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5500 BrakeSmart™ Operations Manual

1. 3 5 TERMINAL CONNECTIONS Ha Gs 8 OROS 8 T2 T6 T4 T4 TB 5500 HORIZONTAL CENTRIFUGE VOLTAGE CONVERSION 220 480 _ TERM e OG E LOW VOLTAGE HIGH VOLTAGE PATH C NACADNRSA5500N5500 VC DWG SORE RIS i JM L PREUUINARY ISSUED PRO 16 94 CHK DESCRIP DATE SCRIPTOR UATE APR DRAW NO A 5500 REVISIONS 78 KILLARK CONTROL PANEL EXTERNAL 79 CURLEE CONTROL PANEL EXTERNAL 80 KILLARK CONTROL PANEL INTERNAL Transformer under main power circuit breaker S oft Start Main Power Circuit Breaker Power Distribution Block kl f 1 Relay 1 Peu E Relay 3 la DAY Relay 4 Main Drive Starter MEN kann ka ke Control Pover Breaker oe qu E Relay 5 Backdrive Circuit Breaker WE Relay 6 Feed Pump Circuit Breaker W k PLC Feed Pump Starter ser 5 Power Supply Feed Pump Starter Overload ROE mai ISB 2 SOT Backdrie Starter Fwd TB 2 Backdrive Starter Overload Current Transducer Backdrive Starter Rev TB 1 CURLEE CONTROL PANEL INTERNAL Transfor Main Power Circuit Soft Start Relay 1 Power Distribution Relay 2 Relay 3 Relay 4 Maindrive Sta Control Power Circuit Breaker Relay 5 Backdrive Circuit Relay 6 Feed Pump Bre Md densas ia Feed Pump Sta ISB 2 base TB 2
2. m 7 s Full Load Current i gat Power Factor 5 0 5 1C 15 Voltage Variations Installation amp Operation 2 3 124 First Time Start Up Be sure that all power to motor and accessories is olf Be sure the motor shaft is disconnected from the load and will not cause mechanical rotation of the motor shaft po om 10 Make sure thal he mechanical inslalla ion is secure All bolls ard nuls are tightened etc If mator has been in storage or idle for some time chezk windiac insulation integrity with a Megger Inspec ell electrical connections for proper terminatior clearance mechanical strength and electrical continuity Be sure all shipping materials and braces if used are remover from motor shaft Manually rotate the motor shaft to ensure that it rotates freely Replace all panels and covers that were removed during installation Momentari y apply power and check the direction of rp ation of the motar shaft If mator rotation is wrong be sure pawer is off and change the motor lead connections Verify rotation directior before you continus Start the motor and ensure operatior is smooth without excessive vihration ar noise run the motor for 1 hour with no Icad connected After 1 hour of operation disconnect power and connect tre load to the motor shaft Verify all coupling guards and protective devices are installed Ensure moto
3. Carefully raise the conveyor to a vertical position with the front end gearbox end resting on a very clean surface Remove the rear bearing housing by unscrewing the six 6 1 4 capscrews Using two 2 of the screws Just removed place them in the two 2 Jackscrew locations and evenly jack the solids end bearing seal housing Item 11 out Inspect the two 2 oil seals and the O Ring for any damage If damaged or worn remove them Inspect the ball bearing If it is in good condition go to Step 10 If the bearing must be replaced due to wear or damage reinsert the six 6 capscrews in the rear bearing housing to stabilize it for pulling the ball bearing Use a slide hammer type bearing puller to extract the bearing Remove the six 6 capscrews from the rear bearing housing and using two 2 of them Jack out the bearing housing the retainer tube assembly will come out with the rear bearing housing Remove the six 6 capscrews from the retainer tube flange Pull the retainer tube assembly out Inspect the front oil seals for wear or damage If the front oil seals are worn or damaged they will have to be replaced To replace the two 2 front oil seals the bearing must be pulled Replace the rear bearing housing into the conveyor and replace the six 6 capscrews Remove the ball bearing using a slide hammer type bearing puller 38 16 Remove the oil seal retaining ring 17 Pull the two 2 oil seals and rep
4. calibration Spring Configuration 5 Sizes 1 5 inclusive Clearance Required for adjustment Size 6 amp Larger 105 CALIBRATION SPACERS The torque limiter is shipped from the factory either with the torque setting pre adjusted as specified at the time of the order or furnished unset for adjustment at the time of installation units are supplied with minimum spacer only to prevent from locking up unless required otherwise by customer TORQUE ADJUSTMENT SIZE 6 AND LARGER To facilitate adjustment under the high loads these larger units use number of adjusting bolts See Fig 12 When building assemble all components as Fig 12 but omit the adjustment spacer Be careful to stack the disc springs correctly This is generally as shown in Fig 12 but reference should be made to the assembly drawing as the number and method of stacking can vary Assemble the pillars 10B springs 10A washers 10C and adjustment bolts 10E into the adjusting nut 11A and lightly tighten the bolts so that as the adjusting nut is tightened the hexagon engages with the groove in the slide plate Tighten the adjusting nut as far as possible using the bolts to equalize the length of each spring stacks so that all pillars are engaged with the groove on the slide plate To increase the torque tighten each bolt by an equal amount but not enough to disengage the hexagons from the slide plate One or two turns of th
5. Slide Plate Adjusting Nut 112 TURCK Inductive Sensors Barrels H and EH Barrel Barrel Metal Miniature with Potted In Cable Smooth picoprox 2 Wire DC Requires Remote Amplifier 5 30 VDC ariable Resistance Output NAMUR EN 50227 Sensor Selection Part Number Bi 1 AEHO4 YO 2 811 5 6 5 1 Bi1 5 H0B YI a Ni 2 H0B Yl Ni 3 EH6 5 Y1 gt gt 5 EH6 5K Y1 JORGUE EH6 5K Y1 ME Factory Mutual approval applies only when used with Factory Mutual approved switching amplifiers Note YO and Y1 units have identical electrical properties See Section for differences in European approvals ACCESSORIES Accessories and mounting devices be found in Section J Remote Amplifier required Consult TURCK multimodul or Automation Controls catalog CABLE CONDUCTOR Cable PVC Jacket 2 meter standard length Copper Conductor 4 26 AWG insulated EH6 5 H08 24 AWG MATERIAL Barrel Stainless Steel Locknuts Lockwashers Stainless Steel Sensing Face End Cap 12 GF30 Trogamid T Plastic C189 TURCK Inc 3000 Campus Drive Minneapolis MN 55441 Application Support 1 800 544 PROX Fax 763 553 0708 www turck com 113 TURCK Inductive Sensors Barrels 5 618 Y0 Bi 5 618 Y0X 8110 630 0 Bi10 G30 YOX 71 647 1 647 Y1X Ni 5 G12 YO Ni 15 612 Y0X Ni10 G18 YO 10 618 YOX Ni15 630 YO 25 647 Y1 Bi 2 EG12 YOK
6. engaging must therefore be carried out at a speed slow enough to allow the unit to fully re engage and then accelerate the mass of the driven machine If this is attempted at too high speed e g by direction line starting the set torque of the unit can be exceeded causing tripping in the opposite direction The limiting re engaging speed depends on factors such as the inertia of the driven plant elasticity of the drive and the torque setting of the Autogard so it is not possible to give exact limiting re engaging speeds However as guide for most applications it should be under rather than over 100 RPM Many drives incorporate jogging facility which can be used for re engaging DISASSEMBLY PROCEDURE 1 Measure and make note of the position of the adjusting nut on the hub before proceeding with disassembly 2 With spring end up loosen the setscrews and remove the adjusting nut spring spacer limit switch plate slide plate and drive balls 3 Carefully work drive plate over spline so as not to damage bearing material on I D of drive plate 4 Clean all parts thoroughly and inspect the bearing surfaces Carefully blend out any scratches 5 Reassemble MAINTENANCE The frequency of maintenance will depend on the operating environment and number of trips but once every 2 000 operating hours should be adequate in most applications Proceed as follows If requested a grease fitting is located at either the end of
7. Bi 22612210727 Bi 2 GI2 YOX N115 630 YOX 2 5 30 VDC Variable Resistance Output NAMUR EN 50227 1 0 71005400 1 1 74010000 3 0 71006000 3 1 74015000 5 0 71006200 5 1 14020000 T 9 1006800 7 1 1020200 2 9 71005500 2 1 14010100 4 0 71006100 4 1 74015100 6 0 71006300 6 1 74020100 25 47 8 0 51 M1006900 mr Pe Ps em Factory Mutual approval applies only when used with Factory Mutual approved switching amplifiers Note YO and Y1 units have identical electrical properties See Section A for differences in European approvals Cable Conductor Cable PVC Jacket 2 meter standard length Copper Conductor 612 24 AWG PVC insulated G18 G30 G47 MATERIAL ACCESSORIES Barrel Locknuts CPS Chrome Plated Brass Accessories and mounting devices can be found in SS Stainless Steel Section 1 Sensing Face 12 GF30 Plastic Remote Amplifier required Consult TURCK End Cap G12 G18 G30 PUR Plastic multimodul or Automation Control catalog C193 TURCK Inc 3000 Campus Drive Minneapolis MN 55441 Application Support 1 800 544 PROX Fax 763 553 0708 www turck com 114 BALDOR MOTORS AND DRIVES Explosion Proof AC and DE Motors MOTORS AND DRIVES iaia 2 Integral Horsepower AC Induction Motors ODP WPI WPII Enclosure TEFC Enclosure Explosion Proof Install
8. No of Bolt Dimensions Inches M Bolts Size Dia Max Bolt Depth Bolt Circle Sprocket Bore in Adapter Dia 1 6 8 32 25 1 750 1 376 1 378 1 375 2 6 10 24 31 2 500 2 126 2 128 2 125 3 6 1 4x20 38 3 375 2 876 2 878 2 875 4 6 5 16x18 1 50 4 125 3 5015 3 5035 3 500 5 6 3 8x16 62 5 687 5 0015 5 0035 5 000 Attach sprocket sheave etc onto adapter prior to reassembly Use bolts of a length that provides no more engagement in the adapter 4 than the maximum shown in Table 1 Make sure there are no protrusions inside the adapter which might interfere with the hub The unit may then be reassembled per instructions 2 Mounting Sprocket or Sheave on Models 402 and 409 3 Proper Spring Check to see that the correct number of springs is being used to release torque Table 4 DO NOT TIGHTEN THE SPRINGS BEYOND ITS MINIMUM OPERATING LENGTH with the torque limiter engaged or the springs will not allow sufficient movement of the slide plate to let the balls leave their seats during an overload Damage to the machinery or to the Autogard will result 4 Lubrication The needle bearing spline surfaces plate faces and balls have the proper type and amount of lubricant applied during the assembly at the factory No further lubrication should be required at initial installation MOUNTING TORQUE LIMITER ON SHAFT MODEL 406 Mount the torque limiter hubs on the shafts in the same manner as described For coupling units Model 406 m
9. Only qualified personnel should attempt to install operate or maintain this equipment Do not by pass protective devices or safety guards Safety features are designed to prevent damage to personnel or equipment These devices can only provide protection if they remain operative Avoid the use of automatic reset devices if the automatic restarting of equipment can be hazardous to personnel or equipment Be sure the load is properly coupled to the motor shaft before applying power The shaft key must be fully captive by the load device Improper coupling can cause harm to personnel or equipment if the load decouples from the shaft during operation Use proper care and procedures that are sate during handling lifting installing operating and maintaining operations Impropar methods may cause muscle strain or other ham Before performing any motor maintenance procedure be sure that the equipment connected to the motor shaft cannot cause shaft rotation If the load can cause shaft rotation disconnect the load from the motor shaft before maintenance is performed Unexpected mechanical rotation of the motor parts can cause injury or motor damage Discannect all electrical power from the motor windings and accessory devices before disassembly of tlie motor Electrical shock can cause serious or fatal injury not use these motors in the presence of flammable or combustible vapors or dust These motors are not designed f
10. fi In im 4062 Rear Insert 4050 40 I 29 x amp Scraper de P ia 1655 NEW STYLE HIGH G CENTRIFUGE u AE m ome ROTATING ASSEMBLY ITEM NUMBERS MI AT 4205 A TYP HARD TILE 3402 See Parts List Section For Part Numbers REAR 75 n SECTION 8 ELECTRICAL amp WIRING 76 Wire size and length for 5500 BrakeSmart Skid Unit Main drive motor 60 HP 100 6 4 with 16 4 gexol armored and sheathed 753 1 1 4 753 1 1 4 Back drive motor to J box 3 10 4 with 16 4 gexol armored and sheathed 753 B 1 753 B 3 4 J box to panel 100 10 4 with 16 4 gexol armored and sheathed 753 B 3 4 753 B 1 Vibration and Prox Switches 100 16awg 3 pair shielded armored and sheathed 753 B 3 4 753 B 3 4 Note The 5500 Centrifuge and Duster main drive that has 6 4 gexol armored and sheathed without the 16 4 conductors a 753 B 1 gland is used Hutchison Hayes uses Hawke type 753 glands 77 HUTCHISON HAYES 11 INTERNATIONAL INC DELTA CONNECTEN MOTORS 713 452 0222 FAX 713 45 457 6143 7 6143 HOUSTON TEXAS Ti WYE CONNECTED MOTORS HIGH VOLIAGE LOW VOLTAGE T9 pos Em SERES FARALLEL 16 JI 8 15 T2 T4 7 af Mie HIGH VOLTAGE LOW VOLTAGE SERIES PARALLEL T9 T8 p 76 1 9 6 T8 2 L1 L2 L3 13 T2 MINAL ONNECTIONS
11. 16 17 18 19 20 21 22 23 24 25 If excessive vibration is present during start up shut the unit down immediately and notify HH service representative Do not replace any damaged or worn out Machine Parts with other than HH replacements The customer may replace ordinary wear parts such as oil seals o ring and gaskets replacement list is in the Parts List Section Do not open the cover or attempt removal of shroud or belt guard until the centrifuge is motionless Use the correct tools for any assembly or disassembly work Do not supply slurry into the centrifuge until the unit is fully up to normal operating speed If more than one 1 centrifuge is in operation never attempt to exchange any machined parts Never use a pipe wrench on any part of the centrifuge There is slow down period as the machine decelerates towards shut down Leave the cover shut until the centrifuge is motionless Do not attempt any disassembly before the machine 15 static Never prop the centrifuge cover partially open by using blocks of wood or any other foreign object IMPORTANT CAUTION 26 27 28 Whenever centrifuge cover is opened for cleaning inspection etc one 1 hinge safety pin must be engaged to prevent accidental closing of the cover this procedure should always be followed Flexible connections should be used at all customer piping tie ins Do not attempt any repair
12. 2 X 1 1 4 FLAT AND LOCK NEVER 2 SHOCK MOUNT TO SKID STD SKID 12 SS HEX HEAD WSHR SEIZE SUB BASE TO SHOCK MOUNT 5 8 X 3 1 2 FLAT AND LOCK NEVER 1 BOLT THROUGH SUB BASE 8 SS HEX HEAD WSHR SEIZE EXTRA 2 NUTS UNDER SHOCK MOUNT 8 SS HEAVY 5 8 BASE TO SUB BASE 5 8 X 4 1 2 FLAT AND LOCK NEVER 1 BOLTS THROUGH BASE 4 SS HEX HEAD WSHR SEIZE NEVER 2 FEED TUBE ARM TO BASE 4 SS HEX HEAD 5 8 X 2 LOCK WSHR SEIZE SOCKET NEVER 3 FEED TUBE ARM CAP 6 SS HEAD 3 8 X 1 3 4 SEIZE 3 4 X 1 1 2 FLAT AND LOCK NEVER 4 EYE BOLT HOLES 4 SS HEX HEAD WSHR SEIZE CASE TO BASE 5 8 X 1 1 2 FLAT AND LOCK NEVER 1 BOLTS THROUGH CASE TO BASE 8 SS HEX HEAD WSHR SEIZE NEVER 2 TEFLON IN CASE 6 SS HEX HEAD 5 16 X 1 FLAT AND LOCK WSHR SEIZE 3 COVER SAFETY PIN 1 PLATED HITCH PIN 5 8 X 2 54 GEAR GUARD LOCK TIGHT OR ITEM NEVER POSITION QTY ALLOY TYPE STYLE SIZE SEIZE NEVER 1 BOLTS THROUGH GUARD 6 SS HEX HEAD 3 8 X 1 FLAT AND LOCK WSHR SEIZE NEVER 2 BACK DRIVE LOCK OUT PLATE 4 SS HEX HEAD 3 8 X 1 FLAT AND LOCK WSHR SEIZE NEVER 3 BACK DRIVE LOCK OUT PLATE 4 SS NUT 3 8 NUT SEIZE BELT GUARD BOLTS THROUGH GAURD TO SUB NEVER 1 BASE 6 SS HEX HEAD 3 8 X 1 FLAT AND LOCK WSHR SEIZE SOCKET NEVER 2 TORQUE BLOCK 4 BLACK HEAD 3 8 X 2 SEIZE MD MOTOR TO SUB BASE MAIN DRIVE MOTOR MOUNT TO SUB NEVER 1 BASE 4 SS HEX HEAD 5 8 X 2 FLAT AND LOCK WS
13. 23 15 27 17 6 en et 23 81 28 56 33 3 30 10 11 29 41 85 47 63 CENTRIFUGE SOUL ss o A va Her 5 83 5 14 7 5 8 77 18 31 12 25 13 98 15 12 15 27 17 4 14 298 9 16 PLATE DRM SETTING POUN DEPTH LITERS 19 95 22 1 24 34 PR 77 23 2 32 9 45 37 58 92 57 24 51 33 63 87 DISRECARD SETTINGS 12 AND 1 THEY ARE BEYOND WORKING POOL DEPTH RANCE POWO DEPTM DATA meN 88 n SECTION 4 LUBRICATION 27 RECOMMENDED LUBRICATING GREASE FOR THE 5500 BRAKESMARTT CENTRIFUGE CHEVRON SRI 2 or MOBIL SHC 220 Lubrication fittings are located at the pillow block housing front and rear and on the front and rear hub shafts for conveyor bearing lubrication NOTE The conveyor bearing grease fittings are located inside the machine frame and the cover must be opened to gain access to the grease fittings NOTE Pillow block and conveyor bearings are shipped from our manufacturing plant properly lubricated with grease 28 Hutchison Hayes 5500 Centrifuge Pillow Block Bearings Conveyor Bearings Back Drive Flange Bearings Gearbox Torque Control Linkage Fluid Coupling 138 Fl Oz Cap fill 11 Change oil every 4000 hrs For fire resistant fluid every 10 000 hrs or every two years Lubrication Schedule Frequency 24 Hrs Run Time 2 Shots per fitting 15 Days Purge till relief
14. 300 4 70 130 Over 360 to 449 incl 280 NUS319 200 2 12 60 5 Over 5000 to 5800 incl 355 NU328 300 2 70 130 2 2 Spindle Motors 76 Frame 6207 72 0 22 6 1 D 44 3 Frame 6210 0 32 8 0 0 64 5213 120 23 0491140 158 Weight in grams 008 DB Note Not all oearing sizes are listed For intermediate bearing sizes use the grease volume fcr the next larger size bearing 3 2 Maintenance amp Troubleshooting MN400 127 Lubrication Procedure Be sure lhal Ihe grease you add ng lo molor is compalible with lhe grease already in the motor Consult your Baldor distributor or an authorized service center il grease other than th recommended type is to he Used Caution To avoid damage to motor bearings grease must be kept free pf dirt For an extremely dirty environment contact your Baldor Uistributor or an authorized Baldor Sarvics Csntar for additional information With Grease Outlet Plug 1 Clean all grease fittings 2 Ramova greasa outlat plug 3 If motar is stopped add che recommended amoun of grease If molar is La be greased while running slighlly greater quanlily of grease will have to be added Add grease Slowly until new grease appears at shaft hole in th endplate or purges outlet olug 4 Re ins all grease cutlet plLg Without Grease Outlet Plug 1 Disassemble motor 2 Add recommended amount al grease to bearing and bearing cavity Bearing should be about 1 3 full of grease and out
15. 36 000 LB IN Max Pinion Shaft Torque 363 6 IN 99 28 1 Differential Speed 31 RPM Motor Speed 1750 RPM Motor Sheave 14 O D Centrifuge Sheave 8 025 O D Rated Solids Output 12 000 LBS HR 35 500 MAX Bowl Inside Diameter 16 IN Bowl Length 55 56 IN Package Weight Empty Floormount Unit 7 365 LBS OILFIELD MODEL SKID MOUNTED Normal Bowl Centrifugal Force 2118 G s Normal Bowl Operating Speed 3053 RPM Normal Conveyor Operating Speed 2996 RPM Max Bowl Centrifugal Force 3110 G s Max Bowl Operating Speed 3700 RPM Max Conveyor Operating Speed 3630 RPM GB 53 Gear Unit Max Output Shaft Torque 36 000 LB IN Max Pinion Shaft Torque 679 LB IN Ratio 53 1 Differential Speed 57 RPM Bowl Dimensions Same as Above Package Weight Empty Approx 8 000 LBS SECTION 2 START UP SAFETY Because the 5500 BrakeSmart Centrifuge is a high speed high torque piece of rotating machinery caution should be exercised by operating personnel HH recommends operating personnel review the centrifuge manual before working with the equipment Periodic safety meetings to familiarize new operating personnel with the centrifuges characteristics are also recommended This manual is intended for use by qualified operators familiar with processing equipment and trained for this particular centrifuge Maintenance personnel should be experienced mechanics Electricians should be licensed qualif
16. 4123 DYNASYNC PULLEY P N 4120 MOTOR P N 4786 REMSED FOR BRAKESMART SYSTEM PROPRIETARY RIGHTS ARE INCLUDED IN THE INFORMATION DISCLOSED HEREIN NEITHER THIS DOCUMENT NOR THE INFORMATION DISCLOSED HEREIN SHALL BE REPRODUCED OR TRANSFERRED TO OTHER DOCUMENTS OR USED OR DISCLOSED TO OTHERS FOR MANUFACTURING OR FOR ANY PURPOSE EXCEPT AS SPECIFICALLY AUTHORIZED IN WRITING BY DODGE SXR HUTCHISON HAYES INTERNATIONAL INC 4 BOLT FLANGE BEARING F4BSXR131115 2 REQ D 4135 AUTOGARD TORQUE LIMITER P N 4138 PROX SWITCH P N 4732 UPPER BRACKET UPPER BRACKET P N 4734 P N 4734 LOWER BRACKET P N 4748 P N 4759 A PROX SWITCH P N 4732 LOWER BRACKET P N 4748 EXT ARM P N 4227 5500 BRAKESMART GEARCASE ASSEMBLY NO REMSED PART NUMBERS wa 09 01 04 FULL DATE 11 93 00 DESCRIP TON ISSUED FOR CONSTRUCTION W Q 04 09 02 ALFA REMSIONS 9 5 0412 06 00 DATE DESCRIPTION DATE APR D DATE REMSIONS DRAW NO B 5500 BrakeSmart Gearcase 65 SECTION 7 PARTS LIST 66 PARTS LIST To order parts contact Hutchison Hayes L P P O Box 2965 Houston Texas 77252 3520 East Belt Houston Texas 77015 Tel 713 455 9600 Fax 713 455 7753 800 441 4850 Web site www hutch hayes com Email ewarren O hutch hayes com The parts listed in this section are customer replaceable components except for the machin
17. Bowl extension 1 4053 Axial flow conveyor 1 4054 Solid end conv Bearing Housing 1 4055 Liquid end conv Bearing Housing 1 4056 Accelerator plate 4 4057 Feed nozzle with carbide insert 2 4058 Pillow block 4 4059 Pillow block cover 3 4060 Horse shoe cover 1 4061 Sheave for bowl 4 4062 Wear inserts plows 1 4063 Liquid end conv seal housing 1 4064 Gear flange 1 4065 Bowl assembly with liner 4 4068 Dam plate gasket 1 4072 Horse shoe cover gear end 3 4073 Pillow block flinger 1 4078 Spline adapter 1 4080 Rtn Ring for sol End seal housing 2 4081 Pillow block spacer 1 4083 Solid end conv Seal housing 2 4084 Case flinger 1 4091 Base assy 1 4098 Nameplate 69 5500 BRAKESMART CENTRIFUGE BASE UNIT PARTS LIST CONTINUED Qty Part Description 1 4100 GB 53 gearbox 1 4779 Teflon wear liner for case 70 5500 BRAKE PANEL PARTS LIST Qty Hutch Mfr PN Description PN 6 3164 ISOLATOR 1448 STARTOR RACK 1 425 6583K42 CURRENT TRANSDUCER 2 4252 MK33 LI ISB EX0 24VDC 1 4633 9070T750D1 CONTROL TRANSFOMER P N 9070T750D1 1 4636 9080LBA362106 DISTRIBUTION BLOCK P N9080LBA362106 1 4651 LCID8011G6 CONTACTOR P N LC1D8011G6 2 4653 MKI5 RPN EXO 24 AMPLYFIER CONTROLLER MK15 RPN VDC 24 1 4666 TSXSUP1051 POWER SUPPLY TSXSUP1051 1 4678 MG24443 MINI 9 PRIM
18. Oil Seal Drivesheave 203 4 04032 2 Oil Seal Liquids End 204 4 04068 4 Gasket Plate Dam 207 16 04025 1 O Ring Bowl Extension 301 6 04031 2 Oil Seal Retainer Tube 201 6 04024 1 O Ring Conveyor Liquid End 305 6 04025 1 O Ring Bowl Liquid End 304 6 04022 2 O Ring Accelerator Plate 24D 6 04023 1 O Ring Solids End Seal 300 4 Housing 04020 4 O Ring Feed Nozzle 303 8 04057 4 Feed Nozzle 27 8 04062 4 Wear Insert Scraper Assembly 29 8 04687 1 Belt R3VX670 5 2 04013 6 Vibration Isolators 12 02879 1 Case Seal 1655 5500 New 2 2 02999 1 Wear Plate 5500 Solid Bowl 2 Hub 03047 4 Clamping Shoe for 1655 Case 6 Hinge 03048 4 Eyebolt for 1655 Case Hinge 6 03049 4 Nut for 1655 Hinge Bolt 04691 1 4 Bolt 2 Flange Bearing Indicates Custom Part Available from HH Only HHI 5500 High G Centrifuge BOWL SPEED VS G FORCE HUTCHISON HAYES INTERNATIONAL INC 713 452 0222 FAX 713 457 6143 HOUSTON TEXAS IT 5500 BOWL SPEED c lt ia EE VERA cr m 2 5500 BOWL SPEED VS CENTRIFUGAL FORCE PATH C NACADNRSNCURVESNS500 GF D WG DRAW NO A REMSIONS 94 HUTCHISON HAYES INTERNATIONAL INC SH 1 of 3 7 3 452 0222 FAX 713 457 6143 HOUSTON TEXAS 0 5 A 7e 2 H 69 t O 5Q NOTE GRAPH BASED ON CONPUTER PREDICTED PERFORMANCE 4
19. P N MG24443 1 4679 MGI7415 MINI 9 SEC P N MG17415 1 4716 ETH 2313 HORN ETH 2313 1 4792 TWDXDPPAK4M PLC TWIDO TWDLMDA20DRT 1 4785 TWADAMI2HT ANALOG CARD TWIDO 1 4943 LC2D32G7 CONTACTOR 1 4944 LRD32 OVER LOAD 1 4945 GV2ME32 MOTOR STARTER 1 4946 LC1D25G7 CONTACTOR 1 4947 LRD22 OVERLOAD 1 4948 GV2ME22 MOTOR STARTER 1 4949 FAL3615024M BREAKER 4 4950 CA2KN22G7 RELAY 1 4951 ATSYA8CIIY SOFT START 1 4952 GOLIKI PUSH BUTTON 1 4953 GOL53C3 3 POS SEL SWITCH 1 4954 MUSHROOM RED PUSH 2 4955 GOL2GR33 START STOP PUSH BUTTON 4 4956 GOL3G PILOT LIGHT 2 4957 GOL3R PILOT LIGHT 1 4958 1 DRAIN 1 4959 203611 N34 EX PROOF ENCLOSURE 71 5500 BRAKE PANEL PARTS LIST Continued Qty Hutch Mfr PN Description PN 1 4960 1 10 HANDLE 1 4961 20 X 36 BACK PAN 2 4962 525 01 RELAY 72 BRAKESMART SKID PARTS LIST Hutch PN Mfr PN Description 2653 LPM3046 100 10 4 16 40 GEXOL ARMORED amp SHEATHED 2654 LPM3006 100 6 4 16 4C GEXOL ARMORED amp SHEATHED 2860 1 MOTOR MOUNT 20 HP SLIDE BASE 3083 1 SLIDE BASE MOTOR MT 60HP 2 BOLT 5500 4013 8 ISOLATOR 5500 4019 1 SHEAVE DRIVE DUEL SPEED FORMSPRAG 14 4044 1 SHEAVE DUEL SPEED DRIVE BOWL 4120 1 P N 40H200 SK TIMING SHEAVE 4123 1 QDBUSHING SK X 1 5 8
20. SHAFT 4135 2 FLANGED BEARING P N RC 1 3 8 4138 102700 002 1 AUTOGARD COUPLING MODEL 406 4141 1 SHAFT 1 3 8 FOR AUTOGARD MOD 406 4227 1 BACK DRIVE EXT ARM 1655 NEWPARK 4245 1 NARROW PROFILE SKID 5500 4246 1 NARROW PROFILE SUB BASE 5500 4247 1 5500 NARROW PROFILE GUARD MD 4248 1 5500 NARROW PROFILE GUARD BD 4687 1 BELT R3VX670 5 4732 NI5G12YO 2 PROXSWITCH NI5G12YO 4734 12 2 MOUNT BRACKET FOR PROX SWITCH 4748 2 PROX SWITCH L BRACKET 4755 14 019 142 4 1 60 HP MAIN DRIVE MOTOR 4759 406 2 2 406 2 4786 1 20 EX PROOF MOTOR WITH BRAKE 4787 1 BRAKE SMART PANEL 8 RACK 4788 1 23 8 QD BUSHING 4789 1 1 3 8 BORE QD BUSHING 4790 60 200 1 TIMING SHEAVE 60H200 4791 630 200 1 TIMING BELT 630 H200 73 4100 Z ien Planetary Gear Reducer Liquids End Front ROTATING ASSEMBLY ITEM NUMBERS 74 PROPRIETARY RIGHTS ARE INCLUDED IN THE INFORMATION DISCLOSED HEREIN NEITHER THIS DOCUMENT NOR THE INFORMATION DISCLOSED HEREIN SHALL BE REPRODUCED OR TRANSFERRED TO OTHER DOCUMENTS OR USED OR DISCLOSED TO OTHERS FOR MANUFACTURING OR FOR ANY PURPOSE EXCEPT AS SPECIFICALLY AUTHORIZED IN WRITING BY HUTCHISON HAYES INTERNATIONAL INC n n n M M e n A e 5 Wear Liner a e M M 40574 pics 17 me 4212 x gt
21. ba by a sling around the maunting base The Enlire assembly can be lifled as an assembly for instal alion Do not filt using the motor lugs ar eye bolts provided If the load is unbalanced as witk couplings or additional attachments additional slings or utter teans must be used tu preven tipping In any event the load must be secure betore MN400 121 Section 2 Installation amp Operation Overview Location Mounting Alignment MN400 Installatiar shou d conform to the National Electrical Code as well as local codes and practices Wher other devices are coupled to the motor sacft be sure to install protective devices tc prevent uture accidents Same protective dev ces include coupling belt guard chain guard shaft covers etc These protect against accidental contact wilh moving paris Machinery thal is accessible Lo personnel should provide further protection in the form of guard rails scresning warning Sigas etc The motor should be installed in an area that is protected from direct sunlight corrosives hannful gases or liquids dust metallic particles and vibration Exposure to these can reduce the operating life and degrade parfonnanne Re sure tn allow clearance for ventilation and access for cleaniac repair service and inspections Ventilation is extremely important Be sure the area for ventilation is tut obstiustey Obstructions wil limit the tree passage ot arr Motors get warm and the
22. be visible excessive wear on the seats themselves may require replacement of the drive plate Reassemble and follow INITIAL STARTUP procedure BUILDING PROCEDURE If the components being used are not new they should be inspected for accidental damage or wear Particular attention should be paid to bearing surfaces Any slight damage marks should be carefully blended out Any components showing substantial damage or wear should be replaced GREASE Use good quality grease Units operating in conditions of high or low temperatures may require the appropriate special grease 108 View from Drive Plate to Cage Plate Figure 10 NOTE POSITION OF SPLITS STOP PIN NOTE POSITION OF SPLITS REFER TO FIGURES 10 AND 11 TO ASSIST THE FOLLOWING PROCEDURE C m Check the hub thread by running the adjusting nut down its full length on the hub Grease the needle bearing 2 and assemble onto the hub in this order 1 Thrust washer 2B 2 Needle bearing 2A 3 The second thrust washer 2B Assemble the strut ring 29A onto the hub with the flat face against the thrust bearing Check that it can rotate freely Drive plate pawl sub assembly Lightly oil the pawls and pawl springs 28A and 28B and assemble into the drive plate 3 Check that the pawls can move freely It must be possible to push them into the drive plate flush with the surface and they must move easily from that position due to the sp
23. slide towards gearbox to loosen the back drive belt 4 Remove the proximity counter bracket under the Autogard on the side of the gearbox and the wire clamps on the side of the support arm assembly and lay carefully on the subbase Do not remove or adjust the proximity switch on the bracket 5 Place a sling under the Autogard shaft to carry the weight of the back drive support arm assembly 6 Remove the four 4 bolts from the back drive arm assembly to the base There are two 2 hardened dowel pins for line up purposes Caution must be taken not to break or damage these pins 7 Slide the arm assembly off laying it in clean dry place 8 Place a sling held by the overhead hoist under the gearbox 9 Remove the twelve 12 adaptor hub screws 10 With the sling carrying the gearbox weight carefully withdraw the gearbox and set it on its side in clean clear area Do not attempt to dismantle the gearbox damaged gearbox must be returned to HH for repairs 34 ROTATING ASSEMBLY REMOVAL STEPS l 2 10 11 12 Remove gearbox shroud by removing six 6 capscrews and slowly lifting vertically Carefully remove the drive group enclosure Remove drive belt by moving the motor toward towards the centrifuge using the Nema adjust motor base to slacken the belt The adjusting bolt is 3 4 1 1 8 across the hex flats Disconnect the feed line to centrifuge Untighten feed tube clamp by loosenin
24. switch must be incorporated as the unit is not designated to run continuously disengaged 101 DACA OM 909 28 2 DENE MODEL 406 PRIOR TO INSTALLATION 1 Mounting Sprocket or Sheave A Mounting with tapered bushing Taper lock Q D etc A sprocket sheave or timing belt pulley may be mounted directly on Model 401 by using a tapered bushing Select a sprocket or sheave to fit M dia Of the Autogard Table 1 No key is used with the bushing when mounting on the torque limiter Thoroughly clean all grease and oil from M dia With solvent prior to mounting the bushing Be certain that the bushing is properly mounted and tightened according to the instructions accompanying each bushing CAUTION It is possible to overtighten the bushing capscrews to an extent that will deform the adapter 4 and prevent its free rotation on the hub 1 Make sure that the adapter and bushing assembly is free to rotate on the hub after the bushing is fully tightened To check this the adjusting nut 11 must be backed off to release all pressure from the spring 10 Re tighten adjusting nut to original position after free rotation check is completed sprocket sheave etc may also be mounted on Model 401 by bolting The adapter 4 must be removed for drilling and tapping the mounting holes Table 1 if they were not ordered with the unit See Disassembly Procedure 102 Table 1 Size
25. the full knowledge and assistance of qualified Manufacturer personnel Failure to obtain this assistance may result in rupture of parts involved with possible injury to personnel or damage to equipment Repairs to hard surfaced parts must be performed with strict quality control of materials and methods Hard surfacing materials are brittle and can break off if improperly applied After startup periodic inspection of these parts is necessary to anticipate separation of materials During repairs when equipment may be physically or electronically unstable post barriers or signs announcing hazardous conditions After repairs and before restarting reinstall all guards and reconnect all mechanical and electrical safety devices Q CORROSION EROSION AND PITTING OF ROTATING EQUIPMENT 1 insure high factor of safety under severe operating conditions high speed rotating equipment manufactured by HH is designed after careful stress analysis has been made of highly stressed parts thorough control of metallurgical properties is maintained throughout manufacture and all material is warranted as free of defects at time of shipment It should be noted that equipment subjected to severe erosive or corrosive environment could deteriorate over period of time depending on the severity of the exposure and or possible misuse Users of high speed rotating equipment should be aware of the fact that extremely high forces are brought into
26. 0 1500 2209 2500 3000 3509 4000 3750 NAX SPEED MACHINE 5500 HIGH G CENTRIFUGE Bop DO NOT EXCEED PATH C NACADNRSNSTART 55 DWG re 2183 33 gn ue dE Hom EEE EERSTE LENGER IS Rie li ua EISE SO Da HE At tit FETE vat ING DATE ii s 95 Storage of HH Centrifuge Recommended indoor storage and rust prevention procedures for new horizontal decanting centrifuges long term storage implies periods in excess of three 3 months idle time Note It is the responsibility of the owner to protect and maintain the equipment after shipment from HH If the centrifuge is not to be installed immediately after shipment the unit should be left in the original factory packaging Centrifuge Assembly 1 All accessible openings are closed with tape overwrap plugs etc for protection 2 Nameplates are covered with tape 3 Electrical devices such as the junction box vibration shutdown switch micro switches conduit boxes etc are wrapped with overwrap and protective tape Overwrap refers to any self adherent grease oil and waterproof material which can be molded around component parts 4 The grease lubricated pillow block bearings are filled with the specified grease at the factory prior to shipment 5 The planetary gearbox is filled with the specified lube oil at the factory prior to shipment 6 fluid coupling located at the main drive motor output shaft is fill
27. 04064 S T C Sintered Tungsten Carbide 40 Seal Retaining Rings Customer Replaceable Items Item No Description HH Part 12 Snap Ring Solids Bearing Housing 04036 43 Snap Ring Liquid Seal Housing 04037 Bearings Customer Replaceable Items Item No Description HH Part 100 Rear Pillow Blow Bearing 04042 101 Front Pillow Blow Bearing 04043 102 Conveyor Bearings Rear Solids End 04040 103 Conveyor Thrust Bearings Front 2 4 04041 Oil Seals Customer Replaceable Items Item No Description HH Part 200 Seal for the Rear Seal Housing 04032 201 Seal for the Rear Bearing Housing 04031 202 Sheave Seal 04033 203 Retainer Tube Seal 04030 204 Front Seal Housing Seal 04032 All seals good for 300 F Gaskets Customer Replaceable Items Item No Description HH Part 205 Drive Sheave Gasket 04069 207 Dam Plate Gasket 04068 O Rings Customer Replaceable Items Item No Description HH Part 24d O ring accelerator plate 04022 300 O ring solid end seal housing 04023 304 O ring Liquid hub amp conical section 04025 302 O ring feed nozzle 04020 305 O ring liquid end Seal Housing Inner 04024 306 O ring liquid end seal Housing Inner 04021 Grease Fittings Customer Replaceable Items Item No Description HH No 400 Grease Fitting Non Corroding 1 8 PTF 03089 Straight Type 401 Grease Pressure
28. 5 410 34 435 36 330 27 5 1 2 1300 108 970 81 1040 87 715 65 3 4 3300 275 3520 293 2640 220 CHART 2 ALLOY STEEL IN LBS FT LBS Lubricate with Never Seez or equivalent 57 Flighting Tile Caution Caution The Flighting Tiles used on the 5500 conveyor may be the spray on hard face type or the sintered tungsten carbide backing tile type The backing tile type is comprised of stainless steel backing plate a sintered tungsten carbide tile and copper silver solder sandwich between the two Even though the rotating assembly is comprised of 316 S S the copper will not withstand attack by highly corrosive chemicals such as sulfuric and nitric acids If the copper silver solder tile bond is attacked by corrosive chemicals the result will be tiles coming loose during centrifuge operation To avoid this potentially costly problem always check any chemicals for compatibility with copper silver solder before attempting to introduce them into the centrifuge 58 SECTION 6 PLANETARY GEARBOX AND BACKDRIVE ASSEMBLY 59 Hutchison Hayes L P Model GB 53 GB 100 Planetary Gearbox Instruction Manual CONTENTS Construction Installation Operation Lubrication Maintenance Dismantling Assembly E CE E d de Table 1 Recommended Oil Products 60 1 Construction 1 The reduction gear unit is two 2 stage planetary system The first stage uses two 2 planetary gears and the second stage uses thre
29. 8 Spring Stacks 12 000 50 000 1 05 3 8 210 6 Spring Stacks 9 000 37 500 1 05 4 Spring Stacks 6 000 25 000 1 05 104 INITIAL STARTUP Prior to startup examine torque limiter to make sure it is fully engaged with the balls seated correctly in both plates Obtain initial torque setting by one of the following methods A The setting as furnished will be within 10 of the torque value specified on the order If factory adjustment has been altered during assembly procedure be sure to reposition the adjusting nut in its original location as measured during the first step of the disassembly procedure Secure nut in place with setscrews Torque limiter to be set at job site Sizes 1 through 5 1 Setting by trial adjustments Start up the drive at minimum torque setting If the torque limiter disengages before the normal operating load level is reached progressively tighten the adjusting nut until the drive will start and operate under normal load without tripping Starting torque is usually the highest torque that the torque limiter must transmit but occasionally the torque limiter must be set to accommodate higher peak operating torques After desired torque setting is obtained secure adjusting nut with setscrews 2 Setting to an established specified torque An appropriate setting can be made from Torque Adjustment Chart furnished with the torque limiter if requested at the time of order
30. Backdrive Starter Fwd TB 1 Current Transducer Backdrive Starter Overload Backdrive Starter Rev 82 CONTROL PANEL DEFINITIONS Transformer Transformer used to convert 480 volt power to 110 volt power for control systems Main Power Circuit Breaker used to open the electrical circuit as soon as current climbs to unsafe levels in the panel Used mainly for short circuit protection Power Distribution Block PDB used to make connection of 480 volt incoming power to all other 480 volt systems in the panel Main Drive Starter MDS used to control main drive motor not used until motor is up to speed then engaged to put motor across line Back Drive Circuit Breaker Feed Pump Circuit Breaker BDCB used to open the electrical circuit as soon as current climbs to unsafe levels in the Backdrive circuit Used mainly for short circuit protection used to open the electrical circuit as soon as current climbs to unsafe levels in the Feed Pump circuit Used mainly for short circuit protection Feed Pump Starter FPS used to control the feed pump motor Feed Pump Starter Overload FPSO used to open the electrical circuit as soon as current climbs to unsafe levels in the Feed Pump motor circuit Backdrive Starter Forward BSF used to control Backdrive motor when in a forward direction Back Drive Starter Overload BSO used to open the electrical circuit as soon as current
31. EAD 8 55 HEAD 3 8 X 1 1 4 SEIZE SOC FLAT 242 3 SOLID END HEAD WEAR PLATE 8 55 HEAD 3 8 X 3 4 LOCTITE SOCKET NEVER 4 LIG END HEAD 12 55 HEAD 3 8 X 2 SEIZE SOCKET NEVER 5 DAM PLATES 12 55 HEAD 5 16 X 7 8 SEIZE SOCKET 242 6 DISCHARGE PLOWS 28 55 HEAD 3 8 X 3 4 LOCTITE 52 PILLOW BLOCK BEARINGS BOTH LIQ AND SOLIDS END ARE TYPICAL LOCK TIGHT OR ITEM NEVER POSITION QTY ALLOY TYPE STYLE SIZE SEIZE NEVER 1 PILLOW BLOCKS TO BASE 8 BLACK HEX HEAD 3 4 X 3 SEIZE SOC FLAT NEVER 2 END COVER 4 BLACK HEAD 3 8 X 1 SEIZE SOCKET NEVER 3 HORSE SHOE COVER 12 ss HEAD 3 8 X 1 1 4 SEIZE NEVER 4 CASEFLINGER 2 SS SET CUP 5 16 X 1 2 SEIZE NEVER 5 GREASE FLINGER 6 SS SET CUP 3 8 X 5 8 SEIZE 6 GREASE ZERT 6 PLATED HEX 1 8 7 GREASE RELIEF 1 PLATED HEX 1 8 GEAR END SOCKET NEVER 1 GEAR FLANGE 8 BLACK HEAD 3 8 X 1 1 4 SEIZE SOCKET NEVER 2 GEAR BOX 12 BLACK HEAD 7 16 X 1 3 4 SEIZE DOWEL 3 GEAR FLANGE TO HEAD 4 PIN 1 SHEAVE SOCKET NEVER 1 SHEAVE 8 BLACK HEAD 3 8 X 1 3 4 SEIZE DOWEL 2 SHEAVE TO HEAD 4 PIN 1 53 SUB BASE TO SKID SHOCK MOUNTS LOCK TIGHT OR ITEM NEVER POSITION QTY ALLOY TYPE STYLE SIZE SEIZE 1 2 X 1 1 4 FLAT AND LOCK NEVER 1 SHOCK MOUNT TO SKID LONG SKID 16 SS HEX HEAD WSHR SEIZE 1
32. ELL ARE BALANCING AND STAMPED WITH BOWL ASSEMBLY THEREFORE THEY MUST BE REASSEMBLED WITH V MARKS IN LINE AS SHOWN Jacks rew Hole Typical er CONVEYOR A SEAL r lt n Front Bearing Y Duplex Pair 46 BOWL REAR HUB ASSEMBLY REAR HUB AND BOWL SHELL EXTENSION ARE BALANCED AND STAMPED WITH BOWL ASSEMBLY THEREFORE THEY MUST BE REASSEMBLED WITH V MARKS IN LINE AS SHOWN Bowl Shell Extension Bowl Shell Rear Hub Jackscrew Hole Typical Bowl Shell Extension Conveyor Rear Hub Conveyor Rear Bearing gt Rear Seal Outer pou 47 PLATE DAM ASSEMBLY Line up mark on Plate Dam Front Hub with V mark on hub as shown LA All Plate Dams must be set as shown Plate Dam Oh Front Hub L JETE Gear Box 48 MAINTENANCE CAUTIONS FOR THE 5500 HIGH G CENTRIFUGE Bearings The inner and outer race must be replaced as a set Opened bearing or cleaned parts should be kept covered until assembly Always use a thermometer to check the temperature of oil used to heat the bearings If no heat is used to install bearings use only an arbor press to insert bearings in place Correctly lubricate all bearings before operating the centrifuge Do not wash new bearings with solvent before installing Keep new bearing wrapped and boxed until ready for use Seals Avoid touching the sealing surface Keep seals w
33. HR SEIZE 23 ELECTRIC BACK DRIVE BACK DRIVE LOCK TIGHT OR ITEM NEVER POSITION QTY ALLOY TYPE STYLE SIZE SEIZE NEVER 1 FLANGE BRGS FOR AUTOGARD 4 ss HEX HEAD 1 2 X 3 LOCK WSHR SEIZE 1 2 X 1 3 4 FLAT AND LOCK NEVER 2 BRG MOUNT TO BACK DRIVE ARM 4 SS HEX HEAD WSHR SEIZE 1 2 X 1 3 4 FLAT AND LOCK NEVER 3 BACK DRIVE ARM TO BASE 4 SS HEX HEAD WSHR SEIZE NEVER 4 GEAR GUARD 7 ss HEX HEAD 3 8 X 1 FLAT AND LOCK WSHR SEIZE 3 8 X 1 1 4 FLAT AND LOCK NEVER 5 LOCK OUT PLATE 4 SS HEX HEAD WSHR SEIZE 1 2 X 1 3 4 FLAT AND LOCK NEVER 6 BD MOTOR MOUNT TO SUB BASE 4 SS HEX HEAD WSHR SEIZE SOCKET 242 7 AUTOGARD ON SHAFT 1 BLACK SET CUP HEAD 3 8 SET SCREW LOCTITE MAIN DRIVE NEVER 1 BELT GUARD 5 SS HEX HEAD 3 8 X 1 FLAT AND LOCK WSHR SEIZE 56 RECOMMENDED CAPSCREW SEATING TORQUE Follow recommended seating torques when assembling all socket head cap screws Nominal Size Recommended Seating Torque Coarse Thread Lubricated 1 4 75 in Ibs 6 25 ft 165 5 16 135 lbs 11 25 ft Ibs 3 8 240 in lbs 20 ft Ibs 1 2 600 in lbs 50 ft Ibs CHART I STAINLESS STEEL Nominal Size Recommended Seating Torque Coarse Thread Coarse Thread Dry Lubricated Plain Plated Plain Plated 1 4 150 13 112 9 120 10 90 7 5 5 16 305 25 230 19 245 20 4 185 15 4 3 8 545 4
34. I shot every 72 Hrs Run Time First Oil Change after 500 hrs of operation then every 6 months 6 months Lubricant Chevron SRI 2 Mobil SHC 220 Chevron SRI 2 Mobil SHC 220 Chevron SRI 2 Mobil SHC 220 Royal Purple Synergy Gear Oil ISO Grade 150 SAE 90 AGMA Grade 4EP NEVER SEEZ Compound FORMSPRAG Model 12 4 HSD ABOVE 130 DEG F BELOW 130 DEG F See Vendor Section of this manual for complete filling instructions SAE 10W Fyrquel 550 Houghto Safe 1010 SAE 5W Fyrquel 90 Houghto safe 1010 Pydraul 29E LT After every washing or steam cleaning of the conveyor check the conveyor bearing lubrication 29 Royal Purple NEW IMPROVED SYNERGY HIGH PERFORMANCE GEAR OIL SYNERGY is an ultra tough multi service gear oil designed to smoothly lubricate all types of gears under all conditions Synergy outperforms other E P gear oils because it contains Synslide TM our proprietary synthetic oil film so tough and tenacious it is not squeezed out of the pressure area It virtually eliminates both gear and bearing wear even under severe squeeze film conditions caused by extremely high loads sudden shock loads or low Rpm s Slippery synthetic molecules increase the lubricity and oiliness of SYNERGY Gears run smoother quieter cooler and longer without overhauls SYNERGY is non corrosive to both ferrous and non ferrous metals Its ability to separate rapidly and completely from
35. IBLE FOR DETERMINING THAT MOTOR PERFORMANCE 15 SUTABLE IN B APPUCATION RU mani zar BALDOR ELECTRIC Co 8 een Wi HORZ 254 8T CLI ONLY DRILL RIG W ERAKE 131 AC Induction Motor Performance Data Winding 09WGX927 Type 0946M Enelosure XPFC E 168 0 460 0 458 Ohms NEMA Design Code Service Factor NEMA Nom Rating Duty 40C AMB CONT S F li el Load Characteristics at 460 Volts 60 Hz ER NN mee ws os s ur ome poer poe Baldor Electric Company Fort Smith Arkansas 132
36. ONS amp WEIGHTS BrakeSmart SECTION 11 MISCELLANEOUS Recommended spare parts list Charts Storage SECTION 12 VENDOR DATA Page 78 85 89 92 99 SECTION I INTRODUCTION OVERVIEW HUTCHISON HAYES MODEL 5500 BRAKESMARTT CENTRIFUGE This Service Manual describes the centrifuge and lists instructions for the installation operation and maintenance requirements The basic purpose of this centrifuge is to separate the liquid and solids from the fluid feed slurry stainless steel rotating bowl driven by 60 electric motor is used to centrifuge the slurry that is to sling the solids against its inside wall surface while stainless steel screw conveyor faced with hard tiles gathers and conveys these solids to central discharge area The conveyor drives at a slightly slower RPM through planetary gear reducer The liquids migrate to the front end of the machine and are dispelled through four 4 adjustable plate dam openings to central discharge area For more comprehensive description of how the centrifuge operates see the Operation Section of this manual MODEL 5500 BRAKESMARTT DECANTING CENTRIFUGE Normal Bowl Centrifugal Force 2118 G s Normal Bowl Operating Speed 3053 RPM Normal Conveyor Operating Speed 3022 RPM Max Bowl Centrifugal Force 3110 G s Max Bowl Operating Speed 3700 RPM Max Conveyor Operating Speed 3663 RPM GB 100 Gear Unit Max Output Shaft Torque
37. R ENG ONG a GA DEN aol LENGER MENES uyupi 217 93 52 115 oku TE AN AN ir EEE EE EE Accessories operette ae pal ewe sn e S crue DE hay ane si NOU pe no NG ad MN400 FA ar i a ee AD AER 9 rs AEG DER 2 2 GANYAN BON 64 gt uar AYE Ye e LET YER V DP DES FENG P A ann kant kt ia on pan dn eat EEE FEE UB 2153 AN 3735 Qe ea AT ORE A AR d AR EK RE ET Eno EE TENE SE DE ee Repeated Slats sete rast res G s DRANGE ADS OSE DILE NER DS VERE GE SAS 1 1 1 1 1 1 1 2 14 1 4 1 4 1 4 251 2 1 2 1 2 1 2 1 2459 2 2 2 2 24 2 4 2 4 3 1 3 1 3 1 3 1 3 1 3 3 3 4 3 5 Table pi Contents i 117 Section 1 General Information Overview This manual contains general procedures that apply to Baldor Motor products sure to read and understand the Safety Notice statements in tais manual For your protection do not install operate attempt to derform maintenance procedures Until you understand Warning and Caution statements Warning statement indicates a possible unsafe condition that can cause harm to personne Caution slatement indicales a condilion hal cause damage Lo equipmen Important This instruction manual is no
38. Ras HUTCHISON HAYES L P HH Model 5500 BrakeSmart M Centrifuge Operations Manual Revised January 2005 3520 East Belt Houston Texas 77015 Tel 713 455 9600 e Fax 713 455 7753 800 441 4850 Web Site www hutch hayes com Hutchison Hayes L P NOTICE OF CONFIDENTIALITY This information is highly confidential and is solely for the benefit of Recipient TABLE OF CONTENTS 5500 BRAKESMARTT DECANTING CENTRIFUGE OPERATIONS MANUAL SECTION 1 INTRODUCTION Overview Data SECTION 2 START UP Safety Installation Pre Start Safety Precautions Belt Tension Procedure Start Up and Shut Down Procedure High Speed Start Up and Shut Down Procedure Low Speed SECTION 3 OPERATION Over Torque Resetting Autogard B Dam Plate Adjustment Pond Depth Chart SECTION 4 LUBRICATION Grease amp Oil Data Lubrication Schedule SECTION 5 ASSEMBLY amp DISASSEMBLY Gearbox Removal B Rotating Assembly Removal C Conveyor Removal Conveyor Disassembly D Pillow Block Disassembly E Front Bowl Hub F Rear Bowl Hub G Assembly amp Disassembly Tips H Recommended Capscrew Seating Torque I Conveyor Wear Protection SECTION 6 PLANETARY GEARBOX BACKDRIVE ASSEMBLY SECTION 7 PARTS LIST Base Unit BrakeSmart Page 25 29 35 61 68 SECTION 8 ELECTRICAL amp WIRING BrakeSmart SECTION 9 TROUBLE SHOOTING BrakeSmart SECTION 10 ELEVATION DIMENSI
39. Relief Fitting 03088 41 5500 CONVEYOR ASSEMBLY Ios wan DV a VS BEARING HOUSE CONVEYOR SLIDE REMOVING CONVEY OR REAR BEARING VIEW E 42 5500 CONVEYOR ASSEMBLY CONTINUED SPLINE BUSHING CONVEYOR HAMMER PULLER REMOVING CONVEYOR FRONT BEARING VIEW D l SECTION 43 PILLOW BLOCK DISASSEMBLY 1 Stamp the top of the pillow block assemblies with an S for solid and L for liquid also stamp the top with a V with the point directed toward the bowl assembly Be sure to stamp the horseshoe covers and pillow block covers on both sides of the pillow also 2 Remove the six 6 bolts that retain the two 2 horseshoe covers and remove the horseshoe covers 3 Remove eight 8 bolts from the sheave and using jack bolts remove the sheave from the bowl hub 4 For liquid hub remove the gear flange 5 Using a two 2 or three 3 Jaw puller remove the pillow block as an assembly Put a plate across the top of the hub for the stud to push on 6 Remove the two 2 pillow block covers and remove the bearing from the housing 7 Loosen the two 2 setscrews in the pillow block flingers and the case flingers and remove both from the hub 8 Clean all parts thoroughly and assembly in reverse order 44 REAR PILLOW BLOCK ASSEMBLY SOLIDS AND LIQUIDS END 5500 Rear Pillow Block Assembly Solids End 45 BOWL FRONT HUB ASSEMBLY FRONT HUB AND BOWL SH
40. UCED OR TRANSFERRED TO DTHER DOCUMENTS m OR DELLOSED OTHERS FOR MANUFACTURING DH FOR ANT PURPOSE EXCEPT AS SFEDFK1ALLY AUTHORIZED WRITING BY HUTCHISON HAYES INTERNATIONAL INC ND MATERIAL SPEGFIDATENS amp NOTES PART NUNBERS REFERENCE DRAIMHOG ALES SOLIDS END HUTCHISON HAYES 1448 Brdifmart LAYOUT INTERNATIONAL INC MAS GENTREUSE 3 w oui 08 00 04 ar PRU L Paou 448 BrakeSmart 2 90 Components Weights amp Measures Description Weight Ibs 5500 components 5500 Variable Speed Skid Unit 8200 5500 Brake Smart Skid Unit 8300 5500 Oil Field Skid Unit 8200 5500 Hyd Back Drive Unit 10400 5500 Full Hyd Unit 12 800 5500 Base Unit 5 100 5500 Case and Cover 1 000 5500 Rotating Assembly no g b 2 000 5500 Bowl Assembly Complete no conv 1250 5500 Conveyor Assembly Complete 750 GB 53 Gearbox 250 5500 Brake Panel 1100 VFD Control Panel 1 400 SECTION 11 MISCELLANEOUS 92 Recommended Spare Parts List for Two 2 Years Service For the 5500 BrakeSmart Centrifuge HH Part Quantity Description Item Op Spares 2 Years 04043 1 Pillow 1 Bearing Front 101 4 04042 1 Pillow Blk Bearing Rear 100 4 04041 2 Conveyor Bearing Front 103 8 04040 1 Conveyor Bearing Rear 102 4 04032 2 Oil Seal Solids End 200 8 04030 1
41. afe for use with explosive chemically unstable or flammable materials under ALL conditions In some instances it may be necessary for the user to equip the machine with safety devices not ordinarily placed on equipment of this type In other cases the application may be so hazardous that the only prudent operating procedure is to isolate the equipment in an expendable building and operate it by remote control from a safe distance Because HH has no control over these potential dangerous operating conditions we do not guarantee that equipment made by us can be safely used with explosive chemically unstable or flammable materials regardless of whether we installed industry accepted explosion proof accessories The user has the responsibility for insuring that all precautions required by his particular method of operation have been taken P REPAIRS 1 Do not make mechanical or electrical repairs or attempt disassembly unless the equipment has come to complete stop the power is shut off and safety lockout or other padlock is installed on the disconnected circuit The locking device should be tagged to identify the working party 13 Do not make any repairs until dangerous vapors and gases are replaced with clean air HH should be consulted before attempting to make major repairs to any of the rotating equipment we manufacture Under no circumstances should weld repair or other alterations be made to major rotating components without
42. arings 6807 bearings consull oil nisl lubrication MN401 Relubricalion irlerval for 6205 bearing searing 1550Hrs Laing crease lubricalion Relubrication irterval for 6606 bearing searing is 720Hrs using grease lubrication MN400 Maintenance amp Troubleshooting 3 1 126 Table 3 2 Service Conditions Severity of Service Amhient Temperature Atmospheric Type of Bearing Maximum Contamination Standard Clean Little Corrosion Deep Groove Ball Bearing Severe Madeiale dirl Corrasiun Ball Thrust Roller 250 or Severs dirl Aorasivs dust All Beanngs Class H Insulation Corrasian Low Temperature lt 30 C Special h gh tomperature groase is rezammenced Dow Corning DC44 Note that Dow Coming DC44 grease docs nol mix wilh other grease lypss Thoroughly clean bearing amp cavity before adding grease Special low temperature grease i recommended Aeroshell 7 Table 3 3 Lubrication Interval Multiplier Severity of Service Muitipller E 1 Low Ternperatuie E Table 3 4 Bearings Sizes and Types Frame Size Bearing Description NEMA IEC These are the Large bearings Shaft End in each frame size Bearing Width Weight of Volume of grease B mm Grease to to he added oz Grams Up to 210 ind 132 0 30 8 4 Over 210 ta 280 incl 150 6311 im 0 61 s 7 Over 280 to 360 incl 22 5313 3 Over 36D to 449 incl 280 6349 xo Over 5000 Lo 5800 incl 355 6328
43. ary This will convey solids back to the liquid end of the machine and possibly plug off the damn plates 24 PLATE DAMS ADJUSTMENT The four 4 plate dams used to set the Pond depth The plate dams are located in the front hub Access to the plate dams is allowed by raising the centrifuge cover with the machine shut down The plate dams are adjusted by loosening three 3 capscrews and rotating the plate clockwise Maximum Setting i e the highest number engraved on the plate aligned with the arrow mark on the front hub will cause a maximum pond depth giving maximum clarification of the liquid A Minimum Setting 1 the lowest number engraved on the plate aligned with the arrow mark on the front hub will cause a minimum pond depth and will result in the Maximum dryness of the discharged solids IMPORTANT When plate dams indexed by rotation all four 4 dams must be indexed to the same number After adjusting always recheck all twelve 12 capscrews for correct tightness 25 am 4 9 eec 9 16 5 8 11 16 13 15 35218 1 0 5 16 1 2 5 8 asw ma Ma 47 62 m Ro nsi 501 105 NISCH OPNG MAK VULUNE 17 44 CRL S U S 66 LITERS LONE ELEVATLION SCHEMATIC M T UNLESS OTNERUTSE CTORSEMHSES umm 14
44. ation amp Operating Manual 7 02 MN400 116 Table of Contents Section 1 Inforidiq in Ta Ge es ETNE RTS TERS GRETE e AR SARDIS ea ag briten MEET eee rice S SO RE E ETE cogi s aig nas mR ALA ar SOE GOD ML CU S V MURIS C MUS it OA Bocolving we sans mana eim foe te euo ee anta cuya tunuta STAT TIRILL ERT DAR VAS RM Sectlon 2 Installatio r amp Operation cmo asus ske Ge ORT GOES CONS SR S xe gt d bak Suis vise TERS TESS Sud eU NG GANGS T ger SU TESTE SES FR CEN a nios Sb bd cule cran Me GEN o d ai ee eran far Ja NP nn Ne GE Bees Misthg a ANGRET o acoge mie pem ar eJ Ke cn EO PL Mna MER Doweling amp Bolting Section 3 Marntenanca s Tr lbleshooflag u te eget W A WON f cm Met ru coUe ES uuu yaa s mre ie MICE SE AV TIN OR MN c EONS e sus aa ruwaspapas EA CU ESTE GENT G r EG ERE RW 2 SQ TYDE 9 sapo M Fe OR sip KER E
45. be damaged 5 The weight must be carried through the rear hub resting on the stand With the bowl assembly now resting securely in an upright position 6 Remove the twelve 12 3 8 capscrews from the front hub at top end of the bowl assembly 7 Using four 4 bolts just removed screw them into the four 4 jackscrew holes and remove the hub 8 Once the front hub is jacked free it can be lifted out with the overhead hoist 36 10 11 12 13 14 15 Set this front hub pillow block and gearbox adaptor hub assembly in a clean clear space Unbolt the Conveyor Lifter Plate from the gearbox adaptor hub just removed Remove four 4 capscrews from the seal housing at the end of the conveyor and attach the Conveyor Lifter Plate Slowly hoist out the conveyor Set the conveyor upright on smooth clean and clear work area With the hoist still attached to the conveyor secure the conveyor assembly with ropes so it cannot topple over Once secured disconnect the hoist connection and remove the Conveyor Lifter Plate CONVEYOR DISASSEMBLY FRONT CONVEYOR BEARING REMOVAL If the front conveyor bearings are in good condition they do not need to be pulled Disregard Steps 2 3 and 4 and go to Step 5 If the Front Conveyor Bearings are worn out or damaged remove the six 6 capscrews from the liquids and seal housing Jack out the liquids end seal housing using two 2 capscrews just removed Usi
46. board pearing cevity should bs about 1 2 full of grease Note Bearing is 1 3 full when anly ane side of bearing is comp etely full of grease 3 Assemble motor Sample Lubrication Determination Assume NEMA 28567 180 1750 RPM moter driving an exhaust fan in an ambient tempe acure of 43 C and the atmosphere is moderately carrosive 1 Table 3 1 list 9500 hours for stardard conditions 2 Table 3 2 classifies severity of service as Severe 3 Table 3 3 lists a multiplier value of 0 5 far Severe conditions 4 Table 3 4 shows that 1 2 in or 3 9 teaspoon of grease is to be added Note Srraller bearings in size category may require reduced amounts ot grease MN400 Maintenance amp Traubleshooting 3 3 128 Accessories The ollowing is a partial list ol accessories available from Baldor Contact your distributor for availability and pricing information Nols Space nealsrs and RTD s ars slandard on somre molors Beariny RTD Resistance Temperature Detector devices used to measure monilor he lemperalure of he molor bearing during operalion Bearlng Thermocouples Used to measure ar monitor bearing temperatures Bearing Thermostat Temperature device that activates when bearing temperatures are excessive Used wita an extemal circuit ta warn of excessive bearing emperature ar to shut down a motor Conduit Boxes Optianal canduit boxes are available in various sizes to accommacate Ac
47. cessory devices Cord amp Plug Assembly Adds a liae cord and plug for porlable applicalions Drains and Breathers Stairless steel drains with separate breathers are available Drip Covers Designed for use when motor is mounted in a vertical position Contact your Baldor distributor to confirm that tho motor is dasigned for vertical mounting Fan Cover amp Lint Screen pravant build up of debris n the cooling fan Nameplate Additional stainless steel nameplates cre available Roller Bearings Recommended for belt drive applications with a speed 0 1800 RPM or less Rotation Arrow Labels Rotation arrows are supplied on motors designed to opera e one direction only Additional rotation arrows are available Space Heater Added to prevent condensation of moisture within the motor enclosure during periods of shut down or storags Stainless Hardware Stairless steel hardware is available Standard hardware corrasicn resistant zinc plated steel Winding RTD RTD Resistance Temperature Detector devices are Used to measure monitor the temperature of the motor winding during operation Winding Thermocouples Used to measure or monitor winding temperatures Winding Thermostat Temperature device that activates when winding temperatures are excessive Used wit an sxtemal circuit to warn of excessive wincing temperature or to shut down a motor Nale some motors leads for accessory cevices are broughl acl lo a
48. climbs to unsafe levels in the Backdrive motor circuit Back Drive Starter Reverse TB 1 BSR used to control Backdrive motor when in reverse direction Terminal Block 1 used to make connection between motors and motor control devices Current Transducer Measures torque on the backdrive motor TB 2 Terminal Block 2 used to make connection between field sensors and PLC and or relays ISBA1 Intrinsically Safe Barrier 1 used to isolate and amplify proximity switch signal for main drive ISB 2 Intrinsically Safe Barrier 2 used to isolate and amplify proximity switch signal for AutoGard ISB 3 Intrinsically Safe Barrier 3 used to isoloate and amplify vibration signal for the accelerometer ISB 4 Intrinsically Safe Barrier 4 used to isolate and amplify the signal from the current transducer Power Supply Converts 110 volt power to 24 volt power to be used in the control panel 83 CONTOL PANEL DEFINITIONS Continued PLC Programmable Logic Controller is computer like control device that reads inputs and energizes electrical devices called outputs based on a user programmable memory The PLC is responsible for controlling the centrifuge operation Relay 6 Relay 6 is used to turn on off the Autogard light relay is an electrical switch that allows low power to control a higher one A small current energizes the relay which closes a gate allowing a large cu
49. d lie flush with the top of the flange of the slide plate Size 1 uses a single pin all other sizes use double pins see Fig 10 Place the slide plate 7 on the bench with the flange and ball seat face upwards Lightly grease the cage plate 6A and place it on the slide plate with the shallow recess in the bore upwards The correct angular positioning of this plate relative to the ball seats and pins is most important see Fig 10 The cage plate holes must be directly over the ball seatings and the stop pin 7B in the slide plate must be central in the cage plate cutout Ensure that the plate is not 180 degrees out of position the stop pin must be centrally positioned in the wider slot J Insert some grease into each of the cage plate holes and place drive balls SA strut balls 5B in these holes There should be sufficient grease to hold these balls in position when the assembly is inverted K Insert springs 10A into the adjusting nut 11A Some grease in the holes will help hold these positions for the next stages of assembly L Carefully holding the cage plate in position invert the slide plate and pass it over the hub thread to engage with the splines on the hub As soon as the splines are engaged rotate the drive plate until the pawls are symmetrically facing the cutout in the slide plate flange Then push the slide plate fully home holding the cage plate until the last possible moment The drive balls should
50. discharged through four 4 adjustable plate dam nozzles at the liquids discharge area located at the front end of the centrifuge i e the gearbox end BRAKESMART OVER TORQUE PROTECTION A TORQUE CONTROL DEVICE is located at the front of the gearbox referred to as an Autogard coupling If a predetermined torque limit on the Autogard is reached during operation the device will trip sending a signal to the control panel to stop the feed pump and the main drive This protects the screw conveyor and the gearbox from over torque damage If the pre set torque limit is exceeded the Autogard will trip and the unit will shut down An alarm will sound and the Autogard trip light will illuminate When this happens no solids can be conveyed to the solids discharge ports When the Autogard device trips a Press the reset button once to silence the alarm horn and a second time to reset fault lights Wait for the centrifuge to stop c If prior to the over torque condition the back drive was being operated in the off or forward mode turn the back drive switch in reverse momentarily This will re engage the Autogard d Now turn the back drive switch to forward momentarily If the Autogard trips again then repeat step c above e Note The object is to jog the back drive forward and reverse to free up the internal conveyor f Caution Once the conveyor is free it is important not to run the back drive in reverse while the bowl is station
51. e 3 planets 2 All bearings are either ball or cylindrical roller type 3 Lip style oil seals are used at the gearbox cover plates where the output and first stage pinion shafts pass through O Rings are used to seal mating parts which are static with respect to each other 4 Threaded plug openings are provided for oil fill overflow and drain 2 Installation 1 The gearbox is designed to operate in the horizontal plane that is axially in line with the model 5500 centrifuge rotating assembly 2 gearbox is driven by means of a gear flange which attaches at the centrifuge end to the liquids end bowl hub assembly gearbox bolts directly to the other end of the gear flange 3 The gear flange must be accurately aligned within 002 inches runout and secured correctly to the bowl hub before the gearbox is mounted 4 After mounting the gearbox check runout on the first stage side If runout exceeds 005 inches shims may be required 3 Operation 1 Before running the gearbox be sure that the unit is filled to the proper level with lubricating oil 2 For recommended lubricating product see Table 1 3 With the fill opening at top dead center remove the plug from the fill connection and the uppermost level connection which is located on the cover plate furthest away from the centrifuge Pour oil into the fill port located on top of the casing until it starts to overflow from the side port Pl
52. e bolt are normally convenient amount Then tighten the adjusting nut without using excessive force Shortening of the spring stack is by means of the bolts not by the nut Continue with this procedure of alternately tightening bolts and adjusting nut until the correct spring length is achieved then slacken the bolts THE UNIT WILL NOT OPERATE CORRECTLY UNTIL THIS IS DONE When the correct torque setting is achieved remove the pillar bolts completely replace the adjustment spacer and retighten the bolts There must be gap between the thick washer and the bolts There must be gap between the thick washers and the adjusting nut Lock the adjusting nut with the setscrews NOTE IT IS ESSENTIAL THAT ANY SET OF SPRINGS IS NOT USED ABOVE ITS RANGE IF THE SPRINGS ARE OVER TIGHTENED THE BALLS WILL BE PREVENTED FROM ROLLING FROM THE SEATINGS IF SLACKENED TOO FAR SO THAT POSITIVE LOAD IS NOT APPLIED TO THE BALLS ALL TIMES IT IS POSSIBLE THAT ONE OR MORE BALLS MAY REMAIN IN THEIR SEATINGS DURING TRIPPING IN BOTH CASES IT IS PROBABLE THAT 106 DAMAGE WILL OCCUR TO THE MACHINERY OR TO THE AUTOGARD TORQUE LIMITER RESETTING PROCEDURE 1 Shut down the drive 2 Investigate and remove the cause of overload or jam 3 Reset This is achieved either by reversing the driving side of the drive or by taking the driven side forward Note that these units will trip at an accurate torque setting in both directions Re
53. e is noticeably pitted 15 INSTALLATION Location Install the centrifuge unit in location where sufficient headroom is allowed for lifting the bowl out of its frame enclosure A 2 ton overhead hoist should be installed to facilitate inspection or repair work clear area in the vicinity of the centrifuge should be provided to set bowl during inspection or repair d Room should be allowed at the front end of the machine for withdrawing the planetary gearbox A zone approximately 270 wide x 2 6 long from the front end of the gearbox should be kept clear Room should be allowed at the rear end of the machine for withdrawing the feed tube zone approximately 6 wide x 3 0 long from the end of the feed tube support clamp should be kept clear f Clear access space should be provided around the centrifuge The centrifuge isolators should set on smooth level surface on structural members of sufficient strength IMPORTANT CAUTION Since this centrifuge operates at high speed and is subjected to severe wear conditions it is important that any indications of weakening of highly stressed components be recognized before a failure can occur To facilitate this HH recommends monthly visual inspection on highly stressed components such as Bowl Shafts wear plates Wear tiles Conveyor etc If inspection reveals 1 Holes worn through moving parts 2 Wear grooves greater than 1 16 thick
54. e part surface Used for outdoor storage it must be used with overwrap The treated part must have this coating removed with solvent before use Contact each Manufacturer as required to determine if the rust preventives are compatible with the type of oil you are using 98 SECTION 12 VENDOR DATA 99 Index of Vendor Supplied Data Operating Instructions and Service Manuals Refer to this Section before servicing equipment Auto Guard 04038 Baldor Motors amp Drives Main Drive Electric Motor 04755 60 HP 1750 RPM Mfr Varies Back Drive 04139 High Temp Shutdown Switch OPTIONAL At front amp rear pillow block housings United Electric Controls Co Model B 121 120 2000 m201 Explosion Proof Open contact with temp rise to 220 Deg F MFGR MAY VARY 100 Installation and Operation Manual Autogard Torque Limiter 400 Series 28A Pawl 29 Strut Ring 6A Cage Plate 26B Pawl Spring 11A Adjusting Nut 2B Thrust Washers 4J Tape Bearing Journal oe 8 Calibration Spacer 2A Thrust Bearing 1 Hub 20A DH gon 11B Set Screws T BB Inner Strut Balls 4 Adaptor Outer Drive Balls 3A Drive Plate 7 Slide Plate OPERATION The Autogard 400 Series torque limiters disengage the drive completely on overload in both directions of rotation After disengagement the drive is running free which permits high speed operation at or above normal motor speeds A shut down
55. ease over time depends primarily an the type of grease the size of the bearing the speed at which the oearing operates and the severiy of the operating conditions Good results can be obtained if the following recommendations are used in your maintenance program Type of Grease A high grade ball or roller bearing grease should be used Recommended grease tor standerc service conditions is EM Exxon Mobil Equivalent and compatible greases include Texaco Polystar Rykan Premium 2 Pennzoil Pen 2 Lube and Chevron SRI Maximum operating temperature for standard motors 110 C Shutdown temperature in case of a malfunction 115 C Lubrication Intervals Recammenced lubrication intervals are shown in Table 3 1 It s important to realize that the recommended intervals of Tab 3 1 arc based on usc Refer to additional information contained in Tables 3 2 and 3 3 Table 3 1 Lubrication Intervals Rated Speed RPM NEMA IEC Frame Size 10000 5000 3600 1800 1200 san Up to 210 132 an 2700 5500 123001 rs 1800016 220001 Irs Over 210 ta 280 incl 120 3600 Hrs 9500 Hrs 15000 Hrs 18000 Hrs Over 280 to 360 incl 225 2200 Hrs 7400 Hrs 12000 Hrs 15000 Hrs Over 350 to 5800 incl 300 2200 9500 Hrs 7400 Hrs 10500 His Lubrication intervals are for ball bearings roller bearings divide the listed lubrication interval by 2 For 6205 and 6806 be
56. ed items which should be ordered from HH 67 5500 BRAKESMART CENTRIFUGE BASE UNIT PARTS LIST Qty Part Description 2879 5500 Flange gasket 2926 Case hinge washer 2989 Solid head wear plate 2 per set 16 3044 Hinge pin for lid clamp 19 3044P Cotter pin 16 3047 Clamping shoe for case 16 3048 Eyebolt for clamping shoe 17 3049 Nut for clamping shoe 3056 Solid end discharge transition 3057 Liquid end discharge transition 3088 Relief grease fitting 3089 Grease fitting 3123 Expanding dowel pins for PB 3441 Dam plates 3710 Warning stickers N Jo a 4036 Rtn Ring 4037 Rtn Ring 4040 Bearing solid end conv 1 3994 Feed tube Heavy Duty 4 4020 feed nozzle 1 4021 O ring liquid end seal housing Inner 2 4022 O ring accelerator plate 1 4023 O ring solid end seal housing 1 4024 O ring liquid end seal housing Outer 2 4025 O ring bowl ext and liquid head 2 4031 Seal solid end conv Bearing Housing 4 4032 Seal sol And Liquid Seal Housing 1 4034 Case cover assy 1 1 5500 BRAKESMART CENTRIFUGE BASE UNIT PARTS LIST CONTINUED Qty Part Description 2 4041 Bearing liquid end conv 1 4042 Bearing solid end PB 1 4043 Bearing liquid end PB 1 4050 Solid end bowl hub 1 4051 Liquid end bowl hub 1 4052
57. ed with the specified oil at the factory Guidelines for Long Term Storage 1 The centrifuge should be stored in a building with a minimum temperature of 50 10 C The storage area should be a clean dry place free from excessive vibration high humidity dust or corrosive fumes 2 The unit should be tagged with instructions for startup after an extended period of storage Any loose parts should be boxed with rust inhibitor paper No paper should be placed on the base of the box and machined unpainted surfaces should be coated with a rust preventive product The centrifuge assembly should be placed on sturdy wooden platform The platform boards should be spaced with 1 4 gap between the boards 96 5 A protective waterproof shroud should cover the entire centrifuge assembly top and four 4 sides Storage Maintenance 1 The centrifuge rotating assembly should be rotated by hand at least six 6 times every three 3 months 2 Leave the sealed openings on the equipment closed 3 Touch up any damaged paint surfaces 4 Do not paint rotating parts or threaded surfaces 5 Motors should have their shafts rotated every three 3 months in order to keep the bearings lubricated and prevent rusting Coatings amp Oils At regular intervals during equipment storage all exposed machined surfaces unpainted steel parts shafts pipe fittings etc should be examined for signs of rust pitting and moisture Th
58. ened to prevent changes in alignmert Use a flat washer and lock washer under each nut or bolt heac ta hold the motor feet secure Flanged nuts bolts may be used as an atemalive to washers Motor and wiring overload protection disconnects accessories and grounding should conform to the National Electrical Code and lacal codes and practices For ease of making connections an oversize conduit box is provided box can be rotated 360 in 90 increments Auxiliary conduit are provided on some motors for accessories SLth as spate heaters RTD s etc Connect the matar leads as shown nn the connection diagram on the name plate or inside the cover on the conduit box Be sure the following guidelines are met AC power within 10 of rated voltage with rated frequency See motor name plate for ratings OR AC power is within 5 of rated requency with rated voltage OR A combined variation in voltage and frequency of 11034 sum of absolute values of rated values provided the frecuency variation does not exceed 15 vf rated frequency Performance within these voltage and frequency variations are shown in Figure 2 1 MNADD 123 MN400 Changes in Motor Performance Figure 2 1 Motor Performance VS Voltage Variations 29 Maximum Torque Full Load Cument 15 10 d Factor we 527 Efficienzy 5 ae Maximum Torgue 15 10
59. es from Water Synlilm GT rapidly and completely separates from water which is easily drained from the bottom of the oil reservoir Saves Energy Synlilm GT has an extremely low coefficient of friction that is proven to save energy over conventional oils Ia retating equipment these savings frequently exceed the total cost of the oi within several months making what was once an oil expense a profit Extremely Clean Synfilm GT is peckaged in new poly containers has typi cal ISO 4406 Cleanliness I evel of 1413 11 18032 46 and 68 only und is verified by a laser particle counter This is up to 250 times cleaner than other new oils cefivered in steel drums by bulk delivery Reduces Bearing Vibrations The tough oil film of Synfilm coupled with its ability to micro polish contacting bearing elements provides superior bearing lubrication Lenger Oil L e Synfilm GT has outstanding oxidation stability that greatly extends oil change intervals while keeping equipment clean Excellent Corrosion Protection Synfilm GT s tough oil film forme an ionic bend on metal surfaces which avs as preservalive oil daring shutdown and provides instant lubrication at startup Synthetic So vency Synfilm natural solvency cleans up dirty equipment and keeps it clean Compatible with Seals Synfilm GT has excellent seal compatibility Compatible with Other Oils Synlitm GI ts can be mixed with other minera
60. ese parts should be thoroughly cleaned and coated with the appropriate medium listed below 1 Molykote Metal Protector Dow Corning A wax type rust preventative which may be sprayed brushed or dipped onto bare steel parts This product dries to a hard dry film which is almost invisible For long storage periods or shipment overseas an overwrap must be used 2 Rust Veto 342 Houghton Co A soft amber colored material leaving a transparent dry plastic film on the coated part Applied by brushing dipping or spraying it is used for maximum heavy duty protection on interior or exterior surfaces with or without a covering Before using the treated part remove rust veto with solvent 91 3 Rust Veto 377 Houghton Co A light polar type water displacing oil It is used on metal parts stored indoors It can be sprayed on intricate parts and bearings Long term storage requires an overwrap Removal from the treated part is not required before use An equivalent is Antirust 77 WD Oil by International Chemical 4 Rust Veto Concentrate Houghton Co rust preventive that is mixed in one 1 part with nine 9 parts lubricating oil or hydraulic oil etc Itis circulated through gearboxes and hydraulic systems and then drained before shipment Itis compatible with most hydraulic oils and removal is not required before use 5 Ferrocote 346 Quaker Chemical Co heavy oil which leaves soft paste like film on th
61. ess of type horsepower speed load or temperature Metals non corrosive to both ferrous and non ferrous metals All Service shock load high pressure high and low temperature Users ready for a quantum leap in gear box performance 30 Beyond Synthetic GT s recommended for use in gas and steam turbines pumps bearings gears air tools etc Synfilm GT should be considered instead of Synfilm when oil reservoir temperatures exceed 200 F improved low tem perature fludity is desired or when a viscosity grade is not av ilab e in Synfilm Synfilm GT is a long life high film strength energy efi cient synthetic lubricant that significantly increases bearing life and equipment reliability Synfilm GT gains its performance advantages over competing mineral and synthetic oils through its superior blend of synthetic base ols plus Royal Purple s propri Synerlec additive technology This unique additive tech nology is proven to make equipment run smoother cooler qui eter longer and more efficiently Synfilm GT typically replaces conventional low film strength R amp O rust and oxidation inhibited oils that rely solely on their viscosily to protect equipment against wear Exclusive Performance Advantages High Film Strength Synfilm GT protects bearings Far beyond the ability of other turbine oils carrying up to 700 percent greater loads Rapidly Separat
62. f and disconnected and all rotating assemblies have come to complete stop The moving motor may generate DC voltage feed back I CHEMICALS 1 If corrosive and or toxic chemicals or solvents used as part of the process or as cleaning materials become thoroughly familiar with the properties of the products and their hazards the precautions necessary to handle the product 11 2 safely and follow all manufacturer recommendations for type of product being handled a Use in well ventilated area and keep employee exposure below permissible limits If flammable take care to prevent fire or explosion c Avoid contact with the skin and eyes wear goggles gloves shields etc as required by the nature of the solvent or chemical If in doubt whether a product is dangerous or not Assume It Is Take all necessary precautions to avoid personal injury J VENTILATION l Toxic fumes if present in the system must not be permitted to escape to the operating area They should be adequately vented away form the worker in accordance with applicable environmental regulations If in doubt whether any vapor is toxic or not Assume It Is Take all necessary precautions to avoid personal injury or adverse health effects Worker exposure should be maintained below the permissible limit and at the lowest feasible level If it is necessary to enter an area where toxic vapors are present consult with responsible a
63. flow through Soft Start Soft start is an electronic device that regulates the maximum main drive current during start up Once the main drive reaches operating speed the soft start is taken off line 84 SECTION 9 TROUBLE SHOOTING 85 TROUBLE SHOOTING THE HUTCHISON HAYES BRAKESMARTT SYSTEM CONTROL PANEL IS EQUIPPED WITH FAULT LIGHTS SHOULD YOU ENCOUNTER PROBLEM THE FAULT LIGHTS ARE THE FIRST INDICATION OF WHAT THE PROBLEM MIGHT BE ONCE FAULT LIGHT IS ACTIVATED THE RESET BUTTON THE FRONT OF THE CONTROL PANEL WILL HAVE TO BE PRESSED ONCE WILL SILENCE THE HORN AND THE SECOND TIME WILL CLEAR THE FAULT AFTER FAULT HAS OCCURRED APPROPRIATE ADJUSTMENTS SHOULD BE MADE TO PREVENT IT FROM REOCCURRING 86 Centrifuge Trouble Shooting BEFORE PERFORMING ANY REMEDIES FOLLOW THE PROPER TAG OUT PROCEDURES Problem Possible Cause Remedy Unit will not start No power Blown fuses Drive starter Soft start drive failure Overheated Drive Check source Replace amp trace cause Repair or replace Repair or replace Cool restart trace problem Autogard tripped Reset fault light reset Autogard Centrifuge shuts down Blown fuse Replace trace cause Overload relays tripped Reset Overheated drive motor Vibration switch tripped Torque control switch tripped Cool trace cause Reset trace cause Reset trace cause Excessive Vibration Isola
64. g four 4 bolts Do not remove feed tube clamp cover Remove feed tube It pulls straight out Remove the front and rear pillow block dowel pins by jacking them out using the threaded connection at the top of the pins to withdraw them Remove pillow block bolts Fully open centrifuge cover and secure one 1 safety latch pins Using hardened capscrews attach bowl lift lugs at front and rear of bowl Using the bowl spreader bar attach shackles to lifting lugs and slowly lift the bowl and gearbox assembly as a unit using the 2 ton overhead hoist Set the assembly down horizontally in a clean clear area 35 CONVEYOR REMOVAL Positioning bowl for conveyor removal After gearbox removal 1 With bowl assembly now sitting horizontally in clear clean work area remove the bowl spreader bar 2 Attach the conveyor lifter to adaptor hub at gearbox end of centrifuge using four 4 7 16 14 UNC X 2 3 4 long bolt with heavy hex head nuts The gearbox must be removed prior to this procedure 3 Place the bowl assembly on support stand as shown in Figure 1 Bowl Shell Extension Centrifuge Pulley Recommended Stand P Floor Line FIGURE 1 4 Height H in diagram must be tall enough so the drive sheave pulley clears the floor by at least two 2 inches CAUTION Never allow the drive shaft to contact any surface during this lifting procedure It is not designed to carry any load and can easily
65. he cost of warranty repairs made by centers otrer than Baldor Authorized Service Centers WILL NOT be paid unless first authorized in writing by Baldor 8 Claims by a purchaser that a niotor is defective even when a failure resuts within one hour after beirg placed into s rvice are not always justified Iheretore Baldor Authorized Service entes must determine from ths condition of tae motor as delivered to the center whether o not the motor is defect ve If n the opinion of a Baldor Autharized Service Center a molor did nat fail as a result of defects in mater al or workmanship the center is to proceed with repairs only if tFe purchaser agrees ta pay for such repairs If tle decision is in dispute the purchaser should still pay for the repairs and submit the paid invoice and the Althorized Service Carter s signed Service report ta Balcor for further consideration 7 This warranty gives you specific legal rights and you may also have other ichts which vary from state to sta e Note that Baldor Super E 3 Premium Efficiency electric motors are warranted for a period af three 3 years Baldor IEEE 841 electric mo ors are warrariled for a period of five 5 years All ather terms and conditions af the Limited Warranty statement apply MN405 General niprmation 1 1 118 Safety Notice 1 2 General Infornatio1 This equipment contains high voltage Elect ical shock can cause serious or fatal injury Only qualified personnel should attempt
66. heat mus be dissipated to orevent damage These motors are not designed for atmospheric conditions that require explosion proof operation They must NOT be used in the presence o f ammable or combustible vapors or dus 1 ODP motors are suitable only for indoor applications 2 TEFC and WPII motors are sutable for indoor or outdoor standard service apolications The motor must be securcly installed to a rigid foundation or mounting surface to minimize vibration and maintain al gament between the motor and shaft load Failure to provide a proper mounting suraze may cause vibration misalignment and bearing damage Foundat on caos and sole plates are designed to acl as spacers for he equipmen they support If these devices are usec be sure that they are evenly supported by the foundation or mounting surface After ins allation is complete anc accurate alignment of the motor and load is accomplished the base should be g outed to the foundation to maintain this alignmen The stardard motor base is designed for horizontal pr vertical mounting Adjustable or sliding rails are designed for hor zonla mounling cnly Consult your Baldar distributor ar aulhurized Baldor Service Cerler for further information Accurate elignaont of the motor with the driven squipmen is oxtromoly important 1 Direct Coupling For drive use flexible couplings if possible Carsult the drive or equipment nianufacturer for niore information Mechanical vib
67. id the motor windings must be protected from moisture This can be done by applying power to the motors space heater if available while the motor is in storage Each Baldor motor is packager for ease of handling and to prevent entry contarninants 1 Toavod condensation inside the motor do not Unpack until the motor has reached room temperature Room temperature is the temperature of the pom in which it will be installed The packing provides insLlation from temperature changes during transpartation 2 V hen the motor has reached room temperature remove all protective wrapping material from the motor eo The motor should be lifted using the lifting lugs or eye bolts prov ded 1 Use he lugs or eya bolls provided to lifl the molar Never allempl In l Ihe molar and addilional equipmenl connected Ip Ihe molor by lhis method The lugs or eye provided arg desigred lo he molar Never fil the matar by the motor shaft ar the hoad of 2 motar 2 When lifting a WPI weatherproof Type 2 motor do not lift the mozar by inserting liftirg lugs into holes on top of the cooling hood Trese lugs are to be used for hood removal only spreader bar should he used to lift the motor by the cast lifting lugs Iccated on the motor frame If the motor must be mounted to a plate with the driver equipment such as pump compressor ete it may not he possible tn lift Ihe matar alone Fnr this case tae assembly should
68. ied personnel familiar with electrical safety procedures CAUTION Persons without recommended experience may not understand the instructions listed in this manual A GENERAL 1 Read all manuals and instructions before attempting to install or operate equipment and follow all recommendations 2 Follow all lubricating and or greasing procedures and schedules recommended in the equipment instructions 3 If nameplates are lost damaged or removed replace them They have been affixed to the equipment to provide warnings instructions etc for the maintenance and operating personnel 4 Do not operate belt driven or chain driven equipment without guards If equipment was purchased without guards user is responsible for providing proper guards that meet all applicable codes 5 Make periodic checks for loose bolts on rotating assemblies the supporting structure covers hatches guards and piping connections 6 Do not operate equipment if excessive vibration or abnormal noise develops 7 If the equipment is supplied with covers or guards do not remove these until the equipment has come to a complete stop 8 Never operate equipment with parts that have not been manufactured or approved by the original equipment manufacturer B HANDLING 1 Safe practices for lifting and handling equipment should be followed Hoists and slings should be of adequate capacity inspected regularly and in good repair 2 Always use extra caut
69. in moving parts 3 Cracks present is moving parts 4 Chemical pitting to a depth of 1 16 or greater in moving parts DO NOT OPERATE THE EQUIPMENT UNTIL REPAIRS ARE MADE FAILURE TO FOLLOW THE ABOVE RECOMMENDATIONS MAY RESULT IN SEVERE PERSONAL INJURY OR PROPERTY DAMAGE 16 PIPING Customer piping tie ins to the centrifuge should be made with flexible connections Customer tie in at feed tube should have a suitable pipe support so that no weight is imposed on the centrifuge feed tube A flexible connection is required here flush line should be provided at the feed tube tie in HH recommends hot water ball valve should be located as close as possible to the feed line to prevent plugging the flush branch with solids Use a screen at the pump suction to protect the pump and centrifuge from oversize solids Liquid discharge lines should have a minimum of per ft slope HH recommends installation of a pressure indicator in the feed line upstream of the customer tie in to regulate the feed supply to the centrifuge 17 PRESTART SAFETY PRECAUTIONS FAILURE TO FOLLOW THE RECOMMENDED SAFETY PRECAUTIONS LISTED BELOW MAY RESULT IN SEVERE PERSONAL INJURY OR PROPERTY DAMAGE Read through this entire list before attempting start up Initial Installation 1 10 11 12 13 14 15 The correct bowl rotation must be verified The bowl should rotate counter clockwise when viewed from
70. installation operation and maintenance of electrical equipment Be sure that you are sompletely familiar with NEMA publication MG 2 safety standards for construction and quide far selectinr installation and use nf electric mntors and generators the National Electrical Cade and local cades and practices Unsafe installation o use cause caridiliuns thal lead lo seriaus fatal injury Only qualified personnel should attempt the installation operation and maintenance of this equipment WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING Do not touch electrical connections before you first ensure that power has been disconnected Electrical shock can cause serious or fatal injury Only qualified personnel should attempt the Installatlon operatlon and malntenance of this equlpment Be sure the system is properly grounded before applying power Do not apply AC power before you ensure that all grounding instructions have been followed Electrical shack can cause serious or fatal injury National Electrical Code and Local codes must bc carcfully followcd Avoid extended exposure to machinery with high noise levels Be sure to wesr ear protective devices to reduce harmful effects to your hearing This equipment may be connected to other machinery that has rotating parts or parts that are driven by this equipment Improper use can cause serious or fatal injury
71. ion when lifting moving or holding worn parts since these may be sharp slippery or weakened Never place hands feet or head at possible pinch points Always provide a sufficiently large cleared area around the equipment during maintenance C ROTATING EQUIPMENT 1 Do not exceed the maximum speed process material specific gravity process pressure or temperature or maximum design feed rate as specified on the equipment nameplate or within the operating manual 2 Do not use a pipe wrench on any part of the rotating equipment 3 not interchange parts that have been balanced as an assembly 4 Do not attempt to utilize the rotating equipment in an application for which it was not originally selected 5 When taking samples or removing any material from equipment like grinders screw conveyors open throat pumps etc make sure all machine components are at rest and the power is shut off with the disconnect switch locked in the off position 6 Do not get rags loose clothing sticks etc near rotating or moving parts 7 equipment must coast complete stop Do not brake it by hand or in any other way force it to stop unless it is equipped with braking mechanism supplied by the original equipment manufacturer 8 Do not operate the rotating equipment unless the direction of the rotating part or assembly conforms to that of the Instruction and or Operation Manual 9 Ifarotating assembly must be turned by hand
72. l oils and most synthetic oils It is not compatible with silicone or glycol syn thetics Environmentally Responsible Synfilm GT components TSCA listed and meet RCRA and requirements Synfilm GT extends drain ntervals eliminates premature oil changes decreases the amount of oil purchased and disposed of and conserves energy Royal Purple Ltd 1 Royal Purple Lane e Porter Texas 77365 Phone 281 354 8630 Fax 281 354 7690 www royslpurple com 52003 09 01 3l FILM GT urpose Industrial Oil Beyond Synthetic ISO Grade AGMA Grade tam 4 AN AOU A 4 at Kise AKG GN AR SANE ME v zm ZR 9 CONDES FONS UTR MA con All propeities are typical and may vary Check with manufacturer regarding availability with 14 13 11 cleanliness GT s solvenev cleans wear metals and deposits lef behind by previous oils These wear metals and deposits can become soluble in the new oil causing abnormal alues on used oil analysis until equipment is clean Royal Purple Ltd 1 Royal Purple Lane w Porter Texas 77365 50003 8 01 Phone 281 354 8600 Fax 281 354 7600 www royalpurple com 32 SECTION 5 ASSEMBLY AND DISASSEMBLY 33 BRAKESMART BACK DRIVE GB53 GEARBOX REMOVAL STEPS 1 Follow all lock out and tag out safety procedures Insure power is off 2 Remove back drive motor belt guard and gear guard 3 Loosen motor and
73. lace them 18 Remove the rear bearing housing Now access is clear for removal and inspection of the retainer tube seal RETAINER TUBE SEAL REMOVAL 1 Reach into the conveyor and remove the four 4 1 4 capscrews on the seal retainer plate 2 Pull the seal retainer plate out 3 Inspect the oil seal and replace if worn or damaged 39 Part Numbers Hutchison Hayes 5500 BrakeSmart Centrifuge 16 HH Machined Components Item Description HH Part No 1 Bowl 04065 1A Bowl Liner 2 Bowl Extension 04052 3 Conveyor 04053 6 Flinger 04073 9 Rear Hub 04050 10 Conveyor Bearing Housing Solids End 04054 11 Conveyor Bearing Seal Housing Solids 04083 End 12 Retainer Ring 04071 13 Retainer Tube 04010 15 Pillow Block Housing 04058 Pillow Block Housing 04058 Bearing End Plate 18 Spacer Ring 04081 19 Flinger Cover 04060 19A Flinger Cover nearest gearbox 04072 20 Flinger 04073 21 Case Flinger 04084 22 Feed Tube Assembly 04009 13994 24 Accelerator Plate Assembly 04056 27 Feed Nozzle 04057 28 Wear Liner 2 Feed Nozzle 04046 29 Solids Discharge Wear Insert 04062 35 Drive Sheave 04061 04001 36 Drive Sheave Seal Housing 04087 37 Conveyor Bearing Housing Liquids End 04055 38 Splined Adapter 04078 39 Front Hub 04051 40 Seal Housing Liquids End 04063 41 Plate Dam 04067 42 Gearbox Adaptor Hub
74. moving properly across coaling fins Excessive dirt build up an motar Clean mator Check voltage at all phases should be approximately equal to isolate and correct ths problem Check air gap clearance and bearings Tighlen Thru Bells Check input voltaye at sach phase to motor eck stator res stance at all three phases for balance Perform dizlectric test and repair as required Inspect all electrical cenineclians or proper termination clearance mechanical strength and electrical continuity Refer a motor lead connect on diagram Check and align motor and driven equ pment Reduce belt tension ta proper pcint for load Reduce the end from driven machine Renove until cavity is approxiniately filled Add grease until cav ty is approximately filled Clean bsaring cavity and bearing Repack wth correct grease until cavity is approximately fil ed Check and alicn motor and driven equ pment I amp clate and eliminate cause of rubbing Have rolar balance checked are repaired al your Baldor Service Center Tune system or contact your Baldor Service Center for assistance Remove rolor and foreign malerial Reinstall rotor Check insulation irtegrity Clean ventilation operings Replace bearing Clean all grease from cavity and new bearing Repack with correct greasa until cavity is approximate y 4 filled Maintenance amp Troubleshooting 3 5 130 78 LE T 9 53 CUSTOMER 15 RESPONS
75. n MNADD 125 Section 3 Maintenance amp Troubleshooting WARNING UL rated motors must only be serviced by authorized Baldor Service Centers if these motors are to be returned to a flammable and or explosive atmosphere General Inspection Inspect the motar at regular intervals approximately svery 500 hours nf operation or every 3 months whichever occurs first Keep the matar clean and the ventilation vpenirgs clear The following steps should be performed at each nspectiarn WARNING Do not touch electrical connections before you first ensure that power has been disconnected Electrical shock can cause serlous or fatal injury Only qualified personnel should attempt the installation operation and maintenance of this equipment 1 Cheek thal the motor is clean Check that the inte ior and exterior of the motor is free nf dirt nil grease ate Oily vapnr papar textile lint ete san accumulate and black motor ventilation If tho motor is rot properly ventilated overhealing can occur and cause early raclor failu e 2 Usea Megger periodically ta ensure that the integrity of the winding insulation has been maintained Record the Megger readings Immediately investigat any significant drop in insulation resistance 3 Check all electrical connectors be sure that they are tight Lubrication amp Bearings Bearing grease will Iose ils lubricaling abilily over lime nol suddenly The lubricaling ability of a gr
76. n the control panel as 0 100 Do not exceed 100 torque or the autoguard will trip and shut the unit down No value is displayed when the back drive selector switch is on the off position Take samples of the liquid and solids discharge for analysis to justify further adjustments Low Speed Mode for High Density Fluids Shut Down Procedure Reduce feed rate to minimum then press the feed pump stop button Select off on the back drive selector switch Open the flush valve on the feed inlet pipe and flush with appropriate fluid until liquid discharge comes out clear Then turn off flush valve Press the centrifuge main drive stop button Wait for bowl to come to rest Turn back drive selector switch to the forward position for two 2 minutes Turn back drive switch to the off position 22 n SECTION 3 OPERATION 23 OPERATION The slurry to be separated is pumped into the feed tube axially located at the rear of the machine The slurry is directed into a feed chamber where it is dispersed by four 4 externally mounted feed nozzles and directed by centrifugal force along and against the inside wall of the bowl This ring of slurry or pond will contain solids against the bowl wall These solids are scrolled forward over a beach area by screw conveyor and discharged through four 4 ports at the solids end of the centrifuge located in the rear The lighter liquids migrate forward and are
77. ng a slide hammer type bearing puller remove the two 2 bearings Remove the Conveyor Bearing Housing by removing the eight 8 capscrews and jacking it out using two 2 of the removed capscrews This opens the end of the Conveyor Tube and allows access to the Accelerator Plate and Feed Chamber Liner ACCELERATOR PLATE AND FEED NOZZLES 1 The accelerator plate is removed by inserting the long T handle wrench into the conveyor tube and screwing it tightly into threaded hub on the centerline of the accelerator plate 2 With the T handle wrench attached firmly loosen the two 2 3 8 setscrews and the two 2 3 8 lockscrews from the conveyor tube They are located just forward from the feed nozzle located on the outside of the conveyor tube 3 With the setscrews and lockscrews backed off enough to allow the plate to be pulled out slowly withdraw the accelerator plate 37 10 11 12 13 14 15 Remove the four 4 externally mounted feed nozzles by unscrewing two 2 capscrews at each nozzle and withdrawing each nozzle by gripping its flange and pulling it out Note the condition of the O Ring on each feed nozzle T handle wrench available from HH CONVEYOR REAR BEARING HOUSING REMOVAL Remove the conveyor as per the previous Conveyor Removal Section but set the conveyor in a horizontal position on a clean clear work surface Remove the conveyor lifter plate from the front of the conveyor
78. now be engaged with the seatings in the drive plate and the pawls pushed almost completely into the drive plate by the flange on the slide plate There should be small gap about 0 010 inches 0 25mm between the slide plate flange and the drive plate M Hold the slide plate in this position against the cage plate spring pressure and screw the nut spring assembly onto the hub until the springs are against the slide plate with a positive pressure more than the cage plate spring load so that the slide plate is held in position 110 Figure 11 Clamping collar Gi 1 O Dadjusting nut CS cage plate Stop pin Pawl Goa Socket head cap screws Calibration spacer 2 5 Inner strut balls 4 Outer drive balls Strut ring Thrust bearing y 28 Thrust washers G Adapter 15 Tape bearing thrust 17 Tape bearing journal Cage plate spring Sizes 1 amp 2 111 SIZE 6 AND LARGER See Fig 12 These units differ from the smaller sizes in three respects and the assembly procedure is as for the smaller units apart from these features 1 The tape bearings in the adapter are replaced by a ball bearing 2 The torque springs are guided on pillars instead of being housed in the adjusting nut Disc springs are normally used on these sizes 3 See notes Torque Adjustment regarding assembly of the spring System on these larger units Figure 12 Pillar
79. ns supplied by the manufacturer 5 outlet connections of all safety devices should be installed in manner that will not cause injury to personnel should discharge or actuation occur 6 Before attempting maintenance on pressurized equipment reduce internal pressure to atmospheric pressure M HOT COLD PRODUCTS 1 When working with very hot or very cold processes or products extreme caution should be used to avoid personal injury N LEAKAGE AND SPILLAGE 1 Any leakage in the system should be quickly corrected 2 Any type of spillage oil water etc should be quickly cleaned off floors walls equipment lines etc and the entire operating area kept clean DANGEROUS MATERIAL APPLICATIONS HH makes both standard equipment and equipment furnished with certain explosion proof accessories motor controls etc as specified by the purchaser Standard equipment not furnished with explosion proof accessories must never be used with explosive chemically unstable or flammable materials of any kind Severe personal injury or property damage could result When we supply equipment furnished with explosion proof accessories whether we are the manufacturer or not we warrant that the particular accessories we describe as explosion proof comply with accepted industry standards for that term However this does not mean and we cannot and do not guarantee that one of our machines furnished with explosion proof accessories is s
80. nts of the National Electric Code and local electric codes Use circuit breakers or fused disconnects between equipment and power source Never touch electrical components with wet hands or when standing on a wet surface Insulate yourself from ground and use insulated tools When handling electrical equipment take care to avoid contacting live parts Assume all circuits are live Check with voltmeter Label all control circuits clearly Keep electrical controls and motors clean and free of dust dust prevents thorough air circulation generating heat heat in turn can ignite the dust or flammable vapors if present in the atmosphere Never wash electrical equipment unless it is constructed for that purpose Never wash live electrical equipment H ELECTRICAL Repairs 1 Only qualified personnel familiar with electrical safety procedures and the construction and operation of the equipment should work on electrical equipment De energize all power before opening any electrical enclosure or before connecting and disconnecting test equipment and components Provide safety lockout at the power source Use only approved safety rubber gloves and mats insulated tools and eye shields when doing electrical work Periodically inspect and operate all of the automatic shut off devices and monitoring systems provided On DC powered equipment do not perform any inspection mechanical or electrical until the power has been turned of
81. onents Anti seize compound should be used on stainless steel fasteners because of their tendency to gall when used with mating stainless steel parts Follow the recommended torque values shown in the torque chart in the Service Manual Conveyors equipped with carbide tiles should never be set down directly on a concrete floor The carbide is very brittle and tile damage could result Monitor items such as drive belts O Rings seals and vibration isolators These items will become brittle with age and deterioration will adversely affect centrifuge performance Replace these items when indicated by inspection 51 5500 HARDWARE INVENTORY LOCK TIGHT OR ITEM NEVER POSITION QTY ALLOY TYPE STYLE SIZE SEIZE CONVEYOR SOCKET 242 1 ACCELERATOR PLATE 2 55 SET CUP HEAD 3 8 X 1 LOCTITE SOCKET 242 2 FEED NOZZLES 8 55 HEAD 1 2 X 3 4 LOCTITE SOCKET NEVER 3 SPLINE ADAPTER 8 BLACK HEAD 3 8 X 1 SEIZE DOWEL 4 SPLINE ADAPTER 4 PIN 3 8 X 1 SOCKET NEVER 5 LIQ BRG HOUSING 12 BLACK HEAD 3 8 X 1 3 4 SEIZE SOCKET NEVER 6 LIQ BRG HSG SEAL COVER 6 55 HEAD 3 8 X 1 1 4 SEISE SOCKET NEVER 7 SOLID END 6 55 HEAD 5 16 X 3 3 4 SEIZE 8 SOLID END BRG HSG SEAL COVER HELD BY ABOVE BOWL SOCKET NEVER 1 BOWL EXTENTION 12 55 HEAD 3 8 X 1 1 4 SEIZE SOCKET NEVER 2 SOLID END H
82. or atmospheric conditions that require explosion proof operation MNADD 119 Safety Notice Conlinusd MN400 WARNING WARNING Caution Caution Caution Caution Caution Motors that to be used flammabla and or explosive atmospheres must display the UL label on the nameplate Specific service conditions for these motors are defined in 70 529 UL rated motors must only be serviced by authorized Baldor Service Centers If these motors are to be returned to a flammable and or explosive atmosphere prevent premature equipinent failure dainage qualified maintenance personnel should perform maintenance Do not lift the motor and its driven load by the motor lifting hardware The motor lifting hardware is adequate for lifting only the motor Disconnect the load from the motor shaft before moving the motor If bolts are used for lifting a motor be sure they are sccurcly tightened The lifting direction should not exceed a 20 angle from the shank of the eye bolt or lifting lug Excessive lifting angles can cause damage To prevent equipment damage be sure that the electrical service is not capable of delivering more than the maximum motor rated amps listed on the rating plate If a HI POT test High Potential Insulation test must be performed follow the precautlons and procedure In NEMA MG 1 and MG 2 standards to avoid equipment damage If you have any questiun
83. ount the torque limiter assembly on one of the shafts and the coupling hub part 15 16 or 18 on the other shaft Bring the shafts together and align the coupling carefully checking with a dial indicator For optimum life maintain alignment within the limits shown in Table 3 103 Table 3 Model Size Allowable Angular Allowable Gap between Misalignment Parallel Hub amp Adapter Misalignment 403 1 5 0 0 Min Max 404 1 5 0 0 405 1 5 5 deg 0 406 1 005 08 16 2 008 80 16 3 010 08 25 4 10 deg 013 08 28 5 017 27 31 6 020 127 31 7 028 20 39 TORQUE ADJUSTMENT DATA Table 4 Standard Torque Adjustment Y Inches Clearance Movement to Spring CA disengage Size In X Spring Assembly Torque Min Range Allowable Qty Positions Lb In 1 8 100 250 075 059 6 Outer 75 188 075 Required 4 Outer 50 125 075 2 Outer 25 63 075 2 8 Outer 400 2 000 20 None 112 6 Outer 300 1 500 20 Required 4 Outer 200 1 000 20 3 6 Inner amp Outer 1 700 6 000 20 None 137 6 Outer 1 200 3 000 20 Required 4 Outer 800 2 100 20 3 Outer 600 1 600 20 4 8 Inner 2 500 10 000 1 20 None 137 8 Outer 2 000 6 800 20 Required 6 Outer 1 500 5 100 20 4 Outer 1 000 3 400 20 5 8 Inner 8 000 22500 40 None 173 8 Outer 6 000 17 000 40 Required 6 Outer 4 500 12 750 40 4 Outer 3 000 8 500 40 6
84. play when their equipment is in operation Any weakening of highly stressed members by misuse erosion corrosion chemical pitting or stress cracking must be guarded against to prevent possible metal failure In the interest of longer and safer operation of the equipment HH recommends that the equipment owner maintain periodic at least monthly inspection on highly stressed rotating and or moving parts which are subjected to erosive or corrosive wear 4 The following points should be noted and the recommended action taken a Do not operate equipment when 1 Holes are wearing through rotating and or moving parts 2 Grooves greater than 1 16 deep are worn in rotating and or moving parts 3 Evidence of cracks is present especially in rotating and or moving parts 4 Chemical pitting of 1 16 depth or greater on rotating and or moving parts 5 Component surfaces are covered with a light corrosion or etching b Chemical pitting is observed 14 cases of chemical pitting even less than 1 16 depth should be watched carefully This pitting action is almost always due to the breakdown of the passive film on stainless surfaces in the presence of chlorides This often occurs under product cake that has not been sufficiently cleaned from the surface High temperature low pH and high acidity accelerate the pitting action 5 Contact HH regarding the repair or replacement of rotating and or moving parts whose surfac
85. quid and solids discharge for analysis to justify further adjustments High Speed Mode for Low Density Fluids Shut Down Procedure 1 Reduce feed rate to minimum then press the feed pump stop button 2 Select off on the back drive selector switch 3 Open the flush valve on the feed inlet pipe and flush with appropriate fluid until liquid discharge comes out clear Then turn off flush valve 4 Press the centrifuge main drive stop button Wait for bowl to come to rest 5 Turn back drive selector switch to the forward position for two 2 minutes 6 Turn back drive switch to the off position 21 5500 BrakeSmart Low Speed Mode for High Density Fluids Start Up Procedure Read through Pre Start Safety Precautions Turn main breaker on the control panel to the position Pull out the emergency stop button Power light should be illuminated Select the off position on the back drive start button Press the main drive start button The centrifuge bowl will reach full speed in approximately ninety 90 seconds Select the conveyor speed by turning back drive selector switch to Reverse 15 rpm not recommended b Off 38 rpm dryer solids discharge but higher torque can cause plugging c Forward 60 rpm highest solids throughput but wetter solids Start feed pump at minimum speed Increase to desired flow rate Note If operating in the reverse mode the torque value is displayed o
86. r is oroperly ventilated Coupled Start Up This procedure assumes a amp oupled start up Also that the first tims start up procedure was successful m Won 4 Check the coupling and ensure all guards and protective tevices are installed Check that the caupling is praperly aligned and nol binding The first coupled start up shoud be with no load Apply aower verify that the load s not cransmitting excessive vibration back lo the motor trough the couplirg or the foundalion Vibration shauld be at an acceptable level Run for approximalely 1 hour with he driven equipmenl n an un oaded randilinn Ihe equipmen can now be loaded and operated within specitied limits Do nct exceed the name plate ratings fcr amperes far steady ccntinuous loads Jogging and Repeated Starts Repeated starts and or jogs of induction motors generally reduce the 0 the m tar winding insulation much greater amourit of heat is produced by each acceleration ar jog than thar by the same motor under full load If it is nacessary to to repeatedly start or jeg the motor it is advisable to check the application with your local Baldor distributor or Baldar Service Center Heating Duty rating and maximum ambient temperature are stated on the motor name plate Do not exceed these values is any question regercing sele operation conlacl your local Baldor distributor or Baldor Service Center 2 4 Ins allation amp Operatio
87. rapped in soft tissue until ready for installation Threaded Connections All threaded connections and pilot diameters should be wiped clean and lubricated with an anti galling compound such as NEVER SEEZ Torque all screws on the rotating assembly per the Recommended Capscrew Seating Torque charts shown in the Start Up Section of this Manual To help prevent capscrew failure if excessive torque is required to seat mating parts during assembly the over torqued screws should be removed discarded and replaced with new screws installed at the correct torque O Rings Inspect for nicks and cuts before installing if damaged do not install Lubricate O Rings for easier installation 49 Machined Parts Clean with degreasing solvent before reassembly Set parts on clean work area and protect finished surfaces and openings on the part Be sure to align any balanced parts on the rotating assembly by matching the V Marks stamped on the parts If more than one 1 centrifuge is owned do not interchange any parts which comprise a balanced rotating assembly 50 Some Assembly and Disassembly Tips Read the Service Manual Keep all mating surfaces free from dirt and handle carefully to avoid nicks and burrs to the mating surfaces Check the inside of the conveyor for solids build up Not cleaning solids build up can be the cause of vibration problems Lubricate O Rings and fasteners when reassembling centrifuge comp
88. ration anc rougar ess during operation may indicate poor alignment Use dial indicators to check alignment The space between coupling hubs shoud be maintained recommended by the co ipling manufacturer 2 End Play Adjustment The axial posilion of lhe molar frame wilh respec a ils load is also extremely imparlanl The malcr aearings are nol designed for excessive exlemal axial thrust loads Improper ad istment will cause failure 3 Pulley Ratio The oulley ratio should not exceed 8 1 4 Belt Drive Aligr sheaves carefully ta minim ze belt wear and axial bearing loads see End Play Adjustment Belt tension should be sufficient to prevent slippage at azed speed and load However belt sliprage may occur during starting Caution Do not over tension belts 5 Sleeve bearing ractnrs are only suitable for coupled loads Installation amp Operation 2 1 122 Doweling amp Bolting Power Connection Conduit Box AC Power 2 2 amp Operation After propsr alignment is verified dowel pins should be inserted through the motor fest inta the foundation This will maintain the correct motor position should motor removal bs required Baldor motors designed for dowsling 1 e Bot om Drill dawel hales in diagcnally oppos te motor feet in the locatians provided Drill corresponding holes in the foundation Ream all holes Install proper fitting dowels Mounting bolts must be carefully tight
89. ring pressure Additional Notes for SR units If the pawl locating pins 28C are not already in place they should now be carefully fitted after removal of the pawls and springs Note the pins must be positioned with the seam away from the pawl see Fig 10 28C Re assemble pawls and springs and check that they still have free movement Assemble the drive plate onto the strut ring Lightly grease the bearing surface of the hub and assemble the tape thrust bearing against the flange If tape journal bearing 4J is included carefully position in the bore of the adapter 4 and assemble onto the hub Make sure the tape bearing stays in position during this assembly and check that the adapter can then turn freely on the hub 109 Connect the adapter to the drive plate with capscrews 20A and roll pins 7B Check that the drive plate adapter assembly can rotate freely on the hub H On size 1 and 2 SR units assemble the cage plate spring 6B onto the hub ensuring that it is housed in the counterbore in the strut ring and that the coils are not intertwined On size 3 and larger a bayonet type of cage plate retention is used The cage plate is placed in the slide plate with the stop pin notch 90 to proper location The stop pin 7B should now be installed per Fig 10 Note position of splits in rollpins I Check that the stop pin 7B is correctly positioned in the slide plate 7 and is not loose or damaged It shoul
90. rrent to flow through Relay 5 Relay 5 used to turn on off the Vibration Light A relay is an electrical switch that allows a low power to control a higher one A small current energizes the relay which closes a gate allowing alarge current to flow through Control Power Circuit Breaker CPCB is used to open the electrical circuit as soon as current climbs to unsafe levels in the Control Power circuit 480 volt primary and 110 volt secondary Relay 4 Relay 4 is used to turn on off the Alarm Horn A relay is an electrical switch that allows a low power to control a higher one A small current energizes the relay which closes a gate allowing a large current to flow through Relay 3 Relay 3 is used to start stop the Feed Pump relay is an electrical switch that allows a low power to control a higher one A small current energizes the relay which closes a gate allowing a large current to flow through Relay 2 Relay 2 is used to start stop the Backdrive in a forward direction A relay is an electrical switch that allows a low power to control a higher one A small current energizes the relay which closes a gate allowing a large current to flow through Relay 1 Relay 1 is used to start stop the Backdrive in a reverse direction A relay is an electrical switch that allows a low power to control a higher one A small current energizes the relay which closes a gate allowing a large current to
91. s to the gearbox at the front of the machine beyond replacement of the pinion shaft oil seal 19 5500 BRAKESMARTT CENTRIFUGE BELT TENSIONING PROCEDURE FIGURE 1 Remove Belt Guard 4 5 5 FORCE Measure Distance L in V BELTS inches Divide by 64 Force required to deflect belt 4 to 5 5 Lbs Do not over tighten belts NA Do not over tighten belts 20 6 7 5500 BrakeSmart High Speed Mode for Low Density Fluids Start Up Procedure Read through Pre Start Safety Precautions Turn main breaker on the control panel to the position Pull out the emergency stop button Power light should be illuminated Select the off position on the back drive start button Press the main drive start button The centrifuge bowl will reach full speed in approximately ninety 90 seconds Select the conveyor speed by turning back drive selector switch to a Reverse 55 rpm dryer solids discharge but higher torque can cause plugging b Off 58 rpm highest solids through put but wetter solids c Forward not available in high speed mode Start feed pump at minimum speed Increase to desired flow rate Note If operating in the reverse mode the torque value is displayed on the control panel as 0 100 Do not exceed 100 torque or the autoguard will trip and shut the unit down No value is displayed when the back drive selector switch is on the off position 8 Take samples of the li
92. s ur arc uncertain abuul any steterncnt or prosedure or if you require additional intormation please contact your Baldo distributor or an Authorized Baldor Service Center General n prmation 1 3 120 Receiving Storage Unpacking Handling 1 4 General Infonnatio1 Each Baldor Electric Motor is thoroughly tested at the lactony and carefully packaged for shipment When you receive your motor there are several things you should do immediately 1 Observe the condition of the shipping container and report any damage immediately the commercial carrier that delivered your mator 2 Verify that che part number tre motor you received is the same as the part number listed on your purchase order If the motor is nat put inta service immeciately the motor must be stored in a clean dry And warm acation Sevsral precautionary steps must be pe formed ta avoid motor damage during storage 1 Use a Megger periodically to ensure that the integrity of tae wirding insulation has been maintained Record the Megger readings Immediately investigate any significant drop in insulation resistance Do not lubricate bearings during storage Motor bearings are packed with grease factory Excassive grease can damage insulation quality Rolale motor shafl al least 10 lums every two months during slorage more freqvently if possible This will prevenl bearing damage due Lo slorage 4 Ifthe storage location is damp or hum
93. separale conduit box located cn the side of the matcr housing Lnless otherwise specified 3 4 Maintenance amp Troubleshooting MN400 129 Symptom Motor will not start Excessive humming Molor Over Healing Bearing Over I leating Vibratiar Growling ar whining MN400 Table 3 5 Troubleshooting Chart Possible Causes Usually caused by line trouble such as single phasing al the slarter High Voltage Eccentric air gan Overload Compare aclual amps measured with nameplats rating Single Phasing Improper ventilalion Untalanced voltage Rator rubbing on stator Over voltage or under voltage Open stator winding Grounded wirding Improper connections Misalignrr ent Excessive belt tension Excessive end thrust xcessive yreass ir bearing nsufficient grease in bearing Dirt in bsarinc Misalignrr ent Rubhing between rotating parts and stationary parts Ralor aul of balance Resonance Foreign rralerial air gap ventilation openings hearing Possible Solutions Check source af power Check overlvads fuses conlrols elc Check input line connections Have mctor serviced at local Baldar service center Locale and remove Source of excessive friclion in moter or mad Reduce load or replace with motor of greater capacity Check current at I phases should be approximately equal to isolate and correct the problem Check exlemial cooling lar lo be sure air is
94. t intended to include a comprehensive listing of all details for all procedures required for installation operation and meintenance This manual describes general guidelines that apply to most ot the motor products shipped by Baldor H you have a question about a procedure or are uncertain about any defail Da Not Proceed Please contact your Baldor distributor for mora information or clarification Before you install operate or perfonn maintenance become familiar with the following NEMA Publication MG 2 Safety Standard for Construction and guide for Ssleclion Ins allalion and Use of Eleclr c Molors and Gsne a ors The National Electrical Code Local codes and Practices Limited Warranty 1 Baldor Electric motors are warranted fcr a period of one 11 year from date of shipment from the factary or factory warehcuse against dafects in material and war manship Ta allow for stoc ing and or fabrication period and ta provide one year of actual service the warranty period is extended for an additional period of six B months total of eighteen 18 months froni the original date of shipment froni the factory or factory warehouse stock In no case will the warranty period be extended tor a longer period Baldor extends this limited warranty to each buyer of tae electric motor far the purpose of resale and to the original purchaser for use 2 Baldor will at 16 optlon repalr or replace motor which falls due to defects In material or
95. the gear box end front of centrifuge looking inboard The Back Drive should rotate clockwise when viewed from the Gearbox end in the forward run direction The drive group enclosure guard the gearbox shroud and the back drive belt guard must be secured in place Check to see that the centrifuge unit is clear of rags ropes wires or any other material which could catch or snag rotating parts All bolts and capscrews must be engaged per recommended torque requirements shown in Charts 1 and 2 at the end of this section All rings and seals should be in good condition and securely fastened The centrifuge cover should be tightly secured The frame bolts should be fully tightened Check all lubrication points See Lubrication Section Verify that all seal fittings at explosion proof motor and control are sealed with CHICO X Fiber and or sealing compound The drive belt should be checked for correct tension Caution Over tightening belts can damage the fluid coupling See Figure 1 at the end of this list Electrical grounding straps must be secured in place where required Maximum Speed specific gravity or pressure indicated on the centrifuge name plate is not to be exceeded No work is to be performed on the electrical system unless the power is shut off Check the line voltage on initial start up to ascertain that the voltage applied to the motor controller is the same voltage that the motor is wired for 18
96. the hub or the outer diameter of the adapter Apply good quality lithium grease to all grease points A general inspection of the unit should also be performed at this time checking that all fasteners are tight etc For unusual conditions such as a very high RPM high ambient temperatures high vibration or dirty environment more frequent or special maintenance may be required 107 It is good practice when other equipment in the drive train is down for service to make general inspection of the torque limiter Check for tightness of the torque limiter on its shaft tightness of the sprocket etc and check for appearance of adequate lubrication This may be done by backing off the adjusting nut and separating the plate set to permit viewing the interior components If there is any indication that further servicing may be desirable the torque limiter should be disassembled and inspected as described above under DISASSEMBLY PROCEDURE NOTE If after the drive has been in operation for some time and the torque limiter suddenly starts disengaging for no apparent reason check to see whether something in the drive train or driven machine such as normal wear a bad bearing damaged sprocket misalignment change in machine duty etc may be the cause of the problem visual inspection of the drive and slide plate is then recommended Follow disassembly procedure above Note that although ball path between the ball seats should normally
97. tors improperly secured Flexible piping not used at machine connections Conveyor flights plugged with solids Conveyor dead chamber filled with product Loose fasteners or components Gearbox misaligned Pillow block or conveyor bearings damaged Check and tighten any loose bolts Repipe Flush or clean as required Remove feed tube amp flush conveyor with high pressure Tighten Recheck runout Install new bearings 87 Problem Possible Cause Remedy Poor separation Solids too wet Solids discharge too dry Incorrect Pond Depth Feed rate too high Feed viscosity too high Conveyor speed too fast G force too low Pond depth too high Feed rate too high Conveyor speed too slow Pond depth too low Change setting Repair or replace Lower diferential speed Increase G force Lower pond depth Lower feed rate Increase conveyor speed Increase pond depth 88 Hed SECTION 10 ELEVATIONS DIMENSIONS amp WEIGHTS 89 PLANETARY GEARBOX FRONT PILLOW BLK ASSY REAR PILLOW BLK ASSY OUTLINE GEARBOX BELT GUARD SLURRY INLET 11 2 NPT 20 13 16 GT TO Oo LIQUIDS OUTLET SOLIDS OUTLET 47 7 6 42 7 16 34 5 8 UNLESS HOTED OTHERM9E ALL OWS ARE IN NCHES PROPRETARY FICHTS ARE IN THE INFORMATION DISDUISED HEREN NEITHER THS DOCUNENT HOR THE NFORNATKIN DISCLOSED HEREN SHALL BE REPROD
98. uantity of oil 5 Wipe off any spilled oil Run the unit briefly and check for leaks 6 Dismantling We recommend that the gearbox not be dismantled because special handling procedures are required for maintenance of these units clean room environment and thorough knowledge of clearances and fits are required With the exception of replacement of the first stage pinion bearing and seal the gearbox should be returned to its manufacturer for inspection and damage and or wear assessment An incorrectly reassembled planetary gearbox could cause major damage to the unit the centrifuge and could pose a potentially lethal danger to operating personnel 62 7 Assembly 1 Use care to prevent any foreign debris from entering the gearbox 2 Secure capscrews using proper torque 1 4 20 Capscrews 150 in Ibs 5 16 18 Capscrews 305 in Ibs 2 Change O Ring whenever the gearbox is opened up 63 TABLE 1 RECOMMENDED OIL PRODUCT ROYAL PURPLE SYNERGY GEAR OIL ISO GRADE 150 SAE 90 AGMA GR 4EP 64 HUTCHISON HAYES INTERNATIONAL INC 715 455 9600 FAX 713 455 7753 HOUSTON TEXAS TOLERANCES UNLESS NOTED OTHERWISE ALL DIM S ARE IN INCHES FRACTIONAL DIM S 41 64 DECIMAL DIM S A 010 4 005 001 FINISH ALL OVER 32 63 MICRO IN DYNASYNC PULLEY P N 4790 1 375 DIA SHAFT P N 4141 DODGE BUSHING P N 4789 DYNA SYNC BELT 2 WIDE P N 4781 DODGE BUSHING
99. ug tightly after filling Use Teflon tape The required oil quantity is approximately one 1 gallon 4 On initial operation check the direction of rotation of the gearbox It should be counter clockwise as you stand at the gearbox end facing the centrifuge 61 5 If excessive temperature on the casing above 180 deg F occurs stop the centrifuge and check for the cause 6 If excessive noise and or vibration occur suddenly stop the centrifuge and check for the cause 4 Lubrication 1 Gears are lubricated by oil bath 2 Refer to Table 1 for recommended lubricating product 3 Never add a different brand of lubricating oil to the existing supply Mixing oil must be strictly avoided 4 When changing brands flush gear unit thoroughly before filling 5 Maintenance 1 Oil Change Intervals First change after 500 hours of operation then every six 6 months or 2500 operating hours whichever comes first 2 Any unusually severe operating conditions such as rapid ambient temperature fluctuations or the presence of corrosive gases in the operating area could affect the life and characteristics of the lubricating product Contact the manufacturing company for recommendations to follow 3 For extended storage of the GB 53 30 days or longer fill the unit with a corrosion preventive oil and run for a short period after flushing 4 Restarting the Unit Empty and flush the gearbox Refill with the correct type and q
100. use caution Avoid sharp edges and close areas where fingers may be cut or trapped example pulleys D PUMP 1 If positive displacement pumps are used in the process be sure discharge line is unobstructed before starting the pump 2 In plants using any type of grinder with the discharge directly connected to a pump be sure that the pump is in operation before putting any product into the grinder 3 Do not run a positive displacement pump dry E EXPLOSION PROOF EQUIPMENT l Do not operate equipment driven by an explosion proof motor and control until all seal fittings are properly sealed with recommended fiber or compound and tagged Never use abrasive material or a file to remove corrosion from explosion proof equipment Cover screws and bolts used to hold explosion proof joints together must always be tight and only of the type and material recommended by the manufacturer 10 F MOTOR 1 2 3 Do not neglect to check that the line voltage applied to the motor controller is the same voltage for which the motor is wired Always follow motor manufacturer s specifications on bearing lubrication Do not attempt to operate a motor that is overheated due to frequent starts and stops Allow the motor to cool to ambient temperature as designated on the motor nameplate before each restart G ELECTRICAL General l 2 Install and ground all equipment permanent and portable in accordance with requireme
101. uthorities for recommendations concerning safety Use NIOSH approved breathing apparatus when working with toxic or hazardous materials or with materials that reduce the oxygen concentration in the air such as carbon dioxide K COMBUSTIBLE PRODUCTS l If combustible products are used as part of the process or as cleaning products become thoroughly familiar with the safety precautions necessary to handle the product Follow all recommendations to avoid personal injury or property damage that could be caused by fire or explosion L PRESSURE VESSELS I Vessels operating under internal pressure should be maintained and inspected in accordance with the manufacturer instructions and or applicable local or state codes If corrosion or erosion is expected frequency of inspection should be increased Qualified personnel should make all necessary repairs Vessels operating under internal pressure should be provided with a safety device to relieve excess pressure in accordance with the Unfired Pressure Vessels Code Safety devices should be in good operating condition at all times It is recommended that they be inspected and tested frequently and maintained in accordance with manufacturer instructions and or applicable local and state codes 12 4 If any repair on safety device is necessary return it to the manufacturer Inexperienced personnel should never attempt repair Any adjustment should be made according to the recommendatio
102. water prevents sludge and wear found in wet gear boxes such as cooling tower gear boxes SYNERGY employs unique dense high molecular weight synthetic cushioning additive to prevent fatigue failure in gears subjected to sudden loads SYNERGY S exclusive performance advantages Severe Service performs under loads where other E P gear oils fail Lower Coefficient of Friction saves energy and reduces temperatures High Temperature Performance eliminates harmful deposits extends oil drains Cushioning Molecules reduces fatigue failures in bearings and gears Environmentally Safe non toxic as all components are on TSCA s approved list and fully comply with all OSHA and EPA guidelines Synslide TM proprietary slippery tenacious ultra tough synthetic film Prevents Corrosion protects both ferrous and non ferrous metals during operation and shut down Water Separation complete separation of oil and water to prevent emulsion Compatibility 100 compatible with both mineral and synthetic gear oils Customer Benefits Saves Money Saves energy extends gear box life and reduces down time Multi Applications one oil for all gears spur helial herringbone worm etc Multi Conditions for all speeds all horsepower all loads and all temperatures Superior Lubrication smoother quieter cooler more efficient gear boxes Recommended For Gear Boxes regardl
103. workmanship during the warranty period if a lhe purchaser presents Ihe defaclive molar al or ships il orapaid lo the Baldor plant Fort Smith Arkansas ar one of tre Baldor Authorized Service Centers and b the purchaser gives written notification conceming the motor and the claimed delect including the date purchased the task performed by the Baldor motor and the problem encountered 3 Baldor will nct pay the cost of rericval of any electric motor from any cqvipment the cost ef delivery to Fort Smith Arkansas or a Baldor Authorized Service Center or the cost of any incidental or consequential damages resulting from the slaimed defec s Some states da not allow the exclusion or limitation of incidental or consequential damages so the above amp xclisinn may not app y tn you Any implied warranty given by laws shall he limited to the duration of the warranty pericd hereunde Some states do not allow limitations on how long an implied warranly lasts so above limilalion may apply lo you 4 Baldor Aulhorized Service Centers when convinced lo their salisfaclipn lhal Baldor motor developed defects in ma erial or workmansh p w hin Ihe warranly period are aulhorized Lo proceed wilh Ihe required repairs Lo fulfill Baldor s warranty when the cost of suca repairs to be paid by Ba dor does not exceed Baldor s warranty repair allowance Baldor will ot pay overtime premium repair charges without prior written authorization 5 T

5500 BrakeSmart™ Operations Manual

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5500 BrakeSmart&trade; Operations Manual

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5500 BrakeSmart™ Operations Manual