ALPHA700 Manual

Particle classifier ALPHA 700

Contents ALPHA 700

Contents Safety warnings .........................................................1 Icons used and danger warnings ...................................................... 1 Suitable use of the particle classifier ................................................. 2 General safety warnings ................................................................. 2 Safety in handling and storage ......................................................... 3 Technical specifications of the classifier ............................................ 4

Description of the particle classifier .........................6 Operating principle of the particle classifier ....................................... 9 Vibrations ..................................................................................... 11 Classifier options ........................................................................... 13 Classifiers with cooling system ........................................................ 14

Transport and assembly .............................................16 Transport ...................................................................................... 16 Work prior to assembly ................................................................... 18 Tools necessary for assembly, disassembly and maintenance .............. 18 Assembly ...................................................................................... 19 Work after assembly ...................................................................... 22

Start-up ......................................................................23 Commissioning .............................................................................. 23 Ignition period ............................................................................... 23

Operation ...................................................................25 Commissioning a plant .................................................................... 25 Settings during operation ................................................................ 26

Maintenance ..............................................................27 Standard maintenance .................................................................... 27 Special maintenance (for ceramic particle classifiers only) ................... 29 Removing the rotor ........................................................................ 30 Assembling the rotor ...................................................................... 33 Tightening the trapezoidal belts ....................................................... 33 Spare parts lists ............................................................................. 34 Lubrication .................................................................................... 36

Fault search ...............................................................37 Appendices ................................................................38 Electrical appendix ......................................................................... 38

Contact details Contact persons: Sergio Alegre and Javier Peña Manufacturer / Technical Service: ECUTEC Barcelona SL Address: Gran Vía de les Corts Catalanes 701, 3er 1ª A Postcode: 08013 Barcelona SPAIN Tel. (+34) 932 477 700 rev.02.2011

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Contents ALPHA 700

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Safety warnings ALPHA 700

1. Safety warnings 1.1 Icons used and danger warnings The terms DANGER, ATTENTION, CAUTION and WARNING indicate specific dangers or special information that requires particular attention. The term NOTE refers to information that does not involve danger to persons.

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DANGER Indicates danger of death and personal injury if the necessary precautions are not taken. ATTENTION Indicates that severe personal injury can occur if the necessary precautions are not taken. CAUTION Indicates that minor personal injury can occur if the necessary precautions are not taken. WARNING Indicates that exclusively material damage can occur if the necessary precautions are not taken. NOTE



Notes contain relevant technical information that may not be obvious to a specialist technician. Follow the points indicated exactly to avoid damage to the machine. Stickers: Electric risk, mechanical risk, earth ELECTRICAL RISK The electrical risk sticker is used to indicate zones and / or elements of the machine which present a risk of electrical shock. MECHANICAL RISK The mechanical risk sticker is used to indicate zones and/or elements of the machine that present risk of physical injury, such as being trapped, hit or cut. EARTH The earth sticker is used to indicate a valid and effective earth at one point in the machinery.

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Safety warnings ALPHA 700 1.2 Suitable use of the particle classifier The objective of particle classifier ALPHA 700 is the classification of pulverised products for the mining, chemistry or pharmaceutical industries where these materials are used, for example, to produce paints or plastics. The classifier can be used to classify fine materials in a range between 7μm and 40μm. The raw material may be either minerals, pigments, foodstuffs or ground chemical materials with a particle size smaller than 2 mm. To guarantee optimum classification, the starting material must be dry with a degree of moisture lower than 0.5%. If the moisture level is higher than 0.5% you must set up a device for drying the starting material. During assembly, disassembly, commissioning, operation and maintenance, the particle classifier must only be handled by qualified staff1.

1.3 General safety warnings Changes of any kind to any of the machine's parts are not permitted and may be grounds for the termination of the machine's warranty. Adherence to occupational health and safety guidelines is especially important for low and medium voltage systems. The assembly, operation and maintenance, the mechanical and electrical installations, the transport, construction and commissioning must be performed or supervised by qualified staff1 with the adequate specialist knowledge. ATTENTION

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Machine in operation. Unforeseeable damage in the event of an emergency. It is recommended that emergency stops are installed in the necessary places, in order to stop the machine in the event of an emergency. The particle classifier must be only be started up and operated if it has been thoroughly checked mechanically and if all the doors and inspection holes are closed. Staff should check that the size of the particles in the ground raw material does not exceed 2 mm and that its degree of humidity is no greater than 0.5%. The staff must use personal protection equipment such as hard hats, gloves, ear protection, etc. It is important to avoid operations that jeopardise the health of staff or the safety of the particle classifier. ATTENTION

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Working at a height. Falls and blows. The user must take into account the risks of working at a height with relation to the assembly, use and maintenance of equipment.

1. Qualified staff are those who, based on their training, experience and knowledge of the applicable norms, standards, safety rules and operating conditions, have been authorised by the plant safety officer to do the required work. They must be capable of recognising and avoiding potential injury and damage.

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Safety warnings ALPHA 700 Unauthorised alterations and the reproduction of the particle classifier are prohibited. The instruction manual must always be kept in an easily accessible place for future consultation. The plant safety officer must guarantee that the staff can use this document regularly.

1.4 Safety in handling and storage The products supplied are indicated in the packing list. Immediately on receiving the elements, check that all the products have been delivered. When you manipulate the ECUTEC products, ensure that the lifting and transport equipment can withstand the loads.



NOTE The classifier is delivered pre-assembled and with grease in the bearings. There are different ways of packaging, depending on the dimensions of the classifier and the method of transport. The symbols marked on the packaging indicate how to proceed. They have the following meanings:

This way up

Fragile

Keep dry

Keep cool

Centre of gravity

Use no hand hook

Attach here

The classifier must be stored in a dry place, with no vibrations. The different parts cannot be stored one on top of another. If the machinery must be stored outdoors, it must be carefully covered and protected from moisture. Unless otherwise stated in the contract, the unit must not be exposed to extreme environmental factors such as chemical products, high pollution, moisture or temperatures greater than 0ºC/ 32 F or 20ºC/ 68 F. Do not use the eyebolts (DIN 580) of the motor to manipulate the machine.

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Safety warnings ALPHA 700 1.5 Technical specifications of the classifier Serial number

0173

Customer Name Address Project

Moengo Minerals Paramaribo/Surinam 09.008

Type of machine

ALPHA 700

Design/operation data Length Width Height

2257 1786 4200

mm mm mm

Machine weight Rotor weight Rotor speed (maximum working speed) Motor pulley (diameter) Machine pulley (diameter) Relationship Transmission belt length Upper bearing type Lower bearing type Grease type

3300 730

kg kg

1200

rpm

315 355 0.88 3550 SKF SKF Klueber

mm mm mm 23024 CC W33 C3 23024 CC W 33 C3 ISOFLEX NBU 15

Electric motor data Rated power Speed (maximum working) Voltage Frequency (maxim. working) Protection type Size Protection against explosion Thermal resistance Supplementary cooling system Motor weight Manufacturer/Type

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37 1360 440 46 IP55 225S

kW rpm V Hz F IMB3

No 1PTC Yes 300 HELMKE

kg DOR 225S-4S-1G-031

Safety warnings ALPHA 700 Special design Ceramic rotor Ceramic material Ceramic Linning Polyurethane coating Rust-proof Hardening process Monitoring system

No No Al2O3 No No No No

Process data Air flo Feed rate

26.350 7.2

m3/h T/h

Installation Grip points

4

F. STA. (N) F1 F2 F3 F4

F. DYN: (N) HORZ. 8250 8250 8250 8250

VERT. 1250 1250 1250 1250

625 625 625 625

Analogue signals Speed sensor Safety system

10 - 30 48 - 240

V V

PNP AC/DC

Digital outputs Sensor PT100 Machine vibration sensor Bearing condition sensor

4 - 20 No No

mA

3 wires

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Description of the particle classifier ALPHA 700

2. Description of the particle classifier The ALPHA 700 has been designed for the classification of pulverised products and thus can obtain granulometric distribution suitable for the various markets to which you can direct the final product. The range of products to classify is very broad, such as minerals, pigments and foodstuffs. The classifier is comprised of 3 bodies. A first body containing the classifier rotor.

1 Fig. 1

Motor

2

Bearings support

First body of classifier

A second body with the fines output.

1 Fig. 2

Fines output

Second body of classifier

A third body with the input of material and output of coarse material.

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Description of the particle classifier ALPHA 700

Fig. 3

1

Coarse material output

3

Level sensor connection

2

Feed

Third body of classifier

The first body contains the support for the bearings, which are only on one side of the rotor, the upper part of the classifier. The shaft is made of high-quality steel and welded to the rotor, generating a rigid unit. The shaft rests on a pair of ball bearings that have been designed to work uninterrupted for 10,000 hours.



NOTE In some special designs, the connection between the shaft and rotor can be made using a hexagonal bolt.

1 Fig. 4

Hexagonal bolt DIN912 M8x20

2

Lock washer

Special join between axis and rotor

The casing of the bearings has been designed with connections for the periodic greasing. In addition to containing radial seals that do not let contamination into the bearings and, moreover, form a barrier to keep the grease in contact with the bearings. To seal between the rotor and the stator correctly, an air seal plus a labyrinth ring have been designed, which impede coarse material getting into the rotor. The power transmission system is performed by the upper part of the machine and by means of trapezoidal belts. All the machines are delivered with temperature probes to control the temperature of the bearings.

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Description of the particle classifier ALPHA 700 In addition, the machine may also be supplied with probes for vibrations and the condition of the bearings. There are different versions of the machine according to the requirements, some examples are: – Ceramic rotor – Polyamide rotor – Ceramic-coated casing – Polyurethane-coated casing – Stainless steel – System for monitoring the machine's bearings and vibrations The particle classifier may be supplied as part of the whole plant assembly or as a single unit. Example of the assembly of a classifier in a plant.

2

4

6

8

3

9

1 7

1 Flow regulation valve

2 Feed silo

3 Rotary valve for feed

4 Particle classifier

5 Rotary valve for coarse material output

6 Filter

7 Rotary valve for fines output

8 Butterfly valve

9 Suction fan Fig. 5

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Example of a plant

Description of the particle classifier ALPHA 700 If the particle classifier has been delivered as a single part, the fines output valve and the components that make up the plant are not supplied.

2.1 Operating principle of the particle classifier For optimum classification, the starting material must be ground and dry with a maximum degree of moisture of 0.5%.

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WARNING Internal damage. Machine breakage. Do not allow a particle size greater than 2 mm. NOTE



– The staff must check the size of the particles before operation. – If the moisture content is higher than 0.5% you must set up a device for drying the starting material.

2

3

1

4

1

Starting material input

2

Separation area

3

Fine material output

4

Coarse material output

Fig. 6

Operating principle

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Description of the particle classifier ALPHA 700 The machine can be fed in two ways, mixed with the suction air or through the upper part of the machine. The feed type configuration depends on the quantity to feed and the product to classify (see figure 6). If it enters through the upper part, the product falls towards the machine due to gravity. In the two types of feed it is absolutely necessary to use a rotary valve to be able to regulate the dosage and generate the correct sealing without interference from outside. The Alpha classifier is connected to a fan that causes a suction flow that passes through the rotor. Inside the machine, the product is displaced towards the rotor due to the suction current. Once the product reaches the height of the rotor, it is displaced at high speed in a cyclonic movement and thus the coarser particles are expelled by a filter located at the end of the circuit. The coarse product is collected by the lower casing and is expelled from the machine by a rotary valve. The general rules to be able to configure the machine are the following: – At higher speeds, the cut point is closer and, consequently, you will achieve a finer product but in less quantity. – With a greater air flow, the cut point is not as close and, as such, you will obtain a coarser product and the production quantity will increase. – With a greater feed, the cut point is not as close and, as such, you will obtain a coarser product and the production quantity will increase. The minimum components to be able to produce with this type of machinery are the following: – Rotary valve for feed with a well-sealed circuit and a good dosage. – Rotary valve for coarse material output with a well-sealed circuit. – Suction fan. – Bag filter

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Description of the particle classifier ALPHA 700

1 Fig. 7

Upper part feed

2

Lower part feed

Segundo cuerpo del clasificador

2.2 Vibrations Knowledge of vibrations is one of the best methods for determining the condition of a machine. For this reason it is recommended to use an ongoing monitoring system. In some machines such as those with the ceramic rotor, this element is absolutely necessary. In these cases, due to the safety of the machinery and the staff, it must not be operated without analysing the vibrations. WARNING

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Internal damage. Machine breakage. The system must be connected to the electric panel so it can cut the power supply when the alarm values are exceeded. NOTE To avoid minimum signal loss, you should not use cables of more than 3 metres long, from the module to the measurement point.

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Description of the particle classifier ALPHA 700

Machine vibrations probe

1 Fig. 8

2

Bearings condition probe

Vibration sensor

When you start up the machine for the first time (see section 4) you must check the vibrations to identify the tensions, resonances and faults of assembly before any major problem occurs. The normal vibration value must be set. The best way to calculate this value from the bearings is in the horizontal direction.



NOTE The vibrations measured out of the frequency range 3 to 1000 Hz must not be considered vibrations coming from the machine. Intensity (mm/s) 11

These working conditions must be avoided at all times, given that parts of the machine may suffer irreversible damage in minutes, hours or days.

WARNING

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Internal damage. Machine breakage. Vibration intensity must not exceed 11 mm/s. Should it do so, shut down the machine and contact the manufacturer. NOTE The testing of the machine must be more thorough if the vibration intensity in the bearings exceeds 4.5 mm/s.

Description of the particle classifier ALPHA 700 A very large increase in vibrations in a very short period may mean it is off-balance, so we recommend you analyse the condition of the rotor and, if possible, rebalance.

2.3 Classifier options Rotor and ceramic coatings Some materials must be processed with ceramic parts due to their high abrasiveness. For these cases, ECUTEC supplies the machines with ceramic components that require more rigorous care than the steel components. – Ceramic is brittle so it should never be hit. – During the rotor assembly process, you must take extreme care that the rotor does not come into contact with the other parts. – Sharp changes in temperature are not recommendable for the ceramic parts. – The maintenance and revisions must be increased with respect to the steel parts (see the maintenance list in point 6.3). – Vibrations must also be strictly monitored. Please contact ECUTEC staff regarding any queries you may have.

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WARNING Internal damage. Machine breakage. Never exceed the maximum rotor speed. – Due to the abrasive power of these products, the machine must be balanced more frequently. – In addition, we recommend you have a replacement ceramic rotor due to its fragility, so the interruption of the production process is kept to a minimum. – All the surface coated with ceramic must be checked and repaired with Epoxy cement. Polyurethane parts These are used for abrasive materials with low abrasiveness. The treatments are the following: – Do not clean or use solvents. – Do not allow high temperatures. Motor In some applications, as they work at a low rpm, it is necessary to connect a supplementary fan to cool the motor. You must take into consideration: – This must be switched on at the same time as the motor. – The machine may never function if this fan is off. – It must remain free of dust and dirt.

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Description of the particle classifier ALPHA 700 2.4 Classifiers with cooling system Introduction Depending on the product to be treated and the working and environmental conditions, certain classifiers may be supplied with an air-oil cooling system for the bearing casing. The cooling circuit system will be comprised of a 100litre oil tank, a suction pump, an air cooler and the flexible hoses needed for the connection to the various elements. All the screwed connections will use 1" BSP screws.

1

2 3

4

5

1

Oil discharge from the bearing casing

2

Oil injection into the bearing casing

3

Oil collector

4

Air cooler pump

5

Oil collector/pump suction discharge

Fig. 9

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Cooling system

Description of the particle classifier ALPHA 700 Operation of the cooling system There are different ways to operate the cooling system, depending on the complexity required. Option 1- Circuit always in operation: Cooling of the bearings is forced regardless of their temperature. During the start-up operation the cooling system connects in parallel with the classifier motor. Option 2 - Circuit regulated by the temperature of the bearings: The temperature of the bearings is compared to a pre-set setpoint and when the temperature exceeds the setpoint the cooling system connects. The cooling system continues to operate in this way until a minimum disconnection temperature value is reached. Type of oil ECUTEC recommends the use of KLUBER AIRPRESS 15 oil, which has obtained the best results in the tests performed on the machinery. This oil has been designed for most of the industry, but in the event of special requirements please contact our staff before performing start-up.

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Transport and assembly ALPHA 700

3. Transport and assembly 3.1 Transport Due to the weight of the particle classifier and its respective parts, the transport and assembly imply significant risks. For this reason, all the individual parts that cannot be moved manually due to their weight or shape are provided with fixing elements. ATTENTION

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Falling objects. Risk of crushing and blows. – Due to the weight, only use suitable lifting machinery that has been officially checked and approved for transport and assembly. – When lifting individual parts, only use the existing fixing points. Lifting the motor casing part

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Transport and assembly ALPHA 700 Lifting the fines output part

Lifting the coarse output part

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Transport and assembly ALPHA 700 3.2 Work prior to assembly All the brackets must be cleaned of the accumulated grease and dirt. The use of an industrial solvent is recommended. Always use fasteners of 8.8 quality or higher. All the bolts must be fixed with Loctite 2701. The tightening torques are indicated in the following table.

Metric M5 M6 M8 M10 M12 M14 M16 M16x10.5 M18x10.5 M20 M24 M24x2 M30 M30x2 M36 M36x3 M42 M48 M48x3

Quality of fastener 8.8 10.9 Torque Nm 6 10 25 49 86 135 210 225 325 410 710 780 1450 1600 2450 2650 4070 6140 6213

8,5 14 35 69 120 190 295 315 460 580 1000 1100 2000 2250 3560 5720 8640

3.3 Tools necessary for assembly, disassembly and maintenance – Socket wrenches for hexagon screws between M8 and M24 – Double ended spanners between M8 and M24 – Set of spanners for bolts DIN 912 – Extractor for bearings with outer diameter of 100 mm, inner diameter of 50 mm – Grease pump – Rubber mallet

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Transport and assembly ALPHA 700 3.4 Assembly The three assemblies of the particle classifier may be pre-assembled on the ground or assembled directly at the operation site. NOTE



– The transporting of each machine element must only be done by personnel authorised to handle the corresponding transport devices. – The particles classifier must be installed on a horizontal, level surface that is resistant enough to bear the total weight of the equipment. In general, the machine shall be delivered in three parts, which must be assembled before their final positioning. The first step is to place the body containing the fines output on a base that is stable and capable of resisting the weight of the machine. Assembly Add and spread silicon or polyurethane on the flange to seal the inside of the machine from the outside. For example Loctite 5910. Orient and place the casing containing the rotor and the bearing support. The orientation depends on the customer's needs and it has different positions.

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Transport and assembly ALPHA 700 Add and spread silicon or polyurethane on the flange that joins the seal with the closure of the fines output.

1

Area to apply silicon

2 Hexagonal bolt M16x50 DIN 933

3

Spring washer 12 DIN 127

4 Hexagon nut

5

Sealing flange

Fig. 10

Assembly 1: Fitting the motor casing

Once the two parts are in the correct position, use the following components to fix the two parts: o Hexagonal bolt M16x50 DIN 933 (16 units) o Spring washer 16 DIN 127 (32 units) o Hexagon nut (24 units) To do the following step, you must open the door and place the following elements through the lower part of the sealing flange: o Hexagonal bolt M16x30 DIN 933 (8 units) o Spring washer 16 DIN 127 (8 units)

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Transport and assembly ALPHA 700 Assembly 2

1

Area to apply silicon

2 Hexagonal bolt M16x45 DIN 933

3

Spring washer 16 DIN 127

4 Hexagon nut

Fig. 11

Assembly 2: Fitting the motor casing

Then place the casing containing the coarse material output and, as with the others, add silicon and the corresponding fasteners: o Hexagonal bolt M16x45 DIN 933 (28 units) o Spring washer 16 DIN 127 (56 units) o Hexagon nut (28 units) Once assembled, place the temperature probes if they are not installed and those of vibrations if they have been supplied (optional).

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Transport and assembly ALPHA 700 3.5 Work after assembly Once all the parts are joined and correctly tightened, you must check the tolerance between the moving and fixed parts. To do this, you must open the door and verify that the space between the rotor and the seal is 0.5 - 1.2 mm.

1 Fig. 12

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Labyrinth seal

Checking the seal

Start-up ALPHA 700

4. Start-up 4.1 Commissioning Before commissioning the classifier for the first time you have to check the following: • Check the condition of the rotor (the rotor turns without problems, the fins are OK). • Check the distance between the rotor and the labyrinth seal (the space between the rotor and labyrinth seal must be between 0.5 and 1.2 mm). • Check the belts. • Check the lubrication.

4.2 Ignition period WARNING Internal and/or external damage. Machine breakage.

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– The commissioning of the machine should be carried out by ECUTEC personnel. If the client decides to dispense with ECUTEC staff, the company can decide to cancel the warranty and all personal harm or material damage shall be the client's responsibility. NOTE



During the commissioning of the machine, the 2 lubrication points in the bearings must be greased with approximately 15 g of grease (ISOFLEX NBU 15 from KLÜBER). ECUTEC recommends starting the machine by increasing the revolutions in 2 or 3 steps up to the maximum number of revolutions. This operation should take approximately 6 hours. During commissioning or after changing the bearings, you must check the following points: – Check the power. – Check that it turns gently.

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Start-up ALPHA 700 – Verify the rotation direction.

Fig. 13

Rotation direction

– Verify the vibrations and that the temperatures do not exceed the standard values (max. 95ºC) It is advisable to grease the machine after the first 30 hours of operation.

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Operation ALPHA 700

5. Operation 5.1 Commissioning a plant

2

4

6

8

3

9

1 7

1 Flow regulation valve

2 Feed silo

3 Rotary valve for feed

4 Particle classifier

5 Rotary valve for coarse material output

6 Filter

7 Rotary valve for fines output

8 Butterfly valve

9 Suction fan Fig. 14

Commissioning a plant

To commission a plant the following order must be respected: 1. 2. 3. 4. 5. 6.

Turn on the classifier cooling fan and motor. Turn on the valves for coarse and fine output to empty the respective silos. Turn on the suction fan. Open the butterfly valve to create a circulation of air between the classifier and the filter. Turn on the rotary valve for feed. Adjust the input butterfly valve to regulate the air flow.

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Operation ALPHA 700

DANGER Machine in movement. Serious injury or death. – Keep limbs away from rotating elements such as fans or shafts.

¬

– The maximum speed indicated in the table of characteristics is the maximum working speed. This speed should not be exceeded under any circumstances due to the high risk of material damage or personal injury, including risk of death. – If the client exceeds this working speed, ECUTEC may decide to terminate the warranty of the machine and all personal harm or material damage shall be the client's responsibility. – Before starting up the machine, verify that the frequency adjuster has been limited so the machine cannot exceed the maximum rotation speed.

5.2 Settings during operation The general rules to be able to configure the machine are the following: – At higher speeds, the cut point is closer and, as such, you will obtain a finer product but with less quantity. – With a greater air flow, the cut point is less close and, as such, you will obtain a coarser product and production will increase. – With a greater feed, the cut point is less close and, as such, you will obtain a coarser product and production will increase.

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Maintenance ALPHA 700

6. Maintenance DANGER Electrocution and/or cuts on limbs. Serious injury or death. – Maintenance tasks may only be carried out on machines which have been disconnected from the mains or with the power supply sectioned off.

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– Do not proceed to make any adjustments or cable connections with the power supply switched on. – Use lockout devices and the corresponding warnings signs in order to prevent the machine from being started up accidentally. – If there is more than one power source, ensure that they are all switched off. – Make sure fans and moving parts have come to a full stop before starting maintenance procedures. – Regular reviews must be carried out on the status of the earth to ensure its integrity. Repair if not in optimum condition. CAUTION

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Blows and cuts on limbs. Minor injuries. – If there are sharp, burred or panelled pieces, use protective gloves. – If there are blocked elements, use the proper tools and lubricants to release these.

6.1 Standard maintenance The following inspections and maintenance work must be performed regularly. Lubrication It is advisable to install a central greasing unit, for example Vogel type. ECUTEC tests the machines with Isoflex NBU 15 grease from Klueber so we recommend you use this grease. Alternatively, some equivalents are listed at the end of section 6.7. NOTE



– During the commissioning period, it is mandatory to use Isoflex NBU 15 grease. If you wish to use another grease, ECUTEC personnel must confirm its use. – The warranty may be cancelled in the event of not complying with this requirement. Using unsuitable greases or applying grease excessively can cause high temperatures, which may lead to the shaft dilating excessively and therefore increasing the probability of breakage. You must consider the ambient conditions to be able to increase or decrease the periods between lubrications. An increase in temperature at constant operating conditions may indicate insufficient grease.

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Maintenance ALPHA 700 Bearings and seals The bearings must be changed regularly. The service life of the bearings may be longer or shorter, depending on the operating conditions (product, humidity, temperature). The history of measurements from the monitoring system (see section 2.3) must be used as an indicator of the condition of the bearings. Bearings breaking very frequently may indicate bad greasing, insufficient balancing or defects in some parts. Whenever you replace bearings, you must change them for the types that ECUTEC indicates and, if possible, from one of the following manufacturers: SKF, NSK or FAG. Belts Do not over-tension the belts as this may cause excessive tensions in the shafts of the machines. Excessive temperatures in the bearings may indicate excessive tension. Labyrinth seal The labyrinth seal is the element that allows you to keep the area of material to classify separate from the area of fine material. Therefore, an increase in particles in the fine product may indicate this part is excessively worn. In addition, this seal must be kept perfectly clean so it can do its job. The replacement period of this element must be adapted to the characteristics of material to classify. It is very important to check the distance between the labyrinth seal and the rotor. This must be between 0.5 mm and 1.2 mm.



NOTE If coarse particles are found in the labyrinth joint, contact the manufacturer. Bolted joints The bolted joints must be checked every 10,000 h. Electric motor See the manual from the supplier.

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Maintenance ALPHA 700 6.2 Special maintenance (for ceramic particle classifiers only) Labyrinth seal In these classifiers, the design of the seal has been modified to lengthen its lifetime. The distance between the rotor must be observed, as with the standard classifiers at between 0.5 and 1.2 mm. In this case you must check it by placing a material that can be distorted between the rotor and seal. To do so, follow these steps: – Lift the rotor. – Place a material that can be deformed (chewing gum, plasticine, etc.). – Lower the rotor and bolt it. – Unscrew and lift the rotor. – Finally remove the distorted object and measure its thickness after being distorted. Condition of the ceramic At intervals of a certain number of hours, check the condition of the ceramic. If some of the parts that cover the casing have come off, they must replaced with new parts, always using Epoxy adhesives. The verification must centre, above all, on the points where the most wear occurs, such as union elbows, points where the material hits directly, etc. We recommend the disassembly of the different bodies for this verification.

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Maintenance ALPHA 700 6.3 Removing the rotor Step 1

1

Tensing system

2

Belt protector

Fig. 15

Loosening the belts

Step 2

The remove the tightening bolts of the pulley and move it towards the lower part of the machine using a rubber mallet. Once the pulleys are out, remove the M12x25 bolts and use the elevation screws to lift the rotor. You can use the holes made in the ribs of the bearing support to lift the rotor.

Step 3 Step 4

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Start the process of dismantling the rotor by removing the belt protector. Once this has been removed, you must loosen the belts and remove them.

Maintenance ALPHA 700

1

Tightening bolts

3

M12x25 bolts

Fig. 16

2

Elevation screws

Extracting the pulleys

To perform the maintenance of the bearings, follow these steps: Step 1

Remove the screw and washer from the block (pos. 12, pos. 13).

Step 2

Remove the inner hexagonal bolts and lock washers (pos.14 and 15) Remove the cover that protects the bearings (pos. 38.01.10) and the radial seal (pos. 17). Remove the inner hexagonal bolts and washers from the block (pos. 21 and 20) Remove the bearings casing (pos. 38.01.01) using a large extractor. Along with the casing, also remove the upper bearing (pos. 16). Remove the spacer between bearings (pos. 38.01.09) and the lower bearing (pos. 16) using a bearing extractor.

Step 3 Step 4 Step 5 Step 6

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Maintenance ALPHA 700 Step 7

Finally remove the radial seal (pos. 24) and lower protective cover (pos. 38.01.04).

38

38

38

38 38

38 38

Fig. 17

Extracting the bearings

Table of classifier maintenance for non-abrasive materials:

Parts to check

Change (hours)

Bearings

10000

Radial seals

10000

Revision (hours)

Balancing

15000

Tensioning

6000

Labyrinth seal

6000

Distance between rotor and seal

6000

Greasing

10000

500-1000

Table of classifier maintenance for abrasive materials:

Parts to check

Change (hours)

Bearings

10000

Radial seals

10000

Balancing

6000

Tensioning

6000

Labyrinth seal

6000

Distance between rotor and seal Greasing Rotor

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NOTE Once it is assembled, retighten the belt.

2500 2500

10000

Ceramic lining



Revision (hours)

500-1000 500

6000

500

Maintenance ALPHA 700 6.4 Assembling the rotor To assemble the motor, follow the same steps in reverse order as for removing it.

6.5 Tightening the trapezoidal belts Once you have assembled the rotor, you must tension the trapezoidal belts using the tensioning system incorporated next to the motor. Check the tension of the belts in the following way:

a

Distance between shafts

t

Tensioning depth

Fig. 18

F

Tensioning force

Tensioning the belts

The tensioning depth is calculated using the formula:

t = a x 0.016 The tensioning force authorised is selected according to the following table depending on the type of section and the diameter of the smallest transmission pulley. Type of profile SPZ SPA SPB SPC

Effective Ø of the small pulley (mm)

Tensioning force (N)

67 - 95

10 - 15

100 - 140

15 - 20

100 - 132

20 - 27

140 - 200

28 - 35

160 - 224

35 - 50

236 - 315

50 - 65

224 - 355

60 - 90

375 - 560

90 - 120

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Maintenance ALPHA 700 Example of tightening: In the machine, you have to measure the distance between shafts of 1,050 mm, and an effective diameter of the small transmission pulley of 250 mm. The name of the belt is SPB. Using the distance between shafts, calculate the tensioning depth. t= 1,050 mm x 0.016 = 16.8 mm P 17 mm According to the table, the tensioning force must be between 50 and 65 N. The tension of the belt is optimum when, with a tensioning depth of 17 mm, it has a tensioning force of between 50 and 65 N.

6.6 Spare parts lists Spare parts list 1

38

38

38

38 38

38 38

Fig. 19

34/47

Spare parts list 1

Pos.

Name

38.01.00

Bearings casing

38.01.01

Rotor

38.01.07

Lower protector

38.01.09

Spacer

38.01.10

Upper protector

38.01.11

Upper ring

12

Lock washer

13

Lock washer

14

Inner hexagonal bolt DIN 912 M8x20

Maintenance ALPHA 700 38.01.08

Lower ring

15

Lock washer A8 DIN 127

16

Bearing 23024 CC/W33 C3

17

Radial seal CR135x160x15 CRSA1

20

Inner hexagonal bolt DIN 912 M10x25

21

Lock washer A12 DIN 127

23

PT 100 M8x25 (no image)

24

Balance weight (no image)

26

Grease Isoflex NBU 15 (no image)

38.01.02 CD

Ceramic rotor (ceramic version only)

Tab. 1

List of spare parts table 1

Spare parts list 2l

38

Fig. 20

Spare parts list 2

Pos.

Name

38.00.01

Seal

12

Motor 225M

13

Pulley SPB 17/B d=350

14

Belts DIN 2215 B/17 Lw=3550

15

Pulley SPB 17/B d=315

46

RPM sensor (no image)

59

Ceramic coating (ceramic version only), (no image)

38.00.01CD

Ceramic seal (ceramic version only)

60

Vibration sensor (version with vibration analysis only)

Tab. 2

List of spare parts table 2

35/47

Maintenance ALPHA 700 6.7 Lubrication The machine has two lubrication points. These are in the upper part of the machine. The system is designed to be greased by a manual pump or an automatic greasing system. If possible, use the grease suggested by KLÜBER. ECUTEC recommends the ISOFLEX NBU-15. The machine has some holes for releasing the excess grease.

1 Fig. 21

Lubrication holes

2

Release of grease

Location of lubrication holes

NOTE – ECUTEC recommends regreasing the bearings every 500-1000 hours for locations with environmental temperatures between 20 ºC and 35 ºC, in hotter countries the regreasing period must be shorter. – The machine is delivered with lubricant but it is advisable to regrease after the first 30 hours of running.



– During the commissioning period, it is mandatory to use Isoflex NBU 15 grease. If you wish to use another grease, ECUTEC personnel must confirm its use. – The warranty may be cancelled in the event of not complying with this requirement. – When you change the bearings, ECUTEC advises that you check the grease holes and look for possible obstructions. .

Product

Type Isoflex NBU-15 Beacon 325 Mobilgrease 28 Berulub FR 16

Tab. 3

36/47

Table of recommended greases

Fault search ALPHA 700

7. Fault search

Fault

Cause

Solution

Rotor clogged

• particles too large

• check the size of the feed

• transmission shaft dilated

• monitor the bearings

Fine material does not correspond to the setting

• rotor diameter is not • change the rotor correct • input butterfly valve • adjust the input butterfly changed valve • length of seal between the rotor and the stator too long

• change the labyrinth seal

Length of seal between the rotor and the stator too long

• wear or deformity

• change the labyrinth seal

Bearings noisy

• bearings broken

• change the bearings

The rotor shaft cannot be moved

• bearings broken

• change the bearings

Excessive temperature in the bearings

• excessive tensioning

• loosen

• bearings damaged

• bearing change

• insufficient grease

• grease

• bearings damaged

• bearing change

• rotor out-of-balance

• rebalance

High vibrations

37/47

Appendices ALPHA 700

8. Appendices 8.1 Electrical appendix Components necessary for the functioning of the machine • The machine is configured by modifying the speed, for which the use of a frequency converter is required. • The machine has 3-wire temperature probes to monitor the temperature so it is necessary to install displays for two probes. • ECUTEC supplies a speed sensor and a display that must be installed in the control panel. The sensor is PNP type. • The protection systems of the motors must be installed and, depending on the motor, they are delivered with PTC or PT-100. • During machine maintenance, it must be impossible to operate the machine. Therefore, an emergency stop switch or disconnector switch must be installed at a distance of less than 2 metres from the machine.

Requirements of the control panel • The classifier must have a frequency converter that allows you to monitor the speed. • It must have a general ammeter and voltmeter and ones for the classifier and main fan. • ECUTEC recommends the use of a PLC to check the components. • There must be outputs and inputs for PT-100 temperature probes. • There must be outputs and inputs for vibration probes. • Below some examples are shown. These do not reflect the real powers, but do reflect the way of operation.

38/47

L1 L2 L3 +(24VDC) 18(230V) 19(230) PE

TIx

x/5A

UCFx

NSxxxA

U

PE

3

Vx

M ~

V

(POS.x)

ALPHA 700

xKW-xA

Mx

L3

6

5

W

37KW

4

3

Xx Ux

L2

L1

2

1

Wx PE

PE

x/5A

PAx A

PA

RRx

4.1

E0000

PB

READY

R1C

R1B

83

84

COM AO1

R2C

LOAD INDICATOR

PCx

R1A

R1C R1B R1A

BREAKING RESISTOR

VW3-A66704

AMMETER

81

80

PE

R2C

R2A

R2A

86

87

WHITE

PE

LI1

+24V START

POTENTIOMETER FOR VELOCITY

10KOh 10Rounds

QPx

85

AI1

+10

BROWN

QSx

89

FTx

88

83

7.1

KMx

14

13

96

95

A2

98

97

THERMISTOR PROTECTION RELAY

4.3

A1

T2

T1

90

91

THERMISTOR

RRx

Xx

BROWN WHITE

90M

Fig. 22 GREEN

L1 /3.1 L2 /3.1 L3 /3.1 +(24VDC) 18(230V) 19(230V) PE /3.1

/4.1

/4.1

/4.1

Appendices

ALPHA 700

Examples of circuit diagrams

General electric circuit

39/47

Analogue inputs circuit 1

7.8/

SLOT x

8.8/ PE +(24VDC) -(0V)

UAx

11 12

24VDC

-

201 14

PULSE INPUT

7

202 13

5

-

EA0025

GREEN

EA0035 x(M-)

EA0035

PT100 BEARING UP TEMPERATURE (POS.x)

x(S-)

EA0025

SENSOR SPEED 4-20mA (POS.x)

x(M+)

EA0005

EA0025 IWx

x(M-)

XX

BTx

WHITE

IWx

x(I+)

4

ANALOGIC OUTPUT 4-20mA

FREQUENCY VOLTAGE CURRENT CONVERTER P&F KFU8- FSSP-1.0

EA0004

15

X

s

+

200

BROWN

40/47 BROWN

EA0005M x(M+)

EA0006

WHITE

EA0026

GREEN

EA0036 x(M-)

EA0036

PT100 BEARING DOWN TEMPERATURE (POS.x)

IWx

x(S-)

EA0026

BTx

EA0026

Fig. 23 BROWN

BDx

IWx

x(I+)

x(M-)

ANALOGICS INPUTS

IWx...x

RACK x/SLOT x

TERMINAL N§ BIT

Appendices ALPHA 700

EA0006M

PE

/5.8

EA0000

CONTROL VIBRATION BEARING UP WARNING 4-20mA (POS.x)

x(M-)

EA0021

CONTROL VIBRATION WARNING 4-20mA (POS.x)

x(I+)

EA0001

IWx

x(M-)

EA0020

/6.8

EA0001M

/5.8

EA0000M

IWx

x(I+)

EA0000

BROWN

/5.8

EA0020

WHITE

/6.8

EA0001 BROWN

/6.8

EA0021 WHITE

/6.8

EA0002

x(M-)

EA0022

CONTROL VIBRATION BEARING DOWN WARNING 4-20mA (POS.x)

IWx

x(I+)

EA0002

BROWN

/6.8

EA0022 WHITE

/6.8

EA0002M

Fig. 24

SLOT x

6.8/

IWx

x(I+)

x(M-)

ANALOGICS INPUTS

IWx...x

RACK x/SLOT x

TERMINAL N§ BIT

PE /9.1

Appendices

ALPHA 700

Analogue inputs circuit 2

41/47

Fig. 25

42/47

Digital inputs circuit 1

3.8/ PE 18(230V) 19(230V) +(24VDC)

SLOT x

2.8/

2.8/

2.8/

x.1

THERMISTOR RELAY FAULT ALPHA 700 (POS.x)

READY ALPHA 700 (POS.x)

E0001

98

97

x.0

E0000

2.4

E0000

2.7

FTx

SENSOR MAX. LEVEL ALPHA 700 (POS.x)

x.2

E0002

Xx E0000

BNx

+

L

18

N

19

230V

PE

PE

32

31

THERMIC COOLER (POS.x)

x.3

E0003

3.3

QGx

/5.1

/5.1

/5.1

DIGITALS INPUTS

x.0...3

RACK x/SLOT x

BIT TERMINAL N§

PE /5.1 18(230V) 19(230V) +(24VDC)

Appendices ALPHA 700

Fig. 26

PE 18(230V) 19(230V) +(24VDC)

SLOT x

5.8/

5.8/

5.8/

5.8/

BMxx

+

E0009

ALARM

L

N

19

230V

18

CONTROL VIBRATION BEARING UP ALARM (POS.x)

EA0021

CONTROL VIBRATION BEARING UP WARNING (POS.x)

EA0021M

x.9

+

+

EA0001

4-20mA OUT1

E0009

x.8

E0008

Xx E0008

WARNING

Xx

PE

PE

EA0002

EA0022 x.10

E0010

WARNING

E0010

EA0002M

+

CONTROL VIBRATION BEARING DOWN WARNING (POS.x)

4-20mA OUT2

BLANCO

MARRON

BLANCO

MARRON

CONTROL VIBRATION BEARING DOWN ALARM (POS.x)

x.11

E0011

E0011

+

ALARM

/7.1

/8.6

/8.5

/8.5

/8.4

/8.4

/8.3

DIGITALS INPUTS

x.8...11

RACK x/SLOT x

BIT TERMINAL N§

+(24VDC)

PE /8.1

EA0002M

EA0002 EA0022

EA0001M

EA0001 EA0021

Appendices

ALPHA 700

Digital inputs circuit 2

43/47

44/47

Fig. 27

Digital inputs circuit 3

SLOT x

4.8/

4.8/

4.8/

PE 18(230V) 19(230V) +(24VDC)

4.8/

x.4

x.5

WARNING

Xx E0006

+

E0007

ALARM

CONTROL VIBRATION ALARM (POS.x)

EA0020

CONTROL VIBRATION WARKING (POS.x)

EA0000M

x.7

+

+

EA0000 4-20mA

E0007 x.6

E0006

BMx

Xx

L

WHITE

18

N

19

230V

BROWN

PE

PE

/8.2

/8.2

/8.1

/6.1

/6.1

/6.1

DIGITALS INPUTS

x.4...7

RACK x/SLOT x

BIT TERMINAL N§

PE /6.1 18(230V) 19(230V) +(24VDC)

EA0000M

EA0000 EA0020

Appendices ALPHA 700

Fig. 28

x.00...03

RACK x/SLOT x

DIGITALS OUTPUTS

TERMINAL N§ BIT

+(24VDC)

1L

4 x.03

3 x.02

2 x.01

1

KMx

300

3.2

QGx

S0000

START COOLER

x.00

A1

A2

43

44

SLOT x

-E(0V +(24VDC) )

/9.1

6.8/

Appendices

ALPHA 700

Digital outputs circuit

45/47

46/47

Fig. 29

2.8/

2.8/

2.8/

2.8/

PE

L1 L2 L3

x-xA

QGx

Motor cooling circuit 2

3

M ~

xKW-xA COOLER (POS.x)

Mx

Vx

4

7.1

44

43

Wx PE

6

5

3

1

Xx Ux

7.1 xA

KMx

6

5

4

3

2

1

4.7

32

31

PE /4.1

Appendices ALPHA 700

Appendices ALPHA 700 Configuration of the process operations To achieve the quality and quantity established by ECUTEC in addition to the protection of the components and staff, you must follow the instructions below: ATTENTION

¬

Rotating element. Cuts and personal injuries. First connect all the output rotary valves (filter and classifier). Never connect the feed rotary valve first (10 s. approx.). • The first element to be connected is the classifier, thus it protects against coarse product getting into the area of fine product. (30 s. approx.) • If the motor has a cooling fan, this must be connected at the same time as the motor. • The following element is the connection of the system for cleaning the filter. (10 s. approx.) • Once all the systems that ensure the accumulated product output in the different elements are connected, then connect the fan. (60 s. approx.) • When the classifier and the fan are in full operation, this is the moment to open the butterfly valve that is between the filter and the fan and that closes the circuit. (15 s. approx.) • Finally, start the feed.

Rules for stopping the machine The following rules must be followed to protect people, the machine or quality. • Whenever an alarm is triggered in any of the elements, you must stop all the elements that are behind this, for example if the classifier stops, the valve, fan and filter must be stopped. • The temperature probes of the machines must be configured with an alarm at 85 ºC and a machine shutdown at 95 ºC. • The vibration systems must have an alarm configured at 7 mm/s and a machine shut down at 11 mm/s. • Any PTC or thermal signal must stop the components for their safety. • If the cooling fan is not connected, you cannot continue with the sequence.

47/47