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section 1

1. 0 5HP 1 1A 460 VAC 0 5HP MOTOR 50 He 3 PH i i 1 2 CORD 90 60007588 H 3 8 NPT CORD FITTING TBS 2535 SWITCH 60003533 A eS ee OE dij TUBE 60009864 m RELIEF A sale Ales 5 DEGEN 60508006 A ATT ama n 60009863 TE e pes FUSE HOLDER 0007214 FUSES 15 CENTRIFUGE BOWL FUSE HOLDER FEED PUMP INPUT FUSES 60003493 3 60007214 INPUT FUSES 1 FUSES 3 0 AMP FUSE HOLDER FUSE HOLDER 59 60008792 3 G0003486 3 G0007585 3 FUSES 40 A AIR 60003484 3 000 CONDITIONER 40 60009813 g x 15171 THERMOSTAT E Mi ee D 16 12 INPUT CONTROL i AX 60009974 SENSOR TIT DC X3 733 60009972 CABLE SEE T ajaja wj gt x BLK zi 120VAC THHN 14 AWG z CONVEYOR e THHN 18 n amp CONTROLLER 20HP A 5 q mom 0007241 zi 1 Bg 2 RED HA E 20 A CS a e E OUTPUT COM TO AC 159 8 e4VDC 15 E CONTROLLER 15HP TEMP COM 9125 8 ors 8 25 5 00008360 AC PRESSURE FAI
2. 14 47 16 0111 HOLES NOTES 1 3 4 44 TYP 4 FE HINGE PLATE 13490 01 003 1 ONE 1 UNIT COMPLETE E 2 DD BASE GAS SPRING MOUNT 2 2 COATING TYPE PSX 700 BASE GAS SPRING MOUNT 1 18056 02 GAS SPRING G0012457 3 LUBRICATION SEE MANUFACTURING SHEET IN MANUAL COVER SAFETY PIN ASSEMBLY 18059 02 A MAIN BEARINGS PER APPLICATION 457 COVER HANDLE 18061 01 B CONVEYOR BEARINGS PER APPLICATION A EN gt NGA ea C GEAR BOX PER APPLICATION ENCLOSURE ISOLATOR MOUNT REAR 00012076 4 OPERATING SPEED S SEE MANUFACTURING SHEET IN MANUAL 5 1 8 130 4 I 5 8 16 VERTICAL MOTOR MOUNT 15968 01 002 5 MOTORS ARE EXPLOSION PROOF LIQUID DISCHARGE DETAIL zum 4 7 8 124 1 U TOOL KIT 12016 00 001 4 13 16 122 BUSHING 2 125 BORE 0003563 La 7 8 12 HUB SHEAVE 8 0 00003562 1 R DRIVE BELT 00009762 6 Q ISOLATOR MOUNTS CA1595X1 2 6 AR GER BETAL 1 P ELECTRICAL ENCLOSURE ASSEMBLY 16622 01 006 21 O ENCLOSURE ISOLATOR MOUNT FRONT 00012075 GEAR UNIT 52 1 13223 22 CONTROL ENCLOSURE ASSEMBLY 16545 01 006 MOTOR 20HP 0008902 SEE NOTE 5 MOTOR 50HP 0008901 SEE NOTE 5 D BELT GUARD 13985 01 004 i FEED TUBE SUPPORT 9539 01 GE OSO GEAR UNIT GUARD 9856 01 008
3. 3 4 Feed and Discharge 3 6 Fresi Waler SUDD UT 3 6 Compressed 3 6 mod REM E e ee 3 7 3 7 Polarity Test 3 9 Machine Star RETE T 3 9 01 Aug 11 TOC 1 DE 1000LPVFDCentrifuge CONTENTS Section Page Date 4 Operating instructions nn nenn h 4 1 01 Aug 11 GENE ee en 4 1 A 4 1 Operating ealely ts 4 1 4 2 4 3 Normal 4 5 Gold Climate SIS up e 4 6 A TT 4 7 Alarm and Fault Messages au nenne 4 11 Bearing Femperalures AAA 4 11 Motor eth ete ipei bets MAG Mv 4 11 System 4 12 6 ns 4 13 4 14 NE DESI IU io odds 4 15 Pump WFD ee 4 16 Temperalure lrengs usada TT 4 17 VED Faut ee ee 4 17 A 4 18 PUMO SCUD Emden 4 18 o H
4. SEAL HOUSING en _ gt Gu 5 Ft AH x a Y i ji DO OX E Y ae ur ae S r O RINGS f f 22 CONVEYOR 4 SSSSSNNNNS s GZ BEARING HOUSING Figure 5 6 Liquid End Seal Housing Removal Cleaning Inspection and Repair After removing and disassembling rotating assembly clean inspect and repair as follows 1 Wash off mud and debris from conveyor and interior and exterior of bowl assembly 2 Inspect conveyor for missing tiles distorted or gouged flights burrs or other obvious damage Replace conveyor if serious defects are found 3 Inspect conveyor feed nozzles for obvious wear Rotate 180 degrees and reinstall if damage is apparent but not severe Replace nozzles if found highly damaged To help preserve dynamic balance always replace nozzles in pairs that are opposite to each other 4 Inspect feed accelerator inside conveyor for gouges fractures or distortion If replacement is required remove three set screws securing feed accelerator and tap from the solid end to remove accelerator 5 Inspect solid discharge wear inserts on bowl assembly for cracks fractures or other damage and replace if seriously damaged 6 Inspect bowl interior and exterior for gouges scratches or other damage that may affect performance 7 Check pillow blo
5. 1 CABLE SPEED SENSOR 2 METER CUT DOWN TO 36 INCHES G0007862 17 SPEED SENSOR 1244 EMBEDABLE 000786 16 RTD SENSOR 31655 136 WRE PVC 00008090 15 RTD SENSOR BEARING 31655 41 WIRE PVC COAT 00008089 14 FITTING STRAIGHT 500 NPT 250 375 000448 1 15 VERATON SWTCH 6000505 INH 12 FITTING 90 DEGREE ELBOW 500 NPT 500 625 60001 11 CABLEMARINE SHIPBOARD GEXOL INSUL 16 5 COND 55 INCHES 6000716 10 FERRULE 26AW6 O SOLID END RID SENSOR SE I Lp Tor rese oie ios 36108 FERRULE 600058 3 07 FERRULE 16AWG 600044 N 1 06 SPEED SENSOR ASSY LENGTH IS 36 16615 06 1 05 SOLID END RTD ASSY LENGTH IS 136 16615 05 LIQUID END RTD ASSY LENGTH IS 41 16615 04 VIBRATION SWITCH ASSY LENGTH IS 55 16615 03 IN JUNTO BOX SENSOR ELECTRONICS ASSY Ez 1000 BASE ELECTICAL COMPONENT KIT 16615 01 PART REF G A 14758 00 004 REF W S 14594 00 010 3 3N tes a ADDED mas e MENS SEO PARTS LIST FOR VFD DE 1000 NI REVISED LOCATION OF SENSORS x CONNECTION POINTS ADDED ITEMS 18 19 20 21 22 p un BASE SENSOR SYSTEM N mu A 87 REVISE EM DESCRPTON BE CLEARER 2 DAR CHANGED TEM 12 NAS 18 252 25 08 21 08 Aaa ON ee mon 3727 WS lo ES Im 1274
6. E EN WKN 222 22 e hin unt 30 ER OX 1 A COMPLETE STAGE ONE ASSY _____ __ Ax 01 COMPLETE GEAR UNIT QTY ITEM AG Nein N LZ A A PARS UST As DE 1000 GEAR UNIT 52 1 ANT de 4 5 0 WS 15 jux 11 12 93 NS A y fm 909 rc foo 100 2 15 90 DERRICK OR PROSPECTS OR THER ENT OR INSTALLATION OF DERRICK EQUIPMENT OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY CORPORATION TO DERRICK OR BY OTHERS FOR THE SPECIFIC REASON OUTLINED IN THE TRANSMITTAL WHETHER 1 1 5 2 O THE DESIGNS AND INFORMATION CONTAINED ON THIS DRAWNG OR COPIES REMAIN THE EXCLUSIVE PROPERTY DERRICK ENT MA MAN C GREASE IN GREASE GREASE e HERE QUT HERE uas C4 GREASE COMES QUT HERE LUBRICATION 4 MAINTENANCE SCHEDULE 20597 Ur TINA BRENCIN 30s 8 1 7 6 CLEAN OUT UNDER FLINGER COVERS MONTHLY en E OHR B 2 2 7 un 1 Nc mas 3 1 o C MIXING LUBRICANTS MAY CAUSE CATASTROPHIC FAILURE DRAIN amp REPLACE ALL FLUIDS EVERY e 120 DAYS OR 1800 HRS OF USE eS HH Ad ee ee 8 1 0 Ad m E YN LUBRICATION amp MAINTENANCE SCHEDULE Z N EL DERRICK VFD CENTRIFUGE OM A A 6 11 92 NTS PA REV CHANGE om CCS 12 8 10 Bin qo CORPORAT
7. GRN OPERATIONAL GRN MOTOR RUNNING a GRN RUNNING RUNNING SET SPEED GRY ALARM PRESENT GRY NOT RUNNING GRY MOTOR NOT RUNNING GRYS NATAT SET SPEED GRN DIFFERENTIAL SPEED MET Cra MEINE RED DIFFERENTIAL SPEED CANNOT NAT ACCELERATING BE MET AT CURRENT BOWL SPEED Us Run Alarm Ready Yo Fault MOTOR DECELERATING GRN PLC COMMUNICATION E GRY NOT DECELERATING RED NO PLC COMMUNICATION Motor Ref Speed In Range OT nline Speed RPM OUTPUT CURRENT MOTOR SPEED SETTING VFD Status ferential Motor Current En 0 1440 122 665 9 v PERCENTAGE OF MAXIMUM P ACCEPTABLE TEMPERATURE RISE DIFFERENTIAL SPEED SETTIN em eatsin n RTT Actual 30 0 1441 T gt EXT joe PRESENT OUTPUT POWER Power 0 1 KW TOTAL HOURS OF OPERATION ACTUAL DIFFERENTIAL SPEED Torque Nm ACTUAL MOTOR SPEED Max DEC Actual Hours Motor 80 0 1 3 MAXIMUM AVAILABLE TORQUE PRESENT VFD 8 PERCENTAGE BASED ON DIFFERENTIAL SETTING AVAILABLE TORQUE firma iM TEMPERATURE CURRENTLY UTILIZED Figure 4 11 Conveyor VFD Screen 01 Aug 11 4 15 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS GRN NO ALARM FAULT GRN RUNNING RED ALARM FAULT PRESENT GRY OFF GRN OPERATIONAL GRN MOTOR RUNNING GRY MOTOR STOPPED GRN ROTATING AT SET SPEED Grasa X NOTAT SET SPEED Pump Run Alarm GRY ALARM PRESENT Y
8. 16615 00 002 A VED XP DE 1000 LP CENTRIFUGE LOW PROFILE REVISE RECOMMENDED SERVICE SIZE WAS 150A BASED ON 119A CONNECTED LOAD REDUCER BOWL MOTOR CHANGED GLAND TO 1 50 ENTRY N al nva INI ADD WIRE NUMBERS 2 8 10 12 14 22 ADD WIRE LABELS AT 16584 01 004 ADD FITTINGS AT CONDENSOR MOTOR AND XP ENCLOSURE INTRINSIC WIRE 09 28 11 REVISE WIRE SIZES FOR BOWL AND CONVEYOR WAS 6AWG BOWL AND 10AWG CONVEYOR oun CHANGED ORDER OF TERMINAL BLOCK WRING IN 16584 01 004 JUNCTION BOX SPARE 03 18 1 METE man WIRING SCHEMATIC 460 i 480V 60 HZ REVISE CIRCUIT FEEDING AIR CONDITIONER NOW USES 24VDC WAS 230VAC de REMISE COLOR EZ N N INTERCHANGED POSITIONS OF SPEED SENSOR AND TEMP SENSOR SOLID END REORDERED CONNECTIONS WERE TERMINALS SEZ om JFS 02 07 03 NONE BEN REVISE GROUND BAR WAS 00007610 REMSE REFERENCE DRAWING WAS 16615 00 02 16 12 MINOR WIRING REVISIONS TO REFLECT ACTUAL WIRING 05 11 TERMINAL BLOCK LABELING TO MATCH JUNCTION BOX ASSEMBLY CHANGE DATE KD DATE SCALE AN REVISE HMI TO PROGRAMMED PART WAS 00008825 Y N REVISE CORD FITTING AT PURGE UNIT WAS 00004418 REVISE CABLE ASSEMBLY NUMBERS UPDATED ETHERNET 0000 NUMS 00009966 WAS 7951 9967 WAS 9873 9968 WAS THE DESIGNS AND INFORMATION CONTAINED ON THIS DRAWING OR COPIES REMAIN THE EXCLUSIVE PROPERTY OF DERRICK N o 12 07 10 REVISE ETHERNET CABLES WERE
9. DERRICK DE 1000LP Centrifuge Variable Frequency Drive Issued 15 Jan 11 Rev 01 Aug 11 Maintenance amp Operation Manual Derrick Equipment Company 15630 Export Plaza Drive Houston Texas 77032 Phone 281 590 3003 Toll Free 1 866 DERRICK Fax 281 442 6948 www derrickequipment com DERRICK UNIT NUMBER IS KEY TO DERRICK SERVICE All inquiries to Derrick must include the equipment unit number The stainless steel unit number tag attached to each piece of Derrick equipment is your key to efficient service and support Typical Derrick Unit Number This unique number gives vital information to Service personnel who use it to identify the correct parts when filling orders provide accurate responses to service questions track documentation and trace the equipment s history or configuration In short the unit number provides the critical information needed to ensure that Derrick customers receive the best possible service The unit number consists of a two character alphabetic prefix that identifies the equipment type and a series of numeric characters that signify the sequence of the machines manufacture For example unit number 000001 would be the first screening machine manufactured by Derrick Alphabetic prefixes currently in use are MA Screening Machine AD Desilter and Desander DG Degasser AG Mud Agitator CF Centrifuge SF Screen Frame To ensure that it will remain intact over many years of
10. 1 DONE SUCCESSFUL CLEANOUT BOWL amp CONVEYOR RUNNING Faults RETURNING TO SET SPEEDS Conveyor Jog Conveyor Motor Operation 179 RPM Horne JOG SPEED OF CONVEYOR MOTOR IN MANUAL MODE SELECT MANUAL CLEANOUT CONVEYOR JOG DIRECTION ONLY TERMINATE CLEANOUT Figure 4 19 Clean Out Screen 01 Aug 11 4 19 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS Automatic Cleanout When the automatic option is selected the system will perform a cleanout cycle for a pre set duration The bowl operates in the forward direction at 300 RPM while the conveyor operates in the forward direction at a speed that varies from 8 to 30 RPM If excessive resistance is encountered during the cleanout the system will pause and alert the operator that the automatic cleanout has been unable to clear the centrifuge Operator intervention is then required to repeat the automatic cleanout operation Manual Cleanout If the manual cleanout option is selected the operator may elect to jog the conveyor in forward and reverse with the bowl set at zero RPM If desired however the operator may choose to operate the bowl as well as the conveyor Reverse rotation of the conveyor is governed by a timer that terminates reverse operation after a pre set interval The primary purpose of the manual cleanout mode is to permit jogging the conveyor in an effort to remove impacted material NORMAL SHUTDOWN The normal shutdown procedure is to be used for controlled st
11. CONTROL TRANSFORMER T1 M1 THERMAL PROTECTORS F6 F7 HIGH REFRIGERANT FUSE PRESSURE SWITCH F1 COMPRESSOR FAULT SIGNAL CONTACTOR K20 POWER RELAY K10 M1 THERMAL CONTACTOR K30 manae Figure 5 15 Air Conditioner Electrical Components ALARM AND FAULT MESSAGES Intervention is required if a message appears to alert the operator to an anomaly that has occurred Alarm messages signify that the prevailing condition must be corrected or the centrifuge may be shut down automatically Fault messages inform the operator that a failure requiring automatic shutdown has occurred Refer to the following table for alarm and fault messages and their causes and corrective actions for assistance in analyzing messages 5 40 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE Alarm and Fault Messages Air Conditioner Compressor Motor Overload Fault Motor drawing excessive current Replace air conditioner compressor motor if defective or remove other cause of excessive current draw Air Conditioner Internal Fan Motor Overload Fault Motor drawing excessive current Replace internal fan motor if defective or remove other cause of excessive current draw Air Conditioner Refrigerant Pressure High or Low Fault Check refrigerant pressure high If pressure is high reduce refrigerant quantity if low pressure indicates over charging and correct leak s and re charge system low pressure indicates system leakage Bowl Ex
12. WARNING DO NOT ATTEMPT TO OPERATE MACHINE WITH SHIPPING COMPONENTS INSTALLED 15 Jan 11 3 9 DE 1000LPVFDCentrifuge DERRICK CORPORATION SECTION 4 OPERATING INSTRUCTIONS GENERAL The procedures in this section are for use only by trained personnel who are qualified to operate high speed rotating equipment Initial and normal startup operation shutdown and emergency shutdown procedures are included Following the startup and operation procedures detailed information on the control screens is provided to assist the operator and technician in understanding centrifuge operation and fully utilizing its capabilities The centrifuge is designed to be operated only for the purpose specified at the time of purchase Operation in any other application requires consultation with Derrick engineering SOFTWARE VERSION The operating procedures in this section apply to DE 1000LP VFD centrifuges having software Version 3 1 4 installed The software version is shown on the Setup screen Figure 4 16 Although operating procedures are generally identical an earlier software version may cause some screens to appear slightly different from those shown on the following pages OPERATING SAFETY WARNING ALL OPERATING AND MAINTENANCE PERSONNEL MUST READ AND UNDERSTAND ALL SAFETY INFORMATION IN THIS MANUAL BEFORE WORKING WITH THE EQUIPMENT WARNING BE SURE THAT COVER IS CLOSED AND SECURED AND ALL PERSONNEL ARE CLEAR BEFORE STARTING MA
13. DERRICK SECTION 1 INTRODUCTION OVERVIEW This manual provides instructions for installing and operating the DE 1000LP Variable Frequency Drive VFD centrifuge Figure 1 1 The manual is divided into several sections to assist the user in readily accessing the information Instructions include description theory of operation safety installation and maintenance Reference drawings are provided to facilitate parts location and ordering as well as for understanding of equipment operation and assist in troubleshooting Figure 1 1 DE 1000LP Variable Frequency Drive VFD Centrifuge SAFETY Section 2 of this manual contains relevant safety information for both operation and maintenance of this equipment Be sure this information is read and understood by all personnel DO NOT operate the equipment if defective or faulty mechanical or electrical components are detected 15 Jun 11 DE 1000LPVFDCentrifuge INTRODUCTION EQUIPMENT USE The DE 1000LP VFD centrifuge is designed expressly for removing low and high specific gravity solids from slurries In one type of processing solids are removed and the liquid is returned for recirculation Alternatively solids are returned to the active system and the liquid is discarded Derrick Corporation does not authorize any other use of this equipment Intended usage of the equipment includes compliance with the operating maintenance and safety procedures included in this manual
14. AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY CORPORATION OF PARTS OR ASSEMBLIES TO DERRICK OR BY OTHERS FOR THE SPECIFIC REASON OUTLINED IN THE TRANSMITTAL WHETHER 4 e e 9 24 12 WRITTEN OR VERBAL 590 DUKE ROAD BUFFALO NY 14225 U S A 4 5 LO WE CENT MAN XP CABLE ASSY W CABLE GLAND 6C 16AWG 60009767 YA ELBOW 3 4 CRH EL29 NIPPLE 3 4 NPLE 75 COND ZA PURGE SYSTEM G0007865 CONDENSOR FAN MOTOR 2
15. AIR 0 Le LT REGULATOR INERT 2 barg GAS Dn v TIMER INDICATOR 2 S B H PINCH VALVES YELLOW PURGING LOGIC GAUGE PRESSURE OR 7 ALARM GATE INDICATOR 1 RED B PURGE ENCLOSURE IT nd VALVE PRESSURE TEST 5 ml MOL PLUGGED 2 PRETE IN UNE RESTRICTOR T DP ENCLOSURE PRESSURE PURGE OUTLET TO PRESSURIZED ENCLOSURE DP LO RLV CONNECTION Figure 1 3 Leakage Compensation Circuit Schematic Diagram Output Signal The purge system provides an intrinsically safe power output This output consists of a low voltage electrical lead connected from the purge unit to an intrinsic barrier in the electrical panel When the purging phase is completed this output signal closes the main contactor in the electrical panel which then energizes all components in the control cabinet 15 Jun 11 1 5 DE 1000LPVFDCentrifuge INTRODUCTION Vibration Switch The vibration switch Figure 1 4 is a safety device designed to protect personnel and equipment by shutting down the centrifuge in case of excessive vibration Normally the switch contacts are held closed by a mechanical latch However strong vibration or a shock of 2 Gs will overcome the magnetic latch causing the switch armature to break away from the normally closed position providing an input to the PLC A reset button on the side of the switch must
16. DESCRIPTION Major components of the centrifuge Figure 1 2 consist of the rotating assembly control cabinet bowl and conveyor drive motors operator control panel HMI purge system vibration switch and case base assembly and skid The following paragraphs describe these components BOWL DRIVE MOTOR ROTATING ASSEMBLY PURGE SYSTEM SKID OPERATOR CONTROL PANEL HMI CONVEYOR DRIVE MOTOR GEARBOX CONTROL ELECTRICAL CABINET PANEL CASE A ee VIBRATION LIQUID SWITCH DISCHARGE SOLID DISCHARGE Figure 1 2 DE 1000LP VFD Centrifuge Major Components 1 2 15 Jun 11 DE 1000LPVFDCentrifuge INTRODUCTION Rotating Assembly The rotating assembly consists of a cylindrically shaped stainless steel bowl conveyor assembly and related components The bowl consists of a straight stainless steel cylinder with a conical section at the discharge end and a flat liguid bowl head at the opposite end Openings are provided at both ends to permit liquid and solid discharges The bowl ends are supported by roller bearings having grease fittings to facilitate periodic lubrication Bowl Assembly The liquid bowl head at the liquid discharge end contains movable effluent ports that permit manual adjustment of the liquid level remaining in the bowl during rotation Index marks are provided on the weirs to facilitate precise adjustment The liquid level or pond depth along with other factors helps determine the liqui
17. 19mm Replace line if undersize Check for stable air pressure of 60 115psi 4 8barg Adjust air pressure if low Excessive leakage from Check for leakage at cabinet door gasket and at all potential cabinet sources of leakage Maximum permissible leakage is 2 5cfm Correct as required Tube between relief valve and Check that coupling nuts are tight and tube is undamaged flow sensor not air tight Correct as required Purge flow sensor out of Unscrew diaphragm housing from sensor and using a calibration or defective suitable plug close off 12mm threaded opening in top of valve module Turn on system and check purge indicator color If indicator becomes amber re calibrate or replace sensor diaphragm Contact Derrick for assistance if color change does not occur Failure Mode 11 Purge System Fails To Turn On Power After Purge Time Has Elapsed No power to system Check and correct power loss Main power contactor turned owitch on contactor off Check and replace fuse s If blown S 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE TROUBLESHOOTING DE 1000LP VFD CENTRIFUGE Failure Mode 11 Purge System Fails To Turn On Power After Purge Time Has Elapsed Cont d Purge cycle not completed Press indicator button on timer valve If purge time has been completed indicator button will return when released If button does not return allow additional time for cycle to complete Low
18. GENERAL This section describes preventive and corrective maintenance procedures for the DE 1000LP VFD centrifuge Obvious procedures are omitted Before beginning any centrifuge maintenance shut down lock out and tag out equipment WARNING HIGH VOLTAGE MAY BE PRESENT ALWAYS OPEN FUSED DISCONNECT SUPPLYING ELECTRIC POWER TO THE EQUIPMENT AND LOCK OUT AND TAG OUT POWER SUPPLY BEFORE PERFORMING ANY MAINTENANCE PROCEDURES WARNING FAILURE TO WEAR SAFETY GLASSES MAY RESULT IN SERIOUS EYE INJURY OR PERMANENT LOSS OF VISION SAFETY GLASSES MUST BE WORN AT ALL TIMES WHILE PERFORMING ANY MAINTENANCE PROCEDURE PREVENTIVE MAINTENANCE Preventive maintenance consists of inspection cleaning and lubrication These routine procedures will ensure maximum life and trouble free operation While the maintenance schedule presented in this section should remain flexible modifications should be based on experience with operating the equipment at your facilities A maintenance log should be kept to help establish a preventive maintenance schedule as well as to monitor and adjust the schedule as necessary throughout the equipments life When establishing a preventive maintenance schedule consider duty cycle ambient temperature and operating environment The recommended preventive maintenance schedule is presented in the table below Refer to the lubrication chart on the following page for applicable lubricants and quantities PREVENTIVE MAINTEN
19. Loctte Solid End Bow Head _ s Grease iting 2 NA Solid End Bow Head 10 5846x1HxSRHd 8 Ant Seize 252 in b 28 6Nm Sold End Bow Head 11 6 144in 10 16 3Nm Sold End Seal Housing 18 8 Ant Seize eainbio4Nm PuleySmeme 0 14 6 Unspecified Flinger Cover 18 8 Ant Seize 252 in b 28 5Nm Case Plows _ 01 Aug 11 5 29 DE 1000LPVFDCentrifuge MAINTENANCE SOLID END HARDWARE TORQUE SPECIFICATIONS 27 vero Sta 8 Ant Seize Feed Noze SSS LIQUID END HARDWARE LOCATIONS 16 T Rei d 1 722222 PLA 74 5 30 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE LIQUID END HARDWARE TORQUE SPECIFICATIONS 2 4 1 1 2 ix SK a 8 AmSeze 252 285 Liquid End Bearing Housing gt 14 6 ASee _ Finger Cover 16 88 6 1 5 8 AntrSeize 252 1 Spine Hub 7 5 a a 30 48 Pin 7 16 20 x 2 1 2 N A 31 87 Pin 3 24 20 x 2 1 2 N A 6 T 2 4on Serial numbers below CF000272 2 on serial numbers CF000272 thru CF000678 0 on serial numbers above CF000979 21 4 on serial numbers below CF000272 6 on serial numbers CF000272 thru CF000678 9 on serial numbers abo
20. PARTS SALES amp SERVICE LOCATIONS Houston Oilfield Headquarters 866 DERRICK 337 7425 281 590 3003 North Texas Bridgeport 405 208 4070 South Texas Corpus Christi 361 299 6080 West Texas Midland 405 397 4089 East Texas Arkansas and Louisiana 281 546 1166 Casper 307 265 0445 Williston 701 572 0722 15 Jun 11 DE 1000LPVFDCentrifuge DERRICK CORPORATION SECTION 2 SAFETY GENERAL This section contains a summary of WARNINGS used in this manual and a list of material safety data sheets MSDSs applicable to the equipment The centrifuge has been designed to perform the stated functions safely WARNINGS All persons responsible for operation and maintenance of this equipment must read and understand all safety information in this manual prior to operating and or maintaining the equipment The safety warnings listed below are included in applicable procedures throughout this manual Sound WARNING TO PROTECT AGAINST HEARING LOSS HEARING PROTECTION SHOULD BE WORN AT ALL TIMES WHEN WORKING ON OR NEAR DERRICK MACHINES Electrical Hazards WARNING TO AVOID SERIOUS PERSONAL INJURY BE SURE EQUIPMENT IS LOCKED OUT TAGGED OUT DE ENERGIZED AND HAS STOPPED ROTATING BEFORE PERFORMING MAINTENANCE AND OR ADJUSTMENTS WARNING DRIVE MOTOR MUST BE OPERATED AT THE DESIGNATED SUPPLY VOLTAGE WARNING HIGH VOLTAGE MAY BE PRESENT BE SURE FUSED DISCONNECT SUPPLYING ELECTRIC POWER TO THI
21. gt 20 HP MOTOR MOUNT 14554 01 003 KR CASE COVER 9591 01 002 x 1 D LOWER CASE 590 01 SKID MA d T 71 ROTATING ASSEMBLY W TILES 59 1 8 mW OE Re 51 1 4 P 01 RADIAL CENTRIFUGE ASSEMBLY 460 60HZ 1502 1302 No PARTNAME DESCRIPTION ee 2 iui 14 9 16 584 369 215 1 G 1 COVER CAN BE MOUNTED cc FOR OPPOSITE SIDE OPENING N e 1 CG 66 1 2 Mijail Sm 1689 1 FE tt 14 COVER OPEN u 15 16 m 5 1295 rca B 212 826 m 1 1 36 7 16 926 SOLID DISCHARGE 78 1 2 1994 zl LIQUID DISCHARGE 82 2083 173 1 4 4401 El REFERENCE DRAWINGS STATIC LOAD 7420 LBS 3366 KG ELECTRICAL COMPONENTS PARTS LIST 16615 00 IN ELECTRICAL WIRING SCHEMATIC 14394 00 023 RT GENERAL ARRANGEMENT FOR ZN ES _DE 1000LP VED CENTRIFUGE 460 60 3 FA e Jon 9775 00 uc 10 T7 ADDED ITEM EE UPDATED VIEWS CHANGE C y om CCS 11 YN em 7 30 12 THE DESIGNS AND INFORMATION CONTAINED ON THIS DRAWING OR COPIES REMAIN THE EXCLUSIVE PROPERTY OF DERRICK ADDED TENS BB THRU DD CORPORATION BUFFALO NEW YORK U S A AND ARE NOT TO BE REPRODUCED WITHOUT THE WRITTEN PERMISSION OF DERRICK SHEET SIZE DERRICK N ERI 6 25 12 CORPORATION THE INFORMATION CONTAINED ON THIS DRAWING SHALL ONLY BE USED BY CUSTOMERS OR PROSPECTS OR THEIR DRAWING NO
22. is insufficient 5 Replace any component found having damage that cannot be easily repaired Replace all seals O rings and bearings 6 Place all cleaned components in clean plastic bags to prevent contamination Installation 1 Insert new seal into seal housing Figure 5 13 and secure with retaining ring 2 Install new O ring into external groove of seal housing 3 Insert new seal into bearing housing and secure with retaining ring 4 Insert new bearing into bearing housing and fully seat against shoulder 5 Insert bearing housing into conveyor opening place seal over bearing housing and secure both housings to conveyor with screws Tighten screws in accordance with Hardware Torque Specifications 6 Re install conveyor in bowl assembly and install bowl assembly on centrifuge in accordance with Rotating Assembly Maintenance 5 26 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE TOOL LIST The following tool list includes all tools and equipment supplied to facilitate maintenance of the DE 1000LP VFD centrifuge Each component is listed with its part number quantity supplied and use or application DE 1000 VFD CENTRIFUGE TOOL LIST Allen 33212 Long Arm Allen Wrenches 3 32 to 1 2 Various rotating assembly hardware 30008667 Socket 15 16 1 2 Drive Remove and install pillow block bolts OTC 1039 Bearing Puller 2 Jaw 10 Reach 0 to 12 Spread Remove main bearing inner race from liquid bowl head shaft HXCB
23. supply line must have a minimum diameter of 3 4 20mm The supply must be clean non flammable and from a non hazardous area The cleanliness requirements are as follows Solid particles 0 5um particle size lt 1um max 1000 particles m Humidity 40 C pressure dewpoint Oil content x0 01mg m concentration total oil For applications where ambient temperature Tamb lt 0 C the air supply should be Class 2 1 1 with humidity 70 C pressure dewpoint 3 6 15 Jan 11 DE 1000LPVFDCentrifuge INSTALLATION FEED PUMP The customer is required to supply a feed pump for delivering slurry to the centrifuge The recommended pump is a progressing cavity type having a fixed ratio gearbox and 15 HP maximum inverter duty pump drive motor The motor must be capable of operating in the 180 to 2700 RPM 6 to 90 Hz speed range and also meet all other application requirements including voltage frequency and area of classification The pump size motor and gearbox ratio must be chosen to deliver the maximum desired flow at a pump rotor speed determined by the manufacturer to be low enough to prevent accelerated wear of the rotor and or stator The pump must be connected to the centrifuge s control system as described under Electric Power Connections in this section so that its operation can be supervised by the centrifuge ELECTRIC POWER CONNECTIONS The centrifuge drive motors require three phase line power and ground connections In ad
24. 1 13 FLINGER COVER OUTBOARD FLANGE SIDE 9670 00 001 1 1 12 O RING 4 000 ID X 125 J ORV ARP 2422 L1 1 Tit _ 1 1 10 PILLOW BLOCK FLINGER OUTBOARD FLANGE SIDE 9514 00 001 5 SE f A A nen 1 1 09 BEARNG NU 225 CSIO RA 513 00 1 3 3 08 PILLOW BLOCK FEINER 90M 00 MES DC De t C DC DC DC DC DC DC DC C C DC an M A oO ESSE vam XJ gt EE EE ERE Eq NE EI E pp Exp t E OS 4 211411 VAR 7 SPERO Emm dedo id a Az 1 NS cz CASE FLINGER FA KR ar CONVEYOR ASSY W HARD SURFACING er COMPLETE ROTATING ASSY W TILES SE bi lid 2 2 06 O RING 46 CS10 RA 316 00 zzz Mp HE W 42 B T a im nS L 03 CONVEYOR ASSY L gt x EE SE Bas Catt DA ow SI T m uy E NY q FEED NOZZLE ASSY N ES ponen ER T 7 l T OX COMPLETE ROTATING ASSY W HS M 1 d N N COMPLETE SET CENTRIFUGE ROTATING ASSEMBLY FOR A DERRICK DE 1000LP e 12 0 12 KW TS 2 24 92 1 41 2 Y fom CUS 2 22 1 O ___
25. 2 HEX HEAD BOLT 0008178 NO TORQUE FEED TUBE MOUNTING BLOCK A 1 37 30 x 1 5MM X 1 4W EXTERNAL SNAP RING 00003966 ROTODIFF PORT BLOCK NOTES 3 8 X 1 PIN STEEL PP1354 680L SPLINE HUB 1 MATERIAL HEX SOCKET BOLTS 1 35 SET SET SCREW PP1134 714 PORT BLOCK ALLOY STEEL TENSILE STRENGTH 190 000 PSI MINIMUM HEAT TREATED 6 34 5 16 18 X 3 4 HEX SOCKET SKCS 31 18X075 GEARBOX TO GEARBOX FLANGE STAINLESS STEEL TENSILE STRENGTH 80 000 PSI MINIMUM xxx 6 33 M16 X 35 HEX SOCKET ALY PLD 13635 37 ROTODIFF TO ROTODIFF FLANGE 2 QUANTITY LISTED IS PER ROTATING ASSEMBLY 3 8 PLUG SS PKR 8 HP50N SS 35 FT LBS BOWL EXTENSION 3 A ITEMS 02 amp 21 QTYS ARE 4 FOUR FOR UNITS PRIOR TO SERIAL NUMBER CF000272 17 PIN 3 8 24 X 2 1 2 STEEL 13775 00 PILLOW BLOCK B ITEM 02 QTY IS 2 TWO amp ITEM 21 QTY IS 6 SIX FOR UNITS WTH SERIAL NUMBERS 18 PIN 7 16 20 X 2 1 2 STEEL 60003955 PILLOW BLOCK IN THE RANGE OF CF000272 TO CF000678 5 8 11 X 2 1 4 HEX HEAD BOLT 00008202 197 FT LBS PILLOW BLOCK N C ITEM 02 QTY IS 0 ZERO amp ITEM 21 QTY IS 9 NINE FOR UNITS WITH SERIAL NUMBERS 3 8 16 X 1 2 SS SET SCREW CUP POINT 00003950 SEAL HOUSING ABOVE CF000679 8 27 1 2213 X 1 SS HEX SOCKET 60002156 53 FT LBS FEED NOZZLE D ITEMS 35 amp 37 ARE NOT REQUIRED AFTER UNIT CF000678 5 16 18 X 7 8 SS HEX SOCKET 00001578 144 1 5 EFFLUENT PORT E ITEM 33 TO BE USED WITH ROTODIFF ASSY 107 D6V B 3 8 16 X 3 4
26. Current A DC Bus V AT TIME OF FAULT 3 1 0 1 681 0 FAULT TYPE BUS VOLTAGE AT TIME OF FAULT 1 Status 2 Alarm 1 Alarm 2 VFD CURRENT AT TIME OF FAULT 3855 8199 0 0 2 75 1 9922 3 77 1 9065 VIEW COMPLETE FAULT HISTORY Pump VFD Fault History INDICATES WHEN DRIVE WAS LAST POWERED UP Figure 4 13 Pump VFD Fault Status Screen 4 16 01 Aug 11 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS TEMPERATURE TRENDS The historical temperature trends of all three VFDs are shown on the Temperature Trend screen Figure 4 14 This screen is accessible from the Bowl VFD screen FFD Temperature 1 Min Thursday August 09 2007 Friday Auc Update SCROLL LEFT OR RIGHT gt VFD TEMPERATURES 30 Min 4 Operation Home DISPLAY 30 MINUTE 18 TREND SCREEN PAUSE Figure 4 14 VFD Temperature Trend Screen VFD FAULT RESET The Fault Reset screen Figure 4 15 informs the operator of the readiness of each VFD Faulted or No Fault and permits resetting a faulted VFD The screen may be selected from either the Clean Out or Operation screen If high conveyor torque causes a reduction in the pump flow rate the message Flowrate Reduction is displayed on the Operation or Clean Out screen to inform the operator that the pump is operating at a reduced flow rate This message also appears on the Fault Reset screen After removing the cause of the reduced flow rate RESET is selected on the Fault Reset screen t
27. EL296 El es TT oe ai ale E sE E FUSE HOLDER L3 RED FusE 05 A 460 VAC 460 460 VAC NOTE eno a Fe BROWN XP CABLE ASSY c0009182 1 60004195 4govac 60 Hz 3 PH 60 Hz 3 PH 60 Hz 3 PH CABINET IS SHIPPED WITH TERMINALS 3 AND 4 JUMPERED c B W CABLE CLAND sa M 222 REMOVED BY CUSTOMER REMOTE PUMP ENABLE IS USED ee O ee ee E 00009451 2 Y OTH SWITCH SENSOR SENSOR SENSOR PROVIDED BY OTHERS 0009597 0009596 DO PLACE JUMPER BETWEEN TERMINALS 1 AND 2 AS PUMP SOLID END LIQUID END AA A LE M m AWG REV 2 USED FIRST ON REV 9 USED FIRST ON MAY START UNINTENTIONALLY G0008896 G0003015 SWITCH 60008089 G0008090 00007861 SENSOR CENTRIFUGE CF1415 AND CENTRIFUGE CF1699 AND 60007163 CABLE 00007862 CABLE CONTROL PANEL CF6031 CONTROL PANEL CF6197 THESE TERMINALS ARE NOT INTENDED FOR INTRINSICALLY SAFE CIRCUITS CONTACT DERRICK CORPORATION IF REMOTE PUMP START STOP CONTACTS 2 NPT PLUG REV 4 USED FIRST ON ARE TO BE LOCATED IN A HAZARDOUS AREA Sue 20 SUPPLY 480 VOLTS 3 PH 60 HZ RECOMMENDED CABLE HOOK UP CENTRIFUGE 071445 AND RECOMMEND 125 AMP SERVICE QTY D COPPER COND PER PHASE SIZED FUR 125 AMP CONTROL PANEL CF6043 BASED ON CONNECTED LOAD OF 100 AT 75C TEMP RISE AND 40C AMBIENT MAIN POWER DISCONNECT A USE XP SEALING GLAND FOR A 2 NPT REF G A 4 14738 00 008 SUPPLIED BY CUSTOMER REF P L 16545 00 006 REF
28. From Memory Card to Controller Re loading of PLC program from otart centrifuge and resume operation memory card completed PLC battery connections not secure Check connections and correct if necessary Reduce feed rate Conveyor torque exceeds pre set limit Following automatic shutdown perform cleanout procedure to remove solids buildup and re start centrifuge at reduced feed rate Conveyor VFD Alarm Ref Troubleshooting Section of User Manual Temperature sensor signal cable Check and correct connection refer to electrical disconnected schematic diagram in Section 8 VFD temperature too high Check Conveyor VFD status screen for temperature and alarm shut down lock out and tag out centrifuge to determine and correct cause of overheating VFD load too high Reduce pump feed rate 01 Aug 11 5 43 DE 1000LPVFDCentrifuge MAINTENANCE Alarm and Fault Messages Conveyor VFD Communications Error Conveyor VFD not communicating with Confirm that green LED next to Ethernet cable is PLC lighted indicating that hub is functional Check connections between conveyor VFD and PLC and correct any defects Replace conveyor VFD if no other defect is found Conveyor VFD Fault and Shutdown Ref Troubleshooting Section of User Manual VFD fault detected causing shutdown Check and replace conveyor VFD Conveyor VFD Ground Warn Alarm Ref Troubleshooting Section of User Manual Conveyor motor has path to ground Check fo
29. INTRINSIC BARRIER 2 CONNECTION PRESENT e E Sens sE Sensor st simu _ 4 20 Analod 5 20 Analog 4 20 Analog GRN MIN SIGNAL SUPPLIED GRN 24VDC AT CLICK TO TOGGLE TO VFD CORRESPONDING PIN BETWEEN SOLID END BEARING RED NO SIGNAL OR LOW SIGNAL RED 24VDC NOT PRESENT AND CABINET RTD SIGNALS Figure 4 6 Diagnostics Screen 4 12 01 Aug 11 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS PERFORMANCE STATUS Current performance information is shown on the Centrifuge Status screen Figure 4 7 Cabinet enclosure temperature as well as VFD temperatures and other status details are shown in Figure 4 8 Parameters displayed include bearing temperatures bowl speed and sensor condition status of safety devices vibration switch emergency stop and bowl overspeed air conditioner operation and operating hours Operating status of the air conditioner is also shown note differences between screens for centrifuge with and without RTD sensor to detect cabinet interior temperature Exiting this screen returns to the previous screen Safety shutdowns are denoted by color change from green to red and display of a word explaining cause of shutdown DISPLAY STATUS SCREEN SHOWING GRN BOWL SENSOR PRESENT ALL AIR CONDITIONER PARAMETERS RED BOWL SENSOR NOT PRESENT PRESENT BEARING TEMPERATURES fety Air Conditioner Hours GRN ANALOG SIGNAL PRESENT sens SENSOR INPUT Current Run TIME RED NO ANALOG SIG
30. Ready Fault Reverse _ ACCELERATING GRN PLC COMMUNICATION He owrate Reduction Mode cel GRY NOT ACCELERATING RED NO PLE COMMUNICATION Speed RPM Pump Speed VFD Status GRN DECELERATING PUMP SPEED PERCENTAGE OF Motor 36 Current DC Bus GRY NOT DECELERATING TOTAL AVAILABLE AND Ret 5 0 0 0 683 0 v MOTOR 5 22 Temp Heatsink OUTPUT CURRENT s 103 8 30 3 ACTUAL PUMP AND Remote Inputs Torque tCode Power PERCENTAGE OF MAXIMUM ACCEPTABLE TEMPERATURE RISE LAS Y TEL PRESENT OUTPUT POWER MOTOR OPERATING CHARACTERISTICS CLOSED 0 0 Aux Pump Start STATUS TANK HIGH LOW LEVEL SWITCHES BOTH Hours 0 0 TOTAL HOURS OF OPERATION MUST BE CLOSED FOR OPEN PUMP TO RUN CODE NUMBER OF PRESENT FAULT PRESENT ACTUAL PRESENT VFD CLICK ON NUMBER TO VIEW FAULT MOTOR TORQUE Nm TEMPERATURE STATUS SCREEN FOR DESCRIPTION Figure 4 12 Pump VFD Screen PUMP VFD FAULT STATUS The three most recent pump faults are shown on the Pump VFD Fault Status screen Figure 4 13 The screen shows the fault number time of occurrence and description of the most recent fault The fault code and time of occurrence are shown for the second and third most recent faults VFD POWERUP MARKER TIME OF FAULT VFD HOURS HOURS Pump VFD Fault Status 1 9934 x Code Time Fault Name 1 13 2 2548 Ground Fault OUTPUT FREQUENCY Speed Hz
31. Release and remove two ratchet straps Using a 1 ton hoist lift rotating assembly slowly and evenly about 5 Remove shipping brackets under rotating assembly Remove rubber shipping strips under rotating assembly and bearing pillow blocks Figure 3 4 Using a suitable solvent clean pillow block mounting surfaces and alignment pin holes Check for and remove any nicks or burrs Slowly lower rotating assembly until pillow blocks contact base but maintain support by hoist 8 Apply anti seize compound to pillow block bolts and tapered alignment pins 10 11 12 13 14 15 Insert pillow block bolts and alignment pins through pillow blocks Tap alignment pins into place Hand tighten pillow block bolts and then release hoist Tighten pillow block bolts in accordance with applicable torque specification in Section 5 Adjust effluent ports if necessary from factory setting of 3 4 Close case cover and evenly tighten all cover bolts sequentially beginning at the center and moving toward ends Rotate bowl manually to confirm that no binding or rubbing is present Adjust drive belt tension in accordance with preventive maintenance in Section 5 Install belt guard and gearbox guard ROTATING ASSEMBLY SHIPPING BRACKETS BEARING PILLOW BLOCK SHIPPING STRIPS Figure 3 4 Shipping Components Locations 15 Jan 11 3 5 DE 1000LPVFDCentrifuge INSTALLATION FEED AND DISCHARGE CONNECTIONS For vibration isolation
32. a flexible line must be connected to the feed tube A source of fresh water is required for flushing the centrifuge prior to shutdown To connect the flush line install a tee fitting in the feed line with shutoff valves to permit selection of either the feed line or the flush line Figure 3 5 The shutoff valves are required to prevent flush water from flowing back into the centrifuge feed If a customer supplied liquid discharge line is used the line must be flexible for vibration isolation Since the discharge cake is very heavy and sticky because of the lack of free liquid the centrifuge should be installed over the receptacle that is to receive the discharged solids If this is not possible a slide or chute is needed to convey the solids At least a 45 degree angle is required to ensure self cleaning or a wash system must be provided to prevent material buildup FEED FEED VALVE TUBE FEED ro CENTRIFUGE gt FLUSH VALVE FLUSH LINE Figure 3 5 Feed and Flush Connections FRESH WATER SUPPLY A fresh water line with ball type shutoff valve is required to facilitate dilution of slurry when required and for performing cleanout prior to shutdown The line is to be connected to the centrifuge using a tee in the feed tube line COMPRESSED AIR The centrifuge requires a source of clean preferably instrument quality filtered dry compressed air or nitrogen at 60 to 115 PSI at 16SCFM for operation of the control cabinet purge system The
33. after purge cycle is completed DERRICK DE 1000 CORPORATION VFD Centrifuge Clean Out Operation Setup Alarms Brg Temps Cent Status Diagnostics Motor Torgs 01 Aug 11 4 5 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS NORMAL STARTUP 5 With Home screen displayed select Operation to display the following screen Derrick Centrifuge O tion Bowl 2 Conveyor Pum mp 90 x A MEK m 00 00 00 00 Q0 6 Using up and down arrows set Bowl and Conveyor Input RPMs at desired speeds 750RPM minimum 7 Select START to turn on centrifuge Note that Bowl and Conveyor speeds will gradually rise until settings are reached and Torque for bowl and conveyor will rise If pump drive motor data has been changed since previous startup select Autotune to tune motor to VFD 8 When bowl speed has reached speed setting select Pump STAHT to start feed pump and slowly introduce feed to centrifuge O Note Pump will not start until actual bowl speed is within 120RPM of setting 9 Adjust feed rate Bowl speed and or Conveyor speed as required to optimize centrifuge operation Select Data screens at any time to review and monitor centrifuge operating characteristics including air conditioner status elapsed operating time and VFD data O Note Depending on conveyor differential speed setting at bowl speeds above 300RPM conveyor motor may rotate in opposite direction COLD CLIMATE STA
34. an external air filtration system installed on the outside of the control cabinet Components installed in the control unit include air filtration pressure and purge flow measurement purge timing and local visual indication of 1 4 15 Jun 11 DE 1000LPVFDCentrifuge INTRODUCTION pressurized alarm and flow sensed It also provides the required output to turn on power to the cabinet Relief Valve RLV The relief valve unit is installed on the left side of the control cabinet to provide a means of limiting the maximum pressure experienced by the cabinet during operation The relief valve incorporates a spark arrestor to prevent sparks from being ejected from the cabinet into the hazardous area The relief valve is combined with the flow measurement mechanism to provide feedback to the control unit Leakage Compensation Operation Initially a high flow of protective gas is passed into the control cabinet Figure 1 3 This flow is verified and performs the purging phase of the operation When the purge time has elapsed the flow of protective gas is controlled by an adjustable leakage compensation valve In addition to maintaining pressurization this valve compensates for any leakage from the cabinet For proper functioning of the leakage compensation valve leakage from the cabinet must exceed 5 l min Insufficient leakage will cause the relief valve to cycle open and closed continuously E CEOP EOE oc SEERNE AA OI oi PURGE FILTER SUPPLY
35. bearing temperatures bowl speed bowl and conveyor torques cabinet interior temperature and vibration are transmitted to the PLC which then responds with corresponding outputs to govern centrifuge operation Critical status information is displayed on the control panel as well as alarm and fault messages that signal the operator of any potential or imminent malfunctions Any excessive variation from a pre set limit causes the PLC to automatically shut down the centrifuge and display an explanatory message for the cause of the shutdown In addition emergency shutdown may be performed by the operator at any time from the front panel The positive displacement feed pump is fully controlled by the PLC in either manual or automatic operation Automatic operation provides maximum throughput as the optimum feed rate is assured by the PLC under varying operating conditions Feed is automatically increased until the pre set torque limit is reached by either the bowl or conveyor drive motor If feed slurry properties change the feed rate is automatically adjusted to remain within the torque limit 1 8 15 Jun 11 DE 1000LPVFDCentrifuge INTRODUCTION PRODUCT SUPPORT Derrick Corporation offers 24 hour per day 7 day per week product support Product support Includes screen replacement ordering information and repair replacement parts and service for the entire product line Refer to the following table for the parts service center nearest you
36. bearing until grease escapes from drain hole located between pillow block and liquid bowl head Wipe off surplus grease and distribute grease by rotating liquid bowl head one revolution clockwise and then one revolution counterclockwise 13 Check and adjust runout of outside diameter of gearbox as described in the steps below Axial runout may not exceed 0 002 0 05mm total indicator reading TIR 5 14 DE 1000LPVFDCentrifuge 01 Aug 11 MAINTENANCE 14 To measure and adjust runout proceed as follows a Clean surface of gearbox where dial indicator plunger will make contact b Install indicator holder with magnetic base in either position shown C Position plunger of dial indicator into contact with outside diameter at horizontal centerline of gearbox d Manually rotate the gearbox until dial indicator is at its lowest reading and zero out dial indicator PLUNGER POSITIONED AT HORIZONTAL CENTERLINE OF GEARBOX e Manually rotate the gearbox MEMES indi dee until reading on dial indicator is highest mark across gearbox and flange along axial centerline where surfaces mate 01 Aug 11 5 15 DE 1000LPVFDCentrifuge MAINTENANCE Reassembly and Installation Cont d f Manually rotate gearbox until mark LOCATION made in step e is at top um g Loosen hex head screw closest to gt E mark as well as both screws to each d side of the mark h Insert shim having approximate thickness
37. d Sy BEARING PILLOW INNERRACE BLOCK PILLOW BLOCK COVER FLINGER PILLOW BLOCK GEAR FLANGE COVER Figure 5 9 Liquid End Main Bearing Installation 5 18 01 Aug 11 DE 1000LPVFDCentrifuge 10 11 12 13 MAINTENANCE Remove flat head screws securing inboard pillow block cover to pillow block and slide pillow block and bearing outer race and rollers off liquid bowl head Loosen set screw securing inboard flinger to liquid bowl head Using a suitable puller and extreme care to avoid damaging bearing seat or shoulder on liquid bowl head remove bearing inner race from bowl head Discard inner race Slide inboard pillow block cover and flinger off bowl head Separate O ring from pillow block cover and discard O ring Using a suitable puller remove bearing outer race and rollers from pillow block Discard outer race and rollers Cleaning Inspection and Repair 1 Clean all components with a suitable cleaner degreasing agent and blow dry with filtered compressed air Remove any corrosion to facilitate inspection 2 Inspect bowl heads for scratches nicks burrs or deformation that may affect suitability for returning to service Blend out any minor surface defects Replace bowl head if shaft is obviously deformed or serious flaws are found that render the bowl head unserviceable 3 Test fit a new bearing inner race on the main bearing journal If the journal is undersize the inner race will slide e
38. defects Replace bowl head if shaft is obviously deformed or serious flaws are found that render the bowl head unserviceable 3 Inspect pillow block covers flingers and flinger covers for corrosion distortion nicks cracks burrs fractures or other defects Repair any minor defects 4 Replace any component that cannot be easily repaired Replace all O rings seals and bearings o Place all cleaned components in clean plastic bags to prevent contamination Installation 1 Insert new seal into liquid end seal housing Figure 5 12 and secure with retaining ring Install new O rings in external grooves of seal housing 2 Place one new thrust bearing on bore of bearing housing and using a suitable tool tap bearing evenly into place against shoulder of bearing housing Orient second thrust bearing with part number up to facilitate identification and install into housing on top of previous bearing 3 Install new O rings into external grooves of seal housing 4 Position seal housing on bearing housing and secure with screws Tighten screws in accordance with Hardware Torque Specifications 5 Replace solid end bearing in accordance with the following procedure Re install conveyor after completing replacement of both bearings and all conveyor repairs Solid End Bearing Removal 1 Remove conveyor from rotating assembly in accordance with Hotating Assembly Maintenance If not previously done Remove screws securing seal hous
39. least every 6 to 24 months depending on site conditions Visual Inspection and Checks 1 Inspect condition of relief valve and spark arrestor Remove all debris and corrosion or replace relief valve 2 Check drain air supply filters on cabinet exterior PURGE SYSTEM AIR FILTERS BALSTON BALSTON bed LI AIR FILTER ELEMENT 01 Aug 11 5 5 DE 1000LPVFDCentrifuge MAINTENANCE Visual Inspection and Checks Cont d 4 Atleast every two years check the following additional items Apparatus is suitable for the hazardous location There are no unauthorized modifications Quality of the air supply is correct refer to Compressed Air in Section 3 Approval labels are legible and undamaged e Power to the centrifuge is shut down upon loss of air pressure Initial Purge Time Setting The initial purge time is factory set to 14 minutes If purge time varies excessively the digital timer system inside the purge unit may be adjusted to restore the correct interval The time intervals marked on each valve are additive In the photo below the timer shows that total purge time available is 38 minutes 164 848 4442 If testing reveals that purge time has varied from this setting the purge time should be changed by opening or closing one or more valves When making an adjustment note that valves are either open or closed no intermediate setting is possible 151 4127 NOT OVERTIGHTEN
40. minor surface defects Replace bowl head if shaft is obviously deformed or serious flaws are found that render the bowl head unserviceable 3 Test fit a new bearing inner race on the main bearing journal If the journal is undersize the inner race will slide easily onto the journal Replace the bowl head if journal is undersize 4 Inspect pillow block covers flingers and flinger covers for corrosion distortion nicks cracks burrs fractures or other defects Repair any minor defects 5 Replace any component that cannot be easily repaired Replace all O rings seals and bearings 6 Place all cleaned components in clean plastic bags to prevent contamination Installation A CLEAN HEATED OIL BATH TO HEAT BEARING INNER RACE DO NOT USE T WARNING IN THE FOLLOWING STEP USE EITHER A BEARING HEATER OR A TORCH AS THIS WILL DAMAGE THE BEARING 5 22 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE Place bearing inner race in a bearing heater Figure 5 10 or heated clean oil bath and heat to approximately 230 110 C Do not use a torch to heat the inner race as this will damage the race 2 Wearing insulated gloves remove heated inner race from bearing heater and immediately slide onto bearing journal until seated against bowl head shoulder Allow inner race to cool until unmovable on solid bowl head 3 Slide inboard pillow block flinger onto shaft followed by pillow block cover Do not tighten flinger set screw at thi
41. of dial indicator measurement between flange and gearbox Shim should barely contact threads of screw hole closest to mark made in step e i Tighten screws loosened in step g j Repeat steps d through i if required until TIR does not exceed 0 002 0 05mm k Trim projecting shim stock 15 After completing gearbox installation install top cover over gearbox 16 Install drive belt and apply adequate tension to prevent slippage 17 Install feed tube and secure in its support 18 Close cover and secure by tightening screws MAIN BEARING REPLACEMENT This procedure describes replacement of the main bearings installed in the pillow blocks Refer to Tools and Equipment for tools used in the removal and installation procedures Excessive noise or vibration during centrifuge operation may indicate defective bearings If such conditions are evident the bearings should be inspected for looseness and replaced if necessary Bearing replacement must be performed by properly trained and qualified personnel To prevent contamination of the new bearings and internal components of the centrifuge the replacement procedure must be performed in a clean environment The ends of the rotating assembly are supported by roller bearings fitted within pillow blocks Components on each side of the pillow block form a labyrinth grease cavity which prevents contaminants from entering The roller bearing has a separate inner race which must be rem
42. or no pressure at power Check and adjust pressure if low switch output bulkhead and or at power switch Tubing to power switch Check that coupling nuts are tight and that tubing is not leaking damaged Correct any defects Defective power switch Check that power switch contacts close at 20 psi 1 4 barg Replace switch if contacts fail to close Incorrect purge time Check timer setting and reset to minimum available purge time Re check system operation at new setting If system functions properly return purge time to original setting If system fails to close switch contact Derrick for assistance Failure Mode 12 Purge System Relief Valve Remains Open Or Opens Intermittently Leakage compensation valve Adjust leakage compensation valve by turning adjustment out of adjustment causing high clockwise to reduce pressure cabinet pressure Debris on relief valve disk Remove relief valve cover and clean valve disk as required If allowing air leakage necessary to remove disk and spring from relief valve mark location of disk before removal to ensure proper installation If cleaning disk fails to eliminate problem contact Derrick for assistance Failure Mode 13 Air Conditioner Evaporator Faan Fails to Go On Poor electrical connection Shut down lock out and tag out electric power to centrifuge Open control cabinet door and locate fan at upper right Remove 8 screws securing fan to air conditioner housing and sepa
43. parameters as follows a Input data from the pump and pump motor nameplates Note Correct pump data is critical to achieving the desired feed rate to the centrifuge b Select Download to update VFD settings with new motor data This will cause pump to autotune at the next startup Select Disable for Tank High and Low Level inputs if they will not be used When finished making required changes click X in upper right corner to return to Setup screen then select Home to return to Home screen 11 Select Operation to display the following screen Derrick Centrifuge Operation Bowl O Conveyor Pump c 2125005 SEHE 4 SEO 4 v y 0 0 0 0 0 Tongue Pump 0 0 0 0 0 0 uus LE Ls mI Bass Brad VET Stee Prem URP WT a wo WI Yra ome 12 Using up and down arrow buttons set Bowl Input RPM at 20 RPM and set Conveyor Input RPM at 5 RPM 4 4 01 Aug 11 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS 13 Select START to confirm direction of rotation for bowl conveyor feed pump and air conditioner condenser motors as follows e Bowl Counterclockwise viewed from fan end Conveyor Clockwise viewed from fan end Feed pump Per manufacturer s data e Air conditioner condenser Clockwise viewed from fan end 14 Correct reverse rotation by shutting down power and switching any two of the three power leads at the terminal block s inside the cabinet refer to Se
44. rigorous service the heavy gage tag is riveted to a structural member such as the shaker support structure It is not to be confused with any other identifier on the machine such as a vibrator motor serial number For convenient availability the unit number is also recorded in the Operation and Maintenance manual shipped with the equipment When contacting Derrick for any equipment question or need always have the unit number in your possession It s the best way to get the most efficient service from our dedicated Service and Engineering personnel DERRICK CORPORATION ABOUT THIS MANUAL In this electronic manual all sections and paragraphs listed in the CONTENTS are linked to the corresponding text Navigate the electronic manual as follows 1 To view any desired information display the CONTENTS page and move the cursor to the desired paragraph or section title To display the desired information click on the listing when the pointing finger appears over the text When finished viewing the text press Alt left arrow key to return to the CONTENTS page If desired to return to the same information press Alt right arrow To locate a different item repeat steps 1 and 2 Blank pages are included to facilitate accurate two sided printing on a standard copier To print any individual section simply enter the PDF page number range at the top of the screen not the page number at the bottom of each pag
45. rotating assembly Place gearbox in plastic bag to prevent contamination BEARING PILLOW BLOCK Figure 5 4 Gearbox Removal 9 Tighten nuts on pillow block alignment pins to jack out pins and remove pins 10 Remove bolts securing pillow blocks to base mounting pads 11 Attach lifting straps at two locations on rotating assembly and using a hoist capable of supporting approximately 2000 Ibs 910kg lift and remove rotating assembly from case 12 Note locations of all shims found between pillow blocks and base mounting pads and remove and retain shims 13 Apply protective coating to mating surfaces of pillow blocks and base 14 Remove liquid bowl head assembly as follows a b 5 10 Hoist and orient rotating assembly vertically with solids end down and insert end into slot in vertical stand Figure 5 5 while continuing to support weight with the hoist Note locations of alignment marks on liquid bowl head to ensure proper orientation during reassembly Remove 12 screws securing liquid bowl head to bowl assembly Thread four jack screws into four threaded jack screw holes in bowl head and tighten evenly until head has separated from bowl Attach a second hoist to liquid bowl head flange and begin to lift bowl head off bowl with pillow block and splined shaft attached If bowl head does not fully separate from bowl lower head down until just enough space remains to insert a pry bar Carefully pry bowl head evenly
46. similar lifting aids to the electric motor or other non designated portions of the unit Use of spreader bars is recommended 15 Jan 11 3 3 DE 1000LPVFDCentrifuge INSTALLATION EQUIPMENT HANDLING CONT D LIFTING HOOK SLING SPREADER BAR irr LIS mal LLE PET Figure 3 2 Lifting Arrangement EQUIPMENT POSITIONING AND LEVELING The centrifuge must be properly leveled for satisfactory operation The equipment must be leveled along the length and width of the unit Figure 3 3 2 foot or torpedo level is recommended Non compressible shims should be used as required to level the machine Figure 3 3 DE 1000LP VFD Centrifuge Leveling LOWER AND SECURE ROTATING ASSEMBLY Note Retain shipping brackets that support rotating assembly after removal The brackets must be re installed whenever the machine is moved as they prevent damage to the rotating assembly bearings during transit Shipping brackets prevent bearing damage during transit and rubber strips protect the pillow block mounting surfaces After final positioning and leveling of the centrifuge the shipping brackets and covers must be removed and the rotating assembly secured to the base 3 4 15 Jan 11 DE 1000LPVFDCentrifuge INSTALLATION Each shipping component is labeled DISCONNECT BEFORE STARTUP To remove the shipping components proceed as follows 1 du Remove belt guard and gearbox guard Open case cover
47. system turn off compressed air supply to cabinet purge unit 4 20 01 Aug 11 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS AUTOMATIC SHUTDOWN The centrifuge has built in safety features to protect the equipment These features will result in automatic shutdown of the centrifuge before damage occurs The following paragraphs describe these automatic shutdowns Excessive Vibration Excessive vibration of the centrifuge will cause the vibration switch to interrupt electric power to the centrifuge run relay shutting down the machine Such excessive vibration may occur during startup or normal operation due to slumping of the wall cake or other unbalanced condition of the bowl The machine may be re started by pressing the reset button on the vibration switch and then using the Normal Startup procedure above If the machine continually trips during normal startup flush the bowl with fresh water while running the automatic cleanout routine Main Bearing Temperatures Temperature sensors are installed on the liquid and solid end main bearings and connected to the PLC Bearing temperatures are continuously displayed on the Operation screen An alarm message is displayed on the control panel when bearing temperature exceeds 225 107 C If temperature rises to 250 F 120 a fault message appears and the centrifuge is shut down Excessively high bearing temperatures usually indicate bearing failure which can result from inadequat
48. 00009966 9967 9968 9969 60009767 WAS 11881 01 025 az WAS ie 05 24 11 9872 9969 WAS 9871 CORPORATION BUFFALO NEW YORK U S A AND ARE NOT TO BE REPRODUCED WITHOUT THE WRITTEN PERMISSION OF DERRICK CORPORATION THE INFORMATION CONTAINED ON THIS DRAWING SHALL ONLY BE USED BY CUSTOMERS OR PROSPECTS OR THEIR sm rc JFS 12 15 10 DERRICK LA NJ REMSE BOWL amp CONV CABLE ASSY WAS 17378 01 amp 17279 01 REVISE INCOMING CABLE DA 6 08 17 REV DC BUS FUSE HOLDER WAS 00007585 2 AND 00007625 2 REV DC WIRE TO WHI 10 11 MIN ADD ENCLOSURE HEATER AND 2000 VA CPT OMIT 500VA CPT ADD THERMOSTAT DA 04 13 N ADD RTD SENSOR FOR THERMOSTAT AND WIRING AC UNIT AND CONVEYOR CONTROLLER Na 04 05 11 AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY T E JAN ASSY WAS 17377 01 ADD RELIEF VALVE A REVISE WIRING TO TEMPERATURE SENSOR REVISE TEMPERATURE SENSOR WAS 60009973 4 RELAYS FUSES AND RELATED WIRING CHANGE XP ENCLOSURE WAS 1662200005 8 REVISE DC BUS WRE WAS 10GA OF PARTS OR ASSEMBLIES TO DERRICK OR BY OTHERS FOR THE SPECIFIC REASON OUTLINED IN THE TRANSMITTAL WHETHER CORPORATION CHANGE CHANGE CHANGE CHANGE DATE WRITTEN OR VERBAL 394 0 0 _ 0 2 5 590 DUKE ROAD BUFFALO 14225 U S A 00 CENT MAN 1 2 3 1 1 66 O RING STOCK 70D NIT CORD 21 tt 65 HEXPLUUG PKR 8 HPSON SS IN wic a
49. 0012008 fX 32 RED 11 15 FUSE 5 A BI DT i lt 18 AWG SHIELDED 31 BLK 30 RED u E BLK lt Fry 9H RED RED BLK pod 24 Aer EA INTRINSIC 120 lt G0012047 gt AN9A RED U INTRINSIC aac BARRIER 5 5 SHIELDED BARRIER m sis y C0007918 elel BLUE INTRINSIC WIRING 18AWG gt R13 e a gt 0 NON INTRINSIC 17244 01 32 PEE Z INTRINSIC C0009286 8 4 lt lt aj lt lt TERMINAL BLOCKS Y TOGGLE Ws ero 154 e TB2 8 18 AWG TERMINAL BLOCKS TB1 VIBPATIDA SOLID 600120482 T Ali z G0009324 gt 2 gt GREEN 4 PT 5 6000857 2 lt 25 2 MONITOR P END gt T G0008544 URANGE 2 GT t 60008562 8 GREY 4 P cT FH sur G0008563X3 URANGE 4 PT 60007012222 END GROUND SHIELDS 5 60009839x2 JUMPER 2 PT zl AT THIS END ONLY E Rio e 2 4 x X2 NN n PO queo 1111315 uuu SPARE SPARE SPARE 60012013 3333 23233 a X TERMINAL COVERS TERMINAL BLOCK TERMINAL BLOCK 5 5 R1 2 P572 00002873 POWER DISTRIBUTION BLOCK 60008892 60008892 G0008891 GROUND SHIELDS e a3 4 60005309 OWER DISTRIBUTION BLOC
50. 07980 11 DIN RAIL PER JWC Y 16545 00 006 ADDED ITEMS 119 123 1 ori 8 7 6 5 4 3 2 1 CENT MAN DERRICK CORPORATION SECTION 9 INSTALLATION AND MAINTENANCE LOG PURPOSE This section should be used by operating and maintenance personnel to record historical information gathered during the installation and operation of the Derrick equipment If properly kept the log will be useful for altering maintenance intervals and intercepting trends that may indicate the need for changing operating procedures Each entry in the log should be dated for future reference and tracking If required additional pages may be added to the log by copying a blank page or simply inserting ruled paper at the rear of the section Installation and Maintenance Notes 15 Jan 11 9 1 DE 1000LPVFDCentrifuge INSTALLATION amp MAINTENANCE LOG 15 Jan 11 DE 1000LPVFDCentrifuge INSTALLATION AND MAINTENANCE LOG 15 Jan 11 DE 1000LPVFDCentrifuge INSTALLATION amp MAINTENANCE LOG 15 Jan 11 DE 1000LPVFDCentrifuge INSTALLATION AND MAINTENANCE LOG 15 Jan 11 DE 1000LPVFDCentrifuge INSTALLATION amp MAINTENANCE LOG 15 Jan 11 DE 1000LPVFDCentrifuge DERRICK CORPORATION Equipment Model Characteristics Document No PE S 069 03 03 CERTIFICATE OF ORIGIN Centrifuge DE 1000 GBD DE 1000 FHD DE 1000 VED 0 600VAC 50 60Hz 3PH Derrick Corporation acknowledges that the above
51. 1 SS HEX SOCKET 00003064 52 IN LBS L E SEAL HOUSING LA HARDWARE PARTS LIST 3 8 16 X 1 1 2 SS HEX SOCKET G0003066 52 IN LBS L E BEARING HOUSING VANER SEEDEDE 3751701 1 103 5 16 X 5 16 X 3 KEY G0003872 L E BOWL HEAD ZONES GE fc NVBlee 3 7 0 3 IL 4 02 5 16 X 1 PIN STEEL PP32 N A 680L L BOWL HEAD o 712 3 8 16 X 1 1 4 SS HEX SOCKET 60003065 252 IN LBS L E BOWL HEAD APTA MW ERRICK CORPORATION E B 90 DUKE ROAD BUFFALO NY 14225 U S A CORPORATION THE INFORMATION CONTAINED ON THIS DRAWING SHALL ONLY BE USED BY CUSTOMERS OR PROSPECTS OR THEIR DRAWING NO ITEM HARDWARE REQUIRED PART NO PER PC TORQUE SETTING LUBRICANT REFERENCE PART OF PARTS OR ASES TO TO DERRICK OR BY OTHERS FOR THE SPECIFIC REASON OUTUNED INTHE TRANSMITTAL WHETHER _ 14394 0 SPEED SENSOR LIQUID END RTD SENSOR E D C N 1 128 FITTING CORD 500 NPT 500 625 DA PPT 3 ___ 27 TERMINAL 16AWG ___ PVM GRN M 1 1 26 HEAT SHRINK GREEN YELLOW 21 INCHES 0057 IN 1 25 CABLE INTRINSIC 18AWG 18C T 162 GE oma 24 FITTING CORD 500 NPT X 375 500 DA 00001687 1 N 31 22 FERRUEWRE IAWG BU 6000648 1 1 20 SEALING 050 __ 19 FITNGCORD 500 NPT X 125 250 DA 1000071 1
52. 4 64 MOUNTING RING 0680 Y B 11 65 BEARING HOUSING FLINGER 4 B 11 8 BOWL HADEXENSON CO tT GEARBOXES ap 111 1 60 jcoPNG 1000625 22 O 00 JB 1 j 57 O RING 227 9024 04 CS10 RA 524 00 1 56_ CARBIDE INSERT 9824 01 CSi0 RA 629 TC lt Pre 155 4 174 SINGLE LEAD CONVEYOR 14 SS Be 1 1 54 SEAL HOUSING SE 33 00 59 JB 1 47 RETAINER RING RR475 CS10 RA 328 00 75 44220 __ 1 1 14 BEARING HOUSING gt 1 1 31 50005 DISCH WEAR INSERTS 9547 00 510 530 a IN o ON SS ZUN GA IG OT Y L O 2 2402 a EN SS bA IIIT m zm EI LIEU eee gt EN ON Du x TES Ns qs 1 1 Ts O RING 249 CST0 RA 325 00 SS E Hz B _ 1 1 52 BALL BEARING 6017 CS10 RA 511 00 d Lm I B 1 1 151 RETAINER RING RR425 CS10 RA 327 00 19 55 JB 2 2 50 SEAL GARLOCK 24600 7374 CS10 RA 310 00 S Ex cto Y gt N E wje 1 1 46 FEED ACCELERATOR BUMP We DID 40 722 ei B 1 L1 145 O RING 261 CS10 RA 323 00 N c RN Ar gt 101 a 14 1 4 SINGLE LEAD CONVEYOR 7 KN Ge Ji NS US SE lt 22 B _ 1 1 435 O RING 252 CS10 RA 322 00 DIDAS Ty 1B 12 12 1539 THRU
53. 622 00 00 590 DUKE ROAD BUFFALO NY 14225 U S A NT BOM PUR 8 7 6 5 4 3 2 1 2 1 1639600007 JENCLOSURE ASSEMBLY O SPECIAL TOOL PURGE PRESSURE MEASURING KIT 60008378 6 1 1640 0100 7 DOORASSEMBLY _ 8 1 640402009 UPPER oO 9 1 1682201005 EXPLOSION PROOF ELECTRICAL ASSEMBLY D 23 21 20 51 50 i S lt gt Ps FANWHEEL 8 BACKWARD CURVED SKR lt S A CS 3 5 STA ya 77 N N Y N N G N N 2 N N N N 2 VO N N 2 NF N SS 2 OC N S Z N 2 N 5 5 AN S N R q C 87 5 gt gt C 47 1 CRHRE64 REDUCER 2 X1 1 4 5 S 4 12 uer 13 42 6 1 742001 NCTHERMOSTATMOUNTINGBRACKET 26 N 7 68 1 76000874 WIREDUCL112X2X81l14 777 69 1 300985 WIREDUCLi112X2X17 73 8 DOORLATCH Bf so 1 6000759955 COMPACTFLASHMEMORYCARD 81 190007252 WIREDUCTFASTENERMOUNT 82 __ 510 6 88 80005519 WIRESADDLE MEDIUM 86 1 00009 ETHERNETCABLEX94 ETHSW50HP 89 0000880 TERMINALBLOCKCOVER 350MOM 90 1 160002873 TRANSFORMER COVER 96 1 737301 CORDASSEMBLY BOWLMOTOR TO ENCLOSURE 98 1 173820 CORDASSEMBLY NTRINSIC PURGE SYSTEM 2 71 99 1 800001686 9 FITTING C
54. 707 TUR ITEM 28 REVISE 25 WAS 153 std FRONT A FOR ACCURACY REVISE PARTS LIST TO INCLUDE MORE DETAILS SEE MODEL SPACE FOR ORIGINAL PARTS AAA AAN oe LIST FOR REV 1 5 02 23 12 us DESIGNS AND INFORMATION CONTAINED ON THIS DRAWING OR COPIES REMAIN THE EXCLUSIVE PROPERTY OF DERRICK REVISE ITEMS 15 amp 16 WAS 60008126 AND 8127 CORPORATION BUFFALO NEW YORK U S A AND ARE NOT TO BE REPRODUCED WITHOUT THE WRITTEN PERMISSION OF DERRICK SIZE C E DERRICK A NEE 09 01 10 CORPORATION THE INFORMATION CONTAINED ON THIS DRAWING SHALL ONLY BE USED BY CUSTOMERS OR PROSPECTS OR THER DRAWING NO AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY CORPORATION Y N DELETE ITEMS 23 AND 24 DUPLICATES OF 18 AND 20 zZ OF PARTS OR ASSEMBLIES TO DERRICK OR BY OTHERS FOR THE SPECIFIC REASON OUTLINED IN THE TRANSMITTAL WHETHER 1 6 6 1 E 08 25 09 WRITTEN OR VERBAL 590 DUKE ROAD BUFF 4 6 8 BOM CENT MAN ALO NY 14225 U S A NAMEPLATE DETAIL 2 11 16 68 27 11 1 2 NPT 2 PLACES 1 2 14 d 5 5 8 142 _ 2 1 4 57 ADALET ASSEMBLY NOTES 1 INSTALL METRIC STAINLESS BOLT AND WASHER AS SHOWN REF 4758 00 007 REF W S 14594 00 018 REF 16545 00 002 9909 7 16 2 5 8 4 7 16 6 7 1 2 8 3 8 9 3 4 5 13 16 4 7 16 DO 2 3 4 Q we 02 12 ALL HOLES 10 52 TAPPED HO
55. ANCE SCHEDULE Inspect feed tube connection for leaks and tighten connection clamp as 4 Each shift required Inspect liquid discharge connection for leaks Tighten connection and or yi Each shift add silicone sealant to prevent leakage Grease rotating assembly bearings Figure 5 1 One shot each shift Remove feed tube clean interior of tube and reinstall Weekly Check gearbox fluid level with fill plug at 12 o clock position Every 2 weeks Check interior and exterior of case for accumulated solids and clean as required Purge conveyor bearings Every 2 weeks Remove belt cover inspect belt for damage and check adjust tension Monthly 01 Aug 11 5 1 DE 1000LPVFDCentrifuge MAINTENANCE PREVENTIVE MAINTENANCE CONT D PREVENTIVE MAINTENANCE SCHEDULE Remove and clean flinger covers Monthly Grease bowl and conveyor motors Ten Shots Quarterly CONVEYOR BEARING LLOWEBLOCE GREASE FITTING DRAIN HOLE 4 MAIN BEARING GREASE FITTING EA 2 F li GREASE FITTING Figure 5 1 Rotating Assembly Lubrication Points 5 2 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE LUBRICATION CHART The following chart lists the Derrick approved lubricants for the DE 1000LP VFD centrifuge rotating assembly gearbox and drive motors DERRICK APPROVED LUBRICANTS DE 1000LP VFD CENTRIFUGE OILS Chevron SRI NLGI 2 SRI 2 Main amp Conveyor Bearings otandard Shell Aeroshell 14 Main amp Co
56. Bowi VFD Conv VFD Pump Home LIQUID END BEARING TEMPERATURE OF SOLID END BEARING At Startup GRN DRIVE OPERATIONAL ADJUST CONVEYOR GRN DRIVE RUNNING RED DRIVE FAULT DIFFERENTIAL SPEED GRY DRIVE OFF ADJUST FEED PUMP OUTPUT ADJUST BOWL SPEED gt gt _ FEED PUMP OUTPUT Actual RPM Actual RPM Actual OF TOTAL AVAILABLE BOWL OPERATING DATA 0 0 0 0 0 Torque e D 95 CENTRIFUGE IS 0 0 OPERATING PUMP OPERATING DATA CONVEYOR OPERATING DATA LIQUID END BEARING TEMPERATURE Faults PUMP OPERATING UNDER AUTOMATIC CONTROL Clean Out Alarms VFD Conv VFD Pump VFD Home SOLID END BEARING TEMPERATURE SCREEN SELECTION INITIATE CONTROLLED SHUTDOWN BUTTONS 8 DIFFERENTIAL SPEED MAINTAINED UNTIL BOWL SLOWS TO PRE SET SHUTDOWN SPEED THEN CONVEYOR RED BACKGROUND ACTIVE ALARM PRESENT SLOWS TO STOP Running Figure 4 2 Operation Screens 4 8 01 Aug 11 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS Bowl Speed The faster the bowl speed the faster solids are settled through the pond to the outer wall of the bowl and conveyed out of the centrifuge but faster processing results in wetter solids discharge To reduce wetness the slurry must remain in the bowl longer subjecting it to the settling process for a longer duration before being conveyed out the solids discharge Conversely reducing bowl speed may be desirable for thick heavy slurry to extract on
57. CHINE WARNING BE SURE THAT ALL SHIPPING COMPONENTS HAVE BEEN REMOVED AND BEARING PILLOW BLOCKS ARE PROPERLY TIGHTENED WARNING ALWAYS ALLOW MACHINE TO COAST TO A COMPLETE STOP BEFORE OPENING COVER OR REMOVING GUARDS WARNING DO NOT OPERATE CENTRIFUGE IF EXCESSIVE NOISE OR VIBRATION DEVELOPS ALWAYS CONFIRM THAT VIBRATION SWITCH AND OTHER SAFETY DEVICES ARE FUNCTIONAL 01 Aug 11 4 1 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS PURGE SYSTEM Purge Cycle During startup the control cabinet purge system drives out all gases from the cabinet interior and then maintains positive pressure within the control cabinet to prevent entry of any potentially explosive gases Purge system operation begins when the system senses sufficient air pressure inside the cabinet Initially the purge unit performs a 16 minute rapid purge cycle at 16 CFM During the rapid purge cycle the purge system prevents application of electric power to the cabinet At the end of the rapid purge cycle the purge system closes the main electrical contactor allowing electric power to flow to the cabinet The centrifuge may then be started After the rapid purge cycle the purge system maintains positive pressure within the cabinet to prevent entry of hazardous gases automatically compensating for pressure loss due to cabinet leakage If at any time a loss of cabinet pressure is detected the main contactor opens immediately disconnecting power If a shutdown occur
58. D status screen permits the operator to view various operational characteristics of the VFD such as present alarms or faults power voltage and current outputs motor and bowl speeds direction of motor rotation VFD temperature and motor torque GRN NO ALARM FAULT PRESENT RED ALARM FAULT PRESENT GRN MOTOR RUNNING GRN RUNNING GRN OPERATIONAL GRY Y RUNNING GRY MOTOR NOT RUNNING GRY ALARM ROTATING SET SPEED GRY SET SPEED GRN PLC COMMUNICATION p larm orward RED NO PLC COMMUNICATION pp CO Ready reverse Q eee MOTOR ACCELERATING V 2 ory NOT ACCELERATING Q Online Speed RPM o e GRN MOTOR DECELERATING BOWL SPEED SETTING Motor Bowl Current DC Bus GRY NOT DECELERATING 215 3000 0 0 So _ PRESENT OUTPUT CURRENT PLC CALCULATED Actual 0 0 temp Heatsink U MOTOR SPEED 95 4 F 35 3 PERCENTAGE OF MAXIMUM dad 0 Wer PERMISSIBLE TEMPERATURE RISE GRN BELOW OVERSPEED Tor E RED EXCEEDING OVERSPEED PRESENT OUTPUT POWER TOLERANCE 75 ur NOR ie 2 7 TOTAL HOURS OF VFD OPERATION PERCENTAGE OF TOTAL Diagnostics VFD Temp VIEW TEMPERATURE UNCONTROLLED BOWL STOPPAGE TREND SCREEN CLICK TO SWITCH TO VFD CONTROL FOR REDUCED STOPPAGE TIME PRESENT VFD TEMPERATURE VIEW DIAGNOSTICS SCREEN BOWL STOPPING UNDER VFD CONTROL FOR FASTER STOPPAGE Figure 4 10 Bowl VFD Screen GRN NO ALARM FAULT RED ALARM FAULT PRESENT
59. E Removal Cont d 2 Record alignment marks on sheave and then remove screws securing sheave to solid bowl head Thread two jack screws into sheave and alternately turn each screw a few turns at a time until sheave is separated from solid bowl head remove sheave and outboard flinger cover Grasp sheave and pull from solid bowl head 10 Remove flathead screws securing outboard pillow block cover to pillow block and remove cover Separate O ring from pillow block cover and discard O ring Remove flat head screws securing inboard pillow block cover to pillow block and slide pillow block and bearing outer race and rollers off solids bowl head Loosen set screw securing inboard flinger to solid bowl head Using a suitable puller and extreme care to avoid damaging bearing seat or shoulder on solid bowl head remove bearing inner race from bowl head Discard inner race Slide inboard pillow block cover and flinger off bowl head Separate O ring from pillow block cover and discard O ring Using a suitable puller remove bearing outer race and rollers from pillow block Discard outer race and rollers Cleaning Inspection and Repair 1 Clean all components with a suitable cleaner degreasing agent and blow dry with filtered compressed air Remove any corrosion to facilitate inspection 2 Inspect bowl heads for scratches nicks burrs or deformation that may affect suitability for returning to service Blend out any
60. ED Login Software Version SOFTWARE VERSIONS DISPLAY MAX MIN DE 1000 BOWL amp DIFFERENTIAL PLC Rev 3 0 4 ADJUST DISPLAY SPEED SETTINGS AND HMI Rev 3 0 8 BRIGHTNESS PUMP SETTINGS TO SUIT AMBIENT FOR EACH OPERATOR E Display Brightness LIGHTING T5 x o VIEW PUMP OPERATING Operating Range i CHARACTERISTICS Pump Sep Temperature Units Diagnostics C Home ELECT DESIRED VIEW CORRESPONDING SCREEN TETTE UNIT Figure 4 16 Setup Screen PUMP SETUP The pump operating characteristics are viewed on the Pump Setup screen Figure 4 17 Information keyed in from the pump and drive motor operating specifications is displayed to inform the operator of current motor and pump information Derrick Centrifuge Pump Setup X PUMP OUTPUT IN Motor Data Pump Data GALLONS PER REVOLUTION Current Output Rev PUMP DRIVE MOTOR 4 EE S R OPERATING DATA J 3 10 00 Gear Box Ratio Auto Flow Rate 95 TOGGLE BETWEEN Low Level HP amp NM Update VFD Settings TOGGLE HIGH LOW Download d LEVEL MONITORING d ON AND OFF Figure 4 17 Pump Setup Screen 4 18 01 Aug 11 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS LOGIN The Login screen Figure 4 18 is accessed from the Setup screen Figure 4 14 It permits authorized personnel to enter a password required to display restricted screens These screens permit supervisory personnel to re set operating characterist
61. EN POSITIONED AT FINAL INSTALLATION SITE WARNING ALL OPERATING AND MAINTENANCE PERSONNEL MUST READ AND UNDERSTAND ALL SAFETY INFORMATION IN THIS MANUAL BEFORE WORKING WITH THE EQUIPMENT WARNING BE SURE THAT TOP COVER IS CLOSED AND SECURED AND ALL PERSONNEL ARE CLEAR BEFORE STARTING MACHINE WARNING BEFORE STARTING CENTRIFUGE BE SURE THAT ALL SHIPPING BRACKETS HAVE BEEN REMOVED AND BEARING PILLOW BLOCKS ARE PROPERLY TIGHTENED WARNING ALWAYS ALLOW MACHINE TO COAST TO A COMPLETE STOP BEFORE OPENING TOP COVER OR REMOVING GUARDS WARNING DO NOT OPERATE CENTRIFUGE IF EXCESSIVE NOISE OR VIBRATION DEVELOPS ALWAYS CONFIRM THAT VIBRATION SWITCH AND OTHER SAFETY DEVICES ARE FUNCTIONAL Maintenance WARNING HIGH VOLTAGE MAY BE PRESENT ALWAYS OPEN FUSED DISCONNECT SUPPLYING ELECTRIC POWER TO THE EQUIPMENT AND LOCK OUT AND TAG OUT POWER SUPPLY BEFORE PERFORMING ANY MAINTENANCE AND OR ADJUSTMENTS OF EQUIPMENT 2 2 15 Apr 11 DE 1000LPVFDCentrifuge SAFETY Storage HUMIDITY ENVIRONMENT GREATER THAN 50 RH EQUIPMENT MUST BE STORED IN A LOW HUMIDITY ENVIRONMENT N WARNING CENTRIFUGE MAY BE DAMAGED BY STORING IN A HIGH MATERIAL SAFETY DATA SHEETS MSDSs Material Safety Data Sheets MSDSs advise personnel of the properties and any possible hazards associated with these materials Emergency first aid procedures special precautions emergency telephone number and other relevant data are contained in the MSDSs T
62. F38 16X250 Hex Head Jack Bolt 3 8 16 x 2 1 2 Long 2 Separate gearbox from flange HXCBF31 18X400 Hex Head Jack Bolt 5 16 18 x 4 Long 4 Separate conveyor bearing housing from liquid end bowl head shaft HXCBF38 16X400 Hex Head Jack Bolt 3 8 16 x 4 Long Separate conveyor bearing housing from solid end bowl head shaft 10792 00 Vertical Lifting Bracket 1 Lift solid end bowl head and conveyor from bowl assembly 10791 00 Vertical Stand Support liquid bowl assembly vertically during maintenance WFSS 31 5 16 Flat Washers Attach vertical lifting bracket to gearbox flange NHHS 31 18 Hex Nut Heavy 5 16 18 Attach vertical lifting bracket to gearbox flange SKCS 38 16x175 Socket Hd Cap Screw 3 8 16 x 1 3 4 Attach vertical lifting bracket to gearbox flange 20004114 Socket Hd Cap Screw 5 16 18 x 1 1 4 Attach vertical lifting bracket to solid end bowl head RED B150X125 Bushing Hex 1 1 4 x 1 1 2 Reduce opening of feed tube CHE SRI 2 Grease Standard 1 Lubricate main bearings and gearbox spline Aeroshell GR 14 Grease Arctic Lubricate main bearings and gearbox spline 01 Aug 11 5 27 DE 1000LPVFDCentrifuge MAINTENANCE DE 1000 VFD CENTRIFUGE TOOL LIST EYE S31 18X113 Eye Bolt 5 16 18 x 1 1 8 2 Lift rotating assembly by gearbox flange PP1127 Grease Gun 1 2 Dia Hose 14 5 Oz 2 Inject grease into gearbox and main bearing fittings Appropriate grease included per climate and customer requi
63. FDCentrifuge MAINTENANCE Alarm and Fault Messages Liquid End Main Bearing High Temperature Fault and Shutdown Insufficient bearing lubrication Lubricate bearings refer to Preventive Maintenance Excess grease Remove grease fitting and direct jet of filtered compressed air to remove grease Incorrect grease Lubricate with recommended grease refer to Preventive Maintenance Defective bearing Replace both main bearings refer to Main Bearing Replacement Pump VFD Alarm Ref Troubleshooting Section of User Manual Pump VFD needs re booting Press STOP and cycle power off and then on If alarm does not clear replace pump VFD Pump VFD Communications Error Pump VFD not communicating with PLC Confirm that green LED next to Ethernet cable is lighted indicating that hub is functional Check connections between pump VFD and PLC and correct any defects Replace pump VFD if no other defect is found Pump VFD Drive OL Alarm Ref Troubleshooting Section of User Manual Pump drive motor drawing excessive Replace motor if defective or remove other cause of current excessive current draw Pump VFD Fault Ref Troubleshooting Section of User Manual VFD fault detected causing shutdown Check and replace pump VFD Pump VFD Ground Warn Alarm Ref Troubleshooting Section of User Manual Pump motor has path to ground Check pump motor and connections to drive output for a grounding remove ground connection P
64. FORE OPENING COVER OR REMOVING GUARDS N WARNING ALWAYS ALLOW MACHINE TO COAST TO A COMPLETE STOP 2 After bowl assembly has coasted to a full stop loosen screws securing case cover until screws are disengaged from lower case and raise cover Remove feed tube and drive belt Remove top cover from gearbox enclosure Attach a suitable lifting strap and hoist to conveyor drive motor DD s Y Remove screws securing both halves of flexible coupling to shafts of conveyor drive motor and gearbox and remove coupling halves Figure 5 3 FLEXIBLE MOTOR COUPLING GEARBOX ADJUSTING BOLT Figure 5 3 Conveyor Drive Flex Coupling 7 Remove nuts and washers securing conveyor drive motor to mounting base and lift and remove motor 8 Remove the gearbox as follows a Remove six screws securing gearbox Figure 5 4 to flange b Install two 3 8 16 jack screws into gearbox flange clearance holes and alternately turn both jack screws a few revolutions at a time to begin separating gearbox from flange c Support gearbox during remainder of procedure using a lifting strap and suitable hoist 01 Aug 11 5 9 DE 1000LPVFDCentrifuge MAINTENANCE Removal and Disassembly Cont d d e Fully separate gearbox from flange by alternately turning jack screws until unit is fully detached With gearbox supported by lifting strap and overhead lifting device CAREFULLY slide gearbox outward until splined shaft is free of
65. ION THE INFORMATION CONTAINED ON THIS DRAWING SHALL ONLY BE USED BY CUSTOMERS OR PROSPECTS OR THEIR DRAWING NO AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY CORPORATION OF PARTS OR ASSEMBLIES TO DERRICK OR BY OTHERS FOR THE SPECIFIC REASON OUTLINED IN THE TRANSMITTAL WHETHER 1 b 4 un 1 WRITTEN OR VERBAL 990 DUKE ROAD BUFFALO NY 14225 U S A MAN 85 L1 V Y Y 4 4 Y 1 1 4 i t FEES AL UN MELLE a 2 2 ea KA SE __ 2 INN YA 5 TI A NA AL OO 5 N 61211 SS Gt TPN S ST _ LLL ZT 4 4 LU 4 e paa aaa pra cha im urine mom Amr li 2 SY REE _ A Ed a 2 27722 2 2 pin prj A NZ fir O B LL NS 5 ATTE 9 LA al 8 Y N E HA NES M Q 15 MO ONE O O 2 e AAA a A RE A a ed SEIZE L LOCKTITE 74 3 8 16 X 1 1 2 HEX HEAD BOLT 60008180 I FEED TUBE SUPPORT FLANGE 140 5 16 18 X 1 2 ALY SET SCREW CUP PT 60004184 NA FLANGE TO KEY 6 39 M6 X 40 HEX SOCKET ALY 7 13635 38 N A ROTODIF TO ROTODIFF FLANGE 3 8 16 X 2 1
66. K COVER G0008893 4 G0008893 4 G0008892 THIS END ONLY SE 13 5191519191519 60008890 3 G0008893 4 EQUIPMENT SUE GROUND 1 1 1 2 NPT SH 1 1 2 NPT EE eec NPT PLUG NPT PLUG SS os NPT 3 4 NPT 1 0 4 8 XP CABLE 05514 2 1 2 NPT CORD FITTING 1 NPT PLUG CORD FITTING CORD FITTING 100 SPARE SHPP 100 INTRINSICALLY RATED CORD FITTING CONTROL CIRCUIT CORD W CABLE GLAND 0009811 CENTRIFUGE POWER 00008809 60001686 erg KR PS JUNCTION BOX FITTING 60009768 Abs CORD FITTING XP CABLE ASSY XP CABLE ASSY lt gt 882200 60009983 BY OTHERS W CABLE GLAND W CABLE GLAND 16584 01 004 A al MENIG BARRIER i POWER CABLE XP 4C 4C 4AWG PUMP RESTART PUMP ENABLE 2 00009286 T SIZED FOR 27A WB OFF SC OFF Ad 60009898 Ads 60009899 REMOTE CONTACT REMOTE N O CONTACT ur C5 ivi e ve 3 sE 4 stl S SE3 6 LEe 7 LEI 8 LE3 9 5 5 10 SP6 SPARE SPARE o IV CABLE ASSY BY OTHERS BY OTHERS BY OTHERS C XN OE EEE 2 W CABLE GLAND EEE 49 9 WHEN CLOSED AND WHEN CLOSED AND L vil ve see se SE3 Lee Lei LES sPS sPe SPARE SPARE 2C 420AWG SHIELDED MAXIMUM PUMP PROGRAMMED PROGRAMMED 17382 01 n CONVEYOR a PUMP WILL RESTART PUMP IS ENABLED ELBOW ELBOW M F 3 4 60008214 15 21 Puis IF PUMP WAS RUNNING RUN A H CRH
67. LE EXCEPT WHERE NOTED 12 PLACES B 8 32 TAPPED HOLE 7 PLACES 7 15 MRE TE BASE SMALL PAN TM3SIO C 1 13 GROUND LUG 250MCM DUAL ONE MTG HOLE MECH G0008896 1 12 TIME DELAY FUSE 1 25 AMP 250V 60096 B 2 11 TIME DELAY FUSE 0 5AMP 600V STYLE ATOR 00045 NOT USED 142 09 0142 ZA 1 08 TRANSFORMER CONT 480V PRI 120V SEC 60002481 ZA 1 07 SMTCH AMP BARRIERINTINIC 00296 2 06 END CLAMP FOR 35 MM DN 160007012 1 05 DIN RAIL 35 X 75MM X 1 5 ZPL STL 6000292 f _ O4 NOTUSED N 1 03 CONTACTOR IEC 100A 1 600V W 120V COIL NCLOSURE EP 10 X14 X6 NEMA 4X 7 amp 9 AL SA1123 1 01 ASSEMBLY 16622 01 005 QTY ITEM PART NAME DESCRIPTION PART NO A V IN rense severa on pae 0 10 13 10 ELECTRICAL CONTROL PANEL FOR IN 08 we tes REV OY NAS ow ores 08 31 104 VFD DE 1000 WITH SKID 460 480 V YES foo MUS fone 05 23 07 fene Lu de palea eee ums il ERR 14 3 C DERRICK CORPORATION THE INFORMATION CONTAINED ON THIS DRAWING SHALL ONLY BE USED BY CUSTOMERS OR PROSPECTS OR THEIR DRAWING NO AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY CORPORATION EN A ASSEMBLIES TO DERRICK OR BY OTHERS FOR THE SPECIFIC REASON OUTLINED IN THE TRANSMITTAL WHETHER 6
68. LURE 28 Se 28 RED e a N 48 o o INVERTER AC COMP MIR 01 2929 29 RED PLC 1 L2 COM G RED 18 AWG SPEED SENSOR 1 EVAP BLWR MIR 01227 22 27 RED 8 x e 60007228 POWER SUPPLY END BARRIER USB PS2 ASSY EMERGENCY STOP PUSHBUTTON ANALOG 4 20MA 2 FANDA RED A A BOWL 18 AWG lt BATTERY 120V 2 60007230 i 60005325 17 p Re CONTROLLER 50HP 5 60008549 10007220 17008009 x EMER STOP CIRCULAR LEGEND STOP 32 3E BLK SPEED SENSOR STRED 5 17 MEMORY CARD 60003552 214 SPEED SENSOR 30 30 REDI T COMPACTFLASH MEC z z zal COM 25 25 TEMP SENSOR SOLID 1 m 60007995 Mele 5 RIS Ea los BK CONNECT SHIELD GROUNDED END ETHERNET MOUSE POINTER ASSY TERMINAL BLOCKS TB3 5 52 T19720730 O e 525 PTE OF ETHERNET CABLE AT SWITCH CABLE 17006 01 oaod Tove G000856e 5 GREY 4 PT NAV E TloT20T3o 9 10 MARKED W GREEN 60009873 6000932406 4 PT z z z A i ne El 4 ETHERNET R445 L1 N G SUIT OUTPUT FUSE HOLDER MAX SWITCH GRO AC 77 AMP ememer 823 ETHERNET AA ABE RED 18 AWG Vi 60012511 2 OUTPUT FU Rus Vit vi O2 25 BLK THHNLS STR BLK DC ETHERNET low D C BUS WIRE DC CABLE SURGE PROTECTOR THHNF8S STR WHT A 60009872 THHN 18 AWG 600038040 THHN 14 STR BLK EB ES FUSE HOLDER I 60012010 2 THHN 14 STR WHT 18 AWG 6
69. Leakage Compensation Test A Magnahelic gage and hose kit available from Derrick is required to monitor cabinet pressure The leakage compensation valve adjustment should be checked for deviation from factory setting as follows 1 SLOWLY open the supply regulator or leakage compensation valve and allow the cabinet pressure to rise until the relief valve opens Check that the relief valve opens at or below 7 0 8 WC 17 4 2 Repeat the relief valve test several times Open the supply regulator to between 60 and 115 psi 4 and 8 barg to start the purge flow Check that the internal logic gage reads 30 psi 2 bar At this time the ALARM PRESSURIZED indicator should be green and the PURGING indicator should be amber If the amber indicator remains off the flow through the relief valve is below the minimum for which the flow sensor has been calibrated Check the air supply pressure at the inlet to the control unit while purging is taking place It must be above the minimum specified pressure ume e He 5 6 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE CONNECT MAGNAHELIC GAGE AT THIS JUNCTION LEAKAGE COMPENSATION VALVE 6 The purge timer will start as soon as the PURGING indicator turns amber Check that the time delay between the PURGING indicator turning amber and the application of power to the control cabinet is not less than the minimum time required for purging the cabinet Times in excess of
70. Min 982 2 TO GREEN AC Running WHEN AIR CONDITIONER CYCLES ON NO OF TIMES AIR CONDITIONER CYCLED IN PAST HOUR Enc _ VFD Max Conv VFD 950 1053 1024 845 VFD Min Pum VED 944 N 103 8 MAXIMUM AVERAGE MINIMUM AVERAGE VFD TEMPERATURE VFD TEMPERATURE PRESENT TEMPERATURE OF EACH VFD Figure 4 8 Cabinet and VFD Temperature Status Screen ALARMS The Alarms screen Figure 4 9 permits the operator to review and acknowledge active alarm messages Each alarm is listed with its status date and time received and description Buttons are provided at the bottom of the screen to facilitate scrolling through the alarms Messages may be acknowledged individually or all alarms may be acknowledged simultaneously Provisions are included for sorting alarms in the order of occurrence and buttons are included for returning to the Operation or Home screen Alarm ack Alarm Description 0 3512005 9 56 55 AM 3 39 01 AM Emergency Stop Switch Activated Shutdown 0 3 5 2005 9 56 55 9 59 00 AM Emergency Stop Switch Actuated Shutdown SCROLL TO FIRST OR LAST LINE ARRANGE LIST BY TIME RECEIVED NAME SCROLL ONE LINE SCROLL MULTIPLE AT A TIME LINES AT A TIME Figure 4 9 Alarms Screen 4 14 01 Aug 11 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS VFD STATUS Status screens Figure 4 10 through 4 12 are selected from the Operation screen Each VF
71. NAL PRESENT sensor NO SENSOR INPUT 0 7 Centrifuge Total Open EXCESSIVE VIBRATION Sr pen Closed 000000 8 Speed Switch N Controller Total __ Closed Ss 000001 6 Open BOWL OVERSPEED CYCLE AIR CONDITIONER DISPLAY STATUS SCREEN SHOWING ON FOR 30 SECONDS TO CHECK TEMPERATURE DETAILS FOR MOTOR ROTATION DIRECTION ENCLOSURE amp VFDs CHANGES TO GREEN AC Running WHEN COMPRESSOR CYCLES ON Centrifuge With RTD Sensor PRESENT BEARING GRN BOWL SENSOR PRESENT TEMPERATURES RED BOWL SENSOR NOT PRESENT Derrick Centrifuge Sfatus Conveyor 99 Pump O S Feedback Bowl afety Air Conditioner Hours GRN ANALOG SIGNAL PRESENT nalog O u RED NO ANALOG SIGNAL PRESENT Sensor NO SENSOR INPUT E Stop Switch Compressor Motor Current Run Time Closed OK 0 2 Vibration Switch Evaporator Fan Motor Centrifuge Total DK 002031 4 Speed Switch Refrigerant Pressure Controller Total S Fk 003326 8 Open EXCESSIVE VIBRATION Open BOWL OVERSPEED Centrifuge Without RTD Sensor Figure 4 7 Centrifuge Status Screen 01 Aug 11 4 13 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS PRESENT AVERAGE OF REPLACE MAXIMUM MINIMUM VED TEMPERATURES CABINET amp VFD TEMPERATURES WITH PRESENT TEMPERATURES Bowl 99 PRESENT CABINET Enclosure INTERIOR TEMPERATURE E ___ CYCLE AIR CONDITIONER BowlVFD ON FOR 30 SECONDS CHANGES 77 Test Reset
72. O CLEAR REPLACE PLC 6 CHECK DRIVE CONNECTIONS AND DRIVES 7 TWO CENTRIFUGES CONNECTED TOGETHER NETWORKED MACHINES MUST BE SEPARATE Figure 5 17 PLC Indicators 5 50 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE YELLOW NORMAL OPERATION OFF VIBRATION SWITCH TRIPPED GREEN POWER inii OR REMOTE E STOP OPERATED YELLOW STEADY NORMAL OPERATION OFF BOWL OVERSPEED GREEN DEVICE OPERATIONAL YELLOW STEADY CENTRIFUGE NOT RUNNING OR OFF YELLOW FLASHING NORMAL OPERATION RED INPUT CIRCUIT FAULT RED SENSOR DISCONNECTED TEMP DISPLAYS 392 F 200 Figure 5 18 Transmitter Intrinsic Barrier Indicators GREEN DEVICE OPERATIONAL RED OFF NOT OPERATIONAL Figure 5 19 Power Supply Indicators 01 Aug 11 5 51 DE 1000LPVFDCentrifuge DERRICK CORPORATION SECTION 8 REFERENCE DRAWINGS This section contains Derrick engineering drawings for your equipment These drawings are included to provide assistance in troubleshooting repair and parts ordering 14738 00 008 General Arrangement DE 1000LP VFD Centrifuge 14394 00 023 Electrical Wiring Schematic DE 1000LP 460 480V 60 Hz XP Centrifuge 9587 00 007 Rotating Assembly DE 1000 Centrifuge Radial Flow 11372 01 Gear Unit DE 1000 Centrifuge 52 1 15 Jan 11 8 1 DE 1000LPVFDCentrifuge
73. ORD 1 500 X1 188 1 375 DIA 104 6000814903 CABLE SHIELDED 18AWG 18 COND LT BLUE CUT 85 LENGTH IT LLE p 110 e USED BY CUSTOMERS OR PROSPECTS OR THEIR AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT OR BY VENDORS IN QUOTING ON OR IN THE 7 SUPPLY OF PARTS OR ASSEMBLIES TO DERRICK OR BY OTHERS FOR THE SPECIFIC REASON OUTLINE IN THE TRANSMITTAL WHETHER WRITTEN OR VERBAL Extr pr Pas 1 12 2011 DERRICK 60012010 HOLDER FUSE 30A 1 POLE 600V MAX MIDGET REVISION HISTORY s 80012012 CONTROL 20 o REV DESCRIPTION a gt CORPORATION Eo TITLE N er EJR 2 8 2011 NEN ITEM 64 WAS G0008008 ITEM 65 WAS G0002714 ITEM 67 QTY WAS 2 ITEM 70 QTY WAS 1 ADDED THERMOSTAT BRKT DJK MFG CONTROL ENCLOSURE ASSEMBLY 2 REGULATOR amp ITEM 113 SENSOR Bks a DE LP EX PROOF E ITEM 32 WAS 00008459 ITEM 41 WAS 50007983 ADDED ITEMS 108 THROUGH 116 DELETED 90003494 2910 2911 AND 2874 5 13 2011 NER 1000 OOF 460 60 3 ITEM 9 WAS 16622 01 005 84 WAS G0007951 85 WAS G0009873 86 WAS G0009871 87 WAS G0009872 94 WAS 11881 01 025 102 SIZETFILEGOPY DWG NO REV 4 WAS G0004418 46 QTY WAS 12 92 QTY WAS 1 ADDED ITEMS 117 amp 118 ITEM 35 PLACEMENT WAS ON 07 ITEM 41 QTY WAS 1 DJK 6 15 2011 AO ITEM 47 WAS G00
74. RTUP In below freezing ambient conditions where steam portable heaters or other means is used to raise the temperature of the centrifuge re lubrication of bearings may be necessary prior to startup If bearing housings reach a temperature of 200 93 C grease may liquefy and drain from bearings This will result in dry running the bearings upon startup To prevent this condition proceed as follows 1 After applying heat and prior to startup pump 15 shots of grease into each main bearing 2 Refill conveyor bearings until grease is observed exiting the appropriate drain hole 3 After machine is started pump an additional five shots of grease into each main bearing 4 Monitor bearing temperatures for the first 2 hours of centrifuge operation O Note It is Normal for Temperatures to Rise for 15 to 30 Minutes After Greasing and Then Return to Normal 4 6 01 Aug 11 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS OPERATION The properties of the inlet slurry and desired separation should be known in advance This information can be used to set and change bowl speed conveyor differential speed and feed rate unless set for automatic control as required during centrifuge operation Continual monitoring of the centrifuge control panel indications as well as the condition of the inlet slurry are essential to achieving desired effluent clarity and solids dryness Rising conveyor torque indicates that one or more operating parame
75. S EQUIPMENT IS OPEN LOCK OUT AND TAG OUT POWER SUPPLY TO PREVENT ACCIDENTAL APPLICATION OF POWER WHILE MAINTENANCE AND OR ADJUSTMENTS ARE IN PROGRESS WARNING ELECTRICAL CONNECTIONS MUST BE MADE IN ACCORDANCE WITH ALL APPLICABLE NATIONAL AND LOCAL CODES FAILURE TO COMPLY MAY RESULT IN AN UNSAFE CONDITION THAT COULD INJURE PERSONNEL OR DAMAGE EQUIPMENT ENSURE THAT ALL ELECTRICAL AND CONDUIT CONNECTIONS ARE SECURE WARNING CENTRIFUGE MUST BE LOCATED IN A NON HAZARDOUS AREA FREE OF FLAMMABLE GASES DO NOT BYPASS PURGE SYSTEM IF NOT CERTAIN THAT ENVIRONMENT IS NON HAZARDOUS A HIGH RISK OF FIRE AND OR EXPLOSION WILL RESULT IF PURGE SYSTEM IS BYPASSED IN A HAZARDOUS AREA 15 Apr 11 2 1 DE 1000LPVFDCentrifuge SAFETY Electrical Hazards Cont d WARNING USE EXTREME CAUTION WHEN OPERATING EQUIPMENT WITH PURGE SYSTEM BYPASSED DANGEROUSLY HIGH VOLTAGE WILL BE PRESENT IN CONTROL CABINET IF DOOR IS OPENED WHILE POWER IS APPLIED Equipment Handling WARNING USE SPREADER BARS TO PREVENT DAMAGE WHEN LIFTING THE EQUIPMENT WARNING TO ENSURE PROPER BALANCE AND ORIENTATION WHEN UNIT IS RAISED AND PREVENT DAMAGE TO COMPONENTS ATTACH LIFTING SLING ONLY AT DESIGNATED LIFT POINTS DO NOT ATTEMPT LIFTING BY ATTACHMENT TO MOTOR OR ANY OTHER LOCATION WARNING BE SURE THAT HANDLING DEVICES HAVE SUFFICIENT LIFTING CAPACITY TO SAFELY HANDLE THE WEIGHT OF THE EQUIPMENT WARNING DO NOT REMOVE SHIPPING BRACKETS UNTIL EQUIPMENT HAS BE
76. SS FLAT HEAD HEX SOCKET FHSK 38 16X75 S 183 IN LBS SOLID HEAD PLOWS A 5 16 18 3 4 55 50 60003059 144 IN LBS WEAR INSERTS 10 24 X 1 4 SS SET SCREW CUP POINT 60003874 CASE FLINGER 3 8 16 X 1 SS HEX SOCKET 60003064 252 IN LBS BOWL EXTENSION x 9 21 5 16 18 X 1 HEX SOCKET ALY SKCS 31 18X100 300 IN LBS 262L ROTODIFF GEARBOX FLANGE 1 20 1 2 13 X 1 SS SET SCREW FULL DOG 00003877 265 IN LBS FEED ACCEL BUMP 72 19 3 8 16 X 1 SS SET SCREW CONE POINT 00003876 75 IN LBS FEED ACCEL BUMP 8 18 3 8 16 X 3 4 SS HEX SOCKET 60003063 252 IN LBS CASE PLOWS 1 4 20 X 5 8 HEX SOCKET SST 60008201 144 IN LBS PILLOW BLOCK FLINGER 8 16 3 8 16 X 1 SS HEX SOCKET 00003064 252 IN LBS SPLINE HUB 16 15 3 8 16 X 1 SS FLAT HEAD HEX SOCKET 60001868 183 IN LBS PILLOW BLOCK COVER N A 6 14 5 16 18 X 4 HEX SOCKET SST 00008200 NO TORQUE FLINGER COVER 8 13 1 4 20 X 1 SS HEX SOCKET 00003056 83 IN LBS PULLEY SHEAVE 1 12 1 4 X 1 PIN STEEL PP1361 680L S E BEARING HOUSING 6 11 5 16 18 X 3 SS HEX SOCKET 00003062 144 IN LBS S E SEAL HOUSING 10 3 8 16 X 1 SS HEX SOCKET 00003064 252 IN LBS S E BOWL HEAD 2 09 PLASTIC CAP 00003467 S E BOWL HEAD 4 108 1 8 NPT X 3 4 SS GREASE FITTING 60003513 S E BOWL HEAD AVA 2 07 5 16 18 X 1 2 SS SET SCREW CUP POINT 00005508 N A 262 S E BOWL HEAD 4 106 1 4 X1 1 4 PIN STEEL 60001744 680 S E BOWL HEAD DN LIST CENTRIFUGE ROTATING ASSEMBLY 4 3 8 16 X
77. ST BEARING 7216 510 510 00 37 _ 37 SEAL HOUSING L E BSE 2772 7 77 Sy B 2 2 36 SEAL GARLOCK 24600 0978 CS10 RA 312 00 NER 2277 2222222 ll 2222 __ 8 2 12 49 SEAL GARLOCK 24600 2462 __________ 510 31 00 c a d 8 1 1 42 RETAINING RING RR500 ES 00 RI ZZ 35 SPRING w 6004365 NY ATL Ae 1 L3 L3 IE 989 9 SS NE X FON CHO 1 1 33 HEAD PLOW 0679 00 0510 650 lt a SP 9 LOTS ANT m c ___ __ 11 1 29 BOWL EXTENSION 9486200 43 26 To Pr 500b BOW HEAD 09 oT 27 gne 0 80 00 O fof i 26 PULLEY SHEAVE 575 PD 20 7 77 38 28 Ne COVER 9629 90 PRA 1 1 1723 PILLOW BLOCK COVER OUTBOARD 9588 00 64 995 0 _____ CHE RES BEES QUID END o SOLIDS END Es RUNE ECAR _2 2 19 FLINGER COVER INBOARD _2 2 18 PILLOW BLOCK COVER INBOARD 89 20 _2 2 17 O RING 4 989 ID X 070 50022 _2 2 16 PILLOW BLOCK 7 9545 00 002 2 2 15 O RING 4987 ID X 103 0005211 1 1 14 PILLOW BLOCK COVER OUTBOARD FLANGE SIDE 946 00 00 ___ 1
78. TENANCE Installation Cont d BEARING INNER RACE TAPPING BEARING INTO PILLOW BLOCK OUTBOARD PILLOW INBOARD PILLOW BLOCK COVER BLOCK COVER LARGE CROSS SECTION SMALL CROSS SECTION O RING O RING Figure 5 10 Main Bearing Installation Details 5 Install new O ring against shoulder of inboard pillow block cover and slide pillow block cover onto shaft 6 Apply sufficient quantity of the bearing grease listed in customer specification to completely cover bearing rollers 7 Slide assembled pillow block and bearing outer race onto inner race previously installed on bearing journal 8 Install new O ring against shoulder of outboard pillow block cover slide pillow block cover onto shaft and rest against pillow block 9 Orient inboard pillow block cover so that flat edge is aligned with bottom of pillow block 10 Apply anti seize compound to four flat head screws and install screws to secure inboard pillow block cover to pillow block Tighten screws in accordance with Hardware Torque Specifications 11 Orient outboard pillow block cover so that flat edge is aligned with bottom of pillow block 12 Apply anti seize compound to four flat head screws and install screws to secure outboard pillow block cover to pillow block and draw bearing into proper position within pillow block Tighten screws in accordance with Hardware Torque Specifications 5 20 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE 13 Slide outboard
79. TRIFUGE UNLESS THE BOWL IS AT A COMPLETE STANDSTILL T WARNING DO NOT OPEN COVER OR ATTEMPT ANY ADJUSTMENT OR 1 Shut down lock out and tag out the centrifuge using the Normal Shutdown procedure described later in this section 2 Open case cover 3 Loosen three screws securing mounting ring to liquid bowl head rotate the effluent port until the desired setting is positioned at the alignment marks and tighten screws All four effluent ports must be set to the same position 4 Close case cover after completing adjustments LIQUID BOWL HEAD ALIGNMENT MARKS EFFLUENT PORT MOUNTING RING RETAINING SCREW Figure 4 3 Effluent Port Adjustment Differential Speed Conveyor Torque Generally a faster conveyor speed results in lower conveyor torque as solids are discharged faster and usually wetter Reducing conveyor speed must be done slowly and cautiously allowing steady state to be reached before further reduction Slower conveyor speeds permit solids to remain in the bowl longer This can permit solids to accumulate in the bowl if the input rate exceeds the discharge rate Therefore the torque must be monitored to prevent overload Torque limit settings control automatic feed reduction and centrifuge shutdown As conveyor torque rises the feed rate is gradually reduced If torque continues to rise the feed rate is more rapidly reduced Upon reaching the maximum conveyor torque setting the centrifuge is shut down At ce
80. _____ ON 590 DUKE ROAD BUFFALO NY 14225 U S A 5 REF 14738 00 004 1 2 3 4 5 6 SILLY 7 72 YIN AZZ 59999550 777 4 7 7 G UN SI SSW 22 n ll SS E 5 S WW N AIR N NN SL N Awe mn N 222 72 1 DOWEL PIN RETAINER PLATE 4033 00 L SEAL 0287 03631 K SHELL FRONT COVER SEAL 7 CS10 GU 308 00 O J 5 10 24 75 8 PLUG w O RING IMP 721FS0 5 PIPE PLUG SHPP 13 p E 11574 00 CS10 GU 507 00 CS10 GU 506 00 HXCS 31 18X75 8 O RING B 6 4 JDWLPN 3 2 0 SPRING WASHR PPi363____ ___ 1 N SECOND STAGE SUN GEAR 11101 00 NM L1 M RETAINING RING _____________ 510 60 317 00_____ 1 f L FIRST STAGE SUN GEAR j1100 00 4 FIRST STAGE THRUST WASHER 19 00 ___2 J FIRST STAGE PLANET GEAR 10800 ___ 2 1 FIRST STAGE JOURNAL BUSHING 11353 01 ___ 2 FIRST STAGE JOURNAL 10987 00 A 1 6 CAGE AND CARRIER FIRST STAGE 13299008 _ 1 F SEAL HOUSING 11029 00 1 E SHELL REAR COVER j1005 00 1 D SHELL FRONT COVER 10986 00 COMPLETE STAGE TWO ASY p SS RETAINING RING CS10 GU 319 00 DOWEL PIN ME EN A B gt gt gt 00 PUES E E ES zei ES sei E TEN
81. an accelerated rate due to the G force imposed by the rotating bowl Sand particles settle almost instantly then the finer lighter particles settle Particles that cannot be settled under the present settings will be discharged with the liquid through the adjustable weirs on the liquid bowl head Liquid exiting the liquid bowl head is directed through the liquid discharge outlet The settled solids form a cake inside the bowl and are transported by the conveyor toward the narrow end of the bowl beach As the solids travel across the beach their free liquid film is lost due to centrifugal squeezing and drainage When they are discharged at high velocity through the solid discharge ports on the bowl they contain only the adsorbed moisture CONTROL SYSTEM Centrifuge operation is supervised by a PLC that interfaces with the VFDs supplying power to the bowl conveyor and feed pump drive motors Monitoring and control of the centrifuge may be performed locally or up to thousands of miles away The environmentally hardened PLC also offers short term data storage and a high degree of operating flexibility The graphical color interface mounted on the control cabinet facilitates communication with the VFDs and provides real time access to system operating characteristics Through the control panel the operator may start up the centrifuge enter and adjust bowl and conveyor speeds set feed rate and shut down the machine Various inputs including main
82. asily onto the journal Replace the bowl head if journal is undersize 4 Inspect pillow block covers flingers and flinger covers for corrosion distortion nicks cracks burrs fractures or other defects Repair any minor defects 5 Replace any component that cannot be easily repaired Replace all O rings seals and bearings 6 Place all cleaned components in clean plastic bags to prevent contamination Installation WARNING IN THE FOLLOWING STEP USE EITHER A BEARING HEATER OR A CLEAN HEATED OIL BATH TO HEAT BEARING INNER RACE DO NOT USE A TORCH AS THIS WILL DAMAGE THE BEARING Place inner race of liquid end bearing in a bearing heater Figure 5 10 or clean heated oil bath and heat to approximately 230 F 110 C Do not use a torch to heat inner race as this will damage the race 2 Wearing insulated gloves remove heated inner race from bearing heater and immediately slide onto bearing journal until seated against bowl head shoulder Allow inner race to cool until unmovable on liquid bowl head 3 Slide inboard pillow block flinger onto shaft Figure 5 9 followed by pillow block cover Do not tighten flinger set screw at this time 4 Position bearing outer race and rollers into chamfer of pillow block Using a suitable tool that contacts only the outer bearing race carefully tap outer race into pillow block until about 1 8 3mm below the surface of the pillow block 01 Aug 11 5 19 DE 1000LPVFDCentrifuge MAIN
83. ating The operator may then view the results of one change before making additional adjustments The following paragraphs describe the effect of changing each parameter Feed Rate When Manual is selected on the Operation screen the operator manually enters the desired rate on the Operation screen If the slurry is low in viscosity and density increasing the feed rate may permit a higher processing rate However as feed rate is increased residence time in the bowl is decreased resulting in more solids in the liquid discharge Also conveyor torque may rise indicating that the conveyor is becoming burdened by moving the increased solids volume at its present speed To reduce the conveyor torque the bowl speed may be lowered the feed rate may be reduced or the conveyor speed may be increased to move the solids out faster The feed rate setting and actual feed rate are shown on the control panel to assist the operator in making adjustments 01 Aug 11 4 7 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS GRN DRIVE OPERATIONAL RED DRIVE FAULT GEN DRIVE RUNNING u dolo GRY DRIVE OFF ADJUST FEED PUMP OUTPUT Bow input RPM 2500 PRESENT RPM amp TORQUE OF BOWL amp CONVEYOR Actual RPM Actual PRESENT PUMP OUTPUT amp RPM 0 0 0 0 Torque e Torque Pump RPM 0 0 INITIATE CENTRIFUGE 0 0 0 0 OPERATION SCREEN SLEECTION Sus Clean Out Alarms Faults TEMPERATURE OF BUTTONS 8
84. bearing flinger onto gearbox flange but leave screw loose 14 Apply a light coat of grease to surface of bowl shaft where gearbox flange mounts 15 Heat flange to 200 F 93 C While handling with insulated gloves orient notch in flange with key on liquid bowl head shaft and install flange on shaft Tighten set screw to secure flange 16 Slide inboard and outboard pillow block flingers close to pillow block covers leaving about 1 16 2mm clearance and tighten set screws on both flingers 17 Install flinger covers and secure with screws 18 Using lifting strap and overhead lifting device orient gearbox with lines scribed during removal aligned and slide gearbox onto splined shaft Insert screws through flange and into Rotodiff insert shims at locations marked during removal and tighten screws Solid End Bearing Removal 1 Remove screws securing inboard and outboard flinger covers Figure 5 11 to pillow block and lift and remove inboard flinger cover INBOARD PILLOW BLOCK COVER PILLOW BLOCK FLINGER OUTBOARD PILLOW BLOCK COVER O RINGS OUTBOARD FLINGER COVER A SHEAVE y m ASS VAAN tec ER ET TE ur s SNS im Se Lm ud OUTER INBOARD FLINGER COVER PILLOW BLOCK Figure 5 11 Solid End Main Bearing Installation 01 Aug 11 5 21 DE 1000LPVFDCentrifuge MAINTENANC
85. cation Failure with Liquid End Bearing Temp Sensor Incorrect or loose connection at If reading is constantly about 392 F 200 C check temperature sensor and correct connection refer to electrical schematic diagram in Section 8 Incorrect connection at PLC Check that all PLC connectors are securely seated Defective temperature sensor If reading is constantly about 392 F 200 C sensor is defective replace sensor Defective liquid end transmitter intrinsic Check connection and or replace transmitter if barrier or poor connection defective Defective bowl VFD Check and replace VFD if defective 5 42 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE Alarm and Fault Messages Communication Failure with Solid End Bearing Temp Sensor If reading is constantly about 392 200 check Temperature sensor connection and correct connection refer to electrical schematic diagram in Section 8 Incorrect connection at PLC Check that all PLC connectors are secure as described in this section Defective temperature sensor If reading is constantly 392 F 20090 sensor is defective replace sensor Poor connection at liquid end If reading is constantly 392 F 200 C check insecure or disconnected transmitter intrinsic barrier or defective transmitter correct connection replace transmitter if defective Defective bowl VFD Check and replace VFD if defective Control Program Downloaded
86. ceeded Maximum Speed Shutdown Incorrect or loose connection at speed If reading on Bowl VFD status screen is about 4000 sensor or defective speed sensor RPM check connection refer to Section 3 if connection is secure replace sensor Bowl VFD has permitted bowl to exceed Replace bowl VFD and re start centrifuge while maximum pre set speed limit monitoring speed closely Bowl High Torque Alarm Reduce Feed Rate Bowl torque exceeds pre set limit Reduce feed rate Bowl High Torque Fault and Shutdown Perform Cleanout and Reduce Feed Rate Bowl torque exceeds pre set limit Following automatic shutdown perform cleanout procedure to remove solids buildup and re start centrifuge at reduced feed rate Bowl VFD Alarm Ref Troubleshooting Section of User Manual Defective bowl VFD Press STOP and cycle power off and then on If alarm does not clear replace bowl VFD Bowl VFD Communications Error Bowl VFD not communicating with PLC Confirm that green LED next to Ethernet cable is lighted indicating that hub is functional Check connections between bowl VFD and PLC and correct any defects Replace bowl VFD if no other defect is found Bowl VFD Drive OL Alarm Ref Troubleshooting Section of User Manual Bowl drive motor drawing excessive Replace motor if defective or remove other cause of current excessive current draw 01 Aug 11 5 41 DE 1000LPVFDCentrifuge MAINTENANCE Alarm and Fault Messages Bow
87. ck bearings and conveyor bearings for looseness noise or rubbing Replace any defective bearings in accordance with bearing replacement procedures in this section 5 12 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE Reassembly and Installation Reassembly and installation of the rotating assembly are basically the reverse of removal Proceed as follows to reassemble and install rotating assembly 1 Prepare and install conveyor into bowl assembly as follows a Apply a light coat of grease to bearing seat and seal surfaces of conveyor to facilitate installation b With bowl in vertical position on vertical stand hoist conveyor above bowl and carefully lower into bowl Remove vertical lifting bracket from conveyor d Install new seal in seal housing Figure 5 6 apply light coat of grease to seal and install seal housing onto bearing housing Apply anti seize compound to screws insert screws through holes of seal housing and tighten into bearing housing in accordance with Hardware Torque Specifications 2 Install new O ring in groove of liquid bowl head apply a light coat of grease to O ring and install liquid bowl head onto bowl Orient bowl head so that alignment marks correspond and secure liquid bowl head to bowl with screws Tighten screws in accordance with Hardware Torque Specifications 3 Remove all nicks and or burrs from pillow blocks and mating surfaces Clean all surfaces of any protective coating applied af
88. crew loose 14 Apply a light coat of grease to surface of bowl shaft where sheave mounts 15 Heat sheave to 200 9390 While handling with insulated gloves orient notch in sheave with key on solid bowl head shaft and install sheave on shaft Secure sheave with screws 16 Slide inboard and outboard pillow block flingers close to pillow block covers leaving about 1 16 2mm clearance and tighten set screws on both flingers 17 Install flinger covers and secure screws 18 Operate hoist to lower rotating assembly into centrifuge until pillow blocks contact base 19 Insert alignment pins into pillow block alignment holes and insert bolts Remove alignment pins and tighten pillow block bolts in accordance with Hardware Torque Specifications 01 Aug 11 5 23 DE 1000LPVFDCentrifuge MAINTENANCE CONVEYOR BEARING REPLACEMENT This procedure requires removal of the conveyor assembly from the bowl assembly Conveyor bearing replacement must be performed in a clean environment by trained qualified personnel If the conveyor bearings are found to be defective it is likely that the conveyor will require complete overhaul Consequently all parts should be carefully inspected and fits and clearances should be measured to determine the suitability of parts for re use Liquid End Thrust Bearings The liquid end contains two thrust bearings a single ball bearing is installed at the solid end Replace all conveyor bearings as a set if e
89. ction 2 and electrical schematic diagram in Section 8 15 After confirming correct motor rotational directions enter desired Bowl Speed of at least 750RPM and enter desired Differential Speed select START to begin centrifuge operation Screen will display actual Bowl Speed Differential Speed and Torque When bowl speed reaches 750RPM START STOP at right side of screen will change to Autotune Derrick Centrifuge Operation Bow Conveyor 90 Pump OG MEN FER Actual Acua Acus GPL 2400 40 0 0 0 PEST Te Start Autotune Sa Cua On Ars 16 Select Autotune to tune pump drive motor to VFD Allow about 60 seconds for autotuning 17 Start centrifuge in accordance with Normal Startup procedure below beginning with step 4 NORMAL STARTUP o Note If Centrifuge is Heated Before Starting Centrifuge Follow COLD CLIMATE STARTUP Instructions Later in This Section to Ensure Proper Bearing Lubrication 1 Without electric power applied open cover and rotate bowl assembly manually to check that the bowl turns freely and no rubbing is felt 2 Close cover tighten all cover bolts to required torque refer to Section 5 and ensure that all guards are in place 3 Verify that all personnel are clear of centrifuge and all guards are in place before applying electric power to equipment 4 Apply electric power to centrifuge The following screen will appear
90. d check wear and replace worn parts Check pump shaft seal and correct any defects Select RESET on Fault Reset screen to reset flow rate Failure Mode 2 Poor Liquid Quality Acceptable Cake Differential speed too low Increase differential speed Increase differential speed and or reduce quantity of solids in feed Excessive amount of solids in Reduce quantity of solids in feed or add dilution stream if feed possible Change in feed characteristics Reduce quantity of solids in feed or generally optimize machines settings i e adjust bowl speed differential speed and weir opening Increase in solids wetness Re optimize machine settings 01 Aug 11 5 35 DE 1000LPVFDCentrifuge MAINTENANCE TROUBLESHOOTING DE 1000LP VFD CENTRIFUGE Failure Mode 2 Poor Liquid Quality Acceptable Cake Cont d Conveyor flights worn Inspect flights through the solid discharge outlets If damage is excessively evident remove and disassemble bowl and inspect conveyor flights carefully refer to Rotating Assembly Maintenance Repair or replace conveyor if required Failure Mode 3 Excessive Vibration Bowl assembly unbalanced Remove and disassemble bowl and inspect conveyor flights due to uneven mechanical refer to Rotating Assembly Maintenance Repair or replace wear worn parts or deformed conveyor if required conveyor flights Conveyor bearing defective Remove and disassemble bowl and inspect conveyor bearing du
91. d content of the discharged solids The conical bowl at the solids end forms an upward sloping beach where solids collect and are continuously discharged through the solids discharge outlet Replaceable wear inserts installed in the solid bowl head protect the openings from wear Conveyor The conveyor assembly is a hollow cylindrical auger that receives the inlet slurry into its interior disperses it through feed nozzles to the bowl assembly and transports the solids to the solids discharge outlet Rotated by an electric motor through a differential gearbox the conveyor turns in the same direction as the bowl but at a slower rate of speed The differential speed setting on the control panel determines the conveyor speed in relation to the bowl speed This relationship remains consistent as bowl speed is varied the conveyor speed varies commensurately but maintains the differential relationship For example a bowl speed of 2000 RPM and a conveyor differential speed of 10 results in the conveyor rotating at a rate of 1990 RPM A drive shaft extending through the bowl head transfers motion from the gearbox to the conveyor The feed tube inserted through the conveyor at the solids end directs inlet slurry against a feed accelerator which rapidly disperses the material through feed nozzles in the conveyor Carbide inserts are installed in the feed nozzles and carbide tiles are welded to the edges of the conveyor flights for wear resistance Ball bea
92. d series of drive belts while the conveyor is directly coupled to a 20 HP electric motor A protective guard covers the sheaves drive belts and conveyor drive flexible coupling for personnel protection Control Cabinet The control cabinet is used to start operate and shut down the centrifuge All operating controls and sensing system components needed for centrifuge operation are installed in the cabinet The cabinet consists of a steel enclosure having a hinged front door Several twist lock fasteners retain the door securely closed and a gasket surrounding the outer edge of the door provides a weather tight seal for protection of the interior electrical and electronic components Fittings are installed at the rear of the cabinet to permit entry of power and sensing cables Variable frequency drives VFDs a programmable logic controller PLC intrinsically safe barriers terminal blocks fuses and other electrical components are installed in the cabinet An air conditioning unit is used to maintain a suitable ambient environment for operation of the electrical equipment and an automatic purge system maintains a positive internal pressure to prevent entry of hazardous vapors The purge system turns on electric power to the cabinet components only after thorough evacuation of flammable gases from the control cabinet interior The operator control panel and mouse are installed on the front of the cabinet above the door An emergency stop butt
93. d steel skid 1 6 15 Jun 11 DE 1000LPVFDCentrifuge INTRODUCTION MECHANICAL OPERATION The centrifuge receives slurry at the sheave end solid discharge end of the machine For best performance the slurry should be screened to 74 microns in vibrating screening machines before being fed to the centrifuge The slurry flows through a feed tube into the rotating bowl where centrifugal force separates liquid from the solids Liquid flows out the liquid discharge connection at the gearbox end of the centrifuge while solids are conveyed to the solid discharge where they fall into a chute at the bottom of the machine The centrifuge is configured to operate on a specific AC voltage supplied in three phase 50Hz or 60Hz Electrical controls are mounted on the electrical control box located at the machine s liquid discharge end Safety devices built into the centrifuge protect personnel and equipment by shutting down the machine in case of excessive bowl or conveyor torque high motor temperature vibration or other malfunction G forces produced by the high speed rotation of a cylindrical bowl separate solids from the feed slurry Centrifuge performance is based on three variable factors G force exerted on the fluid Gravitational force pulling fluid against the outside wall of the centrifuge e Retention time in the centrifuge The longer the slurry remains in the centrifuge the smaller the particle that can be separated Differ
94. dition the customer s feed pump motor must be connected to the centrifuge control system For explosion proof configurations connect the facilitys three phase electric power supply to the contactor in the electrical panel Figure 3 6 For non explosion proof machines power connections are made inside control cabinet as shown Connect the feed pump motor to the terminal block in the bottom left side of the control cabinet as shown The control system can operate a 12 5kW feed pump drive motor The bowl and conveyor drive motors are not dual wound and must be operated at the design voltage For motor characteristics as well as additional information on electrical connections refer to the electrical schematic diagram in Section 8 WARNING CENTRIFUGE MUST BE OPERATED AT THE DESIGNATED SUPPLY VOLTAGE WARNING HIGH VOLTAGE MAY BE PRESENT BE SURE FUSED DISCONNECT SUPPLYING ELECTRIC POWER TO THIS EQUIPMENT IS OPEN LOCK OUT AND TAG OUT POWER SUPPLY TO PREVENT ACCIDENTAL APPLICATION OF POWER WHILE MAKING ELECTRICAL CONNECTIONS WARNING ELECTRICAL CONNECTIONS MUST BE MADE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE NEC AND ALL APPLICABLE LOCAL CODES FAILURE TO COMPLY MAY RESULT IN AN UNSAFE CONDITION THAT COULD INJURE PERSONNEL OR DAMAGE EQUIPMENT ENSURE THAT ALL ELECTRICAL AND CONDUIT CONNECTIONS ARE SECURE A fused disconnect primary power supply is required for this equipment The fused disconnect and interconnecting wiring t
95. e This document contains proprietary information of Derrick Corporation It is intended solely for the information and use of parties operating and maintaining the equipment described herein Such proprietary information may not be used reproduced or disclosed to any other parties for any other purpose without the expressed written permission of Derrick Corporation Continuous improvement is a policy of Derrick Corporation All instructions and procedures are subject to change without notice DERRICK CORPORATION CONTENTS Section Page Date LESS Mem Na 1 1 15 Jun 11 eI 1 1 1 1 o NER RR ro A 1 2 DESC ME 1 2 950 1 7 CONTO 1 8 POUC SUD OM 1 9 SIMA o T 2 1 15 Apr 11 BE ERE O 2 1 YANG ERU tm 2 1 Material Safety Data Sheets 5055 2 3 A 3 1 15 Jan 11 3 1 SO ee 3 1 Installation SeQuence ss 3 1 Required Clearances and 3 2 Equipment Handling unse 3 3 Equipment Positioning and 3 4 Lower and Secure Rotating
96. e G0004364 OJO O O O O O O O O Ring Protective Cover Protective Cover Operator Control Panel HMI RTD Sensor Solid End Bearing Temperature RTD Sensor Liquid End Bearing Temperature 15181 01 001 G0008089 G0008090 G0007861 G0007862 Speed Sensor Cable Speed Sensor Control Cabinet G0008792 G0007583 G0003484 G0002910 G0002911 G0002301 G0002302 G0008005 Fuse 3A Condenser Fan Motor Fuse Cube Style 100A 600V Bowl VFD Fuse Cube Style 40A 600V Pump VFD Fuse Time Delay 2 5A 600Vac Style CC Fuse Time Delay 7A 250Vac Style CC Air Filter Element Type DX Yes O Air Filter Element Type BX Yes Door Latch Z Z O O a CO CO 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE RECOMMENDED SPARE PARTS DE 1000LP VFD CENTRIFUGE Control Cabinet Cont d TROUBLESHOOTING Malfunctions due to operating error or other problem can result in unnecessary machine down time and should be corrected as soon as possible The troubleshooting procedures presented in this section will assist technicians in isolating and correcting malfunctions Fault analysis should proceed logically from the simplest cause to the more complex The most difficult problem is an unexpected shutdown or inability to start Always eliminate obvious causes of malfunction before proceeding to more complex possibilities Since more than one cause may be responsible f
97. e operator in fault analysis CH EM 69 Dangerously high voltage is present in the control cabinet Since opening the control cabinet door and bypassing the cabinet purge system is required to check the indicators only trained qualified personnel should be permitted to perform these procedures Use extreme caution to ensure that the surrounding atmosphere is free of hazardous fumes before opening the cabinet door and bypassing the purge system 5 48 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE WARNING DANGEROUSLY HIGH VOLTAGE IS PRESENT ONLY TRAINED QUALIFIED PERSONNEL SHOULD BE PERMITTED TO OPEN CONTROL CABINET DOOR WHILE POWER IS APPLIED WARNING HAZARDOUS GASES CAN CAUSE EXPLOSION BE CERTAIN THAT SURROUNDING ATMOSPHERE IS CLEAR OF ALL POTENTIALLY EXPLOSIVE GASES BEFORE OPENING CONTROL CABINET DOOR NOT ENABLED BOWL OVERSPEED FAULT 2 E STOP BUTTON PUSHED STOP ASSERTED NORMAL OPERATION VIBRATION SWITCH TRIPPED BUT CENTRIFUGE STOPPED RUNNING NORMAL RUNNING CONDITION GREEN DRIVE ON OFF DRIVE OFF GREEN STEADY DRIVE RUNNING GREEN FLASHING DRIVE READY BUT NOT RUNNING NO FAULTS PRESENT YELLOW FLASHING OR STEADY ALARM PRESENT OR DRIVE NOT ENABLED RED FLASHING OR STEADY FAULT L 3 300 0 25980 1 00068 0 n 0 99000 RED FAULT PRESENT GREEN STEADY DRIVE FUNCTIONAL GREEN FLASHING DRIVE FUNCTIONAL Figure 5 16 VFD Indicators 01 Au
98. e or excessive lubrication contamination or severe wear Refer to Section 5 for main bearing replacement procedure Excessive Bowl Speed A sensor that detects the rotational speed of the bowl provides an input to the PLC that produces a continuous display of actual bowl speed on the Operation and Bowl VFD screens A fault message is displayed and the centrifuge is immediately shut down if speed rises to 3100 RPM To re start the centrifuge allow the bowl to coast to a complete stop and check for and remove the cause of excessive speed refer to Section 5 After correcting defect s re start the machine using the Normal Startup procedure above and re check speed EMERGENCY SHUTDOWN To stop the centrifuge in case of emergency press the EMERGENCY STOP button on the control cabinet select STOP on the Operation screen or open the fused disconnect supplying electric power to the machine Pressing EMERGENCY STOP immediately removes power from the bowl conveyor and pump motors allowing the bowl to coast to a stop This may take more than 15 minutes depending on the bowl speed and amount of material inside the bowl To stop the bowl faster press the STOP button on the Operation screen or display the Bowl VFD screen and press the BOWL IS COASTING TO A STOP button However before pressing this button all alarms faults must be cleared 01 Aug 11 4 21 DE 1000LPVFDCentrifuge Q DERRICK SECTION 5 MAINTENANCE
99. e to inadequate lubrication refer to Conveyor Bearing Replacement Replace conveyor product entry past seal or bearings normal wear Bowl assembly main bearings Remove rotating assembly and replace both bearings refer defective to Main Bearing Replacement Excessive buildup of solids in Perform cleanout procedure refer to Section 4 bowl and or conveyor Failure Mode 4 No Liquid Discharge Untreated Feed Material Exits Liquid Discharge Outlet Buildup of solids between Shut down feed pump and bowl assembly drive motor but keep flights solids not being conveyor motor running and admit rinse water into machine If transported to discharge but solids emerge before bowl fully stops re start centrifuge are discharged with liquid Shut down lock out and tag out electric power Open top cover and insert hose into liquid and solids discharge openings and flush bowl interior with water preferably hot water If flushing is unsuccessful in clearing the blockage remove rotating assembly and remove conveyor to facilitate thorough cleaning refer to Rotating Assembly Maintenance Failure Mode 5 High Power Consumption Machine Clogged oolids accumulated within case Open top cover and thoroughly clean case interior bowl exterior and solids discharge chute Failure Mode 6 Machine Clogged Upon Starting After a Brief Shutdown Excessive solids volume in Perform cleanout procedure refer to Section 4 feed due
100. earbox and attach strap to overhead lifting device Fully separate unit from flange by alternately turning jack screws until unit is fully detached d With gearbox supported by lifting strap and overhead lifting device CAREFULLY slide unit outward until splined shaft free of conveyor Place gearbox in a plastic bag to prevent contamination Figure 5 7 Gearbox Removal 5 Turn flange Figure 5 8 until large access holes in flange align with retaining screws for outboard flinger cover Remove screws securing outboard flinger cover to pillow block and lift and remove flinger cover 6 Remove screws securing flange to liquid bowl head and loosen set screw securing flange to liquid bowl head 01 Aug 11 5 17 DE 1000LPVFDCentrifuge MAINTENANCE Liquid End Bearing Cont d ACCESS HOLE 6 ROTODIFF GEARBOX FLANGE FLANGE ATTACHING SCREW Figure 5 8 Gearbox Flange Attachment 7 Thread two jack screws into flange and alternately turn each screw a few turns at a time until flange is separated from liquid bowl head then grasp flange and pull from liquid bowl head O Note Outboard flinger will remain attached to flange 8 Remove flathead screws securing outboard pillow block cover Figure 5 9 to pillow block and remove cover Separate O ring from pillow block cover and discard O ring PILLOW FLINGER BLOCK COVER O RING BEARING OUTER RACE 27 RA rae SS Ni ee a
101. emperatures are updated in accordance with a pre set interval and scroll buttons are provided to facilitate examination of trends over time Solid and liquid end temperatures are displayed at the right side of the screen The Motor Torque screen is also accessible from the Bearing Temperature screen The operator may return to the Operation or Home screen using the buttons at the lower right of the screen Bearing Temperature 1 Min Thursday August 09 2007 Friday Update 120 SCROLL LEFT OR RIGHT Sw I I BESES PEEL 31061 I CURRENT LIQUID END BEARING TEMPERATURE CURRENT SOLID END BEARING TEMPERATURE Operation Home VIEW MOTOR TORQUE SCREEN Figure 4 4 Bearing Temperature Screen MOTOR TORQUE TREND Bowl and conveyor torque trends may be viewed in graphical form on the Motor Torque trend screen Figure 4 5 Torques are updated in accordance with a pre set interval one Minute and scroll buttons are provided to facilitate examination of trends over time Bowl and conveyor torques are displayed at the right side of the screen The Bearing Temperature screen is also accessible from the Motor Torque screen The operator may return to the Operation or Home screen using the buttons at the lower right of the screen 01 Aug 11 4 11 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS MOTOR TORQUE TREND CONT D Motor Torque 1 Min Thursday Au
102. ential speed of conveyor The faster the conveyor rotates the wetter the solids and the more solids that are discharged All three factors may be manipulated to alter the liquid and solids discharge Retention time is controlled by adjusting the liquid discharge ports on the liquid bowl head to change the pond depth liquid level G force is adjusted by changing the bowl speed on the operator control panel and the conveyor differential speed may be altered by changing the differential speed setting on the control panel The conveying speed is the difference between the bowl and conveyor speeds Adjusting the pond depth requires shutdown of the equipment Another method of altering the discharge results is to change the feed rate During centrifuge operation slurry is pumped through the feed tube into the center of the rotating conveyor Figure 1 5 where it splashes against the feed accelerator The high velocity slurry is then dispersed out four feed nozzles in the periphery of the conveyor cylinder Rotating at a higher speed than the conveyor the bowl creates an additional shearing effect which further increases the slurry s acceleration SLURRY ia ET pr USES LIQUID DISCHARGE SOLID DISCHARGE Figure 1 5 Centrifuge Mechanical Operation 15 Jun 11 re DE 1000LPVFDCentrifuge INTRODUCTION MECHANICAL OPERATION CONT D As the slurry flows in the channels between the conveyor flights the heavy particles settle at
103. ents is critical Electrical polarity determines the actual speed and direction of conveyor motor for any bowl speed setting For example with a bowl speed setting of 2000 RPM and conveyor differential speed set at 60 the conveyor motor will rotate in reverse at 1120 RPM The correct bowl conveyor speed relationship depends on correct wiring polarity If polarity is reversed the same bowl speed setting of 2000 RPM described above would result in an actual conveyor differential speed of about 17 rather than the setting of 60 Pond Depth Four adjustable effluent ports Figure 4 3 are provided on the liquid bowl head to facilitate setting the pond depth all ports must be set identically A higher pond depth increases settling time by permitting more liquid to remain in the bowl However a higher pond depth also reduces the beach area at the solids discharge end of the bowl which will result in a wetter solids discharge Pond depth can only be adjusted with the centrifuge fully stopped and disabled For this reason pond depth is usually adjusted last The factory pond depth setting is usually satisfactory when used in conjunction with feed rate bowl speed and conveyor speed adjustments However if desired results cannot be achieved by other means the pond depth may require re setting 01 Aug 11 4 9 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS Pond Depth Cont d To adjust pond depth proceed as follows MAINTENANCE ON THE CEN
104. eristics 0 600 VAC 50 60Hz 3PH Model Type Ref Various Additional Information None This product was found to be in conformance with U L listed for hazardous locations Class I Division 1 Groups C amp D which is similar to equipment marked as II 2G Ex d IIB T3 for Zone 1 areas Assembled in accordance with National Electrical Code NEC articles 500 thru 506 hazardous locations where applicable Additionally Derrick Corporation certifies that the above listed equipment for the referenced order conformed to the requirements of the specified order at the time of its original shipment by Derrick Corporation in that all construction materials and components were new and unused manufactured for this equipment and that the goods were free of any known defects as to their design material and workmanship This certificate is governed by the applicable purchase order terms in effect at the time of Derrick Corporation s original http qc Certificates Conformance UL European Type PE S doc
105. errick equipment defined by the model number and drawing number associated with your equipment The centrifuge is shipped fully assembled For safety during shipment however the rotating assembly is supported by shipping brackets It must be lowered onto the base and then its bearing pillow blocks secured to the base SAFETY Read and understand ALL safety information presented in this manual before installing and operating this equipment Refer to Section 2 for a summary of Warnings addressing installation operation and maintenance of this equipment Before beginning the installation review the equipment handling procedures in this section Failure to observe proper equipment handling procedures may result in serious personal injury or death and or damage to the equipment WARNING TO ENSURE PROPER BALANCE AND ORIENTATION WHEN UNIT IS RAISED AND PREVENT DAMAGE TO COMPONENTS ATTACH LIFTING SLING ONLY AT DESIGNATED LIFT POINTS DO NOT ATTEMPT LIFTING BY ATTACHMENT TO ANY OTHER LOCATION WARNING BE SURE THAT HANDLING DEVICES HAVE SUFFICIENT LIFTING CAPACITY TO SAFELY HANDLE THE WEIGHT OF THE EQUIPMENT LOWER THE CENTRIFUGE GENTLY INTO PLACE AS JARRING MAY CAUSE DAMAGE WARNING DO NOT REMOVE SHIPPING BRACKETS UNTIL CENTRIFUGE HAS BEEN POSITIONED AT FINAL INSTALLATION SITE INSTALLATION SEQUENCE Following is the sequence of steps for installing the centrifuge The sequence presented may vary depending on the user s facilities a
106. essure is not lower than 0 2 WC 0 5 mbar Check also that the ALARM electrical contacts function properly 3 As soon as the ALARM PRESSURIZED indicator turns red the system will begin re purging and the enclosure power will be switched off 4 While the cabinet is re purging return the leakage compensation valve to its normal working pressure position so that at the end of purging the cabinet pressure should immediately settle down at the correct normal pressure Pressure Sensor Calibration If it is decided that the minimum pressure sensor requires recalibration it must be returned to Derrick for this service Cleaning Purge Unit Filter Do not use solvents on any part of the purge unit filter assembly To clean the filter element unscrew and remove the filter bowl and then unscrew and remove filter element Clean filter element in soapy water or replace element ROTATING ASSEMBLY MAINTENANCE Maintenance of the rotating assembly requires disassembly and can only be performed with the assembly removed from the case After removal from the case the rotating assembly is oriented with the solid end down and placed in the support stand to facilitate removal of the liquid bowl head and conveyor The following paragraphs describe maintenance procedures for the rotating assembly 5 8 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE Removal and Disassembly 1 Shut down lock out and tag out electric power to the centrifuge BE
107. g 11 5 49 DE 1000LPVFDCentrifuge MAINTENANCE CONTROL COMPONENT INDICATORS CONT D GREEN STEADY PLC COMMUNICATING WITH ALL DEVICES GREEN FLASHING ONE OR MORE DEVICES NOT RESPONDING RED FLASHING PLC NOT COMMUNICATING WITH ANY DEVICES OR FAULTED GREEN STEADY RUN MODE NH OFF PROGRAM MODE OFF CONTROLLER MEMORY EMPTY GREEN STEADY PLC OK NORMAL OPERATION i GREEN FLASHING PLC STORING OR LOADING e A PROGRAM NOTE 1 RED FLASHING MAJOR RECOVERABLE FAULT OFF BATTERY GOOD NOTE 2 RED STEADY BATTERY 95 DISCHARGED RED STEADY NON RECOVERABLE FAULT OR NOT INSTALLED F NOTE 3 A OFF NO POWER APPLIED OFF NO POWER TO PLC NOTE 4 GREEN STEADY NORMAL OPERATION RED STEADY SELF TEST UNDERWAY OR UNRECOVERABLE FAULT NOTE 5 GREEN STEADY NORMAL OPERATION GREEN FLASHING PLC READING WRITING TO CARD RED FLASHING INVALID FILE SYSTEM ON CARD GREEN STEADY OR FLASHING NORMAL OPERATION OFF NORMAL OPERATION OFF NORMAL OPERATION GREEN STEADY NORMAL OPERATION GREEN FLASHING NO CONNECTIONS NOTE 6 RED STEADY PORT ALREADY IN USE NOTE 7 RED GREEN FLASHING SELF TEST UNDERWAY NOTES 1 WAIT FOR MEMORY LOAD TO COMPLETE 2 TURN PLC KEY SWITCH FROM PROG TO RUN AND THEN BACK TO REM THEN CYCLE POWER OFF AND ON 3 CYCLE POWER OFF AND ON 4 CHECK PLC POWER SUPPLY 5 CYCLE POWER OFF AND ON IF PROBLEM FAILS T
108. gust 09 2007 Friday Luc Update SCROL LEFT BOWL MOTOR TORQUE OR RIGHT M CONVEYOR EAE MOTOR TORQUE 8 42 31 Operation Home VIEW BEARING PAUSE TEMPERATURE SCREEN Figure 4 5 Motor Torque Trend Screen SYSTEM DIAGNOSTICS Built in system diagnostics continually analyze the DE 1000LP control system for malfunctions The Diagnostics screen Figure 4 6 aids in troubleshooting by displaying any fault in the critical areas of the centrifuge The current operational status of the Bowl Conveyor and Pump VFDs as well as the speed and temperature sensors are displayed on this screen Analog readings in mA are displayed at the bottom of the screen for main bearing temperature sensors and bowl speed sensor The screen is accessible from the Home screen as well as the three VFD screens GRN NO VFD FAULT GRN VFD RUNNING RED VED FAULT GRY VFD NOT RUNNING Derick Centrifuge Diagnostics X Bow Conveyor 99 Pump VFD TEMPERATURE p 5 Alarm Faut Alarm Faut Q Alarm VFD 98 2 102 4 103 8 Pin NOT USED zu Blower v 28 Y Pressure GRN 24VDC PRESENT AT Pin Compressor Pump Enable NOT USED CORRRESPONDING PIN OF 30 Speed Speed Speed ALL THREE VFD S 31 Vibration Vibration 9 Vibration GRY 24VDC NOT PRESENT 32 WRE Stop E Stop E Stop AQUA MORA EDS LE Brg Analog SE Brg Analog Bowl Speed Analog ANALOG SIGNAL LEVEL 7 526 ma 9 362 ma 3 995 ma Q Speed Sensor 1 GRN
109. hese documents are prepared by the product manufacturers which have sole responsibility for accuracy of the information The MSDSs listed below apply to products used in the manufacture of the Derrick equipment Where shown dates are current as of the publication date of this manual The latest MSDSs may be obtained from the product manufacturer PRODUCT APPLICATION MSDS No Date PPG Dimetcote 302H Green 302F0250 Resin Top Coat PPG Dimetcote 302H Clear 302G0910 Cure Top Coat PPG PSX 700 Neutral Tint Resin Undercoat PPG PSX 700FD Cure Undercoat 1302H 5A 04 11 10 1302 01 21 10 PX700T3 02 28 08 PX700FD B 01 11 07 Standard Environment Chevron SRI NLGI 2 Main Conveyor amp Motor Bearings Shell Omala 320 Gearbox 6979 08 03 04 6 510E 07 08 08 Arctic Environment 56200E 9 07 07 08 56170 9 05 20 03 Mobilith SHC 220 03 23 10 Shell AeroShell 14 Main amp Conveyor Bearings Shell AeroShell 7 Drive Motor Bearings Exxon Mobil Mobilith SHC 220 Gearbox Food Grade Chevron SRI NLGI 2 Main Conveyor amp Motor Bearings Exxon Mobil FM 102 Conveyor Bearings Only Shell Omala 320 Gearbox 6979 08 03 04 642363 00 01 17 02 67510E 07 08 08 Loctite Anti Seize Lubricant Fasteners 76764 05 27 09 15 Apr 11 2 3 DE 1000LPVFDCentrifuge DERRICK CORPORATION SECTION 3 INSTALLATION GENERAL This section describes the recommended installation procedure for the D
110. ics and thresholds that govern centrifuge operation ENTER USER NAME ENTER KEY ENTER PASSWORD Figure 4 18 Login Screen CLEAN OUT The Clean Out screen Figure 4 19 is used to set parameters for operating the bowl and or conveyor to remove accumulated process material that is impeding rotation With this screen displayed the operator selects the desired bowl and conveyor RPMs for the cleanout process During cleanout the actual RPMs and torque percentages are displayed below the setpoints Provision is included for selecting the automatic or manual cleanout options When the cleanout process has timed out or was stopped by the operator the Operation screen or the Faults screen may be displayed If automatic reduction of the pump speed is unable to clear out solids from the conveyor the torque will continue to rise and the centrifuge will shut down The clean out procedure should then be used to clear out the impacted solids and return the centrifuge to operational status The following paragraphs explain the two cleanout options automatic and manual ADJUST BOWL SPEED ADJUST CONVEYOR DIFFERENTIAL SPEED WV NS Derrick Centrifuge Clean Out OD anveyor Mode haut RPM Rut RPM y 300 y 9 GREEN SELECTED MODE MANUAL GRAY MODE NOT SELECTED Actual RPM Actual RPM 301 9 8 Automatic Torque Torque Clean Out RUNNING AUTO CLEANOUT START BEGIN CLEANOUT 12 9 1 5 Aa UNDERWAY RUNNING CLEANOUT UNDERWAY
111. in the adjusting slots to apply sufficient belt tension to permit deflection of 5 8 16mm with 20 lbs of pressure exerted at the midpoint of the belt After correct tension is set tighten motor mount bolts Install belt guard and latch in place Insert feed tube into feed tube support until shoulder fully contacts support and tighten screws to specification listed in Hardware Torque Specifications PURGE SYSTEM Bypassing Purge System The purge unit may be bypassed when necessary to apply electric power to the centrifuge while the control cabinet door is open but this should be done only after verifying that the centrifuge is in a non hazardous area After completing the work the purge system must be restored to operation and satisfactory operation confirmed Refer to Section 4 for the purge bypass procedure WARNING USE EXTREME CAUTION WHEN WORKING ON EQUIPMENT WITH PURGE SYSTEM BYPASSED DANGEROUSLY HIGH VOLTAGE WILL BE PRESENT IN ELECTRICAL PANEL AND CONTROL CABINET IF POWER IS APPLIED WARNING FAILURE TO WEAR SAFETY GLASSES MAY RESULT IN SERIOUS EYE INJURY OR PERMANENT LOSS OF VISION SAFETY GLASSES MUST BE WORN AT ALL TIMES WHILE PERFORMING ANY MAINTENANCE PROCEDURE 5 4 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE Inspection and Test Procedures Periodic inspection and test procedures supplemented by any additional requirements imposed by local codes are recommended The following tests should be performed at
112. ing and bearing housing Figure 5 13 to conveyor and remove seal housing and bearing housing Separate seal housing from bearing housing Remove retaining ring securing seal within seal housing Remove and discard seal and O ring from seal housing Extract bearing from bearing housing and discard bearing Remove retaining ring securing seal within bearing housing and remove and discard seal Remove wave spring from solid bowl head shaft 01 Aug 11 5 25 DE 1000LPVFDCentrifuge MAINTENANCE Removal Cont d WAVE 0 SPRING SUREN LIT 27 77 72 BEARING SED m i HOUSING LL SEAL HOUSING SEAL DOSS 3 RETAINING SEAL RING BEARING RETAINING RING Figure 5 13 Solid End Conveyor Bearing installation Cleaning Inspection and Repair 1 Clean all components with a suitable cleaner degreasing agent and blow dry with filtered compressed air Remove any corrosion to facilitate inspection 2 Inspect bowl head shafts for scratches nicks burrs or deformation that may affect suitability for returning to service Blend out any minor surface defects Replace bowl head if shaft is obviously deformed or serious flaws are found that render the bowl head unserviceable 3 Inspect bearing and seal housings for corrosion distortion nicks cracks burrs fractures or other defects Repair any minor defects 4 Check that solid bowl head wave spring has retained its tension Replace if damaged tension
113. l VFD Fault and Shutdown Ref Troubleshooting Section of User Manual VED fault detected causing shutdown Check and replace bowl VFD Bowl VFD Ground Warn Alarm Ref Troubleshooting Section of User Manual Bowl motor has path to ground Check for ground in bowl motor and connections to drive output and correct defect Bowl VFD In Phase Loss Alarm Ref Troubleshooting Section of User Manual Ground detected between VFD and motor in one phase Check wiring between VFD and motor correct defect Check motor winding for grounded phase remove ground if any or replace motor Bowl VFD Power Loss Alarm Ref Troubleshooting Section of User Manual Incoming power loss or low voltage Monitor and correct incoming power defect s supply Bowl VFD Undervoltage Alarm Ref Troubleshooting Section of User Manual Incoming power loss or low voltage Monitor and correct incoming power defect s supply Communication Failure with Bowl Speed Sensor Incorrect or loose connection at speed If reading on Bowl VFD status screen is about 4000 sensor or defective speed sensor RPM check connection at sensor if connection is secure replace sensor Incorrect connection at PLC Check that all connectors are securely seated as described in this section Defective speed sensor Check and replace transmitter intrinsic barrier if transmitter intrinsic barrier defective Defective pump VFD Check and replace VFD if defective Communi
114. l panel and install a jumper across terminals 1 and 4 to disable the purge system Figure 4 1 Label jumper Purge Bypass 5 To restore purge system operation remove the Purge Bypass jumper and close and secure electrical panel door Confirm proper operation of the purge system 4 2 01 Aug 11 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS CONNECT JUMPER ACROSS TERMINALS 1 AND 4 LABEL JUMPER PURGE BYPASS EAT f A TA 4 NS 3 Es 4 Ey E z AMS LM f 1 Dl y T sc Figure 4 1 Purge System Bypass INITIAL STARTUP Note If Rotating Assembly is Heated Before Starting Centrifuge Follow COLD CLIMATE STARTUP Instructions Later in This Section to Ensure Proper Bearing Lubrication Perform the initial startup procedure when the centrifuge is being started for the first time following installation or after the machine has been relocated 1 Check that all tools documents and shipping components have been removed and there are no obstructions to operation Verify that all personnel are clear of equipment Confirm that all operators and maintenance personnel have read and understand all operating and safety information in Section 2 4 Verify that equipment has been installed properly all shipping brackets have been removed and bearing pillow blocks have been tightened to specified torque per Section 5 For explosion proof cabi
115. ly high density materials or larger particles Both the bowl speed setting and actual bowl speed are shown on the control panel The torque percentage of the bowl is also displayed This information is useful in optimizing bowl speed to produce the desired solids dryness and processing speed Conveyor Differential Speed With correct wiring polarity the conveyor responds properly to settings made on the Operation screen Changing the conveyor differential speed adjusts the solids discharge rate Generally a slower differential speed will produce drier solids but reduces the solids discharge rate Increasing conveyor speed reduces drying time leading to wetter discharged solids Reducing conveyor speed results in drier solids discharge However excessively slow conveyor speed permits solids to accumulate in the bowl possibly causing an overload condition The drying time is reduced by increasing the conveyor differential speed which will increase the wetness of the solids Reducing the conveyor differential speed raises the settling time which will produce drier solids Both the conveyor speed setting and actual conveyor speed are shown on the control panel In addition the conveyor torque percentage is shown to assist in optimizing conveyor speed to produce the desired solids dryness and processing speed Since the conveyor differential speed is controlled by the PLC relative to the bowl speed setting wiring polarity of electrical compon
116. may appear on the operator control panel in case of equipment malfunction alarm and fault numbers may appear directly on the VFD screens An alarm is a condition that if neglected may stop the drive A fault is a condition that stops the drive The following tables list these alarm and fault numbers and the corresponding text This information is useful for operators and Derrick personnel to diagnose equipment malfunctions To expedite troubleshooting record the code number before calling for service and then relay this information to the service engineer ALARM CROSS REFERENCE IntDBRes OvrHeat BiPolar Conflict Brake Slipped Drive OL Level 1 Motor Type Cflct Adj VoltRef Drive OL Level 1 NP Hz Conflict Home Not Set 01 Aug 11 5 47 DE 1000LPVFDCentrifuge 6 8 _ 9 MAINTENANCE ALARM CROSS REFERENCE FAULT CROSS REFERENCE Powerloss Undeotage ____ 4 41 PhaseUVShot 89 Software Faut Motor Overload ___ 42 Phase vW Shon 90 Encoder Quad Er _ Heatsink OvrTemp 45 CmeistrOwTemp 48 101 2 5 3 4 SW OverCurrent 80 AutoTune Aborted 197 Hardware Faut CONTROL COMPONENT INDICATORS Various indicators are provided to display the operational status of components in the control cabinet Figures 5 16 through 5 19 locate and define the indications shown on these components Where applicable corrective actions are included to assist th
117. nd previous experience with this type of equipment 1 Read and understand all safety information in Section 2 before installing and operating this equipment 2 Read and understand the equipment handling procedures in this section before lifting and moving the equipment Position and level equipment at installation site Hemove shipping components and lower and secure the rotating assembly to the base Adjust drive belt refer to Section 5 Connect liquid discharge line oo Remove feed tube from rotating assembly 15 Jan 11 3 1 DE 1000LPVFDCentrifuge INSTALLATION INSTALLATION SEQUENCE CONT D 8 If discharge duct is to be used connect duct to solids discharge chute 9 Install feed component and connect flexible feed lines to inlet feed and flushing liquid flanges 10 Connect electric power supply to the equipment and connect feed pump to terminals of feed pump controller 11 Refer to Section 4 for startup and operating procedures REQUIRED CLEARANCES AND POSITIONING oufficient space should be provided around the equipment to facilitate access for maintenance inspection and adjustment Typical operation and maintenance functions include the following activities 1 Access and operate the system control panel 2 Open and close the control cabinet door Figure 3 1 3 Open and close top cover 4 Grease rotating assembly bearings 5 Check and fill gearbox 6 Connect and disconnect feed and li
118. net turn on compressed air to purge system Apply electric power to centrifuge The following screen will appear on explosion proof cabinet displayed after purge cycle is completed DERRICK DE 1000 CORPORATION VFD Centrifuge Clean Out Operation Setup Alarms Brg Temps Cent Status Diagnostics Motor Torgs 01 Aug 11 4 3 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS INITIAL STARTUP CONT D 7 Without the centrifuge running perform the following safety checks to confirm that connections are correct between control cabinet and centrifuge e Operate emergency stop button and check for Emergency Stop alarm message on control panel e Pull out emergency stop button to clear alarm message e vibration switch housing horizontally with a rubber rawhide mallet and check for High Vibration Fault message on control panel Press reset button on vibration switch to clear alarm message 8 Select Cent Status to verify that machine is ready for operation Correct any deficiencies before proceeding with startup procedure If condition is satisfactory click in the upper right corner to return to the Home screen 9 Select Setup and then select Pump Setup to view pump operating information Derrick Cenrifuge Pump Setup X Motor Data Pump Data em a T 3 oen 1 Power Teer ZT Ratio E u unis Reduction 56 Update VFD Settings Pump Stop Stop 10 Configure pump
119. nt No PE S 073 04 00 DERRICK CORPORATION SHIPPING FINAL INSPECTION AND RUN TEST CERTIFICATE Equipment Centrifuges Model DE 1000 GBD DE 1000 FHD DE 1000 VFD DE 7200 VED Characteristics 0 600VAC 50 60Hz 3PH The product listed above was inspected and found to be in conformance with Derrick Corporation s internal coating run test and assembly inspection documents that were required for the type of equipment manufactured in accordance with the Derrick quality system This certificate is governed by the applicable purchase order terms in effect at the time of Derrick Corporation s original shipment of the referenced product z s A Ar r ner Pit AW AWE LA I 4 Date 29 December 2011 Signature Jennifer Polanowski Derrick Corporation http dmc sps qc Certificates Shipping Final Inspection and Run Test PE S 073 04 00 doc Revison Number 2 Revision Date 29 December 201 1 Doc 5 036 02 06 Date 20 J 2011 DERRICK un CORPORATION CERTIFICATE OF CONFORMANCE Equipment Mining amp Oilfield equipment manufactured specifically for Hazardous Location Areas including but not limited to Flo Line amp Cleaners Flo Line Primers Agitators Vacu Flo Degassers DE 1000TM Centrifuges Centrifugal Pumps Flo Line Scalpers etc Name and Address of Manufacturer Derrick Corporation 590 Duke Road Buffalo NY 14225 Rating and Principle Charact
120. nveyor Bearings Chevron SRI NLGI 2 SRI 2 Motor Bearings Main amp Standard Conveyor Shell Aeroshell 14 Motor Bearings Main amp Arctic Conveyor A R Exxon Mobil FM 102 Food Grade Conveyor Bearings Only Standard DRIVE BELT REPLACEMENT WARNING HIGH VOLTAGE MAY BE PRESENT ALWAYS OPEN FUSED DISCONNECT SUPPLYING ELECTRIC POWER TO THE EQUIPMENT AND LOCK OUT AND TAG OUT POWER SUPPLY BEFORE PERFORMING ANY MAINTENANCE PROCEDURES WARNING FAILURE TO WEAR SAFETY GLASSES MAY RESULT IN SERIOUS EYE INJURY OR PERMANENT LOSS OF VISION SAFETY GLASSES MUST BE WORN AT ALL TIMES WHILE PERFORMING ANY MAINTENANCE PROCEDURE The drive belt should be replaced if inspection reveals damage or deterioration To replace the belt proceed as follows 1 Loosen screws securing feed tube clamp and slide out feed tube 2 Release latches and remove belt guard covering sheaves 3 Loosen bolts securing bowl drive motor mounting plate to base Figure 5 2 lift motor to loosen belt and slip belt off sheaves 01 Aug 11 5 3 DE 1000LPVFDCentrifuge MAINTENANCE DRIVE BELT REPLACEMENT CONT D MOTOR MOUNT ADJUSTING SLOT MOTOR MOUNT BOLT DRIVE MOTOR Figure 5 2 Drive Belt Tensioning 4 Check sheave parallel alignment using a straight edge Adjust position s of sheave s to achieve parallel alignment within 0 0156 0 4mm Install new belt on drive motor and bowl assembly sheaves Move motor mount downward
121. o return the pump to the normal flow rate After any fault be sure that the centrifuge has come to a complete stop before attempting to re start GRN DRIVE RUNNING GR N DRIVE OPERATIONAL GRY DRIVE OFF RED DRIVE FAULT pow Derrick Centrifuge Fault Reset x Bowl Conveyor Pump Last Fault 075 Last Fault 075 VFD Faulted No Fault No Fault RESET Pump RESET DRIVE TO Automatic Pump Flowrate Reduction OFF CLEAR FAULT Bowl Faut Status Conv Faut Status Faulk Status AUTOMATIC PUMP FLOW RATE REDUCTION Figure 4 15 Fault Reset Screen 01 Aug 11 4 17 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS SETUP SCREEN The Setup screen Figure 4 16 permits the operator to view the number of the software version installed in the PLC and control panel HMI bowl and differential speed settings and feed pump characteristics as well as set personal preferences The operator may adjust the brightness of the control panel screen and select the temperature units C or F that will be shown on other screens Options are provided to select the Login Diagnostics or Home screens If Login is selected prompting will appear to enter a user name and password which is available only to authorized personnel Once the screen is entered authorized personnel may set or change bowl conveyor and pump VFD parameters DISPLAY LOGIN SCREEN TO PERMIT ACCESS TO RESTRICTED SCREENS Derrick Centrifuge Setup CURRENTLY INSTALL
122. o the equipment must be suitably sized and in accordance with National Electrical Code NEC standards and all other applicable state and local codes Additional wiring requirements are as follows 1 The fused disconnect device shall have sufficient interrupting capacity to clear the maximum fault current capability of the power supply system 2 The GND connections in the electrical panel and control cabinet must be connected to a known ground 15 Jan 11 3 7 DE 1000LPVFDCentrifuge INSTALLATION ELECTRIC POWER CONNECTIONS CONT D L3 FEED PUMP __ CONNECTIONS L2 FEED PUMP CONNECTIONS GROUND CONNECTION INPUT POWER CONNECTIONS GROUND CONNECTION Non Explosion Proof Centrifuge Electrical Connections Figure 3 6 Input Power and Feed Pump Connections 3 8 15 Jan 11 DE 1000LPVFDCentrifuge INSTALLATION POLARITY TEST WARNING BE CERTAIN THAT MOTORS ROTATE IN CORRECT DIRECTION N INCORRECT POLARITY OF CONVEYOR MOTOR WILL CAUSE CONVEYOR TO ROTATE AT AN INCORRECT SPEED WHICH WILL RESULT IN PROCESSING PROBLEMS In the following procedure polarity is critical Be certain that all motors rotate in the correct directions Simply checking to see if solids are discharged out the solid end DOES NOT ensure correct polarity If conveyor motor is wired incorrectly the conveyor may become plugged or flooded depending on the speed settings of the bowl and conveyor Test for correct polarity of all connec
123. ompensation valve until the cycling stops and the cabinet pressure starts to fall Carefully adjust the leakage compensation valve until the cabinet pressure is stable This pressure will be the normal working pressure and should be about 5 WC 12 5 mbarg 01 Aug 11 5 7 DE 1000LPVFDCentrifuge MAINTENANCE Leakage Compensation Test Cont d c If at the end of purging the cabinet pressure falls below the minimum pressure sensor setting and the leakage compensation valve is fully open the system will start to purge again This indicates excessive leakage from the cabinet In this case check the cabinet for leakage and reduce or eliminate the leaks After sealing cabinet leakage at the end of purging the cabinet should stay pressurized and the relief valve action will be as in a or b above Proceed with adjustments described in the preceding steps Note When air conditioner goes off the relief valve may vent momentarily This is normal Minimum Pressure Sensor Setting The setting of the minimum pressure sensor should be checked as follows 1 Note the position of the leakage compensation valve knob by marking knob with a pencil at the 12 00 o clock position 2 Slowly lower the cabinet pressure by closing the leakage compensation valve further counting the number of turns from the normal working pressure position Note the pressure at which the alarm pressurized indicator changes from green to red and check that this pr
124. on to the right of the control panel permits instantaneous shutdown of VFDs motor drives in case of emergency For centrifuges installed in hazardous environments a purge system is installed in the control cabinet to provide a continuous flow of air to prevent the cabinet interior from accumulating explosive vapors When power is applied to the centrifuge the cabinet purge system initiates a 16 minute rapid purge cycle at 16 CFM This cycle consists of five complete air exchanges When the rapid purge cycle is completed the purge system automatically closes a switch that supplies power to the cabinet Cabinet Purge System Before power is applied to the centrifuge the purge system purges the control cabinet of any flammable gas that may have entered the cabinet while it was not pressurized The system also maintains positive pressure and automatically compensates for any leakage within the control cabinet to prevent entry of flammable gas The system has FM UL ATEX and IECEx certifications The purge unit has a visual indication of purge system status Minimum pressure and purge flow sensors provide an output signal to the control unit if the purge system is not maintaining satisfactory pressure within the cabinet Major components of the purge system are described in the following paragraphs Control Unit The control unit contains a pneumatic logic circuit that controls the cabinet purge and pressurization It receives filtered air from
125. opping of operation Normal shutdown is performed for routine activities such as cleaning lubrication inspection or adjustment Note Proper shutdown and flushing of the bowl can prevent high vibration at the next startup NORMAL SHUTDOWN ER Stop the feed pump Initially continue the supply of fresh flushing water to remove all solids from conveyor and bowl Continue flushing for 3 to 5 minutes after feed pump has been shut down Regardless of shutdown duration the conveyor operates at a pre set differential speed while the bowl decelerates to a stop This process cleans the bowl during the shutdown The centrifugal force holds the flushing liquid against the bowl wall during the flushing procedure As the speed gradually drops during the shutdown period the solids chute can also be flushed Fittings on the hinge side of the case permit attachment of a hose to wash the exterior of the rotating assembly and interior of the case assembly Conveyor gearbox drive motor automatically shuts down when bowl speed falls to less than 200RPM After the centrifuge comes to a complete stop which may take more than 15 minutes after interrupting power to the bowl motor the centrifuge should be restarted for 20 to 30 seconds to clear away solids released during collapse of the water ring Run automatic cleanout procedure Open fused disconnect supplying electric power to the machine and lock out and tag out machine For cabinet with purge
126. or a malfunction the technician must proceed methodically to eliminate all possible causes and take all corrective actions at each step of the troubleshooting process In general an unexpected centrifuge shutdown is due to an interruption of electric power that has turned off the bowl drive motor Safety components are installed in key areas of the centrifuge electrical control system to shut down the electric motor if safety parameters such as motor temperature vibration or conveyor torque are exceeded The power interruption may be due to one or more factors including a local power failure In case of control system malfunction with electric power shut down locked out and tagged out check that PLC connectors are fully seated in their receptacles Correct as necessary before proceeding with further troubleshooting 5 34 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE The troubleshooting chart consists of failure modes possible cause s and recommended course s of action All electrical continuity checks in this procedure are performed without electric power supplied to the centrifuge Lock out and tag out equipment before attempting to perform any continuity check ELECTRIC POWER APPLIED TO CENTRIFUGE LOCK OUT AND TAG OUT WARNING CONTINUITY CHECKS MUST BE PERFORMED WITHOUT ELECTRIC POWER BEFORE ATTEMPTING CONTINUITY CHECKS TROUBLESHOOTING DE 1000LP VFD CENTRIFUGE Insufficient solids in feed Check feed pump if require
127. oved from the bowl head shaft following removal of the bearing The pillow block bearings must be replaced as a set Consequently if one bearing is found defective always replace both bearings 5 16 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE Liquid End Bearing Removal WARNING TO AVOID SERIOUS PERSONAL INJURY BE SURE EQUIPMENT IS LOCKED OUT TAGGED OUT DE ENERGIZED AND HAS STOPPED ROTATING BEFORE PERFORMING MAINTENANCE AND OR ADJUSTMENTS 1 Shut down lock out and tag out electric power to the centrifuge Allow rotating assembly to coast to a full stop 2 Open case cover and remove screws securing pillow blocks at liquid and solids ends to case 3 Using a suitable hoist lift rotating assembly to separate pillow blocks from bottom of case leaving sufficient clearance to permit removal of pillow blocks 4 Remove gearbox from liquid bowl head Figure 5 7 as follows a Scribe a line across gearbox and flange to ensure correct positioning upon installation Using a 14mm hex wrench remove six screws securing gearbox to flange b To ensure correct placement of shim s mark location of shim s between flange and gearbox Install two 3 8 16 jack screws into flange clearance holes that are 180 apart Using a 9 16 box wrench alternately turn both jack screws a few revolutions at a time to begin separating gearbox from flange c To support unit during remainder of removal procedure place lifting strap around g
128. quid discharge lines 32 813mm Min Figure 3 1 Required Control Cabinet Door Clearance 3 2 15 Jan 11 DE 1000LPVFDCentrifuge INSTALLATION EQUIPMENT HANDLING WARNING USE SPREADER BARS TO PREVENT DAMAGE WHEN LIFTING THE EQUIPMENT WARNING TO ENSURE PROPER BALANCE AND ORIENTATION WHEN UNIT IS RAISED AND PREVENT DAMAGE TO COMPONENTS ATTACH LIFTING SLINGS ONLY TO LABELLED LIFTING POINTS DO NOT ATTEMPT LIFTING BY ATTACHMENT TO ANY OTHER LOCATION WARNING BE SURE THAT HANDLING DEVICES HAVE SUFFICIENT LIFTING CAPACITY TO SAFELY HANDLE THE WEIGHT OF THE EQUIPMENT WARNING DO NOT REMOVE SHIPPING BRACKETS UNTIL EQUIPMENT HAS BEEN POSITIONED AT FINAL INSTALLATION SITE WARNING WHEN USING AN OVERHEAD LIFTING DEVICE USE ALL FOUR LIFTING POINTS PROVIDED The centrifuge is shipped fully assembled and installed on a shipping skid A label indicating the weight of the unit was affixed to the machine Refer to the general arrangement drawing in Section 8 for equipment weight and other technical data While the centrifuge is still mounted on the shipping skid it may be transported on the ground using a forklift After the machine is removed from the shipping skid an overhead lifting device is required Four reinforced lifting lugs are built into the equipment frame to allow attachment of an overhead lifting device Figure 3 2 Lifting points are labeled LIFT HERE ONLY DO NOT attempt lifting equipment by attaching slings or
129. r differential speed and or pump feed rate Interior temperature of control cabinet Check that air conditioner is operating repair or too high causing shutdown replace as indicated Inspect cabinet interior and remove cause of high temperature if any Re start centrifuge after removing cause of high temperature Emergency Stop Switch Activated Shutdown EMERGENCY STOP pressed Remove cause for emergency stop and then re start centrifuge High Vibration Fault and Shutdown Correct Problem and Press Reset Button Excessive vibration has caused Rotating assembly overloaded or clogged producing vibration switch to trip resulting in out of balance condition Remove cause of power interruption and centrifuge excessive vibration and re start centrifuge shutdown Liquid End Main Bearing High Temperature Alarm Temperature sensor connection If reading is constantly about 392 F 200 C check insecure or disconnected and correct connection refer to electrical schematic diagram in Section 8 Insufficient bearing lubrication Lubricate bearings refer to Preventive Maintenance in this section Excess grease Remove grease fitting and direct jet of filtered compressed air to remove grease Incorrect grease Lubricate with recommended grease refer to Preventive Maintenance in this section Defective bearing Replace both main bearings refer to Main Bearing Replacement in this section 01 Aug 11 5 45 DE 1000LPV
130. r TN Rr NEN 4 19 eee o AA 4 19 Normal SAUIOWN 4 20 Automatic M 4 21 Emergency einen 4 21 Srt a 5 1 01 Aug 11 T EAT 5 1 Preventive nennen nnne nnne nnns 5 1 L picaton Char ansehe 5 3 Drive Belt Replacement inicios ia 5 3 Purge TEE rial end 5 4 Rotating Assembly 5 8 Main Bearing Replacement eese nennen 5 16 Conveyor Bearing 5 24 Ent utor ierat med actu td unb 5 27 Hardware Torque 5 5 28 TOC 2 01 Aug 11 DE 1000LPVFDCentrifuge CONTENTS Section Page Date 51210 216510472 erm 5 31 Recommended Spare 5 32 TFOUDICSMOOUNG ensien 5 34 Alarm and Fault Messages Sod euo 5 40 VFD Alarm and Fault Cross References 5 47 Control Component nnns 5 48 6 7 Not Used 8 1 15 Jan 11 9 1 15 Jan 11 8 Reference Drawings ann a 9 Installation and Maintenance Log 01 Aug 11 TOC 3 DE 1000LPVFDCentrifuge
131. r ground in conveyor motor and connections to drive output and correct defect Conveyor VFD In Phase Loss Alarm Ref Troubleshooting Section of User Manual Ground detected between VFD and Check wiring between VFD and motor correct motor in one phase defect s Check motor winding for grounded phase remove ground if any Conveyor VFD Power Loss Alarm Ref Troubleshooting Section of User Manual Incoming power loss or low voltage Monitor and correct incoming power defect s supply Conveyor VFD Undervoltage Alarm Ref Troubleshooting Section of User Manual Incoming power loss or low voltage Monitor and correct incoming power defect s supply Electrical Enclosure High Temperature Alarm PLC has detected high temperature Check that air conditioner is operative repair or inside control cabinet replace air conditioner if defective Check VFD temperatures refer to Section 4 replace VFD if defective Reduce load by decreasing bowl conveyor differential speed and or pump feed rate 5 44 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE Alarm and Fault Messages Electrical Enclosure High Temperature Fault and Shutdown PLC has shut down centrifuge due to high temperature inside control cabinet Check that air conditioner is operative repair or replace air conditioner if defective Check VFD temperatures refer to Section 4 replace VFD if defective Reduce load by decreasing bowl conveyo
132. rate fan from housing While supporting fan check that fan plugs are securely connected and that all leads are secure in connectors Correct as required continue trouble shooting if leads are secure Fan motor bearings binding or With fan separated from air conditioner housing unplug and seized remove fan Check that fan rotates freely and no rubbing is detected Replace fan if rubbing or binding is found High temperature switch motor Using an ohmmeter check for continuity across 2 light gray winding defective motor leads of fan connector Figure 5 14 amp 5 15 If meter indicates an open circuit verify that leads are securely connected correct as needed If connections are secure replace fan 5 38 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE X216 X216 X216 B 0 PRESSURE COMPRESSOR FAILURE FAILURE FAILURE X1OL10L20L X30M O2 O3 4 GNY8 LEGEND POWER CABLE B1 THERMOSTAT F1 HIGH REFRIGERANT PRESSURE SWITCH F2 FUSE F4 M3 THERMAL PROTECTOR CONTACT F5 LOW REFRIGERANT PRESSURE SWITCH F6 F7 M1 THERMAL PROTECTORS F8 M1 THERMAL PROTECTOR CONTACTS K10 FAULT SIGNAL RELAY K15 1 THERMAL PROTECTOR RELAY K20 COMPRESSOR CONTACTOR K30 POWER CONTACTOR M1 COMPRESSOR M2 CONDENSER FAN M3 EVAPORATOR FAN T1 CONTROL TRANSFORMER X1 X3 TERMINAL BOARD Figure 5 14 Air Conditioner Electrical Schematic Diagram 01 Aug 11 5 39 DE 1000LPVFDCentrifuge MAINTENANCE TROUBLESHOOTING CONT D
133. rements HARDWARE TORQUE SPECIFICATIONS Use only hardware that is approved by Derrick Corporation The use of potentially inferior non Derrick approved hardware may result in serious injury to personnel and or damage to equipment Additionally any warranty in force whether written or implied may be voided by use of unapproved hardware Contact Derrick Corporation with questions pertaining to hardware type and usage associated with Derrick centrifuges WARNING USE OF INFERIOR NON DERRICK APPROVED HARDWARE MAY RESULT IN SERIOUS INJURY TO PERSONNEL AND OR DAMAGE TO EQUIPMENT Recommended seating torque specifications lubricants and other hardware installation specifications for the various types and sizes of hardware used on the centrifuge are shown and described in the following tables Use the following procedure when tightening hardware 1 Use only a calibrated torque wrench 2 Apply specified lubricant to hardware before installing 3 When tightening more than one bolt alternate tightening between bolts 4 Always approach the final torque in several stages 5 28 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE 24 27 11 25 18 7 19 8 2220 e dia mmm VA 17 14 NNNM ER D i 38 LARGA T altra aa mam Lam 1 AI T SOLID END HARDWARE LOCATIONS SOLID END HARDWARE TORQUE SPECIFICATIONS 6 4
134. rings support both ends of the conveyor Gearbox The 5211 ratio differential reduction gearbox rotates the conveyor at a slower speed than the bowl assembly The motor is coupled to the gearbox by a flexible coupling which permits compliance with slight alignment variations The conveyor s rotational speed varies directly with bowl speed maintaining a consistent differential relationship for solids conveyance The gearbox is an overhung load with one end supported by the liquid end conveyor bearing The gearbox output shaft driven by the second stage planetary gears engages internal splines in the conveyor to transmit rotary motion During an overload condition excessive solids in the conveyor may overburden the motor causing motor torque to increase as it attempts to maintain the differential speed setting If the conveyor s pre set torque limit is reached the control system automatically reduces the feed rate to enable the conveyor to clear the excess solids When the centrifuge is operating at the reduced feed rate the Operation screen displays a message to inform the operator of the modified status Unless the over torque condition is removed the centrifuge will be shut down automatically 15 Jun 11 S DE 1000LPVFDCentrifuge INTRODUCTION Drive Motors The centrifuge is powered by two inverter duty 1800 RPM three phase explosion proof electric motors The 50 HP bowl drive motor is transmitted to the bowl assembly by a sheave an
135. rtain conveyor speeds the drive motor must reverse direction to accommodate the differential speed relationship with the bowl If this occurs the centrifuge control system automatically assumes control of the feed pump to reduce its flow rate The message Automatic Flowrate appears on the Operation screen to alert personnel that the feed pump is under automatic control 4 10 01 Aug 11 DE 1000LPVFDCentrifuge OPERATING INSTRUCTIONS When the reduced feed rate is reached a 20 second timer is started Upon expiration of the timed interval a new conveyor differential speed is applied to correspond with the revised flow rate The pump feed rate returns to the previous rate when the new differential speed is reached Manual control of the feed pump is then restored This action releases the feed pump from automatic control and clears the Automatic Flowrate message from the screen ALARM AND FAULT MESSAGES During centrifuge operation a message may appear to alert the operator to an anomaly that requires operator intervention Alarm messages signify that the prevailing condition must be corrected or the centrifuge may be shut down automatically Fault messages inform the operator that a failure requiring automatic shutdown has occurred Refer to Section 5 for alarm messages and their causes and corrective actions BEARING TEMPERATURES Bearing temperature trends may be viewed in graphical form on the Bearing Temperature screen Figure 4 4 T
136. s during centrifuge operation the purge system performs another 16 minute rapid purge before power is restored to the cabinet Purge System Bypass WARNING CENTRIFUGE MUST BE LOCATED IN A NON HAZARDOUS AREA FREE OF FLAMMABLE GASES DO NOT BYPASS PURGE SYSTEM IF NOT CERTAIN THAT ENVIRONMENT IS NON HAZARDOUS A HIGH RISK OF FIRE AND OR EXPLOSION WILL RESULT IF PURGE SYSTEM IS BYPASSED IN A HAZARDOUS AREA If the centrifuge is located in a non hazardous environment the purge system may be turned off A high risk of fire and or explosion will result if purge system is bypassed in a hazardous area Also with the purge system bypassed the centrifuge will remain energized if the control cabinet door is opened Consequently use extreme caution when operating the equipment or performing any procedure with purge system bypassed If the centrifuge is moved to a hazardous environment the bypass must be removed and satisfactory purge system operation confirmed WARNING USE EXTREME CAUTION WHEN OPERATING EQUIPMENT WITH PURGE SYSTEM BYPASSED DANGEROUSLY HIGH VOLTAGE WILL BE PRESENT IN CONTROL CABINET IF DOOR IS OPENED WHILE POWER IS APPLIED To bypass the purge system proceed as follows 1 Be certain that centrifuge is in a non hazardous environment then shut down lock out and tag out electric power to centrifuge Remove bolts securing electrical panel door and open door Locate intrinsic barrier at upper right side of electrica
137. s time 4 Position bearing outer race and rollers into chamfer of pillow block Using a suitable tool that contacts only the outer bearing race carefully tap outer race into pillow block until about 1 8 3mm below the surface of the pillow block 5 Install new small cross section O ring against shoulder of inboard pillow block cover and slide pillow block cover onto shaft 6 Apply sufficient quantity of bearing grease listed in customer specification to completely cover bearing rollers 7 Slide assembled pillow block and bearing outer race onto inner race previously installed on bearing journal 8 Install new large cross section O ring against shoulder of outboard pillow block cover slide pillow block cover onto shaft and rest against pillow block 9 Orient inboard pillow block cover so that flat edge is aligned with bottom of pillow block 10 Apply anti seize compound to four flat head screws and install screws to secure inboard pillow block cover to pillow block Tighten screws in accordance with Hardware Torque Specifications 11 Orient outboard pillow block cover so that flat edge is aligned with bottom of pillow block 12 Apply anti seize compound to four flat head screws and install screws to secure outboard pillow block cover to pillow block and draw bearing into proper position within pillow block Tighten screws in accordance with Hardware Torque Specifications 13 Slide outboard bearing flinger onto sheave but leave s
138. set forth product is manufactured in the United States of America as of the data of this certificate This certificate is governed by the applicable purchase order terms in effect at the time of Derrick Corporation s original shipment of the referenced product Date 29 December 2011 RIA Uy uf Signature Jennifer J Polanowski Derrick Corporation http dmc sps qc Certificates Origin Standard PE S 069 03 03 doc Revison Number 2 Revision Date 29 December 201 1 Document No PE S 009 08 00 DERRICK CORPORATION CERTIFICATE OF QUALITY Equipment Centrifuges Model DE 1000 M DE 1000 M FHD DE 1000 VED DE 7200 VED Characteristics 0 600V AC 50 60Hz 3PH Derrick Corporation acknowledges that the above set forth product conformed to the requirements for the applicable purchase order at the time of its original shipment by Derrick Corporation in that all construction materials and components were new and unused were manufactured for this product and that it was free of any known defects as to their design material and workmanship This certificate is governed by the applicable purchase order terms in effect at the time of Derrick Corporation s original shipment of the referenced product Date 29 December 2011 Signature Jennifer J Polanowski Derrick Corporation http dmc sps qc Certificates Quality PE S 009 08 00 doc Revison Number 2 Revision Date 29 December 201 1 Docume
139. ter removal Reinstall shims in proper locations as noted during removal Clean alignment pins before reinstalling and apply anti seize compound Orient rotating assembly to horizontal position and carefully lower into case until about 1 2 13mm above base Insert bolts through pillow blocks and start threads into base Do not tighten bolts Lower rotating assembly fully onto base Insert alignment pins through pillow blocks and lightly tap into holes to fully align pillow blocks with base mounting holes 10 Tighten bolts in accordance with applicable specification in Hardware Torque Specifications to secure pillow blocks to base 01 Aug 11 5 13 DE 1000LPVFDCentrifuge MAINTENANCE Reassembly and Installation Cont d 11 Install gearbox as follows a Insert new O ring into groove in gear flange and apply grease to shaft to facilitate installation Place lifting strap on gearbox and using an overhead lifting device CAREFULLY lift and position gearbox to engage splined shaft with internal spline of conveyor Insert six new hex head screws through gearbox flange and into threaded mounting holes of gearbox Alternately turn each screw a few revolutions at a time to evenly draw the gearbox and flange together Tighten the mounting screws using a star pattern typical for circular bolt patterns Refer to Hardware Torque Specifications for torque values GEAR FLANGE 12 Inject grease into conveyor
140. ters should be lowered to reduce torque Conversely falling conveyor torque shows that speed can be raised and or feed rate increased Operating parameters should be adjusted as required to optimize centrifuge operation and prevent automatic shutdown due to excessive bowl or conveyor torque The Operation screen Figure 4 2 permits the operator to view current operating information for the bowl conveyor and pump and adjust the parameters as required to meet changing conditions Through this screen the operator may view and set bowl and conveyor RPMs and torque percentages set feed pump flow rate and view bearing temperatures Adjustments of the conveyor and bowl speeds may be performed using up and down arrows or by entering actual numbers on the numeric keypad In addition options are provided for stopping the centrifuge displaying VFD operation screens and selecting Status Clean Out Faults Alarms and Home screens The following parameters affect centrifuge operation Feed rate pond depth bowl speed and conveyor speed Adjustment of one parameter may produce the desired clarity of liquid effluent and solids dryness Or the desired performance may be achieved by further adjustment It is important to understand the interdependence of the operating parameters Changing one characteristic results in other effects that may warrant additional adjustments Except for pond depth these parameters can be adjusted while the centrifuge is oper
141. the minimum are permitted and a tolerance of 20 is normally acceptable If the time is too short it must be increased accordingly 7 After power has been applied via the control unit the purging valve will close and the air flow into the cabinet will be controlled by the leakage compensation valve The setting of the leakage compensation valve should now be checked One of the following three conditions will be occurring a If a considerable quantity of air continues to flow out the relief valve after power has been applied the leakage compensation valve is too far open and the air flow is holding the relief valve open continuously To correct this condition slowly close the leakage compensation valve The cabinet pressure will start to fall as the flow decreases but eventually the relief valve will close and the cabinet pressure will rise again At this point the relief valve may start to open intermittently as the cabinet pressure rises to the point where it exceeds the relief valve opening pressure When the relief valve opens the pressure will fall quickly to the point where the relief valve re closes and the cabinet pressure starts to rise again If the relief valve is opening intermittently the leakage compensation valve is open slightly too far When the relief valve opens the cabinet pressure falls quickly to the point where the relief valve re closes and the cabinet pressure starts to rise again Continue to close the leakage c
142. then be manually pressed to close the contacts and re engage the magnetic latch The vibration trip level is adjustable by means of a set point control which adjusts the air gap between the magnet and latch arm plate Turning the screw counterclockwise reduces the vibration set point in terms of G force needed to trip the armature When the control is turned fully clockwise the switch will trip at the maximum rated vibration level The vibration switch is mounted on the centrifuge base in an orientation that is most affected by out of balance vibration of the bowl assembly Clogging of the conveyor or worn bearings may produce sufficiently high vibration to trip the switch VIBRATION SWITCH Figure 1 4 Vibration Switch Case Base And Skid The stainless steel upper and lower case halves provide a sealed protective enclosure that fully surrounds the bowl assembly The liquid discharge pipe and the solid discharge chute are installed at the bottom of the lower case half Mating baffles installed inside the top and bottom case halves separate the solids and liquid Bolts secure the top and bottom halves together and a rubber gasket in the top case seals the two halves A separate two piece enclosure encloses the gearbox at the liquid end of the bowl assembly The case is bolted onto the welded steel base assembly which contains mounting provisions for the bearing pillow blocks and feed tube support The base assembly is bolted to the welde
143. tions as follows 1 Apply power to centrifuge 2 Confirm direction of rotation for air conditioner condenser and evaporator motors by selecting Test AC on Centrifuge Status screen refer to Section 4 to turn on motors Rotation is to be as follows a Condenser motor Clockwise viewed from fan end b Evaporator motor Clockwise viewed from inside cabinet 3 Correct reverse rotation of air conditioner motors by shutting down power and switching any two of the three power leads at the motor or terminal strip refer to Figure 3 6 and electrical schematic diagram in Section 8 WARNING EQUIPMENT WILL BE DAMAGED IF AIR CONDITIONER EVAPORATOR AND OR CONDENSER MOTOR ROTATES IN OPPOSITE DIRECTION CORRECT ROTATION BEFORE OPERATING MACHINE 4 Run bowl at 20 RPM with a conveyor differential speed of 5 RPM 5 Confirm direction of rotation for bowl conveyor and feed pump motors as follows a Bowl Counterclockwise viewed from fan end b Conveyor Clockwise viewed from fan end Feed pump Per manufacturer s data 6 Correct reverse rotation of bowl or conveyor motor by shutting down power and switching any two of the three power leads at the motor or terminal strip refer to Figure 3 6 and electrical schematic diagram in Section 8 If feed pump rotation is incorrect refer to manufacturer s data for information to reverse rotation MACHINE STARTUP Refer to Section 4 for initial startup and operating procedures for the centrifuge
144. to sedimentation in Prevent future repetition by clearing feed line immediately after shutting down machine Failure Mode 7 Machine Shutdown Due to Excessive Power Consumption During Startup Discharge chute clogged Clear discharge chute of all accumulated solids supply line 5 36 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE TROUBLESHOOTING DE 1000LP VFD CENTRIFUGE Failure Mode 8 Excessively High Main Bearing Temperature Insufficient lubrication Lubricate bearings refer to Preventive Maintenance Excessive grease Remove grease fitting and direct jet of filtered compressed air to remove grease Incorrect grease Lubricate with recommended grease refer to Preventive Maintenance Defective bearing Replace both main bearings refer to Main Bearing Replacement Failure Mode 9 Purge System Purges Correctly But Alarm Goes On At End Of Purge Interval And Purge Cycle Is Repeated Actual cabinet pressure below Check cabinet pressure with a Magnahelic gage Adjust setting of minimum pressure minimum pressure sensor to correspond with actual cabinet Sensor pressure Leakage compensation valve Increase cabinet pressure by turning leakage compensation setting to low causing re valve adjustment counterclockwise Contact Derrick for purge to occur assistance if problem is not corrected Failure Mode 10 Purging Indicator Does Not Become Amber During Purging Low air pressure Check that air supply line is at least 3 4
145. ump VFD In Phase Loss Alarm Ref Troubleshooting Section of User Manual Ground detected between VFD and Check wiring between VFD and motor correct pump motor in one phase defect s Check motor winding for grounded phase remove ground if any or replace motor Replace VFD Pump VFD Power Loss Alarm Ref Troubleshooting Section of User Manual Incoming power loss or low voltage Monitor and correct incoming power defect s supply 5 46 DE 1000LPVFDCentrifuge O i gt uk MAINTENANCE Alarm and Fault Messages Solid End Main Bearing High Temperature Alarm Insufficient bearing lubrication Lubricate bearings refer to Preventive Maintenance Excess grease Remove grease fitting and direct jet of filtered compressed air to remove grease Incorrect grease Lubricate with recommended grease refer to Preventive Maintenance Defective bearing Replace both main bearings refer to Main Bearing Replacement Solid End Main Bearing High Temperature Fault and Shutdown Insufficient bearing lubrication Lubricate bearings refer to Preventive Maintenance Excess grease Remove grease fitting and direct jet of filtered compressed air to remove grease Incorrect grease Lubricate with recommended grease refer to Preventive Maintenance Defective bearing Replace both main bearings refer to Main Bearing Replacement VFD ALARM AND FAULT CROSS REFERENCES In addition to alarm and fault messages that
146. until it releases from bowl and lift and remove bowl head Remove and discard O ring from bowl head 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE GEAR FLANGE 72 NUN Jam SS PILLOW BLOCK ARO rr FEE SASS SSS SI Og A SCREW P A ae LIQUID BOWL HEAD Ya SM eas ul a NDS CX Fee Ol j FAC SS N im 2 7 O RING W l 2 D 910 il BOWL nf 5 A 52 E p m SS Figure 5 5 Liquid Bowl Head Removal 15 Remove conveyor assembly as follows a Remove four screws securing liquid end seal housing to conveyor Figure 5 6 and using jack screws to separate seal housing from bearing housing remove seal housing Discard seal b Position vertical lifting bracket on conveyor and secure with four screws Attach a hoist capable of lifting at least 750 lbs 340kg to vertical lifting bracket d Slowly lift conveyor from bowl assembly using care to avoid allowing conveyor to contact interior of bowl e Orient conveyor horizontally and place on a support that does not contact tiles 01 Aug 11 5 11 DE 1000LPVFDCentrifuge MAINTENANCE Removal and Disassembly Cont d SEAL RETAINING RING BEARING SCREW
147. ve CF000679 PARTS REPLACEMENT Defective parts should be replaced as soon as possible to prevent further damage to equipment Refer to the general arrangement drawing rotating assembly drawing and electrical drawings in Section 8 for Derrick component locations and part numbers 01 Aug 11 5 31 DE 1000LPVFDCentrifuge MAINTENANCE RECOMMENDED SPARE PARTS The following table lists the recommended spare parts required to support a single DE 1000LP VFD Centrifuge for two years However since all potential part replacements cannot be predicted the complete spare parts inventory should be based on the users experience with similar equipment RECOMMENDED SPARE PARTS DE 1000LP VFD CENTRIFUGE SHELL OMALA320G Yes S 4 Sets 2 Pair 2 Pair A O i gt uk m o E U lt MAINTENANCE RECOMMENDED SPARE PARTS DE 1000LP VFD CENTRIFUGE 9540 00 Feed Tube ORVI ARP 242 G0003211 G0003212 O Ring Main Bearing Inboard Coupling Gearbox Pinion to Conveyor Motor O Ring Gear Flange O Ring Main Bearing Outboard O O O O G0008125 G0004365 9524 00 Wave Spring Conveyor Support Bearing Feed Nozzle Assembly Yes 20008359 Variable Frequency Drive Bowl Drive Variable Frequency Drive 20HP Conveyor G0007241 Drive Variable Frequency Drive 15HP Pump G0008360 Dri riv
148. xcessive vibration end play or radial looseness if found 1 Remove conveyor from rotating assembly in accordance with Rotating Assembly Maintenance in this section 2 With conveyor supported remove screws securing lifting bracket to conveyor and remove lifting bracket 3 Remove screws securing liquid end seal housing Figure 5 12 to bearing housing and remove seal housing Remove and discard O rings installed in external grooves of seal housing 4 Using a suitable hammer type puller extract both thrust bearings from liquid end bearing housing Discard bearings 5 Remove retaining ring securing seal in seal housing and remove and discard seal SEAL RETAINING RING BEARING _ SCREW SEAL HOUSING FR JAN SN e I REX SS es 4 N O RINGS BEL 22 44 O A 4 f i A CONVEYOR BEARING HOUSING d 4 Figure 5 12 Liquid End Conveyor Thrust Bearings installation 5 24 01 Aug 11 DE 1000LPVFDCentrifuge MAINTENANCE Cleaning Inspection and Repair 1 Clean all components with a suitable cleaner degreasing agent and blow dry with filtered compressed air Remove any corrosion to facilitate inspection 2 Inspect bowl heads for scratches nicks burrs or deformation that may affect suitability for returning to service Blend out any minor surface

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