EQUIPMENT OWNERS MANUAL MATTHIESEN SCREW CONVEYOR

Transcription

1 PASSION COMMITMENT QUALITY NORTH W.W. WHITE RD. SAN ANTONIO, TEXAS /27/07 rev A EQUIPMENT OWNERS MANUAL MATTHIESEN SCREW CONVEYOR

2 TABLE OF CONTENTS 1) General Safety Instruction...3 2) Unpacking Information...4 3) Warranty Information...5 4) Installation Instructions ) Electrical Information...8 6) Machine Specifications...9 7) Screw Conveyor Operation ) Extended Shutdown Instructions ) Troubleshooting Information ) Lubrication Information ) Cleaning and Sanitizing Instruction ) Assembly Drawing ) Decal Reorder Sheet ) Inspection Report

3 GENERAL SAFETY INSTRUCTION BE SURE THAT PERSONS USING OR OPERATING THIS EQUIPMENT READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE USE. All equipment developed by Matthiesen has been assembled and fully tested for proper alignment and safe operation, under correct usage, prior to delivery. Many accidents occur from incorrect use or misuse of equipment or tools in all types of work situations. Matthiesen cannot be held responsible for injury or damage resulting from such misuse. Listed below are some general precautions specifically related to ice processing and its environment that should be followed at all times. 1. Only properly trained and qualified personnel should be allowed to operate or service this equipment. 2. Minors must never be allowed to operate or work in close proximity to this equipment. 3. Do not ever attempt to service or clean this equipment while it is operating. Always lock out all power sources. 4. Observe all posted WARNINGS on equipment and associated systems, to avoid personal or property damage. Never remove, deface, or cover up any posted WARNING or SAFETY markings. 5. Before re-starting any equipment, be certain all personnel and foreign objects are clear of equipment. 6. Do not, under any circumstance insert hands or feet in equipment while operating or equipment is operational. Lock out all power before servicing. 7. Be certain that proper grounding practices are maintained. Do not remove ground conductor prong from electrical plug provided. 8. Avoid excessive accumulation of ice or water on floor where this and other equipment is in use. 9. Do not operate machine without guards in place! Removal of any safety guards or warning labels shall void any/all warranties or claims. 10. Do not climb or use machine as a ladder. 11. Equipment should have adequate work area around it to minimize accidents. Confined areas increase chances for accidents. 12. Matthiesen can not and will not be responsible for any loss or damage, including personal injury or property damage, caused by the acts or omission of parties other than Matthiesen, or in the event of changes or modifications made to the equipment without the knowledge and consent of Matthiesen. Any such changes or modifications shall cause any warranties by Matthiesen to be null and void. 3

4 UNPACKING EQUIPMENT Upon receiving equipment, it is the responsibility of the customer to check for freight damage or missing pars and report immediately to Matthiesen toll free at Wash machine free of dirt, grease, or other debris due to shipping and handling. Machine should be sanitized before use, to avoid any contamination of product prior to powering up any and all equipment. Motors are totally fan cooled/wash down available. 4

5 Passion Commitment Quality MATTHIESEN, warrants this equipment to be free from defects in material and workmanship under normal use and service as follows: 90 DAYS WARRANTY ON ALL PARTS: 90 Days from date of purchase to the original purchaser, MATTHIESEN will at it s election, repair or replace at our factory in San Antonio, Texas, such part or parts found by the manufacturer to be defective. Any part or parts of equipment sent to us for adjustment, repair or replacement, will be shipped with all transportation charges prepaid, and will be returned to the customer with all transportation charges collect. If owner elects to have any malfunctions repaired without the consent of MATTHIESEN during the Warranty Period, MATTHIESEN will exchange only the part or parts found by our factory to be defective with new or factory reconditioned parts. No allowance for labor, transportation or product loss will be allowed. THIS WARRANTY shall not apply to said equipment, or any part thereof, which has been subject to accident, negligence, abuse, misuse, damage by flood, fire, windstorm, or any acts of God. THIS WARRANTY shall not be deemed to place any liability on MATTHIESEN for labor, time loss, and product loss or replacement part purchased by owner without the consent of MATTHIESEN. MATTHIESEN shall be obligated hereby to furnish only the replacement part or parts. MATTHIESEN disclaims all other warranties, express or implied, including warranties of merchantability and of fitness for a particular purpose. Under no circumstances shall MATTHIESEN be liable or responsible for initial or consequential damages caused by any defects in materials, workmanship, or by failure to adhere to any warranties. MATTHIESEN 566 North W W White Road San Antonio, Texas Fax: Phone: /22/06 5

6 INSTALLATION LIFTING AND MOVING: Extreme care must be taken to prevent damage when moving assembled conveyors or components. Spreader bars with slings are the recommended support method for lifting. The unsupported span should be no longer than 10 to 12 feet. Never lift a conveyor with only one support point. Unusually heavy items such as drives or gates shall be considered when choosing support points because of load balance and their bending effect. ASSEMBLY: For safety and and proper operation screw conveyors must be assembled and erected straight and true. It is the responsibility of the purchaser to insure all support and mounting surfaces are level and true so there is not distortion in the conveyor. All component pieces (or conveyor sections) should be placed in proper sequence before assembly is started. Sub-assemblies such as trough end and seal/bearings should be assembled (if not shipped preassembled) and alignment of seals and bearings and seal direction should be checked. For shop assembled Conveyors, Units are match marked, and shipped in the longest sections practical for shipping. Field assembly can be accomplished by connection marked joints and in accordance with packing list and or drawing if applicable. In field erection, the mounting surfaces for supporting the conveyor must be level and true sor there is no distortion in the conveyor. Shims or grout should be used when required. Check for straightness as assembly is made. For conveyor assemblies purchased as parts or merchandise, assemble as follows: 1 Place conveyor troughs in proper sequence with inlet and discharge spout properly located. 2 Connect the trough flanges loosely. Do not tighten bolts. 3 Align the trough bottom centerlines perfectly using piano wire (or equivalent) then tighten flange bolts. 4 Tighten all anchor bolts. Assembly of conveyor screws should always begin at the thrust end. If the thrust end is not designated, assembly should begin at the drive end. If a thrust end is designated, assembly should begin at the drive end. If a thrust end is designated, assemble trough end and thrust bearing. Insert the end, or drive shaft, in the end bearing. Do not tighten set screws until conveyor assembly is completed. 6

7 Assembly of conveyor screws should always begin at the thrust end. If the thrust end is not designated, assembly should begin at the drive end. If a thrust end is designated, assemble trough end and thrust bearing. Insert the end, or drive shaft, in the end bearing. Do not tighten set screws until conveyor assembly is completed. 1 Place the first screw section in the trough, slipping the end or drive shaft into the pipe end. Secure tightly with coupling bolts. Install so that conveyor end lugs are opposite the carrying side of the flight. 2 Place a coupling shaft into the opposite end of conveyor pipe. Tighten coupling bolts. 3 Slide hanger with bearing over coupling shaft and clamp hanger to trough. 4 Assemble alternately, conveyor screw, couplings and hangers until all screws are installed repeating steps 1,2, and 3. a. With hangers: Assemble screw section so that flighting at each end is approximately 180 degrees from ends of flighting of adjacent sections. Also, adjust conveyor screw and thrust unit so that hangers are equally spaced between adjacent screws. After each hanger is installed, rotate the conveyor by hand to insure that no binding occurs. Remove hanger clamps and bolt hanger to trough with the bearing centered between conveyor screws. b. Without hangers: (close coupled) Assemble screws so that flighting at adjoining ends of screw sections aligns to produce a continuous helix surfaces. (Note: coupling holes have been drilled in assembly to allow for flight alignment.) 5 The end shaft should be inserted through the trough end bearing/seal into the terminal screw section. Install and tighten coupling bolts. The bearing and seal should be adjusted to be true and concentric on the shaft and bolts tightened. If packing gland type seals are used, they should be tightened only enough to prevent leakage. Check waste pack type seals to insure packing is loosed but sufficiently tight to prevent leakage. 6 Install trough covers in proper sequence. Properly locate inlet openings. Handle covers with reasonable care to avoid warping or bending. Attach covers securely to trough. Do not overtighten as cover damage may result. 7 Rotate conveyor by hand to insure no binding occurs. 8 Install drive at proper location and in accordance with separate instructions or drawing provided. Install all guards. 9 Check screw totation for proper direction of material travel after electrical connections have been made, but before attempting to handle material. Incorrect screw rotation can result in serious damage to the conveyor and to related conveying and drive equipment. If necessary, reconnect electrical leads to reverse rotation of conveyor and direction of material flow. 10 Attach all gates, feed chute, discharge chute, etc. and connect all safety devices and controls. Using extreme caution test conveyor to insure proper operation. 7

8 ELECTRICAL Your Matthiesen Screw Conveyor is not equipped with any switches, starters, etc. It is the customer s responsibility to provide power to the unit as well as any switches or controls unless specified. CHECK LOCAL ELECTRICAL CODES FOR PROPER WIRE & WIRING POWER SUPPLY. ALWAYS LOCK-OUT/TAG-OUT POWER SOURCES WHEN INSTALLING OR SERVICING EQUIPMENT. To assure proper operation of the Screw Conveyor equipment you must have a separate circuit to avoid fluctuations in current. Circuit breaker should be sized according to full load amp draw. 8

9 GENERAL MACHINE SPECIFICATIONS All standard screw conveyor components are manufactured in conformity with CEMA standards. Special components are designed and manufactured to the particular job specifications. Screw conveyors may be ordered either as complete units or by individual components. Complete units are normally shop assembled and then match marked and disassembled for shipment and field reassembly. When components only are ordered, shipment is made as ordered and these components must be sorted and aligned in field assembly. Because shop assembled screw conveyors are pre aligned and mach marked at the factory, they are easier to assemble in the field and require minimum installation time. When individual components are ordered, more careful alignment and assembly are required. More time is required for field installation. Assembly bolts are not included with parts orders unless specified, but are included with preassembled units. 9

10 SCREW CONVEYOR OPERATION Product should be installed in compliance with NEC (National Electric Code), OSHA, and other regulatory agencies. Lubricate all bearings and drives per service instructions. Gear reducers are normally shipped without lubricat. Refer to service instructions for lubrication. In start-up of the conveyor, operate several hours empty as a break-in period. Observe for bearing heat up, unusual noises or drive misalignment. Should any of these occur, check the following and take necessary corrective steps. (Non Lubricated hanger bearings may cause some noise.) 1) BEARINGS There are two 4-hole flange bearings. Inspect bearings monthly and grease if necessary. Insufficient or excess lubricant will cause high operating temperatures. 2) ADJUSTMENT Misalignment of trough ends, screw, and hangers may require excessive maintenance and cause reduced equipment life. 3) Check assembly and mounting bolts: tighten if necessary. Do not overload the conveyor. Do not exceed conveyor speed, capacity, material density, or rate of flow for which the conveyor and drive were designed. If the conveyor is to be inoperative for a prolonged period of time, operate conveyor until cleared of all material. This is particularly important when the material conveyed tends to harden or become more viscous, or sticky, if allowed to stand for a period of time. It may be necessary to recenter hanger bearings after running material in conveyor. CAUTION: DO NOT MIX MINERAL OIL WITH SYNTHETIC OIL. THIS WILL REDUCE THE LIFE EXPECTANCY OF THE OIL. HAZARDOUS SCREW CONVEYOR OPERATION Screw conveyors are not normally manufactured or designed to operate handling hazardous material or in a hazardous environment. Hazardous materials can be those that are explosive, flammable, toxic or otherwise dangerous to personnel if they are not completely and thoroughly contained in the conveyor housing. Special construction of screw and conveyor housing with gaskets and special bolted covers can sometimes be used for handling this type of material. Screw conveyors are not made or designed to comply with local, state, or federal codes for unfired pressure vessels. 10

11 EXTENDED SHUTDOWN/STORAGE If the conveyor equipment will be shutdown or stored (beyond one month) the following should be performed: 1) Insure all foreign material is removed from the conveyor and surface coating are in good order. 2) All bearings and drives are lubricated and protected per manufacturer s instructions. 3) Screws are rotated every two weeks. 4) The conveyor is protected from weather, moisture, and extreme temperatures. Do not use plastic or other coverings which promote condensation under the covering. 5) All exposed metal surfaces are coated with a rust preventative oil that is applied per instructions. 6) Prior to start-up, inspection and service instructions contained in this manual must be performed. 11

12 TROUBLESHOOTING PROBLEM CAUSE REMEDY Gauge too light Increase thickness. Consult catalog materials table/ component series for recommendation Eliminate excessive deflection. Premature trough failure Consult catalog for calculation Screw deflection procedure to determine proper pipe size and screw Bent screw Straighten or replace. Check before operation. Gauge too light Increase thickness. Consider hard facing Accelerated flight tip wear Slow conveyor down. Consult catalog engineering section to RPM s too high determine proper trough loading. Increase torque capacity or use Coupling shaft breakage Torque capacity insufficient larger shaft. Check motor amp demand for torque requirements Insufficient number of bolts Increase number of bolts Cease jogging or frequent Shaft hole elongation Conveyor subject to jogging stop/start or overload. If this is or too frequent stop/start, or not possible increase bearing frequent overloads capacity of shaft and/or increase number of bolts. Drive shaft breakage Motors/Heaters overload Inlet trough end bearing failure Discharge trough end bearing failure Hanger bearing failure Excessive torque insufficient torque capacity. Obstruction in conveyor Amp demand excessive for motor Material getting into bearing Insufficient lubrication Shaft slope Material getting into bearing Incorrect alignment Heat due to hot material being conveyed Recalculate HP requirements. Increase torque capacity. Check screw alignment. Recheck horsepower calculations. Check material characteristics. Check capacity. Regulate feed. Add or upgrade seal to keep material out of bearing. Change to outboard bearing. Lubricate properly. Align screw. Check for excessive screw deflection and for bent screw. Add or upgrade seal Change to outboard bearing Cut off flight at center of discharge Align hanger Use appropriate bearing material Hanger bearing failure Heat due to insufficient 12 Properly lubricate

13 (cont d) lubrication Thrust due to pipe pressing on bearing insert Improper material causing premature wear Check coupling bolts and holes for elongation and wear. Replace as necessary. Readjust screw/hanger assembly to get proper clearances Consult catalog for proper material due to temperature, trough loading, and speed. Check to insure coupling shaft material and bearing material are compatible. 13

14 LUBRICATION The bearings are lubricated at the factory. Because of use in wet conditions they should be checked or lubricated periodically. Matthiesen recommends the use of food grade lubricants on all necessary parts. Flange bearing Food grade bearing grease Matthiesen stocks the following Lubriplate products: STK# PT560 FMO 9OO AW Food grade gear oil RS035 FGL 1 Food grade grease RS036 FMO 350 Food grade spray Flange bearings When establishing a lubrication schedule, note that a small amount of grease at frequent intervals is preferable; as to a large amount at infrequent intervals. SCREW CONVEYOR BEARINGS QUANTITY PART # DESCRIPTION HOLE FLANGE 4 HOLE FLANGE BEARING Matthiesen offers the following Mobil product for their gear drive motors: STK# PT215 SCH634 Low Temperature Synthetic Lubrication SCREW CONVEYOR DRIVES QUANTITY PART # DESCRIPTION 1 MTR HP 3 PH 60hz 240/460V 14

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53 CLEANING AND SANITIZING INSTRUCTIONS Equipment: The Matthiesen Screw Conveyor Materials Required o Water hose with spray nozzle attached to potable water source. o Pressurized detergent spray unit with application hose and spray nozzle. o Portable, hand operated pressure sprayer (2-3 gallon size). o Auxiliary equipment: Brooms and brushes, sponges, wipes and plastic sheets to cover sensitive equipment. o Personnel/supplies plastic or rubber gloves, boots, head cover, aprons/coveralls, eye safety glasses. o Moderately alkaline detergent (Mix per vendor instructions) o Sanitizer: Quaternary ammonium Special Instructions o Avoid eye and skin contact with chemicals o Maintain adequate ventilation. Recommended Frequency of Cleaning o Recommended weekly or more often, if necessary. Procedure 1. Remove residual ice and drain. 2. Shut down and lock out unit (electrical). 3. When essential, hand- clean the motor and controls and cover with plastic sheets. 4. Rinse inside walls, breakers, and exterior with potable water. 5. Spray the detergent solution on all pre-rinsed surfaces with detailed brushing, as required, until free of debris. 6. Rinse free of detergent with warm water (< 130 F) and inspect for cleanliness. Repeat cleaning and rinsing until thoroughly clean. Note: It may be necessary to turn on the screw conveyor, applying detergent and rinsing alternatively to obtain thorough cleaning. 7. Spray sanitizer (quaternary ammonium) at 200 ppm on screw and interior housing and allow to dry. 8. Leave unit locked out until the next shift s operation. 53

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55 DECAL REORDER SHEET DECAL NUMBER DECAL IDENTIFICATION D D D D D

56 DECAL REORDER SHEET DECAL NUMBER DECAL IDENTIFICATION D D D D

57 VISUAL: CLEANLINESS: INSPECTION REPORT PASS FAIL DECALS: PASS FAIL MECHANICAL: MOTOR PASS FAIL FINAL INSPECTION: DRY TEST RUN PASS FAIL VISUAL PASS FAIL FASTENERS FOR TIGHTNESS PASS FAIL (Test frequency 1 every 10 bolts) COMMENTS: INSPECTED BY DATE: SERIAL NUMBER G:\equipment manuals\screw conveyor\inspection report Created by: Ron de Leon Approved by: Pete Ruiz Date: 06/17/06 57