 3
Level Sensor
- CH 3
Level Sensor
- CH 4
Level Sensor
- CH 4
Autogard
Prox.
88
MAG. N/0
24 VDC +
24 VDC -24 VDC +
24 VDC --
Output 1+
Output 1 -Display +
Display --
18 AWG Gray
18 AWG White
18 AWG Gray
18 AWG White
Output 1+
Output 1 -Input 1+
Input 1--
Input 1+
Input 1-Analog 1+
Analog 1--
18 AWG Gray
18 AWG White
18 AWG Gray
18 AWG White
Output 1-100
Output 1-106
Output 1-207
Output 1-107
Output 1-208
Output 1-108
Main Contact A1
Pager - Power
Transmitter Pin 7-Transmitter Pin 7+
Transmitter Pin 8-Transmitter Pin 8+
18 AWG Red
18 AWG Red
18 AWG Gray
18 AWG Gray
18 AWG Gray
18 AWG Gray
Output 1-109
M1-A2
M1-A1
Main Contact A2
18 AWG Red
18 AWG White
DC Buss
Receptacle
Auxiliary
Contactor
89
90
91
92
93
94
95
96
SECTION 9
TROUBLE SHOOTING
97
Possible Cause
Vibration switch tripped
Remedy
Reset switch
No power
Check source
Blown fuses
Drive starter
Repair or replace
Drive failure
Repair or replace
Overheated Drive
Reset
Excessive Vibration
Correct Pack-Off in
Centrifuge
Repipe
Loose fasteners or
components
Tighten
Gearbox or Rotodiff
misaligned
Repair or replace
Readjust temperature
Readjust
Emulsification of liquids or
degradation of solids
(* Hydraulic Unit Only)
99
SECTION 10
ELEVATIONS, DIMENSIONS & WEIGHTS
100
101
102
103
104
8200
8200
10400
12,800
5,100
1,000
2,000
1250
750
250
1,400
105
SECTION 11
MISCELLANEOUS
106
Quantity
04043
04042
04041
04040
04032
04030
04032
04068
04025
04031
04024
04025
04022
04023
1
1
2
1
2
1
2
4
1
2
1
1
2
1
04020
*04057
*04062
04045
04013
*04008
*04097
4
4
4
1
6
1
1
*04099
Description
Pillow Blk. Bearing, Front
Pillow Blk. Bearing, Rear
Conveyor Bearing, Front
Conveyor Bearing, Rear
Oil Seal, Solids End
Oil Seal, Drivesheave
Oil Seal, Liquids End
Gasket, Plate Dam
O-Ring, Bowl Extension
Oil Seal, Retainer Tube
O-Ring, Conveyor Liquid End
O-Ring, Bowl Liquid End
O-Ring, Accelerator Plate
O-Ring, Solids End Seal
Housing
O-Ring, Feed Nozzle
Feed Nozzle
Wear Insert/Scraper Assembly
Drivebelt (3053 Bowl RPM)
Vibration Isolators
Torque Arm, Aluminum
Rub Pad Assembly. (Part of
Overtorque Mechanism
Assembly
Spring, Compression (Part of
Overtorque Mechanism
Assembly
Item
(101)
(100)
(103)
(102)
(200)
(203)
(204)
(207)
(301)
(201)
(305)
(304)
(24D)
(300)
(303)
(27)
(29)
(804)
Op Spares
2 Years
4
4
8
4
8
4
4
16
6
6
6
6
6
4
(950)
(953)
8
8
8
2
12
2
4
(956)
107
108
109
Storage of HH Centrifuge
Recommended indoor storage and rust prevention procedures for new horizontal
decanting centrifuges (long-term storage implies periods in excess of three (3) months
idle time.)
Note:
It is the responsibility of the owner to protect and maintain the equipment after
shipment from HH.
If the centrifuge is not to be installed immediately after shipment, the unit should be
left in the original factory packaging.
Centrifuge Assembly:
1. All accessible openings are closed with tape, overwrap, plugs, etc., for protection.
2. Nameplates are covered with tape.
3. Electrical devices such as the junction box, vibration shutdown switch, microswitches, conduit boxes, etc., are wrapped with overwrap* and protective tape.
*Overwrap refers to any self-adherent, grease, oil and waterproof material which can
be molded around component parts.
4. The grease lubricated pillow block bearings are filled with the specified grease at the
factory prior to shipment.
5. The planetary gearbox is filled with the specified lube oil at the factory prior to
shipment.
6. The fluid coupling (located at the main drive motor output shaft) is filled with the
specified oil at the factory.
Guidelines for Long Term Storage
1. The centrifuge should be stored in a building with a minimum temperature of 50 Deg.
F. (10 Deg. C.). The storage area should be a clean, dry place free from excessive
vibration, high humidity, dust, or corrosive fumes.
2. The unit should be tagged with instructions for startup after an extended period of
storage.
3. Any loose parts should be boxed with rust inhibitor paper. No paper should be placed
on the base of the box and machined unpainted surfaces should be coated with a rust
preventive product.
4. The centrifuge assembly should be placed on a sturdy wooden platform. The
platform boards should be spaced with 1/ 4 gap between the boards.
110
5. A protective waterproof shroud should cover the entire centrifuge assembly, top and
four (4) sides.
Storage Maintenance
1. The centrifuge rotating assembly should be rotated by hand at least six (6) times
every three (3) months.
2. Leave the sealed openings on the equipment closed.
3. Touch-up any damaged paint surfaces.
4. Do not paint rotating parts or threaded surfaces.
5. Motors should have their shafts rotated every three (3) months in order to keep the
bearings lubricated and prevent rusting.
Coatings & Oils
At regular intervals during equipment storage, all exposed-machined surfaces unpainted
steel parts, shafts, pipe fittings, etc., should be examined for signs of rust, pitting, and
moisture.
These parts should be thoroughly cleaned and coated with the appropriate medium listed
below:
1. Molykote Metal Protector (Dow Corning)
A wax type rust preventative, which may be sprayed, brushed, or dipped onto bare steel
parts. This product dries to a hard, dry film, which is almost invisible.
For long storage periods, or shipment overseas, an overwrap must be used.
2.
A soft amber colored material leaving a transparent, dry plastic film on the coated part.
Applied by brushing, dipping or spraying, it is used for maximum heavy-duty protection
on interior or exterior surfaces with or without a covering.
Before using the treated part, remove rust veto with solvent.
111
112
SECTION 12
VENDOR DATA
113
04038
Vibration Switch
Metrix Instrument Co. Model 5097-10
(Explosion Proof Model Available)
04006
04012
04732
Micro Switch
Model LSXA3K Honeywell
Baldor Motors & Drives
Main Drive Electric Motor
60 HP 1750 RPM (Mfr. Varies)
Back Drive
03130
04755
04139
114
OPERATION:
The Autogard 400 Series torque limiters disengage the drive completely on overload in both
directions of rotation. After disengagement the drive is running free, which permits highspeed operation (at or above normal motor speeds). A shut down switch must be
incorporated, as the unit is not designated to run continuously disengaged.
115
PRIOR TO INSTALLATION
1. Mounting Sprocket or Sheave.
A. Mounting with tapered bushing. (Taper-lock, Q.D., etc.)
A sprocket, sheave, or timing belt pulley may be mounted directly on Model 401
by using a tapered bushing. Select a sprocket or sheave to fit M dia. Of the
Autogard (Table 1.) No key is used with the bushing when mounting on the
torque limiter. Thoroughly clean all grease and oil from M dia. With solvent
prior to mounting the bushing. Be certain that the bushing is properly mounted
and tightened according to the instructions accompanying each bushing.
CAUTION: It is possible to overtighten the bushing capscrews to an extent that
will deform the adapter (4) and prevent its free rotation on the hub (1). Make sure
that the adapter and bushing assembly is free to rotate on the hub after the bushing
is fully tightened. To check this, the adjusting nut (11) must be backed off to
release all pressure from the spring (10). Re-tighten adjusting nut to original
position after free-rotation check is completed.
B. A sprocket sheave, etc., may also be mounted on Model 401 by bolting. The
adapter (4) must be removed for drilling and tapping the mounting holes (Table 1)
if they were not ordered with the unit. See Disassembly Procedure.
116
Table 1
Size No. of
Bolts
1
2
3
4
5
6
6
6
6
6
Bolt
Size
Dimensions -Inches
#8-32
#10-24
1/ 4x20
5/16x18
3/8x16
Bolt Circle
Dia.
1.750
2.500
3.375
4.125
5.687
M
Dia.
Sprocket Bore
1.376/1.378
2.126/2.128
2.876/2.878
3.5015/3.5035
5.0015//5.0035
1.375
2.125
2.875
3.500
5.000
Attach sprocket, sheave, etc., onto adapter prior to reassembly. Use bolts of a length that
provides no more engagement in the adapter (4) than the maximum shown in Table 1.
Make sure there are no protrusions inside the adapter, which might interfere with the hub.
The unit may then be reassembled per instructions.
2. Mounting Sprocket or Sheave on Models 402 and 409.
3. Proper Spring
Check to see that the correct number of springs is being used to release torque (Table
4). DO NOT TIGHTEN THE SPRINGS BEYOND ITS MINIMUM OPERATING
LENGTH (with the torque limiter engaged) or the springs will not allow sufficient
movement of the slide plate to let the balls leave their seats during an overload.
Damage to the machinery or to the Autogard will result.
4. Lubrication
The needle bearing, spline surfaces, plate faces and balls have the proper type and
amount of lubricant applied during the assembly at the factory. No further lubrication
should be required at initial installation.
117
Table 3
Model
Size
403*
404
405
406
Allowable Angular
Misalignment
15
15
15
1
2
3
4
5
6
7
Gap between
Hub & Adapter
Allowable
Parallel
Misalignment
0
0
0
.005
.008
.010
.013
.017
.020
.028
0
0
.5 deg
.10 deg.
Min.
Max.
.08
.80
.08
.08
.12
.12
.20
.16
.16
.25
.25
.31
.31
.39
Y - Inches
Size
Spring Assembly
Qty
8
6
4
2
8
6
4
6
6
4
3
8
8
6
4
8
8
6
4
8
6
4
Positions
Outer
Outer
Outer
Outer
Outer
Outer
Outer
Inner & Outer
Outer
Outer
Outer
Inner &Outer
Outer
Outer
Outer
Inner &Outer
Outer
Outer
Outer
Spring Stacks
Spring Stacks
Spring Stacks
Torque
Range
Lb. In.
100-250
75-188
50-125
25-63
400-2,000
300-1,500
200-1,000
1,700-6,000
1,200-3,000
800-2,100
600-1,600
2,500-10,000
2,000-6,800
1,500-5,100
1,000-3,400
8,000-22500
6,000-17,000
4,500-12,750
3,000-8,500
12,000-50,000
9,000-37,500
6,000-25,000
Clearance
CA
In.
Movement to
disengage
X
Min
Allowable
.075
075
075
075
.20
.20
.20
.20
.20
.20
.20
.20
.20
.20
.20
.40
.40
.40
.40
1.05
1.05
1.05
None
Required
.059
None
Required
.112
None
Required
.137
None
Required
.137
None
Required
.173
3/8
.210
118
INITIAL STARTUP
Prior to startup, examine torque limiter to make sure it is fully engaged with the balls
seated correctly in both plates.
Obtain initial torque setting by one of the following methods:
A. The setting as furnished will be within + 10% of the torque value specified on the
order. If the factory adjustment has been altered during assembly procedure, be sure to
reposition the adjusting nut in its original location as measured during the first step of the
disassembly procedure. Secure nut in place with setscrews.
B. Torque limiter to be set at job site Sizes 1 through 5.
1. Setting by trial adjustments:
Start up the drive at minimum torque setting. If the torque limiter disengages before the
normal operating load level is reached, progressively tighten the adjusting nut until the
drive will start and operate under normal load without tripping.
Starting torque is usually the highest torque that the torque limiter must transmit, but
occasionally the torque limiter must be set to accommodate higher peak operating
torques.
After desired torque setting is obtained, secure adjusting nut with setscrews.
2. Setting to an established specified torque:
An appropriate setting can be made from a Torque Adjustment Chart furnished with the
torque limiter if requested at the time of order.
119
CALIBRATION SPACERS
The torque limiter is shipped from the factory either with the torque setting pre-adjusted
as specified at the time of the order, or furnished unset for adjustment at the time of
installation.
All units are supplied with minimum spacer only to prevent from locking up (unless
required otherwise by customer.)
TORQUE ADJUSTMENT
SIZE 6 AND LARGER
To facilitate adjustment under the high loads, these larger units use a number of adjusting
bolts. See Fig 12.
When building, assemble all components as Fig. 12, but omit the adjustment spacer. Be
careful to stack the disc springs correctly. This is generally as shown in Fig 12, but
reference should be made to the assembly drawing as the number and method of stacking
can vary.
Assemble the pillars (10B), springs (10A, washers (10C) and adjustment bolts (10E) into
the adjusting nut (11A), and lightly tighten the bolts, so that as the adjusting nut is
tightened, the hexagon engages with the groove in the slide plate.
Tighten the adjusting nut as far as possible, using the bolts to equalize the length of each
spring stacks, so that all pillars are engaged with the groove on the slide plate.
To increase the torque, tighten each bolt by an equal amount, but not enough to disengage
the hexagons from the slide plate. One or two turns of the bolt are normally a convenient
amount. Then tighten the adjusting nut without using excessive force. Shortening of the
spring stack is by means of the bolts, not by the nut. Continue with this procedure of
alternately tightening bolts and adjusting nut until the correct spring length is achieved,
then slacken the bolts. THE UNIT WILL NOT OPERATE CORRECTLY UNTIL THIS
IS DONE.
When the correct torque setting is achieved, remove the pillar bolts completely, replace
the adjustment spacer, and retighten the bolts. There must be a gap between the thick
washer and the bolts. There must be a gap between the thick washers and the adjusting
nut. Lock the adjusting nut with the setscrews.
NOTE
IT IS ESSENTIAL THAT ANY SET OF SPRINGS IS NOT USED ABOVE ITS
CORRECT RANGE. IF THE SPRINGS ARE OVER-TIGHTENED, THE BALLS
WILL BE PREVENTED FROM ROLLING FROM THE SEATINGS, IF SLACKENED
TOO FAR, SO THAT A POSITIVE LOAD IS NOT APPLIED TO THE BALLS AT
ALL TIMES. IT IS POSSIBLE THAT ONE OR MORE BALLS MAY REMAIN IN
THEIR SEATINGS DURING TRIPPING. IN BOTH CASES IT IS PROBABLE THAT
120
It is good practice when other equipment in the drive train is down for service to make a
general inspection of the torque limiter. Check for tightness of the torque limiter on its
shaft, tightness of the sprocket, etc., and check for appearance of adequate lubrication.
This may be done by backing off the adjusting nut and separating the plate set to permit
viewing the interior components. If there is any indication that further servicing may be
desirable, the torque limiter should be disassembled and inspected as described above
under DISASSEMBLY PROCEDURE.
NOTE: If, after the drive has been in operation for some time and the torque limiter
suddenly starts disengaging for no apparent reason, check to see whether something in
the drive train or driven machine, such as normal wear, a bad bearing, damaged sprocket,
misalignment, change in machine duty, etc., may be the cause of the problem.
A visual inspection of the drive and slide plate is then recommended. Follow
disassembly procedure above. Note that although a ball path between the ball seats
should normally be visible, excessive wear on the seats themselves may require
replacement of the drive plate.
Reassemble and follow INITIAL STARTUP procedure.
BUILDING PROCEDURE
If the components being used are not new, they should be inspected for accidental
damage or wear. Particular attention should be paid to bearing surfaces. Any slight
damage marks should be carefully blended out.
Any components showing substantial damage or wear should be replaced.
GREASE
Use good quality grease. Units operating in conditions of high or low temperatures may
require the appropriate special grease.
122
Connect the adapter to the drive plate with capscrews (20A) and roll pins (7B).
Check that the drive plate/adapter assembly can rotate freely on the hub.
H. On size 1 and 2 SR units, assemble the cage plate spring (6B) onto the hub, ensuring
that it is housed in the counterbore in the strut ring, and that the coils are not
intertwined. On size 3 and larger, a bayonet type of cage plate retention is used. The
cage plate is placed in the slide plate with the stop pin notch 90 to the proper
location. The stop pin (7B) should now be installed per Fig. 10. (Note position of
splits in rollpins.)
I. Check that the stop pin (7B) is correctly positioned in the slide plate (7) and is not
loose or damaged. It should lie flush with the top of the flange of the slide plate.
Size 1 uses a single pin, all other sizes use double pins, see Fig. 10.
Place the slide plate (7) on the bench with the flange and ball seat face upwards.
Lightly grease the cage plate (6A) and place it on the slide plate with the shallow
recess in the bore upwards.
The correct angular positioning of this plate relative to the ball seats and pins is most
important, see Fig 10. The cage plate holes must be directly over the ball seatings,
and the stop pin (7B) in the slide plate must be central in the cage plate cutout.
Ensure that the plate is not 180 degrees out of position the stop pin must be
centrally positioned in the wider slot.
J. Insert some grease into each of the cage plate holes, and place drive balls (5A) and
strut balls (5B) in these holes. There should be sufficient grease to hold these balls in
position when the assembly is inverted.
K. Insert springs (10A) into the adjusting nut (11A). Some grease in the holes will help
hold these positions for the next stages of assembly.
L. Carefully holding the cage plate in position, invert the slide plate, and pass it over the
hub thread to engage with the splines on the hub. As soon as the splines are engaged,
rotate the drive plate until the pawls are symmetrically facing the cutout in the slide
plate flange. Then push the slide plate fully home, holding the cage plate until the
last possible moment.
The drive balls should now be engaged with the seatings in the drive plate, and the
pawls pushed almost completely into the drive plate by the flange on the slide plate.
There should be a small gap, about 0.010 inches (0.25mm) between the slide plate
flange and the drive plate.
M. Hold the slide plate in this position against the cage plate spring pressure, and screw
the nut/spring assembly onto the hub until the springs are against the slide plate with a
positive pressure more than the cage plate spring load so that the slide plate is held in
position.
124
Figure 11
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
SECTION 13
SUPPLEMENT SYSTEM OPERATION
145
SYSTEM OPERATION
Index
Overview
Initial Start Up
Checking Rotation Of Drives
Operating Parameters
Automatic Operation
Start Up
Operation
Shutdown
Alarm Pages
Help Pages
Display Screen Shoots
Start Up
Start Up Help
Operating Parameters
Operating Parameters Help
Main Drive Status
Main Drive Status Help
Back Drive Status
Back Drive Status Help
Feed Drive Status
Feed Drive Status Help
History
History Help
Agitator
Fault Status
Fault Status Help
Run Time Meter
Main Drive Fault Alarm
Main Drive Fault Help
Back Drive Fault Alarm
Back Drive Fault Help
Feed Pump Drive Fault Alarm
Feed Pump Drive Fault Help
Main Drive Overtorque Alarm
Back Drive Overtorque Alarm
Feed Pump Drive Overtorque Alarm
Autogard Tripped Alarm
High Vibration Alarm
Display Screen Shoots Continued
General PLC Fault Alarm
General Rack Fault Alarm
General FIPIO Fault Alarm
146
147
148
149
History
Agitator
Fault Status
Run Time Meter
To access Start up page, press R9 or R10 on the display. The screen should look similar
to the one depicted in the appendices titled Start Up .
The correct rotation of the Main Drive is counter-clockwise looking from the gearbox
end of the centrifuge. Check the rotation of the Main Drive by pressing R2 (Main Start)
on the display to manually start the Main Drive. Manually stop the Main Drive by
pressing R2 (Stop) on the display. If this rotation is not correct, make a note of this so the
phase orientation can be changed at terminals 1, 2, and 3 within terminal block TB1,
located in the bottom of the control panel, after the main incoming power supply from the
rig has be locked out and tagged out.
The correct rotation of the Back Drive is clockwise looking from the gearbox end of the
centrifuge. Check the rotation of the Back Drive by checking that the rotation is forward
if not it can be changed by pressing R6 then press R4 (Back Start Forward) on the display
to manually start the Back Drive in a forward direction. Manually stop the Back Drive
by pressing R4 (Stop) on the display. If this rotation is not correct, make a note of this so
the phase orientation can be changed at terminals 4, 5, and 6 within terminal block TB1,
located in the bottom of the control panel, after the main incoming power supply from the
rig has be locked out and tagged out.
The correct rotation of the Feed Pump Drive is counter-clockwise looking from the drive
end of the Pump. Check the rotation of the Feed Pump Drive by pressing R8 (Feed Start)
on the display to manually start the Feed Pump Drive. Manually stop the Feed Pump
Drive by pressing R8 (Stop) on the display. Never operate a dry Feed Pump for more
than a few seconds when checking rotation. If this rotation is not correct, make a note
of this so the phase orientation can be changed at terminals 7, 8, and 9 within terminal
block TB1, located in the bottom of the control panel, after the main incoming power
supply from the rig has be locked out and tagged out.
Operating Parameters:
The operating parameters are initially set by the PLC when the control panel is energized
to the following default settings:
Main Drive Torque Alert
Back Drive Torque Alert
Feed Pump Torque Alert
Main Drive Torque Alarm
Back Drive Torque Alarm
Feed Pump Torque Alarm
Vibration Alert
Vibration Alarm
Feed pump gearbox ratio
Feed pump GPM per.100
Revolutions.
Feed pump size (60 or 80)
60
60
60
99
99
99
45
60
7.12
22
60
151
0
0
0
These parameters can be adjusted using the Operating Parameters screen accessed by pressing
R9 or R10. The screen should look similar to the one depicted in the appendices titled
Operating Parameters. These operating parameters are used by the PLC in calculating flow
rate and alarm/alert comparison levels. A detail explanation follows:
152
Main Drive Torque Alert: This is the torque level that causes a Main Drive torque alert.
Back Drive Torque Alert: This is the torque level that causes a Back Drive torque alert. When
this torque alert level is reached, the feed pump and back drive speeds will be manipulated in an
attempt to reduce the back drive torque below the alert level. Once the torque level has returned
to normal and remains below the torque alert level, the centrifuge will return to normal operation.
Feed Pump Torque Alert: This is the torque level that causes a Feed Pump Torque alert.
Main Drive Torque Alarm: This is the torque level that causes a Main Drive torque alarm.
When this torque alarm level is reached the Main Drive, Back Drive, and Feed Pump will shut
down.
Back Drive Torque Alarm: This is the torque level that causes a Back Drive torque alarm.
When this torque alarm level is reached the Back Drive, Main Drive, and Feed Pump will shut
down.
Feed Pump Torque Alarm: This is the torque level that causes a Feed Pump Torque alarm.
When this torque alarm level is reached the Feed Pump will shut down.
Vibration Alert: This is the level of vibration that causes a vibration alert. When this level of
vibration is reached the Centrifuge will continue to operate but the vibration status on the Main
Operation screen will show an alert.
Vibration Alarm: This is the level of vibration that causes a vibration alarm. When this vibration
level is reached the Centrifuge will shut down.
Feed Pump Gearbox Ratio: This is the ratio of the gearbox on the feed pump. It is used in a
mathematical equation to display gallons per minute, and set Feed Pump VFD parameters.
Feed Pump GPM per 100 Revolutions: This is the number of gallons displaced per minute for
100 revolutions of the pump. It is used in a mathematical equation to display gallons per minute,
and set Feed Pump VFD parameters.
Feed Pump Size (60 or 80): This is used to select the pump size that is being used. It will
automatically set Feed Pump Gearbox Ratio and Feed Pump GPM per. 100 Revolutions. For
special pumps gearbox ratios and GPM per 100 revolutions can be manually set.
T-3 Motor Configuration ( 0 = no 1 = yes ): This is used to select T-3 Motor Configuration if
applicable in the installation.
Tank Level Indication ( 0 = no 1 = yes ): This is used to select Tank Level Indication if
applicable in the installation.
Weigh Application ( 0 = no 1 = yes ): This is used to select Weigh Application if applicable in
the installation.
Automatic Operation:
153
The amount of system automation controlled by the Centrifuge panel is rig-up dependent,
i.e., pumps, by-pass valves, level detection, etc., but at the very least the Centrifuge panel
will provide for automatic operation of the Centrifuge. Automatic startup of the
Centrifuge is controlled via the Start Up page accessed by pressing R9 or R10. The
screen should look similar to the one depicted in the appendices titled Start Up.
Before attempting to operate the Centrifuge ensure that the system is purged with clean
drilling fluid or base oil, that the Duster is properly installed and ready to process, and
that all of the automated ancillary devices such as bypass vales and flush lines and pumps
are operating correctly.
Start up:
The two main operating variables of the Centrifuge are g force and differential. When
setting g force and differential keep in mind the following guidelines:
1. The minimum g force is 500 and the maximum g force is 2100 with a normal setting
between 1800 and 2100 gs.
2. The minimum differential is 20 and the maximum is 60. Generally the differential is
set according to the amount of solids in the fluid being processed. In large amounts of
solids, set the differential to 60. As the amount of solids in the fluid decreases you can
vary the differential to achieve the maximum separation. With respect to differential it is
always better to error on the high side. Running the Centrifuge with the differential set to
low can result in a shutdown from solids plugging up in the bowl.
Operation:
During operation, the Main Drive and Back Drive torque levels are an indication of the
load on the Centrifuge. During normal processing, the Main Drive torque will be
approximately 25 to 60 percent and the Back drive torque will be approximately 20 to 60
percent. Values greater than these are an indication of excessive loading or plugging of
the Centrifuge. If the torque exceeds the values input on the Operating Parameters page
in the field titled Back Drive Torque Alert then the Centrifuge will manipulate the feed
pump and back drive speeds in an attempt to reduce the Back Drive torque below the
alert level. If the torque continues to increase to a level that exceeds the values in the
fields Main Drive Torque Alarm or Back Drive Torque Alarm then the Centrifuge
will shutdown and sound an alarm.
Shutdown:
Press Shutdown is accomplished by pressing R3 Main Stop. Once the Centrifuge has
come to a complete stop and will be shut down for an extended time period, shut the
panel off by pressing the emergency stop button.
Alarm Pages:
154
Alarm pages will only be displayed when an alarm is present. When viewing an alarm
page read it completely because there is usually help information on the alarm page
155
Help Pages:
Help pages are accessible when the red light above the ? mark is lit. To access these
pages press the ? mark. The ? mark is located to the left of the keypad.
156
Start Up
157
Start Up Help
158
Operating Parameters
159
160
161
162
163
164
165
166
History
167
History Help
168
Agitator
169
Fault Status
170
171
172
Alarm
Main Drive Fault
173
174
Alarm
Back Drive Fault
175
176
Alarm
Feed Pump Drive Fault
177
178
Alarm
Main Drive Overtorque
179
Alarm
Back Drive Overtorque
180
Alarm
Feed Pump Drive Overtorque
181
Alarm
Autoguard Tripped
182
Alarm
High Vibration
183
Alarm
General PLC Fault
184
Alarm
General Rack Fault
185
Alarm
General Fipio Fault
186
Alarm
Input Module Fault
187
188
Alarm
Output Module Fault
189
190
Alarm
Analog Module Fault
191
192
Alarm
Main Drive Fipio Fault At PLC
193
Alarm
Main drive Fipio Fault At VFD
194
195
Alarm
Back Drive Fipio Fault At PLC
196
Alarm
Bach Drive Fipio Fault at VFD
197
198
Alarm
Feed Drive Fipio Fault At PLC
199
Alarm
Feed Drive Fipio Fault At VFD
200
201
Alarm
Main Drive Internal Fault
202
203
Alarm
Main Drive External Fault
204
Alarm
Back Drive Internal Fault
205
206
Alarm
Back Drive External Fault
207
Alarm
Feed Drive Internal Fault
208
209
Alarm
Feed Drive External Fault
210
Alarm
Weigh Module Fault
211
Alarm
Main Drive Motor Thermal
212
Alarm
Back Drive Motor Thermal
213
Alarm
Feed Pump Motor Thermal
214