AOpen DE7200 Series Instrucciones de operaciones

DE-7200 Centrifuge Variable Frequency Drive Issued 30 Oct 09 Rev 01 Jan 14 Maintenance & Operation Manual DISCLAIMER Derrick C

INTRODUCTION 1-2 20 Sep 12 DE-7200VFDCentrifuge EQUIPMENT USE The DE-7200 VFD centrifuge is designed for removing low and high specific gravity soli

MAINTENANCE 5-38 31 Dec 13 DE-7200VFDCentrifuge Figure 5-15. PLC Indicators

MAINTENANCE 31 Dec 13 5-39 DE-7200VFDCentrifuge CONTROL COMPONENT INDICATORS (CONT’D) Figure 5-16. Transmitter/Intrinsic Barrier Indicators Figur

SECTION 8 - REFERENCE DRAWINGS 01 Sep 11 1-1 DE-7200VFDCentrifuge This section contains Derrick engineering drawings for your equipment. These

INTRODUCTION 20 Sep 12 1-3 DE-7200VFDCentrifuge Rotating Assembly The rotating assembly consists of a cylindrically shaped, bowl, conveyor assembly

INTRODUCTION 1-4 20 Sep 12 DE-7200VFDCentrifuge pre-set torque limit is reached, the control system automatically reduces the feed rate to enable th

INTRODUCTION 20 Sep 12 1-5 DE-7200VFDCentrifuge the upper setpoint, the compressor and condenser motors are cycled on to provide cooling. Upon reac

INTRODUCTION 1-6 20 Sep 12 DE-7200VFDCentrifuge The case is bolted onto the welded steel base assembly, which contains mounting provisions for the b

ITEM QTY PART NUMBER DESCRIPTION01 X 16472-01-002 ASSEMBLY COMPLETE02 1 16396-01-008 ENCLOSURE ASSEMBLY03 1 16400-01-003 DOOR ASSEMBLY04 1 16401-01-00

ITEMQTY DRAWING NUMBER DESCRIPTION01 X 16472-01-003 ASSEMBLY COMPLETE02 1 16396-01-003 ENCLOSURE ASSEMBLY03 1 16400-01-003DOOR ASSEMBLY04 1 16401-01-0

ITEMQTYPART NUMBERDESCRIPTION01 X 16472-01-004 ASSEMBLY COMPLETE02 1 16396-01-003ENCLOSURE ASSEMBLY03 1 16400-01-003 DOOR ASSEMBLY04 1 16401-01-002COV

Parts ListITEMQTY DRAWING NUMBER DESCRIPTION 01 X 16472-01-005 ASSEMBLY COMPLETE02 1 16396-01-003 ENCLOSURE ASSEMBLY03 1 16400-01-003DOOR ASSEMBLY

SECTION 9 - INSTALLATION AND MAINTENANCE LOG 30 Oct 09 9-1 DE-7200VFDCentrifuge PURPOSE This section should be used by operating and maintenanc

INTRODUCTION 20 Sep 12 1-7 DE-7200VFDCentrifuge Figure 1-4 Centrifuge Operation CONTROL SYSTEM Centrifuge operation is supervised by a programmab

INSTALLATION & MAINTENANCE LOG 9-2 30 Oct 09 DE-7200VFDCentrifuge

INSTALLATION AND MAINTENANCE LOG 30 Oct 09 9-3 DE-7200VFDCentrifuge

INSTALLATION & MAINTENANCE LOG 9-4 30 Oct 09 DE-7200VFDCentrifuge

INSTALLATION AND MAINTENANCE LOG 30 Oct 09 9-5 DE-7200VFDCentrifuge

INSTALLATION & MAINTENANCE LOG 9-6 30 Oct 09 DE-7200VFDCentrifuge

APPENDIX A - HMI SERVER SYSTEM 15 May 13 A-1 Appendix A-HMIServerSystem DESCRIPTION This Appendix contains instructions for installing, connect

APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM A-2 15 May 13 Appendix A-HMIServerSystem INSTALLATION All safety procedures included in the Operation

APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM 15 May 13 A-3 Appendix A-HMIServerSystem Figure A-3. Electrical Connections to Router Switchgear Box

APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM A-4 15 May 13 Appendix A-HMIServerSystem Control Cabinet Connections to Router Switchgear Box The foll

APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM 15 May 13 A-5 Appendix A-HMIServerSystem 5. Connect a CAT5 cable to Ethernet switch in Switchgear

INTRODUCTION 1-8 20 Sep 12 DE-7200VFDCentrifuge PRODUCT SUPPORT Derrick Corporation offers 24-hour per day, 7-day per week product support. Product

APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM A-6 15 May 13 Appendix A-HMIServerSystem Operation (Cont’d) IP Address If connecting to LAN 1, the sta

APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM 15 May 13 A-7 Appendix A-HMIServerSystem Figure A-7. HMI Server Home Screen Figure A-8. Operation S

APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM A-8 15 May 13 Appendix A-HMIServerSystem Figure A-10. Pump Setup Screen Figure A-11. Support-Activat

APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM 15 May 13 A-9 Appendix A-HMIServerSystem Figure A-14. DeskLock Screen Troubleshooting Network Connec

APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM A-10 15 May 13 Appendix A-HMIServerSystem Figure A-15. Customer PC Test Connections to Ping Routers R

SECTION 2 - SAFETY 30 Sep 13 2-1 DE-7200VFDCentrifuge GENERAL This section contains a summary of WARNINGS used in this manual and a list of mater

SAFETY 2-2 30 Sep 13 DE-7200VFDCentrifuge WARNING! ELECTRICAL CONNECTIONS MUST BE MADE IN ACCORDANCE WITH ALL APPLICABLE NATIONAL AND LOCAL CODES.

SAFETY 30 Sep 13 2-3 DE-7200VFDCentrifuge WARNING! WHILE OPENING AND CLOSING THE CENTRIFUGE COVER, PERSONNEL MUST ENSURE THAT ALL BODY LIMBS AND

SAFETY 2-4 30 Sep 13 DE-7200VFDCentrifuge MSDS’S (CONT’D) MATERIAL DESCRIPTION - WHERE USED MSDS / Date Paints PPG Dimetcote 302H Green 302F0250 Re

SECTION 3 - INSTALLATION 01 Jan 14 3-1 DE-7200VFDCentrifuge GENERAL This section describes the recommended installation procedure for the DE-72

INSTALLATION 3-2 01 Jan 14 DE-7200VFDCentrifuge TOP COVER OPENING/CLOSING PROCEDURES The proper procedures for opening and closing the top cover of

INSTALLATION 01 Jan 14 3-3 DE-7200VFDCentrifuge INSTALLATION SEQUENCE Following is the sequence of steps for installing the centrifuge. The sequen

INSTALLATION 3-4 01 Jan 14 DE-7200VFDCentrifuge REQUIRED CLEARANCES AND POSITIONING (CONT’D) Figure 3-1. Required Opening Clearances for Cabinet Do

INSTALLATION 01 Jan 14 3-5 DE-7200VFDCentrifuge While the centrifuge and control cabinet are still mounted on the shipping skids, they may b

INSTALLATION 3-6 01 Jan 14 DE-7200VFDCentrifuge EQUIPMENT HANDLING (CONT’D) Figure 3-3. DE-7200 Control Cabinet Lifting Arrangement EQUIPMENT POSIT

INSTALLATION 01 Jan 14 3-7 DE-7200VFDCentrifuge Figure 3-4. Centrifuge Installation Site Layout

INSTALLATION 3-8 01 Jan 14 DE-7200VFDCentrifuge EQUIPMENT POSITIONING AND MOUNTING (CONT’D) Figure 3-5. Centrifuge Mounting LIQUID AND SOLID DISCHA

INSTALLATION 01 Jan 14 3-9 DE-7200VFDCentrifuge Liquid Discharge The liquid discharge collector may be bolted directly to the centrifuge case; how

UNIT NUMBER IS KEY TO DERRICK SERVICE All inquiries to Derrick must include the equipment unit number. The stainless steel unit number tag attached t

INSTALLATION 3-10 01 Jan 14 DE-7200VFDCentrifuge LOWER AND SECURE ROTATING ASSEMBLY Note! Do not discard the rubber strips between bearing pillow b

INSTALLATION 01 Jan 14 3-11 DE-7200VFDCentrifuge 3. Install two jack bolts in top half of each pillow block, and thread bolts through lower halve

INSTALLATION 3-12 01 Jan 14 DE-7200VFDCentrifuge FEED AND FLUSH CONNECTIONS (CONT’D) Figure 3-9. Feed Assembly Figure 3-10. Feed Line Connections

INSTALLATION 01 Jan 14 3-13 DE-7200VFDCentrifuge COMPRESSED AIR Explosion-proof control cabinets require a source of clean, preferably instrument

INSTALLATION 3-14 01 Jan 14 DE-7200VFDCentrifuge Note that power may be connected with either a single heavy-gage cable or split between two smaller

INSTALLATION 01 Jan 14 3-15 DE-7200VFDCentrifuge BOWL, CONVEYOR, AND FEED PUMP MOTOR CONNECTIONS The bowl and conveyor drive motors require three-

INSTALLATION 3-16 01 Jan 14 DE-7200VFDCentrifuge TANK LEVEL SWITCH CONNECTIONS (CONT’D) Figure 3-15. Typical Tank Level Switch Connections POLARITY

INSTALLATION 01 Jan 14 3-17 DE-7200VFDCentrifuge WARNING! CENTRIFUGE MUST BE OPERATED AT THE DESIGNATED SUPPLY VOLTAGE. DANGER! DANGER! HIGH VOL

INSTALLATION 3-18 01 Jan 14 DE-7200VFDCentrifuge MACHINE STARTUP Refer to Section 4 for initial startup and operating procedures for the centrifuge.

SECTION 4 - OPERATING INSTRUCTIONS 30 Sep 13 4-1 DE-7200VFDCentrifuge GENERAL The procedures in this section are for use only by trained personn

ABOUT THIS MANUAL In this electronic manual, all sections and paragraphs listed in the CONTENTS are linked to the corresponding text. Navigate

OPERATING INSTRUCTIONS 4-2 30 Sep 13 DE-7200VFDCentrifuge TOP COVER OPENING/CLOSING PROCEDURES The proper procedures for opening and closing the top

OPERATING INSTRUCTIONS 30 Sep 13 4-3 DE-7200VFDCentrifuge DANGER! USE EXTREME CAUTION WHEN OPERATING CENTRIFUGE WITH PURGE SYSTEM BYPASSED. DANGER

OPERATING INSTRUCTIONS 4-4 30 Sep 13 DE-7200VFDCentrifuge INITIAL STARTUP (CONT’D) 6. Apply electric power to centrifuge. The following screen will

OPERATING INSTRUCTIONS 30 Sep 13 4-5 DE-7200VFDCentrifuge b. Select Download to update VFD settings with new motor data. This will cause pump to a

OPERATING INSTRUCTIONS 4-6 30 Sep 13 DE-7200VFDCentrifuge NORMAL STARTUP Note! If Centrifuge is Heated, Before Starting Centrifuge Follow COLD CLIM

OPERATING INSTRUCTIONS 30 Sep 13 4-7 DE-7200VFDCentrifuge Note! Pump will not start until actual bowl speed is within 120RPM of setting. 11. Adjus

OPERATING INSTRUCTIONS 4-8 30 Sep 13 DE-7200VFDCentrifuge OPERATION (CONT’D) Adjustment of one parameter may produce the desired clarity of liquid e

OPERATING INSTRUCTIONS 30 Sep 13 4-9 DE-7200VFDCentrifuge as the torque remains below the set limit. If the slurry is low in viscosity and density,

OPERATING INSTRUCTIONS 4-10 30 Sep 13 DE-7200VFDCentrifuge Pond Depth (Cont’d) Six adjustable weir plates are provided on the liquid bowl head to fa

OPERATING INSTRUCTIONS 30 Sep 13 4-11 DE-7200VFDCentrifuge To adjust pond depth, proceed as follows: WARNING! DO NOT OPEN COVER OR ATTEMPT ANY ADJ

CONTENTS 01 Jan 14 TOC-1 DE-7200VFDCentrifuge Section Page Date 1 - Introduction ...

OPERATING INSTRUCTIONS 4-12 30 Sep 13 DE-7200VFDCentrifuge BEARING TEMPERATURES Bearing temperature trends may be viewed in graphical form on the Be

OPERATING INSTRUCTIONS 30 Sep 13 4-13 DE-7200VFDCentrifuge SYSTEM DIAGNOSTICS Built-in system diagnostics continually analyze the control system fo

OPERATING INSTRUCTIONS 4-14 30 Sep 13 DE-7200VFDCentrifuge ALARM AND FAULT MESSAGES If an alarm or fault occurs, a banner will appear at the bottom

OPERATING INSTRUCTIONS 30 Sep 13 4-15 DE-7200VFDCentrifuge Figure 4-10. Alarm Screen Buttons VFD STATUS Status screens (Figure 4-11 through 4-13

OPERATING INSTRUCTIONS 4-16 30 Sep 13 DE-7200VFDCentrifuge VFD STATUS (CONT’D) Figure 4-12. Conveyor VFD Screen Figure 4-13. Pump VFD Screen PUMP

OPERATING INSTRUCTIONS 30 Sep 13 4-17 DE-7200VFDCentrifuge Figure 4-14. Pump VFD Fault Status Screen VFD TEMPERATURE TRENDS The historical tempera

OPERATING INSTRUCTIONS 4-18 30 Sep 13 DE-7200VFDCentrifuge VFD FAULT RESET (CONT’D) Figure 4-16. Fault Reset Screen SETUP SCREEN The Setup screen (

OPERATING INSTRUCTIONS 30 Sep 13 4-19 DE-7200VFDCentrifuge By entering “User1” for user name and password “1-1-1-1” on the Login screen, the opera

OPERATING INSTRUCTIONS 4-20 30 Sep 13 DE-7200VFDCentrifuge CLEAN OUT (CONT’D) Figure 4-20. Clean Out Screen Provision is included for selecting the

OPERATING INSTRUCTIONS 30 Sep 13 4-21 DE-7200VFDCentrifuge NORMAL SHUTDOWN The normal shutdown procedure is to be used for controlled stopping of o

CONTENTS TOC-2 01 Jan 14 DE-7200VFDCentrifuge Section Page Date 4 - Operating Instructions ...

OPERATING INSTRUCTIONS 4-22 30 Sep 13 DE-7200VFDCentrifuge Excessive Bowl Speed A sensor that detects the rotating speed of the bowl provides an inp

OPERATING INSTRUCTIONS 30 Sep 13 4-23 DE-7200VFDCentrifuge EMERGENCY SHUTDOWN Two options are available to stop the centrifuge in an emergency:

SECTION 5 - MAINTENANCE 31 Dec 13 5-1 DE-7200VFDCentrifuge GENERAL This section describes preventive and corrective maintenance procedures for th

MAINTENANCE 5-2 31 Dec 13 DE-7200VFDCentrifuge PREVENTIVE MAINTENANCE Preventive maintenance consists of inspection, cleaning, and lubrication.

MAINTENANCE 31 Dec 13 5-3 DE-7200VFDCentrifuge LUBRICATION CHART No. Location Amount Interval Type Application Notes 1 Main bearings 6 cm3 (

MAINTENANCE 5-4 31 Dec 13 DE-7200VFDCentrifuge GEARBOX OIL LEVEL CHECK (CONT’D) 4. Rotate gearbox until the housing marks are at top dead center (

MAINTENANCE 31 Dec 13 5-5 DE-7200VFDCentrifuge 9. Re-fill gearbox with correct product and quantity listed in Lubrication Chart. 10. Re-install fil

MAINTENANCE 5-6 31 Dec 13 DE-7200VFDCentrifuge DRIVE BELT REPLACEMENT (CONT’D) Figure 5-2. Conveyor Drive Clutch Figure 5-3. Drive Belt Tensioni

MAINTENANCE 31 Dec 13 5-7 DE-7200VFDCentrifuge PURGE SYSTEM Bypassing Purge System The purge unit may be bypassed when necessary to apply electric p

CONTENTS 01 Jan 14 TOC-3 DE-7200VFDCentrifuge Section Page Date 5 - Maintenance (Cont’d) Troubleshooting ...

MAINTENANCE 5-8 31 Dec 13 DE-7200VFDCentrifuge Visual Inspection and Checks (Cont’d) 3. Check condition of the purge unit air filter element, and

MAINTENANCE 31 Dec 13 5-9 DE-7200VFDCentrifuge Leakage Compensation Test A Magnahelic gage and hose kit available from Derrick is required to monito

MAINTENANCE 5-10 31 Dec 13 DE-7200VFDCentrifuge Minimum Pressure Sensor Setting The setting of the minimum pressure sensor should be checked as fol

MAINTENANCE 31 Dec 13 5-11 DE-7200VFDCentrifuge Cleaning Purge Unit Filter Do not use solvents on any part of the filter assembly installed inside t

MAINTENANCE 5-12 31 Dec 13 DE-7200VFDCentrifuge Rotating Assembly Removal (Cont’d) Figure 5-4. Conveyor Torque Limiter Clutch 6. Loosen nuts secu

MAINTENANCE 31 Dec 13 5-13 DE-7200VFDCentrifuge 10. Attach a hoist capable of lifting at least 4000 lbs (1800 kg) to rotating assembly. 11. Properly

MAINTENANCE 5-14 31 Dec 13 DE-7200VFDCentrifuge Cleaning and Inspection (Cont’d) A (mm) Radial Wear (mm) 19.2 0 20.2 1 21.2 2 22.2 3 23.2 4 24.2

MAINTENANCE 31 Dec 13 5-15 DE-7200VFDCentrifuge HARDWARE TORQUE SPECIFICATIONS Use only hardware that is approved by Derrick Corporation. The use of

MAINTENANCE 5-16 31 Dec 13 DE-7200VFDCentrifuge RECOMMENDED SPARE PARTS (CONT’D) Part No. Description Consumable 2-Yr Qty Base - 16601-00-001

MAINTENANCE 31 Dec 13 5-17 DE-7200VFDCentrifuge Part No. Description Consumable 2-Yr Qty Control Cabinet - 16472-00-002 G0007698 Fuse, 60A,

MAINTENANCE 5-18 31 Dec 13 DE-7200VFDCentrifuge TROUBLESHOOTING (CONT’D) In case of control system malfunction, with electric power shut down, lock

MAINTENANCE 31 Dec 13 5-19 DE-7200VFDCentrifuge TROUBLESHOOTING DE-7200 VFD CENTRIFUGE Possible Cause Isolation Procedure & Corrective Action F

MAINTENANCE 5-20 31 Dec 13 DE-7200VFDCentrifuge TROUBLESHOOTING DE-7200 VFD CENTRIFUGE Possible Cause Isolation Procedure & Corrective Action

MAINTENANCE 31 Dec 13 5-21 DE-7200VFDCentrifuge TROUBLESHOOTING DE-7200 VFD CENTRIFUGE Possible Cause Isolation Procedure & Corrective Action F

MAINTENANCE 5-22 31 Dec 13 DE-7200VFDCentrifuge TROUBLESHOOTING (CONT’D) Figure 5-10. Air Conditioner Electrical Schematic Diagram

MAINTENANCE 31 Dec 13 5-23 DE-7200VFDCentrifuge Figure 5-11. Air Conditioner Electrical Schematic Diagram - 230Vac RTD Sensing

MAINTENANCE 5-24 31 Dec 13 DE-7200VFDCentrifuge Figure 5-12. Air Conditioner Electrical Schematic Diagram - 24Vdc RTD Sensing

MAINTENANCE 31 Dec 13 5-25 DE-7200VFDCentrifuge Figure 5-13. Air Conditioner Electrical Components Locations ALARM AND FAULT MESSAGES Intervention

MAINTENANCE 5-26 31 Dec 13 DE-7200VFDCentrifuge ALARM AND FAULT MESSAGES Cause Corrective Action F1001 - Bowl High Torque Alarm, Reduce Feed Rate

MAINTENANCE 31 Dec 13 5-27 DE-7200VFDCentrifuge ALARM AND FAULT MESSAGES Cause Corrective Action F1017 - Bowl VFD Drive OL Alarm, Ref Troubleshooti

SECTION 1 - INTRODUCTION 20 Sep 12 1-1 DE-7200VFDCentrifuge OVERVIEW This manual provides instructions for installing and operating the DE-7200

MAINTENANCE 5-28 31 Dec 13 DE-7200VFDCentrifuge ALARM AND FAULT MESSAGES Cause Corrective Action F2012 - Conveyor VFD Fault and Shutdown, Ref Trou

MAINTENANCE 31 Dec 13 5-29 DE-7200VFDCentrifuge ALARM AND FAULT MESSAGES Cause Corrective Action F3010 - Pump VFD Communications Error Communicatio

MAINTENANCE 5-30 31 Dec 13 DE-7200VFDCentrifuge ALARM AND FAULT MESSAGES Cause Corrective Action F3021 - Pump Motor Thermal Overload Check Pump Mo

MAINTENANCE 31 Dec 13 5-31 DE-7200VFDCentrifuge ALARM AND FAULT MESSAGES Cause Corrective Action F4003 - Liquid End Main Bearing High Temperature A

MAINTENANCE 5-32 31 Dec 13 DE-7200VFDCentrifuge ALARM AND FAULT MESSAGES Cause Corrective Action F4006 - Solid End Main Bearing High Temperature F

MAINTENANCE 31 Dec 13 5-33 DE-7200VFDCentrifuge ALARM AND FAULT MESSAGES Cause Corrective Action F7022 - Electrical Enclosure High Temperature Faul

MAINTENANCE 5-34 31 Dec 13 DE-7200VFDCentrifuge ALARM AND FAULT MESSAGES Cause Corrective Action F9012 - External Communication Loss, Switched to

MAINTENANCE 31 Dec 13 5-35 DE-7200VFDCentrifuge ALARM AND FAULT MESSAGES Cause Corrective Action F9099 - Centrifuge Sensor I/O Cable Has Been Remov

MAINTENANCE 5-36 31 Dec 13 DE-7200VFDCentrifuge FAULT CROSS REFERENCE No. Fault No. Fault No. Fault 2 Auxiliary Input 38 Phase U to Grnd 8

MAINTENANCE 31 Dec 13 5-37 DE-7200VFDCentrifuge Figure 5-14. VFD Indicators