8.8 10.9
3.4 Assembly
The three assemblies of the particle classifier may be pre-assembled on the ground or assembled directly at the operation site.
In general, the machine shall be delivered in three parts, which must be assembled before their final positioning.
The first step is to place the body containing the fines output on a base that is stable and capable of resisting the weight of the machine.
Assembly
Add and spread silicon or polyurethane on the flange to seal the inside of the machine from the outside. For example Loctite 5910.
Orient and place the casing containing the rotor and the bearing support.
The orientation depends on the customer's needs and it has different positions.
NOTE
– The transporting of each machine element must only be done by personnel authorised to handle the corresponding transport devices.
– The particles classifier must be installed on a horizontal, level surface that is resistant enough to bear the total weight of the equipment.
Add and spread silicon or polyurethane on the flange that joins the seal with the closure of the fines output.
Fig. 10 Assembly 1: Fitting the motor casing
Once the two parts are in the correct position, use the following components to fix the two parts:
o Hexagonal bolt M16x50 DIN 933 (16 units) o Spring washer 16 DIN 127 (32 units) o Hexagon nut (24 units)
To do the following step, you must open the door and place the following elements through the lower part of the sealing flange:
o Hexagonal bolt M16x30 DIN 933 (8 units) o Spring washer 16 DIN 127 (8 units)
1 Area to apply silicon 2 Hexagonal bolt M16x50 DIN 933
3 Spring washer 12 DIN 127 4 Hexagon nut 5 Sealing flange
Assembly 2
Fig. 11 Assembly 2: Fitting the motor casing
Then place the casing containing the coarse material output and, as with the others, add silicon and the corresponding fasteners:
o Hexagonal bolt M16x45 DIN 933 (28 units) o Spring washer 16 DIN 127 (56 units) o Hexagon nut (28 units)
Once assembled, place the temperature probes if they are not installed and those of vibrations if they have been supplied (optional).
1 Area to apply silicon 2 Hexagonal bolt M16x45 DIN 933
3 Spring washer 16 DIN 127 4 Hexagon nut
3.5 Work after assembly
Once all the parts are joined and correctly tightened, you must check the tolerance between the moving and fixed parts. To do this, you must open the door and verify that the space between the rotor and the seal is 0.5 - 1.2 mm.
Fig. 12 Labyrinth seal
1 Checking the seal
4. Start-up
4.1 Commissioning
Before commissioning the classifier for the first time you have to check the following:
• Check the condition of the rotor (the rotor turns without problems, the fins are OK).
• Check the distance between the rotor and the labyrinth seal (the space between the rotor and labyrinth seal must be between 0.5 and 1.2 mm).
• Check the belts.
• Check the lubrication.
4.2 Ignition period
ECUTEC recommends starting the machine by increasing the revolutions in 2 or 3 steps up to the maximum number of revolutions. This operation should take approximately 6 hours.
During commissioning or after changing the bearings, you must check the following points:
– Check the power.
– Check that it turns gently.
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WARNING
Internal and/or external damage. Machine breakage.
– The commissioning of the machine should be carried out by ECUTEC personnel. If the client decides to dispense with ECUTEC staff, the company can decide to cancel the warranty and all personal harm or material damage shall be the client's responsibility.
NOTE
During the commissioning of the machine, the 2 lubrication points in the bearings must be greased with approximately 15 g of grease (ISOFLEX NBU 15 from KLÜBER).
– Verify the rotation direction.
Fig. 13 Rotation direction
– Verify the vibrations and that the temperatures do not exceed the standard values (max. 95ºC)
It is advisable to grease the machine after the first 30 hours of operation.
5. Operation
5.1 Commissioning a plant
Fig. 14 Commissioning a plant
To commission a plant the following order must be respected:
1. Turn on the classifier cooling fan and motor.
2. Turn on the valves for coarse and fine output to empty the respective silos.
3. Turn on the suction fan.
4. Open the butterfly valve to create a circulation of air between the classifier and the filter.
5. Turn on the rotary valve for feed.
6. Adjust the input butterfly valve to regulate the air flow.
1
2
3
4
6
7
8
9
1 Flow regulation valve 2 Feed silo
3 Rotary valve for feed 4 Particle classifier 5 Rotary valve for coarse material output 6 Filter
7 Rotary valve for fines output 8 Butterfly valve 9 Suction fan
5.2 Settings during operation
The general rules to be able to configure the machine are the following:
– At higher speeds, the cut point is closer and, as such, you will obtain a finer product but with less quantity.
– With a greater air flow, the cut point is less close and, as such, you will obtain a coarser product and production will increase.
– With a greater feed, the cut point is less close and, as such, you will obtain a coarser product and production will increase.
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DANGER
Machine in movement. Serious injury or death.
– Keep limbs away from rotating elements such as fans or shafts.
– The maximum speed indicated in the table of characteristics is the maximum working speed. This speed should not be exceeded under any circumstances due to the high risk of material damage or personal injury, including risk of death.
– If the client exceeds this working speed, ECUTEC may decide to terminate the warranty of the machine and all personal harm or material damage shall be the client's responsibility.
– Before starting up the machine, verify that the frequency adjuster has been limited so the machine cannot exceed the maximum rotation speed.
6. Maintenance
6.1 Standard maintenance
The following inspections and maintenance work must be performed regularly.
Lubrication
It is advisable to install a central greasing unit, for example Vogel type.
ECUTEC tests the machines with Isoflex NBU 15 grease from Klueber so we recommend you use this grease. Alternatively, some equivalents are listed at the end of section 6.7.
Using unsuitable greases or applying grease excessively can cause high temperatures, which may lead to the shaft dilating excessively and therefore increasing the probability of breakage.
You must consider the ambient conditions to be able to increase or decrease the periods between lubrications. An increase in temperature at constant operating conditions may indicate insufficient grease.
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DANGER
Electrocution and/or cuts on limbs. Serious injury or death.
– Maintenance tasks may only be carried out on machines which have been disconnected from the mains or with the power supply
sectioned off.
– Do not proceed to make any adjustments or cable connections with the power supply switched on.
– Use lockout devices and the corresponding warnings signs in order to prevent the machine from being started up accidentally.
– If there is more than one power source, ensure that they are all switched off.
– Make sure fans and moving parts have come to a full stop before starting maintenance procedures.
– Regular reviews must be carried out on the status of the earth to ensure its integrity. Repair if not in optimum condition.
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CAUTION
Blows and cuts on limbs. Minor injuries.
– If there are sharp, burred or panelled pieces, use protective gloves.
– If there are blocked elements, use the proper tools and lubricants to release these.
NOTE
– During the commissioning period, it is mandatory to use Isoflex NBU 15 grease. If you wish to use another grease, ECUTEC personnel must confirm its use.
– The warranty may be cancelled in the event of not complying with this requirement.
Bearings and seals
The bearings must be changed regularly. The service life of the bearings may be longer or shorter, depending on the operating conditions (product, humidity, temperature).
The history of measurements from the monitoring system (see section 2.3) must be used as an indicator of the condition of the bearings.
Bearings breaking very frequently may indicate bad greasing, insufficient balancing or defects in some parts.
Whenever you replace bearings, you must change them for the types that ECUTEC indicates and, if possible, from one of the following manufacturers:
SKF, NSK or FAG.
Belts
Do not over-tension the belts as this may cause excessive tensions in the shafts of the machines. Excessive temperatures in the bearings may indicate excessive tension.
Labyrinth seal
The labyrinth seal is the element that allows you to keep the area of material to classify separate from the area of fine material. Therefore, an increase in particles in the fine product may indicate this part is excessively worn. In addition, this seal must be kept perfectly clean so it can do its job.
The replacement period of this element must be adapted to the characteristics of material to classify.
It is very important to check the distance between the labyrinth seal and the rotor. This must be between 0.5 mm and 1.2 mm.
Bolted joints
The bolted joints must be checked every 10,000 h.
Electric motor
See the manual from the supplier.
NOTEIf coarse particles are found in the labyrinth joint, contact the manufacturer.6.2 Special maintenance (for ceramic particle classifiers only)
Labyrinth seal
In these classifiers, the design of the seal has been modified to lengthen its lifetime. The distance between the rotor must be observed, as with the standard classifiers at between 0.5 and 1.2 mm.
In this case you must check it by placing a material that can be distorted between the rotor and seal. To do so, follow these steps:
– Lift the rotor.
– Place a material that can be deformed (chewing gum, plasticine, etc.).
– Lower the rotor and bolt it.
– Unscrew and lift the rotor.
– Finally remove the distorted object and measure its thickness after being distorted.
Condition of the ceramic
At intervals of a certain number of hours, check the condition of the ceramic.
If some of the parts that cover the casing have come off, they must replaced with new parts, always using Epoxy adhesives.
The verification must centre, above all, on the points where the most wear occurs, such as union elbows, points where the material hits directly, etc.
We recommend the disassembly of the different bodies for this verification.
6.3 Removing the rotor
Step 1 Start the process of dismantling the rotor by removing the belt protector. Once this has been removed, you must loosen the belts and remove them.
Fig. 15 Loosening the belts
Step 2 The remove the tightening bolts of the pulley and move it towards the lower part of the machine using a rubber mallet.
Step 3 Once the pulleys are out, remove the M12x25 bolts and use the elevation screws to lift the rotor.
Step 4 You can use the holes made in the ribs of the bearing support to lift the rotor.
1 Tensing system 2 Belt protector
Fig. 16 Extracting the pulleys
To perform the maintenance of the bearings, follow these steps:
Step 1 Remove the screw and washer from the block (pos. 12, pos. 13).
Step 2 Remove the inner hexagonal bolts and lock washers (pos.14 and 15)
Step 3 Remove the cover that protects the bearings (pos. 38.01.10) and the radial seal (pos. 17).
Step 4 Remove the inner hexagonal bolts and washers from the block (pos. 21 and 20)
Step 5 Remove the bearings casing (pos. 38.01.01) using a large extractor.
Along with the casing, also remove the upper bearing (pos. 16).
Step 6 Remove the spacer between bearings (pos. 38.01.09) and the lower bearing (pos. 16) using a bearing extractor.
1 Tightening bolts 2 Elevation screws 3 M12x25 bolts
Step 7 Finally remove the radial seal (pos. 24) and lower protective cover (pos. 38.01.04).
Fig. 17 Extracting the bearings
Table of classifier maintenance for non-abrasive materials:
Table of classifier maintenance for abrasive materials: