PROFAX TR-20000 Manual

TR-20000ROTATOR
OPERATION& MAINTENANCE
MANUAL
TR-20000
INSTRUCTIONMANUAL

PROFAXTR-20000
CONTENTS
•CONTENTS1
•IDENTIFICATIONDATA2
•SAFETYPRECAUTIONS3
1.GeneralSafetyInstruction3
2. InstallationPreparation3
•OPERATIONANDMAINTENANCE4
1.GeneralDescription4
2. MainSpecification4
3.BasicConstruction5
4. Installation6
5.Start-UpOperation7
6.DuringOperation8
7.ShutdownOperation9
8.Maintenance &TroubleshootofMechanicalParts10
•APPENDIXA GENERALARRANGEMENTA
•APPENDIXB ELECTRICALDRAWINGSB
•APPENDIXC ASSEMBLYDRAWINGSC
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PROFAX TR-20000
Purchaser
PONo.
SerilNo.
EquipmentType
Model
LoadingCapacity
RotatingCapacity
VesselSize(Min.)
VesselSize(Max.)
RollerSpeed
PowerSupply
Weight
Color
Quantity
IDENTIFICATIONDATA
PROFAX
66480
TR20-1005
ROTATOR
TR-20000
10MetricTon
15MetricTon
0519at60°includedAngle
CM041at60°includedAngle
0to1959mm/minat 0-900V
110V-1P-60HZ
602KG
SilverGray
6
Pleasequotetheaboveserialno.anddetailswhenorderingsparesorinanyothercommunications
regardingthisequipment.
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PROFAX TR-20000
SAFETYPRECAUTIONS
1.GeneralSafetyInstruction
1.1Thismanualmustbethoroughlyunderstoodpriortoactualinstallationandoperationofthemachine.
Inadditionaltothemanual,pleaserefertoO & M ManualofWeldingEquipment.
1.2Pleaseobserveapplicablelegalandothermandatoryregulationsrelevanttoaccidentpreventionand
environmentprotection.Thesecompulsoryregulationsmayalsodealwithhandlingofhazardous
substances,issuingand/orwamingofpersonalprotectiveequipment,ortrafficregulations.
1.3Installationinstructioncontainedhereinmustbesupplementedbyinstructionscoveringallduties
involvedinsupervisingandnotifyingotherpartiesworkingwithintheareaofoperation.
1.4Observeallbasicsafetyruleslikeusingthecorrecttools,wearingofsafetyharass,etc.
Alwaysusetheliftinglugsprovidedontheequipment.
DONOTCOMPROMISEONSAFETY.
2.InstallationPreparation
2.1Duringdesignandinstallationitisvitaltotakeintoaccountrelevantstandardsandregulations,the
loadbearingcapacityofbuildingorfloororotherattachmentdevices.
2.2Beforestartinginstallation,preparea sketchordrawingshowingtheextentofthePROFAXRotator
Systemanditsrequiredareaofoperationwithrespecttobuilding.
2.3UseonlyoriginalPROFAXcomponents.Whenusingsupplementaryboltorotherfasteners,useonly
thoseaccordingtothespecifiedgrade.
2.4PROFAXRotatorisdesignedforready-to-useandthereisnofurthermechanicalinstallation
requirementexcepttoprovideconnectiontotheelectricalsupply.However,werecommendedthata
thoroughVisualinspectiontobecarriedouttoascert:ainthatnovisualdamagehasoccurredduring
thecourseofshipmentandtransit.
2.5Werecommend,afterthecompletionofinstallationbutbeforetakingtheunitintoservice,itis
commissionedbyrecognizedexpertsinthe field. Weremainnaturallyatyourservicewithhintsand
adviseshouldyourequirethem.Itbettertoaskoncetoomuchandnothingmustbeunclear.We
trustthatwithproperinstallationprocedure,PROFAXRotatorwillprovideyouyearsoftrouble-free
service.
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PROFAX TR-20000
OPERATIONANDMAINTENANCE
1.GeneralDescription
1.1PROFAXTurningRollsorRotatorsarerobustlybuiltandusesthe(tSOOmmxlOOmmPolyurethane
tiresfordurabilityandsuperiortraction.Itisdesignedtowithstandtheruggedandharsh
environmentexpectedofsuchapplication.DetailattentionssuchasgritblastingtoSA2.5forall
structuralsteelworkandpolyurethanepaintworkwillensurethatPROFAXequipmentprovidesyou
withmanyyearsofuninterrupteduse.
1.2PROFAXRotatorsaresuppliedaseitherPoweredRollsorIdlerRolls(unpowered)
2.MainSpecification
1 Model TR-20000
2 Capacity(Loading) 10MetricTon
3 Capacity(Turning) 15MetricTon
4 VesselSize(Min.) 0519at60°includedAngle
5 VesselSize(Max.) 04041at60°includedAngle
6 TyreTypeandSize Polyurethane,O345mmxl30mm
7 ElectricalPanel Yes
8 ControlMeans ViaPushButtonpendantControlC/W5mcable
9 IncomingSupply 110V-1P-60HZ
10 ControlVoltage 24VAC
11 RollerDriveMotor 750WDCMotor
12 RollerSpeed 0to1959mm/minat0~900V
13 SurfacePreparation GritblasttoSA2.5
14 Painting PowderCoating
15 Color SilverGray
16 Weight 602KG
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PROFAX TR-20000
3.BASICCONSTRUCTION
3.1Skid
TineskidisconstructedfromI-Beamsweldedtogetheranddrilledprecisionlyto
accommodatethedifferentcentertocenter(C-C)distancesofRollerFrames.Thecenter-
to-centerdistancebetweentworollsismeasuredfromthecenterofthewheelshaftofone
rolltotheotherasshowninbelow.
TheminimumC-Cforanytypeofskidis432mmwhilethemaximumC-Cvariesfrom
2192mmonwardsdependingonthetypeof skid. Basically,theskidforpoweredrollsis
thesameasthatfortheidlerrolls,onlythata pipeconduitisaddedtotheformerforthe
cablestorunthrough.Theskidmustbeusedona designatedplacewheretheflooris
levelandabletosustaintheloadingfromtheworkpiece.
3.2PrimaryGearbox
ThePrimaryGearboxisofwormdesignandiscoupledtoanDCSquirrelCagemotorvia
flange.Itissuppliedfullyalignedhencenofurtheradjustmentisrequired.
3.3SecondaryGearbox
TheSecondaryGearboxiscoupledtothePrimaryGearboxviaflange.Theoutput
shaftisfittedwitha highqualityheat-treatedpinionandmeshedwiththespur
gearofthesteeldrum.Thisprovidesthebasisofrotationfortheroller.
EachpoweredrollerisequippedwithitsownPrimary/SecondaryGearboxtogether
witha motor.Bothpoweredrollersaresymmetricalandseatonthesameskid
3.4DriveMotor
ThisDriveMotorisDCMotor
3.5ElectricalPanel
AlsoknownastheControlPanel,theElectricalPanelismountedontheLeftmoduleor
dubbedasthePrimaryModule(whenlookingatthegearbox).
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PROFAX TR-20000
4.Installation
4.1PROFAXRotatorsaredesignedforimmediateput-to-useandtinereforenomectnanicalconnectionis
required. However,Inereisa listofsomeguidelinesthatshouldbetakenintoconsiderationduring
installation.
•CheckallquantityagainsttheDetailedPackingList.
•Checkfordamagesfromhandlingorleakinggearboxes.
•Checkforcorrectvoltages.
4.2Procedures
•Selecttheareaforinstallation.Preferably,thisshouldbelevelandabletotaketheloadofwork
piecewithoutsubsequentsoilsettlement.Studytheareaofoperationtoensurethatitwillbe
largeenoughfortheworkpiecewhereextensionwillberequired.
•DonotmixthePoweredandIdlerRollsofdifferentmakersand/ortypes.
•PlaceboththePoweredandIdlerRollsinthebestalignmentpossible.Itisrecommendedto
investinthisinitialsetupprocess.
•Donotanchortheskidstotheflooriftheratiooftheworkpiece'sDiametertoLENGTHISLESS
THAN1.Thisfloating arrangementtendsto"correct"itselfifthereismisalignmentfromthe
setuporfromtheworkpieceitself.
•Thenumberofidlerrollsshouldbeincreasedifpossibleespeciallyinlargerdiametersorthinner
wallthickness.
•Testruntherollsinrotatingmotionsforbothdirectionsandobserveifthereisanyunusualnoise
or smell. Testsruntherollsintravelingmotionsforbothdirectionsandobserveifthereisany
unusualnoiseor smell.
•TesttheStopButtononthePendantControllertoensureitsfunctionality.
•Testrunagaintherollsinrotationmotionsforbothdirectionsandobserveifthereisany
unusualnoiseor smell.
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PROFAX TR-20000
5.Stait-UpOperation
5.1General
•Tooperatet6eRotatorsproperly,itisstronglyrecommendedthattheperson-inchargedbe
knowledgeableenoughofthetheoriesbehindtheoperationofsuchequipment.
•Readthismanualthoroughlybeforeoperation.
•Checktheworkpieceisfreefromencumbrances.
5.2IncludedAngle
Undernormalcircumstancesforgeneralapplication,therotators'centerdistanceof
wheelsapartshouldbeof30°to60°includedangleforconcentricbalancedloads.Thisis
alsothewidelyacceptablestandardindustrypractice.
Apairofrotatorswiththecentersetapartatangleof30°willrequirelesstorqueor
tractivepullwhencomparedwitha similarpairsetatangleof45°or60°.Increasingthe
includedangletowardtheupperlimitoftherecommendedrangewillincreasethetorque
requiredtopulltheworkpiece.Concentricloadsareusuallysetonsmallcenterdistance
apartwhereaseccentricloadsareusuallysetonwidercenterdistanceapart.
5.3WorkPieceAnalysis
Generally,thefactorstobetakenintoconsiderationbeforesettingupa jobareasfollows:
•Rigidity
•Roundness
•Weight
•Diameter
•CenterofGravity
Asidefromtheabove-mentionedfactors,otherprevailingconditionsthatwillaffectthe
rotationmustalsobeconsidered,suchasprotrusionsofsaggingduetothinmaterial
and/orbiggerdiameters.
5.4RollerAlignment
Rolleralignmentsettingisveryimportantbecauseitwillgreatlyaffectthejob
longitudinally,thatis,fromrollingandfallingovertherotators.Hence,theuserneedsto
ensurethat
•thecenterlineofthepoweredandidlerunitsareparallel,and
•thefloorhastobeflatandeven.
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PROFAX TR-20000
5.5HeightoverWidth"Toppling"
Itisalwaysa goodpracticetoensurethattheoutsidediameterofthejobshouldnot
exceeditslengthwhenperformingallthenormalsettings.Furthermore,shouldthelength
begreaterthanitsdiameter,extracaremustbetakenwhenanchoringtherotatorsonthe
floor.Theusercanalsoemployadditionalidlerunitstoincreasethestabilityofthejob
wheninoperation.
5.6PowerONProcedure
•FollowthisPowerONProcedurewhenevertheequipmentwillbe used:
No Task Results
1 Tumonthewallisolator. Voltageissuppliedtothemainpanel.
2 Tumonisolatormainswitchonmain
electricalpanel. Poweristurnedon.
3 TumthePotentiometerto"Low"andtest
thefunctionofallbuttons,especiallythe
E-Stop.
Allbuttonsshouldfunctionaccordingtoits
purposespecifiedinAppendixB
•NotethatFunctionTestisonlypossibleifthereisnoworkpiecemountedontherotators.In
casethereisa workpiece,commonsensemustprevail.
•Allcontrolsofthependantmustbetestedtoensurethattheyoperateasitisintended.
6.DuringOperation
Observethefollowingguidelineswheneveroperatingtheequipment:
•Beforerotatinganyworkpiece,bringthespeeddowntominimumbyturningthe
potentiometerto5.
•Startrotatingtheworkpieceindesireddirectionandincreasingthespeedgradually.
•AlwaysensurethattheworkpieceisingoodcontactwiththePowerandIdlerunits
used.
•Whena Powerunitisusedwithmorethanoneidlerunit,thePowerunitshouldalways
belocatedatoneendofthevesselsoastoensurecontactwiththeloadandprevent
slipping.
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PROFAX TR-20000
•Incaserollerslippageoccurs,itcanusuallybeovercomeby:
increasingtheunitscenterdistancetoincreasetraction;
->removingdirtandgreasesfromtherollssurfaceandworkpiecesurface;
->redistributingtheloadonthePowerandIdlerunitsinordertomakegreater
proportionoftheloadlieonthePowerunitsandhence,increasetraction;
->ensuringthatrotatorshavethesameheightanddiameterinordertoprevent
cylindricalworkpiecefrommovingalongthelongitudinalaxis;and
->checkingthesquarenessoftherotators.ThisisdonebyaligningthePower
RollandIdlerRollwitheachotherandmakingtheirdiagonalsequal.
Incaseofdoubtsofthemachinefunctionalities,alwaysreporttothesupervisorand
discontinuetheuseoftheequipmentuntilithasbeenrectifiedandcertifiedbyan
authorizedmaintenancepersonnel.
IGNORANCEISNOTANEXCUSE!
7.ShutdownOperation
7.1PowerOFFProcedure
•FollowthisPowerOFFProcedureafteroperatingtheequipment:
No.
Task Results
1 DepressSTOPbutton Equipmentstopsoperation.
2 DepressEmergencySTOPbutton
onelectricalpanel NopowertoMainContactor
3 Tumoffmainswitchontheelectricalpanel PoweristumedofftheBreaker.
4 TumoffwallIsolator PowerOFFtothemainpanel.
7.2Cleartheoperationareaandkeepalltoolsintheirproperlocation.
PRACTICEGOODHOUSEKEEPINM
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