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
1

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.
2

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.
3

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
4

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).
5

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.
6

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.
7

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.
8

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
9

PROFAX TR-20000
8.Maintenance& TroubleshootofMechanicalParts
8.1MaintenanceRoutineForTheEquipment
•RecommendedMaintenanceRoutinefortheEquipment
No.
Component Inspection/ Action Interval
1 ElectricalPanel CleanwithlightCompressedAir 3months
2 FilteratPanel Replace 6months
3 Pendant OpenandcleanbyapplyingWD40atmovingparts 3months
4 Bolt& Fastener Visualoncorrosion,missing Weekly
5 WarningLabels
Visual, replacewheretorn weekly
8.2TroubleshootingofMechanicalParts
•TroubleshootingofMechanicalParts
Problem PossibleCause Solution
IndicatorLight
Failstolight
1.Nopower
2. Fuseblown
3.Faultyindicatorlight
4. Faultypowerswitch
1.Checkpowersupply
2. Checkandreplacefuse
3.Checkandreplaceindicator
4. Checkandreplacepowerswitch
Fuseblown 1.FaultyPCboard
2. Faultymotor
3.Faultyorbadtransformer
1.Checkandreplacecontrolbox
2. Checkandreplacemotor
3.Checkandreplacecontrolbox
Powerrollfailsto
turn
1.FaultyPCboardorcontrolbox
2. Faultymotor
3.Faultyforward/off/reverse
switch
1.Voltagetomotorshouldvaryfrom0 to
90VDCinrelationtothespeedcontrol.
Ifoutputiserraticornon-existing
replacecontrolbox.
2. Checkandreplacemotor
3.Checktoseeifswitchisincorrect
position. Mustbeineitherforwardor
reversepositiontorun.Testswitch
continuity
Workpiece
motionis
intermittent 1.Driverolltensionadjustment 1.Adjustdriverolltension
10

PROFAX TR-20000
APPENDIXA
GENERALARRANGEMENT
TheGeneralArrangementisa CADmoduleillustratingthegeneralset-upoftheequipment.Themain
specificationsoftheequipmentarealsolistedintheGA.TheGeneralArrangementfortheTR-20000
ROTATORispresentedinthesucceedingpages.
A

C~C:?19?175?1,31?87?43?
SpecificationforRotator-PowerUnit
1 Model PR-10000
2 Capacity(loading) 5 MetricTon
3 Capacity(Tuming) 15MetricTon
4 VesselSize(Min) 0519at60°includedAngle
5 VesselSize(Max) 04t)41at60°includedAngle
6 TyreTypeandSize polyurettiane.0345cnmX13Onim
7 ElectricalPanel YES
8 RollerSpeed 0to1959mm/minat
0~90V
9 IncomingSupply 110V-1P-60H2
10 ControlVoltage 24VAC
11 ControlMeans ViaPusti ButtonPendantcht 5mCable
12 RollerDriveMotor 750WDCMotor
13 SurfacePreparation GritblasttoSA2.5
14 Painting Powdercoating
15 Color SilverGray
16 Qty eUnil
17 EstWeight 354KG
TR-20000
GA
'Rotator- Powerunit
PR-10000

Specification for Rotator-PowerUnit
1 Model
IR-10000
2 Gapacity(loading) 5 Metric
Ton
3 Capacity(Tuming) N.A
4 VesselSize
(Min) 0519 at60° includedAngle
5 VesselSize
(Max) 04041 at60° includedAngle
6 TyreType
and Size polyurethane,0345mmX13Omm
7 ElectricalPanel NO
8 SurfacePreparation Gritblast
to SA2.5
9 Painting Powdercoating
10 Color SilverGray
11 Qty 9Uiiit
12 EstWeight 248KG
HMK I MIT
ZHANG I2012/Q7/2S
PROJBCT/ilOOa :
TR-20000
GA
Rotator - Idleunit
R-10000
1 OF1

PROFAX TR-20000
APPENDIXB
ElectricalDrawings
ElectricalDrawingsarecompiledinthissectiontogivetheusera detailedgraphicalillustrationofthe
electricalcomponentsandcircuitdiagramsassociatedwiththeequipment.
B

DRAWINGLIST
SalesOrderNo 166480 ItemNo i
Customer/Project PROFAX
No. ofUnits J6
Product ReferenceNo TR-20000-EID1-110V
Model TR-20000 Revision 01
PreparedBy: ApprovedBy: IssuedTo:IssuedTo:
No 1 DrawingNo.; Sht RevDescription Qty/UnitRemarks
1:TR-20000-EIC1-110V 1\1 ControlPanelEquipmentList N/A
2 TR-20000-EI01-110V 1 01 PowerControlCircuitDiagramN/A
3 TR-20000-EI02-110V 1 01ControlCircuitDiagramN/A
4 TR-20000-EI03-110V 1 01 BlockDiagramN/A
5 TR-20000-EIP1-110V 1 01 OutsideViewofControlPanelDiagram N/A
6 TR-20000-EIP2-110V1 1 | 01 OutsideViewofControlPanelDiagram N/A
7 TR-20000-EIP3-110V 1 01 OutsideViewofPendantControllerDiagram N/A
8 TR-20000-EIW1-110V 1 01 CableList N/A
i
•
j
i
1
1
1
Note:

CONTROLPANELEQUIPMENTLIST
SalesOrderNo.: 66480 Customer/Project: PROFAX
ItemNo.: ModelNo: TR-20000
No. ofUnits: 6 ReferenceNo.: TR-20000-EIC1-110V
Revison: 01
PreparedBy: ApprovedBy: IssuedTo:
1°
No. SymbolNo. Description Type Qty/Unit Brand Remarks
1 CP1 CONTROLPANEL H380xW380xD175 I
2 PL1 PILOTLIGHTSWITHINTEGRALLED AD16-22D/SACDC24V(Red) 1 APT
3 SW1
2-SATY PUTSELECTORSWITCHES LAY37 1
SANLI
4 PT1 TRANSFORMER IP:110VOP:220V/110V/24V/0V(100W) 1 JUCHE
5 PCB DCMOTORCONTROLLER XJB110-90H-O(750W/AC110/DC90V) 1 XAJONG
6 MCB THERMALMAGNETICCIRCUITBREAKER DZ47-632PC6 I
7 MCF/MCR
3-POLE CONTACTORS GMC-12ACDC24V50/60HZ LG
8 CR1 RELAY MY2NJAC24V 1 OMRON
9 -RELAYSOCKETFORMY2N PYF08A-E 1 OMRON
10 -RELAYHOLD-DOWNCLIPS PYC-A1 OMRON
11 F1 DOMESTICCARTRIDGEFUSE RT14-20(10x38)2A 1 MIRO
12 F2 DOMESTICCARTRIDGEFUSE RT14-20(10x38)10A 1 MIRO
13 F1-F2 MODULARFUSECARRIERS RT18-32(10x38)32A MIRO
14 SPW NOISEFILTER FC2213-6-01 1 QITONG
15 TBI TERMINALBLOCKS TBR-10 14 TEND
16 TBI LEADRAIL DIN I
17 GROUDNCOPPERBARS 1
18 TBI WIREGROOVE 25*30*1000 I
19 D1 POWERCABLE RW3*1.31*3M I QIAOPU
20 D1 CABLEGLANDS KB-1 1
21 TBI WIREGROOVE 25*30*1000 '
Rev:01
ReleasedDate: 08Aug.2012

CONTROLPANELEQUIPMENTLIST
SalesOrder No.:
66480
Customer/Project:
PROFAX
Item No.: Model No: TR-20000
No. ofUnits: 6 Reference No.: TR-20000-EIC1-110V
Revison : 01
Prepared By:
Approved By:
Issued To:
y
No.
Symbol No.
Description Type Qty/Unit Brand Remarks
22 PI ALUMINIUMGREHAUSE H240*W150*D115 1
23 VR1 POTENTIONMETER RV24YN
20S B502 1 COSMOS
24 -POTENTIONMETERKNOB RW100C 1 COSMOS
25 E.STOP MUSHROOMHEADPUSH-BUTTONS LAY37 (Red)
1 SAN LI
26 PBO PUSH-BUTTONS LAY37
(Red)
1 SANLI
27 PB1 PUSH-BUTTONS LAY37(Green) 1 SANLI
28 PB2 PUSH-BUTTONS LAY37(Yellow) 1 SANLI
!
29 D2 CABLEGLANDS M22 1
30 CABLEGLANDS M25 1
31 REDUCER UCX50/80-10*40-200/19-A 1
CHENTA
32 MOTOR 750W/DC90V/1800RPM
019 ForceCooling 1 CHANGYIH
Rev. 01
ReleasedDate : 08 Aug. 2012

MCB
Hi'
PE
^F1/10A2 SW1
PE
SPW
32
L1A*
PCBA-
F+
F-
V1V2V3
L2
373635
DRAWN
MCF
10
750W
E.STOP
I1
33
110V
lOOVA
I< I
II
PT1
MCR
APPROVED
NAME
WU DATE
2012/08/08
PROJECT/MODEL;
TR-20000
CLIENT:
24
DWGNAMEPowerControlCircuit
Diagram
DWG. NO. TR-20000-EI01-110V
SCALE:
N/A
REVISION:
01
SHEETNO:
1 0F1
SIZE: A4

24™ 25
r"
PBOI
I
34
PL1
_J
CR1
L.
PB1-p
29
MCR:
28
MCFQ
PB2:
27
MCF:
30
MCRr
.J
MCF MCR
CR1
31
PROJECT/MODEL:
TR-20000
CLIENT:
NAME DATE CLIENT:
DRAWN WU 2012/08/08
CLIENT:
SCALE:
N/A
REVISION:
01
APPROVED
DWG. NAME: ControlCircuitDiagram
SCALE:
N/A
REVISION:
01
APPROVED
DWG. NO. : TR-20000-EI02-110V SHEETNO:
10F1
SIZE: A4