Contents
Safety warnings ...1
Icons used and danger warnings ... 1
Suitable use of the particle classifier ... 2
General safety warnings ... 2
Safety in handling and storage ... 3
Technical specifications of the classifier ... 4
Description of the particle classifier ...6
Operating principle of the particle classifier ... 9
Vibrations ... 11
Classifier options ... 13
Classifiers with cooling system ... 14
Transport and assembly ...16
Transport ... 16
Work prior to assembly ... 18
Tools necessary for assembly, disassembly and maintenance ... 18
Assembly ... 19
Work after assembly ... 22
Start-up ...23
Commissioning ... 23
Ignition period ... 23
Operation ...25
Commissioning a plant ... 25
Settings during operation ... 26
Maintenance ...27
Standard maintenance ... 27
Special maintenance (for ceramic particle classifiers only) ... 29
Removing the rotor ... 30
Assembling the rotor ... 33
Tightening the trapezoidal belts ... 33
Spare parts lists ... 34
Lubrication ... 36
Fault search ...37
Appendices ...38
Electrical appendix ... 38
Contact details
Contact persons: Sergio Alegre and Javier Peña
Manufacturer / Technical Service: ECUTEC Barcelona SL
Address: Gran Vía de les Corts Catalanes 701, 3er 1ª A
Postcode: 08013 Barcelona SPAIN
Tel. (+34) 932 477 700
1. Safety warnings
1.1 Icons used and danger warnings
The terms DANGER, ATTENTION, CAUTION and WARNING indicate specific dangers or special information that requires particular attention. The term NOTE refers to information that does not involve danger to persons.
Stickers: Electric risk, mechanical risk, earth
¬
DANGERIndicates danger of death and personal injury if the necessary precautions are not taken.¬
ATTENTIONIndicates that severe personal injury can occur if the necessaryprecautions are not taken.
¬
CAUTIONIndicates that minor personal injury can occur if the necessaryprecautions are not taken.
¬
WARNINGIndicates that exclusively material damage can occur if the necessaryprecautions are not taken.
NOTE
Notes contain relevant technical information that may not be obvious to a specialist technician. Follow the points indicated exactly to avoid damage to the machine.
ELECTRICAL RISK
The electrical risk sticker is used to indicate zones and / or elements of the machine which present a risk of electrical shock.
MECHANICAL RISK
The mechanical risk sticker is used to indicate zones and/or elements of the machine that present risk of physical injury, such as being trapped, hit or cut.
EARTH
The earth sticker is used to indicate a valid and effective earth at one point in the machinery.
1.2 Suitable use of the particle classifier
The objective of particle classifier ALPHA 700 is the classification of pulverised products for the mining, chemistry or pharmaceutical industries where these materials are used, for example, to produce paints or plastics. The classifier can be used to classify fine materials in a range between 7μm and 40μm.
The raw material may be either minerals, pigments, foodstuffs or ground chemical materials with a particle size smaller than 2 mm.
To guarantee optimum classification, the starting material must be dry with a degree of moisture lower than 0.5%. If the moisture level is higher than 0.5% you must set up a device for drying the starting material.
During assembly, disassembly, commissioning, operation and
maintenance, the particle classifier must only be handled by qualified staff1.
1.3 General safety warnings
Changes of any kind to any of the machine's parts are not permitted and may be grounds for the termination of the machine's warranty.
Adherence to occupational health and safety guidelines is especially important for low and medium voltage systems.
The assembly, operation and maintenance, the mechanical and electrical installations, the transport, construction and commissioning must be performed or supervised by qualified staff1 with the adequate specialist knowledge.
The particle classifier must be only be started up and operated if it has been thoroughly checked mechanically and if all the doors and inspection holes are closed.
Staff should check that the size of the particles in the ground raw material does not exceed 2 mm and that its degree of humidity is no greater than 0.5%. The staff must use personal protection equipment such as hard hats, gloves, ear protection, etc.
It is important to avoid operations that jeopardise the health of staff or the safety of the particle classifier.
1. Qualified staff are those who, based on their training, experience and knowledge of the applicable norms, standards,
¬
ATTENTION
Machine in operation. Unforeseeable damage in the event of an emergency.
It is recommended that emergency stops are installed in the necessary places, in order to stop the machine in the event of an emergency.
¬
ATTENTION
Working at a height. Falls and blows.
The user must take into account the risks of working at a height with relation to the assembly, use and maintenance of equipment.
Unauthorised alterations and the reproduction of the particle classifier are prohibited.
The instruction manual must always be kept in an easily accessible place for future consultation.
The plant safety officer must guarantee that the staff can use this document regularly.
1.4 Safety in handling and storage
The products supplied are indicated in the packing list. Immediately on receiving the elements, check that all the products have been delivered. When you manipulate the ECUTEC products, ensure that the lifting and transport equipment can withstand the loads.
There are different ways of packaging, depending on the dimensions of the classifier and the method of transport.
The symbols marked on the packaging indicate how to proceed. They have the following meanings:
The classifier must be stored in a dry place, with no vibrations. The different parts cannot be stored one on top of another.
If the machinery must be stored outdoors, it must be carefully covered and protected from moisture.
Unless otherwise stated in the contract, the unit must not be exposed to extreme environmental factors such as chemical products, high pollution, moisture or temperatures greater than 0ºC/ 32 F or 20ºC/ 68 F.
Do not use the eyebolts (DIN 580) of the motor to manipulate the machine.
NOTEThe classifier is delivered pre-assembled and with grease in thebearings. This way up Fragile Keep dry Keep cool Centre of gravity Use no hand hook Attach here
1.5 Technical specifications of the classifier
Serial number
0173
Customer Name Moengo Minerals Address Paramaribo/Surinam Project 09.008
Type of machine
ALPHA 700
Design/operation data
Length 2257 mm Width 1786 mm Height 4200 mm Machine weight 3300 kg Rotor weight 730 kgRotor speed (maximum
working speed) 1200 rpm
Motor pulley (diameter) 315 mm Machine pulley (diameter) 355 mm
Relationship 0.88
Transmission belt length 3550 mm
Upper bearing type SKF 23024 CC W33 C3 Lower bearing type SKF 23024 CC W 33 C3 Grease type Klueber ISOFLEX NBU 15
Electric motor data
Rated power 37 kW
Speed (maximum working) 1360 rpm
Voltage 440 V
Frequency (maxim. working) 46 Hz
Protection type IP55 F
Size 225S IMB3 Protection against explosion No Thermal resistance 1PTC Supplementary cooling system Yes Motor weight 300 kg
Special design
Ceramic rotor No Ceramic material No Ceramic Linning Al2O3 Polyurethane coating No Rust-proof No Hardening process No Monitoring system No
Process data
Air flo 26.350 m3/h Feed rate 7.2 T/hInstallation
Grip points 4 F. STA. (N) F. DYN: (N) HORZ. VERT. F1 8250 1250 625 F2 8250 1250 625 F3 8250 1250 625 F4 8250 1250 625Analogue signals
Speed sensor 10 - 30 V PNPSafety system 48 - 240 V AC/DC
Digital outputs
Sensor PT100 4 - 20 mA 3 wires
Machine vibration sensor No Bearing condition sensor No
2. Description of the particle classifier
The ALPHA 700 has been designed for the classification of pulverised products and thus can obtain granulometric distribution suitable for the various markets to which you can direct the final product.
The range of products to classify is very broad, such as minerals, pigments and foodstuffs.
The classifier is comprised of 3 bodies. A first body containing the classifier rotor.
Fig. 1 First body of classifier
A second body with the fines output.
Fig. 2 Second body of classifier
1 Motor 2 Bearings support
Fig. 3 Third body of classifier
The first body contains the support for the bearings, which are only on one side of the rotor, the upper part of the classifier.
The shaft is made of high-quality steel and welded to the rotor, generating a rigid unit. The shaft rests on a pair of ball bearings that have been designed to work uninterrupted for 10,000 hours.
Fig. 4 Special join between axis and rotor
The casing of the bearings has been designed with connections for the periodic greasing. In addition to containing radial seals that do not let contamination into the bearings and, moreover, form a barrier to keep the grease in contact with the bearings.
To seal between the rotor and the stator correctly, an air seal plus a labyrinth ring have been designed, which impede coarse material getting into the rotor.
The power transmission system is performed by the upper part of the machine and by means of trapezoidal belts.
All the machines are delivered with temperature probes to control the temperature of the bearings.
1 Coarse material output 2 Feed 3 Level sensor connection
NOTEIn some special designs, the connection between the shaft and rotor can be made using a hexagonal bolt.In addition, the machine may also be supplied with probes for vibrations and the condition of the bearings.
There are different versions of the machine according to the requirements, some examples are:
– Ceramic rotor – Polyamide rotor – Ceramic-coated casing – Polyurethane-coated casing – Stainless steel
– System for monitoring the machine's bearings and vibrations
The particle classifier may be supplied as part of the whole plant assembly or as a single unit.
Example of the assembly of a classifier in a plant.
1 2 3 4 6 7 8 9
1 Flow regulation valve 2 Feed silo 3 Rotary valve for feed 4 Particle classifier 5 Rotary valve for coarse material output 6 Filter
7 Rotary valve for fines output 8 Butterfly valve 9 Suction fan
If the particle classifier has been delivered as a single part, the fines output valve and the components that make up the plant are not supplied.
2.1 Operating principle of the particle classifier
For optimum classification, the starting material must be ground and dry with a maximum degree of moisture of 0.5%.
Fig. 6 Operating principle
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WARNINGInternal damage. Machine breakage.Do not allow a particle size greater than 2 mm.
NOTE
– The staff must check the size of the particles before operation. – If the moisture content is higher than 0.5% you must set up a device
for drying the starting material.
1 2
3
4
1 Starting material input 2 Separation area 3 Fine material output 4 Coarse material output
The machine can be fed in two ways, mixed with the suction air or through the upper part of the machine.
The feed type configuration depends on the quantity to feed and the product to classify (see figure 6).
If it enters through the upper part, the product falls towards the machine due to gravity. In the two types of feed it is absolutely necessary to use a rotary valve to be able to regulate the dosage and generate the correct sealing without interference from outside.
The Alpha classifier is connected to a fan that causes a suction flow that passes through the rotor. Inside the machine, the product is displaced towards the rotor due to the suction current.
Once the product reaches the height of the rotor, it is displaced at high speed in a cyclonic movement and thus the coarser particles are expelled by a filter located at the end of the circuit.
The coarse product is collected by the lower casing and is expelled from the machine by a rotary valve.
The general rules to be able to configure the machine are the following: – At higher speeds, the cut point is closer and, consequently, you will
achieve a finer product but in less quantity.
– With a greater air flow, the cut point is not as close and, as such, you will obtain a coarser product and the production quantity will increase. – With a greater feed, the cut point is not as close and, as such, you will
obtain a coarser product and the production quantity will increase. The minimum components to be able to produce with this type of machinery are the following:
– Rotary valve for feed with a well-sealed circuit and a good dosage. – Rotary valve for coarse material output with a well-sealed circuit. – Suction fan.
Fig. 7 Segundo cuerpo del clasificador
2.2 Vibrations
Knowledge of vibrations is one of the best methods for determining the condition of a machine. For this reason it is recommended to use an ongoing monitoring system. In some machines such as those with the ceramic rotor, this element is absolutely necessary. In these cases, due to the safety of the machinery and the staff, it must not be operated without analysing the vibrations.
1 Upper part feed 2 Lower part feed
¬
WARNING
Internal damage. Machine breakage.
The system must be connected to the electric panel so it can cut the power supply when the alarm values are exceeded.
NOTETo avoid minimum signal loss, you should not use cables of more than 3 metres long, from the module to the measurement point.Fig. 8 Vibration sensor
When you start up the machine for the first time (see section 4) you must check the vibrations to identify the tensions, resonances and faults of assembly before any major problem occurs.
The normal vibration value must be set. The best way to calculate this value from the bearings is in the horizontal direction.
1 Machine vibrations probe 2 Bearings condition probe
NOTEThe vibrations measured out of the frequency range 3 to 1000 Hz must not be considered vibrations coming from the machine.Intensity (mm/s) Condition
<1.8 Good operation value.
1,8 - 4,5 Operation value in which the machine may work safely.
4,5 - 11
Under these conditions the machine may be used temporarily for short periods, given that
irreversible damage (for example in the bearings) is possible. “Short periods” means a few days and less than a week.
>11 These working conditions must be avoided at all times, given that parts of the machine may suffer irreversible damage in minutes, hours or days.
¬
WARNING
Internal damage. Machine breakage.
Vibration intensity must not exceed 11 mm/s. Should it do so, shut down the machine and contact the manufacturer.
NOTEThe testing of the machine must be more thorough if the vibration intensity in the bearings exceeds 4.5 mm/s.A very large increase in vibrations in a very short period may mean it is off-balance, so we recommend you analyse the condition of the rotor and, if possible, rebalance.
2.3 Classifier options
Rotor and ceramic coatings
Some materials must be processed with ceramic parts due to their high abrasiveness. For these cases, ECUTEC supplies the machines with ceramic components that require more rigorous care than the steel components. – Ceramic is brittle so it should never be hit.
– During the rotor assembly process, you must take extreme care that the rotor does not come into contact with the other parts.
– Sharp changes in temperature are not recommendable for the ceramic parts.
– The maintenance and revisions must be increased with respect to the steel parts (see the maintenance list in point 6.3).
– Vibrations must also be strictly monitored. Please contact ECUTEC staff regarding any queries you may have.
– Due to the abrasive power of these products, the machine must be balanced more frequently.
– In addition, we recommend you have a replacement ceramic rotor due to its fragility, so the interruption of the production process is kept to a minimum.
– All the surface coated with ceramic must be checked and repaired with Epoxy cement.
Polyurethane parts
These are used for abrasive materials with low abrasiveness. The treatments are the following:
– Do not clean or use solvents. – Do not allow high temperatures.
Motor
In some applications, as they work at a low rpm, it is necessary to connect a supplementary fan to cool the motor. You must take into consideration: – This must be switched on at the same time as the motor.
– The machine may never function if this fan is off. – It must remain free of dust and dirt.
¬
WARNINGInternal damage. Machine breakage.2.4 Classifiers with cooling system
Introduction
Depending on the product to be treated and the working and environmental conditions, certain classifiers may be supplied with an air-oil cooling system for the bearing casing. The cooling circuit system will be comprised of a 100-litre oil tank, a suction pump, an air cooler and the flexible hoses needed for the connection to the various elements. All the screwed connections will use 1" BSP screws.
Fig. 9 Cooling system
1
2 3
4
5
1 Oil discharge from the bearing
casing 2 Oil injection into the bearing casing
3 Oil collector 4 Air cooler pump 5 Oil collector/pump suction discharge
Operation of the cooling system
There are different ways to operate the cooling system, depending on the complexity required.
Option 1- Circuit always in operation: Cooling of the bearings is forced regardless of their temperature. During the start-up operation the cooling system connects in parallel with the classifier motor.
Option 2 - Circuit regulated by the temperature of the bearings: The
temperature of the bearings is compared to a pre-set setpoint and when the temperature exceeds the setpoint the cooling system connects. The cooling system continues to operate in this way until a minimum disconnection temperature value is reached.
Type of oil
ECUTEC recommends the use of KLUBER AIRPRESS 15 oil, which has obtained the best results in the tests performed on the machinery. This oil has been designed for most of the industry, but in the event of special requirements please contact our staff before performing start-up.
3. Transport and assembly
3.1 Transport
Due to the weight of the particle classifier and its respective parts, the transport and assembly imply significant risks. For this reason, all the individual parts that cannot be moved manually due to their weight or shape are provided with fixing elements.
Lifting the motor casing part
¬
ATTENTION
Falling objects. Risk of crushing and blows.
– Due to the weight, only use suitable lifting machinery that has been officially checked and approved for transport and assembly.
Lifting the fines output part
3.2 Work prior to assembly
All the brackets must be cleaned of the accumulated grease and dirt. The use of an industrial solvent is recommended.
Always use fasteners of 8.8 quality or higher. All the bolts must be fixed with Loctite 2701.
The tightening torques are indicated in the following table.
3.3 Tools necessary for assembly, disassembly and maintenance
– Socket wrenches for hexagon screws between M8 and M24 – Double ended spanners between M8 and M24
– Set of spanners for bolts DIN 912
– Extractor for bearings with outer diameter of 100 mm, inner diameter of 50 mm
– Grease pump – Rubber mallet
Metric
Quality of fastener
8.8
10.9
Torque Nm
M5 6 8,5 M6 10 14 M8 25 35 M10 49 69 M12 86 120 M14 135 190 M16 210 295 M16x10.5 225 315 M18x10.5 325 460 M20 410 580 M24 710 1000 M24x2 780 1100 M30 1450 2000 M30x2 1600 2250 M36 2450 3560 M36x3 2650 M42 4070 5720 M48 6140 8640 M48x3 62133.4 Assembly
The three assemblies of the particle classifier may be pre-assembled on the ground or assembled directly at the operation site.
In general, the machine shall be delivered in three parts, which must be assembled before their final positioning.
The first step is to place the body containing the fines output on a base that is stable and capable of resisting the weight of the machine.
Assembly
Add and spread silicon or polyurethane on the flange to seal the inside of the machine from the outside. For example Loctite 5910.
Orient and place the casing containing the rotor and the bearing support. The orientation depends on the customer's needs and it has different positions.
NOTE
– The transporting of each machine element must only be done by personnel authorised to handle the corresponding transport devices. – The particles classifier must be installed on a horizontal, level surface
Add and spread silicon or polyurethane on the flange that joins the seal with the closure of the fines output.
Fig. 10 Assembly 1: Fitting the motor casing
Once the two parts are in the correct position, use the following components to fix the two parts:
o Hexagonal bolt M16x50 DIN 933 (16 units) o Spring washer 16 DIN 127 (32 units) o Hexagon nut (24 units)
To do the following step, you must open the door and place the following elements through the lower part of the sealing flange:
o Hexagonal bolt M16x30 DIN 933 (8 units) o Spring washer 16 DIN 127 (8 units)
1 Area to apply silicon 2 Hexagonal bolt M16x50
DIN 933
3 Spring washer 12 DIN 127 4 Hexagon nut 5 Sealing flange
Assembly 2
Fig. 11 Assembly 2: Fitting the motor casing
Then place the casing containing the coarse material output and, as with the others, add silicon and the corresponding fasteners:
o Hexagonal bolt M16x45 DIN 933 (28 units) o Spring washer 16 DIN 127 (56 units) o Hexagon nut (28 units)
Once assembled, place the temperature probes if they are not installed and those of vibrations if they have been supplied (optional).
1 Area to apply silicon 2 Hexagonal bolt M16x45
DIN 933
3.5 Work after assembly
Once all the parts are joined and correctly tightened, you must check the tolerance between the moving and fixed parts. To do this, you must open the door and verify that the space between the rotor and the seal is 0.5 - 1.2 mm.
Fig. 12 Labyrinth seal
4. Start-up
4.1 Commissioning
Before commissioning the classifier for the first time you have to check the following:
• Check the condition of the rotor (the rotor turns without problems, the fins are OK).
• Check the distance between the rotor and the labyrinth seal (the space between the rotor and labyrinth seal must be between 0.5 and 1.2 mm). • Check the belts.
• Check the lubrication.
4.2 Ignition period
ECUTEC recommends starting the machine by increasing the revolutions in 2 or 3 steps up to the maximum number of revolutions. This operation should take approximately 6 hours.
During commissioning or after changing the bearings, you must check the following points:
– Check the power.
– Check that it turns gently.
¬
WARNING
Internal and/or external damage. Machine breakage.
– The commissioning of the machine should be carried out by ECUTEC personnel. If the client decides to dispense with ECUTEC staff, the company can decide to cancel the warranty and all personal harm or material damage shall be the client's responsibility.
NOTE
During the commissioning of the machine, the 2 lubrication points in the bearings must be greased with approximately 15 g of grease (ISOFLEX NBU 15 from KLÜBER).
– Verify the rotation direction.
Fig. 13 Rotation direction
– Verify the vibrations and that the temperatures do not exceed the standard values (max. 95ºC)
5. Operation
5.1 Commissioning a plant
Fig. 14 Commissioning a plant
To commission a plant the following order must be respected: 1. Turn on the classifier cooling fan and motor.
2. Turn on the valves for coarse and fine output to empty the respective silos.
3. Turn on the suction fan.
4. Open the butterfly valve to create a circulation of air between the classifier and the filter.
5. Turn on the rotary valve for feed.
6. Adjust the input butterfly valve to regulate the air flow.
1 2 3 4 6 7 8 9
1 Flow regulation valve 2 Feed silo 3 Rotary valve for feed 4 Particle classifier 5 Rotary valve for coarse material output 6 Filter
7 Rotary valve for fines output 8 Butterfly valve 9 Suction fan
5.2 Settings during operation
The general rules to be able to configure the machine are the following: – At higher speeds, the cut point is closer and, as such, you will obtain a
finer product but with less quantity.
– With a greater air flow, the cut point is less close and, as such, you will obtain a coarser product and production will increase.
– With a greater feed, the cut point is less close and, as such, you will obtain a coarser product and production will increase.
¬
DANGER
Machine in movement. Serious injury or death.
– Keep limbs away from rotating elements such as fans or shafts. – The maximum speed indicated in the table of characteristics is the
maximum working speed. This speed should not be exceeded under any circumstances due to the high risk of material damage or personal injury, including risk of death.
– If the client exceeds this working speed, ECUTEC may decide to terminate the warranty of the machine and all personal harm or material damage shall be the client's responsibility.
– Before starting up the machine, verify that the frequency adjuster has been limited so the machine cannot exceed the maximum rotation speed.
6. Maintenance
6.1 Standard maintenance
The following inspections and maintenance work must be performed regularly.
Lubrication
It is advisable to install a central greasing unit, for example Vogel type. ECUTEC tests the machines with Isoflex NBU 15 grease from Klueber so we recommend you use this grease. Alternatively, some equivalents are listed at the end of section 6.7.
Using unsuitable greases or applying grease excessively can cause high temperatures, which may lead to the shaft dilating excessively and therefore increasing the probability of breakage.
You must consider the ambient conditions to be able to increase or decrease the periods between lubrications. An increase in temperature at constant operating conditions may indicate insufficient grease.
¬
DANGER
Electrocution and/or cuts on limbs. Serious injury or death.
– Maintenance tasks may only be carried out on machines which have been disconnected from the mains or with the power supply
sectioned off.
– Do not proceed to make any adjustments or cable connections with the power supply switched on.
– Use lockout devices and the corresponding warnings signs in order to prevent the machine from being started up accidentally.
– If there is more than one power source, ensure that they are all switched off.
– Make sure fans and moving parts have come to a full stop before starting maintenance procedures.
– Regular reviews must be carried out on the status of the earth to ensure its integrity. Repair if not in optimum condition.
¬
CAUTION
Blows and cuts on limbs. Minor injuries.
– If there are sharp, burred or panelled pieces, use protective gloves. – If there are blocked elements, use the proper tools and lubricants to
release these.
NOTE
– During the commissioning period, it is mandatory to use Isoflex NBU 15 grease. If you wish to use another grease, ECUTEC personnel must confirm its use.
– The warranty may be cancelled in the event of not complying with this requirement.
Bearings and seals
The bearings must be changed regularly. The service life of the bearings may be longer or shorter, depending on the operating conditions (product, humidity, temperature).
The history of measurements from the monitoring system (see section 2.3) must be used as an indicator of the condition of the bearings.
Bearings breaking very frequently may indicate bad greasing, insufficient balancing or defects in some parts.
Whenever you replace bearings, you must change them for the types that ECUTEC indicates and, if possible, from one of the following manufacturers: SKF, NSK or FAG.
Belts
Do not over-tension the belts as this may cause excessive tensions in the shafts of the machines. Excessive temperatures in the bearings may indicate excessive tension.
Labyrinth seal
The labyrinth seal is the element that allows you to keep the area of material to classify separate from the area of fine material. Therefore, an increase in particles in the fine product may indicate this part is excessively worn. In addition, this seal must be kept perfectly clean so it can do its job. The replacement period of this element must be adapted to the characteristics of material to classify.
It is very important to check the distance between the labyrinth seal and the rotor. This must be between 0.5 mm and 1.2 mm.
Bolted joints
The bolted joints must be checked every 10,000 h.
Electric motor
See the manual from the supplier.
NOTEIf coarse particles are found in the labyrinth joint, contact the manufacturer.6.2 Special maintenance (for ceramic particle classifiers only)
Labyrinth seal
In these classifiers, the design of the seal has been modified to lengthen its lifetime. The distance between the rotor must be observed, as with the standard classifiers at between 0.5 and 1.2 mm.
In this case you must check it by placing a material that can be distorted between the rotor and seal. To do so, follow these steps:
– Lift the rotor.
– Place a material that can be deformed (chewing gum, plasticine, etc.). – Lower the rotor and bolt it.
– Unscrew and lift the rotor.
– Finally remove the distorted object and measure its thickness after being distorted.
Condition of the ceramic
At intervals of a certain number of hours, check the condition of the ceramic. If some of the parts that cover the casing have come off, they must replaced with new parts, always using Epoxy adhesives.
The verification must centre, above all, on the points where the most wear occurs, such as union elbows, points where the material hits directly, etc. We recommend the disassembly of the different bodies for this verification.
6.3 Removing the rotor
Step 1 Start the process of dismantling the rotor by removing the belt protector. Once this has been removed, you must loosen the belts and remove them.
Fig. 15 Loosening the belts
Step 2 The remove the tightening bolts of the pulley and move it towards the lower part of the machine using a rubber mallet.
Step 3 Once the pulleys are out, remove the M12x25 bolts and use the elevation screws to lift the rotor.
Step 4 You can use the holes made in the ribs of the bearing support to lift the rotor.
Fig. 16 Extracting the pulleys
To perform the maintenance of the bearings, follow these steps:
Step 1 Remove the screw and washer from the block (pos. 12, pos. 13). Step 2 Remove the inner hexagonal bolts and lock washers
(pos.14 and 15)
Step 3 Remove the cover that protects the bearings (pos. 38.01.10) and the radial seal (pos. 17).
Step 4 Remove the inner hexagonal bolts and washers from the block (pos. 21 and 20)
Step 5 Remove the bearings casing (pos. 38.01.01) using a large extractor. Along with the casing, also remove the upper bearing (pos. 16). Step 6 Remove the spacer between bearings (pos. 38.01.09) and the lower
bearing (pos. 16) using a bearing extractor.
1 Tightening bolts 2 Elevation screws 3 M12x25 bolts
Step 7 Finally remove the radial seal (pos. 24) and lower protective cover (pos. 38.01.04).
Fig. 17 Extracting the bearings
Table of classifier maintenance for non-abrasive materials:
Table of classifier maintenance for abrasive materials:
Parts to check
Change (hours) Revision (hours)
Bearings 10000
Radial seals 10000
Balancing 15000
Tensioning 6000
Labyrinth seal 6000
Distance between rotor and seal 6000
Greasing 10000 500-1000
Parts to check
Change (hours) Revision (hours)
Bearings 10000
Radial seals 10000
Balancing 6000
Tensioning 6000
Labyrinth seal 6000 2500
Distance between rotor and seal 2500
Greasing 10000 500-1000 Ceramic lining 500 Rotor 6000 500 38 38 38 38 38 38 38
6.4 Assembling the rotor
To assemble the motor, follow the same steps in reverse order as for removing it.
6.5 Tightening the trapezoidal belts
Once you have assembled the rotor, you must tension the trapezoidal belts using the tensioning system incorporated next to the motor.
Check the tension of the belts in the following way:
Fig. 18 Tensioning the belts
The tensioning depth is calculated using the formula:
t = a x 0.016
The tensioning force authorised is selected according to the following table depending on the type of section and the diameter of the smallest transmission pulley.
Type of
profile small pulley (mm)Effective Ø of the Tensioning force (N)
SPZ 67 - 95 10 - 15 100 - 140 15 - 20 SPA 100 - 132 20 - 27 140 - 200 28 - 35 SPB 160 - 224 35 - 50 236 - 315 50 - 65 SPC 224 - 355 60 - 90 375 - 560 90 - 120
a Distance between shafts F Tensioning force t Tensioning depth
Example of tightening:
In the machine, you have to measure the distance between shafts of 1,050 mm, and an effective diameter of the small transmission pulley of 250 mm. The name of the belt is SPB.
Using the distance between shafts, calculate the tensioning depth. t= 1,050 mm x 0.016 = 16.8 mm P 17 mm
According to the table, the tensioning force must be between 50 and 65 N. The tension of the belt is optimum when, with a tensioning depth of 17 mm, it has a tensioning force of between 50 and 65 N.
6.6 Spare parts lists
Spare parts list 1
Fig. 19 Spare parts list 1
Pos. Name 38.01.00 Bearings casing 38.01.01 Rotor 38.01.07 Lower protector 38.01.09 Spacer 38.01.10 Upper protector 38.01.11 Upper ring 12 Lock washer 13 Lock washer 38 38 38 38 38 38 38
Tab. 1 List of spare parts table 1
Spare parts list 2
l
Fig. 20 Spare parts list 2
Tab. 2 List of spare parts table 2
38.01.08 Lower ring
15 Lock washer A8 DIN 127 16 Bearing 23024 CC/W33 C3 17 Radial seal CR135x160x15 CRSA1 20 Inner hexagonal bolt DIN 912 M10x25 21 Lock washer A12 DIN 127 23 PT 100 M8x25 (no image) 24 Balance weight (no image) 26 Grease Isoflex NBU 15 (no image) 38.01.02 CD Ceramic rotor (ceramic version only)
Pos. Name 38.00.01 Seal 12 Motor 225M 13 Pulley SPB 17/B d=350 14 Belts DIN 2215 B/17 Lw=3550 15 Pulley SPB 17/B d=315
46 RPM sensor (no image)
59 Ceramic coating (ceramic version only), (no image) 38.00.01 CD Ceramic seal (ceramic version only)
60 Vibration sensor (version with vibration analysis only)
6.7 Lubrication
The machine has two lubrication points. These are in the upper part of the machine. The system is designed to be greased by a manual pump or an automatic greasing system.
If possible, use the grease suggested by KLÜBER. ECUTEC recommends the ISOFLEX NBU-15.
The machine has some holes for releasing the excess grease.
Fig. 21 Location of lubrication holes
.
1 Lubrication holes 2 Release of grease
NOTE
– ECUTEC recommends regreasing the bearings every 500-1000 hours for locations with environmental temperatures between 20 ºC and 35 ºC, in hotter countries the regreasing period must be shorter.
– The machine is delivered with lubricant but it is advisable to regrease after the first 30 hours of running.
– During the commissioning period, it is mandatory to use Isoflex NBU 15 grease. If you wish to use another grease, ECUTEC personnel must confirm its use.
– The warranty may be cancelled in the event of not complying with this requirement.
– When you change the bearings, ECUTEC advises that you check the grease holes and look for possible obstructions.
Product Type
Isoflex NBU-15
Beacon 325 Mobilgrease 28
7. Fault search
Fault Cause Solution
Rotor clogged • particles too large • check the size of the feed • transmission shaft
dilated • monitor the bearings Fine material does
not correspond to the setting
• rotor diameter is not
correct • change the rotor • input butterfly valve
changed • adjust the input butterfly valve • length of seal
between the rotor and the stator too long
• change the labyrinth seal
Length of seal between the rotor and the stator too long
• wear or deformity • change the labyrinth seal
Bearings noisy • bearings broken • change the bearings The rotor shaft
cannot be moved • bearings broken • change the bearings Excessive
temperature in the bearings
• excessive
tensioning • loosen
• bearings damaged • bearing change • insufficient grease • grease
High vibrations • bearings damaged • bearing change • rotor out-of-balance • rebalance
8. Appendices
8.1 Electrical appendix
Components necessary for the functioning of the
machine
• The machine is configured by modifying the speed, for which the use of a frequency converter is required.
• The machine has 3-wire temperature probes to monitor the temperature so it is necessary to install displays for two probes.
• ECUTEC supplies a speed sensor and a display that must be installed in the control panel. The sensor is PNP type.
• The protection systems of the motors must be installed and, depending on the motor, they are delivered with PTC or PT-100.
• During machine maintenance, it must be impossible to operate the machine. Therefore, an emergency stop switch or disconnector switch must be installed at a distance of less than 2 metres from the machine.
Requirements of the control panel
• The classifier must have a frequency converter that allows you to monitor the speed.
• It must have a general ammeter and voltmeter and ones for the classifier and main fan.
• ECUTEC recommends the use of a PLC to check the components. • There must be outputs and inputs for PT-100 temperature probes. • There must be outputs and inputs for vibration probes.
• Below some examples are shown. These do not reflect the real powers, but do reflect the way of operation.
Examples of circuit diagrams
Fig. 22 General electric circuit
L1 L2 L3 +(24VDC) 18(230V) 19(230) PE L1 PE L2 U xKW -xA (POS.x) L3 V 37KW W PE 80 81 AMMETER A P A BREAKING RESIST OR PB READY E0000 COM 83 LOAD INDICA T OR AO1 84 PE +10 BROWN 85 AI1 GREEN 86
POTENTIOMETER FOR VELOCITY
WHITE 87 PE ST A RT +24V LI1 88 89 83 A1 THERMIST OR PROTECTION RELA Y A2 T1 T2 THERMIST OR L1 L2 L3 +(24VDC) 18(230V) 19(230V) PE WHITE BROWN M 3 ~ UCFx FTx 4.1 7.1 4.3 /3.1 /3.1 /3.1 /4.1 /4.1 /4.1 /3.1 QSx NSxxxA 2 4 6 1 3 5 x/5A x/5A R1B R1C R1A 95 96 97 98 13 14 10KOh 10Rounds VW3-A66704 R2A R2C P Ax R1C R1B R1A R2C R2A RRx Xx Ux Vx Wx Mx PCx QPx TIx KMx PE RRx 90 91 Xx 90M ALPHA 700
Fig. 23 Analogue inputs circuit 1 SLOT x UAx -(0V) PE +(24VDC) 24VDC 11 12 15 5 BROWN EA0004 x(I+) IWx SENSOR SPEED 4-20mA (POS.x) 7 PULSE INPUT FREQUENCY VOL TA GE CURRENT CONVER TER
P&F KFU8- FSSP-1.0 ANALOGIC OUTPUT
4-20mA 14 13 4 -x(M-) BROWN EA0005 x(M+) WHITE EA0025 x(S-) IWx PT100 BEARING UP TEMPERA TURE (POS.x) GREEN EA0035 x(M-) BROWN EA0006 x(M+) WHITE EA0026 x(S-) IWx PT100
BEARING DOWN TEMPERA
TURE (POS.x) GREEN EA0036 x(M-) x(I+) IWx x(M-) TERMINAL N§
BIT RACK x/SLOT
x
IWx...x ANALOGICS INPUTS
202 201 200 X EA0006M EA0036 EA0026 EA0026 EA0005M EA0035 EA0025 EA0025 X X BDx s +-BTx BTx 8.8/ 7.8/
Fig. 24 Analogue inputs circuit 2 SLOT x 6.8/ /5.8 /5.8 /5.8 /6.8 /6.8 /6.8 /6.8 /6.8 /6.8 /9.1 PE EA0000 BROWN EA0000 x(I+) IWx CONTROL VIBRA TION W A RNING 4-20mA (POS.x) EA0020 WHITE EA0020 x(M-) EA0000M EA0001 BROWN EA0001 x(I+) IWx CONTROL VIBRA TION BEARING UP W A RNING 4-20mA (POS.x) EA0021 WHITE EA0021 x(M-) EA0001M EA0002 BROWN EA0002 x(I+) IWx CONTROL VIBRA TION BEARING DOWN W ARNING 4-20mA (POS.x) EA0022 WHITE EA0022 x(M-) EA0002M x(I+) IWx x(M-) PE TERMINAL N§
BIT RACK x/SLOT
x
SLOT x 3.8/ 2.4 2.7 3.3 /5.1 /5.1 /5.1 /5.1 PE 18(230V) 19(230V) +(24VDC) E0000 E0000 x.0 READY ALPHA 700 (POS.x) E0001 x.1 THERMIST OR RELA Y FA U LT ALPHA 700 (POS.x) BNx E0002 x.2 SENSOR
MAX. LEVEL ALPHA
700 (POS.x) L 230V NP E E0003 x.3
THERMIC COOLER (POS.x)
PE 18(230V) 19(230V) +(24VDC) BIT TERMINAL N§ RACK x/SLOT x x.0...3 DIGIT ALS INPUTS FTx Xx E0000 + 18 19 PE QGx 31 32 97 98
Fig. 26 Digital inputs circuit 2 SLOT x 5.8/ 5.8/ 5.8/ 5.8/ /8.3 /8.4 /8.4 /8.5 /8.5 /8.6 /8.1 /7.1 PE 18(230V) 19(230V) +(24VDC) BMxx E0008 x.8 CONTROL VIBRA TION BEARING UP W A RNING (POS.x) WA R N IN G + 4-20mA OUT1 + ALARM E0009 x.9 CONTROL VIBRA TION BEARING UP ALARM (POS.x) L 230V NP E 4-20mA OUT2 E0010 x.10 CONTROL VIBRA TION BEARING DOWN W A RNING (POS.x) W A RNING +
BLANCO MARRON BLANCO MARRON
+ E001 1 x.11 CONTROL VIBRA TION BEARING DOWN ALARM (POS.x) ALARM
EA0001 EA0021 EA0001M EA0002 EA0022 EA0002M PE +(24VDC) BIT TERMINAL
N§ RACK x/SLOT x x.8...1 1 DIGIT A LS INPUTS EA0001 EA0021 EA0021M EA0002 EA0022 EA0002M E0009 Xx 18 19 PE E0010 E001 1 Xx E0008 +
Fig. 27 Digital inputs circuit 3 SLOT x 4.8/ 4.8/ 4.8/ 4.8/ /8.1 /8.2 /8.2 /6.1 /6.1 /6.1 /6.1 PE 18(230V) 19(230V) +(24VDC) x.4 x.5 BMx E0006 x.6 CONTROL VIBRA TION W ARKING (POS.x) W ARNING + 4-20mA + ALARM E0007 x.7 CONTROL VIBRA TION ALARM (POS.x) L 230V N WHITE BROWN PE
EA0000 EA0020 EA0000M
PE 18(230V) 19(230V) +(24VDC) BIT TERMINAL N§ RACK x/SLOT x x.4...7 DIGIT ALS INPUTS EA0000M EA0020 EA0000 E0007 Xx Xx E0006 + 18 19 PE
Fig. 28 Digital outputs circuit SLOT x -E(0V) +(24VDC) ST AR T COOLER 1 x.00 S0000 300 2 x.01 3 x.02 4 x.03 1L x.00...03 RACK x/SLOT x DIGIT ALS OUTPUTS TERMINAL N§ BIT +(24VDC) KMx A1 A2 43 44 QGx 6.8 / 3.2 /9.1
Fig. 29 Motor cooling circuit 2.8/ 2.8/ 2.8/ 2.8/ 7.1 7.1 4.7 /4.1 L1 L2 L3 PE xKW -xA COOLER (POS.x) PE Mx Xx Ux Vx Wx PE 1 3 5 6 4 2 KMx xA QGx x-xA 1 3 5 2 4 6 44 43 31 32 M 3~
Configuration of the process operations
To achieve the quality and quantity established by ECUTEC in addition to the protection of the components and staff, you must follow the instructions below:
• The first element to be connected is the classifier, thus it protects against coarse product getting into the area of fine product. (30 s. approx.)
• If the motor has a cooling fan, this must be connected at the same time as the motor.
• The following element is the connection of the system for cleaning the filter. (10 s. approx.)
• Once all the systems that ensure the accumulated product output in the different elements are connected, then connect the fan. (60 s. approx.) • When the classifier and the fan are in full operation, this is the moment
to open the butterfly valve that is between the filter and the fan and that closes the circuit. (15 s. approx.)
• Finally, start the feed.
Rules for stopping the machine
The following rules must be followed to protect people, the machine or quality.
• Whenever an alarm is triggered in any of the elements, you must stop all the elements that are behind this, for example if the classifier stops, the valve, fan and filter must be stopped.
• The temperature probes of the machines must be configured with an alarm at 85 ºC and a machine shutdown at 95 ºC.
• The vibration systems must have an alarm configured at 7 mm/s and a machine shut down at 11 mm/s.
• Any PTC or thermal signal must stop the components for their safety. • If the cooling fan is not connected, you cannot continue with the
sequence.
¬
ATTENTION
Rotating element. Cuts and personal injuries.
First connect all the output rotary valves (filter and classifier). Never connect the feed rotary valve first (10 s. approx.).
