DE-7200 Centrifuge Variable Frequency Drive Issued 30 Oct 09 Rev 01 Jan 14 Maintenance & Operation Manual DISCLAIMER Derrick Corporation has taken care to ensure that all of its maintenance and operation manuals are accurate. However, we offer no guarantees or warranties in this regard. Our manuals are provided only as a guide to assist with the maintenance and operation. Derrick Corporation takes no responsibility for any losses, damage, or injuries that may occur as a result of using any of our manuals.
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.
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. 2. To display the desired information, click on the listing when the pointing finger appears over the text. 3. When finished viewing the text, press Alt + left arrow key to return to the CONTENTS page. 4.
CONTENTS Section Page 1 - Introduction ............................................................................................. 1-1 Date 15 Feb 12 Overview ................................................................................................. 1-1 Safety ...................................................................................................... 1-1 Sound Emission ...................................................................................... 1-1 Equipment Use ...........
CONTENTS Section Page 4 - Operating Instructions ............................................................................ 4-1 Date 30 Sep 13 General .................................................................................................... 4-1 Software Version ..................................................................................... 4-1 Operating Safety ......................................................................................
CONTENTS Section Page Date 5 - Maintenance (Cont’d) Troubleshooting ....................................................................................... 5-17 Alarm and Fault Messages ...................................................................... 5-25 VFD Alarm and Fault Cross References .................................................. 5-32 Control Component Indicators ................................................................. 5-33 6-7 - Not Used 8 - Reference Drawings ................
SECTION 1 - INTRODUCTION OVERVIEW This manual provides instructions for installing and operating the DE-7200 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.
INTRODUCTION EQUIPMENT USE The DE-7200 VFD centrifuge is designed 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 or processed by a second centrifuge. Derrick Corporation does not authorize any other use of this equipment.
INTRODUCTION Rotating Assembly The rotating assembly consists of a cylindrically shaped, bowl, conveyor assembly, gearbox, and related components. The bowl consists of a straight cylinder with a conical section at the solid discharge end and a flat liquid bowl head at the opposite end. Openings are provided at both ends to permit liquid and solid discharges. The bowl ends are supported by roller bearings having grease fittings to facilitate periodic lubrication.
INTRODUCTION 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.
INTRODUCTION the upper setpoint, the compressor and condenser motors are cycled on to provide cooling. Upon reaching the low temperature setting, the air conditioner is shut down. The evaporator fan operates continuously whenever the cabinet is energized to maintain a continuous flow of conditioned air over cabinet components. Purge System (Hazardous Environment Only) For operation in a hazardous environment, the control cabinet is equipped with a purge system.
INTRODUCTION The case is bolted onto the welded steel base assembly, which contains mounting provisions for the bearing pillow blocks. The base assembly supports the centrifuge components and contains hollow rubber vibration isolators that engage with centering pins attached to the mounting platform. MECHANICAL OPERATION The centrifuge receives slurry at the liquid discharge end of the machine.
INTRODUCTION Figure 1-4 Centrifuge Operation CONTROL SYSTEM Centrifuge operation is supervised by a programmable logic controller (PLC) that interfaces with the variable frequency drives (VFDs) supplying power to the bowl, conveyor, and feed pump drive motors. Monitoring and control of the centrifuge may be performed locally or remotely. The environmentally hardened PLC also offers short-term data storage and a high degree of operating flexibility.
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. PARTS SALES & SERVICE LOCATIONS Colorado Grand Junction - 970.241.2417 Louisiana Broussard - 877.635.3354 New York - Corporate Headquarters Buffalo - 716.683.9010 Oklahoma Oklahoma City - 405.
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.
SAFETY 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. Equipment Handling WARNING! TO ENSURE PROPER BALANCE AND ORIENTATION WHEN UNIT IS RAISED AND PREVENT DAMAGE TO COMPONENTS, ATTACH LIFTING SLING ONLY AT DESIGNATED LIFT POINTS.
SAFETY WARNING! WHILE OPENING AND CLOSING THE CENTRIFUGE COVER, PERSONNEL MUST ENSURE THAT ALL BODY LIMBS AND ANY OTHER ITEMS ARE CLEAR OF THE COVER GAP. TWO HANDS MUST BE USED, WITH BOTH HANDS ON THE COVER HANDLES AT ALL TIMES. DERRICK RECOMMENDS HAVING A HOIST AVAILABLE IF ADDITIONAL ASSISTANCE IS DESIRED DURING THE OPENING/CLOSING PROCEDURE. Maintenance DANGER! HIGH VOLTAGE! SHUT DOWN, LOCK OUT, AND TAG OUT ELECTRIC POWER, AND ENSURE THAT EQUIPMENT HAS STOPPED ROTATING BEFORE WORKING ON THIS EQUIPMENT.
SAFETY MSDS’S (CONT’D) MATERIAL DESCRIPTION - WHERE USED MSDS / Date Paints PPG Dimetcote 302H Green 302F0250 Resin - Top Coat 1302H-5A / 04-11-10 PPG Dimetcote 302H Clear 302G0910 Cure - Top Coat 1302H-B / 01-21-10 PPG PSX 700 Neutral Tint Resin - Undercoat PX700T3 / 02-28-08 PPG PSX 700FD Cure - Undercoat PX700FD-B / 01-11-07 Lubricants Shell Albida EP2 - Main & Conveyor Bearings 57089L / 06-18-09 Exxon Mobil SHC 629 - Conveyor Drive Gearbox Mobil SHC 629 / 01-13-09 Exxon Mobil Polyrex EM -
SECTION 3 - INSTALLATION GENERAL This section describes the recommended installation procedure for the DE-7200 VFD centrifuge. 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.
INSTALLATION TOP COVER OPENING/CLOSING PROCEDURES The proper procedures for opening and closing the top cover of the centrifuge must always be followed. Two operators using both hands are required to open the cover. Derrick recommends having a hoist available if additional assistance is desired during the opening/closing of the centrifuge cover. To open and close the cover, proceed as follows: 1. Shut down, lock out, tag out electric power to centrifuge, and allow rotating assembly to coast to a full stop.
INSTALLATION INSTALLATION SEQUENCE Following is the sequence of steps for installing the centrifuge. The sequence presented may vary depending on the user’s facilities and previous experience with this type of equipment. 1. Read and understand all safety information in Section 2 before installing and operating this equipment. 2. Read and understand the equipment handling procedures in this section before lifting and positioning the equipment. 3. Position and level equipment at installation site. 4.
INSTALLATION REQUIRED CLEARANCES AND POSITIONING (CONT’D) Figure 3-1. Required Opening Clearances for Cabinet Door and Electrical Panel EQUIPMENT HANDLING WARNING! TO ENSURE PROPER BALANCE AND ORIENTATION WHEN UNIT IS RAISED AND PREVENT DAMAGE TO COMPONENTS, ATTACH LIFTING SLINGS 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.
INSTALLATION While the centrifuge and control cabinet are still mounted on the shipping skids, they may be transported on the ground using a forklift. After the equipment is removed from the shipping skid, an overhead lifting device is required. Four reinforced lifting lugs are built into the centrifuge frame to allow attachment of an overheadlifting device (Figure 3-2). Lifting points are labeled “LIFT HERE ONLY”.
INSTALLATION EQUIPMENT HANDLING (CONT’D) Figure 3-3. DE-7200 Control Cabinet Lifting Arrangement EQUIPMENT POSITIONING AND MOUNTING Base plates are required when installing the centrifuge. Lay out the installation site and locate the base plates in accordance with Figure 3-4. The base plates have 1-9/16” x 1-9/16” (40mm x 40mm) centering posts. They may be either bolted or welded to the mounting platform to properly position and prevent movement of the centrifuge.
Figure 3-4.
INSTALLATION EQUIPMENT POSITIONING AND MOUNTING (CONT’D) Figure 3-5. Centrifuge Mounting LIQUID AND SOLID DISCHARGE CHUTES Observe the design considerations shown in Figure 3-6 when fabricating the liquid and solid discharge chutes. To determine dimensions and mounting hole arrangements, refer to general arrangement drawing in Section 8. Figure 3-6.
INSTALLATION Liquid Discharge The liquid discharge collector may be bolted directly to the centrifuge case; however, the piping connection should have a flexible joint. When fabricating the discharge piping, follow the dimensional and piping requirements shown in Figure 3-6. Since liquid exiting the centrifuge is not pressurized, the piping must be pitched to facilitate gravity drainage. Solid Discharge Chute A three-sided solid discharge extension may be bolted to the discharge flange.
INSTALLATION LOWER AND SECURE ROTATING ASSEMBLY Note! Do not discard the rubber strips between bearing pillow blocks, cover, and base after removal. These strips must be re-installed whenever the machine is moved to prevent damage to the rotating assembly bearings during transit. Following final positioning and leveling of the centrifuge, shipping blocks inserted between the bearing pillow blocks and the base, as well as between the case and base, must be removed.
INSTALLATION 3. Install two jack bolts in top half of each pillow block, and thread bolts through lower halves. 4. Turn jack bolts clockwise to lift pillow blocks sufficiently to permit removal of all shipping blocks, and remove blocks. 5. Clean mounting surfaces of lower pillow block halves and base, and then apply a light coating of grease or corrosion inhibitor to both surfaces. 6.
INSTALLATION FEED AND FLUSH CONNECTIONS (CONT’D) Figure 3-9. Feed Assembly Figure 3-10. Feed Line Connections Figure 3-11.
INSTALLATION COMPRESSED AIR Explosion-proof control cabinets require a source of clean, preferably instrument quality, filtered, dry compressed air or nitrogen at 60 to 115 PSI at 20SCFM for operation of the control cabinet purge system. The supply line must have a minimum diameter of 3/4” (20mm). The supply must be clean, non-flammable, and from a non-hazardous area. The cleanliness requirements are as follows: Solid particles: 0.5µm
INSTALLATION Note that power may be connected with either a single heavy-gage cable or split between two smaller, lighter cables. The smaller-gage cables used for the split-input connections are generally easier to handle. If the input is split (Figure 3-13), be sure to group conductors of the same phase/color. Cable size depends on machine voltage requirements and cable length. Refer to applicable electrical schematic diagram in Section 8 for cable sizing requirements.
INSTALLATION BOWL, CONVEYOR, AND FEED PUMP MOTOR CONNECTIONS The bowl and conveyor drive motors require three-phase VFD power and ground connections. Power is derived through connections to terminal blocks inside the control cabinet. Similarly, the customer’s feed pump motor must be connected to the centrifuge control system for control of its operation. Connect the bowl, conveyor, and feed pump motors to terminal blocks in the bottom left side of the control cabinet as shown in Figure 3-14.
INSTALLATION TANK LEVEL SWITCH CONNECTIONS (CONT’D) Figure 3-15. Typical Tank Level Switch Connections POLARITY TEST WARNING! BE CERTAIN THAT MOTORS ROTATE IN CORRECT DIRECTION. 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.
INSTALLATION WARNING! CENTRIFUGE MUST BE OPERATED AT THE DESIGNATED SUPPLY VOLTAGE. DANGER! DANGER! HIGH VOLTAGE! SHUT DOWN, LOCK OUT, AND TAG OUT ELECTRIC POWER, AND ENSURE THAT EQUIPMENT HAS STOPPED ROTATING BEFORE WORKING ON THIS EQUIPMENT. IF THE INPUT POWER IS SPLIT, BE SURE THAT PHASING IS CORRECT BEFORE APPLYING POWER TO CENTRIFUGE. WARNING! ELECTRICAL CONNECTIONS MUST BE MADE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE (NEC) AND ALL APPLICABLE LOCAL CODES.
INSTALLATION MACHINE STARTUP Refer to Section 4 for initial startup and operating procedures for the centrifuge. WARNING! DO NOT ATTEMPT TO OPERATE MACHINE WITH SHIPPING BRACKETS INSTALLED.
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.
OPERATING INSTRUCTIONS TOP COVER OPENING/CLOSING PROCEDURES The proper procedures for opening and closing the top cover of the centrifuge must always be followed. Two operators using both hands are required to open the cover. Derrick recommends having a hoist available if additional assistance is desired during the opening/closing of the centrifuge cover. To open and close the cover, proceed as follows: 1.
OPERATING INSTRUCTIONS DANGER! USE EXTREME CAUTION WHEN OPERATING CENTRIFUGE WITH PURGE SYSTEM BYPASSED. DANGEROUSLY HIGH VOLTAGE WILL BE PRESENT IN CONTROL CABINET IF DOOR IS OPENED WHILE POWER IS APPLIED. To bypass the purge system, proceed as follows: 1. Be certain that control cabinet is in a non-hazardous environment; then shut down, lock out, and tag out electric power to centrifuge. 2. Remove bolts securing electrical panel door at right side of cabinet, and open door. 3.
OPERATING INSTRUCTIONS INITIAL STARTUP (CONT’D) 6. Apply electric power to centrifuge. The following screen will appear (on explosion-proof cabinet, displayed after purge cycle is completed): 7. Without the centrifuge running, perform the following safety checks to confirm that connections are correct between control cabinet and centrifuge: • Operate emergency stop buttons on junction box and control cabinet, and check for Emergency Stop alarm message on control panel.
OPERATING INSTRUCTIONS b. Select Download to update VFD settings with new motor data. This will cause pump to autotune at the next startup. c. Select Disable for Tank High and Low Level inputs, if they will not be used. d. When finished making required changes, click “X” in upper right corner to return to Setup screen. Select Home to return to Home screen. 12. Select Operation to display the following screen: 13.
OPERATING INSTRUCTIONS NORMAL STARTUP 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.
OPERATING INSTRUCTIONS Note! Pump will not start until actual bowl speed is within 120RPM of setting. 11. 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. Note! Depending on conveyor differential speed setting, at bowl speeds above 300RPM conveyor motor may rotate in opposite direction.
OPERATING INSTRUCTIONS OPERATION (CONT’D) Adjustment of one parameter may produce the desired clarity of liquid effluent and solids dryness. Or the desired performance may be achieved by further adjustment. It is important to understand the interdependence of the operating parameters. Changing one characteristic results in other effects that may warrant additional adjustments. Except for pond depth, these parameters can be adjusted while the centrifuge is operating.
OPERATING INSTRUCTIONS as the torque remains below the set limit. If the slurry is low in viscosity and density, operation will continue in the flow priority mode. However, conveyor torque may rise if solids volume increases, as the conveyor may become burdened in moving the increased solids volume at the present feed rate and bowl speed.
OPERATING INSTRUCTIONS Pond Depth (Cont’d) Six adjustable weir plates are provided on the liquid bowl head to facilitate setting the pond depth; all ports must be set identically. A deeper pond depth (move weir plates toward 380mm) increases settling time by permitting more liquid to remain in the bowl. However, a deeper pond depth also reduces the beach area at the solids discharge end of the bowl, which will result in a wetter solids discharge.
OPERATING INSTRUCTIONS To adjust pond depth, proceed as follows: WARNING! DO NOT OPEN COVER OR ATTEMPT ANY ADJUSTMENT OR MAINTENANCE ON THE CENTRIFUGE UNLESS THE BOWL IS AT A COMPLETE STANDSTILL. 1. Shut down, lock out, and tag out the centrifuge using the Normal Shutdown procedure described later in this section. 2. Remove access plate from the inlet side of the case cover. 3.
OPERATING INSTRUCTIONS BEARING TEMPERATURES Bearing temperature trends may be viewed in graphical form on the Bearing Temperature screen (Figure 4-5). Temperatures are updated at one-minute intervals, and scroll buttons are provided to facilitate examination of trends. 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.
OPERATING INSTRUCTIONS SYSTEM DIAGNOSTICS Built-in system diagnostics continually analyze the control system for malfunctions. The Diagnostics screen (Figure 4-7) aids in troubleshooting by displaying any fault in the critical areas of the centrifuge. The current operational status of the Bowl, Conveyor, and Pump VFDs, as well as the speed and temperature sensors are displayed on this screen.
OPERATING INSTRUCTIONS ALARM AND FAULT MESSAGES If an alarm or fault occurs, a banner will appear at the bottom of the Operation screen (Figure 4-9) to alert the operator of a malfunction. 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. If desired, the operator may display the present and past alarms and the status of each alarm.
OPERATING INSTRUCTIONS Figure 4-10. Alarm Screen Buttons VFD STATUS Status screens (Figure 4-11 through 4-13) are selected from the Operation screen. Each VFD status screen permits the operator to view various operational characteristics of the VFD such as present alarms or faults, power, voltage, and current outputs; motor and component speeds; direction of motor rotation; VFD temperature; and motor torque.
OPERATING INSTRUCTIONS VFD STATUS (CONT’D) Figure 4-12. Conveyor VFD Screen Figure 4-13. Pump VFD Screen PUMP VFD FAULT STATUS The three most recent pump faults are shown on the Pump VFD Fault Status screen (Figure 414). 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.
OPERATING INSTRUCTIONS Figure 4-14. Pump VFD Fault Status Screen VFD TEMPERATURE TRENDS The historical temperature trends of all three VFDs are shown on the Temperature Trend screen (Figure 4-15). This screen is accessible from the Bowl VFD screen. Figure 4-15. VFD Temperature Trend Screen VFD FAULT RESET The Fault Reset screen (Figure 4-16) informs the operator of the readiness of each VFD—Faulted or No Fault—and permits resetting a faulted VFD.
OPERATING INSTRUCTIONS VFD FAULT RESET (CONT’D) Figure 4-16. Fault Reset Screen SETUP SCREEN The Setup screen (Figure 4-17) permits the operator to view the software version installed in the PLC and control panel (HMI), view feed pump characteristics, adjust panel brightness, select the temperature units (°C or °F) that will be shown on other screens, and set personal preferences. In addition, by selecting Login an authorized operator may access restricted screens.
OPERATING INSTRUCTIONS By entering “User1” for user name and password “1-1-1-1” on the Login screen, the operating range screen is displayed (Figure 4-18). The user may then set the maximum and minimum limits for the following parameters: • Bowl speed • Conveyor differential speed • Pump GPM Figure 4-18. Operating Range Screen PUMP SETUP SCREEN Pump parameters are input and viewed on the Pump Setup screen (Figure 4-19), which is accessed from the Setup screen.
OPERATING INSTRUCTIONS CLEAN OUT (CONT’D) Figure 4-20. Clean Out Screen 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.
OPERATING INSTRUCTIONS NORMAL SHUTDOWN The normal shutdown procedure is to be used for controlled stopping of operation. Normal shutdown is performed for routine activities such as cleaning, lubrication, inspection, or adjustment. Note! Proper shutdown and flushing of the bowl can prevent high vibration at the next startup. Step 1 2 Procedure Stop the feed pump. Open supply of fresh flushing liquid to remove all solids from conveyor and bowl.
OPERATING INSTRUCTIONS Excessive Bowl Speed A sensor that detects the rotating 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 3100RPM. To re-start the centrifuge, allow the bowl to coast to a complete stop, check for and remove the cause of excessive speed as described in Section 5.
OPERATING INSTRUCTIONS EMERGENCY SHUTDOWN Two options are available to stop the centrifuge in an emergency: Electric power shutdown or mechanical shutdown. The type of emergency dictates the shutdown method. If emergency is electricity related, power must be shut down immediately. However, if the emergency requires the fastest possible means of stopping the bowl, the alternative mechanical shutdown procedure should be used to bring the bowl to a stop more quickly. Electric Power Shutdown 1.
SECTION 5 - MAINTENANCE GENERAL This section describes preventive and corrective maintenance procedures for the DE-7200 VFD centrifuge. Obvious procedures are omitted. Before beginning any centrifuge maintenance, shut down, lock out, and tag out equipment. DANGER! HIGH VOLTAGE! SHUT DOWN, LOCK OUT, AND TAG OUT ELECTRIC POWER, AND ENSURE THAT EQUIPMENT HAS STOPPED ROTATING BEFORE WORKING ON THIS EQUIPMENT. SAFETY GLASSES MUST BE WORN AT ALL TIMES WHILE PERFORMING ANY MAINTENANCE PROCEDURE.
MAINTENANCE PREVENTIVE MAINTENANCE Preventive maintenance consists of inspection, cleaning, and lubrication. These routine procedures will ensure maximum life and trouble-free operation. While the maintenance schedule presented in this section should remain flexible, modifications should be based on experience with operating the equipment at your facilities.
MAINTENANCE LUBRICATION CHART No. Location Amount Interval Type Application Notes 1 Main bearings 6 cm3 (3 strokes) 40 Hrs Shell Albida EP2 Centrifuge running Manual grease gun 2 Conveyor bearing Inject grease until it exits outlet port 500 Hrs Shell Albida EP2 Centrifuge stationary Manual grease gun 3 Bowl drive motor 4 5 Conveyor drive motor Conveyor drive gearbox 0.5 Oz (10 shots) 5 qts (4.
MAINTENANCE GEARBOX OIL LEVEL CHECK (CONT’D) 4. Rotate gearbox until the housing marks are at top dead center (Figure 5-1). Note! Placing a straight edge between grease fitting and housing markings will help align marks at top dead center. 5. Remove fill and vent plugs, and check that oil level is at fill plug opening. If level is low, replenish with recommended oil. 6. Re-install fill and vent plugs, and tighten securely. 7. Close and secure top cover. Figure 5-1.
MAINTENANCE 9. Re-fill gearbox with correct product and quantity listed in Lubrication Chart. 10. Re-install fill and vent plugs, and tighten securely. 11. Close and secure top cover. DRIVE BELT REPLACEMENT DANGER! HIGH VOLTAGE! SHUT DOWN, LOCK OUT, AND TAG OUT ELECTRIC POWER, AND ENSURE THAT EQUIPMENT HAS STOPPED ROTATING BEFORE WORKING ON THIS EQUIPMENT. SAFETY GLASSES MUST BE WORN AT ALL TIMES WHILE PERFORMING ANY MAINTENANCE PROCEDURE.
MAINTENANCE DRIVE BELT REPLACEMENT (CONT’D) Figure 5-2. Conveyor Drive Clutch Figure 5-3.
MAINTENANCE 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 system bypass procedure.
MAINTENANCE Visual Inspection and Checks (Cont’d) 3. Check condition of the purge unit air filter element, and clean or replace as necessary. 4. At least every two years, check the following additional items: a. There are no unauthorized modifications. b. Quality of the air supply is correct (refer to Compressed Air in Section 3). c. Approval labels are legible and undamaged. d. Power to the centrifuge is shut down upon loss of air pressure.
MAINTENANCE 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. Connect Magnahelic gage to test point shown below. 2. Open the supply regulator to between 60 and 115 psi (4 and 8 barg) to start the purge flow. 3. Check that the internal logic gage reads 30 psi (2 bar). 4.
MAINTENANCE 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.
MAINTENANCE Cleaning Purge Unit Filter Do not use solvents on any part of the filter assembly installed inside the purge unit. To clean the filter element, unscrew and remove the filter bowl and then unscrew and remove filter element. Clean filter element in soapy water or replace element. ROTATING ASSEMBLY MAINTENANCE Maintenance of the rotating assembly is limited to removal, cleaning, inspection, and replacement of wear inserts.
MAINTENANCE Rotating Assembly Removal (Cont’d) Figure 5-4. Conveyor Torque Limiter Clutch 6. Loosen nuts securing bowl drive motor to base, turn tensioning bolt to release tension, and remove belts from bowl sheave. 7. Remove liquid and solid end temperature sensors (Figure 5-5) from main bearing pillow blocks. Figure 5-5. Solid End Temperature and Speed Sensors 8. Disconnect speed sensor cable from speed sensor. 9.
MAINTENANCE 10. Attach a hoist capable of lifting at least 4000 lbs (1800 kg) to rotating assembly. 11. Properly balance the hoisting straps to ensure that the assembly remains horizontal during lifting, and slowly hoist rotating assembly until clear of base. 12. Lower rotating assembly onto a cradle that is capable of supporting its weight. Figure 5-6. Bearing Pillow Block Cleaning and Inspection 1.
MAINTENANCE Cleaning and Inspection (Cont’d) A (mm) 19.2 20.2 21.2 22.2 23.2 24.2 25.2 26.2 27.2 28.2 29.2 Radial Wear (mm) 0 1 2 3 4 5 6 7 8 9 10 Figure 5-9. Conveyor Flight Wear Measurement Installation 1. Using a suitable hoist capable of lifting at least 4000 lbs (1800 kg), lift rotating assembly from cradle and lower onto base with pillow blocks in close alignment with mounting holes. 2.
MAINTENANCE HARDWARE TORQUE SPECIFICATIONS Use only hardware that is approved by Derrick Corporation. The use of potentially inferior, nonDerrick 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.
MAINTENANCE RECOMMENDED SPARE PARTS (CONT’D) Part No.
MAINTENANCE Part No. Description Consumable 2-Yr Qty Control Cabinet - 16472-00-002 G0007698 Fuse, 60A, Class J No 3 G0008792 Fuse, 3A, Class CC No 3 G0003493 Fuse, 15A, Class CC No 3 G0007225 Fuse, 150A, Class J No 2 G0007632 Fuse, 225A, Class T No 3 G0002910 Fuse, 2.
MAINTENANCE TROUBLESHOOTING (CONT’D) 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. Troubleshooting Chart The troubleshooting chart consists of failure modes, possible cause(s), and recommended course(s) of action.
MAINTENANCE TROUBLESHOOTING DE-7200 VFD CENTRIFUGE Possible Cause Isolation Procedure & Corrective Action Failure Mode 3: Excessive Vibration Excessive buildup of solids in bowl and/or conveyor. Perform cleanout procedure (refer to Preventive Maintenance). Bowl assembly main bearings defective. Replace rotating assembly (refer to Rotating Assembly Maintenance).
MAINTENANCE TROUBLESHOOTING DE-7200 VFD CENTRIFUGE Possible Cause Isolation Procedure & Corrective Action Failure Mode 9: Purge System Purges Correctly, But Alarm Goes On At End Of Purge Interval And Purge Cycle Is Repeated Actual cabinet pressure below setting of minimum pressure sensor Check cabinet for leakage and correct any defects. Leakage compensation valve setting to low, causing repurge to occur Increase cabinet pressure by turning leakage compensation valve adjustment counter-clockwise.
MAINTENANCE TROUBLESHOOTING DE-7200 VFD CENTRIFUGE Possible Cause Isolation Procedure & Corrective Action Failure Mode 13: Air Conditioner Evaporator Fan 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 eight screws securing fan to air conditioner housing, and separate fan from housing.
MAINTENANCE TROUBLESHOOTING (CONT’D) Figure 5-10.
MAINTENANCE Figure 5-11.
MAINTENANCE Figure 5-12.
MAINTENANCE Figure 5-13. Air Conditioner Electrical Components Locations ALARM AND FAULT MESSAGES Intervention is required if a control panel message appears to alert the operator that an anomaly 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.
MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F1001 - Bowl High Torque Alarm, Reduce Feed Rate Bowl torque exceeds pre-set limit Reduce feed rate and/or reduce bowl speed. F1002 - Bowl High Torque Fault and Shutdown, Perform Cleanout and Reduce Feed Rate Bowl torque exceeds pre-set limit After bowl has stopped rotating, perform cleanout procedure to remove solids buildup, and re-start centrifuge at reduced feed rate.
MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F1017 - Bowl VFD Drive OL Alarm, Ref Troubleshooting Section of User Manual Feed rate causing overload Reduce feed rate or reduce bowl speed. Bowl drive motor drawing excessive current Replace motor if defective. F1021 - Bowl Motor Thermal Overload Check Bowl Motor Temperature and Thermistor Bowl drive motor shut down due to high temperature or defective thermistor in motor winding Check motor temperature.
MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F2012 - Conveyor VFD Fault and Shutdown, Ref Troubleshooting Section of User Manual Conveyor VFD fault Identify fault from operator control panel. Perform indicated corrective action. F2013 - Conveyor VFD Ground Warn Alarm, Ref Troubleshooting Section of User Manual Conveyor VFD has detected high current leakage to ground Check condition of cable and all connections between conveyor VFD and conveyor motor, and correct any defects.
MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F3010 - Pump VFD Communications Error Communication lost between pump VFD and PLC Confirm that green LED next to Ethernet cable on Ethernet switch is lighted, indicating that hub is functional. Check connections between pump VFD and PLC, and correct any defects. Replace pump VFD, if no other defect is found. F3011 - Pump VFD Alarm, Ref Troubleshooting Section of User Manual Pump VFD alarm Identify alarm from operator control panel.
MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F3021 - Pump Motor Thermal Overload Check Pump Motor Temperature and Thermistor Pump drive motor shut down due to high temperature or defective thermistor in motor winding Check motor temperature. Allow motor to cool, and then check for continuity across thermistor leads. If open circuit is found, replace motor. Bad connection(s) Check connections at TB2-3 and 4, at transmitter/intrinsic barrier, and at pump VFD. Correct as required.
MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F4003 - Liquid End Main Bearing High Temperature Alarm Incorrect or loose connection at temperature sensor If reading is constantly about 392°F (200°C), check and correct connection (refer to Section 3 and electrical schematic diagram in Section 8). Insufficient bearing lubrication Lubricate bearings (refer to Preventive Maintenance).
MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F4006 - 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 into opening to remove grease. Incorrect grease Lubricate with recommended grease (refer to Preventive Maintenance). Defective bearing Contact Derrick Service department for assistance.
MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F7022 - Electrical Enclosure High Temperature Fault and Shutdown Control cabinet interior temperature has exceeded alarm setpoint Check status/operation of air conditioner; repair or replace if defective. Reduce load by decreasing bowl, conveyor differential speed, and/or pump feed rate. Interior temperature of control cabinet too high, causing shutdown Check that air conditioner is operating; repair or replace, as indicated.
MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F9012 - External Communication Loss, Switched to Local Control Profibus not working, remote control is disabled and control has automatically switched to local Check and correct any defects in Profibus connections, and attempt to re-start in Remote operating mode.
MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F9099 - Centrifuge Sensor I/O Cable Has Been Removed, Reconnect I/O Cable to Run Centrifuge Sensor cable is disconnected from control cabinet receptacle Plug in connector at upper left of cabinet, and then re-start centrifuge. VFD ALARM AND FAULT CROSS REFERENCES In addition to alarm and fault messages that may appear on the operator control panel, in case of equipment malfunction alarm and fault numbers may appear directly on the VFD screens.
MAINTENANCE FAULT CROSS REFERENCE No. Fault No. Fault No.
MAINTENANCE Figure 5-14.
MAINTENANCE Figure 5-15.
MAINTENANCE CONTROL COMPONENT INDICATORS (CONT’D) Figure 5-16. Transmitter/Intrinsic Barrier Indicators Figure 5-17.
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.
D C B A QTY X 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 3 2 1 1 3 3 1 6 8 1 2 2 2 6 3 1 1 2 PART NUMBER 16472-01-002 16396-01-008 16400-01-003 16401-01-002 16402-01-001 16404-01-004 16404-02-004 16404-03-004 16404-01-003 16405-01 16597-01 16598-01 G0002881 16403-01 17006-01 15197-01-003 G0007573 G0007690 G0007689 G0007588 G0002603 G0002604 16607-02 G0008966 G0008891 G0008941 G0008942 G0007213 G0005309 G0007221 G0007698 G0007223 G0007998 G0008507 G0008562 G0009839 G0007214 G0007224 G0007225 G000
D C B A QTY X 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 6 2 2 6 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 2 1 1 2 3 1 1 1 8 8 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 3 2 2 7 2 1 3 2 2 2 2 3 1 1 3 3 3 1 1 1 1 1 35 28 13 2 8 4 1 1 1 1 4 1 1 1 1 1 1 7 DRAWING NUMBER 16472-01-003 16396-01-003 16400-01-003 16401-01-002 16402-01-001 16404-01-004 16404-02-004 16404-03-004 16404-01-003 16405-01 16597-01 16598-01 G0002881 16403-01 15197-01-003 G0009358 G0009359 G0009360 G0007588 G0002603 G00026
D C B A QTY X 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 3 1 4 3 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 2 1 1 2 3 1 1 1 8 8 7 2 2 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 3 2 2 3 2 2 1 2 1 2 2 2 1 1 3 6 3 8 4 3 6 1 1 1 1 1 1 1 1 1 1 1 1 1 2 6 2 1 1 7 PART NUMBER 16472-01-004 16396-01-003 16400-01-003 16401-01-002 16402-01-001 16404-01-004 16404-02-004 16404-03-004 16404-01-003 16405-01 16597-01 16598-01 G0002881 16403-01 15197-01-003 G0009350 G0009351 G0009352 G0007588 G0002603 G0002604 166
7 6 Parts List D C B A 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 X 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 3 2 1 1 3 3 1 6 2 2 2 2 2 6 3 1 1 2 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 8 1 7 1 1 1 1 8 1 1 1 1 1 35 28 13 1 1 1 1 1 1 2 2 6 2 2 4 8 1
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.
INSTALLATION & MAINTENANCE LOG 9-2 DE-7200VFDCentrifuge 30 Oct 09
INSTALLATION AND MAINTENANCE LOG 30 Oct 09 9-3 DE-7200VFDCentrifuge
INSTALLATION & MAINTENANCE LOG 9-4 DE-7200VFDCentrifuge 30 Oct 09
INSTALLATION AND MAINTENANCE LOG 30 Oct 09 9-5 DE-7200VFDCentrifuge
INSTALLATION & MAINTENANCE LOG 9-6 DE-7200VFDCentrifuge 30 Oct 09
APPENDIX A - HMI SERVER SYSTEM DESCRIPTION This Appendix contains instructions for installing, connecting, and operating the HMI Server System, which consists of an HMI Server and Router Switchgear Box (Figure A-1). The system permits remote monitoring for the Derrick DE-7200 and DE-1000 Variable Frequency Drive (VFD) centrifuges. By connecting a customer-supplied PC or laptop computer to the server, the operator can monitor two to four centrifuges from a single location separate from the control cabinets.
APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM INSTALLATION All safety procedures included in the Operation and Maintenance manual are to be followed when installing the HMI Server System components. Installation is performed in the following sequence: • Install server in safe area on a desktop or wall. • Install Router Switchgear Box on a suitable wall in hazardous area.
APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Figure A-3. Electrical Connections to Router Switchgear Box 3. Tighten nut properly on cable gland to ensure proper sealing. 4. Close and secure cover of Router Switchgear Box after completing connections. 5. Plug in HMI Server and PC power cords.
APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Control Cabinet Connections to Router Switchgear Box The following procedure describes the interconnection of control cabinets with the HMI Server. Refer to drawing 18309-00 for additional assistance in making the connections, and note that cables must be no more 328’ (100m) long. All cabling must be properly dressed, protected from chafing, and secured appropriately. 1.
APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM 5. Connect a CAT5 cable to Ethernet switch in Switchgear Box, and connect opposite end to LAN 1 port on HMI Server (Figure A-6). 6. Tighten nuts properly on all cable glands to ensure proper sealing. 7. Connect a CAT5 cable from LAN 2 port of HMI Server to Ethernet switch port. 8. Connect a CAT5 cable from LAN port of customer-supplied computer to second port of Ethernet switch. Figure A-6.
APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Operation (Cont’d) IP Address If connecting to LAN 1, the static IP address of the PCs must be set to the following IP addresses: PC IP Address Subnet Mask PC 1 100.100.10.201 255.255.255.0 PC 2 100.100.10.202 255.255.255.0 PC 3 100.100.10.203 255.255.255.0 In addition, note that no other component may be on the network with an address between 100.100.10.1 to 100.100.10.199, as these are reserved for the HMI Server system. Addresses 100.100.10.
APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Figure A-7. HMI Server Home Screen Figure A-8. Operation Screen - Centrifuge 1 Figure A-9.
APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Figure A-10. Pump Setup Screen Figure A-11. Support-Activation Screen Figure A-12. Alarms Screen Figure A-13.
APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Figure A-14. DeskLock Screen Troubleshooting Network Connectivity The following IP addresses of all system components permit entry into the router configuration to verify that the router is communicating: Router 1 Router 2 Router 3 Router 4 HMI Server PC Activation PLC X1 WAN Port https://100.100.10.1 https://100.100.10.2 https://100.100.10.3 https://100.100.10.4 LAN Port #1 100.100.10.101 100.100.10.100 X2 LAN Port https://100.100.100.101 https://100.100.
APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Figure A-15. Customer PC Test Connections to Ping Routers REFERENCE DRAWINGS Drawings included in this appendix are listed in Table A-1. These drawings are included to assist in the installation and operation of the HMI Server. Table A-1.
