BTU TCA Manuals

Manuals and User Guides for BTU TCA. We have 1 BTU TCA manual available for free PDF download: System Manual

BTU TCA System Manual

BTU TCA System Manual (262 pages)

Brand: BTU | Category: Industrial Equipment | Size: 19.1 MB

Table of Contents

Tca/Tcas System Manual

3
- Limitation of Liability
  2
- List of Revisions
  2
  - Table of Contents
    3
- Contents
  4
- Introduction
  7
- How-To-Use Instructions
  7
- Technical Help
  7
- Equipment Label
  8
- Tools and Equipment
  9
- Manual Description
  10
- Related Manuals
  10
- Symbols, Abbreviations, and Terms
  11
- Safety
  19
- Precautions for Hydrogen Equipment
  19
- Material Safety Data Sheets
  19
- Safety Precautions
  20
- Safety Identification
  23
- Electrical Hazards
  24
- Safety Labels
  25
- Standard and Optional Safety Equipment
  33
- Safety Procedures
  36
- Lockout/Tagout Procedure (Without Main Disconnect Switch Option
  36
- Lockout/Tagout Procedure (with Main Disconnect Switch Option
  37
- Emergency Stop Procedure
  40
- Disposal of Equipment
  41
- Environmentally Responsible Recycling of Equipment
  41
- Shipping Material
  41
- End-Of-Life Decommissioning
  41
- Disposal of Hazardous Maintenance Materials
  42
Chapter 1 Tm 5250517 Rev. 0 Page 1-1 Apr 15/2003

43
- System Description
  43
- Equipment Description
  44
- Equipment Locator
  53
- Conveyor System
  54
- Frame and Panel System
  54
- Conveyor Control
  57
- Electrical and Control System
  57
- Electrical Distribution
  57
- Gas Control
  57
- Light Tower, Three- or Four-Color (Option)
  58
- Main Control Panel (MC-98)
  59
- Atmosphere Control Panel (Hydrogen Furnaces Only)
  61
- Atmosphere System
  61
- Heating System
  64
- Cooling System
  66
- Muffle System
  66
Chapter 2 Tm 5250517 Rev. 0 Page 2-1 Apr 15/2003

67
- Installation
  67
- Facility Requirements
  68
- Plumbing Requirements
  68
- Exhaust Requirements
  69
- Water Requirements
  69
- CDA and N2 Requirements
  71
- Air Requirements
  73
- Cooling System Requirements
  73
- Electrical Requirements
  73
- H2 Requirements (if Applicable)
  73
- Heating System Requirements
  73
- Electrical Requirements
  74
- Equipment Data
  74
- Exhaust Requirements
  74
- Procedures
  76
- Receive
  76
- Move
  78
- Store
  81
- Adjust the Furnace Level
  82
- Install Light Tower (Option)
  82
- Install PC
  82
- Install the Belt
  82
- Installation
  82
- Set up the Product Feed Conveyor
  83
- Assemble the Equipment (if Shipped in Separate Sections)
  84
- Connect Electrical Supply
  87
- Installation Checklist
  88
Operation !

89
- Operation
  89
- General
  90
- Summarized Checklist
  91
- Calculate Cover Gas Flow (All Furnaces)
  92
- Calculate Atmosphere Curtain Flow Rates
  94
- Start and Operate
  95
- Emergency Shutdown
  100
- Idle the Furnace
  100
- Normal Shutdown
  100
- System Alerts or Alarms
  101
- Respond to Interlock and Alarm Conditions
  102
- Operate an EMO
  104
- Operate Options
  104
- Operate the Belt Cleaners
  104
- Operate the Hand Crank (Option)
  104
- Operate the O2 Analyzer (Option)
  104
- Operate the Product Feed Conveyor (Option)
  104
- Operate the Heat Barrier
  105
Troubleshooting !

107
Chapter 5 Tm 5250517 Rev. 0 Page 5-1 Apr 15/2003

117
- Preventive Maintenance
  117
- Adjust the Furnace Level
  119
- Clean the Conveyor System
  119
- Clean the Exhaust Stacks
  119
- Clean the External Surfaces
  119
- Conveyor System
  119
- Frame and Panel System
  119
- Lubricate the Idler Pulley Bearings
  119
- Maintain the Drive System
  119
- Preventive Maintenance Schedule
  119
- Replace the Silicone Gaskets
  119
- Adjust Product Tracking Sensor
  120
- Adjust the Belt at the Entrance
  120
- Adjust the Conveyor Belt System
  120
- Adjust the Drive Chain Tension
  120
- Adjust the Exit Table Drive Pulley (External Belt Drive)
  120
- Adjust the Exit Table Drive Pulley (Internal Belt Drive)
  120
- Calibrate TC Inputs and Belt Speed
  120
- Electrical and Control System
  120
- Replace the Drive Motor Brushes
  120
- Replace the UPS Battery
  120
- Adjust Automatic Gas Sampling System
  121
- Atmosphere System
  121
- Calibrate the O Analyzer with Calibrated Gas (Option)
  121
- Delete Temporary Files
  121
- Replace O2 Gas Line Filter
  121
- Replace the Air/Gas Filters
  121
- Replace the Light Tower Lamps
  121
- Run Disk Defragmenter
  121
- Run Error-Checking (Windows NT Systems)
  121
- Adjust Temperature-Actuated Water Valves
  122
- Calibrate the MSA Gas Monitor System with Calibrated Gas (Option)
  122
- Cooling System
  122
- Heating System
  122
- Inspect the Separation Joint
  123
- Overall Furnace
  123
- Adjust the Furnace Level
  124
- Clean the External Surfaces
  127
- Replace the Silicone Gaskets
  128
- Clean the Exhaust Stacks
  130
- Frame and Panel System
  130
- Conveyor System
  134
- Clean the Conveyor System
  136
- Maintain the Drive System
  138
- Lubricate the Drive Chain and the Drive Chain Sprockets
  139
- Lubricate the Idler Pulley Bearings
  141
- Fill the Drive Motor Oil
  143
- Adjust the Exit Table Drive Pulley (External Belt Drive)
  145
- Adjust the Conveyor Belt System
  148
- Adjust the Exit Table Drive Pulley (Internal Belt Drive)
  150
- Adjust the Belt at the Entrance
  152
- Adjust the Drive Chain Tension
  154
- Adjust the Belt Tracking
  156
- Replace the Drive Motor Brushes
  162
- Maintain the Ultrasonic Belt Cleaner (Option)
  164
- Electrical and Control System
  166
- Replace the UPS Battery
  166
- Calibrate TC Inputs and Belt Speed
  168
- Adjust Product Tracking Sensor
  169
- Reset CB
  170
- Replace a Fuse
  171
- Replace the MCP Lamps
  172
- Replace the Light Tower Lamps
  174
- Delete Temporary Files
  176
- Run Error-Checking (Windows NT Systems)
  177
- Run Disk Defragmenter
  179
- Atmosphere System
  181
- Replace the Air/Gas Filters
  181
- Replace O2 Gas Line Filter
  183
- Adjust Automatic Gas Sampling System
  185
- Calibrate the O
  186
- Calibrate the MSA Gas Monitor System with Calibrated Gas (Option)
  187
- Adjust Temperature-Actuated Water Valves
  188
- Cooling System
  188
- Heating System
  188
- Muffle System
  188
Corrective Maintenance !

189
- Leak Test (Metal Muffle Only)
  190
- Overall Furnace
  190
- Conveyor System
  192
- Frame and Panel System
  192
- Shorten the Conveyor Belt
  192
- Electrical and Control System
  194
- Test Furnace Interlocks
  194
- Atmosphere System
  195
- Test Gas System
  195
- Do a Temperature Profile
  197
- Test a Timed Flow Purge (H 2 Only)
  198
- Cooling System
  199
- Heating System
  199
Chapter 7 Tm 5250517 Rev. 0 Page 7-1 Apr 15/2003

201
- Frame and Panel System
  202
- Overall Furnace
  202
- Conveyor System
  204
- Replace the Access Panels
  204
- Replace the Drive Return Rollers
  204
- Replace the Conveyor Belt (Belt Installed Now)
  206
- Install the Conveyor Belt (no Belt Installed Now)
  210
- Replace the Drive Shear Pin
  211
- Replace the Drive Motor
  214
- Replace the Drive Motor Optical Encoder
  216
- Replace the Ultrasonic Belt Cleaner (Option)
  218
- Electrical and Control System
  221
- Replace the UPS
  221
- Replace the Main Power Disconnect Switch (Option)
  223
- Replace the FCU
  225
- Replace the PC
  227
- Replace the Belt Speed Module
  230
- Replace the SSR
  232
- Replace the Light Tower
  234
- Atmosphere System
  236
- Replace the Flowmeters
  236
- Replace the Atmosphere Curtain Assembly (Teflon-Coated)
  238
- Replace the Atmosphere Curtain Assembly (Sheet-Metal)
  240
- Replace a Gas Dispersion Tube
  242
- Heating System
  244
- Replace the TC
  244
- Replace the Heater
  248
- Cooling System
  250
- Muffle System
  250

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