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PC Series Vacuum Ceramic Filter

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1. Fig 1 2 Back View Driven by the main shaft the filter plate rotates to the direction of scraper Under effect of vacuum system vacuum pump filtrate tank distributor and relevant pipes the filter plate below slurry level absorbs the slurry while the filter plate from slurry level to scraper makes the material absorbed on it dry The filtrate goes into filtrate tank where from it is drained through discharge system filtrate pump and relevant pipes When the filter plate reaches the position of scraper the cake is taken out by scraper and then given through discharge chute onto conveying belt After discharge of material the filter plate is cleaned in the way of pressure flowing cleaning takes place once after each circle of rotation So a few of residue caused by clearance between filter plate and scraper is cleaned out and the function of filter plate is restored during operation After certain time normally 7 hours it is necessary to clean the filter plate by means of detergent normally it is nitric acid depending on characteristics of material and ultrasonic So the materials amp foreign matters stopped in pores of filter plate or absorbed on surface of filter plate are cleaned out and the function of filter plate is restored during operation The Vacuum Ceramic Filter adopts PLC full automatic control system Both full automatic operation and manual operation are possible to provide flexibility amp convenien
2. 4 4 Maintenance cycle Detail table of maintenance cycle Maintenance cycle Maintenance Item Remarks Halfyear_ 1year w So ooo f fo Danesa S e cara Distribution Valve oller stiren gears tubricant o o Change Change 50 engine oil once in the first 500 hours roller stirrer axle s lubricant TET 160g for roller amp axle 20g for other parts Ee a a E A issues ee weer ik aem o o a 19 User s Manual Shengnuo Group Ultrasonic producer Electrode of filtrate level Electric device Switches and buttons Pilot lamp 20 Appearance Stirrer warning Operation stops Stirrer warning delay or overtime of startup Stirrer warning frequency transformer error Roller warn operation stops Roller warning delay or overtime of startup Roller warning frequency transformer error Filtrate Tank warning level is low Filtrate Tank waming level is high Filling overtime Filtrate Tank warns itself is not under vacuum condition and stops working Under the automatic working condition the time of filling the filtrate Tank is too long Liquidometer of slurry tank error PART 5 FAULT CLEARANCE Cause analyses Frequency transformer Stops working Stirrer s engine stops working Frequency transformer is too hot electric relay trip Frequency transformer stops working Roller s engine stops working Frequency transformer is too hot electric relay trip 1 electrode out of control o
3. PART 3 OPERATION icc io Oo 13 3 4 Operation Panel ccesiouioxssiviesnnsancowieceivemnnenivawe aa sie niren aes ence aaa awe 13 3 2 Automatic OPER AUON vii snsciersersntvnticunsdevina sind aendeinnpuninevordesuibasosdendulswbsnenbssumtinienbeswieinids 14 3 3 Manual operation method 0 cc eccescceceeeeeneeeeeeeeneeeeeeeeeaeeeeeseeeeeeeeeeeeeeaaees 15 3 45 How to shut down si iinsessinsinsasasevnazinssanniesnsstanieindbieaanae teahinsdinaibendetesebwanennihasoimiebersdun 15 Coho tO CleaniNe in ee a eee 15 3 6 HOW to stop cleaning si gandtecisnicd Ses undies oatizaseduisetvdaidonntienlensltnanca e E 16 3 7 Checking and Ajustment during operating and cleaning c cee 16 3 0 TOUCH SCEN imeona a saa ee E 17 3 9 Operation notice eeseesseesesseesrrssserrrsssrerrrsssrerrrsserernnsssstersnsssteerassereesassereenns 18 PART 4 MAINTENANCE iss sciisiecesascendepnraitednvrurtincunncinuniciensuvnscsvicduvisiuendeswasdolidenesinndioswadiogdes 19 4 1 Changing and adjusting the Filter Plates 00 nonseseesnsseserrseresrrsrrsrrreresrrsresres 19 4 2 Adjustment OF scraper cnuriinnnnddnnatmnmnm nnn iana aaa Ea aaa an 19 4 3 Adjustment of distribution head sscscceecsavnssrcsscsssrssnveronssnnesesavsaoenavecversnees 19 4 4 Maintenance Cycle eeser eesriie eiieeii earns weed ensede ses tidien sediri 19 PART 5 FAULT CLEARANCE ooo eee eececeeeesneeeeesaeeesesaneeeesaeeeseeaeeeeesaeeeseeaeeees 21 PART 6 ELECTRIC
4. it means system is in manual method 1H auto pilot lamp when the lamp is flashing it means automatic operation is starting when the lamp is on it means system s automatic operation has been started up auto method is on 4H clean pilot lamp when the lamp is on it means system is in cleaning process 3H Pause pilot lamp when the lamp is on it means the system is paused CMP Touch screen Make use of the touch button can operate system manually Through the error information on the screen can find out the cause of the error There are also operating situation and operating notice displayed on the screen 6 1 1 2 Touch screen CMP introduction as follows 6 1 1 2 1 Home page homepage page then press the manual button to on and off all engine and valves Manual operation and clean setting press and turn it to the manual operating b Input amp output state press and turn it to the input amp output state page can exam the on amp off situation of all parts c Warning record press and turn it to the warning record page can find out the cause of error white words mean the happening error black words mean the wn mm Anshan special wear resisting cleared error equipment plant d Parameter enters Press and turn it to parameter enter page then can enter Fig 6 1 1 Homepage Screen User s Manual Shengnuo Group and amend the parameter e Production statis
5. 5 Agitating system Agitating device is the key part of the filter because the state of particles suspended in slurry directly influences the production indexes amp smooth running of the filter Our agitating system is designed as an integrated unit f Support Crank consisting of drive motor reduction gear horizontal shaft connecting Connecting bar bar crank and rake Stander i Drive Elastic The rake is designed as plate type supporting net structure Under coupling CHO Zonta precondition of no increasing of deadweight the rake can improve the shaft performance of filtering because it makes the materials to be filtered be distributed evenly in slurry tank Elastic coupling is added on horizontal Fig 2 5 Agitating System shaft to increase the safety of agitating system s running The reduction ratio of agitating device is designed as 1 90 The maximum speed rate of agitating is 3 75s v which can be determined by customer in accordance with state of material settling 1 2 2 6 Ultrasonic cleaning system The outlook of ultrasonic cleaning device is shown in Fig 2 6 The ultrasonic cleaning system consists of power supply box and energy converter The working principle of ultrasonic cleaning system is the follows Through energy converter the high frequency oscillation signals from ultrasonic generator are changed to high frequency mechanical oscillations which are transmitted into media Wh
6. Ceramic Filters and to further bring the excellent performance of Vacuum Ceramic Filters into full play So far Shengnuo Group is the largest Vacuum Ceramic Filter products supplier in China 1 3 1 Advanced Features of the 2nd generation VCF It was in mid 1990s that the foreign companies started to develop and popularize to use Vacuum Ceramic Filters in scale At that time neither the quality nor performance of the ceramic filter plate and Vacuum Ceramic Filters was perfect enough Aiming at properties and production technology of metallic ore beneficiation materials our factory optimized systematically the ceramic filter plates and Vacuum Ceramic Filters to upgrade the technology to the level of second generation depending on the domestically famous scientific and research institutions like Tsinghua Universities The specific measures were as follows 1 3 2 Improvement of ceramic filter plate a A1203 with high hardness good quality and better hydrophilicity was selected as main material and material of clay category with high effective composition and stable physical and chemical properties was selected as auxiliary material The sintering technology with high temperature but small temperature difference was adopted to produce filter plate with high strength easy to clean out high productivity and long service life It has been proven that the technical features of the improved ceramic filter plates have superiority over the similar products ma
7. Inspect the discharge valve and its the control air course The Slurry tank discharge air time the value should be more than the actual Inspect the discharge valve return route Inspect the Slurry tank flushing hydraulic pressure Again supposes the note full water time the parameter Check is there any electricity in the return circuit it should be 1 2A identify is the fuse link broken Check is the shock board short circuits is the connection broken circuit board change original part adjust again check the error number from the window of frequency transformer find the solution from the introduction check signal return circuit 5A3 Check signal line 5A2 Change or cut off Speed setting potentiometer Check cut off machine 2Q1 is the connection 2KM1 connected Check frequency transformer s error number from its window Check and fix the circuit Check frequency transformer s error number from its window Check signal line s 5A5 return circuit Check signal line 5A4 Check link line and potentiometer Check broken circuit device 1Q1 contactor VKM1 User s Manual 18 Conveyer belt is no working 19 Acid pump overloading The operation signal is not connected to PLC 126 Acid pump is overloading 117 0 Shengnuo Group Check signal s return circuit check acid pump and its engine warning Signal line is broken 5A1 Check 5A1 circuit 20 Fan of electri
8. button on the operating box and the touch screen and then by using the left turn right turn switch and crashstop button to check and repair conveniently 3 1 7 Stirrer s speeding potentiometer For stepless adjustment of stirrer s frequency According to the character of material and requirement technology the solid do p J q y 8 q By not deposit the standardization 3 1 8 Roller s speeding potentiometer For stepless adjustment of roller s frequency The principle is that the roller turns faster the production will be bigger But the production should be according to real situation 3 1 9 Touch screen To show the state of the machine alarm information and manual control startup shutdown open close valve display and amend machine s reference number and so on 3 1 10 Pilot lamp to show the working state of the machine Example o lamp off Q lamp on Q lamp flashing The details as below Manual Auto Pause Cleaning Remarks o o o o No option after turning on or Emergency stop Q o o o Manual state O o o From manual to auto startup o Q o o Automatic state o o amp o Pause state O o o o From auto to manual shutdown o o Q Manual wash o o o Q Auto wash O O Q Q Pilot lamp checking when startup Table 1 Lamp Indications 3 2 Automatic operation In normal production the filter machine works automatically and accordingly to the program which is set up already by using PLC The progress startup prod
9. improvement of equipment and overall optimization the performance the second generation of the complete Vacuum Ceramic Filter has been greatly improved to fully meet the requirement of filtering materials from the beneficiation plants of copper lead zinc iron silver gold and sulphur It has been proven from the production practice that the operation of equipment is reliable and the technical indexes are excellent Up till now the customers of Fushun Hongtoushan Copper Mine Sichuan Huili Lead zinc Mine Wuhan Iron and Steel Complex Jiangsu Weigang Iron Ore Mine and Chengde Baotong Mining that used the first generation of Vacuum Ceramic Filter made by others but not satisfactory with the products have changed to use our products Development History of VCF The first generation of Vacuum Ceramic Filter was developed by foreign companies The Vacuum Ceramic Filter was successfully developed by Outokumpu Finland in early 1980s and popularized to use in early 1990s The main utilization fields included nonferrous metallurgical mines and non metallic concentrates filtering such as copper lead zinc and sulphur The second generation of Vacuum Ceramic Filter is to change the slip casting type filter plate into two piece binding type filter plate so that the strength of filter plate increases and the performance of Vacuum Ceramic Filter is improved We have done a lot of tests with Tsinghua University in the national laboratory to make fundamenta
10. is open until reach the new highest level the acid pump start working the concentration of acid will be about 1 After a set time ultrasonic producer start working Both acid and ultrasonic clean the Filter Plates together After a set time the cleaning is stopped and reverse circulation valve is remained 14 User s Manual Shengnuo Group open in the time setting clean the tubes and Filter Plates wash and empty the slurry tank After all that is finished the next production period will start 3 3 Manual operation method When there is a particular need or a accident we use manual method to start up or shut down the valves Do not use manual method operating the machine unless you know the working principle and all the parts of equipment very well 3 4 How to shut down 3 4 1 Press pause button to shut down To stop a regular working machine for a little while press pause button then the feeding valve is closed and all other parts of machine will stop working except the stirrer If there are some minor failures as follows the system will pause automatically the engine of acid pump is too hot the water level of filtrate pump is too high the engine of filter pump is too hot the engine of vacuum pump is too hot the filtrate backwash is failure and the roller s frequency transformer is failure After the problems are solved just press the reset button then the machine will be back to the automatic working stat
11. it as a good opportunity to further develop the technology of Vacuum Ceramic Filter Subject to a serial improvement and modification our Vacuum Ceramic Filter product now has extensive application and safer and reliable operation The technical performance is excellent From this point of view we have promote the development of ceramic filtering technique Our Vacuum Ceramic Filter product belongs to second generation of Vacuum Ceramic Filter products In 2002 14x30m Vacuum Ceramic Filters were selected in the technical modification project of Donganshan Sinter Plant which has become the largest model project for using ceramic filtering technique in the country even in the world According to the calculation Ansteel Donganshan Sinter Plant is able to increase economic benefit of about 30 million Yuan per year due to energy conservation consumables reduction simplified thickening and filtering flowsheet to avoid metal losses and so on The most important is that the project has solved pollution problem of Yangliu River which was polluted for dozens of years by Donganshan Sinter Plant gained obvious economic and social benefits and made the enterprise which was almost shut down revitalize again 11 User s Manual Shengnuo Group PART 2 THE INSTALLATION 2 1 The installation processes The installation is according to the steps below Framework case stirrer roller scraping System tube system electric system PLC To separate the mac
12. 2 and continues to repeat all the time When the water is being discharged connect the coil terminals of electromagnetism switch A to connector pin connect to power by connector be of no effect At this moment the working process when liquid level reaches E1 electric relay cut off connection points are closed water pump starts discharging When the liquid level reaches E2 electric relay is connected connection points are open water pump stops discharging and this cycle will repeat all the time 6 2 2 1 4 The use of the controller controller s eight legs plug connect to 220V AC power O connector pin connect to transducer s electrode E1 E2 E3 connector pin on the output terminal of DC electric relay The following test should be done for meter before use Connect eight legs plug to 220V AC power then connect connector pin state remain unchange then short 27 User s Manual Shengnuo Group circuit connector pin at this moment should hear a sound of electric relay connecting a multimeter can be applied to measure output connecting point should be cut off should be connected then cut off Mshort circuit state remain unchanged then cut off short circuit cable electric relay release to last state output points are connected are cut off means meter is normal test is done Electrode stick and container s in
13. CONTROL SYSTEM o 00 cece eeenceeeenneeeeeeeeeeesaeeeeenaeeeees 22 6 1 Operation of electric control system 0 0 0 eee eeeeeeeesneeeeeeeaeeeeeeaeeeeeeaeeeeeeaeeees 22 6 2 Electric drawing and relative information cece eee eee eres een eeeees 26 6 3 Electric COIS ecascgecessercscseda dec cennccincvisnatgnantened dae Saw AE E EE RESEO REA EERE 30 User s Manual 1 2 Shengnuo Group PART 1 INTRODUCTION Descriptions 1 1 1 General The Vacuum Ceramic Filter consists of ceramic filter plate rotator slurry tank discharge scraper distributor agitating device cleaning device including ultrasonic cleaning amp acid cleaning frame vacuum system pipe system filtrate discharge system automatic lubricating system automatic acid dosing system discharge chute valve and PLC automatic control system can be made as remote control system The structure of main parts of the filter is shown in the following figure Ceramic tering box plate a Distributor gitating Rotator Discharge fi scraper Ultrasonic baffle Energy accumulator Discharge chute j br ive for rotator Frame Fig 1 1 Front View 1 1 2 Working principle Ceramic plate Main shaft trasonic Filter Filtrate Pasty material Fig 1 3 Work Principle Control r FEEN ive f Agitating Distributor agitating system j device Control box Drive for rotator
14. PC Series Vacuum Ceramic Filter User s Instructions Manual Shengnuo Group 3nd Edition Ownership of copyright All information given in this document including text images and designs is copy righted and owned by Shengnuo Group Receiving of the manual doesn t mean the receiver has been granted the right to edit either whole or part the document or dispatch it to any third party without formal permission of Shengnuo Group User s Manual Shengnuo Group Table of Contents PART 1 INTRODUCTION iis siscaestsacssensieicacinniintavanicancevarkecsnunlicinanimnanadeaned eonssianinedemieiavabion 3 1 1 Dict a eas 9 ae eee ee ee ee eee eee 3 1 2 Performance and FORCES sisiicanieisisoacesounynscilbcondcdvaviencaidadansedpanendedibcouiuedebmoatedMeintebe 3 1 3 Introductions to Shengnuo Group sessessesrsrrsrrsererrrsrrsrrseresrnsresreneresrnsrrnsresees 8 1 4 Development History Of VCP isiissis cctsasisannnnniniisnaraiamndasndiamani maaan 10 PART 2 THE INSTALLATION 65 cs ssvsnccsssisncesssvincnsstasensaviavnceansosvasancnvacnannberncerstnrnasaniande 12 2 1 The installation PFOCESSES siaininntrsnceiisaiounnsosnundsienisy srdvansnennesvierspanlnissuncaiddiivnnainnsivsinaigidah 12 2 2 TO POISE IAG EUNNG i ovicnacessavantesewsanetanaicin ba tewtannawnenisshashacaapapnedsuncabadtihndshodahedandsn arsenite 12 2 3 MAST AM ARI ON icsiccenssesnwnbecaiernracanceveusoncrententessceotntupbceuexwsaeaiedenhaouetenteatowaneaeuaumnencenctente 12
15. anual operation 6 1 3 2 1 Interlock of roller s prograde and rollback 6 1 3 2 2 When turn on acid pump the backflush valve and running water pump will be opened automatically and vacuum valve will be closed When open the backflush valve the running water pump will be opened automatically 6 1 3 2 3 The slurry in the slurry tank must cover the ultrasonic board the slurry is more than 68 then plug the ultrasonic producer to the power supply 6 1 3 2 4 Feeding and discharging are interlocks to each other 6 2 Electric drawing and relative information To know the electric control system well the relative information of electric drawing meters and control parts will be shown as follows 6 2 1 Electric principle drawing see Fig 6 2 1 6 2 2 Compilation of relative device s information 6 2 2 1 Introduction of UDK 201 G model electric level control UDK 201 G model electric level control is mainly used for controlling the feeding and discharging of running water and sewage 6 2 2 1 1 Working principle Auto control system consist s the connection of three terminals and transducer E1 E2 E3 three electrode sticks through the connection of three terminals and a engine s end 6 2 2 1 2 The working principle of UDK 201 G model Connect the coil terminals of electromagnetism switch A and terminal of connector pin through close touch point connect 220V AC 5 380V AC power be of no effect after the meter
16. ater 4 1 3 According to the graph as below take off the bolt firstly then screw off the nut and take out the Filter Plates horizontally from the fixed bolt 4 1 4 According to the Filter Plates s abrasion to fix and discard the boards 4 1 5 Installation is the other way round to disassembly to position the Filter Plates is according to the number of filling pieces 4 1 6 Refer to the dry Filter Plates after installation make sure the Filter Plates is completely wet before filtering 4 2 Adjustment of scraper 4 2 1 Release the locking bolt of the locking nut and adjusting bolt of the reversal bolt NO 4 4 2 2 To decrease the gap between the Scraper and the Filter Plates need to solid the adjusting bolt to increase the gap need to loosen the bolt the suitable gap is 0 5 0 8mm 4 2 3 After adjusting locking the nut and locking the reversal bolt gentlely 4 2 4 If the scraper and the Filter Plates are not parallel adjust by loosing the bolt NO 6 but make sure the dimension accord with the drawing then locking the bolt 4 3 Adjustment of distribution head 4 3 1 To adjust the pressure of the distribution head 4 3 2 Locking the nut make the spring s length meets the requirement 35mm to realize the adjustment 4 3 3 To adjust the position of the backflush 4 3 4 Loosen the bolt of the fan shape board turn the board to a certain position locking the bolt the best backflush position is the Filter Plates just pass the scraper
17. c box is Fan s engine is overloading 130 0 check fan s engine overloading or switch of switch of power is off 19A switch the power on 9Q power is off signal line is broken 5B6 check signal line s return circuit 5B7 21 Fan of electric box is Fan s engine is overloading 131 0 check fan s engine overloading or switch of powers switch is off 9Q switch the power on power is off signal line is broken 5B7 check signal line s return circuit Table 4 Error Checking List of Frequency Transformer Error No Error s appearance Key points for checking solutions When increasing speed transformer output Isit increasing speed Longer the time of speed 8 electricity cut off output suddenly is output short increasing circuit landing A When operation is even speed transformer Burden change suddenly or eliminate the burden s change 3 output electricity cut off output not is output short circuit ni landing a When the operation is lowing the speed Lower speed suddenly to Longer the time of speed transformer output electricity cut off operate is output short circuit reducing Ei output landing When increasing the speed because of Is acceleration too slow Decrease accelerating time recycled power make the main return DC 3 circuit s voltage is too high stop output E This situation also can happen when power system has voltage waves When operation is even speed because of Burde
18. ce Performance and Features 1 2 1 Performance a Vacuum gt 0 09MPa except for plateau area b Rotating speed of filtering disc 0 41 5s r frequency changeable stepless speed regulation c Rotating speed of agitating device 0 3 75s r frequency changeable stepless speed regulation 3 User s Manual Shengnuo Group d Pressure for reverse cleaning 0 06 0 12MPa continuously adjustable e Restore of filter plate function through reverse cleaning cleaning takes place once after each circle of rotation through combined cleaning ultrasonic and detergent that normally takes place once every 7 hours each time 45 minutes depending on characteristics of material and on technological process 1 2 2 Structural Features 1 2 2 1 Ceramic Filter Plate By utilizing the production technology of our patent the filter plate consisting of two pieces of cavity structures which is produced by mainly using corundum based material The process include raw material classification cleaning amp selecting mixing high accuracy molding through die stamping stage wise high temperature roasting repetitious painting of function layer cleaning amp choosing finalizing gluing performance testing packing and placing in storehouse Filtering tube Repetitious roasting and layer after layer painting are adopted Thus Gontiaation the arrangement of pores interior is big exterior is small normally with diameter of 1 0m is clear
19. ce valve Clear water Pressure 0 3 0 5 MPa is for allied wash solid content lt 5ppm Cleaning is 45min each time Consumption of water is 5 7 m per set each time the time and consumption are reference valve Acid for cleaning The concentration of nitric acid for cleaning is 30 40 and it will be diluted in the allied wash Cleaning is 45min each time The consumption of water is 20L per set each time the time and consumption are reference valve Ore magma s condition PH 1 12 temperature 5 10 C Hydrofluoric acid phosphoric acid hot alkali and organic solution are not allowed to be contained Vitriol is not recommended and kept away from chloride g Condition of environment Temperature 5 50 C water is strictly prohibited for electronic device h Storage condition for Vacuum Ceramic Filter Temperature 5 50 C Moisture lt 80 12 3 1 User s Manual Shengnuo Group PART 3 OPERATION Operation Panel 3 1 1 Switch of system operating method To choose the machine works manually or automatically according to program After connecting to the power or crush stopping the machine will be at initial state The operator can choose the operating method by press this button In normal situation after choosing to work automatically the equipment will start up roller stirrer filtering pump vacuum pump close discharging valve open feeding valve and be in work state If there is a problem in any step or part the
20. charging time is too small The discharge valve has not been closed The Slurry tank flushing washing pressure is insufficient The Slurry tank flush valve has not been opened return circuit of ultrasonic is broken o shock board s circuit is broken or short circuit producer s circuit is broken Filtrate pump s engine is overloading e Frequency transformer error I19 0 signal line 5A3 is broken operation signal of frequency transformer I18 not delivered PLC circuit is broken 5A2 o Frequency transformer is not working potentiometer VR2 s inner connection no good or broken Nothree item plug frequency transformer no power output Operation error of frequency transformer Operation signal l18 no delivered to PLC short circuit Frequency transformer error 121 0 Signal line 5A5 broken Operation signal of frequency transformer 120 is not delivered PLC circuit SA4 broken o Frequency transformer is not working speed setting potentiometer VR1 inner connection is no good or leading line is open o No three item plug frequency transformer no power output 33 Shengnuo Group check feeding valve and pipe check is there enough slurry set feeding time according to the actual needs Inspect the ore valve and its control air course Press the reset button start control power source or check KA return route Inspect the direct current power supply system
21. chine or start it up again When the pause switch is on to a normally working machine the machine will stop working for a certain period Meantime the roller vacuum pump filtering pump will be stopped feeding valve is open stirrer will work until the pause switch is off the machine will start to work again During the period of the machine works automatically if the alarm goes off the machine will be paused too In such case the operator need to re set the alarm by using the reset reposition switch and then use the pause button to start up the machine again The pause button will not working when the machine is starting up stopped and during the period of cleaning 3 1 4 Reset reposition button To set the alarm again Because of the machinery s failure or other failure make a warning of the machine stop working before you start up again you must fix the failure and reset the alarm by using the reset button then start up the machine 3 1 5 Crashstop button Crashstop the working program and empty the ore magma tank Because of any accident or particular operator can shut down the machine by using this button During the machine works automatically if the stirrer stop the system will be at the Crashstop state 3 1 6 Button of roller maintenance When checking and maintaining the roller and the Filter Plates the system is at manual or pause state to turn off the manual 13 User s Manual Shengnuo Group
22. clean without water in the slurry tank the water must cover the shock board then can connect to the power 3 Temperature of cleaning liquid cannot higher than 60 C 4 Ultrasonic producer s engine box must keep away from water very hot and causticity air 5 Ultrasonic transducer must be carried carefully cannot be crashed and shocked 6 The connection of shock board must keep dry and insulating 6 2 2 3 4 Maintenance of cleaning device 1 When slurry level reach 70 under manual operation state press startup of ultrasonic on the touch screen then it will work 2 There are two situations can cause ultrasonic producer shut down one is overloading instantly at moment turn off the power for a moment then turn on again will be fine If it is overloading all the time need to check the connection box carefully to see what is wrong the producer connection or shock board If is cable then dry it if is shock board then change it The maintenance must be done by a specialist 3 During the operation pay attention to the fan change it if it is broken 6 3 Electric errors After an error if it is not serious then the electric system will pause if it is serious then the machine will have a crashstop meantime the alarm JB will warn The operator can find out the reason of error from error warning record page on the touch screen then repair it If it is a regular error the problem can be solved according to the el
23. cleaning acid cleaning will be used too 3 5 How to cleaning By using the clean button to realize the cleaning when operator set this button at manual position the system will start to clean immediately when operator set it at automatic position the system will start to clean according to prearranged cyclical time When the machine is working automatically if starting to wash at this moment firstly the system will shut the machine down then empty the tank the actual cleaning will be started When the cleaning starts if the machine is manual state system will pass the shutdown step after flushing the cleaning progress will start sThe cleaning will accord with the set program include the method and the time of cleaning acid ultrasonic or allied cleaning the time setting need refer to the quality of cleaning staff and the cleaning result During the cleaning the PH on the Filter Plates needs to be check regularly PH 1 1 5 is OK if is not the volume of the acid supply need to be adjusted If the cleaning starts from the automatic state after cleaning finished the system will get into automatic startup start to work regularly if the cleaning starts from the manual state after cleaning finished the system will be back to 15 User s Manual Shengnuo Group manual working method When it is cleaning if the running water s pressure lt 0 3 MPa then there is a possibility of the strong acid
24. connects to the 220V AC power suppose the level is below E2 electromagnetism stick under this situation in the control cables the audion G1 connected G2 cut off so the electric relay will not attach Because of are the often close points the engine will start to work and start up the water pump fill the filtrate Tank at moment liquid level is raising and the green pilot lamp is on When the level reaches E2 the situation remains the same When the level reach E1 the electrode E1 E2 E3 will be on state at moment audion in the control cables G1 is cut off G2 is on state so the electric relay is not attached connecting Fig 6 2 1 Principle Drawings of UDK 201 G points change from often close point to often open point meantime through E1 E2 water resistance electric relay will lock itself water pump stops At this moment liquid level is 26 User s Manual Shengnuo Group decreasing the pilot lamp is red When the level reduces under E1 because of the effect of the self lock the situation remains unchanged When the liquid level is lower than E2 the control cable goes back to the last situation connection point change from often open point to often close point water pump start filling the can Under regular situation the liquid level should always be kept between E1 and E2 When the water is being discharged connect the coil terminals of electromagnetism switch to connector pin c
25. de domestically and abroad on the market through the comparative application in Fushun Hongtoushang Copper Mine Sichuan Huili Lead zinc Mine Jiangshu Weigang Iron Ore Mine Ansteel Wuyang Mining Company Shandong Lunan Mining Company Chengde Baotong Mining Jinchuan Nickel Industry and so on 1 3 2 1 Improvement of gas liquid distribution system Because the metallic materials have high density the filtering cake is easy to adhere on the filter plate with strong adhesive force high scraping resistance so the filter plate and Scraper bar are very easy to be damaged Meanwhile due to high hardness of metallic material the particles sucked into the pore are not easy to wash out and the reverse flushing in the production process is not as thorough as expected so after a cycle of operation the combined pickling and ultrasonic cleaning will not be desirable the filter plate will be blocked seriously the operation will be in abnormal conditions and the service life of the plate will be greatly reduced as time passes Additionally the distribution valve is added on the suck off pipeline to facilitate the customers to adjust the output and water content of the filtering cakes satisfying the demand of the customers 1 3 2 2 Improvement of mechanical structure There is a big difference between metallic ore beneficiation flowsheets and the properties of materials are quit different too In order to increase the adaptation of Vacuum Ceramic Filter
26. e 3 4 2 Press manual automatic button to shut down When the machine is working regularly set the manual automatic button in the manual position the machine will get into stopping program for details please read the automatic operation method after the stopping program ends the system goes back to the manual state 3 4 3 A short time shut down for maintenance To turn on the maintain button press pause to shut the machine down at moment all buttons on the control panel are locked except one which can control roller s direction and make the short time maintenance more convenient After the maintenance just switch off the maintain pause button then the machine will work again 3 4 4 Crash stop When the machine is working regularly after pressing crashstop button all the engines will be shut down After a short period the discharging valve will open and flush the tank solve the emergency Before starting up again unlock the crashstop button press the reset button to reset then choose a operation method to start up If there are any serious failure as follows a failure of starting up the stirrer roller and vacuum pump vacuum pressure has a failure stirrer has a failure 3 4 5 A long time shutdown Before the long time shutdown the machine needs to be cleaned completely and carefully especially the roller Filter Plates slurry ore magma tank and the automatic ultrasonic
27. e connection plate is welded onto drum body while the ceramic filter plate is mounted on the connection plate As a complete unit the main shaft with drum body amp connection plate is fabricated installed and calibrated to ensure the accuracy The rotator is made from No 304 material imported that reaches a service life over 15 years Ilate Main shaft Filtrate tube Drum body cone ion P Fig 2 2 Rotator Structures Filter below 60m adopts direct drive through driving device motor and reduction gear and rotator This kind of drive possesses the advantages of simple structure and reliable running Filter over 60m2 adopts such a drive driving device is put beneath main shaft soundless tooth form chain is used This kind of drive possesses advantages such as the arrangement is optimum the dimension of the filter is reduced the problems drive surface sealing is difficult noise is big wear of part is severe operating rate is low are solved The problems such as complicated maintenance difficult adjustment amp repair are also solved The design reduction ratio of drive system is 1 1003 Steeples speed adjustment 0 41 5s r is possible through frequency converter that can well meet customer s requirement of adjusting production indexes Motors and reduction gears belong to common equipment Manufacturing technology of such equipment in China is guaranteed Therefore it is unnecessary to import such equipment
28. e filtrate discharge valve and its pipeline Reset the value of filtrate filling the time until to the production actual value change the battery check pump s overloading check or change the electric relay check any missing item in contactor check signal in circuit User s Manual 7 10 14 16 Feeding time is too long warning Uncontrolled voltage warning The time of Slurry tank discharging air is too long warning The time of cleaning water too is long warning Ultrasonic cleaning effect is not good some or particular Filter Plates Filtrate pump s engine is overloading warning Error of roller s frequency transformer warning Roller s startup time is too long no signal response Operation error of roller s frequency transformer no signal response Error of stirrer s frequency transformer warning Starting time of stirrer is too long no signal response feeding pipe is blocked feeding valve is closed slurry feeding is not enough max feeding time setting is too short aleakage in discharging valve The systems control voltage has not attracted for the 1KA relay gathers There is something wrong with the Direct current power supply 18LQ system When cleaning the time of the Slurry tank discharging air is more than the definite value The row of ore valve has not been opened The Slurry tank air dis
29. e setting point the feeding system ultrasonic liquid meter need to be checked 3 7 2 Filter Plates During the operating and cleaning process Filter Plates need to be checked regularly if there are damages they need to be fixed immediately 3 7 3 Vacuum degree The vacuum degree determines the difference of pressure between filter cake and Filter Plates It is a main factor and to be checked regularly through reading the vacuum pressure s meter 3 7 4 Backflush pressure during the regular operating Backflush pressure during the regular operating should be 0 08 0 12 MPa if the pressure is higher than that adjust the pressure immediately to avoid the damage of the Filter Plates if it is lower check the filtering core is clean or not the pressure is normal or not the decompression valve is normal or not The reason of very low backflush pressure is the filtering core is blocked A standardization of checking the condition of filtering core is the different volume between before filtering and after filtering 3 7 5 Backflush pressure during startup and cleaning During the startup and cleaning the machine backflush by using running water the pressure before filtering should be 0 3 0 5 MPa if it is lower than that check the machine as follows the supply of running water is normal or not pipe pump is normal or not the filtering core is blocked or not 16 User s Manual Shengnuo Group 3 8 Touch screen Functio
30. ectric principle drawing and relative information 6 3 1 Parameter establishment of the filter machine on the touch screen Does a filter production craft parameter establishment whether related filter regular production these parameters establish are improper but also can have the breakdown Therefore time establishment parameter please refers to the following explanation to carry on The Explanation of a filter various electricity s parameter establishment 6 3 1 1 Vacuum Processing time Establishment scope 1 600 Second General Hypothesis 120 Second this value should be bigger than Filter Plates which Filled ore the time 6 3 1 2 Vacuum inspection time Hypothesis scope 1 60 Second General Hypothesis 20second 6 3 1 3 Extension of opening the ore Emitting valve Establishment scope 5 200 Second General Hypothesis 60 Second 6 3 1 4 the time of ore Emitting valve 30 User s Manual Shengnuo Group Establishment scope 1 30 Second General Hypothesis 2 Second 6 3 1 5 washing time of tank Establishment scope 1 30 Second General Hypothesis 5 Second 6 3 1 6 washing time of Pipeline Establishment scope 1 30 Second General Hypothesis 10 Second 6 3 1 7 the time of filling the Cleaning water Establishment scope 1 30 Second General Hypothesis 10 Second 6 3 1 8 the time of washing and Discharging the air Establishment scope 1 30 Second General Hypothesis 30 Second 6 3 1 9 The time of filling the filtrate Establ
31. een the ultrasonic cleaning time should be 5 10 min longer than acid clean The actual setting is according to actual situation a Caution The remaining time for next cleaning on this page shows the remaining time and is not for setting The self cleaning time gap 8 hours cleans take each work period as suitable Fig 6 1 7 Password Input Screen 6 1 1 2 8 Setting of cleaning time and method When the cleaning method does not choose the clean procedure can not normally carry out When choice when touches the acid cleaning with the finger or the ultrasonic wave the circle diagram frame attempts the frame to white for selects this cleaning method touches again attempts the frame to change darkly for cancels this cleaning method 6 1 2 Filter machine s operation 6 1 2 1 The preparation for starting up First closes left side of the electricity cabinet the main power switch Q transforms in paraneter enter the cabinet gate the change over switch HK observes the voltmeter V whether three phase voltage reading is normal Observes on the manostat the voltmeter and whether the indicating lamp is normal After normal release the crashstop button on the ign mite cle operation panel 4SB according to the replacement the button 2SB this time in the x remainin cabinet control power source then starts puts through After connecting to the power time te Peit gt auto clean then start up and ope
32. eturn route leads the way Vacuum degree is not enough The filtrate discharge valve has not closed strictly The filtrate fills the time Supposes the definite value too small smaller than fact production situation Electrical voltage in the PLC power source is low vacuum s engine overloading electric relay broken any missing item in power supply signal line short circuit 32 Table 3 Questionnaire of electrical system s error Opinion of dispose Inspect whether the vacuum pipeline the ceramics filter the board leaks air filtrates the opening on the vacuum degree regulating valve to is too big Check table pitch point and its line According to produces the actual situation to enactment this value generally for gt 0 7 Pakistan about Once enactment This time should be bigger than for the ore arrives the pulp cover ceramics filter the board the time When the tank does not have the pulp you should inspect gives the ore pipeline Change or inspect the air passage of the valvet Clean the contamination between the electrode The electrode flange plate wiring column scours the water change SW1 Inspection filtrate discharge valve and pipeline inspects whether there is the vacuum degree and the Aspiration pipeline Inspect the electrode and the segment or the electrode controller SW3 e Inspect vacuum return route the discharge valve on the filtrate pot Inspect th
33. fing 6 3 2 2 When cleaning the machine please pay the most attention to keep the electrically controlled cabinet the box the part on the operating box board away from the water In order to avoid the nonessential losses 6 3 2 3 Keep dustproof away from electrically controlled cabinet battery case 6 3 2 4 The filter production environment is worse some many electric conduction dust Therefore in attention regular cleaning up electrically controlled cabinet battery case electrical part dust This is very important General a month cleans up a time specifically regards the production environment dust size to deliberate 6 3 2 5 The cleaning of Filtrate Tank s power connection port 6 3 2 6 The electricity pitch point fluid position control electrode is the stainless steel stick center the lower extremity with the insulation Porcelain isolation the time steadily in the filtrate dressing medicine fluid has been able to 31 User s Manual Shengnuo Group deposit on the electrode the insulation Porcelain on on the electrode root s insulation pole like this can cause between the electrode to short circuit creates the vacation fluid position signal Therefore must regularly clean up this electrode the concrete time visible pulp nature deliberates General the magnetic separation pulp a month cleans up a time chemistry elects pulp 20 day to clean up time 6 3 2 7 Maintenance of Ore tank liquidometer The measurin
34. flows into the Filter Plates so checking the relevant link and take a action to the problem are necessary after regain the hydraulic pressure then start to clean 3 6 How to stop cleaning If need to stop the cleaning process can set the cleaning method at manual position the cleaning process will be stopped the machine will wash out the acid on the Filter Plates then goes back to the initial state Refer to the crashstop of the acid wash the machine will warn acid not cleaned reset or clean at moment if the water pressure has no problem can reset alarm start up automatic operation If there isno other choice but to stop the machine operator must wash out the acid on the Filter Plates and in the slurry tank by manual control The steps as follows 3 6 1 Turn the roller manually 3 6 2 Hand open the backflush valve of the running water 3 6 3 Check the backflush pressure it should be 0 08 0 12 MPa 3 6 4 Open the flushing valve of slurry tank to clean for 3 min 3 6 5 Backflush must last at least 10 min 3 7 Checking and Ajustment during operating and cleaning 3 7 1 Ore magma s level To keep ore magma s level in a certain height is very important the higher level the longer time for producing the filter cake the higher production and the moisture of the filter cake will also increase Using the touch screen to set the liquid level and the delayed reaction if the liquid level is different from th
35. from foreign countries Motors and reduction gears made by great enterprises in China can provide perfect operation performance good reliability amp interchangeability and also remarkably save customer s cost for maintenance amp repair 1 2 2 3 Distributor u Piping for The distributor is designed to have slurry absorbing zone drying zone suck dry Distrib Bracket reverse cleaning zone and pre loosening zone behind suck dry zone The advantage of pre loosening zone is Before the cake reaches the position in front of scraper the vacuum is disappeared thus the resistance for scraping is diminished and the friction force between scraper cake and filter plate is reduced Thus the service life of scraper and filter plate is prolonged and the thorough scraping out of cake is ensured Besides the reverse cleaning Piping resistance becomes small and the restoring of filter plate function can be well reverse iping for cleaning slurry sucking carried out All these are favorable for increase of equipment operation Fig 2 3 Distributor Structure capability and improvement of other production indexes The distributor is supported by bracket having double support points Compared with cantilever support the double support points bracket has the following advantages support force is distributed evenly static and dynamic discs of 5 User s Manual Shengnuo Group distributor are ma
36. g rod of the ore liquidometer measures is inserted in ore magma it measure the capacitance between the material and the pole which if contacts comes indirectly to reflect the material the altitude Therefore must pay attention This surface of pole should not have the powdered ore and so on after cleaning this pole should not be buried by slime You should pay attention to the production and must wash the pole regularly In order to avoid produces the false signal NO Indicated Errors 1 Reports without the vacuum 2 filtrate pot the high spacing warning 3 The filtrate surpasses the low spacing warning 4 the time of the filtrate fills is too long warming 5 The PLC memory electrical voltage is low warning 6 Vacuum overloading warning Analysis of the error The vacuum pipeline and the system leak air The power connection of vacuum meter is not stable often opening point is closed or shaked or the holding wire is separated The value of the vacuum is too high the parameter establishment is inappropriate or the Slurry tank does not have pulp causing by the failure filtrates discharge valve wrong signal High spacing electrode leakage The electrode controller SWI loses control The filtrate discharged valve has not been closed strictly There is something wrong with the vacuum or attracts attracts the thick liquid pipeline The low spacing the electricity pitch point electrode r
37. han 5 years In the design of energy converter all unfavorable working conditions are considered Full coverage and no dead corner cleaning of filter plate is ensured The casing of energy converter is made of stainless steel that is wear resistant and corrosion resistant 1 2 2 7 Automatic Control System The automatic control system consists fully of imported PLC elements and electric actuating parts The programs for control are optimized reasonably that allow both automatic operation and manual operation thus the manipulation is easy and flexible Slurry level filtrate level pump s operation state and valve s operation state can be directly amp visually displayed There is long life amp convenient light touch keys for sending commands Frequency changeable stepless speed adjustment for rotator and agitating system is stable reliable and of energy saving type Troubles amp failures of equipment can be displayed at any time with complete information The switch for trouble shooting allows positive amp negative rotating of rotator that provides Fig 2 7 PLC System convenience for maintenance amp repair and is favorable for increase of operating rate The automatic control system is equipped with the followings vacuum protection to avoid trouble expansion belt interlocking to prevent trouble transfer temporary stop switch amp emergent stop switch to facilitate maintenance amp repair and treatment of emergenc
38. hine follows the contrary steps 2 2 To hoist machine After the equipment is delivered to the work place choose a matching crane according to the weight of the equipment then hoist the machine by hooking the lifting bolt on the machine Keeping the balance and even the speed is necessary during the process 2 3 Installation a The installation needs conform to the actual circumstance The pipe s drop in level and slope should satisfy the demand of feeding discharging overflowing and so on meantime the convenience of discharging transportation space for operating testing repairing should be considered b The foundation of the machine can bear the weight of the machine and a certain degree of shock proof c The bottom of the machine should have at least 1m high space d The filtering pump should be installed 3m lower than the bottom of the machine e All the leg like supports must be on a horizontal surface The error of the height of both rollers ends should be less than 2mm f To ensure the machine works regularly and efficiently the following conditions are required Compressed air for VCF Pressure 0 5 0 7MPa Maximum of instantaneous consumption of air 40m h diameter of solid lt 5um Circulating water Pressure 0 5 0 7 MPa is for sealing the vacuum pump s water ring cleaning the ore magma tank Cleaning is 20min each time Consumption of water is 6 8m per set each time the time and consumption are referen
39. ice The function of ultrasonic producer is to change the power supply of regular frequency 50HZ into the power supply of ultrasonic wave 25KHZ Transducer is provided This device use the modern electronic technology the inverter circuit use new model switch IGBT Circuit is more stable and reliable System has overloading protection delay power supply and power stable Transducer The shell of transducer is made of stainless steel take the argon arc welding to make the sealed shell resonance is installed in side shell Transducer is transform the ultrasonic into mechanical oscillations then transmit to cleaning liquid 6 2 2 3 2 Working principle of ultrasonic cleaning device Ultrasonic cleaning device is to use higher than 20KHZ frequency through transducer to transform high frequency mechanical oscillations to cleaning liquid In the cleaning process high and low frequency ultrasonic radiate in turns make the liquid flowing and produce many mini bubbles These mini bubbles can produce high pressure suddenly and continuously bombard 29 User s Manual Shengnuo Group object surface and the dirty mark in the blind side constantly quickly peeling off This kind of function calls to get empty to turn erosion function the super voice wave makes use of this kind of function realization to clean function 6 2 2 3 3 Introduction and notice 1 Voltage is 220V 50HZ 2 Cleaning liquid must be added strictly prohibit to
40. ighest and lowest value or control value on the interface Continue value or switch value 1 or 2 e J J Interface output value two lines 4 20mA or work place display e Choose roof position and inner wall installation method 2 6 2 2 2 4 technological Regulations 28 User s Manual Shengnuo Group 9060B meter s two lines 4 20mA s loading can be 10000hm deliver distance can be 1 km Precision is 0 5 the switch output can indentified as single and two points electric relay output Transducer structure can be hard stick and soft stick can choose install from the top or one side 9060B staff level meter s head should be in the circumstance of lower than 200 C 10Mpa transform parts is between 30 C 60 C 6 2 2 2 5 Regulated program Instrument in the lab has been determined At work place if the difference is too big then needs indicate again steps as below 6 2 2 3 1 After installment check the connection line 2 Adjust the liquid level to zero adjust potentiometer PZ 102 make the output is 4 00 mA 3 Adjust to a certain level for example 50 adjust PS 104 4 Potentiometer make the output is 12 00MA 5 Adjust the liquid level to zero if there is a error then repeat the step 2 3 Introduction to ultrasonic cleaning device 6 2 2 3 1 The structure Ultrasonic clean devices include power supply and transducer 2 Fig 6 2 3 Principle Drawing of Ultrasonic Cleaning Dev
41. ile the ultrasonic in regular thin to dense amp dense to thin change radiates forward in the detergent the detergent flow generates tens of thousands of micro bubbles The micro bubbles existed in detergent oscillate under effect of sound field 6 User s Manual Shengnuo Group As the sound pressure reaches a certain level the micro bubbles expand quickly Power supply box Energy converter until they abruptly shrink The abrupt shrinkage of micro bubbles generates shock wave producing thousands of atmospheres which break the non soluble matters adhered on filter plate surface and make the matters be distributed in detergent Under effect of shock wave the particles stopped in pores of ceramic filter plate are also separated from the plate thus the plate is cleaned In the design of power supply box the followings are adopted world advanced integration technique high power metallic oxide semiconductor field effect Fig 2 6 Ultrasonic Cleaning System transistors MOSFET pulse width homogenizing PWH technique voltage controlled oscillators VCO x band microwave transmitters XMT Protective measures in relation to overload over current over voltage under voltage and soft starting are provided to electric loops Voltage in a wide range of fluctuation can be used safely The manipulation is very easy Field effect transistors and integrated circuits are made from elements amp parts imported that can last for more t
42. ilot lamp 1H is on it means the system is in automatic processing During the production the situation can be known and controlled through each meters and touch screen The situation of the close open of all pipes the level of filtrate tank and slurry tank and the feeding valve can be known in the production state and input output page Automatic clean turn the cleaning method 2SA to the right In the leaning nethod l tine stting ain automatic processing after the machine reach the setting time system will acid ultrasonic clean itself and goes back to the auto working process after the cleaning acid time Semi auto cleaning in the auto working process can get into the semi auto cleaning any time At moment can turn the clean method 2 eeding deviation highest slrry S A to the left the cleaning pilot lamp 4H is on system gets into etting semi auto clean processing and the whole processing is same to the auto one When the cleaning finished the system will go back to the manual Fig 6 1 10 Cleaning amp Time Setting state Automatic shutdown in the auto workin rocess turn the clean Manual operation amp g P clean pladning setting miin startup 1 S A totheleft the manual position system gets ERETT vacuum filtering roller pump pump into automatic shutdown state Stop feeding discharging and i closing all pumps and valves If want to work again m
43. ing strength causing low pressure lt 0 12MPa by higher pressure the plate will be broken for reverse cleaning that is very unfavorable for restoring of plate function through cleaning Thus the capability of filter is low that causes increment of filter numbers which means high investment and high operation cost for customer The ceramic filter plates produced by our plant have been proved as successful in many beneficiation plants treating ores of copper lead zinc iron silver sulfur gold etc The filter plates are of high strength easy to be cleaned for restoring of plate function The maximum pressure for reverse cleaning reaches 0 3MPa that increases the performance of reverse cleaning amp combined cleaning and raises remarkably the operation indexes of the filter The service life of the filter exceeds 2 years that saves the investment amp operation cost of customer In Fushun Hongtoushan Copper Ore Mine of Liaoning province Weigang Iron Ore Mine of Jiangsu province Baiyinnuoer Lead Zinc Ore Mine of Inner Mongolian province and Huili Lead Zinc Ore Mine of Sichuan province the Vacuum Ceramic Filters made by our plant have successfully replaced the unsatisfactory filters made by other plants 1 2 2 2 Rotator User s Manual Shengnuo Group The rotator consists of main shaft drum body connection plate and rotator s drive The main shaft is welded with drum body as a unit The inside is supported by multiple structures Th
44. ishment scope 1 1800Second General Hypothesis 300 Second 6 3 1 10 Max slurry feeding time Max filling time Establishment scope 1 200Second General Hypothesis 30Second 6 3 1 11 Slurry tank lowest fluid position of Slurry tank Establishment scope 0 25 General Hypothesis 10 6 3 1 12 the fluid position of ore tank discharging Establishment scope 20 60 General Hypothesis 40 6 3 1 13 The biggest fluid position hypothesis of filling the ore Establishment scope 40 96 6 3 1 14 Deviation amount hypothesis of filling ore Establishment scope 1 20 6 3 1 15 acid cleaning Establishment scope 1 120 General Hypothesis 4oSecond 6 3 1 16 Ultrasonic cleaning time hypothesis of Ultrasonic Establishment scope 1 120second General Hypothesis 50second 6 3 1 17 The supposes fixed point of self cleaning supposes Establishment scope 1 350hour General Hypothesis 7hour 6 3 1 18 purging method designation of cleaning You can choose two purging methods If you don t choose one the clean procedure will enable to carryout paying attention 6 3 2 Electrical maintenance The daily maintenance of electrical system is very important regarding filter electricity asks the user not to neglect In the electrical system the application electric control part maintenance reference to the factory instruction there are several opinions to refer 6 3 2 1 The waterproofing of electrically controlled cabinet and electrically controlled box waterproo
45. l increase in the performance so we own independent intellectual property right on the product The third generation of Vacuum Ceramic Filter is to optimize and improve the overall structure of the existing Vacuum Ceramic Filter according to the characteristics of iron concentrates in order to make the filter fully meet the requirements of iron concentrates filtering and to upgrade substantially the technical performance The application of Vacuum Ceramic Filter in domestic metallurgical mine started from Guangdong Fankou Lead zinc Mine They first imported the filter in 1995 and then other enterprises like Hongtoushan Copper Mine followed Just from then on the domestic Vacuum Ceramic Filter makers started to develop Vacuum Ceramic Filter There was almost no trouble for Vacuum Ceramic Filters developed by others and used directly in the ferrous metallurgical mines because of location of the factories Their products are sold mainly to the ferrous metallurgical field without much change But it is different with our situation The nearest enterprise is Ansteel and all beneficiation plants are of iron ore beneficiation Our first customer is Donganshan Sinter Plant Due to the fine disseminated grain size of iron material and direct floatation with fat acid the floatation concentrates are fine slimy and sticky and difficult to filter causing high water content of filtering cake serious loss of metals pollution of surroundings and bad quality of sinte
46. ltrate Discharge System 1 To be connected with suck dry pipeline distributor 2 connected with slurry sucking pipeline distributor 3 Filtrate 4 Vacuum pump 5 Filtrate tank 6 Anti corrosion chemical pump 1 2 2 10 Slurry Tank and Framework The shape of slurry tank is designed as per filter s working principle and per agitating system s moving track with the goal of reducing material s settlement In the design static and dynamic loads are systematically analyzed According to careful calculation the structural form and material specification are determined Besides the slurry tank and framework are integrated together as one unit through a reasonably designed supporting plate thus providing robustness and reliability The slurry tank is made of 5mm thick No 304 stainless steel providing a service life more than 15 years 1 2 2 11 Advantages in the aspects of technical development application and popularization of Vacuum Ceramic Filter Shengnuo Group has developed second generation of Vacuum Ceramic Filter characterized by better performance and wide utilization using the internationally advanced ceramic technology depending on the domestic technical forces of tens of scientific and research institutions including Tsinghua University and combining with the properties of all kinds of filtering materials and technological conditions The filters have been used in more than 30 enterprises all over China covering the materials of
47. material properties had brought a great difficulty to the Vacuum Ceramic Filter At the first the agitating system was overloaded within short period of time the agitating rake was unable to move due to pressing down We immediately modified the matching power transmission method and installation mode of the agitating system This problem was solved but the other one came Because the iron concentrates have high density the adhesion on the surface of filter was very high so the scraping resistance is high thus causing serious damage of filter plate and Scraper bar and further causing unsatisfactory reverse flushing and unexpected availability of the Vacuum Ceramic Filter Through repeated practices a pre fluffing mechanism was added to the distributor in the design in this case filtering cake would be fluffed before touching the Scraper bar The second problem was solved and came the next one which is a problem of filter plate of the Vacuum Ceramic Filter As the core components of the Vacuum Ceramic Filter much more concerns were given to it However we took roundabout course at the beginning of the development At that time we worked with several experts of silicon carbide and refractory and spent a long time to determine the recipe and production process The samples were sent to Hongtoushan Copper Mine for test the technical performance was not so bad but there existed many problems like uneven distribution of material on the filter surface sc
48. n can unlock the system system works again 3SB Method optional switch Left is operate Right is maintain Use for switching the between automatic operating and roller s maintenance Before the roller works right turn the switch start the roller s maintenance function at moment can switch the roller maintain 3SA to prograde or rollback When the machine is working press pause button 1SB to pause the machine then right turn the method 3SA the machine will go back from the operation process start the maintenance function at moment use 3SA to prograde or rollback When the maintenance finished switch it back to the left press the reset button again the machine will resume to work When the switch is at maintain method other buttons on the touch screen will be disappeared 4SB System crashstop button Use for crashstop the working machine The button is mechanical self locking button can be released by turning right When it is pressed it will cut off the power supply 3SA roll maintain switch Use for switch the roller between prograde and rollback This switch will only work when the method 3SB is at maintain position right VR1 stir speed adjusting potentiometer use for adjusting the stirrer s working speed VR2 roll speed adjusting potentiometer use for adjusting the roller s working speed 1 2H manual pilot lamp when the lamp is on
49. n Limit Unit Setting Min Max Roller s startup amp shutdown manual control Stirrer s startup amp shutdown manual control EE Vacuum pump startup amp shutdown manual control Filtering pump startup amp shutdown manual control Discharging valve of slurry tank off on manual control Discharging valve clean off on manual control off on Backflush s filtrate valve off on manual control off on Backflush s running water valve off on manual control off on Feeding control valve 40 96 Cleaning method acid clean no yes yes Cleaning method ultrasonic no yes yes Time setting acid clean 1 120 min 45 Time setting ultrasonic 1 120 min 50 Feeding valve off on manual control off on Flushing valve of slurry tank off on manual control off on Vacuum pipe valve off on manual control off on Filtrate discharging valve off on manual control off on Ultrasonic off on manual control off on Acid pump startup shutdown manual control off on Warning records finding off on Auto wash circulating setting point 1 350 hour 7 Auto wash circulating circulation time hour 7 Alarm goes off checking impulse off on Alarm s lamp flash checking impulse off on Actual volume level of slurry o 100 Actual pressure of backflush optional o 40 0 1pa Working hour of automatic method
50. n is change greatly or eliminate the burden s change A recycled power make the main return DC not according to needs to use 3 circuit s voltage is too high stop output brakes or increase the E This situation also can happen when power power FR HC system has voltage waves 34
51. ner wall must have at least 100mm gap if there are two level controller in one container the gap between two electrode sticks must more than 300mm Avoiding juxtapose controller and electromagnetism switch Especially separate the meter and power line and high pressure line to avoid interference 6 2 2 1 5 Maintain Electrode stick in the liquid should be cleaned every six months with sand paper to clean electrode stick To avoid the resistance is too high check the stainless steel s electrode is solid or not and the electrode and container inner wall s insulation 6 2 2 2 SENS9060 shockproof meter introduction of switch 6 2 2 2 1 Summarization SENSE9060B shockproof meter is use for measuring oil water and powder this instrument indentifies as continuing volume and switch output reducing the effect of flowing temperature and media greatly making use of radio frequency and measurement of capacitance technology together and making the compound electric capacity of lying the quality opposite with the height of thing single 6 2 2 2 2 Drawing of structure and principle See Fig 6 2 2 1 Sor 24 VDC 2 Sia T 2avpc ee DN50 BR HAAI Sek Hot BT PN16 BR PN25 EEES Fig 6 2 2 Connecting Terminals 6 2 2 2 3 Considerations for choosing a model Temperature scope and pressure inside tank Tank height material conductor or not any holes on the inner wall and placket s measurement H
52. o hour The last date time and method of cleaning Vacuum working time 1 120 1sec 120 Vacuum checking time 10 200 0 1sec 200 Delayed opening of discharging valve 5 200 1sec 60 Flushing time of discharging valve 1 30 Min 2 Flushing time of slurry tank 1 30 Min 5 Flushing time of Filter Plates 1 30 Min 10 Max filling time of slurry tank 1 30 Min 30 Max empty time of slurry tank 1 30 Min 30 Max slurry feeding time 1 30 Min 30 Max filling time of filtrate tank 1 30 Min 5 Max pressure of backflush optional 0 1pa Setting point of tank s lowest level o 10 10 Setting point of filtering level 20 60 60 Resetting time for operation 10 6000 01sec 1200 Set word of command o No word of command o 32767 Table 2 Functions on Touch Screen 17 User s Manual Shengnuo Group 3 9 Operation notice 3 9 1 The condition of regular operating 3 9 1 1 Pressure of air supply 0 5 0 7Mpa pressure of feeding discharging and drain valve 0 1Mpa 3 9 1 2 Pressure of clear water for back washing 0 3 0 5 Mpa 3 9 1 3 Pressure of mineral chute water 0 5 Mpa 3 9 2 The problems need to be checked and solved during the production 3 9 2 1 The operator cannot do manual operation unless knowing the working principle and process very well 3 9 2 2 Adjust the vacuum s water volume the water volume can be determined from the sound of the vacuum pump the condition of air and the vacuum degree The louder of the n
53. oise means too much water the vacuum degree is less than 0 08 Mpa means water volume is too small 3 9 2 3 Stirring frequency should be adjusted to 24Hz rolling speed should be adjusted according to concentration of slurry and thickness of filter cake 3 9 2 4 Checking the condition of the distribution head using lubricant to lubricate every work period 3 9 2 5 Check the lubricant cup every work period ifthereis a shortage fill up at once 50 engine oil 3 9 2 6 Check the backflush pressure before and after filtering when the difference exceeds 0 1 Mpa means the filtering core for backflush is blocked should be changed 3 9 2 7 Always check the conveyer belt the conveyer belt stops the filter machine shuts down 3 9 2 8 Check the accumulation of ore on the scraper and the discharging groove clean them in time to prevent the damage to the scraper 3 9 2 9 If there is any ore magma in the groove when manual operating turn on the stirrer to prevent the deposition 3 9 2 10 If there is a necessary to crashtop or pause firstly increase the rolling speed after the filter cake is thinner then crashstop or pause 3 9 2 11 Operator check the temperature and the sound of engine every work period if there are any errors must be solved and reported in time 3 9 2 12 Operators check all the valves to see will they be opened nimbly every work period 3 9 2 13 If the machine stops for 30min or above caused by failures or othe
54. onnect to power by connector be of no effect At this stage the working process is when liquid level reaches E1 electric relay is attached connection point will cut off water pump start to discharge When liquid level reaches E2 connection point will be connected water pump stops discharging and continue to repeat this cycle 6 2 2 1 3 Introduction of UDK 201 GH model electric level control After the meter connect to the 220V AC power suppose the liquid level is under E2 under this situation the electroded will not be connected amplifier s audion G1 cut off G2 connected electric relay attached terminals will close the engine starts up the water pump to fill the can At moment the level is raising and green pilot lamp is on When the liquid level reaches E2 the situation remains the same When the level reaches E1 E1 E2 E3 the electrode is connected by the liquid G1 connected G2 cut off electric relay released connection points will open water pump shuts down When the level reduces below E1 because of E1 E2 water resistance between the electrodes are self locked water pump remain stop The pilot lamp is red When the level is lower than E2 G1 cut off G2 connected electric relay connected connection points are closed control cables go back to the last state water pump start to filling the liquid can again In normal condition the liquid level is always kept between E1 and E
55. r Before technical modification iron concentrate filtering of Donganshan Sinter Plant was an internationally difficult problem in the beneficiation circle Many scientific research institutions at home and abroad 10 User s Manual Shengnuo Group have done a lot of test on the filtering of iron concentrates of Donganshan Sinter Plant with disc filter and disc press filt er In 1998 Outokumpu did the test with Vacuum Ceramic Filter in Donganshan Sinter Plant but the results were not satisfactory Donganshan Sinter Plant has been using the complicated thickening and filtering flowsheet with three stages thickening and two stages filtering to maintain the production However with the development of steel enterprises the existing problems have already affected the normal operation of Ansteel The management of Ansteel had several meetings with the final resolution of stop operation of the plant Facing this situation Donganshan Sinter Plant was more than happy to accept the new technique and new equipment Through discussions the agreement for commercial test was reached But the tribulation started after we sent our prototype machine to the site and installed it and commissioned Comparing with nonferrous concentrates the iron concentrates has high density and high hardness Because the magnetite concentrates with coarse size and fast settling speed from No 2 beneficiation workshop was filtered joining with floatation concentrates the complicated
56. r change engine coupling pump s engine 2 check electromagnetism valve and startup system 3 check or adjust water pressure 4 change the broken parts 1 repair amp change electromagnetism valve and air valve 2 resupply the water 3 repair amp change the broken parts Repair change 6 1 PART 6 ELECTRIC CONTROL SYSTEM Operation of electric control system 6 1 1 Operating introductions on electric component 6 1 1 1 Introduction of system s operating panel 1SA Startup switch use for choosing the working method of electric control system There are three positions left is manual middle is vacant right is auto 2SA Optional switch of cleaning method use for choosing the cleaning method There are three positions left is manual middle is vacant right is auto During the filter machine s working period left turn the switch the u system gets into semi automatic the pilot lamp 4H will be on During the working period right turn the switch switch locked system starts counting time automatically and will clean automatically according to the time setting 1SB pause button press once the system will be paused press again the system will work again This button will only work when the machine is working automatically 2SB reset button when the operation is starting press this button can start up the power supply after fault clearance press this butto
57. r electric relay no working 2 discharging valve is not closed 1 filtrate pump no working 2 discharging filtrate too slow 3 electrode out of control or electric relay no working 4 filtrate pump s discharging valve is not open Electrode amp electric relay no working 1 check the vacuum pump is working or not 2 check the valve of the filtrate Tank is normal or not 3check water sealing is normal or not 4 check pipe filtrate Tank distribution valve and fix the leakage 5 check leakage on Filter Plates 6 check pressure gauge 7 check discharging valve of filtrate canis closed or not 1 cleaning valve is not open 2 no water supply 3 sewage s discharging valve is not closed Liquidometer no working Fault clearance Check repair or change it Check repair or change it Check repair or change it Off and on the power reset if it continue to warn check the engine and frequency transformer Repair or change it Repair or change it Off and on the power reset if it continue to warn check the engine and frequency transformer 1 repair amp change the electrode or electric relay 2 check amp repair electromagnetism valve and pellet valve 3 fill half of filtrate tank then start up the filter machine 1 repair or change the engine or pump 2 adjust the adjusting valve on the filtrate pump 3 repair amp change the electrode or electric relay 4 repair discharging electromagnetism or pellet valve 5 half the filtrate Change them 1 repai
58. r reason the machine should be cleaned by allied wash firstly to prevent the Filter Plates being blocked 3 9 3 Combined wash 3 9 3 1 When empty the slurry tank and clean it check the accumulation of ore magma if there is any need to be cleaned assistance with hands Every time when you wash it the liquidometer on the bottom must be cleaned 3 9 3 2 Before cleaning make sure there are acid in the acid can dilute the acid according to the concentration the acid concentration should be 30 40 and not allowed to be more than 40 When adding and diluting the acid must pay attention to the safety wash the spattered acid on the skin immediately 3 9 3 3 No matter the manual or automatic wash pay attention to the water level in the slurry tank before startup the ultrasonic wash the water level must be over the Filter Plates 3 9 3 4 Check the acid degree on the Filter Plates PH 1 3 if it is necessary adjust the feeding volume of acid accordingly 3 9 3 5 Interrupting the cleaning process caused by a failure the Filter Plates and the slurry tank should be cleaned by hand 18 User s Manual Shengnuo Group PART 4 MAINTENANCE Before maintaining make sure the machine is at the shutdown or maintenance stage 4 1 Changing and adjusting the Filter Plates 4 1 1 Setting the machine at maintenance stage at moment manually control the roller rollback 4 1 2 Clean the Filter Plates which is going to be removed and its surroundings by w
59. ratches in the surface by coarse size particles angle of rupture falling off of surface layer difficult cleaning and restoration for the iron concentrates of Donganshan Sinter Plant Under this circumstance we worked with the reputable and most senior professors of National laboratory of Tsinghua University and jointly tackled the key problems Through thousands of tests we selected the recipe of high strength high percentage of opening area even distribution and easy for cleaning and restoration from dozens of recipes meanwhile we improved the equipment and modified technological process finally the problems of the filter plate were solved At the same time we changed Siemens PLC of serial S7200 into the products of GE or Schneider changed ultrasonic level meter into radio frequency level meter and changed all electrical elements into Schneider s product thus enhancing the anti interference ability of the overall control system and further working reliably and smoothly In order to avoid flowing back of slurry to damage other completing equipment when the non return valve fails one more pipeline was added to make operation of the filter even safer Additionally we modified the scraping mechanism and simplify the overall structure so that it is not only simple and neat but also easy for adjustment All in all the project of Donganshan Sinter Plant was a litmus test for us in developing the Vacuum Ceramic Filter We have stood up the test and taken
60. rate the machine according to production 6 1 2 2 Manual operation 6 1 1 2 1 Turn startup to the left manual the pilot lamp 2H is on system get into manual operation method The manual operation of the Bue clischa electric system must be worked under this situation 6 1 1 2 2 To operate by pressing the buttons on the manual operation and cleaning setting on the touch screen C M P during the operation pay attention to the closing of pipe s valve and the operation should be Helay discharging pipe clean according to the handbook Caution when finishing the manual operation all the buttons on each page should Fig 6 1 9 Parameter Input Screen 2 cut off and then select the switch to change to another operation method During the manual operation press crashstop 4S B everything will be stopped But must cut off all the touch buttons on the screen before release the crashstop button otherwise the machine will continue to work the accident can be occurred 6 1 2 3 Automatic operation 24 User s Manual 6 1 2 3 1 6 1 2 3 2 6 1 2 3 3 6 1 2 3 4 6 1 2 3 5 2 Shengnuo Group How to start up the automatic operation release the crashstop 4S B check the air pressure conveyer belt and the preparation of all pipes When they are ready can turn the startup to the right then the machine will start working automatically After starting up the machine the p
61. ress the i crashstop the often opening point is cut off so when the crashstop is dark it high working low acid pump i int j a zci mno vacuum Jey level level overload means this point is cut off 18 0 The others are the same acid pump over loading is connected to the overloading protection point of hot electric relay 6RJ often IEE MT ubo TS rolle roller sStirrerstirrer s olling error rolling error Dark means it is cut off the engine is overloaded other protection roller error opening point when it is white means this point is connected the engine is normal gt R gr i stirrer error white are normal After starting up they are still dark means error icture turns intu white means connected Fig 6 1 4 PLC Input State 1 Output state part When the circle is white means the machine is connected and working Example vacuum valve change into white means connected to the power at moment the vacuum valve is closed Discharging valve is closed when it is connected to the power opened when it is not 6 1 1 2 4 Filter machine s working state page State di splay main When it shows auto operation means the machine working automatically Acid high working low cleaning time shows the remaining time in the acid clean filtrate filling timer leve level leve 2 Mula 9 a gt amp gt amp shows the time of the filtrate level raise to the working le
62. system will stop starting up the program and go back the manual state Refer to the working filter machine operator can shut the machine down by setting the auto manual at manual Then the feeding valve will closed the machine will keep working till the slurry reduce to a certain level After cleaning the discharging valve the discharging valve will open After the ore magma tank is empty the engine will stop the cleaning valve will open and clean the tank the machine will stop after cleaning then discharging valve is open the system is at manual state 3 1 2 Switch of Filter Plates cleaning To choose the cleaning will be the manual method or automatic method according to program No matter the machine is at manual state or auto state the operator just need to set the switch at manual position the machine will start cleaning immediately If the machine is working automatically firstly the automatic working will stop then empty the tank and clean it if it is working manually the machine will pass the stop step after cleaning the tank then start to clean the Filter Plates When you set the Filter Plates cleaning in Auto position if the machine is at automatic working state the machine will not start to clean automatically till the circulating time is finished If the machine is at manual state the machine will pass other steps to clean the Filter Plates 3 1 3 Switch of pause To pause the ma
63. tched well sealing performance is good loss of vacuum and reverse cleaning pressure is small These advantages are favorable for increase of production indexes reduction of wear of parts decrease of operation cost and rise of equipment availability The dynamic disc of distributor is made of self lubricating Teflon of which the sealing performance is good and the service life is long Other parts are made from No 316 material that possesses high anti wear and anti corrosion capability 1 2 2 4 Piping There are two loops of piping Piping 1 is used for reverse cleaning for restoring of filter plate function and flushing out of detergent Piping 2 is used to loosen the accumulations in discharge valve and to provide water seal for vacuum pump Such kind of design possesses the following advantages the length of piping for cleaning is diminished the resistance for cleaning is reduced the production index of filter is raised the back flowing of slurry due to Pressure reducing Filtering failure of piping parts is avoided the safety of filter running is valve device increased On piping 1 energy storing tank is connected that is used Fig 2 4 Pipeline Outlook to balance and control the cleaning pressure thus ensure the performance of cleaning The piping and parts mounted on it are able to withstand a pressure of 16kg cm2 No 316 material can meet requirement about high reverse cleaning pressure and anti corrosion 1 2 2
64. the beneficiation plants of copper lead zinc iron silver gold and sulphur The results are so good that the obvious economic and social benefits are achieved Introductions to Shengnuo Group Shengnuo Group has started to develop and make Vacuum Ceramic Filter since 1990s The factory has developed a serial Vacuum Ceramic Filter of 0 25 120m until now and has owned independent intellectual property right for Vacuum Ceramic Filter and ceramic filter plate The products have been sold to all corners of the country based on the advanced technical strength excellent performance of products and high quality after sales services in the last 7 years Our customers can be 8 User s Manual Shengnuo Group found from Shandong in the east to Xinjiang in the west from Yunnan in the south to Heilongjiang in the north According to the statistics 150 sets of Vacuum Ceramic Filters and 1115 sets of ceramic filter plates have been sold out up till now thus making the factory become the largest Vacuum Ceramic Filter products supplier in China and the quality of products and after sales services are high appreciated by the customers Through large scale production practice and products popularization and application we have accumulated many experiences and returned them to the technical and production links and customers after uninterrupted summarization to improve continuously the design and manufacturing level and practical application level of Vacuum
65. the resistance at restoring of filter plate s function is small the cleaning of filter plate is easy the surface Function surface kaci layer is of high strength and wear resistant The two pieces of cavity structures are glued together using epoxy glue imported The gluing is of high strength and is corrosion resistant amp wear resistant Filtering tube is made from Teflon or stainless steel Teflon tube possesses better ductility that provides better capability against Fig 24 Outlook of Filter Plate temperature changes and deformation Stainless steel tube possesses high strength but less capability against deformation The customer can choose different kinds of filtering tube according to working conditions Now there are different kinds of ceramic filter plate in the market Due to irregular crystal structure of silicon carbide the filter plate made of silicon carbide possesses disadvantages such as pore channel is irregular cleaning for eliminating stoppage is difficult brittleness is high wear resistant capability is low there is no capability against chemical corrosion There is ceramic filter plate which is roasted in the way that the two pieces of cavity structures are together as one unit This kind of filter plate possesses advantages such high rate of finished products due to less times of roasting and less technological processes and low cost of production But it possesses the disadvantage of low glu
66. the strength of the parts like mixing drum frame and so on and the relevant power are strengthened during design to make them meet the requirements of all kinds of material filtering 1 3 2 3 Improvement of pipeline system User s Manual Shengnuo Group One pipeline was adopted for the first generation of the vacuum ceramic filter With long single pipeline the resistance was very high for the reverse flushing and flushing results was not so good At the same time it is very to have slurry flow back block the whole pipeline and affect the normal operation when the non return valve is in fault condition Aiming at this problem single pipeline was changed to 2 pipelines to shorten the length of reverse flushing pipeline and improve the reverse flushing effect meanwhile the pressure relieve valve and safety valve are installed on the pipeline to raise the safety of the operation 1 3 2 4 Improvement of automatic control system The ultrasonic level meter was adopted for the first generation of Vacuum Ceramic Filter The fluctuation of level of slurry and water vapor may cause malfunction of the level meter Therefore the radio frequency level meter was adopted to replace ultrasonic level meter and PLC made by GE or Schneider was selected and the electrical elements of Siemens or Schneider were used to improve interference killing ability of the whole control system thus making the equipment running smoothly and reliably After systematic
67. tic display Press and turn to the production statistic display page The accumulating time of automatic operation last cleaning method the next automatic cleaning time can be seen on this page 6 1 1 2 2 Manual operation page Manual operation amp main The manual operation of the following graph will be effected after startup switch cleaning setting EULER EASES at 15A turn to manua and manual pilot lamp 2H is on stirrer roller In the graph all the buttons are off except the tank s discharging valve Caution after manual operation all the buttons should be turned off on the screen Fig 6 1 2 Manual Operation 6 1 1 2 3 PLC input amp output state page Plt INPUT Alf i main In the following page white is on black is off Refer to the connection graph of PLC manual auto pause dur Banua input amp output to check this part Pay attention to the actual connecting situation of l O E WE E E the hard switches often opening point often closing point If 1 If 16 3 Ih 4 crash roller rolle e reset maintain Input state on the panel of operating box part stop forwards back 18 5 i If Picture turns intu white means connected Examples crashstop 4SB the connecting point of electric circuit is often opening point so the crashstop changes into white in the graph it means the often opening point is connected I8 1 PLC input address When p
68. uction automatic shutdown allied wash startup again The detail as below To turn on the main power supply use reset button to turn on the power control to set the system in auto position the cleaning method s button is set in auto too When the machine get into the startup program the stirrer roller vacuum pump filtering pump will start up the discharging valve close the running water enter into reverse circulation pipe the ore magma slurry will feed into the tank after a prearranged time the running water will be changed for filtrate for reverse circulation And then the ultrasonic liquid meter and feeding valve control the liquid level the electrode in the filtrate tank and discharging valve control the liquid level and start solid liquid separation After a set working period the machine shut down automatically close feeding valve the machine will continue to work till the slurry level reduce to the set level system start to clean the discharging valve after reaching the set time the discharging valve will be opened and empty the slurry tank to the lowest level then engine stops the slurry tank will be washed according to time setting then vacuum pump filtering pump stirrer stop filtrate discharging valve vacuum pipe valve and reverse circulation valve are closed The system get into allied wash program the running water valve of reverse circulation is open discharging valve is closed cleaning valve of slurry tank
69. ust start up on g o again flush filtrate back _ Pause when machine is paused all parts will be shut down and closed except the stirrer pause only can be used when the machine is operating automatically and pilot lamp 3H is on Fig 6 1 11 Setting of Cleaning and Manual Operations Pause by operator press once to pause the machine and press again to work Pause by accident during the production the system can be paused by some failures After fault clearance press reset 2 S B and pause 1SB can release the pause and work again Crashstop when crashstop the system will discharge the slurry from the tank Please pay attention crashstop by operator when there is a emergency during the production press crashstop 4S B the whole parts will be shut down the output power supply will be cut off crashstop by accident when a crashstop is caused by the serious the system will discharge the slurry automatically 6 1 2 4 Roller s maintenance refer to manual operation 6 1 2 4 1 6 1 2 4 2 6 1 2 4 3 6 1 2 4 4 6 1 2 4 5 startup switch to left manual position this is manual operation method the pilot lamp 2H is on at the same time turn the method 3SB to maintain At moment can turn roller maintenance 3SA to the left roller turning forwards will stop when the switch is released turn to right the roller
70. vel If this time is too long 1S the 11 3 it means the vacuum and the filtrate system have problem Slurry level shows the acid clean ultrasonic filtrate fillin slurry level in the slurry tank The data will be shown as percentage Fig 6 1 5 State Display 23 User s Manual Shengnuo Group production statistic main 6 1 1 2 5 production statistics page Shows the accumulating time of filter machi ne s auto working time last cleaning method remaining time for next cleaning c accumulating time of auto operation ounting backwards the function will be only effected when the machine is working E automatically method of last cleaning 0000 6 1 1 2 6 PLC s parameter page remaining time to in ix page in total ntering the code t n the parameter s pages and set the next auto clean Six pag otal by e Etne co DORE P e page e parameter Press the parameter enter on the home page the left corner appears enter code a key board will be shown key in AAA then press Enter will enter into each Fig 6 1 6 Production Statistic parameter s pages After parameter has been amended the go back this page Caution This operation must be handled by the production technician the regular cannot enter parameter to avoid any damage to the regular operation 6 1 1 2 7 parameter enter page part The detail is in the parameter establishment of filter machine on the touch scr
71. will rollback at moment roller is rolling slowly speed control s potentiometer is not working There is no system switch and roller switch on the control panel among some machines but the control can be affected though the touch screen When machine operating automatically can press the pause 1SB to pause it at moment turn method 3SB to the right the maintain position by turning the roller switch right and left to control rolling forwards backwards and slowly When back from it turn 3SB to operate position left press reset can go back to the auto stage If change auto to manual can switch the method to manual 25 User s Manual Shengnuo Group Caution After you turn it the discharging valve will open if you want to close it can be realized though touch screen 6 1 3 Electric system s error analyses There are error checking and finding in the electric system the relative information will give the reason and the part of that error 6 1 3 1 Error s finding If an error is occurred during the production the alarm will warn At the same time of warning machine will pause by little error and shut down by serious accident At moment the cause of accident should be checked on the screen and the alarm will not stop before the problem is solved The following details are on the warning page 6 1 3 2 Interlock protection in electric control system Interlock protection in m
72. y cases PLC elements themselves have remote control interfaces connected through cables with industrial television in control room All the information within PLC can be displayed as visualized figures at screen of industrial television that facilitates the monitoring of running state of different filters Remote manipulation of filter is also possible because there is function of transmitting production data Power is supplied separately to PLC system frequency changing elements and dynamic electricity system they are arranged in separated cabinets to avoid mutual interference The hardware of automatic system is imported from Schneider Co of France Siemens AG of Germany and Mitsubishi Co of Japan 1 2 2 8 Discharge scraping system User s Manual Shengnuo Group The discharge scraping system is a patent of our plant possessing advantages of simple structure and easy operation amp maintenance The scraper is made from tool purpose ceramic material containing 95 of Al203 demonstrating good mechanical properties and anti wear capability 1 2 2 9 Vacuum amp Filtrate Discharging System The vacuum system consists of vacuum pump filtrate tank anti corrosion chemical pump and relevant pipelines The pipeline system adopts advanced design to ensure a vacuity gt 0 098MPa except in area with high altitude The principle of vacuum amp filtrate discharge system is shown in the following figure Fig 2 8 Principles of Fi

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