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1. 41 29 LIQUID END e SOLID END C amm ROTATING ASSEMBLY LOCKTITE 4 4 3 8 16 X 1 1 2 HEX HEAD BOLT 60008180 N A FEED TUBE SUPPORT FLANGE 40 5 16 18 X 1 2 ALY SET SCREW CUP PT 00004184 N A FLANGE TO KEY xxx 6 39 16 X 40 HEX SOCKET 13635 38 N A ROTODIFF TO ROTODIFF FLANGE AAA FEED TUBE MOUNTING BLOCK A NOTES 1 MATERIAL HEX SOCKET BOLTS ALLOY STEEL TENSILE STRENGTH 190 000 PSI MINIMUM HEAT TREATED L6 34 5 16 18 X 3 4 HEX SOCKET 7 SKCS 31 18x075 N A STAINLESS STEEL TENSILE STRENGTH 80 000 PSI MINIMUM AMA 6 33 M16 X 35 HEX SOCKET ALY PLD ______ 13635 37 N A 2 QUANTITY LISTED IS PER ROTATING ASSEMBLY 1 3 48 55 8 50 55 35 185 3 A ITEMS 02 amp 21 QTYS ARE 4 FOUR FOR UNITS PRIOR TO SERIAL NUMBER 00272 B ITEM 02 QTY IS 2 TWO amp ITEM 21 QTY IS 6 SIX FOR UNITS WTH SERIAL NUMBERS 4 30 8 PIN 7 16 20 X2 1 2 STEEL ________ 0003955 N A IN THE RANGE OF CF000272 TO CF000678 A C ITEM 02 QTY IS 0 ZERO amp ITEM 21 QTY IS 9 NINE FOR UNITS WITH SERIAL NUMBERS 2 28 3 8 16 X 1 2 SS SET SCREW CUP POINT 000090 N A ABOVE CF000679 3 27 1 2 13 X 1 SS HEX SOCKET 1 60000158 53rrtgS FEED D ITEMS 35 amp 37 ARE NOT REQUIRED AFTER UN
2. 73 E E fe 2 2 722 PTS DISS N iil 2 274 N NA juu S lt LIQUID END E SOLIDS END A CENTRIFUGE ROTATING ASSEMBLY FOR NS mU das en 2723792 nns 175172 FN be lt 00 00 C ERRICK CORPORATION 90 DUKE ROAD BUFFALO NY 14225 U S A R N I NEN N SH RY MYON 5 10 24 75 8 PLUG w O RNG IMP 721FSO 5 SHPP 13 C CS10 GU 505 00 CS10 GU 507 00 CS10 GU 506 00 HXCS 31 18X75 8 P B 5 25 20 63 8 SECOND STAGE SUN GEAR fiioi 00 4 K FIRST STAGE THRUST 10996 00 FIRST STAGE JOURNAL BUSHING 11353 0 D A 00 ceu 05 00 COMPLETE STAGE TWO ASSY pra COMPLETE STAGE ONE asy NA stole WS s s Jon 11 12 83 Ja WIS TZ L PARTS LIST 11 50 00 DE 1000 GEAR UNIT 52 1 01 COMPLETE GEAR UNIT A UAE __________ TE low DJS 1 30 98 ITEM DESCRIPTION PART NUMBER e TOR USA NOT BE ERICO MOT PEO OS op re fro 100 2713708 DERRICK ok CORPORATION THE INFORMATION CONTI BE USED BY CUSTOMERS OR PROSPECTS OR THER DA NSTALLATON OF DEREK OR VENDORS QUOTING ON OR MRE SUPPLY CORPORATION MRITTEN OR VERBAL PS 1 1 3 ut 2 O 590 DUKE ROAD BUFFALO NY 1
3. DE 1000 FHD DE 1000 VED DE 7200 Characteristics 0 600VAC 50 60Hz 3PH Derrick Corporation acknowledges that the above set forth product conformed to the requirements for the applicable purchase order at the time of its original shipment by Derrick Corporation in that all construction materials and components were new and unused were manufactured for this product and that it was free of any known defects as to their design material and workmanship This certificate is governed by the applicable purchase order terms in effect at the time of Derrick Corporation s original shipment of the referenced product Beten Date 29 December 2011 Signature Jennifer J Polanowski Derrick Corporation http dmc sps qc Certificates Quality PE S 009 08 00 doc Revison Number 2 Revision Date 29 December 2011 Document No PE S 073 04 00 DERRICK CORPORATION SHIPPING FINAL INSPECTION AND RUN TEST CERTIFICATE Equipment Centrifuges Model DE 1000 GBD DE 1000 FHD DE 1000 VFD DE 7200 VFD Characteristics 0 600VAC 50 60Hz 3PH The product listed above was inspected and found to be in conformance with Derrick Corporation s internal coating run test and assembly inspection documents that were required for the type of equipment manufactured in accordance with the Derrick quality system This certificate is governed by the applicable purchase order terms in effect at the time of Derrick Corporati
4. OF MAXIMUM MOTOR OPERATING Aux Pump Enable m ACCEPTABLE TEMPERATURE RISE CHARACTERISTICS Or CLOSED PRESENT OUTPUT POWER STATUS OF TANK HIGH LOW Aux Pump Start LEVEL SWITCHES BOTH lt Hou 0 0 TOTAL HOURS OF OPERATION MUST BE CLOSED FOR OPEN PUMP TO RUN CODE NUMBER OF PRESENT FAULT PRESENT ACTUAL PRESENT VFD CLICK ON NUMBER TO VIEW FAULT MOTOR TORQUE Nm TEMPERATURE STATUS SCREEN FOR DESCRIPTION Figure 4 13 Pump VFD Screen PUMP VFD FAULT STATUS The three most recent pump faults are shown on the Pump VFD Fault Status screen Figure 4 14 The screen shows the fault number time of occurrence and description of the most recent fault The fault code and time of occurrence are shown for the second and third most recent faults VFD POWERUP MARKER TIME OF FAULT VFD HOURS HOURS Pump VFD Faut Status 1 9934 x Code Time Fault Name 1 13 2 2548 Ground Fault OUTPUT FREQUENCY Speed Hz Current DC Bus V AT TIME OF FAULT 3 1 0 1 681 0 FAULT TYPE BUS VOLTAGE AT TIME OF FAULT is1 Status 2 Alarm 1 Alarm 2 VFD CURRENT AT TIME OF FAULT 3855 9199 9 2 75 1 9922 3 77 1 9065 VIEW COMPLETE Pump VFD Fault History FAULT HISTORY INDICATES WHEN DRIVE WAS LAST POWERED UP Figure 4 14 Pump VFD Fault Status Screen 4 16 30 Sep 13 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS TEMPERATURE TRENDS The historical temperature trends of all three VFDs are shown on the Temperature
5. JES MIS jw 05 25 07 5 a ma l WO 05 20 05 te foo FS 08 20 08 DERRICK BE REPRODUCED WITHOUT THE WRITTEN PERMISSION OF DERRICK i CORPORATION SHALL ONLY BE USED BY CUSTOMERS OR PROSPECTS OR THER ORAWING NO EQUIPMENT OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY SPECIFIC REASON OUTUNED IN THE TRANSMITTAL WHETHER 16622 00 005 1590 DUKE ROAD BUFFALO NY 14225 U S A 4 O O A CENT BOM PUR V 8 7 6 5 WV 4 3 2 1 ITEM QTY DRAWING NUMBER DESCRIPTION ITEM QTY DRAWING NUMBER DESCRIPTION 1 x 16545 01 006 ASSEMBLY COMPLETE 125 1 60008214 M F ELBOW 3 4 2 1 116396 01 007 IENCLOSURE ASSEMBLY 126 1 EL29 CORD FITTING 90 DEGREE 3 1 30008359 DRIVE 50 HP 460 60 HZ 127 1 INPLE 75 COND COND NIPPLE 4 1 G0007241 DRIVE 20 HP 460 60 HZ CONVEYOR 128 1 60008073 IHOLDER FUSE ULTRASAFE 60 AMP 600V 2P CLASS J 5 1 30008360 DRIVE 15 HP 460 60 HZ FEED PUMP 129 4 100004286 STOP TERMINAL BLOCK 6 1 116400 01 006 IDOOR ASSEMBLY 130 1 ISHPP 200 PLUG 2 NPT SQ HD 7 1 16404 01 009 ICO
6. SRY NOT DECELERATING RED NO PLC SER Motor Ref Speed In Range nline Sj RPM OUTPUT CURRENT MOTOR SPEED SETTING VFD Status rential Motor Current B 0 1440 12 2 665 9 v PERCENTAGE OF MAXIMUM ACCEPTABLE TEMPERATURE RISE DIFFERENTIAL SPEED emo RN Actual 1441 Temp Heatsink 99 7 F 372 PRESENT OUTPUT POWER ACTUAL DIFFERENTIAL SPEED Power 7 Torque Nm 0 1 TOTAL HOURS OF OPERATION ACTUAL MOTOR SPEED ux Actual H Motor 80 0 1 3 PR MAXIMUM AVAILABLE TORQUE PRESENT VFD BASED ON DIFFERENTIAL SETTING AVAILABLE TORQUE PRESENTACTUAL TEMPERATURE CURRENTLY UTILIZED TORQUE Nm Figure 4 12 Conveyor VFD Screen 30 Sep 13 4 15 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS 5 VFD STATUS CONT D GRN NO ALARM FAULT _ GRN RUNNING RED ALARM FAULT PRESENT SRN MOTOR RUNNING GRY MOTOR STOPPED GRY OFF GRN ROTATING AT SET SPEED GRN OPERATIONAL X GRY NOT AT SET SPEED GRY ALARM PRESENT Pump Run Alarm Orward pd R uo Ready Fault Reverse Gesce GRN ACCELERATING GRN PLC COMMUNICATION Onine Flowrate Reduction Mode cel GRY NOT ACCELERATING RED NO PLC COMMUNICATION Speed Pump Speed VFD Status GRN DECELERATING PUMP SPEED PERCENTAGE OF Motor 36 Current DC Bus GRY NOT DECELERATING TOTAL AVAILABLE AND 5 0 0 0 683 0 v MOTOR Temp Heatsink OUTPUT CURRENT 103 8 30 3 Vin 4 TZ Inputs Torque Ay n rds
7. 4 Atleast every two years check the following additional items Apparatus is suitable for the hazardous location There are no unauthorized modifications Quality of the air supply is correct refer to Compressed Air in Section 3 Approval labels are legible and undamaged e Power to the centrifuge is shut down upon loss of air pressure o Initial Purge Time Setting The initial purge time is factory set to 14 minutes If purge time varies excessively the digital timer system inside the purge unit may be adjusted to restore the correct interval The time intervals marked on each valve are additive In the photo below the timer shows that total purge time available is 38 minutes 16 8 8 4 2 If testing reveals that purge time has varied from this setting the purge time should be changed by opening or closing one or more valves When making an adjustment note that valves are either open or closed no intermediate setting is possible 5 6 01 Jan 14 DE 1000LPVFDCentrifuge MAINTENANCE 2 FL 272 e Leakage Compensation Test A Magnahelic gage and hose kit available from Derrick is required to monitor cabinet pressure The leakage compensation valve adjustment should be checked for deviation from factory setting as follows 1 pu SLOWLY open the supply regulator or leakage compensation valve and allow the cabinet pressure to rise until the relief valve opens Check that the relief valve opens
8. MAINTENANCE RECOMMENDED SPARE PARTS DE 1000LP VFD CENTRIFUGE G0004195 Fuse 0 5A 2 G0002926 Fuse 1 25A 1 G0009286 Intrinsic Barrier Purge System 1 G0003493 Fuse 15A Air Conditioner No 3 TROUBLESHOOTING Malfunctions due to operating error or other problem can result in unnecessary machine down time and should be corrected as soon as possible The troubleshooting procedures presented in this section will assist technicians in isolating and correcting malfunctions Fault analysis should proceed logically from the simplest cause to the more complex The most difficult problem is an unexpected shutdown or inability to start Always eliminate obvious causes of malfunction before proceeding to more complex possibilities Since more than one cause may be responsible for a malfunction the technician must proceed methodically to eliminate all possible causes and take all corrective actions at each step of the troubleshooting process In general an unexpected centrifuge shutdown is due to an interruption of electric power that has turned off the bowl drive motor Safety components are installed in key areas of the centrifuge electrical control system to shut down the electric motor if safety parameters such as motor temperature vibration or conveyor torque are exceeded The power interruption may be due to one or more factors including a local power failure In case of control system m
9. REFERENCE DRAWNGS A ELECTRICAL COMPONENTS PARTS LIST 16615 00 ELECTRICAL WIRING SCHEMATIC 14394 00 023 ITEM O WAS G0008128 AND QTY WAS 4 ADDED ITEM W PER DRR 2560 CONES mw roo JESS 5 95 1 GENERAL ARRANGEMENT FOR 2 10001 VED CENTRFUGE 460 60 3 Ca EEE heal re Es DERRICK LN dab A E GYM st bana o TS ae on sue we ene 14 58 0 oce w usa JS XP CABLE ASSY W CABLE GLAND 6C FIGAWG 0009767 A ELBOW 3 4 CRH EL29 3 4 NPLE 75 COND 60003533 1 2 NPT CORD FITTING 90 A G0013391 1 2 LOCKNUT 60009340 1 2 GASKET 1290 1 2 BUSHING PURGE SYSTEM 60007865 TUBE lt 50009864 v ELBOW 00080062 An SENSOR 60009972 CABLE CONVEYOR THHN 18 AWG CONTROLLER 20HP 60007241 STOP PUSHBUTTON 60005325 D EMER STOP CIRCULAR LEGEND 60007244 Ca Lom es MAR
10. SEAL GARLOCK 24600 7374 OSTO RA 310 00 A AM SEAL GARLOCK 24600 2462 510 311 00 1 48 BEARING HOUSING SZ 19553 00 001 YA IB 1 f1 47 RETAINER RING RR475 1 510 328 00 1 f1 46 FEED ACCELERATOR BUMP 19557 00 B 5 04620 CS10 RA 323 00 eB t 41 4 SINGLE LEAD CONVEYOR 9562 01 005 8 08622 CS10 RA 322 00 B 1 f1 42 RETAINING RING RR500 CSt0 RA 326 00 Be ofif a suN HB 5550 1 BEARING HOUSING L 921 00 eB 2 2 99 THRUST BEARING 726 CS10 RA 510 00 eB 1 CS10 RA 321 00 1 Sr ESA lt S y SS Bene NEGA FR SZ VAN ro 7 37 SEAL HOUSING L si CS10 RA 312 00 1 34 LINER 1 0 95920 1 33 BOWL HEAD PLow 10579 00 0510 650 SOLIDS DISCH WEAR INSERTS 9547 00 510 630 1 1 29 BOWL EXTENSION 200 1 28 SOLID BOW HEAD 9463 00 00 V 1 27 BEARING NUP 225 CSI0 RA 512 00 1 26 PULLEY SHEAVE 5 75 PD 9546 00 1 1 25 FEED PIPE E 1 1 24 FINGER COVER OUTBOARD U 9670 00 z L 1 1 23 PILLOW BLOCK COVER OUTBOARD 5680 J 2 Bw rr 9153 00 L 1 1 21 uouo Bow HEAD 5 0 9505 00 00 4 20 EFFLUENT PORTS amp
11. This section should be used by operating and maintenance personnel to record historical information gathered during the installation and operation of the Derrick equipment If properly kept the log will be useful for altering maintenance intervals and intercepting trends that may indicate the need for changing operating procedures Each entry in the log should be dated for future reference and tracking If required additional pages may be added to the log by copying a blank page or simply inserting ruled paper at the rear of the section Installation and Maintenance Notes 15 Jan 11 9 1 DE 1000LPVFDCentrifuge INSTALLATION amp MAINTENANCE LOG 9 2 15 Jan 11 DE 1000LPVFDCentrifuge INSTALLATION AND MAINTENANCE LOG 15 Jan 11 9 3 DE 1000LPVFDCentrifuge INSTALLATION amp MAINTENANCE LOG 9 4 15 Jan 11 DE 1000LPVFDCentrifuge INSTALLATION AND MAINTENANCE LOG 15 Jan 11 9 5 DE 1000LPVFDCentrifuge INSTALLATION amp MAINTENANCE LOG 9 6 15 Jan 11 DE 1000LPVFDCentrifuge DERRICK CO
12. 1 2 15 Aug 13 DE 1000LPVFDCentrifuge INTRODUCTION Bowl Assembly The liquid bowl head at the liquid discharge end contains movable effluent ports that permit manual adjustment of the liquid level remaining in the bowl during rotation Index marks are provided on the weirs to facilitate precise adjustment The liquid level or pond depth along with other factors helps determine the liquid content of the discharged solids The conical bowl at the solids end forms an upward sloping beach where solids collect and are continuously discharged through the solids discharge outlet Replaceable wear inserts installed in the solid bowl head protect the openings from wear Conveyor The conveyor assembly is a hollow cylindrical auger that receives the inlet slurry into its interior disperses it through feed nozzles to the bowl assembly and transports the solids to the solids discharge outlet Rotated by an electric motor through a differential gearbox the conveyor turns in the same direction as the bowl but at a slower rate of speed The differential speed setting on the control panel determines the conveyor speed in relation to the bowl speed This relationship remains consistent as bowl speed is varied the conveyor speed varies commensurately but maintains the differential relationship For example a bowl speed of 2000 RPM and a conveyor differential speed of 10 results in the conveyor rotating at a rate of 1990 RPM A drive shaft extending thr
13. 2 Open case cover 3 Loosen three screws securing mounting ring to liquid bowl head rotate the effluent port until the desired setting is positioned at the alignment marks and tighten screws All four effluent ports must be set to the same position 4 Close case cover after completing adjustments LIQUID BOWL HEAD ALIGNMENT MARKS EFFLUENT PORT MOUNTING RING RETAINING SCREW Figure 4 4 Effluent Port Adjustment 4 10 30 Sep 13 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS Differential Speed Conveyor Torque Generally a faster conveyor speed results in lower conveyor torque as solids are discharged faster and usually wetter Reducing conveyor speed must be done slowly and cautiously allowing steady state to be reached before further reduction Slower conveyor speeds permit solids to remain in the bowl longer This can permit solids to accumulate in the bowl if the input rate exceeds the discharge rate Therefore the torque must be monitored to prevent overload Torque limit settings control automatic feed reduction and centrifuge shutdown As conveyor torque rises the feed rate is gradually reduced If torque continues to rise the feed rate is more rapidly reduced Upon reaching the maximum conveyor torque setting the centrifuge is shut down At certain conveyor speeds the drive motor must reverse direction 10 accommodate the differential speed relationship with the bowl If this occurs the centrifuge control syste
14. 303 10668 07 VN 2 19 FLINGER COVER INBOARD amp 1 1 1 9817 00 18 PILLOW BLOCK COVER INBOARD 95204 17 O RING 4989 10 X 070 60005212 2 16 PLLOW BLOCK 9545 00 02 2 15 O RING 4987 ID X 103 60003211 1 14 PILLOW BLOCK COVER OUTBOARD FLANGE SIDE 9588 00 002 1 13 FLINGER COVER OUTBOARD FLANGE SIDE 9670 00 001 1 12 O RING 4000 D X 125 ORM ARP 242 9522 00 001 1 10 PILLOW BLOCK FLINGER OUTBOARD FLANGE 5 9514 00 01 1 09 BEARING NU 225 CSIO RA 513 00 3 08 PLLOW BLOCK FLINGER 1 9514 00 00 06 O RING 456 2 05 FEED NOZZLE 5 04 CONVEYOR ASSY W HARD SURFACING 1 03 CONVEYOR ASSY W TES ___ 02 COMPLETE ROTATING ASSY W HS Je OX 01 COMPLETE ROTATING ASSY W TLES N COMPLETE SET i ZOO AA d A AY A A A A RN RAIN M f AA f 1 e 1 f W f 2 E SZ zzz RS CC TE III ZZAN HZ A f f Q AS 2 2 et AN M cu S10 RA 316 00 524 00 N K VAN rs we ocio ture 2 16 25 13 LN GA REF 14738 00 008 6 rc
15. BLOWER COMPRESSOR TEMPERATURE FAILURE FAILURE CONTROL M1 THERMAL PROTECTOR RELAY COMPRESSOR CONTACTOR POWER CONTACTOR COMPRESSOR CONDENSER FAN EVAPORATOR FAN CONTROL TRANSFORMER TERMINAL BOARD Figure 5 15 Air Conditioner Electrical Schematic Diagram 230Vac RTD Sensing 01 Jan 14 5 27 DE 1000LPVFDCentrifuge MAINTENANCE B1 F1 POWER CABLE 2 6 2 6 O X2 6 TEMPERATURE CONTROL LEGEND THERMOSTAT CONTROLLED RELAY HIGH REFRIGERANT PRESSURE SWITCH FUSE M3 THERMAL PROTECTOR CONTACT LOW REFRIGERANT PRESSURE SWITCH M1 THERMAL PROTECTORS M1 THERMAL PROTECTOR CONTACTS FAULT SIGNAL RELAY K15 K20 K30 M1 M2 M3 T1 X1 X3 PRESSURE BLOWER COMPRESSOR FAILURE FAILURE FAILURE M1 THERMAL PROTECTOR RELAY COMPRESSOR CONTACTOR POWER CONTACTOR COMPRESSOR CONDENSER FAN EVAPORATOR FAN CONTROL TRANSFORMER TERMINAL BOARD Figure 5 16 Air Conditioner Electrical Schematic Diagram 24Vdc RTD Sensing 5 28 DE 1000LPVFDCentrifuge 01 Jan 14 MAINTENANCE CONTROL TRANSFORMER T1 M1 THERMAL PROTECTORS F6 F7 HIGH REFRIGERANT PRESSURE SWITCH F1 FUSE COMPRESSOR FAULT SIGNAL CONTACTOR K20 POVER RELAY K10 M1 THERMAL CONTACTOR K30 er RELAY Figure 5 17 Air Conditioner Electrical Components ALARM AND FAULT MESSAGES Intervention is required if a message appears to alert the operator to an anomaly that has occurred Alarm messages signify that the prevailing
16. DERRICK DE 1000LP Centrifuge Variable Frequency Drive Issued 15 Jan 11 Rev 01 Jan 14 Maintenance amp Operation Manual DISCLAIMER Derrick Corporation has taken care to ensure that all of its maintenance and operation manuals are accurate However we offer no guarantees or warranties in this regard Our manuals are provided only as a guide to assist with the maintenance and operation Derrick Corporation takes no responsibility for any losses damage or injuries that may occur as a result of using any of our manuals It is ultimately the operators responsibility to ensure that the operation repair and maintenance of equipment complies with all applicable national and local regulations including safety regulations THIS MANUAL IS PROVIDED BY DERRICK CORPORATION ON AN AS IS BASIS AND DERRICK CORPORATION EXPRESSLY DISCLAIMS ANY AND ALL WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL DERRICK CORPORATION BE LIABLE FOR ANY DIRECT INDIRECT INCIDENTAL PUNITIVE OR CONSEQUENTIAL DAMAGES OF ANY KIND WHATSOEVER WITH RESPECT TO THE MANUAL AND EQUIPMENT Derrick Equipment Company 15630 Export Plaza Drive Houston Texas 77032 Phone 281 590 3003 Toll Free 1 866 DERRICK Fax 281 442 6948 www derrickequipment com DERRICK CORPORATION UNIT NUMBER IS KEY TO DERRICK SERVICE All inquiries to Derrick must include the equipment unit n
17. Prior to placement of equipment verify that electricity is available at the equipment site and that feed line and discharge chute if any are provided Also ensure that clearances around the equipment are adequate Prepare the installation site as follows 1 Provide adequate clearances to perform the following activities a Operate controls on electrical panel b Open and close the control cabinet door Figure 3 1 3 2 30 Sep 13 DE 1000LPVFDCentrifuge INSTALLATION Open and close top cover d Grease main and gearbox bearings e Check and fill gearbox f Connect and disconnect feed and discharge lines 2 Confirm that mounting structure is properly positioned and adequate to support the weight of the centrifuge 3 Verify that electric power supply available at the site matches the centrifuge power requirements 4 Check that liquid discharge line flange matches the liquid discharge connection on the machine 32 813mm An IRA iugum HENRI Be Figure 3 1 Required Control Cabinet Door Clearance EQUIPMENT HANDLING WARNING USE SPREADER BARS TO PREVENT DAMAGE WHEN LIFTING THE EQUIPMENT WARNING TO ENSURE PROPER BALANCE AND ORIENTATION WHEN UNIT IS RAISED AND PREVENT DAMAGE TO COMPONENTS ATTACH LIFTING SLINGS ONLY TO LABELLED LIFTING POINTS DO NOT ATTEMPT LIFTING BY ATTACHMENT TO ANY OTHER LOCATION WARNING BE SURE THAT HANDLING DEVICES HAV
18. 1 T BUSHNG 2125 BRE o 4 778 124 ske G Q TISOLATOR MOUNTS 1 P ELECTRICAL ENCLOSURE ASSEMBLY 16622 01 006 ANZ o ENCLOSURE ISOLATOR MOUNT FRONT G0012075 O Jj LN GARUNTSS 1 ooo i i i 1 TM CONTROL ENCLOSURE ASSEMBLY 16545 0i 08 TTL MODR 2HP 10009200 Sr D 1 K MOTOR SOP G0008901 SEE NOTE 5 D BLT GUARD 1195 0 04 1 H FEED TUBE SUPPORT 9539 01 1 G GEAR UNT GUARD 9856 01 08 O Jj 1 F 120 HP MOTOR M53 0 03 CASE y 9591 02 02 1 D LOWER CASE 1900 0103 Rj ER wkp __________________1 1 1 B __________________ _ 5 02 1 E 1 TA ROTATING ASSEMBLY W TLES 9587 01 007 SEE MANUFACTURING SHI i 5 1 4 RADIAL CENTRIFUGE ASSEMBLY 460 6082 RT Li ED 1302 No ________ ____ ______ de a d a HH B 23 149 16 584 369 COVER CAN BE MOUNTED FOR OPPOSITE SIDE OPENING 35 1 4 896 a et EPS FEED INLET 36 7 16 926 SOLID DISCHARGE 78 1 2 1994 LIQUID DISCHARGE 82 2083 173 1 4 4401
19. 36 3 G0007585 HOLDER FUSE CUBE STYLE 100 AMP 600V se gt 37 3 G0007583 FUSE CUBE STYLE 100 AMP 600V 38 3 G0003486 FUSE HOLDER CUBE STYLE 60 AMP 600V 39 3 G0003484 FUSE CUBE STYLE 40 AMP 600V 61 40 2 G0007214 FUSE BLOCK 30 AMP 3P CLASS CC 41 2 G0012056 IDIN RAIL 35MM X 14 1 2 62 42 1 G0005309 GROUND BUS BAR 43 3 G0009516 DIN RAIL 35MM X 2 1 2 44 2 60012311 FUSE 60 AMP 600V CLASS J 45 2 G0008563 TERMINAL END PLATE ORANGE 4 PT 46 15 20008562 TERMINAL BLOCK 4 COND GRAY 4 9 47 1 20012559 REDUCER 2 X 1 1 2 48 1 G0007984 IDIN RAIL 35MM X 6 128 49 1 G0007228 COMPACTLOGIX 50 1 G0007231 IETHERNET SWITCH 6 PORT 12 51 4 G0009324 TERMINAL BLOCK GROUND 4 COND GRN YEL 52 1 17244 01 IBARRIER INTRISIC SAFE SPEED SENSOR 13 53 2 117325 01 IBARRIER INTRISIC SAFE RTD SENSOR PROGRAMMED 54 1 G0009286 BARRIER INTRISIC SAFE VIBR SENSOR 55 2 G0008571 TERMINAL BLOCK 2 COND GRN YEL 56 d G0008544 TERMINAL BLOCK END PLATE ORANGE 57 1 G0003565 FILTER HOUSING ELEMENT ORDER G0002301 ELEMENT 58 1 INPLE 50X200S 4 1 2 X 2 PIPE NIPPLE SST 59 1 G0009927 AIR REGULATOR 60 1 117420 01 A C THERMOSTAT MOUNTING BRACKET 61 5 G0008004 1 2 X 1 2 HOSE BARB 62 3 G0008003 1 2 90 DEG STREET ELBOW BRASS A 63 1 IMP 116B 02X02 1 8 90 DEG STREET ELBOW BRASS M 64 1 INPLE 50 S4 1 2 CLOSE NIPPLE SST 65 2 G0002716 1 2 X 1 1 2 PIPE NIPPLE SST e 2 20002719 SPECIAL TOOL PURGE PRESSURE MEASURI
20. Conveyor drive motor shut down due to high temperature or defective thermistor in motor winding Check motor temperature Allow motor to cool and then check for continuity across thermistor leads If open circuit is found replace motor Bad connection s Check connections at TB2 5 and 6 at transmitter intrinsic barrier and at conveyor VFD Correct as required Replace motor if no defects are found Low tank level F3001 Pump Shutdown or Will Not Start Due to Dry Run Protection Alarm Check and re fill feed tank sufficiently to close low level switch F3002 Flow Meter Flow Detection Error Feed Pump has Shutdown Insufficient pump output detected Check and re fill feed tank sufficiently Verify that control valves if any are open to allow material to flow 5 32 DE 1000LPVFDCentrifuge 01 Jan 14 MAINTENANCE ALARM AND FAULT MESSAGES F3010 Pump VFD Communications Error Communication lost between pump VFD and PLC Confirm that green LED next to Ethernet cable on Ethernet switch is lighted indicating that hub is functional Check connections between pump VFD and PLC and correct any defects Replace pump VFD if no other defect is found F3011 Pump VFD Alarm Ref Troubleshooting Section of User Manual Pump VFD alarm Identify alarm from operator control panel Perform indicated corrective action F3012 Pump VFD Fault Ref Troubleshooting Secti
21. Increase differential speed and or reduce quantity of solids in feed Reduce quantity of solids in feed or add dilution stream if possible Reduce quantity of solids in feed or generally optimize machines settings i e adjust bowl speed differential speed and weir opening Re optimize machine settings Reduce feed rate Increase weir opening refer to Section 4 Reduce differential speed Reduce weir opening if improved liquid is desired Inspect flights through the solid discharge outlets If damage is evident remove and disassemble bowl and inspect conveyor flights carefully refer to Rotating Assembly Maintenance Repair or replace conveyor if required 01 Jan 14 MAINTENANCE TROUBLESHOOTING DE 1000LP VFD CENTRIFUGE Failure Mode 3 Excessive Vibration Bowl assembly unbalanced Remove and disassemble bowl and inspect conveyor flights due to uneven mechanical refer to Rotating Assembly Maintenance Repair or replace wear worn parts or deformed conveyor if required conveyor flights Conveyor bearing defective Remove and disassemble bowl and inspect conveyor bearing due to inadequate lubrication refer to Conveyor Bearing Replacement Replace conveyor product entry past seal or bearings normal wear Bowl assembly main bearings Remove rotating assembly and replace both bearings refer defective to Main Bearing Replacement Excessive buildup of solids in Perform cleanout procedure refe
22. LES sPs SP6 SPARE SPARE K 2C 420AWG SHIELDED ZNPT 1 1 2NPT PS WU TESTA PROGRAMMED i ENT 1 3 4 60008214 N 60012559 PUMP IS ENABLED I ELBOW oo IF PUMP WAS RUNNING TO RUN T 7 9 men NOTE z CARE assy 1 CABINET IS SHIPPED MTH TERMINALS 3 AND 4 JUMPERED Gib HE cM cl Is a BROWN BLUE W CABLE GLAND Mr ec om Ps a TO BE REMOVED BY CUSTOMER IF REMOTE PUMP ENABLE IS USED VIBRATION reurenerons a Tan THIN ee 60009587 60009596 DO NOT PLACE JUMPER BETWEEN TERMINALS 1 AND 2 AS PUMP SOLID END LIQUID END AA A maw TAN dier REV 2 USED FIRST ON REV 9 USED FIRST ON MAY START UNINTENTIONALLY a icm mE TTE IC CENTRIFUGE CF1415 AND CENTRIFUGE CF1699 AND E N 60007882 CABLE SNL PANEL ONO PAL m eee 3 REV 4 USED FIRST ON ARE TO BE LOCATED IN A HAZARDOUS AREA un SUPPLY 480 VOLTS 3 PH 60 HZ CENTRIFUGE 4CF1445 AND RECOMMEND 125 AMP SERVICE QTY 1 COPPER COND PER PHASE SIZED FOR 125 AMP A CONTROL PANEL CF6043 BASED ON CONNECTED LOAD OF 100 AMP AT 7SC TEMP RISE AND 40C AMBIENT MAIN PONER DISCONNECT A USE XP SEALING GLAND FOR 2 NPT REF G A 4 14738 00 008 SUPPLIED BY CUSTOMER REF P L 16545 00 006 REF ELP 16615 00 002 A Er MN rers sw ws sp ou non un VD 1000 CENTRIFUGE LOW
23. RR N H Zl 12 i c h 32 I 30 31 19 22 29 41 SOLID END HARDWARE LOCATIONS SOLID END HARDWARE TORQUE SPECIFICATIONS 6 1 4 x 1 1 4 Pin 4 Loctite 680 N A Solid End Bowl Head 7 5 16 18 x 1 2 Set Screw 2 Loctite 262 N A Solid End Bowl Head 8 1 8 NPT x 3 4 Grease Fitting 2 N A N A Solid End Bowl Head 10 3 8 16 x 1 Hx Skt Hd 8 Anti Seize 252 28 5 Solid End Bowl Head 11 5 16 18 x 3 Hx Skt Hd 6 Anti Seize 1144 in Ib 16 3Nm Solid End Seal Housing 12 1 4x 1 Pin 1 Loctite 680 N A Solid End Bearing Housing 13 1 4 20 x 1 Hx Skt Hd 8 Anti Seize 83 in Ib 9 4Nm Pulley Sheave 14 15 16 18 x 4 Hx Hd 6 Anti Seize Unspecified Flinger Cover 15 3 8 16 x 1 Fit Hd Hx Skt 16 Anti Seize 183 in 20 7 Pillow Block Cover 17 1 4 20 x 5 8 Hx Skt Hd 4 Anti Seize 1144 in lb 16 3Nm Pillow Block Flinger 5 16 01 Jan 14 DE 1000LPVFDCentrifuge MAINTENANCE SOLID END HARDWARE TORQUE SPECIFICATIONS 18 3 8 16 x 3 4 Hx Skt Hd 8 Anti Seize 252 in lb 28 5Nm Case Plows 19 3 8 16 x 1 Set Screw 2 Anti Seize 75 in lb 8 5Nm Feed Accelerator Bump 20 1 2 13 x 1 Set Screw 1 Anti Seize 265 in Ib 30Nm Feed Accelerator Bump 22 3 8 16 x 1 Hx Skt Hd 12 Anti Seize 252 in lb 28 5Nm Bowl Extension 23 10 24 x 1 4 Set Screw 2 Anti Seize N A Case Flinger 24 5 16 18 x 3 4 Hx Skt Hd 32 Anti S
24. VIBRATION SWITCH TRIPPED RUNNING NORMAL RUNNING CONDITION GREEN DRIVE ON OFF DRIVE OFF GREEN STEADY DRIVE RUNNING GREEN FLASHING DRIVE READY BUT NOT RUNNING s NO FAULTS PRESENT YELLOW FLASHING OR STEADY ALARM PRESENT OR DRIVE NOT ENABLED RED FLASHING OR STEADY FAULT RED FAULT PRESENT GREEN STEADY DRIVE FUNCTIONAL GREEN FLASHING DRIVE FUNCTIONAL Figure 5 18 VFD Indicators 5 41 DE 1000LPVFDCentrifuge 01 Jan 14 MAINTENANCE GREEN STEADY PLC COMMUNICATING WITH ALL DEVICES GREEN FLASHING ONE OR MORE DEVICES NOT RESPONDING RED FLASHING PLC NOT COMMUNICATING WITH ANY DEVICES OR FAULTED GREEN STEADY RUN MODE x OFF PROGRAM MODE OFF CONTROLLER MEMORY EMPTY GREEN STEADY PLC OK OFF NORMAL OPERATION wt GREEN FLASHING PLC STORING OR LOADING 7 PROGRAM NOTE 1 RED FLASHING MAJOR RECOVERABLE FAULT OFF BATTERY GOOD NOTE 2 RED STEADY BATTERY 95 DISCHARGED RED STEADY NON RECOVERABLE FAULT OR NOT INSTALLED NOTE 3 OFF NO POWER APPLIED OFF NO POWER TO PLC NOTE 4 GREEN STEADY NORMAL OPERATION RED STEADY SELF TEST UNDERWAY OR UNRECOVERABLE FAULT NOTE 5 GREEN STEADY NORMAL OPERATION GREEN FLASHING PLC READING WRITING TO CARD RED FLASHING INVALID FILE SYSTEM ON CARD GREEN STEADY OR FLASHING NORMAL OPERATION OFF NORMAL OPERATION OFF NORMAL OPERATION GREEN STEADY NORMAL O
25. 01 97 WAS 17379 00 107 WAS G0009973 ADDED ITEMS 124 128 m CORPORATION 114 1 60012013 TRANSFORMER CONT 2000VA 480V PRI 120V SEC 5 ADDED ITEMS 119 123 BKS 8 5 2011 ko A SH ITEM 9 WAS 16622 01 005 84 WAS G0007951 85 WAS G0009873 86 WAS G0009871 87 WAS G0009872 94 WAS 11881 01 025 102 Ber MEMO 117 i 256 FITTING ELBOW 75 NPT MEE 4 WAS G0004418 46 QTY WAS 12 92 QTY WAS 1 ADDED ITEMS 117 amp 118 ITEM 35 PLACEMENT WAS ON 07 ITEM 41 QTY WAS 1 DJK 6 15 2011 uec CONTROL ENCLOSURE ASSEMBLY 118 1 _ 60012062 CABLE ASSEMBLY HEATER ITEM 47 WAS G0007980 11 DIN RAIL PER JWC vs lir 80012122 VALVE CHECK T NPT FEMXFEM BRASS 3 ITEM 32 WAS G0008459 ITEM 41 WAS G0007983 ADDED ITEMS 108 THROUGH 116 DELETED G0003494 2910 2911 AND 2874 DSD 5 13 2011 A DE 1000LP EX PROOF 460 60 3 151 T 50012168 COVER WATER DUST 2 ITEM 64 WAS G0008008 ITEM 65 WAS G0002714 ITEM 67 QTY WAS 2 ITEM 70 QTY WAS 1 ADDED THERMOSTAT BRKT AIR DJK mn SIZETFILEGOPY DWG NO REV 122 1 60012167 NIPPLE PIPE 1 XCLOSE SCHED40 30455 REGULATOR amp ITEM 113 SENSOR RTD BKS u D Y 8 90 DEG 1508 30455 1 ITEM 44 WAS G0005309 ITEM 57 WAS 00008526 ITEM 35 REPLACED WITH ITEM 54 ITEM 97 WAS 20002966 2 8 2011 x 16545 00 006 11 pee E ADDED ITEMS 108 112 OL ms T Ert 8 7 6 5 4 3 2 1 CENT MAN Q DERRICK CORPORATION SECTION 9 INSTALLATION AND MAINTENANCE LOG PURPOSE
26. 5 1 Each shift Each shift One shot each shift Remove feed tube clean interior of tube and reinstall Weekly Inspect gearbox for leakage Every 2 weeks Rotate gearbox until fill and overflow plugs are at 12 o clock position required Remove plugs fill gearbox until oil drips from overflow and then Quarterly reinstall plugs Check interior and exterior of case for accumulated solids and clean as Weekly Purge conveyor bearings Every 2 weeks Remove belt cover inspect belt for damage and check adjust tension Monthly Remove and clean flinger covers Grease bowl and conveyor drive motors Monthly Ten Shots Quarterly 5 2 DE 1000LPVFDCentrifuge 01 Jan 14 MAINTENANCE CONVEYOR BEARING PILLOW BLOCK GREASE FITTING DRAIN HOLE MAIN BEARING GREASE FITTING OVERFLOW PLUG CONVEYOR BEARING GREASE FITTING Figure 5 1 Rotating Assembly Lubrication Points 01 Jan 14 5 3 DE 1000LPVFDCentrifuge MAINTENANCE LUBRICATION CHART The following chart lists the Derrick approved lubricants for the DE 1000LP VFD centrifuge rotating assembly gearbox and drive motors DERRICK APPROVED LUBRICANTS DE 1000LP VFD CENTRIFUGE Chevron SRI NLGI 2 SRI 2 Main amp Conveyor Bearings A R Standard Shell Aeroshell 14 Main amp Conveyor Bearings 8 Motor Bearings Main 4 Motor Bearings Main amp Shell Aeroshell 14 Conveyor DRIVE BELT REPL
27. 6000800 18 LIQUID END RTD SENSOR 15 RD SENSOR BEARING 31655 41 WRE PVC CoAT 00008089 I 1111 1 FITTNG STRAIGHT 500 NPT 250 535 048 1 13 smeh coos A AAA E 1 11 CABLE MARINE SHIPBOARD GEXOL INSUL 16 3 COND 55 INCHES 60007163 10 FERRULE 26AWG 60012492 SOLID END RTD SENSOR 12 os FERRULE 24AWG 60008931 36 08 FERRULE 18AWG 60003538 o FERRULE h 6000464 1 06 SPEED SENSOR ASSY LENGTH IS 36 16615 06 1 05 SOLD END RTD ASSY LENGTH IS 136 16615 05 1 04 LIQUID END RTD ASSY LENGTH IS 41 6615 04 1 BRATION SWITCH ASSY LENGTH IS 55 6615 03 1 02 JUNCTION BOX SENSOR ELECTRONICS ASSY 16584 01 005 gt lt 01 DE 1000 BASE ELECTICAL COMPONENT KIT PART NAME A aN we ut ooo PARTS LIST FOR VFD DE 1000 LN J sever tus stow as a mas wee 2 N we ma g ms RR ns OOD 2 BASE SENSOR SYSTEM LN we sto 12 ez wvrz oma AN 98721 secre inem serm 4 75 00 MS joo JS 02 14 07 NONE P N REVISE PARTS UST TO INCLUDE MORE DETALS SEE MODEL SPACE FOR ORIGNAL PARTS REY CHANGE DATE C b VAN UST FOR REV 1 5 02 23 12 THE DESIGNS AND INFORMATION CONTAINED ON THIS DRAWING OR COPIES REMAIN THE EXCLUSI
28. COVER GAP TWO OPERATORS MUST BE USED WITH BOTH HANDS ON THE COVER HANDLES AT ALL TIMES DERRICK RECOMMENDS HAVING A HOIST AVAILABLE IF ADDITIONAL ASSISTANCE IS DESIRED DURING THE OPENING CLOSING PROCEDURE 2 After bowl assembly has coasted to a full stop loosen screws securing case cover until screws are disengaged from lower case and raise cover Remove feed tube and drive belt Remove top cover from gearbox enclosure Attach a suitable lifting strap and hoist to conveyor drive motor Remove screws securing both halves of flexible coupling to shafts of conveyor drive motor and gearbox and remove coupling halves Figure 5 3 gom dp 01 Jan 14 5 9 DE 1000LPVFDCentrifuge MAINTENANCE Removal Cont d FLEXIBLE MOTOR CcOUPLING GEARBOX ADJUSTING BOLT Figure 5 3 Conveyor Drive Flex Coupling 7 Remove nuts and washers securing conveyor drive motor to mounting base and lift and remove motor 8 Remove the gearbox as follows a Remove six screws securing gearbox Figure 5 4 to flange b Install two 3 8 16 jack screws into gearbox flange clearance holes and alternately turn both jack screws a few revolutions at a time to begin separating gearbox from flange Support gearbox during remainder of procedure using a lifting strap and suitable hoist Fully separate gearbox from flange by alternately turning jack screws until unit is fully detached e With gearbox supported by lifting strap and overhead lif
29. DAMAGE EQUIPMENT ENSURE THAT ALL ELECTRICAL AND CONDUIT CONNECTIONS ARE SECURE The centrifuge drive motors require three phase line power and ground connections In addition the customers feed pump motor must be connected to the centrifuge control system For explosion proof configurations connect the facility s three phase electric power supply to the contactor in the electrical panel Figure 3 6 or 3 7 For non explosion proof machines power connections are made inside control cabinet as shown Connect the feed pump motor to the terminal block in the bottom left side of the control cabinet as shown The control system can operate a 12 5kW feed pump drive motor The bowl and conveyor drive motors are not dual wound and must be operated at the design voltage For motor characteristics as well as additional information on electrical connections refer to the electrical schematic diagram in Section 8 A fused disconnect primary power supply is required for this equipment The fused disconnect and interconnecting wiring to the equipment must be suitably sized and in accordance with National Electrical Code NEC standards and all other applicable state and local codes Additional wiring requirements are as follows 1 The fused disconnect device shall have sufficient interrupting capacity to clear the maximum fault current capability of the power supply system 2 The GND connections in the electrical panel and control cabinet must be conn
30. G0001686 IFITTING CORD 1 500 NPT X 1 188 1 375 DIA 100 1 20008809 IFITTING CORD 1 500 X 875 1 000 DIA 0n 101 1 30009811 IFITTING CORD 2 500 X 1 500 1 800 DIA REF W S 14394 00 023 102 1 G0003533 FITTING CORD 500 X 250 375 DIA 90 DEGREE 103 1 30001687 IFITTING CORD 500 X 375 500 DIA 104 gt 30008403 ICABLE SHIELDED 18AWG 18 COND LT BLUE CUT 85 LENGTH DESCHIPTION EY E 105 1 __ 17006 02 USB PS2 ADAPTER AND BRACKET ASSY VFD CENTRIFUGE KIT CORRECTED BALLOON LOCATIONS FOR ITEMS 4 amp 5 Ws 8 1 2013 106 1 30002300 AIR FILTER HOUSING BX ELEMENT ORDER G0002302 ELEMENT pr 15000907 RTD ODEON 2 WIRE GREY REVISE ITEM 53 WAS 0007918 REVISE ITEM 93 QTY WAS 3 REPLACE ITEM 126 WAS 0005864 REPLACE ITEM 127 WAS rigors 108 footer Fa ERBE P A 0009863 yis SE 155 130 131435 43 T J 8 2013 SUPPLY OF BARTS OR OMERE FOR THE HAN 110 1 160012047 HEATER FAN FLR MNT 1200W 120VAC 32 140F 8 Y OTN TEN GS WAS E gt DRAWN 110 1__190012047 CEE RSS TEM WO SAC 3214 ITEM 9 WAS 16622 01 005 27 WAS 50007976 33 WAS G0007012 QTY ITEM 36 WAS 5 42 WAS G0007610 44 WAS G0012311 47 WA DERRICK 3 80012010 HOLDER FUSE 304 1 POLE 600V MAX MIDGET 6 CRH RE 64 75 WAS 17006 02 84 WAS G0009966 85 WAS G0009967 86 WAS G0009968 87 WAS G0009967 95 WAS 17377 01 96 WAS DMM 7 2 2012 er 113 L T 160012012 RELAY CONTROL 4NO 600V 120 COIL 17378
31. In one type of processing solids are removed and the liquid is returned for recirculation Alternatively solids are returned to the active system and the liquid is discarded Derrick Corporation does not authorize any other use of this equipment Intended usage of the equipment includes compliance with the operating maintenance and safety procedures included in this manual DESCRIPTION Major components of the centrifuge Figure 1 2 consist of the rotating assembly control cabinet bowl and conveyor drive motors operator control panel HMI purge system vibration switch and case base assembly and skid The following paragraphs describe these components BOWL DRIVE MOTOR ROTATING ASSEMBLY PURGE SYSTEM SKID en OPERATOR CONTROL 2p A Te TUBE PANEL HMI I i bit di CONVEYOR DRIVE MOTOR GEARBOX CONTROL ELECTRICAL CABINET PANEL CASE VIBRATION LIQUID BASE SWITCH DISCHARGE SOLID DISCHARGE Figure 1 2 DE 1000LP VFD Centrifuge Major Components Rotating Assembly The rotating assembly consists of a cylindrically shaped stainless steel bowl conveyor assembly and related components The bowl consists of a straight stainless steel cylinder with a conical section at the discharge end and a flat liquid bowl head at the opposite end Openings are provided at both ends to permit liquid and solid discharges The bowl ends are supported by roller bearings having grease fittings to facilitate periodic lubrication
32. MOTOR NOT RUNNING ROTATING AT SET SPEED GRY NOT AT SET SPEED GRN PLC COMMUNICATION Run larm forward RED NO PLC BC Ready Qiraut Reverse GRN MOTOR ACCELERATING 2 ony NOT ACCELERATING Online Speed RPM uoc GRN MOTOR DECELERATING BOWL SPEED SETTING Bowl Current DC GRY NOT DECELERATING LER 2157 3000 0 0 2 7685 8 V _____ present OUTPUT CURRENT PLC CALCULATED Actus 0 Temp Heatsink MOTOR SPEED 95 4 F 35 3 7 PERCENTAGE OF MAXIMUM 0 PERMISSIBLE TEMPERATURE RISE GRN BELOW OVERSPEED a 0 0 2 RED EXCEEDING OVERSPEED Motor PRESENT OUTPUT POWER TOLERANCE m 13 pi 7 TOTAL HOURS OF VFD OPERATION TORQUE EXPRESSED AS A PERCENTAGE OF TOTAL Diagnostics VFD Temp VIEW TEMPERATURE UNCONTROLLED BOWL STOPPAGE TREND SCREEN CLICK TO SWITCH TO VFD CONTROL FOR REDUCED STOPPAGE TIME PRESENT VFD TEMPERATURE VIEW DIAGNOSTICS SCREEN BOWL STOPPING UNDER VFD CONTROL FOR FASTER STOPPAGE Figure 4 11 Bowl VFD Screen GRN NO ALARM FAULT RED ALARM FAULT PRESENT GRN OPERATIONAL GRN MOTOR RUNNING GRN RUNNING GRN RUNNING AT SET SPEED GRY ALARM PRESENT GRY RUNNING GRY MOTOR NOT RUNNING ORY NOTAT SET SPEED RED DIFFERENTIAL SPEED CANNOT A MOTOR ACCELERATING u GRY NOT ACCELERATING BE MET AT CURRENT BOWL SPEED ess s Alarm vard Ready Fauk everse E MOTOR DECELERATING GRN PLC COMMUNICATION
33. PLC Figure A 15 Customer PC Test Connections to Ping Routers REFERENCE DRAWINGS Drawings included in this appendix are listed in Table A 1 These drawings are included to assist in the installation and operation of the HMI Server Table A 1 HMI Server Drawings Number Title 17647 00 Remote VFD Centrifuge HMI Server Kit With Activation for Two Three or Four Centrifuges 18308 00 Wiring Diagram for Remote VFD Centrifuge HMI Server Kit 18309 00 Ethernet Connection Diagram for Remote VFD Centrifuge HMI Server Kit A 10 15 Feb 13 HMIServerSystem DERRICK CORPORATION Document No PE S 069 03 03 CERTIFICATE OF ORIGIN Equipment Model Characteristics Centrifuge DE 1000 GBD DE 10007M FHD DE 1000 VFD 0 600VAC 50 60Hz 3PH Dertick Corporation acknowledges that the above set forth product is manufactured in the United States of America as of the data of this certificate This certificate is governed by the applicable purchase order terms in effect at the time of Derrick Corporation s otiginal shipment of the referenced product Date 29 December 2011 http dmc sps qc Certificates Origin Standard PE S 069 03 03 doc Revison Number 2 Revision Date 29 December 201 1 vvv Da U Signature Jennifer J Polanowski Derrick Corporation Document No PE S 009 08 00 ERRICK CORPORATION CERTIFICATE OF QUALITY Equipment Centrifuges Model DE 1000
34. Shutdown ea 4 21 5 Malntenancei lt a 5 1 01 Jan 14 A nA S 5 1 Top Cover Opening Closing 5 1 Preventive Maintenance tenerte iret an 5 2 Lubrication Chart ouai aM eu a dre 5 4 Drive Belt Replacement mision ae eel epa 5 4 Purge System u a 5 5 Rotating Assembly 5 9 TE rated 5 14 Hardware Torque 5 15 TOC 2 01 Jan 14 DE 1000LPVFDCentrifuge CONTENTS Section Page Date 5 Maintenance Cont d Recommended Spare 5 18 Troubleshooting etm 5 21 Alarm and Fault Messages ita 5 29 VFD Alarm and Fault Cross 5 36 Control Component indicators lid 5 37 6 7 Not Used 8 Reference DrawingSs ii iii 8 1 15 Jan 11 9 Installation and Maintenance Log 9 1 15 Jan 11 Appendix A HMI Server System 15 Feb 13 01 Jan 14 TOC 3 DE 1000LPVFDCentrifuge DERRICK CORPORATION SECTION 1 INTRODUCTION OVERVIEW This manual provides instructions for installing and operating the DE 1000LP Variable Frequency Drive VFD centrifuge Figure 1 1 The manual is divided into several sections to assist the user in readily accessing the informa
35. at or below 7 0 8 WC 17 4 2 mbarg Repeat relief test several times Open the supply regulator to between 60 and 115 psi 4 and 8 barg to start the purge flow Check that the internal logic gage reads 30 psi 2 bar At this time the ALARM PRESSURIZED indicator should be green and the PURGING indicator should be amber If the amber indicator remains off the flow through the relief valve is below the minimum for which the flow sensor has been calibrated Check the air supply pressure at the inlet to the control unit while purging is taking place It must be above the minimum specified pressure CONNECT MAGNAHELIC GAGE AT THIS JUNCTION LEAKAGE COMPENSATION VALVE 01 Jan 14 5 7 DE 1000LPVFDCentrifuge MAINTENANCE Leakage Compensation Test Cont d 6 The purge timer will start as soon as the PURGING indicator turns amber Check that the time delay between the PURGING indicator turning amber and the application of power to the control cabinet is not less than the minimum time required for purging the cabinet Times in excess of the minimum are permitted and a tolerance of 20 is normally acceptable If the time is too short it must be increased accordingly 7 After power has been applied via the control unit the purging valve will close and the air flow into the cabinet will be controlled by the leakage compensation valve The setting of the leakage compensation valve should now be checked One of
36. excessive current Reduce feed rate or reduce bowl speed Replace motor if defective F1021 Bowl Motor Thermal Overload Check Bowl Motor Temperature and Thermistor Bowl drive motor shut down due to high temperature or defective thermistor in motor winding Check motor temperature Allow motor to cool and then check for continuity across thermistor leads If open circuit is found replace motor Bad connection s Check connections at TB2 7 and 8 at transmitter intrinsic barrier and at conveyor VFD Correct as required Replace motor if no defects are found F2001 Conveyor High Torque Alarm Reduce Feed Rate Conveyor torque exceeds pre set limit Rate Reduce feed rate and or increase differential speed F2002 Conveyor High Torque Fault and Shutdown Perform Cleanout and Reduce Feed Conveyor torque exceeds pre set limit After bowl has stopped rotating perform cleanout procedure to remove solids buildup and re start centrifuge at reduced feed rate and or higher differential speed Communication lost between conveyor VFD and PLC F2010 Conveyor VFD Communications Error Confirm that green LED next to Ethernet cable on Ethernet switch is lighted indicating that hub is functional Check connections between conveyor VFD and PLC and correct any defects Replace conveyor VFD communication module if no other defect is found F2011 Conveyor VFD Alarm Ref Trou ble
37. into contact with conveyor flight Figure 5 5 If measurement is 1 25 4mm or more the conveyor is worn excessively and the rotating assembly should be returned to Derrick for overhaul 0 7052 17 9MM NEW 1 000 25 4MM MAXIMUM ALLOWABLE WEAR Figure 5 5 Conveyor Flight Wear Measurement Installation 1 Remove all nicks and or burrs from pillow blocks and mating surfaces Clean all surfaces of any protective coating applied after removal 2 Reinstall shims in proper locations as noted during removal 01 Jan 14 5 11 DE 1000LPVFDCentrifuge MAINTENANCE Installation Cont d Clean alignment pins before reinstalling and apply anti seize compound 3 4 Orient rotating assembly to horizontal position and carefully lower into case until about 1 2 13mm above base Insert bolts through pillow blocks and start threads into base Do not tighten bolts Lower rotating assembly fully onto base Insert alignment pins through pillow blocks and lightly tap into holes to fully align pillow blocks with base mounting holes Tighten bolts in accordance with applicable specification in Hardware Torque Specifications to secure pillow blocks to base Install gearbox as follows a Insert new O ring into groove in face of gear flange and apply grease to shaft to facilitate installation Place lifting strap on gearbox and using an overhead lifting device CAREFULLY lift and position gearbox to engage s
38. m Dewt Fat inr VED Faut story Fore VIO Fast ster ee fete Com ng ae m cS um 5 um um 5 AA om awe exe Ic i omme 1 e Ab Centrifuges Canertage 2 3 Seng Alarma Figure A 9 VFD Screen Centrifuge 1 15 Feb 13 A 7 HMIServerSystem APPENDIX A VFD CENTRIFUGE HMI SERVER SYSTEM Demen Centntuge t Centrtuge 2 Centtuge 3 06 7190 Demo fersice Tomperames Uni vervon Tempeceture Unite EXIT PROGRAM AND SHUT DOWN DISPLAY CUSTOMER SUPPORT AND PC THEN DISPLAY DESKLOCK SCREEN HMI SERVER ACTIVATION DATA Figure A 10 Pump Setup Screen 24 7 PEU Maintenance amp Operation Manuals Technical Support m Oilfield Support Mining Support HMI Server Activation Figure 11 Support Activation Screen Home aem s A Figure A 12 Alarms Screen mes rr eme ls ee Figure A 13 Cleanout Screen A 8 15 Feb 13 HMIServerSystem REVERT TO WINDOWS SCREEN Restart Windows APPENDIX A VFD CENTRIFUGE HMI SERVER SYSTEM START UP PC ReadOny FTViewPoint PROGRAM INITIATES AUTOMATIC HISTORICAL DATA COLLECTION DataLogStart Shutdown PC Set
39. of the cover gap at all times 5 Raise the cover to the fully opened position and insert a 1 2 12 7mm hardened steel pin through one hinge to lock the cover open 6 After performing the activity that required the cover to be opened reverse steps 2 through 5 to close the cover During the closing procedure ensure that both operators are capable of controlling the cover s descent and that all body limbs and other items remain clear of the gap INSTALLATION SEQUENCE Following is the sequence of steps for installing the centrifuge The sequence presented may vary depending on the user s facilities and previous experience with this type of equipment 1 Read and understand all safety information in Section 2 before installing and operating this equipment 2 Read and understand the equipment handling procedures in this section before lifting and moving the equipment Position and level equipment at installation site Remove shipping components and lower and secure the rotating assembly to the base Adjust drive belt refer to Section 5 Connect liquid discharge line If discharge duct is to be used connect duct to solids discharge chute Connect flexible lines to inlet feed and flushing flanges i9 po us oue Connect electric power supply to the equipment and connect feed pump to terminals of feed pump controller 10 Refer to Section 4 for startup and operating procedures SITE PREPARATION AND CLEARANCE REQUIREMENTS
40. on dial indicator is highest mark across gearbox and flange along axial centerline where surfaces mate INDICATE HERE MARK HERE 01 Jan 14 5 13 DE 1000LPVFDCentrifuge MAINTENANCE f Manually rotate gearbox until mark made in step e is PME at top Loosen hex head screw closest to mark as well as both screws to each side of the mark h Insert shim having approximate thickness of dial indicator measurement between flange and gearbox Shim should barely contact threads of screw hole closest to mark made in step e i Tighten screws loosened in step g j Repeat steps d through i if required until TIR does not exceed 0 002 0 05mm k Trim projecting shim stock 13 After completing gearbox installation install top cover over gearbox 14 Install drive belt and apply adequate tension to prevent slippage 15 Install feed tube and secure in its support 16 Close cover and secure by tightening screws TOOL LIST The following tool list includes all tools and equipment supplied to facilitate maintenance of the DE 1000LP VFD centrifuge Each component is listed with its part number quantity supplied and use or application DE 1000LP VFD CENTRIFUGE TOOL LIST Allen 33212 Long Arm Allen Wrenches 3 32 to 1 2 1 Various rotating assembly hardware G0008667 Socket 15 16 1 2 Drive 1 Remove and install pillow block bolts OTC 1039 Bearing Puller 2 Jaw 10 Reach 0
41. shut down due to high temperature or defective thermistor in motor winding Bad connection s Check motor temperature Allow motor to cool and then check for continuity across thermistor leads If open circuit is found replace motor Check connections at TB2 3 and 4 at transmitter intrinsic barrier and at pump VFD Correct as required Replace motor if no defects are found Stator F3022 Pump Bearing Stator Thermal Overload Check Pump Bearing Temperature and Pump drive motor shut down due to high bearing temperature or high temperature in stator winding Check motor bearing temperature Allow motor to cool and then check for continuity across stator thermistor leads If open circuit is found replace motor Bad connection s F3030 Pump Motor FLA Download to Check connections at TB2 3 and 4 at transmitter intrinsic barrier and at pump VFD Correct as required Replace motor if no defects are found VFD Failed Pump motor FLA download was not successfully completed Repeat pump motor data download procedure Verify that pump drive is on line and stopped F3031 Pump Motor Power Download to VFD Failed Pump motor power download was not successfully completed Repeat pump motor data download procedure Verify that pump drive is on line and stopped F3032 Pump Motor Power Units Download to VFD Failed Pump motor power units download was not successfully completed Repeat p
42. solid discharge ports on the bowl they contain only the adsorbed moisture CONTROL SYSTEM Centrifuge operation is supervised by a PLC that interfaces with the VFDs supplying power to the bowl conveyor and feed pump drive motors Monitoring and control of the centrifuge may be performed locally or up to thousands of miles away The environmentally hardened PLC also offers short term data storage and a high degree of operating flexibility The graphical color interface mounted on the control cabinet facilitates communication with the VFDs and provides real time access to system operating characteristics Through the control panel the operator may start the centrifuge enter and adjust bowl and conveyor speeds set feed rate and shut down the machine 15 Aug 13 1 7 DE 1000LPVFDCentrifuge INTRODUCTION Various inputs including main bearing temperatures bowl speed bowl and conveyor torques cabinet interior temperature and vibration are transmitted to the PLC which then responds with corresponding outputs to govern centrifuge operation Critical status information is displayed on the control panel as well as alarm and fault messages that signal the operator of any potential or imminent malfunctions Any excessive variation from a pre set limit causes the PLC to automatically shut down the centrifuge and display an explanatory message for the cause of the shutdown In addition emergency shutdown may be performed by the operator at any time
43. start the machine using the Normal Startup procedure above and re check speed EMERGENCY SHUTDOWN To stop the centrifuge in case of emergency press the EMERGENCY STOP button on the control cabinet select STOP on the Operation screen or open the fused disconnect supplying electric power to the machine Pressing EMERGENCY STOP immediately removes power from the bowl conveyor and pump motors allowing the bowl to coast to a stop This may take more than 15 minutes depending on the bowl speed and amount of material inside the bowl To stop the bowl faster press the STOP button on the Operation screen or display the Bowl VFD screen and press the BOWL IS COASTING TO A STOP button However before pressing this button all alarms faults must be cleared 30 Sep 13 4 21 DE 1000LPVFDCentrifuge DERRICK CORPORATION SECTION 5 MAINTENANCE GENERAL This section describes preventive and corrective maintenance procedures for the DE 1000LP VFD centrifuge Obvious procedures are omitted Before beginning any centrifuge maintenance shut down lock out and tag out equipment DANGER HIGH VOLTAGE SHUT DOWN LOCK OUT AND TAG OUT ELECTRIC POWER AND ENSURE THAT EQUIPMENT HAS STOPPED ROTATING BEFORE WORKING ON THIS EQUIPMENT WARNING ALWAYS BE AWARE OF WORK AREA HAZARDS TO PROTECT AGAINST SLIPS TRIPS AND FALLS WHEN WORKING ON OR NEAR THIS EQUIPMENT WARNING LOUD NOISE WEAR HEARING PROTECTION AT ALL TIMES WHEN WORKING ON OR NEA
44. startup or normal operation due to slumping of the wall cake or other unbalanced condition of the bowl The machine may be re started by pressing the reset button on the vibration switch and then using the Normal Startup procedure above If the machine continually trips during normal startup flush the bowl with fresh water while running the automatic cleanout routine Main Bearing Temperatures Temperature sensors are installed on the liquid and solid end main bearings and connected to the PLC Bearing temperatures are continuously displayed on the Operation screen An alarm message is displayed on the control panel when bearing temperature exceeds 225 F 107 C If temperature rises to 250 F 120 a fault message appears and the centrifuge is shut down Excessively high bearing temperatures usually indicate bearing failure which can result from inadequate or excessive lubrication contamination or severe wear Refer to Section 5 for main bearing replacement procedure Excessive Bowl Speed A sensor that detects the rotational speed of the bowl provides an input to the PLC that produces a continuous display of actual bowl speed on the Operation and Bowl VFD screens A fault message is displayed and the centrifuge is immediately shut down if speed rises to 3100 RPM To re start the centrifuge allow the bowl to coast to a complete stop and check for and remove the cause of excessive speed refer to Section 5 After correcting defect s re
45. to 30 RPM If excessive resistance is encountered during the cleanout the system will pause and alert the operator that the automatic cleanout has been unable to clear the centrifuge Operator intervention is then required to repeat the automatic cleanout operation Manual Cleanout If the manual cleanout option is selected the operator may elect to jog the conveyor in forward and reverse with the bowl set at zero RPM If desired however the operator may choose to operate the bowl as well as the conveyor Reverse rotation of the conveyor is governed by a timer that terminates reverse operation after a pre set interval The primary purpose of the manual cleanout mode is to permit jogging the conveyor in an effort to remove impacted material NORMAL SHUTDOWN The normal shutdown procedure is to be used for controlled stopping of operation Normal shutdown is performed for routine activities such as cleaning lubrication inspection or adjustment Note Proper shutdown and flushing of the bowl can prevent high vibration at the next startup NORMAL SHUTDOWN 1 Stop the feed pump 2 Initially continue the supply of fresh flushing water to remove all solids from conveyor and bowl Continue flushing for 3 to 5 minutes after feed pump has been shut down Regardless of shutdown duration the conveyor operates at a pre set differential speed while the bowl decelerates to a stop This process cleans the bowl during the shutdown The centrif
46. 0LPVFDCentrifuge OPERATING INSTRUCTIONS Pond Depth Four adjustable effluent ports Figure 4 4 are provided on the liquid bowl head to facilitate setting the pond depth all ports must be set identically A higher pond depth increases settling time by permitting more liquid to remain in the bowl However a higher pond depth also reduces the beach area at the solids discharge end of the bowl which will result in a wetter solids discharge Pond depth can only be adjusted with the centrifuge fully stopped and disabled For this reason pond depth is usually adjusted last The factory pond depth setting is usually satisfactory when used in conjunction with feed rate bowl speed and conveyor speed adjustments However if desired results cannot be achieved by other means the pond depth may require re setting To adjust pond depth proceed as follows WARNING DO NOT OPEN COVER OR ATTEMPT ANY ADJUSTMENT OR MAINTENANCE ON THE CENTRIFUGE UNLESS THE BOWL IS AT A COMPLETE STANDSTILL WARNING WHILE OPENING AND CLOSING THE CENTRIFUGE COVER PERSONNEL MUST ENSURE THAT ALL BODY LIMBS AND ANY OTHER ITEMS ARE CLEAR OF THE COVER GAP TWO OPERATORS MUST BE USED WITH BOTH HANDS ON THE COVER HANDLES AT ALL TIMES DERRICK RECOMMENDS HAVING A HOIST AVAILABLE IF ADDITIONAL ASSISTANCE IS DESIRED DURING THE OPENING CLOSING PROCEDURE 1 Shut down lock out and tag out the centrifuge using the Normal Shutdown procedure described later in this section
47. 1011 Bowl VFD Alarm Ref Troubleshooting Section of User Manual Identify alarm from operator control panel Perform indicated corrective action Bowl VFD fault F1012 Bowl VFD Fault and Shutdown Ref Troubleshooting Section of User Manual Identify fault from operator control panel Perform indicated corrective action F1013 Bowl VFD Ground Warn Alarm Ref Troubleshooting Section of User Manual Bowl VFD has detected high current leakage to ground Check condition of cable and all connections between bowl VFD and bowl motor and correct any defects F1014 Bowl VFD In Phase Loss Alarm Ref Troubleshooting Section of User Manual Bowl VFD has detected unbalance or partial loss of input three phase power Check wiring between VFD and supply source correct defect s Check supply power and correct any defects F1015 Bowl VFD Power Loss Alarm Ref Troubleshooting Section of User Manual Incoming power loss or low voltage supply Check incoming power and correct any defect s 5 30 DE 1000LPVFDCentrifuge 01 Jan 14 MAINTENANCE ALARM AND FAULT MESSAGES F1016 Bowl VFD Undervoltage Alarm Ref Troubleshooting Section of User Manual Incoming power loss or low voltage supply Check incoming power and correct any defect s F1017 Bowl VFD Drive OL Alarm Ref Troubleshooting Section of User Manual Feed rate causing overload Bowl drive motor drawing
48. 2 Shell Omala 320 Gearbox 67510E 07 08 08 Loctite Anti Seize Lubricant Fasteners 76764 05 27 09 2 4 30 Sep 13 DE 1000LPVFDCentrifuge Q DERRICK CORPORATION SECTION 3 INSTALLATION GENERAL This section describes the recommended installation procedure for the Derrick equipment defined by the model number and drawing number associated with your equipment The centrifuge is shipped fully assembled For safety during shipment however the rotating assembly is supported by shipping brackets It must be lowered onto the base and then its bearing pillow blocks secured to the base SAFETY Read and understand ALL safety information presented in this manual before installing and operating this equipment Refer to Section 2 for a summary of Warnings addressing installation operation and maintenance of this equipment Before beginning the installation review the equipment handling procedures in this section Note particularly the information concerning lift points and the use of spreader bars before lifting or moving the equipment Failure to observe proper equipment handling procedures may result in serious personal injury or death and or damage to the equipment WARNING TO ENSURE PROPER BALANCE AND ORIENTATION WHEN UNIT IS RAISED AND PREVENT DAMAGE TO COMPONENTS ATTACH LIFTING SLING ONLY AT DESIGNATED LIFT POINTS DO NOT ATTEMPT LIFTING BY ATTACHMENT TO ANY OTHER LOCATION WARNING BE SURE THAT HANDLING D
49. 3 4 Gr Fitting 2 N A N A Liquid End Bowl Head 14 15 16 18 x 4 Hx Hd 6 Anti Seize Unspecified Flinger Cover 15 3 8 16 x 1 Hx Skt Hd 16 Anti Seize 183 Ib 20 7Nm Pillow Block Cover 16 3 8 16 x 1 Hx Skt Hd 8 Anti Seize 252 in lb 28 5Nm Spline Hub 17 1 4 20 x 5 8 Hx Skt Hd 4 Anti Seize 144 in Ib 16 3Nm Pillow Block Flinger 21 5 16 18 x 1 Hx Skt Hd Loctite 262 300 in Ib 34Nm Gearbox Flange 23 10 24 x 1 4 Set Screw 2 Anti Seize N A Case Flinger 26 5 16 18 x 7 8 Hx Skt Hd 12 Anti Seize 144 in Ib 16 3Nm Effluent Port 28 13 8 16 x 1 2 Set Screw 2 Anti Seize N A Seal Housing 29 5 8 11 x 2 1 4 Hx Hd 4 Anti Seize 197 ft lb 267Nm Pillow Block 30 8 Pin 7 16 20 x 2 1 2 4 Anti Seize N A Pillow Block 31 7 Pin 3 24 20 x 2 1 2 4 Anti Seize N A Pillow Block 34 5 16 18 x 3 4 Hx Skt Hd 6 Anti Seize N A Gearbox to Gearbox Flange 36 3 8 x 1 Pin 2 680 N A Spline Hub 2 4 Serial numbers below CF000272 2 on serial numbers CF000272 thru CF000678 0 on serial numbers above CF000979 21 4on serial numbers below CF000272 6 on serial numbers CF000272 thru CF000678 9 on serial numbers above CF000679 RECOMMENDED SPARE PARTS Defective parts should be replaced as soon as possible to restore the equipment to full operational status Refer to the engineering drawings in Section 8 for Derrick component locations and part numbers The following table lists the recommended spar
50. 4225 U S A 6 O GREASE IN GREASE COMES GREASE IN 2 HERE OUT HERE 1 GREASE COMES OUT HERE LUBRICATION amp MAINTENANCE SCHEDULE 201bs 1 2 I INHIALBREAK IN _ 5065 0 1 2 6 CLEAN OUT UNDER FLINGER COVERS MIXING LUBRICANTS MAY CAUSE CATASTROPHIC FAILURE DRAIN amp REPLACE ALL FLUIDS EVERY 120 DAYS OR 1800 HRS OF USE YN LUBRICATION amp MAINTENANCE SCHEDULE Z N LL I DERRICK VD CENTRIFUGE Z epi de O 6 11 92 sue NIS PAN LR CHANGE CCS 12 8 10 F a LE 9 CORPORATION THE INFORMATION CONTAINED ON THIS DRAWING SHALL ONLY BE USED BY CUSTOMERS OR PROSPECTS OR THEIR DRAWING NO AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY CORPORATION OF PARTS OR ASSEMBLIES TO DERRICK OR BY OTHERS FOR THE SPECIFIC REASON OUTLINED IN THE TRANSMITTAL WHETHER 6 4 7 O 0 O WRITTEN OR VERBAL 590 DUKE ROAD BUFFALO NY 14225 U S A MAN
51. 8 00 008 General Arrangement DE 1000LP VFD Centrifuge 14394 00 023 Electrical Wiring Schematic DE 1000LP 460 480V 60 Hz XP Centrifuge 9587 00 007 Rotating Assembly DE 1000 Centrifuge Radial Flow 11372 01 Gear Unit DE 1000 Centrifuge 52 1 10647 00 010 Lubrication amp Maintenance Schedule DE 1000LP Centrifuge 14894 00 Rotating Assembly Hardware Parts List 16615 00 Parts list DE 1000 Base Sensor System 16622 00 005 XP Electrical Control Panel DE 1000 VFD 16545 00 006 DE 1000 LP Control Enclosure Assembly XP 15 Jan 11 8 1 DE 1000LPVFDCentrifuge 14 67 16 811 HOLES NOTES 99 1 2 6241 5 8 16 1 3 4 44 EE HINGE PLATE 1 ONE 1 UNIT COMPLETE ieu d DD BASE GAS SPRING MOUNT 18056 05 i SPOONING DIENEN 5 1 8 130 _ 3 LUBRICATION SEE MANUFACTURING SHEET IN MANUAL 5 127 AN 1 AA COVER SAFETY PIN ASSEMBLY 1 10902 1 1 0 A MAIN BEARINGS PER APPLICATION 5 1127 B CONVEYOR BEARINGS PER APPLICATION I COVER HINGE 2 _______________ 13490 02 06 N 2 x cover HINGE 1 13490 01 006 C GEAR BOX Bat een 279 Ia TE IN 2 W ENCLOSURE ISOLATOR MOUNT REAR ______ _ 0012076 O 4 OPERATING SPEED S SEE MANUFACTURING SHEET IN MANUAL 5 1 8 130 F MOTOR vor een 5 MOTORS ARE EXPLOSION PROOF LIQUID DISCHARGE DETAIL 4 7 8 124 La 13 16 122
52. ACEMENT DANGER HIGH VOLTAGE SHUT DOWN LOCK OUT AND TAG OUT ELECTRIC POWER AND ENSURE THAT EQUIPMENT HAS STOPPED ROTATING BEFORE WORKING ON THIS EQUIPMENT WARNING VISION HAZARD SAFETY GLASSES MUST BE WORN AT ALL TIMES WHEN WORKING ON OR NEAR THIS EQIPMENT TO PREVENT SERIOUS EYE INJURY OR PERMANENT LOSS OF VISION The drive belt should be replaced if inspection reveals damage or deterioration To replace the belt proceed as follows 1 Loosen screws securing feed tube clamp and slide out feed tube 2 Release latches and remove belt guard covering sheaves 3 Loosen bolts securing bowl drive motor mounting plate to base Figure 5 2 lift motor to loosen belt and slip belt off sheaves 4 Check sheave parallel alignment using a straight edge Adjust position s of sheave s to achieve parallel alignment within 0 0156 0 4mm 5 Install new belt on drive motor and bowl assembly sheaves 6 Move motor mount downward in the adjusting slots to apply sufficient belt tension to permit deflection of 5 8 16mm with 20 lbs of pressure exerted at the midpoint of the belt After correct tension is set tighten motor mount bolts 7 Install belt guard and latch in place 8 Insert feed tube into feed tube support until shoulder fully contacts support and tighten screws to specification listed in Hardware Torque Specifications 5 4 01 Jan 14 DE 1000LPVFDCentrifuge MAINTENANCE MOTOR MOUNT ADJUSTING SLOT MOTOR MOU
53. E SUFFICIENT LIFTING CAPACITY TO SAFELY HANDLE THE WEIGHT OF THE EQUIPMENT WARNING DO NOT REMOVE SHIPPING BRACKETS UNTIL EQUIPMENT HAS BEEN POSITIONED AT FINAL INSTALLATION SITE WARNING WHEN USING AN OVERHEAD LIFTING DEVICE USE ALL FOUR LIFTING POINTS PROVIDED The centrifuge is shipped fully assembled and installed on a shipping skid A label indicating the weight of the unit was affixed to the machine Refer to the general arrangement drawing in Section 8 for equipment weight and other technical data 30 Sep 13 33 DE 1000LPVFDCentrifuge INSTALLATION While the centrifuge is still mounted on the shipping skid it may be transported on the ground using a forklift After the machine is removed from the shipping skid an overhead lifting device is required Four reinforced lifting lugs are built into the equipment frame to allow attachment of an overhead lifting device Figure 3 2 Lifting points are labeled LIFT HERE ONLY DO NOT attempt lifting equipment by attaching slings or similar lifting aids to the electric motor or other non designated portions of the unit Use of spreader bars is recommended LIFTING HOOK SPREADER BAR LI i T Figure 3 2 Lifting Arrangement EQUIPMENT LEVELING The centrifuge must be properly leveled for satisfactory operation The equipment must be leveled along the length and width of the unit Figure 3 3 A 2 foot or torpedo level is recommen
54. EME CAUTION WHEN OPERATING CENTRIFUGE WITH PURGE SYSTEM BYPASSED DANGEROUSLY HIGH VOLTAGE WILL BE PRESENT IN CONTROL CABINET IF DOOR IS OPENED WHILE POWER IS APPLIED To bypass the purge system proceed as follows 1 Be certain that centrifuge is in a non hazardous environment then shut down lock out and tag out electric power to centrifuge Remove bolts securing electrical panel door and open door Locate intrinsic barrier at upper right side of electrical panel and install a jumper across terminals 1 and 4 to disable the purge system Figure 4 1 Label jumper Bypass 5 To restore purge system operation remove the Purge Bypass jumper and close and secure electrical panel door Confirm proper operation of the purge system 30 Sep 13 4 3 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS CONNECT JUMPER ACROSS TERMINALS 1 AND 4 LABEL JUMPER PURGE BYPASS Figure 4 1 Purge System Bypass INITIAL STARTUP Q Note If rotating assembly is heated before starting centrifuge follow COLD CLIMATE STARTUP instructions later in this section to ensure proper bearing lubrication Perform the initial startup procedure when the centrifuge is being started for the first time following installation or after the machine has been relocated 1 Check that all tools documents and shipping components have been removed and there are no obstructions to operation 2 Verify that all personnel are clear of
55. EVICES HAVE SUFFICIENT LIFTING CAPACITY TO SAFELY HANDLE THE WEIGHT OF THE EQUIPMENT LOWER THE CENTRIFUGE GENTLY INTO PLACE AS JARRING MAY CAUSE DAMAGE WARNING DO NOT REMOVE SHIPPING BRACKETS UNTIL CENTRIFUGE HAS BEEN POSITIONED AT FINAL INSTALLATION SITE WARNING WHILE OPENING AND CLOSING THE CENTRIFUGE COVER PERSONNEL MUST ENSURE THAT ALL BODY LIMBS AND ANY OTHER ITEMS ARE CLEAR OF THE COVER GAP TWO OPERATORS MUST BE USED WITH BOTH HANDS ON THE COVER HANDLES AT ALL TIMES DERRICK RECOMMENDS HAVING A HOIST AVAILABLE IF ADDITIONAL ASSISTANCE IS DESIRED DURING THE OPENING CLOSING PROCEDURE 30 Sep 13 3 1 DE 1000LPVFDCentrifuge INSTALLATION TOP COVER OPENING CLOSING PROCEDURES The proper procedures for opening and closing the top cover of the centrifuge must always be followed Two operators using both hands are required to open the cover Derrick recommends having a hoist available if additional assistance is desired during the opening closing of the centrifuge cover To open and close the cover proceed as follows 1 Shut down lock out tag out electric power to centrifuge and allow rotating assembly to coast to a full stop 2 Remove bolts securing cover to base 3 Have two operators using both hands grip the cover handles securely to ensure full control of the cover throughout the opening and closing process 4 As the cover is raised ensure that body limbs of all personnel and any other items remain clear
56. ING MACHINE WARNING BEFORE STARTING CENTRIFUGE BE SURE THAT ALL SHIPPING BRACKETS HAVE BEEN REMOVED AND BEARING PILLOW BLOCKS ARE PROPERLY TIGHTENED WARNING ALWAYS ALLOW MACHINE TO COAST TO A COMPLETE STOP BEFORE OPENING TOP COVER OR REMOVING GUARDS WARNING DO NOT OPERATE CENTRIFUGE IF EXCESSIVE NOISE OR VIBRATION DEVELOPS ALWAYS CONFIRM THAT VIBRATION SWITCH AND OTHER SAFETY DEVICES ARE FUNCTIONAL A A A A 2 2 30 Sep 13 DE 1000LPVFDCentrifuge SAFETY WARNING WHILE OPENING AND CLOSING THE CENTRIFUGE COVER PERSONNEL MUST ENSURE THAT ALL BODY LIMBS AND ANY OTHER ITEMS ARE CLEAR OF THE COVER GAP TWO HANDS MUST BE USED WITH BOTH HANDS ON THE COVER HANDLES AT ALL TIMES DERRICK RECOMMENDS HAVING A HOIST AVAILABLE IF ADDITIONAL ASSISTANCE IS DESIRED DURING THE OPENING CLOSING PROCEDURE Maintenance DANGER HIGH VOLTAGE SHUT DOWN LOCK OUT AND TAG OUT ELECTRIC POWER AND ENSURE THAT EQUIPMENT HAS STOPPED ROTATING BEFORE WORKING ON THIS EQUIPMENT WARNING TWO OPERATORS ARE REQUIRED TO SAFELY OPEN AND CLOSE COVER USING BOTH HANDS TO FULLY SUPPORT COVER THROUGHOUT TRAVEL Storage WARNING CENTRIFUGE MAY BE DAMAGED BY STORING IN A HIGH HUMIDITY ENVIRONMENT GREATER THAN 50 RH EQUIPMENT MUST BE STORED IN A LOW HUMIDITY ENVIRONMENT MATERIAL SAFETY DATA SHEETS MSDSs Material Safety Data Sheets MSDSs advise personnel of the properties and any possible hazards associated with the
57. IT CF000678 B E ITEM 33 BE USED WITH ROTODIFF ASSY 107 D6V B AN E 5 16 18 X 3 4 SS HEX SOCKET 0003059 144 IN LBS WEAR INSERTS ITEM 39 TO BE USED WITH ROTODIFF ASSY 1071 10 24 X 1 4 SS SET SCREW CUP POINT 60003874 CASE FLINGER 12 22 3 8 16 X 1 SS HEX SOCKET 60003064 252 IN LBS BOWL EXTENSION 9 21 5 16 18 X 1 HEX SOCKET ALY SKCS 31 18X100 300 IN LBS 262L ROTODIFF GEARBOX FLANGE 1 20 1 2 13 X1 SS SET SCREW FULL DOG 60005877 265IN 18S FEED ACCEL BUMP 8 18 3 8 16 X 3 4 SS HEX SOCKET 7 5006 232iN LBS CASE PLOWS ___ 8 16 3 8 16 X 1 SS HEX SOCKET 60003064 252 IN LBS SPLINE HUB 16 15 3 8 16 X 1 SS FLAT HEAD HEX SOCKET 00001868 183 IN LBS PILLOW BLOCK COVER AVA L 6 14 5 16 18 X 4 HEX SOCKET SST 60008200 NO TORQUE FLINGER COVER 8 13 1 4 20 X 1 SS HEX SOCKET 1 Go0030560 851 185 PULLEY SHEAVE 1 1 4 1 ste 0 Pest N A 680 S E BEARING HOUSING L6 11 5 6 18 X 55 HEX SOCKET G000302 144IN IBS S E SEAL HOUSING 8 10 3 8 16 X 1 SS HEX SOCKET Gooo3064 252IN 18S S E BOWL HEAD 2 09 0003467 N A S BOW HEAD 4 08 1 8 X 3 4 SS GREASE FITTING 60003513 S E BOW HEAD A AA 5 16 18 X 1 2 SS SET SCREW CUP POINT G0005508 262L S E BOWL HEAD 4 06 1 4 11 4 STEEL ____________
58. KED W GREEN G00093P4DGREEN 4 PT G0008563 DRANGE 4 PT G0008507X2 END THN H STR BIK e THIN M STR WHT FUSE 5 C 60012009 SPACE HEATER A NON INTRINSIC a ae DIT G0009384X3DGREEN 4 PT 60008562 10 GREY 4 PT G0008544 gt DRANGE 2 PT G0008563XDURANGE 4 PT G0004286 x2 END L 1 ise TS A 5 TERMINAL BLOCK g 8 60002873 TERMINAL 9 A ch TERMINAL BLOCKS o ge POWER BLOCK 0008892 50008892 60008891 GROUND SHELDS PL 60005308 SOWER DIS BLOCK COVER 60008803 4 69008882 Na 000490 n ms END ONLY E EIA G0008890 3 GROUND INCOMING GROUND LUG 60007213 bo py I IH _ A co en KA rE s et s E lt gt ew RO nno REN m B Abc d tao tat Mae d SHPP 100 SPARE SHPP 100 SHELDED CABLE CORD FITTING CONTROL 6 UAM CENTRIFUGE POWER se 10 60008809 60001686 1 s G0001687 JUNCTION BOX SUNCTION BOX 4 CORD FITING YP CABLE ASSY INTERFACE GOO00403y86 bs ii 4C 44AWG HIT d a 00009898 G0009899 BY OERS CONTACT Kg Les CONTACT v ve csn scs TAE SHE 9 95 we onl J XP CABLE ASSY BY OTHERS 1 12 1314 15 6 7 9 12 W CABLE GLAND AV XP REDUCER WHEN CLOSED AND WHEN CLOSED AND vil ve ste sel SES Lee Le
59. MPONENT PANEL BOTTOM 131 1 G0013391 1 2 LOCKNUT 8 1 116404 02 009 ICOMPONENT PANEL UPPER 132 1 0009340 1 2 SEALING GASKET 9 1 16622 01 006 EXPLOSION PROOF ELECTRICAL ASSEMBLY WITH HEATER 133 1 P1290 1 2 INSUL BUSHING PLASTIC 10 1 116401 01 005 ICONDENSER COVER D 11 1 G0007865 PURGE UNIT W RELIEF VALVE 12 T 115181 01 001 HMI PROTECTIVE COVER 13 1 117006 01 MOUSE ASSY VFD CENTRIFUGE KIT 14 1 116401 01 006 PURGE COVER 15 1 117365 01 E STOP MOUNTING PLATE 16 1 G0007244 INAME PLATE EMERGENCY STOP 17 1 20005325 BUTTON EMERGENCY STOP 18 1 G0009813 AIR CONDITIONER 3200 WATT 460 60 3 19 1 116404 03 009 ICOMPONENT PANEL LOWER 20 1 115197 01 003 INLET CONE EXTENSION 21 1 G0002604 INLET CONE 22 1 G0007588 AIR CONDITIONER COOLING MOTOR 48 23 El G0002603 FANWHEEL 8 BACKWARD CURVED Pe 24 1 16405 01 001 HMI MOUNTING BRACKET lt 25 1 120008006 RELIEF VALVE SERIAL OF PURGE REQUIRED REPLACEMENT ONLY INCLUDED IN 11 SS 26 1 G0004364 PROTECTIVE COVER No Dr 1 G0007976 INTERFACE 120 VAC PROGRAMMED 53 y M 28 3 G0008891 BLOCK PWR DISTR 3 POLE 2 0 14 29 3 20008892 IBLOCK PWR DISTR 1 POLE 2 0 14 ADDER 2 30 1 G0008889 IBLOCK PWR DISTR 3 POLE 6 350MCM 310A 52 3 31 1 G0007213 GROUND LUG INCOMING 32 1 G0012063 RAIL 35MM X 8 33 13 30008507 TERMINAL BLOCK END BARRIER 34 1 G0003504 ISURGE SUPPRESSOR 120V 60HZ 57 4 35 1 G0003552 POWER SUPPLY 24VDC 5 AMP
60. NG KIT 20008378 67 1 G0007338 IWIRE DUCT 1 1 2 X 2 X 30 3 4 68 60009874 WIRE DUCT 1 1 2 X 2 X 31 1 4 69 1 G0009875 WIRE DUCT 1 1 2X2 X 17 70 1 G0009876 IWIRE DUCT 1 1 2X2 X7 1 2 71 1 G0009877 IWIRE DUCT 1 1 2X 2 X 20 72 1 G0009863 1 8 ELBOW QUICK CONNECT REPLACEMENT ONLY PART OF ITEM 25 73 8 G0008005 IDOOR LATCH 74 1 116403 01 002 A C SUPPORT ANGLE 15 1 G0009864 TUBE 6MM X 12 LONG 76 3 G0003493 IFUSE TIME DELAY 15A 600VAC CLASS CC 77 3 G0008792 FUSE TIME DELAY 3A 600VAC CLASS CC 78 1 G0007230 PLC END BARRIER 79 1 G0007229 IPLC POWER SUPPLY B 80 1 20007995 ICOMPACT FLASH MEMORY CARD 81 G0007252 WIRE DUCT FASTENER MOUNT 82 3510 IWIRE SADDLE SMALL 83 B G0003519 WIRE SADDLE MEDIUM 84 1 G0007951 ETHERNET CABLE X 8 1 2 ETH SW PLC 85 2 G0009873 ETHERNET CABLE X 47 ETH SW HMI amp 15HP 86 1 G0009871 ETHERNET CABLE X 94 ETH SW 50HP 87 1 G0009872 ETHERNET CABLE X 60 1 2 ETH SW 20HP 88 12 G0008893 TERMINAL BLOCK COVER 2 0 89 3 20008890 TERMINAL BLOCK COVER 350MCM 90 1 G0002873 TRANSFORMER COVER 91 20009839 TERMINAL BLOCK JUMPER 92 2 TBS 2535 CORD FITTING 3 4 93 4 ISHPP 100 IPLUG 1 NPT SQ HD 94 1 G0009767 ICORD ASSEMBLY COND FAN MOTOR TO ENCLOSURE 95 1 G0009768 ICORD ASSEMBLY MAIN SUPPLY 96 1 20009899 ICORD ASSEMBLY BOWL MOTOR ENCLOSURE 97 1 20009898 ICORD ASSEMBLY CONVEYOR MOTOR TO ENCLOSURE 98 1 117382 01 CORD ASSEMBLY INTRINSIC PURGE SYSTEM 99 1
61. NT BOLT DRIVE MOTOR Figure 5 2 Drive Belt Tensioning PURGE SYSTEM Bypassing Purge System The purge unit may be bypassed when necessary to apply electric power to the centrifuge while the control cabinet door is open but this should be done only after verifying that the centrifuge is in a non hazardous area After completing the work the purge system must be restored to operation and satisfactory operation confirmed Refer to Section 4 for the purge bypass procedure WARNING USE EXTREME CAUTION WHEN WORKING ON EQUIPMENT WITH PURGE SYSTEM BYPASSED DANGEROUSLY HIGH VOLTAGE WILL BE PRESENT IN ELECTRICAL PANEL AND CONTROL CABINET IF POWER IS APPLIED WARNING FAILURE TO WEAR SAFETY GLASSES MAY RESULT IN SERIOUS EYE INJURY OR PERMANENT LOSS OF VISION SAFETY GLASSES MUST BE WORN AT ALL TIMES WHILE PERFORMING ANY MAINTENANCE PROCEDURE Inspection and Test Procedures Periodic inspection and test procedures supplemented by any additional requirements imposed by local codes are recommended The following tests should be performed at least every 6 to 24 months depending on site conditions 01 Jan 14 5 5 DE 1000LPVFDCentrifuge MAINTENANCE Visual Inspection and Checks 1 Inspect condition of relief valve and spark arrestor Remove all debris and corrosion or replace relief valve 2 Check drain air supply filters on cabinet exterior PURGE SYSTEM AIR FILTERS zi 3 4 a AIR FILTER ELEMENT
62. ON s SCREEN SLEECTION Suus Clean Out Alarms Faults TEMPERATURE OF L BUTTONS 8 LIQUID END BEARING Bowl VFD Conv VFD Pump VFD TEMPERATURE OF SOLID END BEARING Figure 4 2 Operation Screen At Startup DRIVE OPERATIONAL ADJUST CONVEYOR GRN DRIVE RUNNING RED DRIVE FAULT DIFFERENTIAL SPEED GRY DRIVE OFF Deo m B Pump ADJUST BOWL SPEED input RPM 3 2500 y 7 _ FEED PUMP OUTPUT Actual RPM Actual RPM Actual OF TOTAL AVAILABLE BOWL OPERATING DATA 0 0 0 0 0 Torque Torque Pumo 94 CENTRIFUGE IS 0 0 0 0 gt PUMP OPERATING DATA OPERATING CONVEYOR OPERATING DATA LIQUID END BEARING TEMPERATURE Clean Out Alarms Faults PUMP OPERATING UNDER VFD Conv VFD Pump VFD N Home AUTOMATIC CONTROL SOLID END BEARING TEMPERATURE INITIATE CONTROLLED SHUTDOWN TONS DIFFERENTIAL SPEED MAINTAINED UNTIL BOWL SLOWS TO PRE SET SHUTDOWN SPEED THEN CONVEYOR RED BACKGROUND ACTIVE ALARM PRESENT SLOWS TO STOP Figure 4 3 Operation Screen While Running 4 8 30 Sep 13 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS Feed Rate When Manual is selected on the Operation screen the operator manually enters the desired rate on the Operation screen If the slurry is low in viscosity and density increasing the feed rate may permit a higher processing rate However as feed rate is increased residence time in the bowl is decreased resulting in more soli
63. PERATION GREEN FLASHING NO CONNECTIONS NOTE 6 RED STEADY PORT ALREADY IN USE NOTE 7 RED GREEN FLASHING SELF TEST UNDERWAY NOTES WAIT FOR MEMORY LOAD TO COMPLETE TURN PLC KEY SWITCH FROM PROG TO RUN AND THEN BACK TO REM THEN CYCLE POWER OFF AND ON CYCLE POWER OFF AND ON CHECK PLC POWER SUPPLY CYCLE POWER OFF AND ON IF PROBLEM FAILS TO CLEAR REPLACE PLC CHECK DRIVE CONNECTIONS AND DRIVES TNO CENTRIFUGES CONNECTED TOGETHER NETWORKED MACHINES MUST BE SEPARATE nap Figure 5 19 PLC Indicators 5 42 01 Jan 14 DE 1000LPVFDCentrifuge MAINTENANCE CONTROL COMPONENT INDICATORS CONT D YELLOW NORMAL OPERATION OFF VIBRATION SWITCH TRIPPED GREEN POWER APPLIED OR REMOTE E STOP OPERATED YELLOW STEADY NORMAL OPERATION OFF BOWL OVERSPEED GREEN DEVICE OPERATIONAL YELLOW STEADY CENTRIFUGE NOT RUNNING OR OFF YELLOW FLASHING NORMAL OPERATION RED INPUT CIRCUIT FAULT RED SENSOR DISCONNECTED TEMP DISPLAYS 392 F 200 C Figure 5 20 Transmitter Intrinsic Barrier Indicators GREEN DEVICE OPERATIONAL RED OFF NOT OPERATIONAL Figure 5 21 Power Supply Indicators 01 Jan 14 5 43 DE 1000LPVFDCentrifuge DERRICK CORPORATION SECTION 8 REFERENCE DRAWINGS This section contains Derrick engineering drawings for your equipment These drawings are included to provide assistance in troubleshooting repair and parts ordering 1473
64. PERFORMANCE STATUS Current performance information is shown on the Centrifuge Status screen Figure 4 8 Cabinet enclosure temperature as well as VFD temperatures and other status details are shown in Figure 4 9 Parameters displayed include bearing temperatures bowl speed and sensor condition status of safety devices vibration switch emergency stop and bowl overspeed air conditioner operation and operating hours Operating status of the air conditioner is also shown note differences between screens for centrifuge with and without RTD sensor to detect cabinet interior temperature Exiting this screen returns to the previous screen Safety shutdowns are denoted by color change from green to red and display of a word explaining cause of shutdown DISPLAY STATUS SCREEN SHOWING GRN BOWL SENSOR PRESENT ALL AIR CONDITIONER PARAMETERS RED BOWL SENSOR NOT PRESENT PRESENT BEARING TEMPERATURES i LM Aic AST H GRN ANALOG SIGNAL PRESENT E Stop Switch Current Run Time RED ANALOG SIGNAL PRESENT Analog ANALOG SIGNAL FAULT Sensor NO SENSOR INPUT 0 7 Vibration Switch Enclosure Temp Centrifuge Total Open EXCESSIVE VIBRATION F 000000 8 Speed Switch Controller Total IN Open BOWL OVERSPEED LE CYCLE AIR CONDITIONER DISPLAY STATUS SCREEN SHOWING ON FOR 30 SECONDS TO CHECK TEMPERATURE DETAILS FOR MOTOR ROTATION DIRECTION ENCLOSURE amp VFDs CHANGES TO GREEN AC Running
65. PROFILE Aus UN YS URBC A TL UN o oo N VAN E LECIRCAL WRNG SCHEMATIC 460 480 60 HZ VAN ZA VAN EE EE onerous ont 1275 02 16 1247 6 N uoe wor sos anan AO iti SCH fom BW FS T 92 07 05 NONE Nr A ETT ma ATi dida P 5 TA aliada ATT ERES HA ON sss s la NE IU IRI E I 0 N Pe 75 1 2 5 4 5 6 2 4 5 6 7 1 OT T T T TIT I 6 O RING 700 NT C085 21 YA Pr PKR 8 BPS0N SS N w c T 4 MOUNTING RING O 8 A T Tj rex A L L T 68 SS 322 J T i 1 6610 6000825 22 L DRE A TB 58 FEED NOZZLE CASTING 9524 03 L T om RABEN E B 1 156 CARBIDE INSERT X 9524 01 CSI0 RA 629 TC 27 7 8 55 4 Vf SINGLE LEAD CONVEYOR 9562 01 007 8 54 s E 8 Ti i O RING C CSI0 RA 325 00 44 4 2 BAL BEARING 6077 CSI0 RA Sfi 00 4 jul 1 1 RETANER RING RR425 CSI0 RA 327 00
66. R THIS EQUIPMENT WARNING VISION HAZARD SAFETY GLASSES MUST BE WORN AT ALL TIMES WHEN WORKING ON OR NEAR THIS EQIPMENT TO PREVENT SERIOUS EYE INJURY OR PERMANENT LOSS OF VISION WARNING WHILE OPENING AND CLOSING THE CENTRIFUGE COVER PERSONNEL MUST ENSURE THAT ALL BODY LIMBS AND ANY OTHER ITEMS ARE CLEAR OF THE COVER GAP TWO OPERATORS MUST BE USED WITH BOTH HANDS ON THE COVER HANDLES AT ALL TIMES DERRICK RECOMMENDS HAVING A HOIST AVAILABLE IF ADDITIONAL ASSISTANCE IS DESIRED DURING THE OPENING CLOSING PROCEDURE TOP COVER OPENING CLOSING PROCEDURES The proper procedures for opening and closing the top cover of the centrifuge must always be followed Two operators using both hands are required to open the cover Derrick recommends having a hoist available if additional assistance is desired during the opening closing of the centrifuge cover To open and close the cover proceed as follows 1 Shut down lock out tag out electric power to centrifuge and allow rotating assembly to coast to a full stop 2 Remove bolts securing cover to base 3 Have two operators using both hands grip the cover handles securely to ensure full control of the cover throughout the opening and closing process 4 As the cover is raised ensure that body limbs of all personnel and any other items remain clear of the cover gap at all times 5 Raise the cover to the fully opened position and insert a 1 2 12 7mm hardened steel pin through one hinge to
67. RPORATION APPENDIX A HMI SERVER SYSTEM DESCRIPTION This Appendix contains instructions for installing connecting and operating the HMI Server System which consists of an HMI Server and Router Switchgear Box Figure A 1 The system permits remote monitoring for the Derrick DE 7200 and DE 1000 Variable Frequency Drive VFD centrifuges By connecting a customer supplied PC or laptop computer to the server the operator can monitor two to four centrifuges from a single location separate from the control cabinets All monitoring features that can be displayed on the control cabinet operator panel are made available on the remote PC or laptop computer by means of a web based interface In addition the system can be re configured by Derrick to permit remote operation HMI Server POWER SUPPLY 24VDC 5A 100W CIRCUIT BREAKER 3A PLC 480VAC MAX 1 PH ETHERNET SWITCH ROUTERS 1 4 Router Switchgear Box Figure A 1 VFD Centrifuge HMI Server System Components 15 Feb 13 A 1 HMIServerSystem APPENDIX A VFD CENTRIFUGE HMI SERVER SYSTEM INSTALLATION All safety procedures included in the Operation and Maintenance manual are to be followed when installing the HMI Server System components Installation is performed in the following sequence Install server in safe area on a desktop or wall e Install Router Switchgear Box on a suitable wall in hazardous area removed from the explosion proof box and installed in a non e
68. S ARE CLEAR OF THE COVER GAP TWO OPERATORS MUST BE USED WITH BOTH HANDS ON THE COVER HANDLES AT ALL TIMES DERRICK RECOMMENDS HAVING A HOIST AVAILABLE IF ADDITIONAL ASSISTANCE IS DESIRED DURING THE OPENING CLOSING PROCEDURE TOP COVER OPENING CLOSING PROCEDURES The proper procedures for opening and closing the top cover of the centrifuge must always be followed Two operators using both hands are required to open the cover Derrick recommends having a hoist available if additional assistance is desired during the opening closing of the centrifuge cover To open and close the cover proceed as follows 1 Shut down lock out tag out electric power to centrifuge and allow rotating assembly to coast to a full stop 2 Remove bolts securing cover to base 3 Have two operators using both hands grip the cover handles securely to ensure full control of the cover throughout the opening and closing process 4 As the cover is raised ensure that body limbs of all personnel and any other items remain clear of the cover gap at all times 5 Raise the cover to the fully opened position and insert a 1 2 12 7mm hardened steel pin through one hinge to lock the cover open 6 After performing the activity that required the cover to be opened reverse steps 2 through 5 to close the cover During the closing procedure ensure that both operators are capable of controlling the cover s descent and that all body limbs and other items remain clear of the g
69. S AREA 30 Sep 13 2 1 DE 1000LPVFDCentrifuge SAFETY Electrical Hazards Cont d DANGER USE EXTREME CAUTION WHEN OPERATING CENTRIFUGE WITH PURGE SYSTEM BYPASSED DANGEROUSLY HIGH VOLTAGE WILL BE PRESENT IN CONTROL CABINET IF DOOR IS OPENED WHILE POWER IS APPLIED A Equipment Handling WARNING USE SPREADER BARS TO PREVENT DAMAGE WHEN LIFTING THE EQUIPMENT WARNING TO ENSURE PROPER BALANCE AND ORIENTATION WHEN UNIT IS RAISED AND PREVENT DAMAGE TO COMPONENTS ATTACH LIFTING SLING ONLY AT DESIGNATED LIFT POINTS DO NOT ATTEMPT LIFTING BY ATTACHMENT TO MOTOR OR ANY OTHER LOCATION WARNING BE SURE THAT HANDLING DEVICES HAVE SUFFICIENT LIFTING CAPACITY TO SAFELY HANDLE THE WEIGHT OF THE EQUIPMENT WARNING DO NOT REMOVE SHIPPING BRACKETS UNTIL EQUIPMENT HAS BEEN POSITIONED AT FINAL INSTALLATION SITE WARNING WHILE OPENING AND CLOSING THE CENTRIFUGE COVER PERSONNEL MUST ENSURE THAT ALL BODY LIMBS AND ANY OTHER ITEMS ARE CLEAR OF THE COVER GAP TWO HANDS MUST BE USED WITH BOTH HANDS ON THE COVER HANDLES AT ALL TIMES DERRICK RECOMMENDS HAVING A HOIST AVAILABLE IF ADDITIONAL ASSISTANCE IS DESIRED DURING THE OPENING CLOSING PROCEDURE P PP P P gt Operation WARNING ALL OPERATING AND MAINTENANCE PERSONNEL MUST READ AND UNDERSTAND ALL SAFETY INFORMATION IN THIS MANUAL BEFORE WORKING WITH THE EQUIPMENT WARNING BE SURE THAT TOP COVER IS CLOSED AND SECURED AND ALL PERSONNEL ARE CLEAR BEFORE START
70. TROL CABINET Figure A 5 Ethernet Connections to Routers A 4 15 Feb 13 HMIServerSystem APPENDIX A VFD CENTRIFUGE HMI SERVER SYSTEM 5 Connect a CAT5 cable to Ethernet switch in Switchgear Box and connect opposite end to LAN 1 port on HMI Server Figure A 6 6 Tighten nuts properly on all cable glands to ensure proper sealing 7 Connect a 5 cable from LAN 2 port of HMI Server to Ethernet switch port 8 Connect a CAT5 cable from LAN port of customer supplied computer to second port of Ethernet switch USB HIGH MECH DVI LAN1 LAN2 RESISTANCE VGA USB STD USB STD Figure A 6 HMI Server Connection Ports OPERATING HMI SERVER The HMI Server System permits continuous monitoring of up to four centrifuges from a single computer located in a non hazardous area A combination of DE 1000 and DE 7200 centrifuges may be monitored All information displayed on the local Operation screen of each centrifuge may be viewed on the computer System flexibility allows the operator to view all machines simultaneously or individually Startup and Shutdown Both the HMI Server and Router Switchgear Box require 220 240 Vac 50 60Hz power for operation Units are turned on separately Proceed as follows to turn on equipment 1 Apply power to the HMI Server PC will start up once power is applied If PC does not start up press power button or cycle power to PC 2 Once HMI Server boots up the Home screen is disp
71. Trend screen Figure 4 15 This screen is accessible from the Bowl VFD screen VFD Temperature F 1 Min Thursday August 09 2007 Friday amp uc Update chi EE EE we VFD TEMPERATURES SCROLL LEFT OR RIGHT 8 29 58 30 Min Operation Horne DISPLAY 30 MINUTE TREND SCREEN PAUSE Figure 4 15 VFD Temperature Trend Screen VFD FAULT RESET The Fault Reset screen Figure 4 16 informs the operator of the readiness of each VFD Faulted or No Fault and permits resetting a faulted VFD The screen may be selected from either the Clean Out or Operation screen If high conveyor torque causes a reduction in the pump flow rate the message Flowrate Reduction is displayed on the Operation or Clean Out screen to inform the operator that the pump is operating at a reduced flow rate This message also appears on the Fault Reset screen After removing the cause of the reduced flow rate RESET is selected on the Fault Reset screen to return the pump to the normal flow rate After any fault be sure that the centrifuge has come to a complete stop before attempting to re start DRIVE RUNNING DRIVE OPERATIONAL GRY DRIVE OFF RED DRIVE FAULT NS ous reta Fault Reset x oo Bowl Conveyor Pump Last Fault 075 Last Fault 075 VFD Faulted No Fault No Fault IN Pump RESET DRIVE TO Automatic Pump Flowrate Reduction OFF CLEAR FAULT Bowl Fault Status Co
72. Up DeskLock SETUP SCREEN Figure A 14 DeskLock Screen Troubleshooting Network Connectivity The following IP addresses of all system components permit entry into the router configuration to verify that the router is communicating Router 1 Router 2 Router 3 Router 4 HMI Server PC Activation PLC X1 WAN Port https 100 100 10 1 https 100 100 10 2 https 100 100 10 3 https 100 100 10 4 LAN Port 1 100 100 10 101 100 100 10 100 X2 LAN Port https 100 100 100 101 https 100 100 100 101 https 100 100 100 101 https 100 100 100 101 LAN Port 2 Assigned by DHCP LOG ON TO WEB BASED EXIT WINDOWS AND TURN OFF PC PASSWORD PROTECTED Use the following Network Address Translation NAT data to verify that connections are correct and that communication is established between the PLC and routers PLC 1 PLC 2 PLC 3 PLC 4 X1 WAN Port of Router 100 100 10 10 100 100 10 20 100 100 10 30 100 100 10 40 X2 LAN Port of Router 100 100 100 10 100 100 100 10 100 100 100 10 100 100 100 10 To assist in troubleshooting communication defects a customer PC may be connected as shown in Figure A 15 to ping the routers to verify communication 15 Feb 13 A 9 HMIServerSystem APPENDIX A VFD CENTRIFUGE HMI SERVER SYSTEM 8 0 IP ADDRESS 100 100 10 201 PING 100 100 10 3 Router 3 PING 100 100 10 30 PLC IP ADDRESS 100 100 100 201 PING 100 100 100 101 Router 3 PING 100 100 100 10
73. VE PROPERTY OF DERRICK Lis sm wawami DERRICK REF G A 14738 00 004 CORPORATION BUFFALO NEW YORK U S A AND ARE NOT TO BE REPRODUCED WITHOUT THE WRITTEN PERMISSION DERRICK REF WS pasooo Siete cee rA ae II EC 00 pe Eoo DUKE ROAD BUFFALO NY 14225 USA Eli oa gt lt 1 2 14 NPT 5 5 8 142 ALL HOLES 10 32 TAPPED HOLE EXCEPT WHERE NOTED 12 PLACES 8 32 TAPPED HOLE 7 PLACES 2 1 4 57 27 11 1 2 2 PLACES 7 15 MRE BASE SMALL PAN TMSSIO C ADALET ASSEMBLY NOTES 1 13 GROUND LUG 250MCM DUAL ONE MTG HOLE MECH 0000886 1 INSTALL METRIC STAINLESS BOLT AND WASHER AS SHOWN T 12 HIME DELAY FUSE 125 250V 69936 2 11 TME DELAY FUSE 0 5 600V STYLE ATOR 60004195 1 y USED ZA 08 TRANSFORMER CONT 480V PRI 120V SEC G000248 AY 1 07 SWTCH AMP BARRIERINTRINSIC 7 00926 2 06 CLAMP FOR 35 9002 05 DIN RAIL 35 X 7 5MM X 1 5 ZPL 510 7 6000202 A 04 NoT usED IN 60008929 REF CA 14738 00 007 sea ow uc a 2 or j REF W S 14394 00 018 N OA PANE PATTERN REWSE 08 WAS GOODEN DELETE DE 1000 WITH SKID 460 480 V REF 16545 00 002 ZN ovara vur
74. WHEN COMPRESSOR CYCLES ON Centrifuge With RTD Sensor PRESENT BEARING GRN BOWL SENSOR PRESENT TEMPERATURES RED BOWL SENSOR NOT PRESENT Derrick Centrifuge 5 X Conveyor 99 Pump 99 S Feedback Bowl GRN ANALOG SIGNAL PRESENT RED NO ANALOG SIGNAL PRESENT Analog ANALOG SIGNAL FAULT afety Air Conditioner Hours Sensor NO SENSOR INPUT E Stop Switch Compressor Motor Current Run Time Closed 02 Vibration Switch Evaporator Fan Motor Centrifuge Total 002031 4 Speed Switch Refrigerant Pressure Controller Total rw 003326 8 Open EXCESSIVE VIBRATION Open BOWL OVERSPEED Centrifuge Without RTD Sensor Figure 4 8 Centrifuge Status Screen 30 Sep 13 4 13 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS PERFORMANCE STATUS CONT D PRESENT AVERAGE OF VFD TEMPERATURES REPLACE MAXIMUM MINIMUM CABINET amp VFD TEMPERATURES WITH PRESENT TEMPERATURES Bowl PRESENT CABINET ES NO OF TIMES AIR INTERIOR TEMPERATURE CONDITIONER CYCLED 017722 F IN PAST HOUR TO GREEN AC Running WHEN AIR CONDITIONER CYCLES ON Enc Max VFD Max Conv VFD 950 105 3 102 4 Enc Min VFD Min Pump VFD 94 4 X 103 8 x 84 5 MAXIMUM AVERAGE MINIMUM AVERAGE VFD TEMPERATURE VFD TEMPERATURE PRESENT TEMPERATURE OF EACH VFD CYCLE AIR CONDITIONER Bowl VFD ON FOR 30 SECONDS CHANGES 7 1831 Reset Min Max 982 Figur
75. _ 0001744 N A 680 S E BOW HEAD UMH CENTRIFUGE ROTATING ASSEMBLY 3 8 16 X 1 SS HEX SOCKET 60003064 252 IN LBS E SEAL HOUSING LYT HARDWARE PARTS LIST 8 04 3 8 16 X 1 1 2 SS HEX SOCKET 60003066 252 IN LBS A E BEARING HOUSING COS 5 16 X 5 16 X 3 KEY 60003872 L E BOW HEAD AN RECORD COPY FOR REVSIONS 1 THRU 7 2 5204 us 3 21 01 1 5 Ak x 5 16 X 1 PIN STEEL PP1362 680L L E BOW HEAD 12 01 3 8 16 X 1 1 4 SS HEX SOCKET 60003065 252 IN LBS L E BOWL HEAD HARDWARE REQUIRED PART PER PC TORQUE SETTING LUBRICANT REFERENCE PART CORPORATION BUFFALO NEW YORK U S A AND ARE NOT TO BE REPRODUCED WITHOUT THE WRITTEN PERMISSION OF DERRICK peon ERRICK CORPORATION THE INFORMATION CONTAINED ON THIS DRAWING SHALL ONLY BE USED BY CUSTOMERS OR PROSPECTS OR THER DRAWING NO AGENCES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY OF PARTS OR ASSEMBLIES TO DERRICK OR BY OTHERS FOR THE SPECIFIC REASON OUTLINED IN THE TRANSMITTAL WHETHER 1 4394 00 WRITTEN OR VERBAL 9 THE DESIGNS AND INFORMATION CONTAINED ON THIS DRAWING OR COPIES REMAIN THE EXCLUSIVE PROPERTY OF DERRICK Y lt SHEET S R FC CORPORATION abil SPEED SENSOR D CABLE SPEED SENSOR 2 METER CUT DOWN TO 36 INCHES a 17 SPEED SENSOR 12MM EMBEDABLE 0066 B 1 16 SENSOR BEARING 31655 136 coat
76. abinet to provide a means of limiting the maximum pressure experienced by the cabinet during operation The relief valve incorporates a spark arrestor to prevent sparks from being ejected from the cabinet into the hazardous area The relief valve is combined with the flow measurement mechanism to provide feedback to the control unit Leakage Compensation Operation Initially a high flow of protective gas is passed into the control cabinet Figure 1 3 This flow is verified and performs the purging phase of the operation When the purge time has elapsed the flow of protective gas is controlled by an adjustable leakage compensation valve In addition to maintaining pressurization this valve compensates for any leakage from the cabinet For proper functioning of the leakage compensation valve leakage from the cabinet must exceed 5 l min Insufficient leakage will cause the relief valve to cycle open and closed continuously REGULATOR PURGE 8 8 RESERVOIRS oF Ya ATI TIMER VALVE D LOGIC GAUGE PRESSURE PURGE FLOW SENSOR i ALARM INDICATOR 1 RED ALARM GREEN PRESSURIZED PURGE ENCLOSURE F VALVE PRESSURE TEST POINT PLUGGED PURGE VALVE PILOT RESTRICTOR HI ENCLOSURE PRESSURE PURGE OUTLET TO PRESSURIZED ENCLOSURE DP LO RLV CONNECTION Figure 1 3 Leakage Compensation Circuit Schematic Diagram Output Signal The purge system provides an intrin
77. alfunction with electric power shut down locked out and tagged out check that PLC connectors are fully seated in their receptacles Correct as necessary before proceeding with further troubleshooting The troubleshooting chart consists of failure modes possible cause s and recommended course s of action All electrical continuity checks in this procedure are performed without electric power supplied to the centrifuge Lock out and tag out equipment before attempting to perform any continuity check ELECTRIC POWER APPLIED TO CENTRIFUGE LOCK OUT AND TAG OUT ELECTRIC POWER BEFORE ATTEMPTING CONTINUITY CHECKS N WARNING CONTINUITY CHECKS MUST BE PERFORMED WITHOUT 01 Jan 14 5 21 DE 1000LPVFDCentrifuge MAINTENANCE TROUBLESHOOTING DE 1000LP VFD CENTRIFUGE Insufficient solids in feed Drop in feed pump rate Differential speed too low Excessive amount of solids in feed Change in feed characteristics Increase in solids wetness Conveyor flights worn excessively 5 22 DE 1000LPVFDCentrifuge Failure Mode 1 Acceptable Liquid Cake Too Thin Failure Mode 2 Poor Liquid Quality Acceptable Cake Increase feed rate Increase weir opening refer to Section 4 Reduce differential speed Increase feed rate Check feed pump if required check wear and replace worn parts Check pump shaft seal and correct any defects Select RESET on Fault Reset screen to reset flow rate Increase differential speed
78. and conveyor speeds Adjusting the pond depth requires shutdown of the equipment Another method of altering the discharge results is to change the feed rate During centrifuge operation slurry is pumped through the feed tube into the center of the rotating conveyor Figure 1 5 where it splashes against the feed accelerator The high velocity slurry is then dispersed out four feed nozzles in the periphery of the conveyor cylinder Rotating at a higher speed than the conveyor the bowl creates an additional shearing effect which further increases the slurry s acceleration SLURRY n LIQUID DISCHARGE SOLID DISCHARGE Figure 1 5 Centrifuge Mechanical Operation As the slurry flows in the channels between the conveyor flights the heavy particles settle at an accelerated rate due to the G force imposed by the rotating bowl Sand particles settle almost instantly then the finer lighter particles settle Particles that cannot be settled under the present settings will be discharged with the liquid through the adjustable weirs on the liquid bowl head Liquid exiting the liquid bowl head is directed through the liquid discharge outlet The settled solids form a cake inside the bowl and are transported by the conveyor toward the narrow end of the bowl beach As the solids travel across the beach their free liquid film is lost due to centrifugal squeezing and drainage When they are discharged at high velocity through the
79. ap COLD CLIMATE STARTUP In below freezing ambient conditions where steam portable heaters or other means is used to raise the temperature of the centrifuge re lubrication of bearings may be necessary prior to startup If bearing housings reach a temperature of 200 F 93 C grease may liquefy and drain from bearings This will result in dry running the bearings upon startup To prevent this condition proceed as follows 1 After applying heat and prior to startup pump 15 shots of grease into each main bearing 2 Refill conveyor bearings until grease is observed exiting the appropriate drain hole 3 After machine is started pump an additional five shots of grease into each main bearing 4 Monitor bearing temperatures for the first 2 hours of centrifuge operation and then return to normal Note It is normal for temperatures to rise for 15 to 30 minutes after greasing PURGE SYSTEM HAZARDOUS ENVIRONMENT ONLY Purge Cycle During startup the control cabinet purge system drives out all gases from the cabinet interior and then maintains positive pressure within the control cabinet to prevent entry of any potentially explosive gases Purge system operation begins when the system senses sufficient air pressure 4 2 30 Sep 13 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS inside the cabinet Initially the purge unit performs a 16 minute rapid purge cycle at 16 CFM During the rapid purge cycle the purge system prevent
80. ase into gearbox and main bearing fittings Appropriate grease included per climate and customer requirements HARDWARE TORQUE SPECIFICATIONS Use only hardware that is approved by Derrick Corporation The use of potentially inferior non Derrick approved hardware may result in serious injury to personnel and or damage to equipment Additionally any warranty in force whether written or implied may be voided by use of unapproved hardware Contact Derrick Corporation with questions pertaining to hardware type and usage associated with Derrick centrifuges RESULT IN SERIOUS INJURY TO PERSONNEL AND OR DAMAGE TO EQUIPMENT N WARNING USE OF INFERIOR NON DERRICK APPROVED HARDWARE MAY Recommended seating torque specifications lubricants and other hardware installation specifications for the various types and sizes of hardware used on the centrifuge are shown and described on the following pages 01 Jan 14 5 15 DE 1000LPVFDCentrifuge MAINTENANCE HARDWARE TORQUE SPECIFICATIONS CONT D Use the following procedure when tightening hardware 1 Use only a calibrated torque wrench 2 Apply specified lubricant to hardware before installing 3 When tightening more than one bolt alternate tightening between bolts 4 Always approach the final torque in several stages 27 24 27 11 25 19 8 38 HEH SE J X Ve D gt ELA 5 22 el Q LUN ale ur AAA PA EN
81. ating Instructions 2 id 4 1 30 Sep 13 EIC c 4 1 Software Version aio e Eo e oq n apta te e dM E 4 1 OPERATING Salelyz uuu elo db sux d de dict ra Ges 4 1 Top Cover Opening Closing 4 2 Cold Climate Startup os erede E ee 4 2 Purge System Hazardous Environment 4 2 nu EM M area eu He 4 4 Normal on doe b Ea E MW uo en 4 6 Operation e ren ene 4 7 Alarm and Fault Messages fpe i clad 4 11 Bearing 4 11 Motor Torque Trends ae ek 4 12 System Diagnostics ae 4 12 Performance Status ee AUS NE E 4 13 Alarm S Yu Saya sya heen ee 4 14 VFD Statuse ierat 4 15 Pump VFD Fault Status cce e er 4 16 Temperature Trends ee een 4 17 VED Fault Reset 4 17 Setup Screen a M es 4 18 PUMP Sel Du u te Gute 4 18 4 19 EIOS 4 19 cacas 4 20 Automatic Shutdown u eek ee 4 21 Emergency
82. ation valve is fully open the system will start to purge again This indicates excessive leakage from the cabinet In this case check the cabinet for leakage and reduce or eliminate the leaks After sealing cabinet leakage at the end of purging the cabinet should stay pressurized and the relief valve action will be as in a or b above Proceed with adjustments described in the preceding steps Note When air conditioner goes off the relief valve may vent momentarily This is normal Minimum Pressure Sensor Setting The setting of the minimum pressure sensor should be checked as follows 1 Note the position of the leakage compensation valve knob by marking knob with a pencil at the 12 00 o clock position 2 Slowly lower the cabinet pressure by closing the leakage compensation valve further counting the number of turns from the normal working pressure position Note the pressure at which the alarm pressurized indicator changes from green to red and check that this pressure is not lower than 0 2 WC 0 5 mbar Check also that the ALARM electrical contacts function properly 5 8 01 Jan 14 DE 1000LPVFDCentrifuge MAINTENANCE 3 As soon as the ALARM PRESSURIZED indicator turns red the system will begin re purging and the enclosure power will be switched off 4 While the cabinet is re purging return the leakage compensation valve to its normal working pressure position so that at the end of purging the cabinet pressure shoul
83. ayed below the setpoints Provision is included for selecting the automatic or manual cleanout options When the cleanout process has timed out or was stopped by the operator the Operation screen or the Faults screen may be displayed If automatic reduction of the pump speed is unable to clear out solids from the conveyor the torque will continue to rise and the centrifuge will shut down The clean out procedure should then be used to clear out the impacted solids and return the centrifuge to operational status The following paragraphs explain the two cleanout options automatic and manual ADJUST BOWL SPEED ADJUST CONVEYOR DIFFERENTIAL SPEED GREEN SELECTED MODE MANUAL GRAY MODE NOT SELECTED Actual RPM Actual RPM 301 98 Automatic Torque Torque Clean Out RUNNING AUTO CLEANOUT START BEGIN CLEANOUT 12 9 1 5 UNDERWAY RUNNING CLEANOUT UNDERWAY DONE SUCCESSFUL CLEANOUT BOWL amp CONVEYOR RUNNING RETURNING TO SET SPEEDS Conveyor Jog Conveyor Motor JOG SPEED OF CONVEYOR MOTOR IN MANUAL MODE SELECT MANUAL CLEANOUT CONVEYOR JOG DIRECTION ONLY TERMINATE CLEANOUT Figure 4 20 Clean Out Screen 30 Sep 13 4 19 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS Automatic Cleanout When the automatic option is selected the system will perform a cleanout cycle for a pre set duration The bowl operates in the forward direction at 300 RPM while the conveyor operates in the forward direction at a speed that varies from 8
84. condition must be corrected or the centrifuge may be shut down automatically Fault messages inform the operator that a failure requiring automatic shutdown has occurred Refer to the following table for alarm and fault messages and their causes and corrective actions for assistance in analyzing messages 01 Jan 14 5 29 DE 1000LPVFDCentrifuge MAINTENANCE ALARM AND FAULT MESSAGES F1000 Bowl Exceeded Maximum Speed Shutdown Incorrect or loose connection at speed sensor or defective speed sensor Check speed sensor connection refer to Section 3 Replace sensor if defective Bowl VFD malfunction If problem persists contact Derrick Service for assistance Bowl torque exceeds pre set limit F1001 Bowl High Torque Alarm Reduce Feed Rate Reduce feed rate and or reduce bowl speed F1002 Bowl High Torque Fault and Shutdown Perform Cleanout and Reduce Feed Rate Bowl torque exceeds pre set limit After bowl has stopped rotating perform cleanout procedure to remove solids buildup and re start centrifuge at reduced feed rate F1010 Bowl VFD Communications Error Communication lost between bowl VFD and PLC Confirm that green LED next to Ethernet cable on Ethernet switch is lighted indicating that hub is functional Check connections between bowl VFD and PLC and correct any defects Replace bowl VFD communication module if no other defect is found Bowl VFD alarm F
85. d immediately settle down at the correct normal pressure Pressure Sensor Calibration If it is decided that the minimum pressure sensor requires recalibration it must be returned to Derrick for this service Cleaning Purge Unit Filter Do not use solvents on any part of the purge unit filter assembly To clean the filter element unscrew and remove the filter bowl and then unscrew and remove filter element Clean filter element in soapy water or replace element ROTATING ASSEMBLY MAINTENANCE Maintenance of the rotating assembly is limited to cleaning inspection and replacement of wear inserts Excessive noise or vibration during centrifuge operation may indicate defective main or conveyor bearings If such conditions are evident the bearings should be inspected for looseness The rotating assembly must be replaced if main or conveyor bearings are found or if internal damage to the rotating assembly is found or suspected The damaged rotating assembly should be returned to Derrick for overhaul Removal The rotating assembly must be removed for thorough cleaning and inspection To remove the rotating assembly proceed as follows 1 Shut down lock out and tag out electric power to the centrifuge WARNING ALWAYS ALLOW MACHINE TO COAST TO A COMPLETE STOP BEFORE OPENING COVER OR REMOVING GUARDS WARNING WHILE OPENING AND CLOSING THE CENTRIFUGE COVER PERSONNEL MUST ENSURE THAT ALL BODY LIMBS AND ANY OTHER ITEMS ARE CLEAR OF THE
86. ded Non compressible shims should be used as required to level the machine r Figure 3 3 DE 1000LP VFD Centrifuge Leveling LOWER AND SECURE ROTATING ASSEMBLY Note Retain shipping brackets that support rotating assembly after removal The brackets must be re installed whenever the machine is moved as they prevent damage to the rotating assembly bearings during transit 3 4 30 Sep 13 DE 1000LPVFDCentrifuge INSTALLATION Shipping brackets prevent bearing damage during transit and rubber strips protect the pillow block mounting surfaces After final positioning and leveling of the centrifuge the shipping brackets and covers must be removed and the rotating assembly secured to the base Each shipping component is labeled DISCONNECT BEFORE STARTUP To remove the shipping components proceed as follows 1 co TO 10 11 Remove belt guard and gearbox guard Open case cover as described at the beginning of this section Release and remove two ratchet straps Using a 1 ton hoist lift rotating assembly slowly and evenly about 5 Remove shipping brackets under rotating assembly Remove rubber shipping strips under rotating assembly and bearing pillow blocks Figure 3 4 ROTATING ASSEMBLY SHIPPING BRACKETS BEARING PILLOW BLOCK SHIPPING STRIPS Figure 3 4 Shipping Components Locations Using a suitable solvent clean pillow block mounting surfaces and alignment pi
87. ds in the liquid discharge Also conveyor torque may rise indicating that the conveyor is becoming burdened by moving the increased solids volume at its present speed To reduce the conveyor torque the bowl speed may be lowered the feed rate may be reduced or the conveyor speed may be increased to move the solids out faster The feed rate setting and actual feed rate are shown on the control panel to assist the operator in making adjustments Bowl Speed The faster the bowl speed the faster solids are settled through the pond to the outer wall of the bowl and conveyed out of the centrifuge but faster processing results in wetter solids discharge To reduce wetness the slurry must remain in the bowl longer subjecting it to the settling process for a longer duration before being conveyed out the solids discharge Conversely reducing bowl speed may be desirable for thick heavy slurry to extract only high density materials or larger particles Both the bowl speed setting and actual bowl speed are shown on the control panel The torque percentage of the bowl is also displayed This information is useful in optimizing bowl speed to produce the desired solids dryness and processing speed Conveyor Differential Speed With correct wiring polarity the conveyor responds properly to settings made on the Operation screen Changing the conveyor differential speed adjusts the solids discharge rate Generally a slower differential speed will produce dr
88. e MAINTENANCE TROUBLESHOOTING DE 1000LP VFD CENTRIFUGE Failure Mode 8 Excessively High Main Bearing Temperature Insufficient lubrication Lubricate bearings refer to Preventive Maintenance Excessive grease Remove grease fitting and direct jet of filtered compressed air to remove grease Incorrect grease Lubricate with recommended grease refer to Preventive Maintenance Defective bearing Replace both main bearings refer to Main Bearing Replacement Failure Mode 9 Purge System Purges Correctly But Alarm Goes On At End Of Purge Interval And Purge Cycle Is Repeated Actual cabinet pressure below setting of minimum pressure sensor Check cabinet pressure with a Magnahelic gage Adjust minimum pressure sensor to correspond with actual cabinet pressure Leakage compensation valve setting to low causing re purge to occur Increase cabinet pressure by turning leakage compensation valve adjustment counterclockwise Contact Derrick for assistance if problem is not corrected Failure Mode 10 Purging Indicator Does Not Become Amber During Purging Low air pressure Check that air supply line is at least 3 4 19mm Replace line if undersize Check for stable air pressure of 60 115psi 4 8barg Adjust air pressure if low Excessive leakage from Check for leakage at cabinet door gasket and at all potential cabinet sources of leakage Maximum permissible leakage is 2 5cfm Correct as required Tube between relie
89. e electrical equipment and an automatic purge system maintains a positive internal pressure to prevent entry of hazardous vapors The purge system turns on electric power to the cabinet components only after thorough evacuation of flammable gases from the control cabinet interior The operator control panel and mouse are installed on the front of the cabinet above the door An emergency stop button to the right of the control panel permits instantaneous shutdown of VFDs motor drives in case of emergency A thermostatically controlled space heater is installed in the cabinet to warm the interior before power is applied to the electrical components The heater ensures that the interior temperature remains at a minimum of 40 F 4 4 For centrifuges installed in hazardous environments a purge system provides a continuous flow of air to prevent the cabinet interior from accumulating explosive vapors When power is applied to the centrifuge the cabinet purge system initiates a 16 minute rapid purge cycle at 16 CFM This cycle consists of five complete air exchanges When the rapid purge cycle is completed the purge system automatically closes a switch that supplies power to the cabinet During centrifuge operation the purge system maintains a continuous flow of air to provide positive pressure within the control cabinet to prevent entry of flammable gas Minimum pressure and purge flow sensors provide an output signal to the PLC if the purge sys
90. e 4 9 Cabinet and VFD Temperature Status Screen ALARMS The Alarms screen Figure 4 10 permits the operator to review and acknowledge active alarm messages Each alarm is listed with its status date and time received and description Buttons are provided at the bottom of the screen to facilitate scrolling through the alarms Messages may be acknowledged individually or all alarms may be acknowledged simultaneously Provisions are included for sorting alarms in the order of occurrence and buttons are included for returning to the Operation or Home screen Alarm On Alarm eck Alarm Description 9 39 01 AM Emergency Stop Switch Actuated Shutdown 3732005 9 36 35 9 39 00 Emergency Stop Switch Activated Shutdown SCROLL TO FIRST OR LAST LINE ARRANGE LIST BY TIME RECEIVED NAME SCROLL ONE LINE AT A TIME SCROLL MULTIPLE LINES AT A TIME Figure 4 10 Alarms Screen 4 14 30 Sep 13 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS VFD STATUS Status screens Figure 4 11 through 4 13 are selected from the Operation screen Each VFD status screen permits the operator to view various operational characteristics of the VFD such as present alarms or faults power voltage and current outputs motor and bowl speeds direction of motor rotation VED temperature and motor torque GRN NO ALARM FAULT PRESENT RED ALARM FAULT PRESENT GRN RUNNING GRY NOT RUNNING GRN MOTOR RUNNING rada GRY
91. e equipment The centrifuge has been designed to perform the stated functions safely WARNINGS All persons responsible for operation and maintenance of this equipment must read and understand all safety information in this manual prior to operating and or maintaining the equipment The safety warnings listed below are included in applicable procedures throughout this manual Work Area WARNING ALWAYS BE AWARE OF WORK AREA HAZARDS TO PROTECT AGAINST SLIPS TRIPS AND FALLS WHEN WORKING ON OR NEAR THIS EQUIPMENT WARNING LOUD NOISE WEAR HEARING PROTECTION AT ALL TIMES WHEN WORKING ON OR NEAR THIS EQUIPMENT WARNING VISION HAZARD SAFETY GLASSES MUST BE WORN AT ALL TIMES WHEN WORKING ON OR NEAR THIS EQIPMENT TO PREVENT SERIOUS EYE INJURY OR PERMANENT LOSS OF VISION DANGER HIGH VOLTAGE SHUT DOWN LOCK OUT AND TAG OUT ELECTRIC POWER AND ENSURE THAT EQUIPMENT HAS STOPPED ROTATING BEFORE WORKING ON THIS EQUIPMENT WARNING DRIVE MOTOR MUST BE OPERATED AT THE DESIGNATED SUPPLY VOLTAGE WARNING ELECTRICAL CONNECTIONS MUST BE MADE IN ACCORDANCE WITH ALL APPLICABLE NATIONAL AND LOCAL CODES FAILURE TO COMPLY MAY RESULT IN AN UNSAFE CONDITION THAT COULD INJURE PERSONNEL OR DAMAGE EQUIPMENT ENSURE THAT ALL ELECTRICAL AND CONDUIT CONNECTIONS ARE SECURE WARNING DO NOT BYPASS PURGE SYSTEM IF NOT CERTAIN THAT ENVIRONMENT IS NON HAZARDOUS A HIGH RISK OF FIRE AND OR EXPLOSION WILL RESULT IF PURGE SYSTEM IS BYPASSED IN A HAZARDOU
92. e established between the Ethernet switches in the centrifuge control cabinets and the routers in the Router Switchgear Box Ethernet connections are also required from the HMI server to the computer and Ethernet switch in the Router Switchgear Box 15 Feb 13 A 3 HMIServerSystem APPENDIX A VFD CENTRIFUGE HMI SERVER SYSTEM Control Cabinet Connections to Router Switchgear Box The following procedure describes the interconnection of control cabinets with the HMI Server Refer to drawing 18309 00 for additional assistance in making the connections and note that cables must be no more 328 100m long All cabling must be properly dressed protected from chafing and secured appropriately 1 Remove the 1 NPT pipe plug from fitting at left upper left side of each control cabinet and install a cable gland in its place 2 Route a 5 cable through each cable gland to the Ethernet switch at the upper rear of the control cabinet and connect cable to open port at upper left of switch Figure A 4 3 Install a customer supplied 3 4 cable gland in a Router Switchgear Box opening for each centrifuge to be monitored CONNECT ETHERNET CABLE TO VACANT PORT OF CABINET ETHERNET SWITCH Figure A 4 Ethernet Switch Connection Port 4 Route free end of each CAT5 cable through a cable gland in Router Switchgear Box and connect to open port of each router Figure A 5 ETHERNET CABLE TO SERVER LAN 1 PORT ETHERNET FROM EACH CON
93. e parts required to support a single DE 1000LP VFD centrifuge for two years However since all potential part replacements cannot be predicted the complete spare parts inventory should be based on the user s experience with similar equipment 5 18 01 Jan 14 DE 1000LPVFDCentrifuge MAINTENANCE RECOMMENDED SPARE PARTS DE 1000LP VFD CENTRIFUGE Mechanical CHE SRI 2 Grease Std Main Bearing Conveyor 14 5 Oz Tube lt es 12 2 CS10 RA 630 IC Solid Discharge Wear Inserts 8 Pieces Yes 2 Sets CS10 RA 634 IC Yes 2 Pair CS10 RA 650 IC Yes 2 Pair SHELL OMALA320G es 1 gt lt 01 14 5 19 DE 1000LPVFDCentrifuge MAINTENANCE RECOMMENDED SPARE PARTS DE 1000LP VFD CENTRIFUGE Mechanical Cont d Coupling Gearbox Pinion to Conveyor G0004365 Wave Spring Conveyor Support Bearing 1 9524 00 Feed Nozzle Assembly 4 Electrical G0008359 Variable Frequency Drive 50HP Bowl Drive G0007241 Frequency Drive 20HP Conveyor rive G0008360 2 Frequency Drive 15HP Pump G0004364 O Ring Protective Cover 15181 01 001 Protective Cover Operator Control Panel No 1 HMI RTD Sensor Solid End Bearing RTD Sensor Liquid End Bearing No G0007861 Speed Sensor G0007862 Cable Speed Sensor Control Cabinet k G0008349 PLC Battery G0009286 Intrinsic Safe Barrier Vibration Switch 5 20 01 Jan 14 DE 1000LPVFDCentrifuge
94. e screen Select Setup and then click on Pump Setup to view pump operating information Revise any operating information if required and then click in upper right corner to return to Setup screen Select Home to return to Home screen Configure pump parameters as follows a Input data from the pump and pump motor nameplates Note Correct pump data is critical to achieving the desired feed rate to the centrifuge b Select Download to update VFD settings with new motor data This will cause pump to autotune at the next startup Select Disable for Tank High and Low Level inputs if they will not be used d When finished making required changes click X in upper right corner to return to Setup screen then select Home to return to Home screen Select Operation to display the following screen Derrick Centrifuge Operation Bowl O9 COE O9 21250 S Y 2 E Qo 00 A se Bow VFD VFD Pump VFD Home Using up and down arrow buttons set Bowl Input RPM at 20 RPM and set Conveyor Input RPM at 5 RPM Select STAHT to confirm direction of rotation for bowl conveyor feed pump and air conditioner condenser motors as follows e Bowl Counterclockwise viewed from fan end e Conveyor Clockwise viewed from fan end Feed pump Per manufacturer s data Air conditioner condenser Clockwise viewed from fan end Correct reverse rotation by shutting down
95. e switch if contacts fail to close Incorrect purge time Check timer setting and reset to minimum available purge time Re check system operation at new setting If system functions properly return purge time to original setting If system fails to close switch contact Derrick for assistance Failure Mode 12 Purge System Relief Valve Remains Open Or Opens Intermittently Leakage compensation valve out of adjustment causing high cabinet pressure Adjust leakage compensation valve by turning adjustment clockwise to reduce pressure Debris on relief valve disk allowing air leakage Remove relief valve cover and clean valve disk as required If necessary to remove disk and spring from relief valve mark location of disk before removal to ensure proper installation If cleaning disk fails to eliminate problem contact Derrick for assistance Failure Mode 13 Air Conditioner Evaporator Faan Fails to Go On Poor electrical connection Shut down lock out and tag out electric power to centrifuge Open control cabinet door and locate fan at upper right Remove 8 screws securing fan to air conditioner housing and separate fan from housing While supporting fan check that fan plugs are securely connected and that all leads are secure in connectors Correct as required continue trouble shooting if leads are secure Fan motor bearings binding or With fan separated from air conditioner housing unplug and seized remove fan Check
96. e unit number in your possession It s the best way to get the most efficient service from our dedicated Service and Engineering personnel DERRICK CORPORATION ABOUT THIS MANUAL In this electronic manual all sections and paragraphs listed in the CONTENTS are linked to the corresponding text Navigate the electronic manual as follows 1 To view any desired information display the CONTENTS page and move the cursor to the desired paragraph or section title To display the desired information click on the listing when the pointing finger appears over the text When finished viewing the text press left arrow key to return to the CONTENTS page If desired to return to the same information press Alt right arrow To locate a different item repeat steps 1 and 2 Blank pages are included to facilitate accurate two sided printing on a standard copier To print any individual section simply enter the PDF page number range at the top of the screen not the page number at the bottom of each page This document contains proprietary information of Derrick Corporation It is intended solely for the information and use of parties operating and maintaining the equipment described herein Such proprietary information may not be used reproduced or disclosed to any other parties for any other purpose without the expressed written permission of Derrick Corporation Continuous improvement is a policy of Derrick Cor
97. ease Remove grease fitting and direct jet of filtered compressed air into opening to remove grease Incorrect grease Lubricate with recommended grease refer to Preventive Maintenance Defective bearing Contact Derrick Service department for assistance F7011 Air Conditioner Compressor M otor Overload Fault Motor drawing excessive current Confirm proper operation of relays K20 and K30 and adequacy of three phase power supply Check all electrical connections Correct any defects Motor drawing excessive current F7012 Air Conditioner Internal Fan Motor Overload Fault Confirm proper operation of relays K20 and K30 and adequacy of three phase power supply Check all electrical connections Correct any defects F7013 Air Conditioner Refrigerant Pressure High or Low Fault Refrigerant pressure high or low Attempt to re start centrifuge Low pressure will cause immediate shutdown or failure to start high pressure will permit brief operation and then automatic shutdown If low pressure indicated contact Derrick Service for assistance If high pressure indicated continue troubleshooting Condenser motor rotation incorrect or motor defective Check rotation direction and reverse if necessary by switching two leads Condenser cooling fins clogged Use vacuum cleaner to remove all debris from fins Condenser motor defective Check motor and replace if defective If proble
98. ected to a known ground 30 Sep 13 3 7 DE 1000LPVFDCentrifuge INSTALLATION ELECTRIC POWER CONNECTIONS CONT D L3 FEED PUMP CONNECTIONS L2 GRD L1 FEED PUMP CONNECTIONS GROUND CONNECTION INPUT POWER CONNECTIONS GROUND CONNECTION Figure 3 7 Non Explosion Proof Centrifuge Input Power and Feed Pump Connections 3 8 30 Sep 13 DE 1000LPVFDCentrifuge INSTALLATION POLARITY TEST WARNING BE CERTAIN THAT MOTORS ROTATE IN CORRECT DIRECTION N INCORRECT POLARITY OF CONVEYOR MOTOR WILL CAUSE CONVEYOR TO ROTATE AT AN INCORRECT SPEED WHICH WILL RESULT IN PROCESSING PROBLEMS In the following procedure polarity is critical Be certain that all motors rotate in the correct directions Simply checking to see if solids are discharged out the solid end DOES NOT ensure correct polarity If conveyor motor is wired incorrectly the conveyor may become plugged or flooded depending on the speed settings of the bowl and conveyor Test for correct polarity of all connections as follows 1 Apply power to centrifuge 2 Confirm direction of rotation for air conditioner condenser and evaporator motors by selecting Test AC on Centrifuge Status screen refer to Section 4 to turn on motors Rotation is to be as follows a Condenser motor Clockwise viewed from fan end b Evaporator motor Clockwise viewed from inside cabinet 3 Correct reverse rotation of air conditioner motors by shutting down
99. ee Manual 17 IR Volts Range 121 I O Comm Loss 29 Analog In Loss 78 FluxAmpsRef Rang 122 Failure 33 Auto Rstrt Tries 79 Excessive Load 130 Hardware Fault 36 SW OverCurrent 80 AutoTune Aborted 131 Hardware Fault CONTROL COMPONENT INDICATORS Various indicators are provided to display the operational status of components in the control cabinet Figures 5 18 through 5 21 locate and define the indications shown on these components Where applicable corrective actions are included to assist the operator in fault analysis Dangerously high voltage is present in the control cabinet Since opening the control cabinet door and bypassing the cabinet purge system is required to check the indicators only trained qualified personnel should be permitted to perform these procedures Use extreme caution to ensure that the surrounding atmosphere is free of hazardous fumes before opening the cabinet door and bypassing the purge system DANGER HIGH VOLTAGE SHUT DOWN LOCK OUT AND TAG OUT ELECTRIC POWER AND ENSURE THAT EQUIPMENT HAS STOPPED ROTATING BEFORE WORKING ON THIS EQUIPMENT WARNING HAZARDOUS GASES CAN CAUSE EXPLOSION BE CERTAIN THAT SURROUNDING ATMOSPHERE IS CLEAR OF ALL POTENTIALLY EXPLOSIVE GASES BEFORE OPENING CONTROL CABINET DOOR 5 40 01 Jan 14 DE 1000LPVFDCentrifuge MAINTENANCE STOP ASSERTED NORMAL OPERATION NOT ENABLED BOWL OVERSPEED FAULT BUT CENTRIFUGE STOPPED E STOP BUTTON PUSHED
100. eize 144 in Ib 16 3Nm Wear Inserts 25 13 8 16 x 3 4 Fit Hd Hx Skt 4 Anti Seize 183 lb 20 7Nm Solid Head Plows 27 1 2 13 x 1 Hx Skt Hd 8 Anti Seize 53 in Ib O 4Nm Feed Nozzle 29 5 8 11 x 2 1 4 Hx Hd 4 Anti Seize 197 ftIb 267Nm Pillow Block 30 8 Pin 7 16 20 x 2 1 2 4 Anti Seize N A Pillow Block 31 7 Pin 3 8 24 x 2 1 2 4 N A Pillow Block 32 8 Plug 1 Anti Seize 35 ft Ib 47 5Nm Bowl Extension 38 3 8 16 x 2 1 2 Hx Hd 4 Anti Seize Unspecified Feed Tube Mounting Block 41 3 8 16 x 1 1 2 Hx Hd 4 Anti Seize Unspecified Feed Tube Support Flange 16 26 15 Fh o a AIN N AN ZA oS 1 22 CIA FAN NJ 2 ES 0 2 34722204 Z dye gt DR IIC TI pth pm ppm TIEREN f NY T F A e 21 12 4 724 lalis 15 al er ZART 30 31 29 5 E 4 36 LIQUID END HARDWARE LOCATIONS 01 Jan 14 5 17 DE 1000LPVFDCentrifuge MAINTENANCE LIQUID END HARDWARE TORQUE SPECIFICATIONS 1 3 8 16 x 1 1 4 Hx Skt Hd 12 Anti Seize 252 in lb 28 5Nm Liquid End Bowl Head 2 516 1 Pin Loctite 680 N A Liquid End Bowl Head 3 5 16 x 5 16 x 3 Key 1 N A N A Liquid End Bowl Head 4 3 8 16 x 1 1 2 Hx Skt Hd 8 Anti Seize 252 in lb 28 5Nm Liquid End Bearing Housing 5 13 8 16 1 Hx Skt Hd 4 Anti Seize 252 in 16 28 5 Liquid End Seal Housing 8 1 4 NPT x
101. emperatures Adjustments of the conveyor and bowl speeds may be performed using up and down arrows or by entering actual numbers on the numeric keypad In addition options are provided for stopping the centrifuge displaying VFD operation screens and selecting Status Clean Out Faults Alarms and Home screens The following parameters affect centrifuge operation Feed rate pond depth bowl speed and conveyor speed Adjustment of one parameter may produce the desired clarity of liquid effluent and solids dryness Or the desired performance may be achieved by further adjustment It is important to understand the interdependence of the operating parameters Changing one characteristic results in other effects that may warrant additional adjustments Except for pond depth these parameters can be adjusted while the centrifuge is operating The operator may then view the results of one change before making additional adjustments The following paragraphs describe the effect of changing each parameter 30 Sep 13 4 7 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS OPERATION CONT D GRN DRIVE OPERATIONAL RED DRIVE FAULT DRIVE RUNNING ne GRY DRIVE OFF ADJUST FEED ck Centri PUMP OUTPUT Bo Pump O9 input RPM met fM PRESENT RPM amp TORQUE OF BOWL amp CONVEYOR Actual RPM Actual 9o PRESENT PUMP 0 0 0 0 OUTPUT amp RPM Torque Torque Pumo RPM INITIATE CENTRIFUGE 0 0 0 0 0 0 OPERATI
102. enance Defective bearing Contact Derrick Service department for assistance Insufficient bearing lubrication 24004 Liquid End Main Bearing High Temperature Fault and Shutdown Lubricate bearings refer to Preventive Maintenance Excess grease Remove grease fitting and direct jet of filtered compressed air into opening to remove grease Incorrect grease Lubricate with recommended grease refer to Preventive Maintenance Defective bearing Contact Derrick Service department for assistance 24005 Solid End Main Bearing High Temperature Alarm Incorrect or loose connection at temperature sensor If reading is constantly about 392 F 200 C check and correct connection refer to electrical schematic diagram in Section 8 Insufficient bearing lubrication Lubricate bearings refer to Preventive Maintenance Excess grease Remove grease fitting and direct jet of filtered compressed air into opening to remove grease Incorrect grease Defective bearing Lubricate with recommended grease refer to Preventive Maintenance Replace rotating assembly refer to Rotating Assembly Maintenance 01 Jan 14 5 35 DE 1000LPVFDCentrifuge MAINTENANCE ALARM AND FAULT MESSAGES F4006 Solid End Main Bearing High Temperature Fault and Shutdown Insufficient bearing lubrication Lubricate bearings refer to Preventive Maintenance Excess gr
103. equipment Confirm that all operators and maintenance personnel have read and understand all operating and safety information in Section 2 4 Verify that equipment has been installed properly all shipping brackets have been removed and bearing pillow blocks have been tightened to specified torque per Section 5 For explosion proof cabinet turn on compressed air to purge system Apply electric power to centrifuge The following screen will appear on explosion proof cabinet displayed after purge cycle is completed DE 1000 VFD Centrifuge Clean Out Operation Setup Alarms Brg Temps Cent Status Diagnostics Motor Torgs 4 4 30 Sep 13 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS 10 11 Without the centrifuge running perform the following safety checks to confirm that connections are correct between control cabinet and centrifuge e Operate emergency stop button and check for Emergency Stop alarm message on control panel e Pull out emergency stop button to clear alarm message e Tap vibration switch housing horizontally with a rubber or rawhide mallet and check for High Vibration Fault message on control panel e Press reset button on vibration switch to clear alarm message Select Cent Status to verify that machine is ready for operation Correct any deficiencies before proceeding with startup procedure If condition is satisfactory click in the upper right corner to return to the Hom
104. eserved for the HMI Server system Addresses 100 100 10 200 to 100 100 10 255 are reserved for the customer s use The system may be operated from either the local HMI Server PC or a web based program from another PC Refer to nstallation for connection information on both systems Operation from either source is basically identical When using the web based program a username and password are required Depending on which LAN port is to be connected to the HMI Server start the web based program be entering the following information in the web browser For LAN port 1 http 100 100 10 101 FTVP For LAN port 2 http CentHMI0001 FTVP Note CentHMI0001 is identical to PC serial number i e CentHMI0001 CentHMI0002 CentHMI0003 etc Web Based Program To use the web based program enter the following username and password Username readonly Password read After entering the HMI Server program the HOME screen will appear Make desired selection from Home screen to view a single centrifuge operation screen Figure 1 8 or view all centrifuge operation screens side by side The operator may then select additional option s from the displayed screen Figures A 7 through A 13 show the screens that are accessible through both the web and PC based systems Figure A 14 shows the DeskLock screen options A 6 15 Feb 13 HMIServerSystem APPENDIX A VFD CENTRIFUGE HMI SERVER SYSTEM Derrick VFD Centrifuge HMI Server Mach
105. essage to inform the operator of the modified status Unless the over torque condition is removed the centrifuge will be shut down automatically Drive Motors The centrifuge is powered by two inverter duty 1800 RPM three phase explosion proof electric motors The 50 HP bowl drive motor is transmitted to the bowl assembly by a sheave and series of drive belts while the conveyor is directly coupled to a 20 HP electric motor A protective guard covers the sheaves drive belts and conveyor drive flexible coupling for personnel protection 15 Aug 13 1 3 DE 1000LPVFDCentrifuge INTRODUCTION Control Cabinet The control cabinet is used to start operate and shut down the centrifuge All operating controls and sensing system components needed for centrifuge operation are installed in the cabinet The cabinet consists of a steel enclosure having a hinged front door Several twist lock fasteners retain the door securely closed and a gasket surrounding the outer edge of the door provides a weather tight seal for protection of the interior electrical and electronic components Fittings are installed at the rear of the cabinet to permit entry of power and sensing cables Variable frequency drives VFDs a programmable logic controller PLC intrinsically safe barriers terminal blocks fuses and other electrical components are installed in the cabinet An air conditioning unit is used to maintain a suitable ambient environment for operation of th
106. f valve and Check that coupling nuts are tight and tube is undamaged flow sensor not air tight Correct as required Purge flow sensor out of Unscrew diaphragm housing from sensor and using a calibration or defective suitable plug close off 12mm threaded opening in top of valve module Turn on system and check purge indicator color If indicator becomes amber re calibrate or replace sensor diaphragm Contact Derrick for assistance if color change does not occur Failure Mode 11 Purge System Fails To Turn On Power After Purge Time Has Elapsed No power to system Check and correct power loss Main power contactor turned Switch on contactor off Blown fuse Check and replace fuse s if blown 5 24 01 Jan 14 DE 1000LPVFDCentrifuge MAINTENANCE TROUBLESHOOTING DE 1000LP VFD CENTRIFUGE Failure Mode 11 Purge System Fails To Turn On Power After Purge Time Has Elapsed Cont d Purge cycle not completed Press indicator button on timer valve If purge time has been completed indicator button will return when released If button does not return allow additional time for cycle to complete Low or no pressure at power Check and adjust pressure if low switch output bulkhead and or at power switch Tubing to power switch Check that coupling nuts are tight and that tubing is not leaking damaged Correct any defects Defective power switch Check that power switch contacts close at 20 psi 1 4 barg Replac
107. flushing the centrifuge prior to shutdown To connect the flush line install a tee fitting in the feed line with shutoff valves to permit selection of either the feed line or the flush line Figure 3 5 The shutoff valves are required to prevent flush water from flowing back into the centrifuge feed If a customer supplied liquid discharge line is used the line must be flexible for vibration isolation Since the discharge cake is very heavy and sticky because of the lack of free liquid the centrifuge should be installed over the receptacle that is to receive the discharged solids If this is not possible a slide or chute is needed to convey the solids At least a 45 degree angle is required to ensure self cleaning or a wash system must be provided to prevent material buildup FEED T FITTING VALVE FEED LINE CENTRIFUGE LU DR FLUSH VALVE LINE Figure 3 5 Feed and Flush Connections COMPRESSED AIR The centrifuge requires a source of clean preferably instrument quality filtered dry compressed air or nitrogen at 60 to 115 PSI at 16SCFM for operation of the control cabinet purge system The supply line must have a minimum diameter of 3 4 20mm The supply must be clean non flammable and from a non hazardous area The cleanliness requirements are as follows Solid particles 0 5um particle size lt 1um max 1000 particles m Humidity 40 C pressure dewpoint Oil content x0 01mg m concentration total
108. from the front panel The positive displacement feed pump is fully controlled by the PLC in either manual or automatic operation Automatic operation provides maximum throughput as the optimum feed rate is assured by the PLC under varying operating conditions Feed is automatically increased until the pre set torque limit is reached by either the bowl or conveyor drive motor If feed slurry properties change the feed rate is automatically adjusted to remain within the torque limit PRODUCT SUPPORT Derrick Corporation offers 24 hour per day 7 day per week product support Product support includes screen replacement ordering information and repair replacement parts and service for the entire product line Refer to the following table for the parts service center nearest you PARTS SALES amp SERVICE LOCATIONS Grand Junction 970 241 2417 Broussard 877 635 3354 Buffalo 716 683 9010 Oklahoma City 405 208 4070 Houston Oilfield Headquarters 866 DERRICK 337 7425 281 590 3003 North Texas Bridgeport 405 208 4070 South Texas Corpus Christi 361 299 6080 West Texas Midland 405 397 4089 East Texas Arkansas and Louisiana 281 546 1166 Casper 307 265 0445 Williston 701 572 0722 1 8 15 Aug 13 DE 1000LPVFDCentrifuge Q DERRICK CORPORATION SECTION 2 SAFETY GENERAL This section contains a summary of WARNINGS used in this manual and a list of material safety data sheets MSDSs applicable to th
109. guards are in place 3 Verify that all personnel are clear of centrifuge and all guards are in place before applying electric power to equipment 4 Apply electric power to centrifuge The following screen will appear after purge cycle is completed lt DERRICK DE 1000 CORPORATION VFD Centrifuge Clean Out Operation Setup Alarms Brg Temps Cent Status Diagnostics Motor Torgs 5 With Home screen displayed select Operation to display the following screen Derrick Centrifuge Operation Bowl Conveyor OQ Pump y Y y Actual Actual RPM FL U 2 z 2500 Y 30 0 0 0 0 00 0 0 0 0 0 FT RE Sans Clean Alarms VFD Conv Pump VFO Home 4 6 30 Sep 13 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS 6 Using up and down arrows set Bowl and Conveyor Input RPMs at desired speeds 750RPM minimum 7 Select STAHT to turn on centrifuge Note that Bowl and Conveyor speeds will gradually rise until settings are reached and Torque for bowl and conveyor will rise If pump drive motor data has been changed since previous startup select Autotune to tune motor to VFD 8 When bowl speed has reached speed setting select Pump START to start feed pump and slowly introduce feed to centrifuge Note Pump will not start until actual bowl speed is within 120RPM of setting 9 Adjust feed rate Bowl speed and or Conveyor speed as required to optimize centrifuge
110. he centrifuge is configured to operate on a specific AC voltage supplied in three phase 50Hz or 60Hz Electrical controls are mounted on the electrical control box located at the machine s liquid discharge end Safety devices built into the centrifuge protect personnel and equipment by shutting down the machine in case of excessive bowl or conveyor torque high motor temperature vibration or other malfunction G forces produced by the high speed rotation of a cylindrical bowl separate solids from the feed slurry 1 6 15 Aug 13 DE 1000LPVFDCentrifuge INTRODUCTION Centrifuge performance is based on three variable factors e force exerted on the fluid Gravitational force pulling fluid against the outside wall of the centrifuge e Retention time in the centrifuge The longer the slurry remains in the centrifuge the smaller the particle that can be separated e Differential speed of conveyor The faster the conveyor rotates the wetter the solids and the more solids that are discharged All three factors may be manipulated to alter the liquid and solids discharge Retention time is controlled by adjusting the liquid discharge ports on the liquid bowl head to change the pond depth liquid level G force is adjusted by changing the bowl speed on the operator control panel and the conveyor differential speed may be altered by changing the differential speed setting on the control panel The conveying speed is the difference between the bowl
111. ier solids but reduces the solids discharge rate Increasing conveyor speed reduces drying time leading to wetter discharged solids Reducing conveyor speed results in drier solids discharge However excessively slow conveyor speed permits solids to accumulate in the bowl possibly causing an overload condition The drying time is reduced by increasing the conveyor differential speed which will increase the wetness of the solids Reducing the conveyor differential speed raises the settling time which will produce drier solids Both the conveyor speed setting and actual conveyor speed are shown on the control panel In addition the conveyor torque percentage is shown to assist in optimizing conveyor speed to produce the desired solids dryness and processing speed Since the conveyor differential speed is controlled by the PLC relative to the bowl speed setting wiring polarity of electrical components is critical Electrical polarity determines the actual speed and direction of conveyor motor for any bowl speed setting For example with a bowl speed setting of 2000 RPM and conveyor differential speed set at 60 the conveyor motor will rotate in reverse at 1120 RPM The correct bowl conveyor speed relationship depends on correct wiring polarity If polarity is reversed the same bowl speed setting of 2000 RPM described above would result in an actual conveyor differential speed of about 17 rather than the setting of 60 30 Sep 13 4 9 DE 100
112. ig In ConflictB 30 TB Man Ref Cflct 5 Analog In Loss 19 Dig In ConflictC 31 PTC Conflict 6 IntDBRes OvrHeat 20 BiPolar Conflict 32 Brake Slipped 8 Drive OL Level 1 21 Motor Type Cflct 33 AdjVoltRef Cflct 9 Drive OL Level 1 22 Hz Conflict 34 Home Not Set 10 Decel Inhibt 23 MaxFreq Conflict 49 Prove Cflct 11 Waking 24 VHz Neg Slope 50 Prof Step Cflct 12 Motor Thermistor 25 Volts Range 52 PI Config Cflct 2 Auxiliary Input 38 Phase U to Grnd 81 85 Port 1 5 DPI Loss 3 Power Loss 39 Phase V to Grnd 87 IXo VoltageRange 4 UnderVoltage 40 Phase W to Grnd 88 Software Fault 5 OverVoltage 41 Phase UV Short 89 Software Fault 7 Motor Overload 42 Phase VW Short 90 Encoder Quad Err 8 Heatsink OvrTemp 43 Phase UW Short 91 Encoder Loss 9 Trnsistr OvrTemp 48 Params Defaulted 92 Pulse In Loss 12 HW OverCurrent 49 Drive Powerup 93 Hardware Fault 13 Ground Fault 51 QueueCleared 100 Parameter Chksum 15 Load Loss 52 Faults Cleared 101 103 UserSet Chksum 16 Motor Thermistor bb Cntl Bd Overtemp 104 Pwr Brd Chksum1 17 Input Phase Loss 63 Shear Pin 105 Pwr Brd Chksum2 01 Jan 14 5 39 DE 1000LPVFDCentrifuge MAINTENANCE 20 TorgProv Spd Band 64 Drive OverLoad 106 Incompat MCB PB 21 Output PhaseLoss 69 DP Resistance 107 Replaced MCB PB 24 Decel Inhibit 70 Power Unit 108 Anlg Cal Chksum 25 OverSpeed Limit 71 75 Port 1 5 Adapter 120 Mismatch 28 S
113. ilt in system diagnostics continually analyze the DE 1000LP control system for malfunctions The Diagnostics screen Figure 4 7 aids in troubleshooting by displaying any fault in the critical areas of the centrifuge The current operational status of the Bowl Conveyor and Pump VFDs as well as the speed and temperature sensors are displayed on this screen Analog readings in mA are displayed at the bottom of the screen for main bearing temperature sensors and bowl speed sensor The screen is accessible from the Home screen as well as the three VFD screens GRN NO VFD FAULT GRN VFD RUNNING RED VFD FAULT GRY VFD NOT RUNNING rifuge Diagnostics Bow Conveyor Pump VFD TEMPERATURE Faut Q Alarm Q Alarm Q Fault Q Alarm iE 8 2 F 102 4 103 8 F NOT USED AJC Blower Pressure Compressor GRN 24VDC PRESENT AT Pump Enable CORRRESPONDING PIN OF 3 Speed ALL THREE VFD S GRY 24VDC NOT PRESENT Vibration E Stop Bowl Speed Analog ANALOG SIGNAL LEVEL GRN INTRINSIC BARRIER DS m 3 995 ma CONNECTION PRESENT s Speed Sensor RED NO CONNECTION 4 20 Analog 4 20 Analog GRN MIN SIGNAL SUPPLIED GRN 24VDC AT CLICK TO TOGGLE TO VFD CORRESPONDING PIN BETWEEN SOLID END BEARING RED NO SIGNAL OR LOW SIGNAL RED 24VDC NOT PRESENT AND CABINET RTD SIGNALS Figure 4 7 Diagnostics Screen 4 12 30 Sep 13 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS
114. ine 1 2 Machine 3 R gt Pg I A A DE 1000 VFD DE 7200 VFD DE 7200 VFD SELECT DESIRED CENTRIFUGE OPERATION OR VFD SCREEN Wiz VIEW OPERATION SCREENS OF ALL NM CENTRIFUGES T SIMULTANEOUSLY DISPLAY PUMP SETUP SCREEN DISPLAY HM SERVER ACTIVATION SUPPORT DISPLAY ALL TO VIEW PUMP AND PUMP DRIVE SCREEN TO VIEW SOFTWARE CONFIGURATION PRESENT ALARMS MOTOR SPECIFICATIONS AND REQUEST SERVICE AND SUPPORT Figure A 7 HMI Server Home Screen Derrick Conteuge 1 DE 1000 Demo rawa 9290 Emos 08 PUDO sw aam Firm 0 v y m JUMP BACK 2 HOURS STORED DATA AND STOP Centnfuge 1 VI Ds 1 Homo AL Centrifugos JUMP BACK 1 HOUR STOP AND DISPLAY PRESENT TIME NOTES 1 CURRENT NUMBERS ARE SHOWN AT ALL PAUSES 2 ZOOM BY CLICKING AND DRAGGING AREA OF GRAPH DESIRED TO ENLARGE UNDO ZOOM BY RIGHT CLICKING IN GRAPH 3 REFERENCES CHANGE TO CORRESPOND WITH ZOOM 4 GRAPH SHOWS 2 HRS OF DATA Figure A 8 Operation Screen Centrifuge 1 Derrick Centrifuge 1 DE 1000 Demo Shar De Commer VEO Fasa sata 200 T tme T Cem An Q CQ Pac el Awmi uml Man Asm2 s Es um Fem EARS mE m 9 DOO ome im pos soo corse o
115. layed 3 To shut down HMI Server simply press and release power button on Server If Server is inaccessible select Exit Runtime from the Setup screen Next select Shutdown PC on the DeskLock Launcher Note If Server is shut down restart by cycling power or pressing power button Wait at least 30 seconds before re applying power to restart the unit 4 Turn off power to Router Switchgear Box to shut down unit Operation If an existing network infrastructure having a DHCP server is not available to connect to LAN 2 of the HMI Server a four port router with DHCP capability may be used Alternatively the LAN 1 interface may be used on the HMI Server PC to connect to the HMI Server If desired to connect to the LAN 1 interface a basic 10 100 Mbps Ethernet switch will be needed The switch would be installed between the router box and the HMI Server PC instead of a direct connection Additional PCs would then connect to this new customer supplied switch 15 Feb 13 A 5 HMIServerSystem APPENDIX A VFD CENTRIFUGE HMI SERVER SYSTEM Operation Cont d IP Address If connecting to LAN 1 the static IP address of the PCs must be set to the following IP addresses PC IP Address Subnet Mask PC1 100 100 10 201 255 255 255 0 PC2 100 100 10 202 255 255 255 0 100 100 10 203 255 255 255 0 In addition note that other component may be on the network with an address between 100 100 10 1 to 100 100 10 199 as these are r
116. lock the cover open 6 After performing the activity that required the cover to be opened reverse steps 2 through 5 to close the cover During the closing procedure ensure that both operators are capable of controlling the cover s descent and that all body limbs and other items remain clear of the gap 01 Jan 14 5 1 DE 1000LPVFDCentrifuge MAINTENANCE PREVENTIVE MAINTENANCE Preventive maintenance consists of inspection cleaning and lubrication These routine procedures will ensure maximum life and trouble free operation While the maintenance schedule presented in this section should remain flexible modifications should be based on experience with operating the equipment at your facilities A maintenance log should be kept to help establish a preventive maintenance schedule as well as to monitor and adjust the schedule as necessary throughout the equipment s life When establishing a preventive maintenance schedule consider duty cycle ambient temperature and operating environment The recommended preventive maintenance schedule is presented in the table below Refer to the lubrication chart on the following page for applicable lubricants and quantities PREVENTIVE MAINTENANCE SCHEDULE Inspect feed tube connection for leaks and tighten connection clamp as required Inspect liquid discharge connection for leaks Tighten connection and or add silicone sealant to prevent leakage Grease rotating assembly bearings Figure
117. ly Clogging of the conveyor or worn bearings may produce sufficiently high vibration to trip the switch VIBRATION SWITCH Figure 1 4 Vibration Switch Case Base And Skid The stainless steel upper and lower case halves provide a sealed protective enclosure that fully surrounds the bowl assembly The liquid discharge pipe and the solid discharge chute are installed at the bottom of the lower case half Mating baffles installed inside the top and bottom case halves separate the solids and liquid Bolts secure the top and bottom halves together and a rubber gasket in the top case seals the two halves A separate two piece enclosure encloses the gearbox at the liquid end of the bowl assembly The case is bolted onto the welded steel base assembly which contains mounting provisions for the bearing pillow blocks and feed tube support The base assembly is bolted to the welded steel skid MECHANICAL OPERATION The centrifuge receives slurry at the sheave end solid discharge end of the machine For best performance the slurry should be screened to 74 microns in vibrating screening machines before being fed to the centrifuge The slurry flows through a feed tube into the rotating bowl where centrifugal force separates liquid from the solids Liquid flows out the liquid discharge connection at the gearbox end of the centrifuge while solids are conveyed to the solid discharge where they fall into a chute at the bottom of the machine T
118. m automatically assumes control of the feed pump to reduce its flow rate The message Automatic Flowrate appears on the Operation screen to alert personnel that the feed pump is under automatic control When the reduced feed rate is reached a 20 second timer is started Upon expiration of the timed interval a new conveyor differential speed is applied to correspond with the revised flow rate The pump feed rate returns to the previous rate when the new differential speed is reached Manual control of the feed pump is then restored This action releases the feed pump from automatic control and clears the Automatic Flowrate message from the screen ALARM AND FAULT MESSAGES During centrifuge operation a message may appear to alert the operator to an anomaly that requires operator intervention Alarm messages signify that the prevailing condition must be corrected or the centrifuge may be shut down automatically Fault messages inform the operator that a failure requiring automatic shutdown has occurred Refer to Section 5 for alarm messages and their causes and corrective actions BEARING TEMPERATURES Bearing temperature trends may be viewed in graphical form on the Bearing Temperature screen Figure 4 5 Temperatures are updated in accordance with a pre set interval and scroll buttons are provided to facilitate examination of trends over time Solid and liquid end temperatures are displayed at the right side of the screen The Motor Torque scree
119. m persists contact Derrick Service for assistance F7021 Electrical Enclosure High Temperature Alarm Control cabinet interior temperature has exceeded alarm setpoint Check status operation of air conditioner repair or replace if defective Reduce load by decreasing bowl conveyor differential speed and or pump feed rate 5 36 DE 1000LPVFDCentrifuge 01 Jan 14 MAINTENANCE ALARM AND FAULT MESSAGES F7022 Electrical Enclosure High Temperature Fault and Shutdown Control cabinet interior temperature has exceeded alarm setpoint Interior temperature of control cabinet too high causing shutdown Check status operation of air conditioner repair or replace if defective Reduce load by decreasing bowl conveyor differential speed and or pump feed rate Check that air conditioner is operating repair or replace as indicated Inspect cabinet interior and remove cause of high temperature if any Re start centrifuge after removing cause of high temperature F7031 Enclosure Temperature Sensor Error Control cabinet interior temperature sensor not functioning Check sensor and connection Correct any wiring defects and replace sensor if defective F8001 Emergency Stop Switch Activated Shutdown EMERGENCY STOP initiated Remove cause for emergency stop pull out EMERGENCY STOP and then re start centrifuge F8002 Emergency Stop Switch or Belt Guard Senso
120. mp operating characteristics are viewed on the Pump Setup screen Figure 4 18 Information keyed in from the pump and drive motor operating specifications is displayed to inform the operator of current motor and pump information Derrick Centrifuge Pump Setup X PUMP OUTPUT IN GALLONS PER REVOLUTION Motor Data Pump Data Current 42 a0 Output Rev EIE GPR PUMP DRIVE MOTOR OPERATING DATA Power w 40 00 Gear Box HP Ratio Power Auto Flow Rate 96 TOGGLE BETWEEN HP amp NM Update VFD Settings ms S TOGGLE HIGH LOW s LEVEL MONITORING High Level ON AND OFF Rem START Figure 4 18 Pump Setup Screen 4 18 30 Sep 13 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS LOGIN The Login screen Figure 4 19 is accessed from the Setup screen Figure 4 14 It permits authorized personnel to enter a password required to display restricted screens These screens permit supervisory personnel to re set operating characteristics and thresholds that govern centrifuge operation ENTER USER NAME ENTER KEY ENTER PASSWORD Figure 4 19 Login Screen CLEAN OUT The Clean Out screen Figure 4 20 is used to set parameters for operating the bowl and or conveyor to remove accumulated process material that is impeding rotation With this screen displayed the operator selects the desired bowl and conveyor RPMs for the cleanout process During cleanout the actual RPMs and torque percentages are displ
121. n Profibus connections and attempt to re start in Remote operating mode F9021 Signal Loss Bowl Speed Sensor Intrinsic Barrier Minimum analog signal from transmitter intrinsic barrier not received by PLC Check all connections at transmitter intrinsic barrier replace transmitter if all connections are secure F9022 Signal Loss Bowl Speed Sensor or Cable Incorrect or loose connection at speed sensor or defective speed sensor Defective speed sensor transmitter intrinsic barrier Check sensor connections replace sensor if defective Check and replace transmitter intrinsic barrier if defective Pump VFD fault Identify fault from operator control panel Perform indicated corrective action Incorrect or loose connection at speed sensor or defective speed sensor F9032 Signal Loss Bowl Speed Sensor or Cable Check sensor connections replace sensor if defective Defective speed sensor transmitter intrinsic barrier Check and replace transmitter intrinsic barrier if defective Pump VFD fault Identify fault from operator control panel Perform indicated corrective action F9041 Signal Loss Liquid End Bearing Temp Intrinsic Barrier Minimum analog signal from transmitter intrinsic barrier not received by PLC Check all connections at transmitter intrinsic barrier replace transmitter if all connections are secure F9051 Signal Loss Solid End Bearing Temp I
122. n holes Check for and remove any nicks or burrs Slowly lower rotating assembly until pillow blocks contact base but maintain support by hoist Apply anti seize compound to pillow block bolts and tapered alignment pins Insert pillow block bolts and alignment pins through pillow blocks Tap alignment pins into place Hand tighten pillow block bolts and then release hoist Tighten pillow block bolts in accordance with applicable torque specification in Section 5 Adjust effluent ports if necessary from factory setting of 3 4 WARNING WHILE OPENING AND CLOSING THE CENTRIFUGE COVER PERSONNEL MUST ENSURE THAT ALL BODY LIMBS AND ANY OTHER ITEMS ARE CLEAR OF THE COVER GAP TWO OPERATORS MUST BE USED WITH BOTH HANDS ON THE COVER HANDLES AT ALL TIMES DERRICK RECOMMENDS HAVING A HOIST AVAILABLE IF ADDITIONAL ASSISTANCE IS DESIRED DURING THE OPENING CLOSING PROCEDURE 30 Sep 13 3 5 DE 1000LPVFDCentrifuge INSTALLATION LOWER AND SECURE ROTATING ASSEMBLY CONT D 12 Close case cover and evenly tighten all cover bolts sequentially beginning at the center and moving toward ends 13 Rotate bowl manually to confirm that no binding or rubbing is present 14 Adjust drive belt tension in accordance with preventive maintenance in Section 5 15 Install belt guard and gearbox guard FEED AND DISCHARGE CONNECTIONS For vibration isolation a flexible line must be connected to the feed tube A source of fresh water is required for
123. n is also accessible from the Bearing Temperature screen The operator may return to the Operation or Home screen using the buttons at the lower right of the screen Bearing Temperature 1 Min Thursday August 09 2007 Friday Update 150 DERE x CURRENT LIQUID END SCROLL LEFT OR RIGHT E BEARING TEMPERATURE 90 CURRENT SOLID END 68 BEARING TEMPERATURE 30 8 43 35 8 43 35 Torque 41 Operation VIEW MOTOR PAUSE TORQUE SCREEN Figure 4 5 Bearing Temperature Screen 30 Sep 13 4 11 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS MOTOR TORQUE TREND Bowl and conveyor torque trends may be viewed in graphical form on the Motor Torque trend screen Figure 4 6 Torques are updated in accordance with a pre set interval one minute and scroll buttons are provided to facilitate examination of trends over time Bowl and conveyor torques are displayed at the right side of the screen The Bearing Temperature screen is also accessible from the Motor Torque screen The operator may return to the Operation or Home screen using the buttons at the lower right of the screen Motor Torque 1 Min Thursday August 09 2007 Friday Auc Update BOWL MOTOR TORQUE SCROLL LEFT OR RIGHT CONVEYOR MOTOR TORQUE 8 42 31 Brg Temp 4 U bh Operation Home VIEW BEARING PAUSE TEMPERATURE SCREEN Figure 4 6 Motor Torque Trend Screen SYSTEM DIAGNOSTICS Bu
124. ng the startup and operation procedures detailed information on the control screens is provided to assist the operator and technician in understanding centrifuge operation and fully utilizing its capabilities The centrifuge is designed to be operated only for the purpose specified at the time of purchase Operation in any other application requires consultation with Derrick engineering SOFTWARE VERSION The operating procedures in this section apply to DE 1000LP VFD centrifuges having software Version 3 1 6 installed The software version is shown on the Setup screen shown below ANT Operating Range X ESSENS Temperature Units zJ lt Home Although operating procedures are generally identical an earlier software version may cause some screens to appear slightly different from those shown on the following pages OPERATING SAFETY WARNING ALL OPERATING AND MAINTENANCE PERSONNEL MUST READ AND UNDERSTAND ALL SAFETY INFORMATION IN THIS MANUAL BEFORE WORKING WITH THE EQUIPMENT WARNING BE SURE THAT COVER IS CLOSED AND SECURED AND ALL PERSONNEL ARE CLEAR BEFORE STARTING MACHINE WARNING DO NOT OPERATE CENTRIFUGE IF EXCESSIVE NOISE OR VIBRATION DEVELOPS ALWAYS CONFIRM THAT VIBRATION SWITCH AND OTHER SAFETY DEVICES ARE FUNCTIONAL 30 Sep 13 4 1 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS WARNING WHILE OPENING AND CLOSING THE CENTRIFUGE COVER PERSONNEL MUST ENSURE THAT ALL BODY LIMBS AND ANY OTHER ITEM
125. ntrinsic Barrier Minimum analog signal from transmitter intrinsic barrier not received by PLC Check all connections at transmitter intrinsic barrier replace transmitter if all connections are secure Centrifuge 29099 Centrifuge Sensor I O Cable Has Been Removed Reconnect I O Cable to Run Sensor cable is disconnected from control cabinet receptacle Plug in connector at upper left of cabinet and then re start centrifuge 5 38 DE 1000LPVFDCentrifuge 01 Jan 14 MAINTENANCE VFD ALARM AND FAULT CROSS REFERENCES In addition to alarm and fault messages that may appear on the operator control panel in case of equipment malfunction alarm and fault numbers may appear directly on the VFD screens An alarm is a condition that if neglected may stop the drive A fault is a condition that stops the drive The following tables list these alarm and fault numbers and the corresponding text This information is useful for operators and Derrick personnel to diagnose equipment malfunctions To expedite troubleshooting record the code number before calling for service and then relay this information to the service engineer ALARM CROSS REFERENCE 1 Precharge Active 14 Load Loss 27 Speed Ref Cflct 2 UnderVoltage 15 Ground Warn 28 Vit Rang 3 Power Loss 17 Dig In ConflictA 29 Sleep Config 4 Start At PowerUp 18 D
126. nv Fault Status Fault Status AUTOMATIC PUMP FLOW RATE REDUCTION Figure 4 16 Fault Reset Screen 30 Sep 13 4 17 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS SETUP SCREEN The Setup screen Figure 4 17 permits the operator to view the number of the software version installed in the PLC and control panel HMI bowl and differential speed settings and feed pump characteristics as well as set personal preferences The operator may adjust the brightness of the control panel screen and select the temperature units C or that will be shown on other screens Options are provided to select the Login Diagnostics or Home screens If Login is selected prompting will appear to enter a user name and password which is available only to authorized personnel Once the screen is entered authorized personnel may set or change bowl conveyor and pump VFD parameters DISPLAY LOGIN SCREEN TO PERMIT ACCESS TO RESTRICTED SCREENS Derrick Centrifuge Setup CURRENTLY INSTALLED T Software Version SOFTWARE VERSIONS DISPLAY MAX MIN DE 1000 BOWL amp DIFFERENTIAL PLC Rev 3 0 ADJUST DISPLAY SPEED SETTINGS AND HMI Rev 3 0 BRIGHTNESS PUMP GPM SETTINGS FOR EACH OPERATOR Display Brig DUE VIEW PUMP OPERATING TO SUIT AMBIENT LIGHTING CHARACTERISTICS Pump Setup Temperature Units Diagnostics Home SELECT DESIRED VIEW CORRESPONDING SCREEN TEMPERATURE UNIT Figure 4 17 Setup Screen PUMP SETUP SCREEN The pu
127. oil For applications where ambient temperature Tamb lt 0 the air supply should be Class 2 1 1 with humidity 70 C pressure dewpoint FEED PUMP The customer is required to supply a feed pump for delivering slurry to the centrifuge The recommended pump is a progressing cavity type having a fixed ratio gearbox and 15 HP maximum inverter duty pump drive motor The motor must be capable of operating in the 180 to 2700 RPM 6 to 90 Hz speed range and also meet all other application requirements including voltage frequency and area of classification The pump size motor and gearbox ratio must be 3 6 30 Sep 13 DE 1000LPVFDCentrifuge INSTALLATION chosen to deliver the maximum desired flow at a pump rotor speed determined by the manufacturer to be low enough to prevent accelerated wear of the rotor and or stator The pump must be connected to the centrifuge s control system as described under Electric Power Connections in this section so that its operation can be supervised by the centrifuge ELECTRIC POWER CONNECTIONS DANGER HIGH VOLTAGE SHUT DOWN LOCK OUT AND TAG OUT ELECTRIC POWER AND ENSURE THAT EQUIPMENT HAS STOPPED ROTATING BEFORE WORKING ON THIS EQUIPMENT WARNING CENTRIFUGE MUST BE OPERATED AT THE DESIGNATED SUPPLY VOLTAGE WARNING ELECTRICAL CONNECTIONS MUST BE MADE IN ACCORDANCE WITH ALL APPLICABLE NATIONAL AND LOCAL CODES FAILURE TO COMPLY MAY RESULT IN AN UNSAFE CONDITION THAT COULD INJURE PERSONNEL OR
128. on of User Manual Pump VFD fault Identify fault from operator control panel Perform indicated corrective action F3013 Pump VFD Ground Warn Alarm Ref Troubleshooting Section of User Manual Pump VFD has detected high current leakage to ground Check condition of cable and all connections between pump VFD and pump motor and correct any defects F3014 Pump VFD In Phase Loss Alarm Ref Troubleshooting Section of User Manual Pump VFD has detected unbalance or partial loss of input three phase power Check wiring between VFD and supply source correct defect s Check supply power and correct any defects Incoming power loss or low voltage supply F3015 Pump VFD Power Loss Alarm Ref Troubleshooting Section of User Manual Check incoming power and correct any defect s F3016 Pump VFD Undervoltage Alarm Ref Troubleshooting Section of User Manual Incoming power loss or low voltage supply Check incoming power and correct any defect s F3017 Pump VFD Drive OL Alarm Ref Troubleshooting Section of User Manual Pump drive motor drawing excessive current Replace motor if defective or remove other cause of excessive current draw Perform autotune of pump motor drive 01 Jan 14 5 33 DE 1000LPVFDCentrifuge MAINTENANCE ALARM AND FAULT MESSAGES F3021 Pump Motor Thermal Overload Check Pump Motor Temperature and Thermistor Pump drive motor
129. on s original shipment of the referenced product Ass i LAJ Date 29 December 2011 Signature Jennifer J Polanowski Derrick Corporation http dmc sps qc Certificates Shipping Final Inspection and Run Test PE S 073 04 00 doc Revison Number 2 Revision Date 29 December 201 1 Doc PE S 036 02 06 Date 20 January 201 1 DERRICK CORPORATION CERTIFICATE OF CONFORMANCE Equipment Mining amp Oilfield equipment manufactured specifically for Hazardous Location Areas including but not limited to Flo Line Cleaners Flo Line Primers Agitators Vacu Flo Degassers DE 1000 Centrifuges Centrifugal Pumps Flo Line Scalpers etc Name and Address of Manufacturer Derrick Corporation 590 Duke Road Buffalo NY 14225 Rating and Principle Characteristics 0 600 VAC 50 60Hz 3PH Model Type Ref Various Additional Information None This product was found to be in conformance with U L listed for hazardous locations Class I Division 1 Groups C amp D which is similar to equipment marked as II 2G Ex d IIB T3 for Zone 1 areas Assembled in accordance with National Electrical Code NEC articles 500 thru 506 hazardous locations where applicable Additionally Derrick Corporation certifies that the above listed equipment for the referenced order conformed to the requirements of the specified order at the time of its original shipment by Derrick Corporation in that all constr
130. operation Select Data screens at any time to review and monitor centrifuge operating characteristics including air conditioner status elapsed operating time and VFD data Note Depending on conveyor differential speed setting at bowl speeds above 300RPM conveyor motor may rotate in opposite direction OPERATION The properties of the inlet slurry and desired separation should be known in advance This information can be used to set and change bowl speed conveyor differential speed and feed rate unless set for automatic control as required during centrifuge operation Continual monitoring of the centrifuge control panel indications as well as the condition of the inlet slurry are essential to achieving desired effluent clarity and solids dryness Rising conveyor torque indicates that one or more operating parameters should be lowered to reduce torque Conversely falling conveyor torque shows that speed can be raised and or feed rate increased Operating parameters should be adjusted as required to optimize centrifuge operation and prevent automatic shutdown due to excessive bowl or conveyor torque The Operation screen Figures 4 2 and 4 3 permit the operator to view current operating information for the bowl conveyor and pump and adjust the parameters as required to meet changing conditions Through this screen the operator may view and set bowl and conveyor RPMs and torque percentages set feed pump flow rate and view bearing t
131. ough the bowl head transfers motion from the gearbox to the conveyor The feed tube inserted through the conveyor at the solids end directs inlet slurry against a feed accelerator which rapidly disperses the material through feed nozzles in the conveyor Carbide inserts are installed in the feed nozzles and carbide tiles are welded to the edges of the conveyor flights for wear resistance Ball bearings support both ends of the conveyor Gearbox The 52 1 ratio differential reduction gearbox rotates the conveyor at a slower speed than the bowl assembly The motor is coupled to the gearbox by a flexible coupling which permits compliance with slight alignment variations The conveyor s rotational speed varies directly with bowl speed maintaining a consistent differential relationship for solids conveyance The gearbox is an overhung load with one end supported by the liquid end conveyor bearing The gearbox output shaft driven by the second stage planetary gears engages internal splines in the conveyor to transmit rotary motion During an overload condition excessive solids in the conveyor may overburden the motor causing motor torque to increase as it attempts to maintain the differential speed setting If the conveyor s pre set torque limit is reached the control system automatically reduces the feed rate to enable the conveyor to clear the excess solids When the centrifuge is operating at the reduced feed rate the Operation screen displays a m
132. plined shaft with internal spline of conveyor O RING GEAR FLANGE Insert six new hex head screws through gear flange and into threaded mounting holes of gearbox Alternately turn each screw a few revolutions at a time to evenly draw the gearbox and flange together Tighten the mounting screws using a star pattern typical for circular bolt patterns Refer to Hardware Torque Specifications for torque values 10 Inject grease into conveyor bearing until grease escapes from drain hole located between pillow block and liquid bowl head Wipe off surplus grease and distribute grease by rotating liquid bowl head one revolution clockwise and then one revolution counterclockwise 11 Check and adjust runout of outside diameter of gearbox as described in the steps below Axial runout may not exceed 0 002 0 05mm total indicator reading TIR 5 12 DE 1000LPVFDCentrifuge 01 Jan 14 MAINTENANCE 12 To measure and adjust runout proceed as follows a Clean surface of gearbox where dial indicator plunger will make contact b Install indicator holder with magnetic base in either position shown c Position plunger of dial indicator into contact with outside diameter at horizontal centerline of gearbox d Manually rotate the gearbox until dial indicator is at its lowest reading and zero out dial indicator PLUNGER POSITIONED AT HORIZONTAL CENTERLINE OF GEARBOX e Manually rotate the gearbox until reading
133. poration All instructions and procedures are subject to change without notice DERRICK CORPORATION CONTENTS Section Page Date Ts HIESQUELON ana ta 1 1 15 Aug 13 Au Wish 1 1 er O O 1 1 Sound EMISSION Rp 1 1 Equipment Use sei 1 2 1 2 Mechanical Operation ER iaa gan 1 6 Control System een 1 7 Product Support inne 1 8 ng nn 2 1 30 Sep 13 BIEIE TA nee ee P RT 2 1 Waning nn 2 1 Material Safety Data Sheets 5055 2 3 3 Installatllon P 3 1 30 Sep 13 A A EL Eu tlie 3 1 cc erc M HH 3 1 Top Cover Opening Closing Procedures 3 2 Installation Sequence secas m 3 3 Site Preparation and Clearance 3 2 Equipment Handling ea en ea tm 3 3 Equipment LOVE lisas 3 4 Lower and Secure Rotating 3 4 Feed and Discharge 4444 n 3 6 Compressed Air e 3 6 A Po HH 3 6 Electric Power Connections scort 3 7 Polarity Tetto 3 9 RA H eee 3 9 01 Jan 14 1 DE 1000LPVFDCentrifuge CONTENTS Section Page Date 4 Oper
134. power and switching any two of the three power leads at the motor or terminal strip refer to Figure 3 6 and electrical schematic diagram in Section 8 WARNING EQUIPMENT WILL BE DAMAGED IF AIR CONDITIONER EVAPORATOR AND OR CONDENSER MOTOR ROTATES IN OPPOSITE DIRECTION CORRECT ROTATION BEFORE OPERATING MACHINE 4 Run bowl at 20 RPM with a conveyor differential speed of 5 RPM 5 Confirm direction of rotation for bowl conveyor and feed pump motors as follows a Bowl Counterclockwise viewed from fan end b Conveyor Clockwise viewed from fan end c Feed pump Per manufacturer s data 6 Correct reverse rotation of bowl or conveyor motor by shutting down power and switching any two of the three power leads at the motor or terminal strip refer to Figure 3 6 and electrical schematic diagram in Section 8 If feed pump rotation is incorrect refer to manufacturer s data for information to reverse rotation MACHINE STARTUP Refer to Section 4 for initial startup and operating procedures for the centrifuge WARNING DO NOT ATTEMPT TO OPERATE MACHINE WITH SHIPPING COMPONENTS INSTALLED 30 Sep 13 3 9 DE 1000LPVFDCentrifuge Q DERRICK CORPORATION SECTION 4 OPERATING INSTRUCTIONS GENERAL The procedures in this section are for use only by trained personnel who are qualified to operate high speed rotating equipment Initial and normal startup operation shutdown and emergency shutdown procedures are included Followi
135. power and switching any two of the three power leads at the terminal block s inside the cabinet refer to Section 2 and electrical schematic diagram in Section 8 30 Sep 13 4 5 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS INITIAL STARTUP CONT D 15 After confirming correct motor rotational directions enter desired Bowl Speed of at least 750RPM and enter desired Differential Speed select START to begin centrifuge operation Screen will display actual Bowl Speed Differential Speed and Torque When bowl speed reaches 750RPM START STOP at right side of screen will change to Autotune Derrick Centrifuge Operation Bow _ Comeyo Pump Input RPM Input RPM Mara input GEM 2 f A f A y 2400 40 y 0 2400 40 0 0 0 16 4 11 9 Torque Sans FS Bow VFD Conv Pump VFD 16 Select Autotune to tune pump drive motor to VFD Allow about 60 seconds for autotuning 17 Start centrifuge in accordance with Normal Startup procedure below beginning with step 4 NORMAL STARTUP Note If Centrifuge is Heated Before Starting Centrifuge Follow COLD CLIMATE STARTUP Instructions to Ensure Proper Bearing Lubrication 1 Without electric power applied open cover and rotate bowl assembly manually to check that the bowl turns freely and no rubbing is felt 2 Close cover tighten all cover bolts to required torque refer to Section 5 and ensure that all
136. r Trip EMERGENCY STOP initiated or belt guard removed or not secure F8003 High Vibration Fault and Shutdown Correct Problem and Press Reset Button Check and secure belt guard pull out EMERGENCY STOP and then re start centrifuge Rotating assembly unbalanced or mechanical looseness 28004 High Vibration Switch or Bowl Rotating assembly overloaded or clogged bearing failure conveyor wear or loose pillow block bolts producing out of balance condition Remove cause of excessive vibration and re start centrifuge Cover Sensor Trip Case cover not secure Check and secure cover and re start centrifuge Rotating assembly unbalanced or mechanical looseness Rotating assembly overloaded or clogged bearing failure conveyor wear or loose pillow block bolts producing out of balance condition Remove cause of excessive vibration and re start centrifuge Re loading of PLC program from memory card completed F9010 Control Program Downloaded from Memory Card to Controller Start centrifuge and resume operation F9011 Controller Internal Battery Low Replace PLC battery low Replace battery 01 Jan 14 5 97 DE 1000LPVFDCentrifuge MAINTENANCE ALARM AND FAULT MESSAGES F9012 External Communication Loss Switched to Local Control Profibus not working remote control is disabled and control has automatically switched to local Check and correct any defects i
137. r power cable from the customer power source to the circuit breaker in the Router Switchgear Box Figure A 3 Strip and secure cables to circuit breaker terminal A 2 15 Feb 13 HMIServerSystem APPENDIX A VFD CENTRIFUGE HMI SERVER SYSTEM CONNECT 220 240VAC SINGLE PHASE 50 60HZ POWER TO 15A CIRCUIT BREAKER Figure A 3 Electrical Connections to Router Switchgear Box 3 Tighten nut properly on cable gland to ensure proper sealing 4 Close and secure cover of Router Switchgear Box after completing connections 5 Plug in HMI Server and PC power cords Ethernet Connections Required Equipment The following customer supplied components are required for making the Ethernet connections Item Category 5 CAT5 or higher shielded Ethernet cable 1 NPT cable glands Explosion proof 3 4 NPT cable glands Ethernet switch router PC or laptop computer Purpose Quantity Connections between control Maximum 328 100m each cabinets HMI Server amp Router Switchgear Box Ethernet cables from each 1 for each centrifuge control control cabinet to routers in cabinet Router Switchgear Box Ethernet amp power cables into Up to 7 for Router Switchgear Box Router Switchgear Box 1 for Power 2 or 1 for PC 1 4 for Centrifuges Interconnect HMI Server and 1 computer Monitor up to 4 centrifuges 1 3 supports up to 3 connections Server and PC Connection Requirements An Ethernet connection must b
138. r to Section 4 bowl and or conveyor Failure Mode 4 No Liquid Discharge Untreated Feed Material Exits Liquid Discharge Outlet Buildup of solids between flights solids not being transported to discharge but are discharged with liquid Shut down feed pump and bowl assembly drive motor but keep conveyor motor running and admit rinse water into machine If solids emerge before bowl fully stops re start centrifuge Shut down lock out and tag out electric power Open top cover and insert hose into liquid and solids discharge openings and flush bowl interior with water preferably hot water If flushing is unsuccessful in clearing the blockage remove rotating assembly and remove conveyor to facilitate thorough cleaning refer to Hotating Assembly Maintenance Failure Mode 5 High Power Consumption Machine Clogged Solids accumulated within case Open top cover and thoroughly clean case interior bowl exterior and solids discharge chute Failure Mode 6 Machine Clogged Upon Starting After a Brief Shutdown Excessive solids volume in Perform cleanout procedure refer to Section 4 feed due to sedimentation in Prevent future repetition by clearing feed line immediately after supply line shutting down machine Failure Mode 7 Machine Shutdown Due to Excessive Power Consumption During Startup Discharge chute clogged Clear discharge chute of all accumulated solids 01 Jan 14 5 23 DE 1000LPVFDCentrifug
139. s application of electric power to the cabinet At the end of the rapid purge cycle the purge system closes the main electrical contactor allowing electric power to flow to the cabinet The centrifuge may then be started After the rapid purge cycle the purge system maintains positive pressure within the cabinet to prevent entry of hazardous gases automatically compensating for pressure loss due to cabinet leakage If at any time a loss of cabinet pressure is detected the main contactor opens immediately disconnecting power If a shutdown occurs during centrifuge operation the purge system performs another 16 minute rapid purge before power is restored to the cabinet Purge System Bypass WARNING DO NOT BYPASS PURGE SYSTEM IF NOT CERTAIN THAT ENVIRONMENT IS NON HAZARDOUS A HIGH RISK OF FIRE AND OR EXPLOSION WILL RESULT IF PURGE SYSTEM IS BYPASSED IN A HAZARDOUS AREA If the centrifuge is located in a non hazardous environment the purge system may be turned off A high risk of fire and or explosion will result if purge system is bypassed in a hazardous area Also with the purge system bypassed the centrifuge will remain energized if the control cabinet door is opened Consequently use extreme caution when operating the equipment or performing any procedure with purge system bypassed If the centrifuge is moved to a hazardous environment the bypass must be removed and satisfactory purge system operation confirmed DANGER USE EXTR
140. se materials Emergency first aid procedures special precautions emergency telephone number and other relevant data are contained in the MSDSs These documents are prepared by the product manufacturers which have sole responsibility for accuracy of the information The MSDSs listed below apply to products used in the manufacture of the Derrick equipment Where shown dates are current as of the publication date of this manual The latest MSDSs may be obtained from the product manufacturer MATERIAL DESCRIPTION WHERE USED MSDS No Date PPG Dimetcote 302H Green 302F0250 Resin Top Coat 1302H 5A 04 11 10 PPG Dimetcote 302H Clear 302G0910 Cure Top Coat 1302H B 01 21 10 PPG PSX 700 Neutral Tint Resin Undercoat 700 3 02 28 08 PPG PSX 700FD Cure Undercoat PX700FD B 01 11 07 Standard Environment Chevron SRI NLGI 2 Main Conveyor amp Motor Bearings 6979 08 03 04 Shell Omala 320 Gearbox 67510E 07 08 08 Shell AeroShell 14 Main amp Conveyor Bearings 56200E 9 07 07 08 30 Sep 13 2 3 DE 1000LPVFDCentrifuge SAFETY MATERIAL DESCRIPTION WHERE USED MSDS No Date Arctic Environment Shell AeroShell 7 Drive Motor Bearings 56170E 9 05 20 03 Exxon Mobil Mobilith SHC 220 Gearbox Mobilith SHC 220 03 23 10 Food Grade Chevron SRI NLGI 2 Main Conveyor amp Motor Bearings 6979 08 03 04 Exxon Mobil FM 102 Conveyor Bearings Only 642363 00 01 17 0
141. shooting Section of User Manual Conveyor VFD alarm Identify alarm from operator control panel Perform indicated corrective action 01 Jan 14 5 31 DE 1000LPVFDCentrifuge MAINTENANCE ALARM AND FAULT MESSAGES F2012 Conveyor VFD Fault and Shutdown Ref Troubleshooting Section of User Manual Conveyor VFD fault Identify fault from operator control panel Perform indicated corrective action F2013 Conveyor VFD Ground Warn A Conveyor VFD has detected high current leakage to ground larm Ref Troubleshooting Section of User Manual Check condition of cable and all connections between conveyor VFD and conveyor motor and correct any defects Manual F2014 Conveyor VFD In Phase Loss Alarm Ref Troubleshooting Section of User Conveyor VFD has detected unbalance or partial loss of input three phase power Check wiring between VFD and supply source correct defect s Check supply power and correct any defects F2015 Conveyor VFD Power Loss Ala rm Ref Troubleshooting Section of User Manual Incoming power loss or low voltage supply Check incoming power and correct any defect s F2016 Conveyor VFD Undervoltage A Incoming power loss or low voltage supply larm Ref Troubleshooting Section of User Manual Check incoming power and correct any defect s Thermistor F2021 Conveyor Motor Thermal Overload Check Conveyor Motor Temperature and
142. sically safe power output This output consists of a low voltage electrical lead connected from the purge unit to an intrinsic barrier in the electrical panel When the purging phase is completed this output signal closes the main contactor in the electrical panel which then energizes all components in the control cabinet Vibration Switch The vibration switch Figure 1 4 is a safety device designed to protect personnel and equipment by shutting down the centrifuge in case of excessive vibration Normally the switch contacts are held closed by a mechanical latch However strong vibration or a shock of 2 Gs will overcome the magnetic latch causing the switch armature to break away from the normally closed position providing an input to the PLC 15 Aug 13 1 5 DE 1000LPVFDCentrifuge INTRODUCTION Vibration Switch Cont d A reset button on the side of the switch must then be manually pressed to close the contacts and re engage the magnetic latch The vibration trip level is adjustable by means of a set point control which adjusts the air gap between the magnet and latch arm plate Turning the screw counterclockwise reduces the vibration set point in terms of G force needed to trip the armature When the control is turned fully clockwise the switch will trip the maximum rated vibration level The vibration switch is mounted on the centrifuge base in an orientation that is most affected by out of balance vibration of the bowl assemb
143. tem is not maintaining satisfactory pressure within the cabinet For further details of purge system operation refer to Section 4 Cabinet Purge System Before power is applied to the centrifuge the purge system purges the control cabinet of any flammable gas that may have entered the cabinet while it was not pressurized The system also maintains positive pressure and automatically compensates for any leakage within the control cabinet to prevent entry of flammable gas The system has FM UL ATEX and IECEx certifications The purge unit has a visual indication of purge system status Minimum pressure and purge flow sensors provide an output signal to the control unit if the purge system is not maintaining satisfactory pressure within the cabinet Major components of the purge system are described in the following paragraphs Control Unit The control unit contains a pneumatic logic circuit that controls the cabinet purge and pressurization It receives filtered air from an external air filtration system installed on the outside of the control cabinet Components installed in the control unit include air filtration pressure and purge flow measurement purge timing and local visual indication of pressurized alarm and flow sensed It also provides the required output to turn on power to the cabinet 1 4 15 Aug 13 DE 1000LPVFDCentrifuge INTRODUCTION Relief Valve RLV The relief valve unit is installed on the left side of the control c
144. that fan rotates freely and no rubbing is detected Replace fan if rubbing or binding is found High temperature switch motor Using an ohmmeter check for continuity across 2 light gray winding defective motor leads of fan connector Figure 5 14 through 5 17 If meter indicates an open circuit verify that leads are securely connected correct as needed If connections are secure replace fan 01 Jan 14 5 25 DE 1000LPVFDCentrifuge MAINTENANCE X2 6 X2 6 X2 6 D PRESSURE BLOWER COMPRESSOR FAILURE FAILURE FAILURE LEGEND POWER CABLE B1 THERMOSTAT F1 HIGH REFRIGERANT PRESSURE SWITCH F2 FUSE F4 M3 THERMAL PROTECTOR CONTACT F5 LOW REFRIGERANT PRESSURE SWITCH F6 F7 1 THERMAL PROTECTORS F8 M1 THERMAL PROTECTOR CONTACTS K10 FAULT SIGNAL RELAY K15 M1 THERMAL PROTECTOR RELAY K20 COMPRESSOR CONTACTOR K30 POWER CONTACTOR M1 COMPRESSOR M2 CONDENSER FAN M3 EVAPORATOR FAN T1 CONTROL TRANSFORMER X1 X3 TERMINAL BOARD Figure 5 14 Air Conditioner Electrical Schematic Diagram 5 26 01 Jan 14 DE 1000LPVFDCentrifuge POWER CABLE 2 6 2 6 2 6 LEGEND B1 F1 F2 F4 F5 F6 F7 F8 K10 N O CONVEYOR VFD CONTACTS HIGH REFRIGERANT PRESSURE SWITCH FUSE M3 THERMAL PROTECTOR CONTACT LOW REFRIGERANT PRESSURE SWITCH M1 THERMAL PROTECTORS M1 THERMAL PROTECTOR CONTACTS FAULT SIGNAL RELAY PRESSURE FAILURE K15 K20 K30 M1 M2 M3 T1 X1 X3 MAINTENANCE
145. the following three conditions will be occurring a lf a considerable quantity of air continues to flow out the relief valve after power has been applied the leakage compensation valve is too far open and the air flow is holding the relief valve open continuously To correct this condition slowly close the leakage compensation valve The cabinet pressure will start to fall as the flow decreases but eventually the relief valve will close and the cabinet pressure will rise again At this point the relief valve may start to open intermittently as the cabinet pressure rises to the point where it exceeds the relief valve opening pressure When the relief valve opens the pressure will fall quickly to the point where the relief valve re closes and the cabinet pressure starts to rise again b Ifthe relief valve is opening intermittently the leakage compensation valve is open slightly too far When the relief valve opens the cabinet pressure falls quickly to the point where the relief valve re closes and the cabinet pressure starts to rise again Continue to close the leakage compensation valve until the cycling stops and the cabinet pressure starts to fall Carefully adjust the leakage compensation valve until the cabinet pressure is stable This pressure will be the normal working pressure and should be about 5 WC 12 5 mbarg c If at the end of purging the cabinet pressure falls below the minimum pressure sensor setting and the leakage compens
146. ting device CAREFULLY slide gearbox outward until splined shaft is free of conveyor Place gearbox in plastic bag to prevent contamination 9 Tighten nuts on pillow block alignment pins to jack out pins and remove pins 10 Remove bolts securing pillow blocks to base mounting pads 11 Attach lifting straps at two locations on rotating assembly and using a hoist capable of supporting approximately 2000 Ibs 910kg lift and remove rotating assembly from case 12 Note locations of all shims found between pillow blocks and base mounting pads and remove and retain shims 13 Apply protective coating to mating surfaces of pillow blocks and base 5 10 01 Jan 14 DE 1000LPVFDCentrifuge MAINTENANCE BEARING PILLOW BLOCK Figure 5 4 Gearbox Removal Cleaning Inspection and Repair 1 Wash off mud and debris from conveyor and interior and exterior of bowl assembly 2 Inspect solid discharge wear inserts on bowl assembly for cracks fractures or other damage and replace if seriously damaged 3 Inspect bowl exterior for gouges scratches or other damage that may affect performance 4 Check pillow block bearings and conveyor bearings for looseness noise or rubbing If bearing looseness or damage is found replace rotating assembly in accordance with procedures in this section Return defective rotating assembly to Derrick for overhaul 5 Remove inspection plug from bowl extension and insert vernier caliper through hole and
147. tion Personnel responsible for transporting installing operating or performing maintenance on this equipment are required to read and understand the information and instructions in this manual One copy of this manual should be available and accessible at the equipment location For maximum safety and performance no additions and or changes may be made to the equipment without the explicit written permission of Derrick Corporation Genuine Derrick repair replacement parts are required Figure 1 1 DE 1000LP Variable Frequency Drive VFD Centrifuge SAFETY Section 2 of this manual contains relevant safety information for both operation and maintenance of this equipment Be sure this information is read and understood by all personnel DO NOT operate the equipment if defective or faulty mechanical or electrical components are detected SOUND EMISSION Hearing protection is recommended when working on or near the centrifuge Based on measurements taken for technically comparable machinery the centrifuge emits the following airborne sound levels A Weighted Machine Surface Averaged Sound Pressure Level at 1m 86 dBA e A Weighted Machine Surface Averaged Sound Power Level 102 dBA e C Weighted Instantaneous Peak Sound Pressure Level 106 dBA 15 Aug 13 DE 1000LPVFDCentrifuge INTRODUCTION EQUIPMENT USE The DE 1000LP VFD centrifuge is designed expressly for removing low and high specific gravity solids from slurries
148. to 12 Spread 1 Remove main bearing inner race from liquid bowl head shaft HXCBF38 16X250 Hex Head Jack Bolt 3 8 16 x 2 1 2 Long 2 Separate gearbox from flange HXCBF31 18X400 Hex Head Jack Bolt 5 16 18 x 4 Long 4 Separate conveyor bearing housing from liquid end bowl head shaft 5 14 01 Jan 14 DE 1000LPVFDCentrifuge MAINTENANCE DE 1000LP VFD CENTRIFUGE TOOL LIST HXCBF38 16X400 Hex Head Jack Bolt 3 8 16 x 4 Long 4 Separate conveyor bearing housing from solid end bowl head shaft 10792 00 Vertical Lifting Bracket 1 Lift solid end bowl head and conveyor from bowl assembly 10791 00 Vertical Stand 1 Support liquid bowl assembly vertically during maintenance WFSS 31 5 16 Flat Washers 6 Attach vertical lifting bracket to gearbox flange NHHS 31 18 Hex Nut Heavy 5 16 18 6 Attach vertical lifting bracket to gearbox flange SKCS 38 16x175 Socket Hd Cap Screw 3 8 16 x 1 3 4 4 Attach vertical lifting bracket to gearbox flange G00041 14 Socket Hd Cap Screw 5 16 18 x 1 1 4 6 Attach vertical lifting bracket to solid end bowl head RED B150X125 Bushing Hex 1 1 4 x 1 1 2 1 Reduce opening of feed tube CHE SRI 2 Grease Standard 1 Lubricate main bearings and gearbox spline Aeroshell GR 14 Grease Arctic 1 Lubricate main bearings and gearbox spline EYE S31 18X113 Eye Bolt 5 16 18 x 1 1 8 2 Lift rotating assembly by gearbox flange PP1127 Grease Gun 1 2 Dia Hose 14 5 Oz 2 Inject gre
149. uction materials and components were new and unused manufactured for this equipment and that the goods were free of any known defects as to their design material and workmanship This certificate is governed by the applicable purchase order terms in effect at the time of Derrick Corporation s original http dmc sps qc Certificates Conformance UL European Typc PIz S doc
150. ugal force holds the flushing liquid against the bowl wall during the flushing procedure As the speed gradually drops during the shutdown period the solids chute can also be flushed Fittings on the hinge side of the case permit attachment of a hose to wash the exterior of the rotating assembly and interior of the case assembly 3 Conveyor gearbox drive motor automatically shuts down when bowl speed falls to less than 200RPM 4 After the centrifuge comes to a complete stop which may take more than 15 minutes after interrupting power to the bowl motor the centrifuge should be restarted for 20 to 30 seconds to clear away solids released during collapse of the water ring 5 Run automatic cleanout procedure 6 Open fused disconnect supplying electric power to the machine and lock out and tag out machine 7 For cabinet with purge system turn off compressed air supply to cabinet purge unit 4 20 30 Sep 13 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS AUTOMATIC SHUTDOWN The centrifuge has built in safety features to protect the equipment These features will result in automatic shutdown of the centrifuge before damage occurs The following paragraphs describe these automatic shutdowns Excessive Vibration Excessive vibration of the centrifuge will cause the vibration switch to interrupt electric power to the centrifuge run relay shutting down the machine Such excessive vibration may occur during
151. umber The stainless steel unit number tag attached to each piece of Derrick equipment is your key to efficient service and support Typical Derrick Unit Number This unique number gives vital information to Service personnel who use it to identify the correct parts when filling orders provide accurate responses to service questions track documentation and trace the equipment s history or configuration In short the unit number provides the critical information needed to ensure that Derrick customers receive the best possible service The unit number consists of a two character alphabetic prefix that identifies the equipment type and a series of numeric characters that signify the sequence of the machine s manufacture For example unit number MA000001 would be the first screening machine manufactured by Derrick Alphabetic prefixes currently in use are MA Screening Machine AD Desilter and Desander DG Degasser AG Mud Agitator CF Centrifuge SF Screen Frame To ensure that it will remain intact over many years of rigorous service the heavy gage tag is riveted to a structural member such as the shaker support structure It is not to be confused with any other identifier on the machine such as a vibrator motor serial number For convenient availability the unit number is also recorded in the Operation and Maintenance manual shipped with the equipment When contacting Derrick for any equipment question or need always have th
152. ump motor data download procedure Verify that pump drive is on line and stopped Additional Fault Conditions F4001 Centrifuge Start Disable Allow Bowl to Stop Completely View Alarm History for Restart aborted due to bowl rotation during restart attempt Wait for bowl to fully stop check for and clear all faults and verify that bowl is at complete standstill Restart centrifuge F4002 Clean Out Over Torque Fault Excessive torque has caused clean out procedure to abort Attempt to clear using Manual Cleanout procedure in this section If unsuccessful connect a liquid supply line to flush fitting to dilute process material and re attempt Manual Cleanout If still unsuccessful with bowl at complete standstill open cover and remove excessive process material 5 34 DE 1000LPVFDCentrifuge 01 Jan 14 MAINTENANCE ALARM AND FAULT MESSAGES F4003 Liquid End Main Bearing High Temperature Alarm Incorrect or loose connection at temperature sensor If reading is constantly about 392 F 200 C check and correct connection refer to Section 3 and electrical schematic diagram in Section 8 Insufficient bearing lubrication Lubricate bearings refer to Preventive Maintenance Excess grease Remove grease fitting and direct jet of filtered compressed air into opening to remove grease Incorrect grease Lubricate with recommended grease refer to Preventive Maint
153. xplosion proof enclosure in a safe area Note If desired Router Switchgear components mounting plate may be e Connect Ethernet cables between server and pc or laptop e Install 1 NPT cable gland in each control cabinet e Connect Ethernet cables between routers and centrifuge control cabinets Connect electric power to circuit breaker in Router Switchgear Box HMI Server Installation The HMI Server may be placed on a desktop or mounted to a wall in a non hazardous area Mounting brackets and rubber feet are supplied with the server to facilitate wall or desktop installation Figure A 2 Note that the wall mounting brackets have slotted holes to permit minor position adjustment during installation Installing Rubber Feet for Desktop Mounting Installing Wall Mounting Brackets Figure A 2 Server Mounting Options Router Switchgear Box Installation Four mounting lugs are provided on the electrical enclosure for wall mounting Select a mounting location that permits the front cover to be opened for accessing the interior components Refer to drawing 17647 00 for box dimensions and mounting requirements Electric Power Connections The HMI Server and Router Switchgear Box use 220 240Vac single phase 50 60Hz electric power Perform electric power connections as follows 1 Install a 1 NPT explosion proof cable gland in Router Switchgear Box to accept power cord 2 Route 14 AWG 2 5mm or large

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