Muffin Monster Grinder Model 30004T Motor Controller Model PC2220

Transcription

1 Muffin Monster Grinder Model 30004T Motor Controller Model PC2220 PROJECT: Orange County Sanitation District, Project No. P2-89 JWCE SO#: JWCE Rep: Misco Southwest

2 Misco Intermountain Burbank, Suite B Foothill Ranch, CA Training staff with consist of either Roger Antonie, Scott Schnurbush or both. Qualifications are as follows: Engineering degreed. Expert in WW treatment processes. Representatives of JWCE for over 8 years. Started up and trained extensively on JWCE grinders. Expert in grinder operation and maintenance. Expert in grinder-associated controller operation and maintenance. JWC Environmental Corporate 290 Paularino Ave. Costa Mesa CA Manufacturing/Service 2600 South Garnsey St. Santa Ana CA

3 SAFETY INSTRUCTIONS Operations and maintenance personnel are to know and practice all safety instructions. The following two tables list safety concerns and instructions that are to be observed when maintaining and operating this equipment. These instructions are intended to inform personnel of safety concerns and important information crucial to the operation and maintenance of this equipment. All listed safety instructions are intended to emphasize personnel utilizing good safety practices at ALL TIMES. This training manual is not intended to replace the specific grinder s Operation and Maintenance (O&M) manual. Refer to the O&M manual for any question regarding grinder or controller operation, maintenance, or troubleshooting. JWC ENVIRONMENTAL SHALL NOT BE HELD LIABLE FOR ANY IGNORANCE OR DISREGARD OF OSHA, FEDERAL, STATE, OR LOCAL REGULATIONS. WEAR EYE AND EAR PROTECTION. COMPLY WITH ALL OSHA AND OTHER REGULATORY AGENCY SAFETY REQUIREMENTS. JWC ENVIRONMENTAL SHALL NOT BE HELD LIABLE FOR ANY DAMAGES RESULTING FROM CONTROLLER FUNCTIONS THAT ARE TRIGGERED AS A RESULT OF WIRING MISCONNECTIONS, WIRING SHIELDING ERRORS, AND/OR OTHER WIRING ERRORS NOT IN COMPLIANCE WITH OSHA, FEDERAL, STATE, OR LOCAL REGULATIONS. ELECTRICAL HAZARDS. VERIFY AND ENSURE POWER TO THE CONTROLLER IS TURNED OFF, LOCKED OUT, AND TAGGED BEFORE PERFORMING ANY INSTALLATION, SERVICE, OR MAINTENANCE TASK INCLUDING THE REMOVAL OR ATTEMPTING TO REMOVE ANY OBSTRUCTION(S) FROM THE GRINDER JWCE CONTROLLER PANEL CONTROLS DO NOT DISCONNECT POWER WITHIN THE CONTROLLER. SERVICE JWCE CONTROLLERS AND CONNECTED DEVICES ONLY WHEN POWER TO THE CONTROLLER HAS BEEN TURNED OFF, LOCKED OUT, AND TAGGED. THE EQUIPMENT MAY START, STOP, REVERSE, OR RESTART AUTOMATICALLY AFTER POWER LOSS AND RECOVERY. DO NOT ATTEMPT ANY MAINTENANCE ON THE EQUIPMENT DURING A POWER LOSS. ELECTRICAL LOCKOUT PROCEDURES MUST BE PERFORMED PRIOR TO SERVICING ANY EQUIPMENT OR CONNECTED EQUIPMENT. 3

4 SAFETY INSTRUCTIONS (Cont d) KEEP PERSONNEL AND UNAUTHORIZED MATERIAL CLEAR OF CUTTING CHAMBER. PERSONAL AND MECHANICAL HAZARDS EXIST DURING THE PERFORMANCE OF THE GRIND TEST. DO NOT WEAR LOOSE FITTING CLOTHING NEAR GRINDER. PHYSICAL HAZARDS EXIST. ENSURE THAT ADEQUATE ASSISTANCE IS AVAILABLE AND UTILIZED WHEN LIFTING AND/OR TRANSPORTING THE EQUIPMENT, TOOLS, AND SUPPORT EQUIPMENT/MATERIALS. DO NOT LIFT HEAVY EQUIPMENT OVERHEAD OF PERSONNEL. REVIEW ALL MATERIAL SAFETY DATA SHEETS (MSDS) FOR SOLVENTS, CHEMICALS, AND LUBRICANTS TO BE USED WITH THIS EQUIPMENT FOR HANDLING AND SAFETY ISSUES. FLAMMABLE VAPORS MAY FORM EXPLOSIVE MIXTURE WITH AIR. PERFORM ALL SURFACE PREPARATION AND PAINTING IN A WELL VENTILATED NO SMOKING AREA THAT IS IN COMPLIANCE WITH ALL APPLICABLE SAFETY REGULATIONS. AVOID PROLONGED EXPOSURE TO VAPORS. USE AN AIR RESPIRATOR/AIR MASK AND CHEMICAL SAFETY GOGGLES/FACE SHIELD. USE BOTH EYEBOLTS AND A SLOW EVEN PULL WHEN LIFTING CUTTER CARTRIDGE OUT OF MAIN HOUSING. WEAR GLOVES WHEN HANDLING CUTTERS AND SPACERS. 4

5 Muffin Monster 30004T GENERAL The Model 30004T grinder is a solids reduction device that pulverizes influent solids into a particle size (acceptable to sewage type pumps) that facilities free flow and easy disposal of sludge. 5

6 Exploded View - Muffin Monster 30004T 6

7 Grinder Operation PROCESS STEPS 1. Wet or dry solids are transported to the Muffin Monster via the waste stream. 2. The solids are passed through the cutters for size reduction. 3. The ground material is again transported by the waste stream. The small particles pose no threat to down stream equipment. 7

8 Mechanical Specifications Each 30004T assembly is constructed from materials selected for strength, corrosion resistance, and long life. Castings are constructed of ductile iron. Cutters are constructed from 8620 steel and thru hardened to Rockwell C. Shafts are fabricated from two-inch 4140 steel hexagon stock and are supported on each end by heavy duty sealed ball bearings protected by mechanical seals. Maximum operating pressure: 90 PSI (621-kPa) - sealing water NOT required. Weight: approximately 560 pounds (254 kg). Dimensions: Flanges Class inch/152 mm Grinder cutter stack height 12 inches Grinder overall height with motor 56¼ inches/1423 mm Grinder height without drive assembly 28¼ inches/ mm 8

9 Cutter Assembly Helical Stacking The Muffin Monster 30004T utilizes a cutter cartridge consisting of 7-tooth cam cutters on drive and driven shafts. Cutter dimensions are (120mm) diameter and.310 thick (7.874 mm). Dual Shafted Grinder Capable of grinding a much wider variety of solids than single shafted machines. JWC-researched and -determined speed operation results in great torque and few interrupts. Dual counter-rotating shafts direct material and flow toward center of shafts. 9

10 Cutter & Spacer Stacking Illustration Shaft Cutter Indexing dimple on cutter 1 Shaft 2 Spacer 3 Cutters and spacers are alternately stacked on the drive and driven shafts. As each successive cutter and spacer is installed, position the index dimple to the next location (procedure is more fully explained in the O&M manual). Spacers do not have an indexing dimple they can go on the shaft in any manner. 10

11 Mechanical Seals High pressure capability 90 psi (6 bar) Tungsten carbide seal races No seal flush required and no packing gland to adjust BUNA-N elastomers 304SST bushings with retaining ring groove 11

12 Drive Assembly Baldor 5 HP TEFC Motor 460 VAC 29:1 Reduction 3 Phase 1.15 Service Factor 60 Hz 1750 RPM Space Heater 184TC Frame 12

13 Performance Capability Model Flow Rate GPM (m 3 /h) Pressure Drop PSI (bars) Approximate Net Weight lbs (kg) 30004T (136) 0.86 (0.06) 560 (254) 30004T-1206 Dimensions - IN/MM A B C D A 56¼ (1423) 21¼ (534) 28¼ (717.55) 9 1/8 (232) C D B 13

14 Maintenance Preventive and Corrective PREVENTIVE OPERATION Visual Inspection Cutter Wear Inspection Cutter Stack Tightness Inspection Fasteners Inspection Greasing of Gears Drive Assembly Inspection Monthly FREQUENCY After first three months, then every 12 months After first three months, then every 12 months After first three months, then every 12 months 60 months (inspection may show necessary replacement at 36 months) After first three months, then every 12 months CORRECTIVE OPERATION Check grinder for leakage, vibration, noise, excessive heat buildup, or grease seeping form the drive assembly speed reducer. Check grinder processing for proper solids reduction. Worn cutters must be replaced if solids are not being properly reduced or if the grinder jams excessively. Insert a long screwdriver or similar tool in between adjacent cutters on each shaft and move it up and down. Verify none of the cutters or spacers move. If any movement, cutters must be removed, cleaned and restacked. Tighten loose external fasteners. Remove top cover and carefully remove old grease per the O&M manual. Grease gears with grease called out in the O&M manual. Check for excessive noise or temperature rise, motor controller settings, supply voltage and line connections. Make any necessary adjustments or call for service. 14

15 Checkout - Startup Checkout The 30004T Muffin Monster checkout after installation consists of the following: Verify drive assembly has been installed as described in the O&M manual. Verify cutter rotation is correct. Startup 1. Apply power to the motor control panel. 2. Verify that the READY indicator lamp lights. 3. Turn selector switch to HAND, verify the ON FORWARD indicator lights and check for proper cutter stack rotation. 4. Run grinder dry for 5 15 minutes before applying flow. 5. Check the voltage to the control panel and the grinder. 6. Check the amp draw on all three legs of the power supply to the grinder. 7. Check the line operating pressure to the grinder with the unit operating. 8. Verify there are no obvious leaks where pressure has been applied. 15

16 Normal Operation - Shutdown The grinder should be routinely checked for solids size reduction performance. Normal non-fail operation and shutdown is performed as follows: 1. Open the main disconnect at or to the control panel. 2. Set the grinder selector switch to OFF at the control panel. 3. Perform startup as described on previous page (15). 16

17 Emergency Shutdown Procedures In an emergency, the grinder is stopped by removing power to the grinder electric motor by: Opening the user-defined and installed main power circuit breaker disconnect switch. OR Operation of motor controller OFF switch turn to OFF. The PC10 Remote Operator Station EMERGENCY STOP pushbutton can be used to stop grinder operation when the HAND-OFF-REMOTE control is in the REMOTE position. 17

18 Motor Controller PC Controls and protects electrically driven Muffin Monster grinders. 18

19 Controller Specifications Underwriters Laboratory (UL and cul) listed. Factory wired for 460 VAC. Fuse protected control circuitry. Internal humidity: 35% to 85% relative humidity (without condensation). Operating temperature range: 32 F (0 C) to 131 F (55 C). Storage temperature range: -4 F (-20 C) and 150 F (66 C). Shipping weight: 25 to 35 lbs. (12 to 16 Kg). Common Fail and Grinder Run relay contacts 240VAC) (two sets). 19

20 Controller Description 100 to 240 VAC Power Supply 16-point input of 24 VDC, 14-point output of 2A relay 32k steps program capacity 2-point potentiometer USB port 20

21 Controller Description (Cont d) Current Sensor The motor starter has a current sensor on one leg to the starter. When the current draw to the motor starter exceeds the programmed set point, the sensor relay sends a signal to the programmable logic controller (PLC). 21

22 Controller Options Selector Switch 3-position type with HAND-OFF-REMOTE settings. Controller Lights POWER ON - White - lights to indicate the controller has power OFF Green lights when the grinder has power but cutter stack is not rotating ON FORWARD Red lights when the cutter stack is rotating in forward direction (processing material) ON REVERSE Red lights when the cutter stack is rotating in reverse during unjamming sequence MOTOR OVERLOAD Amber lights to indicate sustained grinder motor supply power condition has occurred MOTOR OVERTEMP Amber lights when the grinder motor overheats, opening the grinder motor thermostat CURRENT TRIP Amber lights to indicate the cutter stack can no longer rotate freely RESET Pushbutton The RESET pushbutton resets the controller logic and fail indicators. 22

23 Operation Controller is designed to safely operate and control an electrically-driven grinder as follows: Turns the grinder ON and OFF. Initiates an automatic reversal sequence of the grinder in the event of a jam. Stops the grinder in the event of a fail jam, overload, overtemp - condition. Functions CONTROL AND DETECTION Normal HAND-OFF-REMOTE mode. Automatic reversal sequence on jam detection. Over-current protection. Jam and motor overload protection. Loss of power recovery. Fail contact available. 23

24 MCC Panel Wiring Schematic 24

25 JWCE Panel Wiring Schematic 25

26 Fail Conditions Grinder Jammed If material becomes jammed in the grinder cutting chamber, a grinder high current condition occurs and controller jam current sensor (CT) contacts close. The controller initiates a grinder clearing sequence. In the clearing sequence the grinder stops, reverses rotation for a partial turn, stops, and returns to forward rotation in an attempt to dislodge the jammed material. If the obstruction WAS cleared, the grinder resumes normal operation. If the obstruction WAS NOT cleared, the controller initiates another grinder clearing sequence. If three (3) grinder-clearing reversal sequences occur within 30 seconds and the obstruction has NOT been cleared, the controller initiates a grinder stop, the ON FORWARD indicator goes out, the CURRENT TRIP indicator lights, and the common Fail contact is energized. Turn the control switch to OFF. Press RESET to reset the PLC and the fail indicator. Clear the jam and turn the switch to HAND. Motor Overload When the grinder motor full load amps (FLA) rating has been exceeded, the overload relay (OL) trips (opens) and the grinder is placed in a controller stop mode. The controller stops cutter rotation, the ON FORWARD indicator goes out, the fail indicator lights and the common fail contact is energized. 26

27 Emergency Stop Grinder rotation can be stopped in an emergency by performing one of the following actions: Turn the main power circuit breaker disconnect (power supply to the controller) to the off position. Turn the HAND-OFF-REMOTE switch to OFF. Press the remote operator station EMERGENCY STOP pushbutton (HAND-OFF-REMOTE switch must be in REMOTE. Controller Reset The RESET pushbutton is used to reset the controller logic. If a fail/overload condition occurs, the controller WILL NOT accept a new command until the fail/overload condition is corrected and the controller is reset. 27

28 Power Loss Recovery The grinder starts immediately when main power is restored if main power is removed from the motor controller while the grinder is running in HAND mode or the grinder control switch is set to REMOTE (and Remote Run Permissive contacts are closed). 28

29 Controller Maintenance Requirements MAINTENANCE PROCEDURE FREQUENCY Wiring Inspection Moisture Inspection Dust Inspection Enclosure Seals Inspection 3 Months 3 Months 3 Months 3 Months 29

30 Troubleshooting Potential Problem Possible Solutions Verify that components are not burnt or damaged. Grinder DOES NOT start, READY indicator not lit Grinder DOES NOT start, READY indicator lit Grinder does not Reverse Verify control voltage fuses are good. Verify proper line voltage at terminals L1, L2, and L3 Verify transformer output voltage. Verify the motor controller circuit breaker is closed and operation properly. Verify that components are not burnt or damaged. Verify motor controller grinder control switch is in REMOTE if operating from the remote operator station. HAND Operation Verify the control switch is set to HAND. Check control switch and connections. REMOTE Operation Verify the control switch is set to REMOTE. Check the control switch and connections. Check for a grinder overload condition. Correct any overload condition, reset the controller. Check for a motor overtemp condition. Check motor forward starter contactor (MF). Check current sensor (CT). Check grinder motor reverse contactor (MR) and contactor connections. 30

31 Troubleshooting (Cont d) Motor controller does not reset an overload condition Motor controller does not reset a grinder jammed condition after the grinder has been cleared. Motor controller does not reset a grinder motor overtemp condition after the grinder motor has cooled. Motor space heater does not work. Check the grinder control switch and switch connection. Check motor overload relay Check the grinder control switch and switch connections. Check the current sensor. Check the grinder control switch and switch connections. Check the temp sensor continuity (should be closed), connections. Check the wiring and connections. 31

32 Questions? 32