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DERRICK DE-7200 Maintenance & Operation Manual

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DE-7200 Centrifuge
Variable Frequency Drive
Issued 30 Oct 09
Rev 01 Jan 14
Maintenance & Operation Manual
DISCLAIMER
Derrick Corporation has taken care to ensure that all of its maintenance and operation manuals are accurate. However, we offer no
guarantees or warranties in this regard. Our manuals are provided only as a guide to assist with the maintenance and operation.
Derrick Corporation takes no responsibility for any losses, damage, or injuries that may occur as a result of using any of our manuals.
It is ultimately the operator's responsibility to ensure that the operation, repair, and maintenance of equipment complies with all
applicable national and local regulations, including safety regulations.
THIS MANUAL IS PROVIDED BY DERRICK CORPORATION ON AN "AS IS" BASIS AND DERRICK CORPORATION EXPRESSLY
DISCLAIMS ANY AND ALL WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL DERRICK CORPORATION BE LIABLE
FOR ANY DIRECT, INDIRECT, INCIDENTAL, PUNITIVE, OR CONSEQUENTIAL DAMAGES OF ANY KIND WHATSOEVER WITH
RESPECT TO THE MANUAL AND EQUIPMENT.
Derrick Equipment Company
15630 Export Plaza Drive
Houston, Texas 77032
Phone: 281.590.3003
Toll Free: 1.866.DERRICK
Fax: 281.442.6948
www.derrickequipment.com

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Summary of Contents for DERRICK DE-7200

  • Page 1 Our manuals are provided only as a guide to assist with the maintenance and operation. Derrick Corporation takes no responsibility for any losses, damage, or injuries that may occur as a result of using any of our manuals.
  • Page 3 For convenient availability, the unit number is also recorded in the Operation and Maintenance manual shipped with the equipment. When contacting Derrick for any equipment question or need, always have the unit number in your possession. It’s the best way to get the most efficient service from our...
  • Page 4 (not the page number at the bottom of each page). This document contains proprietary information of Derrick Corporation. It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Derrick Corporation.

  • Page 5: Table Of Contents

    CONTENTS Section Page Date 15 Feb 12 1 - Introduction ..................... 1-1 Overview ....................1-1 Safety ...................... 1-1 Sound Emission ..................1-1 Equipment Use ..................1-2 Description ....................1-2 Mechanical Operation ................1-6 Control System ..................1-7 Product Support ..................1-8 2 - Safety .......................
  • Page 6 CONTENTS Section Page Date 4 - Operating Instructions ................4-1 30 Sep 13 General ....................4-1 Software Version ..................4-1 Operating Safety ..................4-1 Top Cover Opening/Closing Procedures ..........4-2 Purge System (Hazardous Environment Only) ......... 4-2 Initial Startup .................... 4-3 Normal Startup ..................
  • Page 7 CONTENTS Section Page Date 5 - Maintenance (Cont’d) Troubleshooting ..................5-17 Alarm and Fault Messages ..............5-25 VFD Alarm and Fault Cross References ..........5-32 Control Component Indicators ..............5-33 6-7 - Not Used 8 - Reference Drawings ................8-1 01 Sep 11 9 - Installation and Maintenance Log ............

  • Page 9: Introduction

    SECTION 1 - INTRODUCTION OVERVIEW This manual provides instructions for installing and operating the DE-7200 Variable Frequency Drive (VFD) centrifuge (Figure 1-1). The manual is divided into several sections to assist the user in readily accessing the information. Instructions include description, theory of operation, safety, installation, and maintenance.

  • Page 10: Equipment Use

    INTRODUCTION EQUIPMENT USE The DE-7200 VFD centrifuge is designed for removing low and high specific gravity solids from slurries. In one type of processing, solids are removed and the liquid is returned for recirculation. Alternatively, solids are returned to the active system and the liquid is discarded or processed by a second centrifuge.
  • Page 11 INTRODUCTION Rotating Assembly The rotating assembly consists of a cylindrically shaped, bowl, conveyor assembly, gearbox, and related components. The bowl consists of a straight cylinder with a conical section at the solid discharge end and a flat liquid bowl head at the opposite end. Openings are provided at both ends to permit liquid and solid discharges.
  • Page 12 INTRODUCTION pre-set torque limit is reached, the control system automatically reduces the feed rate to enable the conveyor to clear the excess solids. When the centrifuge is operating at the reduced feed rate, the Operation screen displays a message to inform the operator of the modified status. Unless the over-torque condition is removed, the centrifuge will be shut down automatically.
  • Page 13 INTRODUCTION the upper setpoint, the compressor and condenser motors are cycled on to provide cooling. Upon reaching the low temperature setting, the air conditioner is shut down. The evaporator fan operates continuously whenever the cabinet is energized to maintain a continuous flow of conditioned air over cabinet components.

  • Page 14: Mechanical Operation

    INTRODUCTION The case is bolted onto the welded steel base assembly, which contains mounting provisions for the bearing pillow blocks. The base assembly supports the centrifuge components and contains hollow rubber vibration isolators that engage with centering pins attached to the mounting platform.

  • Page 15: Control System

    INTRODUCTION Figure 1-4 Centrifuge Operation CONTROL SYSTEM Centrifuge operation is supervised by a programmable logic controller (PLC) that interfaces with the variable frequency drives (VFDs) supplying power to the bowl, conveyor, and feed pump drive motors. Monitoring and control of the centrifuge may be performed locally or remotely. The environmentally hardened PLC also offers short-term data storage and a high degree of operating flexibility.

  • Page 16: Product Support

    INTRODUCTION PRODUCT SUPPORT Derrick Corporation offers 24-hour per day, 7-day per week product support. Product support includes screen replacement / ordering information and repair / replacement parts and service for the entire product line. Refer to the following table for the parts / service center nearest you.

  • Page 17: General

    SECTION 2 - SAFETY GENERAL This section contains a summary of WARNINGS used in this manual and a list of material safety data sheets (MSDSs) applicable to the equipment. The centrifuge has been designed to perform the stated functions safely. WARNINGS All persons responsible for operation and maintenance of this equipment must read and understand all safety information in this manual prior to operating and/or maintaining the...
  • Page 18 PERSONNEL MUST ENSURE THAT ALL BODY LIMBS AND ANY OTHER ITEMS ARE CLEAR OF THE COVER GAP. TWO HANDS MUST BE USED, WITH BOTH HANDS ON THE COVER HANDLES AT ALL TIMES. DERRICK RECOMMENDS HAVING A HOIST AVAILABLE IF ADDITIONAL ASSISTANCE IS DESIRED DURING THE OPENING/CLOSING PROCEDURE.

  • Page 19: Material Safety Data Sheets (Msdss)

    The MSDSs listed below apply to products used in the manufacture of the Derrick equipment. Where shown, dates are current as of the publication date of this manual. The latest MSDSs may be obtained from the product manufacturer.
  • Page 20 SAFETY MSDS’S (CONT’D) MATERIAL DESCRIPTION - WHERE USED MSDS / Date Paints PPG Dimetcote 302H Green 302F0250 Resin - Top Coat 1302H-5A / 04-11-10 PPG Dimetcote 302H Clear 302G0910 Cure - Top Coat 1302H-B / 01-21-10 PPG PSX 700 Neutral Tint Resin - Undercoat PX700T3 / 02-28-08 PPG PSX 700FD Cure - Undercoat PX700FD-B / 01-11-07...

  • Page 21: Installation

    SECTION 3 - INSTALLATION GENERAL This section describes the recommended installation procedure for the DE-7200 VFD centrifuge. The centrifuge is shipped fully assembled. For safety during shipment, however, the rotating assembly is supported by shipping brackets. It must be lowered onto the base and then its bearing pillow blocks secured to the base.

  • Page 22: Top Cover Opening/Closing Procedures

    The proper procedures for opening and closing the top cover of the centrifuge must always be followed. Two operators using both hands are required to open the cover. Derrick recommends having a hoist available if additional assistance is desired during the opening/closing of the centrifuge cover.

  • Page 23: Installation Sequence

    INSTALLATION INSTALLATION SEQUENCE Following is the sequence of steps for installing the centrifuge. The sequence presented may vary depending on the user’s facilities and previous experience with this type of equipment. 1. Read and understand all safety information in Section 2 before installing and operating this equipment.

  • Page 24: Equipment Handling

    ITEMS ARE CLEAR OF THE COVER GAP. TWO OPERATORS MUST BE USED, WITH BOTH HANDS ON THE COVER HANDLES AT ALL TIMES. DERRICK RECOMMENDS HAVING A HOIST AVAILABLE IF ADDITIONAL ASSISTANCE IS DESIRED DURING THE OPENING/CLOSING PROCEDURE. The centrifuge and control cabinet are shipped fully assembled and installed on shipping skids. A label indicating the weight of each unit was affixed to the machine.
  • Page 25 (Figure 3-3). Lift points are labeled “LIFT HERE ONLY”. DO NOT attempt lifting equipment by attaching slings or similar lifting aids to any other location on the cabinet. Figure 3-2. Lifting Arrangement - DE-7200 Centrifuge 01 Jan 14 DE-7200VFDCentrifuge...

  • Page 26: Equipment Positioning And Mounting

    INSTALLATION EQUIPMENT HANDLING (CONT’D) Figure 3-3. DE-7200 Control Cabinet Lifting Arrangement EQUIPMENT POSITIONING AND MOUNTING Base plates are required when installing the centrifuge. Lay out the installation site and locate the base plates in accordance with Figure 3-4. The base plates have 1-9/16” x 1-9/16” (40mm x 40mm) centering posts.
  • Page 27 INSTALLATION 01 Jan 14 DE-7200VFDCentrifuge...

  • Page 28: Liquid And Solid Discharge Chutes

    INSTALLATION EQUIPMENT POSITIONING AND MOUNTING (CONT’D) Figure 3-5. Centrifuge Mounting LIQUID AND SOLID DISCHARGE CHUTES Observe the design considerations shown in Figure 3-6 when fabricating the liquid and solid discharge chutes. To determine dimensions and mounting hole arrangements, refer to general arrangement drawing in Section 8.

  • Page 29: Equipment Leveling

    INSTALLATION Liquid Discharge The liquid discharge collector may be bolted directly to the centrifuge case; however, the piping connection should have a flexible joint. When fabricating the discharge piping, follow the dimensional and piping requirements shown in Figure 3-6. Since liquid exiting the centrifuge is not pressurized, the piping must be pitched to facilitate gravity drainage.

  • Page 30: Lower And Secure Rotating Assembly

    INSTALLATION LOWER AND SECURE ROTATING ASSEMBLY Note! Do not discard the rubber strips between bearing pillow blocks, cover, and base after removal. These strips must be re-installed whenever the machine is moved to prevent damage to the rotating assembly bearings during transit.

  • Page 31: Feed And Flush Connections

    INSTALLATION 3. Install two jack bolts in top half of each pillow block, and thread bolts through lower halves. 4. Turn jack bolts clockwise to lift pillow blocks sufficiently to permit removal of all shipping blocks, and remove blocks. 5. Clean mounting surfaces of lower pillow block halves and base, and then apply a light coating of grease or corrosion inhibitor to both surfaces.
  • Page 32 INSTALLATION FEED AND FLUSH CONNECTIONS (CONT’D) Figure 3-9. Feed Assembly Figure 3-10. Feed Line Connections Figure 3-11. Top Cover Flush Fitting 3-12 01 Jan 14 DE-7200VFDCentrifuge...

  • Page 33: Compressed Air

    INSTALLATION COMPRESSED AIR Explosion-proof control cabinets require a source of clean, preferably instrument quality, filtered, dry compressed air or nitrogen at 60 to 115 PSI at 20SCFM for operation of the control cabinet purge system. The supply line must have a minimum diameter of 3/4” (20mm). The supply must be clean, non-flammable, and from a non-hazardous area.
  • Page 34 INSTALLATION Note that power may be connected with either a single heavy-gage cable or split between two smaller, lighter cables. The smaller-gage cables used for the split-input connections are generally easier to handle. If the input is split (Figure 3-13), be sure to group conductors of the same phase/color.

  • Page 35: Bowl, Conveyor, And Feed Pump Connections

    INSTALLATION BOWL, CONVEYOR, AND FEED PUMP MOTOR CONNECTIONS The bowl and conveyor drive motors require three-phase VFD power and ground connections. Power is derived through connections to terminal blocks inside the control cabinet. Similarly, the customer’s feed pump motor must be connected to the centrifuge control system for control of its operation.

  • Page 36: Polarity Test

    INSTALLATION TANK LEVEL SWITCH CONNECTIONS (CONT’D) Figure 3-15. Typical Tank Level Switch Connections POLARITY TEST WARNING! BE CERTAIN THAT MOTORS ROTATE IN CORRECT DIRECTION. INCORRECT POLARITY OF CONVEYOR MOTOR WILL CAUSE CONVEYOR TO ROTATE AT AN INCORRECT SPEED, WHICH WILL RESULT IN PROCESSING PROBLEMS.

  • Page 37: Sensor Connections

    INSTALLATION WARNING! CENTRIFUGE MUST BE OPERATED AT THE DESIGNATED SUPPLY VOLTAGE. DANGER! DANGER! HIGH VOLTAGE! SHUT DOWN, LOCK OUT, AND TAG OUT ELECTRIC POWER, AND ENSURE THAT EQUIPMENT HAS STOPPED ROTATING BEFORE WORKING ON THIS EQUIPMENT. IF THE INPUT POWER IS SPLIT, BE SURE THAT PHASING IS CORRECT BEFORE APPLYING POWER TO CENTRIFUGE.

  • Page 38: Machine Startup

    INSTALLATION MACHINE STARTUP Refer to Section 4 for initial startup and operating procedures for the centrifuge. WARNING! DO NOT ATTEMPT TO OPERATE MACHINE WITH SHIPPING BRACKETS INSTALLED. 3-18 01 Jan 14 DE-7200VFDCentrifuge...

  • Page 39: Operating Instructions

    Derrick engineering. SOFTWARE VERSION The operating procedures in this section apply to DE-7200 VFD centrifuges having software Version 3.1.6 installed. The software version is shown on the Setup screen shown below: Although operating procedures are generally identical, an earlier software version may cause some screens to appear slightly different from those shown on the following pages.

  • Page 40: Top Cover Opening/Closing Procedures

    The proper procedures for opening and closing the top cover of the centrifuge must always be followed. Two operators using both hands are required to open the cover. Derrick recommends having a hoist available if additional assistance is desired during the opening/closing of the centrifuge cover.

  • Page 41: Initial Startup

    OPERATING INSTRUCTIONS DANGER! USE EXTREME CAUTION WHEN OPERATING CENTRIFUGE WITH PURGE SYSTEM BYPASSED. DANGEROUSLY HIGH VOLTAGE WILL BE PRESENT IN CONTROL CABINET IF DOOR IS OPENED WHILE POWER IS APPLIED. To bypass the purge system, proceed as follows: 1. Be certain that control cabinet is in a non-hazardous environment; then shut down, lock out, and tag out electric power to centrifuge.
  • Page 42 OPERATING INSTRUCTIONS INITIAL STARTUP (CONT’D) 6. Apply electric power to centrifuge. The following screen will appear (on explosion-proof cabinet, displayed after purge cycle is completed): 7. Without the centrifuge running, perform the following safety checks to confirm that connections are correct between control cabinet and centrifuge: •...
  • Page 43 OPERATING INSTRUCTIONS b. Select Download to update VFD settings with new motor data. This will cause pump to autotune at the next startup. c. Select Disable for Tank High and Low Level inputs, if they will not be used. d. When finished making required changes, click “X” in upper right corner to return to Setup screen.

  • Page 44: Normal Startup

    OPERATING INSTRUCTIONS NORMAL STARTUP Note! If Centrifuge is Heated, Before Starting Centrifuge Follow COLD CLIMATE STARTUP Instructions Later in This Section to Ensure Proper Bearing Lubrication. 1. Without electric power applied, open cover and rotate bowl assembly manually to check that the bowl turns freely and no rubbing is felt.

  • Page 45: Cold Climate Startup

    OPERATING INSTRUCTIONS Note! Pump will not start until actual bowl speed is within 120RPM of setting. 11. Adjust feed rate, Bowl speed, and/or Conveyor speed as required to optimize centrifuge operation. Select Data screens at any time to review and monitor centrifuge operating characteristics, including air conditioner status, elapsed operating time, and VFD data.
  • Page 46 OPERATING INSTRUCTIONS OPERATION (CONT’D) Adjustment of one parameter may produce the desired clarity of liquid effluent and solids dryness. Or the desired performance may be achieved by further adjustment. It is important to understand the interdependence of the operating parameters. Changing one characteristic results in other effects that may warrant additional adjustments.
  • Page 47 OPERATING INSTRUCTIONS as the torque remains below the set limit. If the slurry is low in viscosity and density, operation will continue in the flow priority mode. However, conveyor torque may rise if solids volume increases, as the conveyor may become burdened in moving the increased solids volume at the present feed rate and bowl speed.
  • Page 48 OPERATING INSTRUCTIONS Pond Depth (Cont’d) Six adjustable weir plates are provided on the liquid bowl head to facilitate setting the pond depth; all ports must be set identically. A deeper pond depth (move weir plates toward 380mm) increases settling time by permitting more liquid to remain in the bowl. However, a deeper pond depth also reduces the beach area at the solids discharge end of the bowl, which will result in a wetter solids discharge.
  • Page 49 OPERATING INSTRUCTIONS To adjust pond depth, proceed as follows: WARNING! DO NOT OPEN COVER OR ATTEMPT ANY ADJUSTMENT OR MAINTENANCE ON THE CENTRIFUGE UNLESS THE BOWL IS AT A COMPLETE STANDSTILL. 1. Shut down, lock out, and tag out the centrifuge using the Normal Shutdown procedure described later in this section.

  • Page 50: Bearing Temperatures

    OPERATING INSTRUCTIONS BEARING TEMPERATURES Bearing temperature trends may be viewed in graphical form on the Bearing Temperature screen (Figure 4-5). Temperatures are updated at one-minute intervals, and scroll buttons are provided to facilitate examination of trends. Solid and liquid end temperatures are displayed at the right side of the screen.

  • Page 51: System Diagnostics

    OPERATING INSTRUCTIONS SYSTEM DIAGNOSTICS Built-in system diagnostics continually analyze the control system for malfunctions. The Diagnostics screen (Figure 4-7) aids in troubleshooting by displaying any fault in the critical areas of the centrifuge. The current operational status of the Bowl, Conveyor, and Pump VFDs, as well as the speed and temperature sensors are displayed on this screen.

  • Page 52: Alarm And Fault Messages

    OPERATING INSTRUCTIONS ALARM AND FAULT MESSAGES If an alarm or fault occurs, a banner will appear at the bottom of the Operation screen (Figure 4-9) to alert the operator of a malfunction. Alarm messages signify that the prevailing condition must be corrected or the centrifuge may be shut down automatically.

  • Page 53: Vfd Status

    OPERATING INSTRUCTIONS Figure 4-10. Alarm Screen Buttons VFD STATUS Status screens (Figure 4-11 through 4-13) are selected from the Operation screen. Each VFD status screen permits the operator to view various operational characteristics of the VFD such as present alarms or faults, power, voltage, and current outputs; motor and component speeds; direction of motor rotation;...

  • Page 54: Pump Vfd Fault Status

    OPERATING INSTRUCTIONS VFD STATUS (CONT’D) Figure 4-12. Conveyor VFD Screen Figure 4-13. Pump VFD Screen PUMP VFD FAULT STATUS The three most recent pump faults are shown on the Pump VFD Fault Status screen (Figure 4- 14). The screen shows the fault number, time of occurrence, and description of the most recent fault.

  • Page 55: Vfd Temperature Trends

    OPERATING INSTRUCTIONS Figure 4-14. Pump VFD Fault Status Screen VFD TEMPERATURE TRENDS The historical temperature trends of all three VFDs are shown on the Temperature Trend screen (Figure 4-15). This screen is accessible from the Bowl VFD screen. Figure 4-15. VFD Temperature Trend Screen VFD FAULT RESET The Fault Reset screen (Figure 4-16) informs the operator of the readiness of each VFD—Faulted or No Fault—and permits resetting a faulted VFD.

  • Page 56: Setup Screen

    OPERATING INSTRUCTIONS VFD FAULT RESET (CONT’D) Figure 4-16. Fault Reset Screen SETUP SCREEN The Setup screen (Figure 4-17) permits the operator to view the software version installed in the PLC and control panel (HMI), view feed pump characteristics, adjust panel brightness, select the temperature units (°C or °F) that will be shown on other screens, and set personal preferences.

  • Page 57: Pump Setup Screen

    OPERATING INSTRUCTIONS By entering “User1” for user name and password “1-1-1-1” on the Login screen, the operating range screen is displayed (Figure 4-18). The user may then set the maximum and minimum limits for the following parameters: • Bowl speed •...
  • Page 58 OPERATING INSTRUCTIONS CLEAN OUT (CONT’D) Figure 4-20. Clean Out Screen Provision is included for selecting the automatic or manual cleanout options. When the cleanout process has timed out or was stopped by the operator, the Operation screen or the Faults screen may be displayed.

  • Page 59: Normal Shutdown

    (107°C). If temperature rises to 250°F (120°C), a fault message appears and the centrifuge is shut down. Excessively high bearing temperatures usually indicate bearing failure, which can result from inadequate or excessive lubrication, contamination, or severe wear. Contact Derrick Service department for assistance.
  • Page 60 OPERATING INSTRUCTIONS Excessive Bowl Speed A sensor that detects the rotating speed of the bowl provides an input to the PLC that produces a continuous display of actual bowl speed on the Operation and Bowl VFD screens. A fault message is displayed and the centrifuge is immediately shut down if speed rises to 3100RPM. To re-start the centrifuge, allow the bowl to coast to a complete stop, check for and remove the cause of excessive speed as described in Section 5.

  • Page 61: Emergency Shutdown

    OPERATING INSTRUCTIONS EMERGENCY SHUTDOWN Two options are available to stop the centrifuge in an emergency: Electric power shutdown or mechanical shutdown. The type of emergency dictates the shutdown method. If emergency is electricity related, power must be shut down immediately. However, if the emergency requires the fastest possible means of stopping the bowl, the alternative mechanical shutdown procedure should be used to bring the bowl to a stop more quickly.

  • Page 63: Maintenance

    The proper procedures for opening and closing the top cover of the centrifuge must always be followed. Two operators using both hands are required to open the cover. Derrick recommends having a hoist available if additional assistance is desired during the opening/closing of the centrifuge cover.

  • Page 64: Preventive Maintenance

    MAINTENANCE PREVENTIVE MAINTENANCE Preventive maintenance consists of inspection, cleaning, and lubrication. These routine procedures will ensure maximum life and trouble-free operation. While the maintenance schedule presented in this section should remain flexible, modifications should be based on experience with operating the equipment at your facilities. A maintenance log should be kept to help establish a preventive maintenance schedule, as well as to monitor and adjust the schedule as necessary throughout the equipment’s life.

  • Page 65: Lubrication Chart

    PERSONNEL MUST ENSURE THAT ALL BODY LIMBS AND ANY OTHER ITEMS ARE CLEAR OF THE COVER GAP. TWO OPERATORS MUST BE USED, WITH BOTH HANDS ON THE COVER HANDLES AT ALL TIMES. DERRICK RECOMMENDS HAVING A HOIST AVAILABLE IF ADDITIONAL ASSISTANCE IS DESIRED DURING THE OPENING/CLOSING PROCEDURE.

  • Page 66: Gearbox Oil Change

    PERSONNEL MUST ENSURE THAT ALL BODY LIMBS AND ANY OTHER ITEMS ARE CLEAR OF THE COVER GAP. TWO OPERATORS MUST BE USED, WITH BOTH HANDS ON THE COVER HANDLES AT ALL TIMES. DERRICK RECOMMENDS HAVING A HOIST AVAILABLE IF ADDITIONAL ASSISTANCE IS DESIRED DURING THE OPENING/CLOSING PROCEDURE.

  • Page 67: Drive Belt Replacement

    MAINTENANCE 9. Re-fill gearbox with correct product and quantity listed in Lubrication Chart. 10. Re-install fill and vent plugs, and tighten securely. 11. Close and secure top cover. DRIVE BELT REPLACEMENT DANGER! HIGH VOLTAGE! SHUT DOWN, LOCK OUT, AND TAG OUT ELECTRIC POWER, AND ENSURE THAT EQUIPMENT HAS STOPPED ROTATING BEFORE WORKING ON THIS EQUIPMENT.
  • Page 68 MAINTENANCE DRIVE BELT REPLACEMENT (CONT’D) Figure 5-2. Conveyor Drive Clutch Figure 5-3. Drive Belt Tensioning 31 Dec 13 DE-7200VFDCentrifuge...

  • Page 69: Purge System

    MAINTENANCE PURGE SYSTEM Bypassing Purge System The purge unit may be bypassed when necessary to apply electric power to the centrifuge while the control cabinet door is open, but this should be done only after verifying that the centrifuge is in a non-hazardous area. After completing the work, the purge system must be restored to operation and satisfactory operation confirmed.
  • Page 70 MAINTENANCE Visual Inspection and Checks (Cont’d) 3. Check condition of the purge unit air filter element, and clean or replace as necessary. 4. At least every two years, check the following additional items: a. There are no unauthorized modifications. b. Quality of the air supply is correct (refer to Compressed Air in Section 3). c.
  • Page 71 MAINTENANCE Leakage Compensation Test A Magnahelic gage and hose kit available from Derrick is required to monitor cabinet pressure. The leakage compensation valve adjustment should be checked for deviation from factory setting as follows: 1. Connect Magnahelic gage to test point shown below.
  • Page 72 Note! When air conditioner goes off, the relief valve may vent momentarily. This is normal. Pressure Sensor Calibration If it is decided that the minimum pressure sensor requires recalibration, it must be returned to Derrick for this service. 5-10 31 Dec 13 DE-7200VFDCentrifuge...

  • Page 73: Rotating Assembly Maintenance

    The rotating assembly must be replaced if defective main or conveyor bearings are found, or if internal damage to the rotating assembly is found or suspected. The damaged rotating assembly should be returned to Derrick for overhaul. Rotating Assembly Removal...
  • Page 74 MAINTENANCE Rotating Assembly Removal (Cont’d) Figure 5-4. Conveyor Torque Limiter Clutch 6. Loosen nuts securing bowl drive motor to base, turn tensioning bolt to release tension, and remove belts from bowl sheave. 7. Remove liquid and solid end temperature sensors (Figure 5-5) from main bearing pillow blocks.
  • Page 75 The dimension indicates the radial wear of the flights. For example, a dimension of 24.2mm indicates radial wear of 5mm. c. If radial wear exceeds 6mm, the rotating assembly should be returned to Derrick for overhaul. 31 Dec 13...
  • Page 76 MAINTENANCE Cleaning and Inspection (Cont’d) A (mm) Radial Wear (mm) 19.2 20.2 21.2 22.2 23.2 24.2 25.2 26.2 27.2 28.2 29.2 Figure 5-9. Conveyor Flight Wear Measurement Installation 1. Using a suitable hoist capable of lifting at least 4000 lbs (1800 kg), lift rotating assembly from cradle and lower onto base with pillow blocks in close alignment with mounting holes.

  • Page 77: Hardware Torque Specifications

    2208 RECOMMENDED SPARE PARTS The spare parts list below contains the parts required to support a single DE-7200 centrifuge for two years. The components most susceptible to wear are included; however, all potential part replacements cannot be predicted. The complete spare parts inventory should be based on the user’s experience with similar equipment.
  • Page 78 MAINTENANCE RECOMMENDED SPARE PARTS (CONT’D) Part No. Description Consumable 2-Yr Qty Base - 16601-00-001 G0007725 Taper Pin Bowl - 16603-00-001 G0008986 Gear Oil 5 Gal G0007763 Bolt, Hex Head G0007729 Washer, Flat Case & Cover - 16602-00-001 G0007759 Seal Tape 16929-01 Rubber Seal 1 Set...

  • Page 79: Troubleshooting

    MAINTENANCE Part No. Description Consumable 2-Yr Qty Control Cabinet - 16472-00-002 G0007698 Fuse, 60A, Class J G0008792 Fuse, 3A, Class CC G0003493 Fuse, 15A, Class CC G0007225 Fuse, 150A, Class J G0007632 Fuse, 225A, Class T G0002910 Fuse, 2.5A G0002911 Fuse, 7A G0002301 Air Filter Element, DX...
  • Page 80 Section 8 and description and theory of operation in Section 1 for additional assistance in troubleshooting. TROUBLESHOOTING DE-7200 VFD CENTRIFUGE Possible Cause Isolation Procedure & Corrective Action...
  • Page 81 MAINTENANCE TROUBLESHOOTING DE-7200 VFD CENTRIFUGE Possible Cause Isolation Procedure & Corrective Action Failure Mode 3: Excessive Vibration Excessive buildup of solids in Perform cleanout procedure (refer to Preventive bowl and/or conveyor. Maintenance). Bowl assembly main bearings Replace rotating assembly (refer to Rotating Assembly defective.
  • Page 82 Re-check system operation at new setting. If system functions properly, return purge time to original setting. If system fails to close switch, contact Derrick for assistance. Failure Mode 12: Purge System Relief Valve Remains Open Or Opens Intermittently Leakage compensation valve...
  • Page 83 MAINTENANCE TROUBLESHOOTING DE-7200 VFD CENTRIFUGE Possible Cause Isolation Procedure & Corrective Action Failure Mode 13: Air Conditioner Evaporator Fan Fails to Go On Poor electrical connection Shut down, lock out, and tag out electric power to centrifuge. Open control cabinet door, and locate fan at upper right.
  • Page 84 MAINTENANCE TROUBLESHOOTING (CONT’D) Figure 5-10. Air Conditioner Electrical Schematic Diagram 5-22 31 Dec 13 DE-7200VFDCentrifuge...
  • Page 85 MAINTENANCE Figure 5-11. Air Conditioner Electrical Schematic Diagram - 230Vac RTD Sensing 31 Dec 13 5-23 DE-7200VFDCentrifuge...
  • Page 86 MAINTENANCE Figure 5-12. Air Conditioner Electrical Schematic Diagram - 24Vdc RTD Sensing 5-24 31 Dec 13 DE-7200VFDCentrifuge...

  • Page 87: Alarm And Fault Messages

    F1000 - Bowl Exceeded Maximum Speed, Shutdown Incorrect or loose connection at speed Check speed sensor connection (refer to Section 3). sensor or defective speed sensor Replace sensor if defective. Bowl VFD malfunction If problem persists, contact Derrick Service for assistance. 31 Dec 13 5-25 DE-7200VFDCentrifuge...
  • Page 88 MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F1001 - Bowl High Torque Alarm, Reduce Feed Rate Bowl torque exceeds pre-set limit Reduce feed rate and/or reduce bowl speed. F1002 - Bowl High Torque Fault and Shutdown, Perform Cleanout and Reduce Feed Rate Bowl torque exceeds pre-set limit After bowl has stopped rotating, perform cleanout procedure to remove solids buildup, and re-start...
  • Page 89 MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F1017 - Bowl VFD Drive OL Alarm, Ref Troubleshooting Section of User Manual Feed rate causing overload Reduce feed rate or reduce bowl speed. Bowl drive motor drawing excessive Replace motor if defective. current F1021 - Bowl Motor Thermal Overload Check Bowl Motor Temperature and Thermistor Bowl drive motor shut down due to high...
  • Page 90 MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F2012 - Conveyor VFD Fault and Shutdown, Ref Troubleshooting Section of User Manual Conveyor VFD fault Identify fault from operator control panel. Perform indicated corrective action. F2013 - Conveyor VFD Ground Warn Alarm, Ref Troubleshooting Section of User Manual Conveyor VFD has detected high Check condition of cable and all connections current leakage to ground...
  • Page 91 MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F3010 - Pump VFD Communications Error Communication lost between pump Confirm that green LED next to Ethernet cable on VFD and PLC Ethernet switch is lighted, indicating that hub is functional. Check connections between pump VFD and PLC, and correct any defects.
  • Page 92 MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F3021 - Pump Motor Thermal Overload Check Pump Motor Temperature and Thermistor Pump drive motor shut down due to Check motor temperature. Allow motor to cool, and high temperature or defective thermistor then check for continuity across thermistor leads.
  • Page 93 Incorrect grease Lubricate with recommended grease (refer to Preventive Maintenance). Defective bearing Contact Derrick Service department for assistance. F4004 - Liquid End Main Bearing High Temperature Fault and Shutdown Insufficient bearing lubrication Lubricate bearings (refer to Preventive Maintenance).
  • Page 94 If low pressure indicated, contact Derrick Service for assistance. If high pressure indicated, continue troubleshooting. Condenser motor rotation incorrect or Check rotation direction, and reverse, if necessary, motor defective by switching two leads.
  • Page 95 MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F7022 - Electrical Enclosure High Temperature Fault and Shutdown Control cabinet interior temperature has Check status/operation of air conditioner; repair or exceeded alarm setpoint replace if defective. Reduce load by decreasing bowl, conveyor differential speed, and/or pump feed rate.
  • Page 96 MAINTENANCE ALARM AND FAULT MESSAGES Cause Corrective Action F9012 - External Communication Loss, Switched to Local Control Profibus not working, remote control is Check and correct any defects in Profibus disabled and control has automatically connections, and attempt to re-start in Remote switched to local operating mode.

  • Page 97: Vfd Alarm And Fault Cross References

    The following tables list these alarm and fault numbers and the corresponding text. This information is useful for operators and Derrick personnel to diagnose equipment malfunctions. To expedite troubleshooting, record the code number before calling for service and then relay this information to the service engineer.

  • Page 98: Control Component Indicators

    MAINTENANCE FAULT CROSS REFERENCE No. Fault Fault Fault Auxiliary Input Phase U to Grnd 81-85 Port 1-5 DPI Loss Power Loss Phase V to Grnd IXo VoltageRange UnderVoltage Phase W to Grnd Software Fault OverVoltage Phase UV Short Software Fault Motor Overload Phase VW Short Encoder Quad Err...
  • Page 99 MAINTENANCE Figure 5-14. VFD Indicators 31 Dec 13 5-37 DE-7200VFDCentrifuge...
  • Page 100 MAINTENANCE Figure 5-15. PLC Indicators 5-38 31 Dec 13 DE-7200VFDCentrifuge...
  • Page 101 MAINTENANCE CONTROL COMPONENT INDICATORS (CONT’D) Figure 5-16. Transmitter/Intrinsic Barrier Indicators Figure 5-17. Power Supply Indicators 31 Dec 13 5-39 DE-7200VFDCentrifuge...

  • Page 103: Reference Drawings

    SECTION 8 - REFERENCE DRAWINGS This section contains Derrick engineering drawings for your equipment. These drawings are included to provide assistance in troubleshooting, repair, and parts ordering. Title Number 16590-00-003 General Arrangement - XP Centrifuge 16590-00-004 General Arrangement - Non-XP Centrifuge...
  • Page 141 G0002301 AIR ELEMENT, DX (REPLACEMENT ONLY) USED BY CUSTOMERS OR PROSPECTS OR THEIR AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT, OR BY VENDORS IN QUOTING ON OR IN THE  SUPPLY OF PARTS OR ASSEMBLIES TO DERRICK, OR BY OTHERS FOR THE SPECIFIC REASON OUTLINE IN THE TRANSMITTAL WHETHER WRITTEN OR VERBAL.
  • Page 143 COVER, DISTR BLOCK-FOR G0008891/8892 USED BY CUSTOMERS OR PROSPECTS OR THEIR AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT, OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY OF PARTS OR ASSEMBLIES TO DERRICK, OR BY OTHERS FOR THE SPECIFIC REASON OUTLINE IN THE TRANSMITTAL WHETHER WRITTEN OR VERBAL.
  • Page 145 AND ARE NOT TO BE REPRODUCED WITHOUT THE WRITTEN PERMISSION OF DERRICK CORPORATION. THE INFORMATION CONTAINED ON THIS DRAWING SHALL ONLY BE G0007955 ETHERNET CABLE X 178 (ETH SW-30 HP) USED BY CUSTOMERS OR PROSPECTS OR THEIR AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT, OR BY VENDORS IN QUOTING ON OR IN THE G0002301 AIR ELEMENT, DX (REPLACEMENT ONLY) SUPPLY OF PARTS OR ASSEMBLIES TO DERRICK, OR BY OTHERS FOR THE SPECIFIC REASON OUTLINE IN THE TRANSMITTAL WHETHER WRITTEN OR VERBAL.
  • Page 147 LUG, CRIMP #1 AWG FLATNESS USED BY CUSTOMERS OR PROSPECTS OR THEIR AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT, OR BY VENDORS IN QUOTING ON OR IN THE  SUPPLY OF PARTS OR ASSEMBLIES TO DERRICK, OR BY OTHERS FOR THE SPECIFIC REASON OUTLINE IN THE TRANSMITTAL WHETHER WRITTEN OR VERBAL.

  • Page 149: Installation And Maintenance Log

    This section should be used by operating and maintenance personnel to record historical information gathered during the installation and operation of the Derrick equipment. If properly kept, the log will be useful for altering maintenance intervals and intercepting trends that may indicate the need for changing operating procedures.

  • Page 150: Oct

    INSTALLATION & MAINTENANCE LOG 30 Oct 09 DE-7200VFDCentrifuge...
  • Page 151 INSTALLATION AND MAINTENANCE LOG 30 Oct 09 DE-7200VFDCentrifuge...
  • Page 152 INSTALLATION & MAINTENANCE LOG 30 Oct 09 DE-7200VFDCentrifuge...
  • Page 153 INSTALLATION AND MAINTENANCE LOG 30 Oct 09 DE-7200VFDCentrifuge...
  • Page 154 INSTALLATION & MAINTENANCE LOG 30 Oct 09 DE-7200VFDCentrifuge...
  • Page 155 System, which consists of an HMI Server and Router Switchgear Box (Figure A-1). The system permits remote monitoring for the Derrick DE-7200 and DE-1000 Variable Frequency Drive (VFD) centrifuges. By connecting a customer-supplied PC or laptop computer to the server, the operator can monitor two to four centrifuges from a single location separate from the control cabinets.
  • Page 156 APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM INSTALLATION All safety procedures included in the Operation and Maintenance manual are to be followed when installing the HMI Server System components. Installation is performed in the following sequence: • Install server in safe area on a desktop or wall. •...
  • Page 157 APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Figure A-3. Electrical Connections to Router Switchgear Box 3. Tighten nut properly on cable gland to ensure proper sealing. 4. Close and secure cover of Router Switchgear Box after completing connections. 5. Plug in HMI Server and PC power cords. Ethernet Connections Required Equipment The following customer-supplied components are required for making the Ethernet connections:...
  • Page 158 APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Control Cabinet Connections to Router Switchgear Box The following procedure describes the interconnection of control cabinets with the HMI Server. Refer to drawing 18309-00 for additional assistance in making the connections, and note that cables must be no more 328’...
  • Page 159 The HMI Server System permits continuous monitoring of up to four centrifuges from a single computer located in a non-hazardous area. A combination of DE-1000 and DE-7200 centrifuges may be monitored. All information displayed on the local Operation screen of each centrifuge may be viewed on the computer.
  • Page 160 APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Operation (Cont’d) IP Address If connecting to LAN 1, the static IP address of the PCs must be set to the following IP addresses: IP Address Subnet Mask PC 1 100.100.10.201 255.255.255.0 PC 2 100.100.10.202 255.255.255.0...
  • Page 161 APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Figure A-7. HMI Server Home Screen Figure A-8. Operation Screen - Centrifuge 1 Figure A-9. VFD Screen - Centrifuge 1 15 May 13 Appendix A-HMIServerSystem...
  • Page 162 APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Figure A-10. Pump Setup Screen Figure A-11. Support-Activation Screen Figure A-12. Alarms Screen Figure A-13. Cleanout Screen 15 May 13 Appendix A-HMIServerSystem...
  • Page 163 APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Figure A-14. DeskLock Screen Troubleshooting Network Connectivity The following IP addresses of all system components permit entry into the router configuration to verify that the router is communicating: X1 WAN Port X2 LAN Port Router 1 https://100.100.10.1 https://100.100.100.101...
  • Page 164 APPENDIX A - VFD CENTRIFUGE HMI SERVER SYSTEM Figure A-15. Customer PC Test Connections to Ping Routers REFERENCE DRAWINGS Drawings included in this appendix are listed in Table A-1. These drawings are included to assist in the installation and operation of the HMI Server. Table A-1.

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