Documente Academic
Documente Profesional
Documente Cultură
For
Gimsa Monclova SA de CV
SERIAL No. 0841
INDEX
WARNINGS SECTION I. SECTION II. SECTION III. SECTION IV. HOUSEKEEPING PROCEDURES OPERATING PROCEDURES GENERAL MAINTENANCE PROCEDURES MAINTENANCE ADJUSTMENTS AND PARTS REPLACEMENT PROCEDURES A. B. C. D. E. SECTION V. SECTION VI. SECTION VII. SECTION VIII. Elevator Module Operation, Maintenance and Adjustments Elevator Head Section Elevator Belt Installation / Repair Drive Units - Operation, Maintenance and Adjustments Rotary Screen Abrasive Separator
BLAST POT AIRLINE FILTER & CO-MONITOR DUST COLLECTOR OPERATION AND INSTALLATION DRAWINGS A. General Arrangement Drawing, Sub assembly details Electrical Schematic Drawing
B.
THIS MANUAL CONTAINS SPECIFIC PRECAUTIONARY STATEMENTS RELATIVE TO WORKER SAFETY IN APPROPRIATE SECTIONS. READ THIS MANUAL THOROUGHLY AND COMPLY AS DIRECTED. IT IS IMPOSSIBLE TO LIST ALL OF THE POTENTIAL HAZARDS OF DUST CONTROL EQUIPMENT OR BLAST & RECLAIM SYSTEMS. IT IS IMPERATIVE THAT USE OF THE EQUIPMENT BE DISCUSSED WITH AN ABRASIVE BLAST SYSTEMS REPRESENTATIVE. PERSONNEL INVOLVED WITH THE EQUIPMENT OR SYSTEMS SHOULD BE INSTRUCTED TO CONDUCT THEMSELVES IN A SAFE MANNER.
WARNING
These products & equipment are not, under any circumstances, to be used with sand or silica products of any type, and use of such materials will void warranty. Also, as with the use of any product or equipment, you must be sure to use the proper safety equipment, and to properly train your employees in the use of any equipment or products. The manufacturer, wholesaler and distributor assume no responsibility arising from the failure to use proper safety equipment or the failure to properly train employees in the use of the products and equipment.
WARNING
1. Operating blasting equipment without following written instructions and recommended safety procedures could result in serious injury or death. Before using the equipment, read all instructions, literature, owners manuals, labels, specifications and warnings sent with and affixed to the unit. If operation of the unit is unclear after reading the instruction manual, contact your supervisor for instructions. 2. It is the responsibility of the employer to read all labels, warnings and instructions to users of the equipment who are unable to read. Periodic inspections and instructions in the use of this equipment should be made by supervisory personnel to assure the equipment is being properly used and maintained. 3. To prevent delayed lung injury, do not use abrasives containing free silica. Personal protective equipment is required for all abrasive blasting operations. Observe all applicable local, state and federal safety regulations in conjunction with air line filters and respiratory protection (Reference OSHA 29CFR1910.134.1910.1000 and all subsequent additions or modifications). 4. OSHA regulations require the use of an approved breathing air compressor when using NIOSH approved respirators. Before attaching breathing air lines to the compressor and air filter, determine that the compressor is rated suitable as a supply or breathing air entering the respirator(s). If an oil lubricated compressor is used, it shall have a high temperature or carbon monoxide monitor alarm (or both). Gross contamination of the inlet air to the air compressor or serious compressor malfunction will adversely affect the quality of the breathing air entering the respirator(s). 5. All personnel in the vicinity of abrasive blasting operations should wear NIOSH approved air fed respirators, hoods or helmets. 6. All ways depressurize any vessel before loading media or any maintenance is performed. 7. Never operate blasters without remote controls. OSHA regulations require remote controls on all blast machines. Failure to use remote controls can cause serious injury or death to the operator(s) or other personnel in the blasting area. (Reference OSHA Specifications 29CFR1910.244(b) and all subsequent additions or modifications). 8. Do not modify or alter any equipment or controls without written consent from Abrasive Blast Systems, LLC. 9. The use of modified remote controls or door limit switches can cause unintentional start-up without warning which can result in serious personal injury. 10. Periodically check all hoses and dead-man controls to see that they are in good condition. Repair or replace any valves, hoses or controls 1 that show any sign of wear or leakage.
WARNING
WARNING-CONVEYOR SCREWS
WARNING
WARNING
WARNING
WARNING
(972) 205-9309
NOTE: The Pressure gauge should operate between 2 & 4 of static pressure For most of the operating life of the filter elements
All motors should be locked-out at the disconnect during all maintenance procedures.
WARNING
These products & equipment are not, under any circumstances, to be used with sand or silica products of any type, and use of such materials will void warranty. Also, as with the use of any product or equipment, you must be sure to use the proper safety equipment, and to properly train your employees in the use of any equipment or products. The manufacturer, wholesaler and distributor assume no responsibility arising from the failure to use proper safety equipment or the failure to properly train employees in the use of the products and equipment.
WARNING
17.
All guards and cover plates need to be on the equipment prior to starting the equipment.
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WARNING
Take-up Bolts
2)
Guards- Keep
guards on chains and cover plates on at all times during the operation of the equipment. CHAIN GUARD
3)
Changing Lubricant (Do NOT change oil in sealed for life reducers)
After the first 100 hours of operation, drain out initial oil, flush out the worm gear case with an approved nonflammable, non-toxic solvent, such as Lubriplate Syn Flush, Lubriplate Pure Flush, Whitmores Flushing Oil (#06802030) or Medallion Flushing Oil Kosher (#06812010), and refill. Thereafter, oil should be changed at least every 2,500 operating hours (5,000 for synthetic oil lubricant) or every 6 months (12 months for synthetic oil lubricant), which ever occurs first. Make sure reducer is lubed prior to startup.
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Adjustments- Only allow one individual to adjust the Air-wash separator and slide gate adjustments. It takes time for results to surface. The separator abrasive curtain should be no thicker than 1/8 thick.
Rotary Screen
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Adjustments- Continue
Note the "Full width" Curtain Keep full abrasive curtain. Set according to dimensions shown on the following page RotaryScreenAbrasiveSeparator)
5)
7)
8) 9)
Noise- Listen for squeaks and excessive scraping, and isolate the Walking screws- Watch screw positioning and make sure they do
not shift in positioning. They will always shift in the opposite direction of the abrasive flow. This is due to loose-set screws in bearings extreme overloading, or loose locking collar on the shafts positioned on the ends of the screw. The screw should be repositioned. Loosen all connections and walk the screw back to its original position. Once in position, tighten all connections and locking collars.
Reclaim Bearings-
Do not grease bearings. They are all slow in revolution and they are pre-lubricated and sealed for life.
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bearings require lubrication once every four months due to high RPM. (1750)
Chain
Rubber lagged Boot Pulley Use shims between mounting angle and pillow block bearing
2)
3)
4)
5)
Rubbing- Make sure elevator belt does not rub side walls of housing. It will usually favor one side. Adjust from head section (Top Portion Take-Up bolts)
NOTE: damage caused by rubbing An example of rubbing
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2)
lagged and crowned for proper operation. This pulley is a one piece solid cast assembly. Rubber lagged Head Pulley
3)
4) 5) 6) 7) 8)
Belt center- Make sure the elevator belt is centered in both the head
and boot section of the elevator.
start-up
Elevator alignment- Make sure elevator is in perfect plumb prior to Loose buckets- Do not allow buckets to fall off elevator belts.
ELEVATOR MODULE BELT INSTALLATION, MAINTENANCE AND ADJUSTMENTS a) Hang belt (buckets facing proper direction). Buckets will feed into the separator screw. Attach stretching brackets to buckets each side of pulley. Stretch with "come along" until quite tight. Locate clamps square to belt and tighten to top of head pulley. Clamp with vice grips, etc. Drill and tighten two (2) or more bolts. Remove vise grips and finish drilling and bolting process. Trim off excess belt smooth with belt clamp belt face. Add buckets at regular intervals to fill in void if splicing existing belt. Make sure belt tension and tracking is set EXAMPLE: Installed Belt splice properly prior to operation. Make sure the elevator belt is centered in both the head and boot section of the elevator.
EXAMPLE: Installed Belt splice Note Bucket rotation direction
b)
c)
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e) f) g)
h)
i)
j)
k)
After the first 100 hours of operation, drain out initial oil, flush out the worm gear case with an approved nonflammable, non-toxic solvent, such as Lubriplate Syn Flush, Lubriplate Pure Flush, Whitmores Flushing Oil (#06802030) or MedallionFlushing Oil Kosher (#06812010), and refill. Thereafter, oil should be changed at least every 2,500 operating hours (5,000 for synthetic oil lubricant) or every 6 months (12 months for synthetic oil lubricant), which ever occurs first.
Changing Lubricant (Do NOT change oil in sealed for life reducers)
3)
Oil- (Do NOT change oil in sealed for life reducers) Make sure that Mobil 600W Cylinder(460 wt.) oil is used. Mobil SHC 634 (460 wt.) is a synthetic oil that can be used for high temperature applications. The reducers box lubricant is used. New units usually require lubricant. Sprocket alignment- Make sure that drive sprockets are
in-line with driven sprockets.
4)
All motors should be locked-out at the disconnect during all maintenance procedures.
5)
WARNING
6) 7)
no water is entering into the pits that will damage the equipment. If water is present a sump pump should be positioned in the elevator pit recess area to pump the reclaim pits dry.
Water will damage reclaim components. Keep all areas dry and free of debris.
WARNING
AIR WASH SEPARATOR WITH ROTARY SCALPING DRUM: OPERATION, MAINTENANCE AND ADJUSTMENTS 1) operation.
2) 3)
Clogging- Make sure it does not clog. Clean debris from drum if such
occurs.
4)
2/3rd Baffle adjustment- Set 2/3 baffle 3/8" above angle of repose of abrasive. Make sure it is parallel.
5)
Swing Baffle adjustment- Set swing baffle so 1/8" clearance exists below bottom of baffle and separator lip. This distance is set according to abrasive size. Do not allow jams. The Baffle must swing easily and clear any obstructions. Swing Baffle- Make sure Swing baffle hangs in a vertical position. Counter weights- Adjust
counterweight on the swing baffle (See green arrow) so that it holds back abrasive flow until a full width curtain of abrasive is obtained. Remove some weights if required, especially with lighter abrasives.
6) 7)
8)
Adjust slide gate behind separator to remove desired contamination and spent abrasive. Do not pull out excessive good abrasive. If too much good abrasive is being removed, slightly close the slide gate. Note: Small increments (i.e. 14) are large adjustments.
9)
between edge of abrasive curtain and face of lip. This adjustment is very important and changes drastically with steel grit, Garnet, Coal slag, etc. `
Adjustable baffle- Set bottom adjustable baffle lip so that 1/2" exists
10)
Abrasive level- Check abrasive level each shift. By adding new abrasive into the system on a regular basis, you will have a more consistent blasting profile.
in air to clean the abrasive.
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