Sulzer 10002-0008, Installation, Operating And Maintenance Instructions

Page 1: ...SULZER CONFIDENTIAL Grinder 10000 Open Channel Series Installation Operating and Maintenance Instructions www sulzer com Rev NC 3 2019A EN ...

Page 2: ... van het technisch bestand SV Namn och adress på den person som är auktoriserad att på begäran utarbeta den tekniska dokumentsamlingen tili myndighe terna NO Navn og adresse pa den personen som har tillatelse tit a sette sammen den tekniske filen til myndighetene ved foresp0rsel Fl Viranomaisten vaatiessa teknisten tietojen lomaketta lomakkeen valtuutetun laatijan nimi ja osoite RU Ф И О и адрес л...

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Page 4: ...4 EG gewijzigd door 2005 88 EG DE Wie definiert in Maschinenrichtlinie 2006 42 EG EMV Richtlinie 2004 108 EG Niederspannungsrichtlinie 2014 35 EU Richtlinie 2000 14 EG uber Gerauschemisssionen geandert durch Richtlinie 2005 88 EG SV Sasom definierats av Maskindirektiv 2006 42 EG EMC direktiv 2004 108 EG Direktiv om lagspanning 2014 35 EU Utomhusbullerdirektivet 2000 14 EC andrat av 2005 88 EC FR C...

Page 5: ...ction Safety Recommendations 7 System Design Installation 7 STORAGE 7 WARNING CONTROL DEVICE 8 NOISE LEVELS 9 EXPLOSIVE PRODUCTS HAZARDOUS ATMOSPHERES 9 LUBRICATION 9 START UP PROCEDURE 10 DISMANTLING ADVICE 11 CLEANING INSPECTION 11 RE ASSEMBLY ADVICE 12 EXTENDED SHUTDOWN 12 MAINTENANCE 13 Allowable Wear Tolerances 14 TROUBLESHOOTING 14 Figures 1 Grinder 5 2 Grinder Installation 9 3 Rotation 10 4...

Page 6: ...rsons and must be in accordance with relevant electrical regulations 5 If there is a risk of an accumulation of explosive gases or dust proper ventilation must be performed removing all gases and dust 6 When fitting drives couplings and guards to a grinder unit it is essential that these are correctly fitted aligned and adjusted in accordance with the installation instructions Failure to do so may...

Page 7: ...2 Installation and Operating Instructions Grinder 10000 Open Channel Series SULZER CONFIDENTIAL Nameplate Details ...

Page 8: ...ous machine It is vital that operators are conversant with these Operation and Maintenance Instructions prior to working with the machine When servicing the grinder be certain that the main isolator is off and padlocked Serious injury could result from accidental start up Keep clear of rotating components NEVER inspect or work on or near the cutter chamber without first isolating and locking the g...

Page 9: ...ature exceed specified limits or a jam of the cutter stack occurs This includes a system that reverses the machine in order to clear any such jam An isolator switch will disconnect all electrical supply to the motor and ancillary electrical equipment and is capable of being locked in the OFF position All control and safety devices must be fitted operated and maintained in accordance with the manuf...

Page 10: ... 2kW 22 32 46 84 Limitation of Use Limits of the Machine Description Twin shafted grinder with cutters and spacers enclosed in a cast iron housing meeting various standards speed reducer electric motor and motor controller Intended Use Particle size reduction of municipal industrial sewage waste Maximum Flow Rate 41 4 m3 hr Maximum Process Pressure 6 bar as limited by shaft seals Personnel Informa...

Page 11: ... x 406mm W x 254mm for IP66 enclosure Clearance Required for Operation 150mm over motor fan cover 914mm in front of controller Clearance Required for Maintenance 610mm above 914mm on left or right side of grinder 914mm in front of controller Interface Limits Electrical 120V 1PH 60HZ to 575V 3PH 60HZ 220V 1PH 50HZ to 400V 3PH 50HZ Water N A Hydraulic N A Connection to Other Equipment Two 2 dry cont...

Page 12: ... or its components weigh in excess of 20 kg 45 lb it is recommended that suitable lifting tackle should be used to ensure that personal injury or damage to components does not occur Do not attempt to lift the grinder using only one lifting point Extreme caution should be observed for personnel safety when lifting heavy objects By design the cutters have sharp edges Great care must be taken when ha...

Page 13: ...rds and removable Maintain in place covers must be in place and securely fitted while the machine is running All nuts and bolts securing flanges and base mounting fixtures must be checked for tightness before operation If when starting the grinder does not appear to operate correctly it must be shut down immediately and the cause of the malfunction established before operations are recommenced May...

Page 14: ...rily include noise from other sources or any contribution from building reverberation EXPLOSIVE PRODUCTS HAZARDOUS ATMOSPHERES In certain instances the product being pumped may well be of a hazardous nature In these installations consideration must be given to provide suitable protection and appropriate warnings to safeguard personnel and plant LUBRICATION At 10 000 hr intervals bearings gears and...

Page 15: ... is made to operate 4 On start up check the direction of rotation of the cutters The cutters should rotate towards the centre when viewed from the inlet side 5 Check that the grinder stops when the stop operation is activated 6 Start up the machine and gradually start the feed system to the machine Care should be taken not to overburden the machine Adjust feed to maintain only the smallest practic...

Page 16: ...NG ADVICE When servicing the grinder be certain that the main isolator is tagged out locked out Serious injury could result from accidental start up 1 Disconnect wiring at motor s terminal box es and tag leads for identification 2 Isolate the grinder from influent 3 If necessary the grinder may be completely removed from installation using the recommended lifting equipment 4 Replace the cutter sta...

Page 17: ... motor s terminal box es using tag leads for identification 4 Re open system isolation valves 5 On completion of assembly run through the initial start up procedure EXTENDED SHUTDOWN CAUTION electrical cutting lifting risk is possible Attach lifting equipment and remove the grinder Ensure the machine is adequately supported prior to steam cleaning excluding the drive assembly Coat interior and cut...

Page 18: ...ive assembly then remove top and bottom covers If top or bottom seals housings are contaminated with effluent replace seals Prior to refitting top and bottoms covers fit new gaskets Every 5 years See Figure 4 Remove drive assembly top cover and old grease Inspect gears for damage or wear replace if necessary then replenish grease See Table 1 Lubricants Table 1 Lubricants Manufacturer Lubricant Gea...

Page 19: ...er See Figure 5 TROUBLESHOOTING Symptom Check Solids not reduced Cutter rotation Cutters for wear Cutter stack tightness Grinder motor drive train Loose cutter stack The unit must be stripped down Seal cartridges for damage Cutters for wear Lock nuts loose Excessive noise vibration or reversals Drive gears for wear Seal cartridges for contamination Motor overload Solids overloading Cutters for wea...