Alfa Laval Manual Sep. Aldec 45
Alfa Laval Manual Sep. Aldec 45
Alfa Laval Manual Sep. Aldec 45
Decanter Centrifuge
FRONT
OM English EN
OPERATOR’S
MANUAL
OPERATION
SERVICE
MAINTENANCE
Original instruction
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Decanter Centrifuge Data Sheet
Decanter Specification, Type ALDEC 45
Specification: 882036001-1
Process liquid: Min. 0°C (32°F) - max. 60°C (140°F)
Max. density of compact wet cake at max. bowl speed: 1.2 kg/dm³
Bowl
Maximum main speed: 4200 rpm
Bowl length: 1512 mm
Bowl diameter: 360 mm
Beach angle: 10°
Solids discharge type: 360°-type with 6 wear liners
Solids transportation aids, cylindrical section: Ribs
Solids transportation aids, taper section: Ribs
Material - hubs: AL 111 2377 (Duplex stainless steel)
Material - bowl shell: AL 111 2349 (AISI 316)
Material - bolts: A4-80 (AISI 316)
Material - seals:
Liquid outlet, type: 6
Liquid outlet, radius: 99 mm (fitted from factory: 102 mm)
Conveyor
Material - flights: AL 111 2349 (AISI 316)
Material - hub: AL 111 2327 (Lean duplex stainless steel)
Wear Protection
Bowl solids discharge: Wear liner in tungsten carbide, 6 pieces Part No.
61242068-02
Bowl feed zone liner:
Conveyor flights: TM42 (flame sprayed tungsten carbide)
Conveyor feed zone: Tungsten Carbide wear liners
Frame / casing: Wear liner in upper casing
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Drives
Power supply: 3 x 415 V / 50 Hz
Gearbox, type: Planetary - 2-stage
Gearbox, max. torque: 2.5 kNm
Gearbox, ratio: 1:159
Back drive: Variable Frequency Drive 5.5 kW IEC (400V, 50Hz) - min.
diff. speed 1 rpm and max. diff. speed 23 rpm (Back drive
motor, 400VD, 3000rpm, 50Hz, IEC 132, part no.
61195701-58)
Back drive parts:
Operating main speed: 4200 rpm (IEC)
Max. diff. speed and torque 23 rpm / 2.5 kNm
(at operating speed):
G-force at operating speed: 3549 G
Main motor: 30 kW ABB 400VD Y/D-VFD (200) foot – part No.
61195707-52
Main motor, protection:
Spare Parts
Important: When ordering spare parts, always state:
Machine number and type indicated above
Part number and designation
Quantity
The decanter centrifuge complies with the essential health and safety requirements of council
directives
To meet the requirements, the harmonised standard EN 12547 has been used.
The technical file for decanter centrifuge is compiled and retained by Product Centre Decanters,
Alfa Laval Copenhagen A/S, Maskinvej 5, DK-2860 Søborg, Denmark. Authorised person:
Jan Cederkvist, Mechanical Technology.
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DATASHEET
Noise Declaration
Noise emission data for the decanter declared in accordance with the re-
quirements in EN ISO 4871 and EN12547:
LpAd : Declared A-weighted emission sound pressure level in a free field over a re-
flecting plane at 1 m distance from the decanter
LpAd : KpA=4 dB
The noise does not contain significant impulsive or tonal components and the peak C-
weighted instantaneous sound pressure level LpCpeak is below 130 dB(C) at all operat-
ing speeds.
The emission sound power level is measured according to ISO 9614-2 while operating
the decanter with water as process medium. The sound pressure level is determined
from the measured sound power level according to EN ISO 11203.
The sound pressure level can vary –1dB to 2 dB at different positions around the decanter.
The declared values are based on measurements conducted on typical new decanters.
Note that the sound pressure levels are based on free-field conditions and not guaran-
teed values. In a normal indoor installation the sound pressure level will be significant-
ly higher than the declared free-field sound pressure level due to the reflection of
sound from walls and surroundings.
In order to minimise the sound pressure level at the decanter it is recommended to in-
stall the decanter in a room with low reflection of sound from the walls and always
keep the decanter in a properly maintained condition.
enNOI3640.fm
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Chapter Contents Page
0.0 1 Safety Instructions .............................................................. 1.0-1
EN360009.TOC+
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Chapter Contents Page
3 Operation and Routine Maintenance .................... 3.1-1
0.0-2
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Chapter Contents Page
4 Disassembling and Assembling ................................... 4.0-1
EN360009.TOC+
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1 Safety Instructions
1.01 Safety Instructions
The Decanter
1.0
contd...
SAFETYIN.EN0
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10. Do not attempt dismantling until the decanter has come
to a complete stop, the main power is shut off, and the dis-
connected main switch is locked with a safety lock.
20. Do not operate the decanter with any electrical motor run-
ning in the opposite direction to that indicated by the ar-
rows on the frame or otherwise specified.
contd...
1.0-2
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21. If the decanter is fitted with a frequency inverter, make
sure that the maximum possible frequency will not cause
overspeeding of the decanter. At least two separate pro-
tections against overspeed must be provided. See section
6.9.
22. Do not turn on feed or water before the decanter has at-
tained its full speed.
25. Never start the feed pump or flush the decanter before
opening the discharge valves or starting the discharge
pumps, including any conveying means for the liquid and
solids phases.
27. Do not touch the solids phase discharging from the de-
canter as hard lumps being ejected with high speed might
cause injury.
29. When lifting the decanter, use the slings specified on the
dimensioned drawing.
30. The lifting eyes in the bearing housings, if fitted, must not
be used for lifting the bowl assembly.
contd...
SAFETYIN.EN0
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Electrical Installation
Repairs
contd...
1.0-4
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3. Do not exceed the maximum load carrying capacity of the
lifting tools. Only use the lifting tools for the intended
purpose.
The Motor
contd...
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Corrosion, Erosion and Pitting of Decanter
Equipment It should be recognized that equipment sub-
jected to severe erosive or corrosive environments may deteri-
orate over a period of time, depending upon the severity of ex-
posure and/or possible misuse. Users of high speed centrifu-
gal equipment should be aware of this fact and also that ex-
tremely high forces are brought into play when their equip-
ment is in operation. Any weakening of highly stressed mem-
bers by misuse, erosion, corrosion, chemical pitting, or stress
cracking must be guarded against.
The following points should be noted and the recom-
mended action taken:
1.0-6
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2 - Decanter Operating Principle
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Figure 2.0.1
ATTENTION The liquid and the solids are discharged at roughly the same radius,
and consequently, during start-up, flushing, and irregularities in
process, discharge of liquid through the solids discharge ports may
occur owing to lack of solids in the bowl. This should be taken into
consideration when the decanter is installed.
2.0-2
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2.1 Main Drive
The decanter is driven by an electric motor. The motor shaft
carries a drive pulley, and motive power is transmitted
through V-belts to the bowl pulley to drive the bowl.
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2.2 Back Drive
The purpose of the back drive system is to make it possible to
control the speed of the sunwheel shaft of the gearbox and
consequently to control the differential speed between bowl
and conveyor.
The motor speed signal is sent from the controller to the VFD.
The VFD then controls the speed of the motor. The controller
calculates the differential speed, based on the measured motor
speed. To determine the differential speed, the controller
needs information about the gearbox ratio.
If the motor has to brake to obtain the set speed, then the brak-
ing power could either be dissipated as heat in a resistor bank,
or in case of a full four quadrant inverter be fed back on the
grid. If a VFD is also used for the main drive, then the power
could be fed back via a DC link between the main and back
drive inverters.
contd...
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The bowl speed is measured by an inductive speed sensor lo-
cated on the decanter, and the sunwheel or motor speed and
direction of rotation is either determined by using two sepa-
rate inductive speed sensors, or if an encoder is used, from one
of the channels of the motor encoder.
Firstly, it must be ensured when setting up the speed range for the
variable speed motor that the conveyor can never rotate as fast as or
greater than the bowl speed. This could result in a plugged or clogged
decanter and could even mean a risk of overspeeding the bowl. The
bowl speed is determined by the type of decanter and the process.
Secondly, it must also be ensured that the maximum load does not
exceed the gearbox rating. This will result in damage to the gearbox
and pinion shaft. The maximum gearbox load depends on the size
and type of gearbox fitted.
contd...
2.2-2
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3 Operation and Routine Maintenance
ATTENTION Because the main bearings are filled with grease from the factory, the
running-in procedure described in section 3.8 must be followed in
order to avoid temperature problems.
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3.1.1 Noise and Vibrations
The period of time between the moments when this happens depends
on the difference in the speeds of bowl and conveyor. The higher the
differential speed the shorter the intervals, and vice versa.
3.1-2
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3.2 Start/Stop procedures
A bowl which has not been cleaned, but left clogged by solids
after operation must be cleaned before the decanter is restart-
ed, because dried solids may cause severe unbalance and
eventual generation of an overload condition. See section
3.3.1.
3.2.2.1 Checkpoints
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3.2.3 Start Decanter
Wait 2-4 minutes for the decanter to attain full speed with star
connected circuit before switching to delta connected circuit.
ATTENTION When stopping a decanter with mechanical seals make sure that the
supply of gas continues until the decanter has stopped.
Stop feed and polymer pumps (if used), close feed valve (if fit-
ted).
ATTENTION When flushing decanters for fat and oil applications, optimal flushing
effect is achieved by using flushing liquids holding temperatures above
the melting points of the fats and oils run through the decanter.
Using e.g. cold water might cause solidified lumps of fat/oils to re-
main in the decanter, which in their turn would give unbalance during
decanter rundown and during its successive run-up.
Stop the decanter motor when the bowl is thoroughly flushed.
Do not flush the decanter when it is inactive.
3.2-2
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3.3 Monitoring Operation
Make particularly sure that there is no increase in vibration.
ATTENTION The alarm level for main bearing temperature is 110°C (230°F). At
this temperature level the bearing must be monitored. Especially if
the increase of temperature is very steep or appears without any ob-
vious reason such as after lubrication of the bearing or increased feed
or ambient temperature.
The shut down level is 120° C (248°F). At this temperature the de-
canter must shut down immediately. If after a restart the tempera-
ture again increases to 120°C (248°F), the bearing must be replaced.
After lubrication the temperature may remain high for some hours.
3.3.1 Overload
If the conveyor torque exceeds a higher limit, the main motor will
be also be switched off.
Then it is advisable to have the feed replaced by water until the
bowl speed has reached 300 r p m.
When the bowl has stopped rotating, reset the control system to
operative condition.
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3.3.1.1 Causes of Overload
If the decanter has stopped due to too high torque on the conveyor,
and the decanter is unable to scroll itself free during a new start, or
when running CIP with an AC back drive, the causes of overload
may be as described above, and the only way to clean the bowl will
be to disassemble the bowl according to instructions given in sec-
tion 4.4.1.
3.3-2
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3.3.2 Vibrations
If excessive vibrations occur while the bowl rotates, stop the main
motor immediately and supply liquid to soften the vibrations.
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Robertshaw Vibration Switch (Fig. 3.3.1)
Resetting
This vibration switch is reset manually by pressing the reset button,
see figure 3.3.1 below
Adjusting
To adjust this vibration switch to trip at the correct vibration level,
proceed as follows:
When the decanter is not operating, turn the adjusting screw clock-
wise until the vibraswitch trips.
Then reset it and find the tripping point again. Repeat this pro-
cedure a couple of times to ensure that the correct tripping point has
been found.
Then turn the adjusting screw counterclockwise one time and a
third.
Reset Button
Adjusting Screw
Figure 3.3.1 Resetting the Robertshaw Vibration Switch
ATTENTION Re-adjustment may be required if the vibraswitch shuts off the power
supply because the building where the decanter equipped with vi-
braswitch is operating begins to vibrate heavily.
3.3-4
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3.4 Routine Cleaning Procedure
Before starting a cleaning process, please note that the below
procedure is not product specific and therefore is only intend-
ed as a guide.
Before the decanter is stopped, close the valve to the feed and
raise the differential speed, if possible, in order to transport
the last solids remains out of the bowl. Always make sure to
take precautions against outflow of fluids to other machines
which provide further treatment of the solids after the separa-
tion process, such as for instance sludge drier or the like. This
can be done by redirecting the decanter's slide gates or by-pass
system.
Instructions:
ATTENTION On decanters with paring disc the flow must not exceed the capacity
of the paring disc.
2. Switch off the main motor, but continue to flush. Shut off
the water before the bowl speed decelerates below 300
rpm.
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5. If item 3 and item 4 are not satisfactory, the decanter must
be accelerated to operating speed again, and the proce-
dure is repeated from item 1. If it is not possible to prop-
erly clean the bowl according to the above procedure, the
bowl must be disassembled and then cleaned.
Note!
The optimum flushing time of the decanter very much de-
pends on the operating conditions.
• If the vibrations are not too high at any time, the flushing
is of appropriate length.
3.4-2
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3.5 Performance Optimization
The decanter can be adjusted to suit individual requirements
by varying the following control parameters:
Bowl Speed
Liquid Level
Adjust the liquid level (pond depth) to give the optimal bal-
ance between liquid clarity and solids dryness by selecting dif-
ferent plate dams or power tubes.
In general terms, the centrate becomes more clear and the
cake more wet when diminishing the liquid radius and vice
versa.
Feed rate
contd...
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3.6 Main Drive
ATTENTION Store spare V-belts in a dry and cool place.
Never roll up the V-belts. Sharp bends will damage them.
Before installing new belts, check the pulleys for wear, using,
if necessary, a profile and groove gauge.
When installing new belts, rotate the belt drive a few turns be-
fore measuring the belt tension, repeating this procedure until
the belt tension is correct. For the belt tension values, refer to
section 4.5.
Check the belt tension after 0.5-4 hours of full load opera-
tion and then every 4000 hours, referring to section 4.5 for the
belt tension values, and not forgetting to rotate the belt drive
every time before measuring the belt tension.
All types of V-belts used for the main drive should normally
be exchanged every 16000 hours.
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3.7 Variable Frequency Drive (VFD)
Refer to section 5 ’Supplementary Documentation’ for the spe-
cific descriptions of the electrical motor and the frequency in-
verter and follow the given instructions for service and main-
tenance.
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3.8
Figure 3.8.1
1. Main Bearing, Large End 2. Main Bearing, Smal End
3. Conveyor Bearing, Large End 4. Conveyor Bearing, Small End
5. Discharge opening, Large End 6. Discharge Opening, Small End
3.8-0
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3.8 Lubrication
(Fig. 3.8.1 shows where the lubricating nipples are located)
General
The lubricants for the decanter must always be stored in a cool, dry, in-
door area, and be protected from sunlight. Lubricant properties are very
sensitive to contamination and lubricants must never be stored in open
containers. It is strongly recommended to use lubrication grease supplied
in 400 g (14 ounce) cartridges. If larger containers are used, it is required
to be very careful, avoid any contamination and always keep the contain-
ers completely closed. Lubricant properties will change during storage
and the recommended maximum shelf life from the date of filling of the
lubricant container is 2 years for grease and 10 years for oil.
ATTENTION The lubrication kit supplied with decanter contains two grease guns
labelled with grease type, one for the main bearings and one for the
conveyor bearings. Be very careful not to mix the grease types when
lubricating the bearings or filling the grease guns. Use of wrong
grease in the bearings may result in bearing failure.
The grease gun included in the standard decanter delivery will give
1.5 g (0.05 oz) in each stroke. For part number: see list of tools in
Spare Parts catalogue.
The main bearings shall always be lubricated while the decanter is run-
ning. The optimal lubrication result is obtained if the decanter is lubricat-
ed while running at low speed such as during stopping of the decanter or
towards the end of a low speed CIP cycle. Lubrication at low speed shall
be used whenever possible.
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It is possible to use shorter time intervals, but if a shorter time interval is
used, the quantity of grease shall always be reduced with the same factor
as the time interval.
24-
-------- X grams
300
The grease quantity and the specified lubrication interval must never be
exceeded. Exceeding the specified quantity will cause over-greasing and
risk of high bearing temperatures. Exceeding the time interval will lead to
insufficient lubrication of the bearings.
It is always important to ensure that PT100 sensors are properly fitted and
the tip of the sensor is in good contact with the bearing outer race.
3.8-2
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Temperature peaks
When a bearing is lubricated it is normal that there is a temperature peak
just after lubrication. The temperature peaks are caused by the heat gen-
erated, when grease is pushed away from the rolling elements. The tem-
perature peaks are not critical, unless the bearing temperature exceeds the
temperature limits or does not start to decrease to a normal level after 2-4
hours. If the temperature does not decrease it can be a sign of either bear-
ing contamination or hardened grease inside the bearing. Frequent greas-
ing with smaller quantities will normally lead to smaller temperature
peaks and is therefore recommended, if there are problems with high tem-
perature peaks.
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3.8.2 Lubrication of Conveyor Bearings
(Nipples 3 and 4 in Fig. 3.8.1)
The conveyor bearings shall normally be lubricated for each 1000 hours. Note that
this will coincide with the mandatory visual inspection of bowl, casing and gearbox.
Lubricant quantity, both ends: 30 g (1.06 oz) - 20 strokes with std. grease gun
For decanters operating with feed temperatures above 90°C (200°F), the
lubrication interval shall be shortened to 500 hours.
The decanter can for some applications be equipped with conveyor bear-
ings of the “Solid Oil” type.
The “Solid Oil” bearings are lubricated for life and are, in principle, main-
tenance free, but it is recommended to now and then lubricate these bear-
ings with a smaller amount of grease to protect the bearings against con-
tamination from the outside. Do not use more than 1/4 of the normal
grease quantity in order not to damage the seals.
contd...
3.8-4
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3.8.3 Change of grease type - Compatibility of
greases
If the grease used for a bearing is changed, it must be checked that the
thickener of new grease is compatible with the old grease. If they are
not compatible, the bearings and lubrication channels must be cleaned
and free of old grease before the grease is changed. For main bearings it
is strongly recommended to clean out even if the grease types are listed
as compatible in order to get the optimum result. For conveyor bearings
it is usually enough to purge out the old grease. Lubricating with twice
the amount specified for normal lubrication will ensure this.
Customers using other grease types, please consult Alfa Laval for
advice.
contd...
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Figure 3.8.2
contd...
3.8-6
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3.8.6 Gearbox (Fig. 3.8.2)
Change the oil in the gearbox for each 2000 operating hours.
Lubricant Quantities
Alfa Laval 61203671-10
61203671-16 2.5 kNm : 2.5 Litres (2 3/ 4 quarts)
3.5 kNm DD : 4.0 Litres (4 1/ 4 quarts)
Statoil Mereta 320
In the front face of the gearbox there are two plugs (drain plugs) screwed
into two holes.
Drain the oil from the gearbox into a suitable container as follows:
Rotate the gearbox until the two drain plugs are set in vertical align-
ment.
Remove the upper plug and subsequently the lower plug, and drain
all oil from the gearbox.
After draining, flush the gearbox with clean gearbox oil: Insert one of
the removed drain plugs into the lower hole and pour approx. 1 litre of
gearbox oil through the upper hole, using an oil syringe. Insert the second
plug into the upper hole and rotate the gearbox by hand as fast as possible
and drain it again as described above.
Then refill the gearbox with oil of the quality given in the lubrication
table. To check the oil level, rotate the gearbox until its arrow marked
"UP" points straight up. The oil surface inside the gearbox should then
level with the upper drain hole (see level indication mark in Fig. 3.8.3 be-
low).
Oil level
Figure 3.8.3
contd...
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Decanter Supply including Gearbox Oil Pump
Change the oil in the gearbox at the intervals given in Lubrication Table.
In the front face of the gearbox there are two plugs (drain plugs) screwed
into two holes.
Drain the oil from the gearbox into a suitable container as follows:
Rotate the gearbox until the two drain plugs are set in vertical align-
ment.
First remove the upper plug and then place a hopper in the bottom
plate hole. Rotate the gearbox by 180° and remove the second plug. After
draining, fit the connection for the filling hose into the lower hole and
then connect the filling hose with oil pump to the gearbox. Leave the gear-
box hole with filling hose downwards during refilling of oil.
Refill the gearbox with oil of the quality given in the lubrication table.
To check the oil level, rotate the gearbox until its arrow marked "UP"
points straight up. The oil surface inside the gearbox should then level
with the upper drain hole.
After filling, fit one of the plugs into the upper hole and rotate the
gearbox by 180°. Then remove the filling hose and the connection and fit
the second plug into the hole.
Figure 3.8.4
3.8-8
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3.9 Recommended service intervals
Major service is replacement of all bearings and all seals while intermedi-
ate (or minor) service is replacement of seals only.
It is difficult give a precise answer how often major service and interme-
diate service must be done because the wear and contamination risk is
both application and installation related. Therefore it must be based on ac-
tual application experience. As a rule of thumb it is recommended to carry
out a major service every second year and a minor service in the interme-
diate year. For some applications such as applications with high temper-
atures, frequent CIP, contaminated environment and for decanters with
paring disks, a major service at least once every year is recommended.
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Maintenance Table
Table 3.9.1
contd...
3.9-2
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4 Disassembling and Assembling
WARNING Do not make any disassembly/assembly operations on the decanter
unless the main power is shut off, and the disconnected main switch
is locked with a safety lock.
Replacing parts
Ensure that seals are mounted with the open end pointing the
correct way. See illustrations.
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Special tools
Vibration Dampers
Check regularly and change those crumbled and dampers
whose rubber has swelled or cracked. Do not run the decanter
if any of its dampers is defective.
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Spare Parts Kits
Alfa Laval supplies three types of spare parts kits for the de-
canter:
The major kit for main bearings and conveyor bearings, re-
spectively, contains parts necessary for the complete overhaul
of the decanter. It includes all sealing components and bear-
ings. See volume SPC (Spare Parts Cataloque).
The gearbox kit includes the lip seal for the sun wheel and
the O-ring between the splined nave and the gearbox cover.
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4.1S
Figure 4.1.1
4.1-0
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4.1 Rotating Assembly
Figure 4.1.2
Remove the four screws [2] and the wear liner [3].
Remove the four Hexagon socket fitted bolts [25] from the pil-
low blocks (see Figure 4.1.2).
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Now remove the bowl assembly by means of the lifting tool.
Place the tool on top of the bowl at the centre of gravity
and pull the tow straps around the bowl and place the ends of
the straps in the hook of the crane, as shown in Figure 4.1.3.
ATTENTION Check that the two bars are placed underneath the bowl and the two
straps are placed tightly around the bowl.
Carefully lift the bowl assembly off the lower casing and place
it on the lifting tool.
4.1-2
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Figure 4.1.3
When installing the bowl, clean the pillow block contact sur-
faces and the frame before lowering the bowl into place.
After the bowl has been placed and the pillow blocks aligned,
the four Hexagon socket fitted bolts [25] must be inserted.
Install the wear liner [3] and secure with the four screws [2].
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Figure 4.1.4
4.1-4
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4.1.3 Remove Large End Hub (Fig. 4.1.4)
ATTENTION When removing the large end hub [1], always suspend it with a sling
from a hoist or the like, to avoid excessive load to the needle
bearing [9]. Place a sling around both sides of the pillow block.
Remove 23 of the 24 long screws [3], loosen the last one, and
leave it in place until the end hub [1] is ready to be removed.
The end hub can now be jacked out: Using the three jacking
screws [4], clear it of the bowl.
Be careful not to damage the needle bearing [9].
Remove the loosened long screw [3] left in place and carefully
pull out the end hub [1].
Turn the three jacking screws [4] back to their original posi-
tion. They must not stick out through the large end hub con-
tact surface when the hub is re-installed.
This procedure describes how to install the large end hub with
the gearbox assembled to it. For assembling the gearbox to the
large end hub, see section 4.1.8.
ATTENTION When mounting the large end hub [1], always suspend it with a
sling from a hoist or the like, to avoid excessive load to the needle
bearing [9]. Place a sling around both sides of the pillow block.
Grease the outside of the O-rings [13], [106] and [14].
Place the large end hub [1] on the bowl, being careful not
to damage the needle bearing [9].
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Figure 4.1.5
4.1-6
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4.1.5 Remove Small End Hub (Fig. 4.1.5)
ATTENTION When removing the small end hub [1], always suspend it with a
sling from a hoist or the like, to avoid excessive load to the ball
bearing [3]. Place a sling around both sides of the pillow block.
ATTENTION When mounting the small end hub [1], always suspend it with a
sling from a hoist or the like, to avoid excessive load to the ball
bearing [3]. Place a sling around both sides of the pillow block.
Fill up with grease the ball bearing outer race [3] and distrib-
ute the grease with the fingers.
Place the small end hub [1] on the bowl. To align the holes in
the retaining ring [4] with the holes in the hub [1], use a pin [A]
as indicated in Figure 4.1.6, and secure the ring [4] with the
screws [6]. Replace the pin [A] with a screw [6] when the holes
are aligned. Tighten the screws [6] to a torque of 44 Nm (389
in-lbs). Secure the hub with two of the screws [9], and be care-
ful not to damage the ball bearing [3] during this process.
Fit the remaining six screws [9] and tighten them to a torque of
76 Nm (672 in-lbs).
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Figure 4.1.6
Figure 4.1.7
4.1-8
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out, using the three jacking screws.
Rotate the sunwheel shaft a few turns, to make the splines en-
gage.
2.5 kNm Gearbox Insert the six screws (M16) assembling the gearbox adapter to
3.5 kNm Gearbox
the gearbox and tighten them to a torque of 197 Nm (1743
in-lbs) in the sequence shown in Figure 4.1.8.
Figure 4.1.8
* For P/N, see Spare Parts Catalogue, Section TOOLS AND LUBRICANTS
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4.1.9 Fit New Wear Liners (Fig. 4.1.9).
3.
Figure 4.1.9
Disconnect the wear liner [1] with a small chisel and a ham-
mer. Be careful not to damage the mating surfaces on the
spokes of the hub.
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Mounting of new wear liners:
- The wear liner [1] is placed on the spoke and rotated back
and forth until it feels as if it is floating. Then it is pushed
into place and secured with a rubber band. Be careful that
the gap is completely filled with glue.
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4.2
Figure 4.2.1
4.2-0
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4.2 Main Bearings (Fig. 4.2.1)
Fit the puller block [12] (Figure 4.2.2) on the pinion and use
two of the screws [13] for the gear flange [1] to secure the
block.
Fit the puller tool* on the pillow block, as shown in Figure
4.2.2, and pull off the assembly consisting of pillow block [5],
ball bearing [14], ring [15], V-ring holder [16], and the bearing
cover [6].
Figure 4.2.2
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Disassemble the pillow block: Remove, in the following order,
the four long screws [4], the bearing cover [6], the V-ring hold-
er [16], and the ring [15].
Remove, by hand, the guard ring [17] and the shield [7].
If necessary, remove the eight screws [11] and the splash disc
[8].
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4.2.2 Assemble Main Bearing Large End (Fig. 4.2.1)
Fit the O-Ring [212] on the shield [7] and place the shield on
the pinion. Make sure its 'cut edge' points downwards.
Fit the guard ring [17] on the pinion, its two holes pointing
outwards.
Push the bearing cover [6] on the guard ring [17], its grease
discharge pointing downwards, and then fit the V-Ring hold-
er [16] on the pinion.
Insert the ball bearing [14] into the pillow block [5] and grease
the balls.
Then fit the ring [15] and push carefully the assembly on
the pinion.
ATTENTION The ball bearing must be exchanged after disassembly as it may have
been damaged during removal.
Insert the four long screws [4] attaching the bearing cover [6]
to the pillow block [5], and the four short screws [21] securing
the shield [7].
Tighten all twelve screws.
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Figure 4.2.3
4.2-4
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4.2.3 Disassemble the Main Bearing Small End
(Fig. 4.2.3)
Using two M10 jacking screws, pull off the pulley [28], tight-
ening the jacking screws equally, to avoid pulling the pulley
[28] askew.
Remove the four short screws [21] and the four long screws
[4].
The roller bearing inner race [22] can be removed from the pin-
ion by means of a standard two-armed puller* as shown in
Figure 4.2.4. Two milled recesses in the V-ring holder [16] al-
low space for the puller claws.
Figure 4.2.4
Remove, by hand and in the order mentioned, the remaining
part: V-ring holder [16], bearing cover [6], guard ring [17] and
shield [20].
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4.2.4 Assemble Main Bearing Small End (Fig. 4.2.3)
Fit the O-Ring [211] on the shield [20] and place it on the pin-
ion.
Fit the guard ring [17] on the pinion, its two holes pointing
outwards.
Push the bearing cover [6] on the guard ring [17], grease
discharge pointing downwards, and then fit the V-ring holder
[16] on the pinion.
ATTENTION Don’t use any tool when pushing the main bearing inner race [22]
against the V-ring holder [16] as this may damage the V-ring holder.
When assembling the pulley, it will press the bearing to correct po-
sition.
Insert the roller bearing outer race [22] into the pillow block [5]
and grease the rollers.
Then fit the ring [15] and push carefully the assembly on
the main bearing inner race [22].
Insert the four long screws [4] attaching the bearing cover [6]
to the pillow block [5] and the four short screws [21] securing
the shield [20].
Tighten all eight screws.
Make sure that the O-Rings [23] lie correctly in their grooves,
and that they are not damaged.
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4.3y
Figure 4.3.1
4.3-0
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4.3 Conveyor Bearings (Fig. 4.3.1)
Figure 4.3.2
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Remove the snap ring ([11] in figure 4.3.1).
Insert the puller* [1] as shown in Figure 4.3.3. Tighten the
nut [2] so that the conical ring [5] expands between the needle
bearing outer race [9] and the hub.
Insert the screw [7] and the block [12] by using two of the
screws ([15] in Figure 4.2.1) holding the gearbox flange. Push
off the needle bearing outer race [9] by turning the screw [7].
Figure 4.3.3
4.3-2
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4.3.2 Assemble Conveyor Bearing Large End
(Fig. 4.3.1)
If the end flange [8] has been removed and disassembled, as-
semble the parts in the following order:
Fit the O-ring [105] in the end flange [8].
Insert the end flange [8]. Fit the twelve screws [12] and
tighten them to a torque of 22 Nm (195 in-lbs).
Fit the needle bearing outer race [9] onto the large end hub. Fit
the snap ring [11].
Fit the three O-rings [13], [14], and [106] and grease them.
Fill up with grease the needle bearing outer race [9] and dis-
tribute the grease with the fingers.
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Figure 4.3.4
4.3-4
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4.3.3 Disassemble Conveyor Bearing Small End
(Fig. 4.3.4)
Figure 4.3.5
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4.3.4 Assemble Conveyor Bearing Small End
(Fig. 4.3.4)
Thoroughly clean the retaining ring [1] and insert the O-rings
[5], [102], [103], and [104].
Grease the O-rings [5], [102], [103], and [104].
Place the retaining ring [1] on the conveyor pinion, and push it
into place.
Fit the inner half of the ball bearing inner race [3] onto the pin-
ion.
Fill up with grease the ball bearing outer race [3] and push it
onto the ball bearing inner race [3]. Fit the remaining half of
the inner race.
Fit the O-ring [101] into the ring [2] and grease it a little.
Fit the ring [2] on the pinion and secure it with the twelve
screws [4]. Tighten the screws [4] to a torque of 44 Nm (389 in-
lbs).
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4.4
Figure 4.4.1
4.4 Conveyor
Connect the shackle to the hoist and fit the shackle into the lift-
ing tool hole. Because of its individual design each conveyor
has its own centre of gravity. As consequence of this the axial
point on the lifting tool corresponding to the conveyor centre
of gravity is not the same for all conveyors. To find the actual
conveyor centre of gravity, proceed as follows:
Fit the shackle in the lifting tool centre hole and lift the
conveyor carefully, to see how the it balances.
If the conveyor is not in balance, then insert the shackle
into the next lifting tool hole nearer to the heavy end of the
conveyor and lift the conveyor carefully again.
Repeat this procedure until the conveyor is in balance and
mark the centre of gravity hole of the lifting tool, to facilitate
future disassembling and assembling.
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4.4.2 Insert Conveyor into Bowl (Fig. 4.4.1)
Connect the shackle to the hoist and fit the shackle into the lift-
ing tool hole where the conveyor will be in balance when lifted
and push it carefully into the bowl.
CAUTION Be careful not to cut your fingers, when pushing the conveyor into
the bowl.
Figure 4.4.2
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4.5
Figure 4.5.1
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4.5 Main Drive
Remove the screws and washers [31] and [32] holding the up-
per casing and open the casing [3].
Remove the four screws [30] and remove the feed tube [33].
Loosen the four screws [17] and elevate the motor bracket [10]
by means of the two elevating screws [13].
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Figure 4.5.2
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4.5.2 Assemble Main Drive (Fig. 4.5.1)
Install the three V-belts in the grooves of the pulleys and tight-
en them by means of the two screws [13].
Tighten the V-belts as per instructions given in section
4.5.3.
Secure the motor bracket [10] with the four screws [17],
and tighten them to a torque of 197 Nm (1744 in-lbs).
Install the feed tube [33] and tighten the four screws [30].
Install the upper casing [3] and secure it with the screws and
washers [31] and [32].
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Figure 4.5.3
1 Indicator Arm
2 Rubber Finger Loop
3 Pressure Surface
4 Pocket Clip
5 V-belt
6 Pressure Spring
1. See how to hold the tension tester and choose one of the
ways a, b, or c as shown in Figure 4.5.4.
4.5-4
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Figure 4.5.4
Figure 4.5.5
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7. For safe reading mark the spot of the upper side of the in-
dicator with a thumbnail on the scale and then turn the
tester sideways.
For selection of belt and pulley combinations, see Spare Parts Catalogue.
4.5-6
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For selection of belt and pulley combinations, see Spare Parts Catalogue.
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4.6
Figure 4.6.1
4.6-0
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4.6 Variable Frequency Drive (VFD)
Remove the screws and washers [31] and [32] holding the up-
per casing and open the casing [3].
Remove the two screws and washers [7] and [8] and remove
the sensor bracket [9].
Loosen the setscrew [16], remove the six screws [30] and dis-
engage the two coupling parts [4] and [5] completely. Now the
shaft [33] can be removed.
Install the sensor bracket [10] and secure it with the two
screws [11].
The gap between the sensor and the gearbox adapter must
be 3-4 mm.
Place shims [6] under the motor to level the sunwheel shaft
and the motor shaft within 0.5 mm of each other.
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Install the coupling part [5] and engage it completely on the
motor shaft. Now install the other part of the coupling [4] on
the sunwheel shaft and put the two coupling parts into en-
gaged position, by means of the shaft [33], leaving an axial
play of 3-4 mm (1/8 inch) between them. Tighten the set-
screws, and install and tighten the six screws [30].
Install the sensor bracket [9] and fasten with the two screws [7]
and washers [8].
Install the upper casing [3] and secure with the screws and
washers [31] and [32].
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y
5 Supplementary Documentation
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Supplementary
Alfa Laval Technical Details Rev. 2006-11 OM
4.2
Figure 1
0.2
0.1
0 WEAR LINERS
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Supplementary
Alfa Laval Technical Details Rev. 2006-11 OM
Wear liner assembly (figure 1)
4 Turn the wear liner into place and fix it with securing
plates. Mind to turn the wear liner correctly. Disperse ex-
cess composite so that it fills the gap between feed rotor
and wear liner.
II. Attempt to loosen the wear liner from the backside with a
brass mandrel or the like. Heating to 120-130o C might be
necessary.
III. After removal of the wear liner, the hatched area of the
surface is cleaned, as described under assembly.
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Decanter BCC Operator Manual
Decanter 2Touch Operator Manual
61244584
61211xx1
Revision 1
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61244584
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Decanter BCC Operator Manual
61244584
Contents
1. Basic Operator Manual ......................................................................................................................4
1.1 System .....................................................................................................................................................5
1.2 Navigation................................................................................................................................................6
1.3 Control Bar...............................................................................................................................................8
1.4 User Login Dialog ................................................................................................................................... 11
1.5 Popup Keyboard and Numerical Pad .....................................................................................................12
1.6 Decanter Overview ................................................................................................................................14
1.7 Screen Descriptions ...............................................................................................................................17
1.1 Setpoints ................................................................................................................................................23
1.2 Main Sequence ...................................................................................................................................... 24
1.3 Differential Speed Control .....................................................................................................................30
1.4 Example: Automatic control at feed start .............................................................................................33
1.5 Special start-up function .......................................................................................................................34
2 Appendix A: Faceplates ...................................................................................................................37
3 Appendix B: Sequence Steps ...........................................................................................................39
4 Bibliography ....................................................................................................................................41
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Decanter 2Touch Operator Manual
61244584
This manual is intended for the basic operator of the Decanter centrifuge.
It contains basic information on how to operate the Decanter from the Human-Machine Interface (HMI) panel
of the Basic Core Controller (BCC).
The HMI panel is a 7” touch panel (iX Panel T7A, Beijer Electronics).
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1.1 System
• HMI panel,
• Core Controller
• Frequency Drives
HMI
Core Controller Frequency Drives
The HMI handles the interaction between the human user and the control system.
• View machine and process variables: Speed, torque, temperature, vibration etc.
• Issue commands: Start, stop, pause etc.
• Adjust setpoints: Torque, differential speed
• Acknowledge alarms
• Manual control of equipment and signal forcing
• System configuration: Parameters, settings
The essential job of the Core Controller CPU is to control the differential speed of the screw conveyor inside the
Decanter. The screw conveyor is illustrated in Figure 2.
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Screw Conveyor
Bowl
Feed inlet
Backdrive motor
Maindrive motor
Gearbox
Solids Liquid
outlet outlet
• Control the torque on the screw conveyor: Conveyor torque is a key factor in the Decanter process.
• Maintain the control sequence of the machine: Stop, standby, production, rundown etc.
The frequency drives control the speed of the maindrive and backdrive motors on the Decanter. See the
motors in Figure 2.
• Maindrive (MD): The maindrive motor rotates the bowl with the screw conveyor inside. This rotation
causes the solids to sediment.
• Backdrive (BD): The backdrive motor manipulates the rotation of the screw conveyor though the
gearbox.
Parameter setup, speed setpoints, alarm handling etc. in the frequency drives is managed by the Core
Controller.
1.2 Navigation
The HMI is a touch panel with a software program: Simply tap the panel with a fingertip or stylus to operate it.
The HMI program contains many different screens. The operator can navigate between screens via the
Overview Matrix or the Tab Control.
To get an overview of the HMI screens, tap the Overview button in the lower right corner of the screen (see
Figure 3).
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The screens are organised in a matrix of rows and columns. On top of each column is the main tab. And to the
left of each row is the sub tab. See
Figure 4
Sub tab 1
Main tab 1
The main tabs are numbered from left to right. And the sub tabs are numbered from top to bottom. When the
operator taps an icon in the overview matrix, the HMI program jumps to that screen.
The current main tab and sub tab is highlighted, and the screen number is displayed in the title, as shown in
Figure 5.
To navigate to another screen, simply press another sub tab or main tab.
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Also displayed in Figure 5 are the user login level at the top of the screen and the control bar at the bottom of
the screen. These are explained in the following sections.
The control bar (see Figure 6) is available at the bottom of every screen.
The following buttons for controlling the Decanter centrifuge are available on all machines:
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To prevent the user from unintentionally starting or stopping the Decanter, the buttons must be activated for
a few seconds before the command is accepted. This is indicated by a progress bar as shown in Figure 7.
The diode below the start button flashes when the Decanter is in transition from stopped to production. In
production the diode is steady green as shown in Figure 8. The red diode underneath the stop button shows
that the machine is currently stopped.
Depending on the settings at the installed machine, some of these buttons may also be available:
Low Speed Flush button: Calls for Low Speed Flush mode. If
pushed during production, it triggers the normal shutdown
sequence and starts the Low Speed Flush when the bowl
speed falls below the stop speed. If pushed during
shutdown sequence, it waits until bowl speed falls below
the stop speed and starts the Low Speed Flush sequence.
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The buttons at the right side of the control bar are related to the HMI itself:
The Utilities button opens a menu with Backlight and Print screen
buttons.
Insert a USB memory stick in the USB port of the HMI panel and then
tap the Print button. This stores a screen shot of the currently
displayed screen on the memory stick.
Tap the Login button to display or hide the user login dialog at the
top of the screen.
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The current access level is displayed at the top right corner of all screens. To unfold the user login dialog, press
the login button at the control bar (see Table 3). The folded and unfolded user login dialog is showed in Figure
9.
Folded Dialog
Select a user name from the drop down menu. Then tap the empty password input field to the right of the
user name to open the popup keyboard. Type the correct password followed by the enter key ( ).
There are three user names to choose from in the drop down menu:
Taping the “Logout” button, will decrease a higher login level (i.e. Administrator or Advanced Operator) to the
lowest level (Basic Operator).
The current login level determines the access rights of the user. The basic operator only has limited access to
interacting with the HMI.
Screen elements are greyed out, if they are not available to the operator. An example of this is shown in Figure
10. The operator can view the process variables but does not have access to the start and stop buttons.
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Buttons may also be greyed out due to conditions in the machine or process. For example, the start button is
not available when the Decanter is in production. This is shown in Figure 11.
Figure 11: Start button unavailable (grey), stop button available (blue)
When entering passwords the popup keyboard appears (see Figure 12). For entering numerical values like
setpoints and parameters the numerical pad appears (see Figure 13).
Inactive area
It is possible to grab the keyboard or numerical pad by the inactive area to move it to a different position on
the screen. Tap the escape button (Esc) to close the keyboard or numerical pad popup.
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Inactive area
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The Decanter Overview screen is the main screen for operating the Decanter centrifuge.
It is identified by the screw conveyor icon as shown in Figure 14 and Figure 15.
Setpoint
Dashboard
Faceplate icon on
valve
Actual process value
1.6.1 Dashboard
The dashboard displays the most essential machine information. See Table 5.
The letter in the setpoint field indicates if the setpoint source is local (L) or remote (R).
The torque setpoint is identical to the setpoint S302 on the parameter screen 8.5 BD Parameters (Admin login
only), when the system is in Local mode.
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The differential speed setpoint is identical to the setpoint S301, when the system is in Local mode and under
automatic control (Auto).
If the operator chooses to switch to fixed differential speed control (Diff), the setpoint in the dashboard is the
fixed differential speed, which can be adjusted independently of S301.
The outline on the equipment indicates the status of the equipment. The outline flashes when the motor is
starting/stopping or the valve is opening/closing.
When the motor is completely stopped/started or the valve is completely open/closed, the online colour stops
flashing and becomes solid.
Alarm icon
The colour of the outline depends on the actual settings for the installed machine. Default settings are green
for running/open and transparent for stopped/closed. If the equipment has an active alarm, the alarm icon is
showed at the equipment as shown in Figure 16.
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Tap the equipment to open the faceplate, which contains additional information about the equipment.
The open faceplate for the backdrive motor is shown in Figure 18.
Backdrive
Start Stop
There are two faceplates with additional setpoints for the backdrive motor. There faceplates can be accessed
by tapping the icons for torque and differential speed in the dashboard. See a complete list of all faceplates in
Appendix A: Faceplates.
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Here is a short description of the contents of all the screens in the HMI.
Alarm Acknowledge
Before operating the decanter, make sure that all active alarms have been acknowledged.
The presence of any active alarms is indicated by a red alarm icon at main tab 2. The red alarm icon flashes
until all active alarms have been acknowledged. A grey icon means no active alarms.
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An example of the alarm list on screen 2.1 is shown in Figure 20. Unacknowledged alarms have a red
background colour.
The background colour changes from red to yellow, when the operator has acknowledged an alarm, but the
alarm condition is still fulfilled. See Figure 21.
When the alarm condition is no longer fulfilled, the alarm disappears from the alarm list. Old alarms are shown
in the alarm history on screen 2.2.
• Active Time: Date and time when the alarm was activated
• Group Text: Name of the alarm group
• Text: Alarm number and alarm name.
Alarm Groups
The alarm group determines the behaviour of the Decanter when the alarm is activated:
More information on the alarms and alarm groups can be found in the parameters and alarms manual
(61244587 Decanter BCC Parameters and Alarms) .
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Trend legend
The trend legend is displayed and hidden by tapping the trend. An example is shown in Figure 22.
The various settings for the trend legend are explained in Table 9.
Bowl Speed
Bowl Speed
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Trend History
The 5s trend in screen 3.2 has a log of 70 hours but only displays the last two hours. To extend the trend
backwards in time use the “Show History Mode” button (See Figure 23). This opens the History Time Settings
Popup. Select the Start and End time and tap “OK”.
End Time:
OK Cancel
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Main tabs 7 though 10 contain the parameter setup screens. These are not available to the basic operator.
Refer to the parameters and alarms manual (61244587 Decanter BCC Parameters and Alarms) for more
information on the parameters.
Main tabs 11 though 13 contain the parameter setup screens. These are not available to the basic operator.
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Refer to the parameters and alarms manual (61244587 Decanter BCC Parameters and Alarms) for more
information on the parameters.
1.1 Setpoints
The setpoints can be accessed by tapping the icons for torque and differential speed in the dashboard on
screen 1.1. For higher login levels: Go to screen 8.4 BD Setpoints. All setpoints are listed in Table 15:
Automatic
automatic control
control
Maximum torque in automatic
S302 Torque
control
S303 Filling Diff Fixed differential speed during filling Special Startup
Refer to the parameters and alarms manual (61244587 Decanter BCC Parameters and Alarms) for more
information on the setpoints.
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The main operating sequence of the Decanter is shown in Figure 24. In each circle is a sequence step, and each
arrow is a condition to go from one step to the next. (See also Appendix B: Sequence Steps).
In the centre of the figure is the powered off state. Any active alarms must be acknowledged after powering
up the electrical panel.
10: Offline
Torque
16: HI RPM
18: Rundown
Flush
17: Rundown
Flush
1.2.1 Start
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Press the start button to start up the Decanter. The bowl accelerates and reaches the operating speed, and the
main sequence goes to “Offline”. See Figure 24.
Press the start button again to request feed into the machine. When the feed is running, the sequence goes
from Standby to Production.
If the parameter for automatic feed request (P812) is enabled, the sequence goes to a different offline step (9:
Offline). See Figure 25.
From 9: Offline the sequence goes to 11: Standby after the Offline Delay (P105) has expired. This means that
the operator only has to activate the start button once, to bring the Decanter from 1: Stop to 15: Production.
10: Offline
9: Offline
There are three handshake signals between the Decanter and the Feed System. See Table 16.
Feed System Ready DI222 Feedback from the Feed system: Feed is ready to start
Feed Permissive DO412 Command from the Decanter: Start the feed
Feed Running DI212 Feedback from the Feed system: Feed is running
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The Feed System Ready feedback can be used in different ways depending on the settings at the installed
machine: Not used, Interlock or Stop Feed Alarm. This is illustrated in Figure 26. Interlock brings the sequence
to 11: Standby. Stop Feed Alarm brings the sequence to 10: Offline.
If Feed System
Ready:
10: Offline Feed Permissive
11:Standby
Feed Running
The Feed Permissive command will be activated in the Standby sequence step, if the Feed System Ready
feedback is active.
The feed system should respond to the command by starting the feed and activating the Feed Running
feedback. The Feed Running feedback makes the Decanter continue from Standby to Production.
1.2.4 Production
During production the Torque and Diff Speed setpoints may be modified to improve the Decanter process.
The Auto and Diff buttons on the dashboard of the Decanter Overview screen (see Table 5) may be used to
switch between automatic torque control and fixed differential speed control.
1.2.5 Offline
The Offline button can be used any time during Production to stop the feed to the machine. See Figure 27. The
sequence goes to 10: Offline and the Decanter runs idle at full speed. Use the start button to go back to
Production.
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10: Offline
11:Standby
15: Production
1.2.6 Stop
Press the stop button to start the normal shutdown sequence. This is initiated by flushing at high speed.
When the high speed flush cycle is complete the sequence goes to rundown flush. The bowl decelerates, and
the flushing water is still on.
Finally the sequence goes into rundown, and the bowl decelerates without flushing.
After the automatic shutdown sequence is complete, the Decanter goes from 18: Rundown into 1: Stopped.
However, if low speed flushing automatic start is enabled, the Decanter continues into the low speed flushing
sequence.
During High Speed Flushing the bowl runs at full production speed, and the differential speed of the conveyor
is at the flushing setpoint.
If the Start button is pushed during the flush, the machine returns to Offline. If the Stop button is pushed
again during the Full Speed Flush mode, the machine immediately goes into rundown flush. See Figure 28.
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10: Offline
10: Offline
11:Standby
16: Rundown
Flush
By activating the Stop button, it is also possible to break out of the step 16: Rundown Flush and go
immediately to 17: Rundown.
If an operator prefers to witness and influence the bowl cleaning at full speed, the shutdown sequence may be
different:
• Stop the feed by activating the Offline button. This takes the sequence to 10: Offline.
• Open the flush valve from the faceplate in the Decanter Overview screen 1.1.
The actual torque readings on the Decanter faceplate in the Decanter Overview screen 1.1 can be used to
estimate the amount of solids remaining inside the bowl.
Once the bowl is considered to be clean, the machine is stopped with the Stop button and goes through the
automatic shutdown sequence.
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The number of complete cycles as well as the duration of the forward and backward rotation is configurable.
A complete cycle is shown in Figure 29. First the bowl accelerates in the backwards direction. When the
flushing bowl speed is reached, the reverse flushing timer must elapse, before the bowl decelerates. When
the reverse rotation has stopped begins the forward acceleration, flushing time and deceleration.
LS-Flush Button
or Automatic
Start
21: Lo RPM
Flush R
24: Lo RPM
Flush F
Last cycle
complete
After the last forward low speed flushing step, the sequence actually performs one extra reverse flushing with
the sequence steps numbers 26 though 28. After this the Decanter goes to Stop.
It is possible to break out of the low speed flushing cycle at any time by pressing the stop button.
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The essential job of the Core Controller CPU is to control the differential speed (Dn) of the screw conveyor
inside the Decanter.
Adjusting the differential speed will influence the torque (T) on the screw conveyor.
The torque (load) on the conveyor is an indicator of the amount of solids accumulated inside the decanter.
In Figure 31 is an illustration of how the torque, differential speed and product quality is related.
In general the conveyor torque will increase, when the differential speed is lowered. And the high torque will
typically result in dryer cake (i.e. less liquid in the solids outlet of the Decanter).
A higher differential speed, on the other hand, will increase the transport of solids out of the decanter, and
this will lead to a decrease in conveyor torque.
Torque
Not clear centate
Gearbox
limit
Clear centrate, Dry cake
Wet cake
Differential Speed
Figure 31: Relationship between differential speed, torque and product quality
If the differential speed is lowered to much the torque becomes too high. This will at some point result in less
clear centrate (i.e. more solids in the liquid outlet of the Decanter). The torque might also reach the maximum
level allowed for the gearbox.
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In order to get the best performance out of the decanter, other process factors must also be considered. These
include:
• Bowl speed
• Liquid level in the bowl
• Feed rate into the Decanter.
The feed flow rate as well as the solids concentrations in the feed typically varies throughout the day. This will
impact the load (torque) on the screw conveyor, and may consequently affect the product quality.
The torque mode (T-mode) is used to ensure constantly high product quality.
The T-mode maintains an optimal amount of solids in the decanter. This is achieved by varying the differential
speed of the conveyor according to the measured torque load. The torque setpoint in T-mode is Tmax.
Under special circumstances the Core Controller switches to differential speed mode (Dn-mode)
In Dn-mode the differential speed is kept at the differential speed setpoint (Dnmin).
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In automatic control the Core Controller automatically select between Dn-mode and T-mode depending on the
measured torque. In general the mode that requires the highest differential speed will be selected.
In general, the controller switches to T-mode, when the torque reaches the maximum value (Tmax). This is
illustrated in Figure 32.
Torque
Tmax (S302)
Three different
feed rates
Differential Speed
Dnmin (S301)
Figure 32: Relationship between differential speed and torque at different feed rates, with
indication of Dn-mode and T-mode.
In T-mode the differential speed is adjusted to maintain the torque at the setpoint. The low limit for
differential speed is Dnmin. At this point, the controller switches to Dn-mode.
The setpoints for speed and torque can be modified by the user via the dashboard on the Decanter Overview
screen. See Table 17.
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A text on the dashboard in the Decanter Overview screen 1.1 informs the user of the current control mode.
See Table 18.
The operator can choose to take the Decanter out of automatic control (Auto) and into fixed differential speed
control (Diff).
Diff can be considered as a type of manual control: The torque setpoint is no longer considered, and the speed
is maintained at the setpoint Dnmin (S301).
The “Auto” and “Diff” buttons on the Dashboard in the Decanter Overview screen 1.1 are used to switch
between automatic control and fixed differential speed control.
When the user switches from Auto to Diff, the controller takes the current differential speed as the setpoint
for Diff-control.
The differential speed setpoint during fixed differential speed control can be modified by the user via the
dashboard on the Decanter Overview screen. See Table 5 Table 19.
To avoid problems of torque overload, the torque setpoint (S302) must be set in accordance with the gearbox
size.
To avoid difficulties when turning on the feed, the differential speed setpoint (S301) should not be set too low,
and the initial flow rate should not be too high.
An example of automatic control is shown in Figure 33. First there is no feed into the Decanter, and the
conveyor torque is zero. Then the feed starts, and the torque increases.
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Torque (T)
Tmax (S302)
Feed Rate
0
Differential
Speed (Dn)
Dnmin (S301)
Time
Dn-mode T-mode
Figure 33: Torque and differential speed at feed start
1.4.1 Dn-mode
As long as the feed is off, there is no torque on the conveyor, and therefore the controller is in Dn-mode.
The controller maintains the differential speed at the minimum value (Dnmin)
1.4.2 T-mode
As the feed is started, the torque increases. A rapid increase in torque will cause the controller to switch from
Dn-mode to T-mode. This switch is shown below the time line in Figure 33.
Now the controller increases the differential speed to keep the torque at the maximum value (Tmax).There is a
gradual change in torque and differential speed as the feed rate changes, and it may take a long time before
steady state conditions are reached.
On some Decanters it is an advantage to run at a very low differential speed when starting up the Decanter.
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Special start-up is used on Decanters equipped with a steep cone and baffle disk conveyor. The purpose is to
accumulate sludge inside the bowl and form the sludge seal around the baffle disk as quickly as possible.
Once the sludge seal has formed, the differential speed should be increased to the normal level for
production.
1.5.1 Filling
There are tree differential speed setpoints in play during the special start-up function:
Before the feed is started, the controller operates in Dn-mode the normal setpoint (S301).
During filling the speed is set to a lower value (S303). Immediately after filling the speed is set to a higher value
(S305). This is illustrated in Figure 34.
Torque
Tmax
(S302)
DnInit Prod
(S305) Feed Rate
0
Tseal
(S306)
Differential
Dnmin
Speed
(S301)
Dnfill
(S303) Time
Dn-mode T-mode
Figure 34: Torque and Differential Speed with Special Start-up Function enabled
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The low filling differential speed setpoint causes a fast increase in torque. As the torque reached the seal level
the controller switches from Dn-mode to T-mode.
However, to prevent the torque from rising too high, the differential speed is first accelerated from the low
filling setpoint towards the high initial production setpoint.
1.5.3 Production
The initial production step lasts for 1 second, and then the controller goes to ordinary production with the
Differential Speed Setpoint (S301) and Torque Setpoint (S302) active only.
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2 Appendix A: Faceplates
Here are the available faceplates in the Decanter overview screen.
Decanter process variables
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Please refer to the sequence manual (61244385 Decanter 2Touch Sequences) for a detailed description on all
sequence steps.
1 Stopped
3 Starting VFD
5 Starting VFD
9 Offline
10 Offline
11 Standby
12 Filling
13 Init Production
14 Start Production
15 Production
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16 HI RPM Flush
17 Rundown Flush
18 Rundown
20 Lo RPM Flush R
21 Lo RPM Flush R
22 Lo RPM Flush R
23 Lo RPM Flush F
24 Lo RPM Flush F
25 Lo RPM Flush F
26 Lo RPM Flush R
27 Lo RPM Flush R
28 Lo RPM Flush R
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4 Bibliography
61244587 Decanter BCC Parameters and Alarms.
61244385 Decanter 2Touch Sequences.
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