FERREX Eco Dryer, Maintenance Manual

Page 1: ...MAINTENANCE MANUAL FOR 4 5x45 Eco Dryer Draft Prepared by FERREX ENGINEERING LTD REF 2278 230 Westney Rd Ajax Ontario Canada L1S 7J5 Jun 2016 ...

Page 2: ...OTARY DRYER FERREX ENGINEERING LTD Page 2 Ref 2278 CONTENTS 1 Safety LOTO Procedures page 3 2 Equipment Description page 4 3 Assembly Set Up page 5 4 Operation page 13 5 Maintenance page 14 6 Spare Parts page 19 7 Drawings page 20 ...

Page 3: ... not already done so by depressing the fan stop Push Button 3 On the HMITurn off the drum rotation if not already done so by depressing the drum stop Push Button 4 Primary and Secondary cabinet main power disconnect to the powered off position Place locks and tags on the disconnect handle bracket 5 Check that power is turned off by testing the fan and the drum rotate by depressing the drum start a...

Page 4: ...ing the dryer and will adjust the amount of heat as required to maintain the desired discharge material moisture levels Primary heater consists of 700KW heater unit with a 3 000 to 6 000 cfm fan that injects hot clean air between temperatures of 200 f upto 700 f into the electric dryer Secondary heater consists of 150 kw heater unit with a 600 cfm fan that injects hot clean air between 200 f upto ...

Page 5: ...ube heaters are to be insulated The insulation and the insulation metal coverings including the duct elbows will be supplied and installed during installation The pipe insulation comes in split preformed sections for easy installation including the tape to seal the insulation joint The rolled metal insulation cover is to be cut and strapped to the outside of the insulation Suitable caulking to sea...

Page 6: ...uld be bolted the drum inlet hood and the tube heater discharge as shown The flange connection to the primary tube heater would only be tack welded to allow for a small amount of field adjustment as required It may be required to shim move the tube heater and support frame if a large amount of adjustment is required The tube discharge pipe has an expansion joint located just after the connection t...

Page 7: ...he insulated baghouse inlet pipe At the top of the drum discharge hood the discharge damper is to be bolted to the top of the drum discharge as shown Bolt the insulated discharge pipe to the secondary tube heater Use the garlock seals supplied for the 150 raised face flange connections to the tube heater Use U bolts to secure the insulated baghouse inlet duct to the support brackets Use the small ...

Page 8: ...g and the shell This will cause the seal to wander on the shell and possibly invert back into the hood Use a sharp knife and cut slits in from the outside edge of the seal making sure to only cut deep enough to fit over the bolt holes This will relax the seal on the mounting ring as well as relieve the pucker on the shell surface 6 Work your way down the sides fairly evenly cutting bolt hole slits...

Page 9: ...ng it down tight to the shell does NOT enhance the sealing properties of the FabriSeal All this will do is cause the seal to wear much faster Overlap seal as shown to avoid binding This should be done at 6 O clock to aid in cleaning out possible feed dump Proper Configuration Improper Configuration Seal contact area ...

Page 10: ...lector assembly may be picked up by the lifting lugs Lift the dust collector into place and set it on the structural support and the hopper Bolt the bottom flange of the dust collector to the hopper and the support channels Position holes with drift pins as required 3 Install all walkways and ladders per the general arrangement drawing If possible install the walkways and ladders to the dust colle...

Page 11: ... must be connected to the VFD labled Fan Motor Please refer to the rotation arrows on the fan and motor for proper rotation 6 Field install the Stack Light system close to the dryer This will allow the system to warn the users that the unit is starting up or has a fault 7 Install the level sensor on the bracket Ferrex Engineering will calibrate the level sensor at startup 8 Install the supplied Th...

Page 12: ...70 300 E 002 to run the main 400 Amp 480V 3phase 60Hz power supply to the panel 3 Wire the two 75kw heaters to the main panel as shown on drawing 2270 300 E 002 4 Wire the clean side fan rotary valve for the baghouse and secondary heater fan as per drawing 2270 300 E 002 5 Wire baghouse cleaning valves and baghouse enclosure heater 120V circuits as per drawing 2270 300 E 310 and 2270 300 E 341 ...

Page 13: ...o change up or down 1 The infeed tube vibrator is controlled using a VFD 2 The drum speed is controlled using a VFD 3 The primary heater increase or decrease the temperature to change material moisture level The primary air fan is controlled using a VFD to control the amount of air passing through the heater and drum DO NOT CHANGE THE AIR FLOW VFD 4 The fan needs to be running prior to turning on ...

Page 14: ...l is torn or ripped If so call Ferrex Service to order a new one 7 Gearbox Motor Check temperature of motor Slowly place gloved hand on the motor and if running too hot please call Ferrex Service 8 hours after start up 8 Primary Fan Motor Check the temperature of motor Slowly place a gloved hand on the motor and if running too hot then call Ferrex Service 8 hours after start up 9 Second Fan Motor ...

Page 15: ... empty Monthly 1 Electric cabinet check all fuses if any are blown light indictator If so call Ferrex Service for assistance 2 Idler Rolls Check alignment and roll wear Drum should be running flat against idler roll If roll has excessive wear grooves order new idlers from Ferrex Service Brush lubricate idler rolls to prevent corrosion 3 Thrust Roll Check alignment and roll wear Drum should be runn...

Page 16: ... leaks If there is any fix the leaks next down day 15 Baghouse Blow out dP gauge lines 16 Baghouse Fan Check for noise and vibrartion if too noisy and vibration check bearings and if need to be replaced order a fan spare kit and install at a later date 17 Bagouse Fan Check for Belt wear If loose adjust if starting to wear out call Ferrex Service for new belts when received Quarterly 1 Bearings gre...

Page 17: ...Secondary Heater Check all terminals for damage and to ensure that all terminals are tight and secure Care should be taken not to overtighten terminals 15 Secondary Heater Check enclosure gasket and replace if damaged 16 Secondary Heater Not the position of the over temp thermocouple This is marked on the heater flange Remove bolts from heater and pull heater bundle Care must be taken in removing ...

Page 18: ...sing it is clean and dry 3 Primary Heater Re install heater bundle using new gasket and taking care not to damage the elements Note position of over temp thermocouple Heater bundle MUST be re installed in the same orientation as when it was removed 4 Secondary Heater Open the terminal housing Mark and disconnect all incoming wiring Disconnect conduit Check the housing it is clean and dry 5 Seconda...

Page 19: ...5 Hp Drive Motor 1 Dynamic Dry VFD primary Fan 1 Dynamic Dry VFD baghouse fan 1 Dynamic Dry VFD secondary fan 1 Dynamic Dry HMI configured with program loaded on it 1 Dynamic Dry Infeed level sensor 1 Dynamic Dry Short thermocouple 1 Dynamic Dry Long thermocouple 1 Dynamic Dry 6 channel 19 Thermocouple input module 1 As Needed Equipment Part ID Delivery Time Drive system 10 feet of chain 2 to 3 da...

Page 20: ...ER PANEL 0 2270 300 E 002 SINGLE LINE DIAGRAM SECONDARY HEATER PANEL 0 2270 300 E 200 PLC MODULE LAYOUT 0 2270 300 E 210 DIGITAL DC INPUTS SLOT 1 0 2270 300 E 211 DIGITAL DC RELAY OUTPUTS SLOT 4 0 2270 300 E 212 ANALOG INPUTS SLOT 5 0 2270 300 E 213 ANALOG OUTPUTS SLOT 6 0 2270 300 E 214 ANALOG THERMOCOUPLE INPUTS SLOT 2 0 2270 300 E 215 ANALOG THERMOCOUPLE INPUTS SLOT 3 0 2270 300 E 216 DIGITAL A...