PROFAX TR-20000 Handbuch

TR-20000ROTATOR

OPERATION& MAINTENANCE

MANUAL

TR-20000

INSTRUCTIONMANUAL

PROFAXTR-20000

CONTENTS

•CONTENTS1

•IDENTIFICATIONDATA2

•SAFETYPRECAUTIONS3

1.GeneralSafetyInstruction3

InstallationPreparation3

•OPERATIONANDMAINTENANCE4

1.GeneralDescription4

MainSpecification4

3.BasicConstruction5

Installation6

5.Start-UpOperation7

6.DuringOperation8

7.ShutdownOperation9

8.Maintenance &TroubleshootofMechanicalParts10

•APPENDIXA GENERALARRANGEMENTA

•APPENDIXB ELECTRICALDRAWINGSB

•APPENDIXC ASSEMBLYDRAWINGSC

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

Pleasequotetheaboveserialno.anddetailswhenorderingsparesorinanyothercommunications

regardingthisequipment.

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.

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

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).

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

smell.

Testsruntherollsintravelingmotionsforbothdirectionsandobserveifthereisany

unusualnoiseor

smell.

•TesttheStopButtononthePendantControllertoensureitsfunctionality.

•Testrunagaintherollsinrotationmotionsforbothdirectionsandobserveifthereisany

unusualnoiseor

smell.

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.

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.

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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