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Particle classifier ALPHA 700

Contents ALPHA 700

Contents
Safety warnings .........................................................1
Icons used and danger warnings ...................................................... 1 Suitable use of the particle classifier ................................................. 2 General safety warnings ................................................................. 2 Safety in handling and storage ......................................................... 3 Technical specifications of the classifier ............................................ 4

Description of the particle classifier .........................6
Operating principle of the particle classifier ....................................... 9 Vibrations ..................................................................................... 11 Classifier options ........................................................................... 13 Classifiers with cooling system ........................................................ 14

Transport and assembly .............................................16
Transport ...................................................................................... 16 Work prior to assembly ................................................................... 18 Tools necessary for assembly, disassembly and maintenance .............. 18 Assembly ...................................................................................... 19 Work after assembly ...................................................................... 22

Start-up ......................................................................23
Commissioning .............................................................................. 23 Ignition period ............................................................................... 23

Operation ...................................................................25
Commissioning a plant .................................................................... 25 Settings during operation ................................................................ 26

Maintenance ..............................................................27
Standard maintenance .................................................................... 27 Special maintenance (for ceramic particle classifiers only) ................... 29 Removing the rotor ........................................................................ 30 Assembling the rotor ...................................................................... 33 Tightening the trapezoidal belts ....................................................... 33 Spare parts lists ............................................................................. 34 Lubrication .................................................................................... 36

Fault search ...............................................................37 Appendices ................................................................38
Electrical appendix ......................................................................... 38

Contact details
Contact persons: Sergio Alegre and Javier Peña Manufacturer / Technical Service: ECUTEC Barcelona SL Address: Gran Vía de les Corts Catalanes 701, 3er 1ª A Postcode: 08013 Barcelona SPAIN Tel. (+34) 932 477 700 rev.02.2011

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Contents ALPHA 700

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Safety warnings ALPHA 700

1. Safety warnings
1.1 Icons used and danger warnings
The terms DANGER, ATTENTION, CAUTION and WARNING indicate specific dangers or special information that requires particular attention. The term NOTE refers to information that does not involve danger to persons.

DANGER Indicates danger of death and personal injury if the necessary precautions are not taken. ATTENTION Indicates that severe personal injury can occur if the necessary precautions are not taken. CAUTION Indicates that minor personal injury can occur if the necessary precautions are not taken. WARNING Indicates that exclusively material damage can occur if the necessary precautions are not taken. NOTE Notes contain relevant technical information that may not be obvious to a specialist technician. Follow the points indicated exactly to avoid damage to the machine. Stickers: Electric risk, mechanical risk, earth ELECTRICAL RISK The electrical risk sticker is used to indicate zones and / or elements of the machine which present a risk of electrical shock. MECHANICAL RISK The mechanical risk sticker is used to indicate zones and/or elements of the machine that present risk of physical injury, such as being trapped, hit or cut. EARTH The earth sticker is used to indicate a valid and effective earth at one point in the machinery.

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Safety warnings ALPHA 700 1.2 Suitable use of the particle classifier
The objective of particle classifier ALPHA 700 is the classification of pulverised products for the mining, chemistry or pharmaceutical industries where these materials are used, for example, to produce paints or plastics. The classifier can be used to classify fine materials in a range between 7μm and 40μm. The raw material may be either minerals, pigments, foodstuffs or ground chemical materials with a particle size smaller than 2 mm. To guarantee optimum classification, the starting material must be dry with a degree of moisture lower than 0.5%. If the moisture level is higher than 0.5% you must set up a device for drying the starting material. During assembly, disassembly, commissioning, operation and maintenance, the particle classifier must only be handled by qualified staff1.

1.3 General safety warnings
Changes of any kind to any of the machine's parts are not permitted and may be grounds for the termination of the machine's warranty. Adherence to occupational health and safety guidelines is especially important for low and medium voltage systems. The assembly, operation and maintenance, the mechanical and electrical installations, the transport, construction and commissioning must be performed or supervised by qualified staff1 with the adequate specialist knowledge. ATTENTION

Machine in operation. Unforeseeable damage in the event of an emergency. It is recommended that emergency stops are installed in the necessary places, in order to stop the machine in the event of an emergency. The particle classifier must be only be started up and operated if it has been thoroughly checked mechanically and if all the doors and inspection holes are closed. Staff should check that the size of the particles in the ground raw material does not exceed 2 mm and that its degree of humidity is no greater than 0.5%. The staff must use personal protection equipment such as hard hats, gloves, ear protection, etc. It is important to avoid operations that jeopardise the health of staff or the safety of the particle classifier. ATTENTION

Working at a height. Falls and blows. The user must take into account the risks of working at a height with relation to the assembly, use and maintenance of equipment.

1. Qualified staff are those who, based on their training, experience and knowledge of the applicable norms, standards, safety rules and operating conditions, have been authorised by the plant safety officer to do the required work. They must be capable of recognising and avoiding potential injury and damage.

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When you manipulate the ECUTEC products. There are different ways of packaging.4 Safety in handling and storage The products supplied are indicated in the packing list. check that all the products have been delivered. ensure that the lifting and transport equipment can withstand the loads. Immediately on receiving the elements. Unless otherwise stated in the contract. 3/47 . depending on the dimensions of the classifier and the method of transport. the unit must not be exposed to extreme environmental factors such as chemical products. The instruction manual must always be kept in an easily accessible place for future consultation. The symbols marked on the packaging indicate how to proceed.Safety warnings ALPHA 700 Unauthorised alterations and the reproduction of the particle classifier are prohibited. moisture or temperatures greater than 0ºC/ 32 F or 20ºC/ 68 F. Do not use the eyebolts (DIN 580) of the motor to manipulate the machine. The different parts cannot be stored one on top of another. 1. high pollution. NOTE The classifier is delivered pre-assembled and with grease in the bearings. The plant safety officer must guarantee that the staff can use this document regularly. They have the following meanings: This way up Fragile Keep dry Keep cool Centre of gravity Use no hand hook Attach here The classifier must be stored in a dry place. with no vibrations. If the machinery must be stored outdoors. it must be carefully covered and protected from moisture.

008 Type of machine ALPHA 700 Design/operation data Length Width Height Machine weight Rotor weight Rotor speed (maximum working speed) Motor pulley (diameter) Machine pulley (diameter) Relationship Transmission belt length Upper bearing type Lower bearing type Grease type 2257 1786 4200 3300 730 1200 315 355 0.Safety warnings ALPHA 700 1. working) Protection type Size Protection against explosion Thermal resistance Supplementary cooling system Motor weight Manufacturer/Type 37 1360 440 46 IP55 225S No 1PTC Yes 300 HELMKE kg DOR 225S-4S-1G-031 kW rpm V Hz F IMB3 4/47 .88 3550 SKF SKF Klueber mm mm mm kg kg rpm mm mm mm 23024 CC W33 C3 23024 CC W 33 C3 ISOFLEX NBU 15 Electric motor data Rated power Speed (maximum working) Voltage Frequency (maxim.5 Technical specifications of the classifier Serial number Customer Name Address Project 0173 Moengo Minerals Paramaribo/Surinam 09.

(N) F1 F2 F3 F4 8250 8250 8250 8250 4 F.20 No No mA 3 wires 5/47 .2 m3/h T/h Installation Grip points F. 625 625 625 625 Analogue signals Speed sensor Safety system 10 .Safety warnings ALPHA 700 Special design Ceramic rotor Ceramic material Ceramic Linning Polyurethane coating Rust-proof Hardening process Monitoring system No No Al2O3 No No No No Process data Air flo Feed rate 26. 1250 1250 1250 1250 VERT. DYN: (N) HORZ.240 V V PNP AC/DC Digital outputs Sensor PT100 Machine vibration sensor Bearing condition sensor 4 .30 48 .350 7. STA.

Description of the particle classifier ALPHA 700 2. The classifier is comprised of 3 bodies. Description of the particle classifier The ALPHA 700 has been designed for the classification of pulverised products and thus can obtain granulometric distribution suitable for the various markets to which you can direct the final product. 6/47 . such as minerals. 1 Fig. 1 Fig. A first body containing the classifier rotor. 1 Motor 2 Bearings support First body of classifier A second body with the fines output. The range of products to classify is very broad. 2 Fines output Second body of classifier A third body with the input of material and output of coarse material. pigments and foodstuffs.

Description of the particle classifier ALPHA 700 1 3 Fig. the connection between the shaft and rotor can be made using a hexagonal bolt. NOTE In some special designs. 1 Fig. an air seal plus a labyrinth ring have been designed. To seal between the rotor and the stator correctly. 3 Coarse material output Level sensor connection 2 Feed Third body of classifier The first body contains the support for the bearings. generating a rigid unit. which are only on one side of the rotor. 4 Hexagonal bolt DIN912 M8x20 Special join between axis and rotor 2 Lock washer The casing of the bearings has been designed with connections for the periodic greasing. form a barrier to keep the grease in contact with the bearings. The shaft rests on a pair of ball bearings that have been designed to work uninterrupted for 10. the upper part of the classifier. In addition to containing radial seals that do not let contamination into the bearings and. moreover. All the machines are delivered with temperature probes to control the temperature of the bearings. The shaft is made of high-quality steel and welded to the rotor. 7/47 .000 hours. which impede coarse material getting into the rotor. The power transmission system is performed by the upper part of the machine and by means of trapezoidal belts.

Description of the particle classifier ALPHA 700 In addition. There are different versions of the machine according to the requirements. the machine may also be supplied with probes for vibrations and the condition of the bearings. 2 4 6 3 8 9 1 7 1 Flow regulation valve 3 Rotary valve for feed 5 Rotary valve for coarse material output 7 Rotary valve for fines output 9 Suction fan Fig. 5 Example of a plant 2 Feed silo 4 Particle classifier 6 Filter 8 Butterfly valve 8/47 . some examples are: – Ceramic rotor – Polyamide rotor – Ceramic-coated casing – Polyurethane-coated casing – Stainless steel – System for monitoring the machine's bearings and vibrations The particle classifier may be supplied as part of the whole plant assembly or as a single unit. Example of the assembly of a classifier in a plant.

the starting material must be ground and dry with a maximum degree of moisture of 0. WARNING Internal damage. 6 Starting material input Fine material output Operating principle 2 4 Separation area Coarse material output 9/47 . 2.Description of the particle classifier ALPHA 700 If the particle classifier has been delivered as a single part. the fines output valve and the components that make up the plant are not supplied. 2 3 1 4 1 3 Fig.1 Operating principle of the particle classifier For optimum classification. Machine breakage. NOTE – The staff must check the size of the particles before operation.5% you must set up a device for drying the starting material.5%. – If the moisture content is higher than 0. Do not allow a particle size greater than 2 mm.

Inside the machine. the cut point is not as close and. – Rotary valve for coarse material output with a well-sealed circuit. as such. the cut point is not as close and. the cut point is closer and. – With a greater feed. The general rules to be able to configure the machine are the following: – At higher speeds. – Suction fan. it is displaced at high speed in a cyclonic movement and thus the coarser particles are expelled by a filter located at the end of the circuit. The Alpha classifier is connected to a fan that causes a suction flow that passes through the rotor. you will obtain a coarser product and the production quantity will increase. The feed type configuration depends on the quantity to feed and the product to classify (see figure 6). In the two types of feed it is absolutely necessary to use a rotary valve to be able to regulate the dosage and generate the correct sealing without interference from outside. consequently. The coarse product is collected by the lower casing and is expelled from the machine by a rotary valve. the product is displaced towards the rotor due to the suction current. The minimum components to be able to produce with this type of machinery are the following: – Rotary valve for feed with a well-sealed circuit and a good dosage. Once the product reaches the height of the rotor. you will obtain a coarser product and the production quantity will increase. – Bag filter 10/47 . the product falls towards the machine due to gravity. mixed with the suction air or through the upper part of the machine.Description of the particle classifier ALPHA 700 The machine can be fed in two ways. If it enters through the upper part. you will achieve a finer product but in less quantity. as such. – With a greater air flow.

7 Upper part feed Segundo cuerpo del clasificador 2 Lower part feed 2. 11/47 . In these cases. WARNING Internal damage. For this reason it is recommended to use an ongoing monitoring system. this element is absolutely necessary. NOTE To avoid minimum signal loss. In some machines such as those with the ceramic rotor. Machine breakage.2 Vibrations Knowledge of vibrations is one of the best methods for determining the condition of a machine.Description of the particle classifier ALPHA 700 1 Fig. you should not use cables of more than 3 metres long. it must not be operated without analysing the vibrations. due to the safety of the machinery and the staff. from the module to the measurement point. The system must be connected to the electric panel so it can cut the power supply when the alarm values are exceeded.

Vibration intensity must not exceed 11 mm/s.5 . Machine breakage.4. hours or days. given that irreversible damage (for example in the bearings) is possible. The best way to calculate this value from the bearings is in the horizontal direction. NOTE The testing of the machine must be more thorough if the vibration intensity in the bearings exceeds 4.5 Condition Good operation value.Description of the particle classifier ALPHA 700 1 Fig.11 >11 WARNING Internal damage. Operation value in which the machine may work safely. shut down the machine and contact the manufacturer. These working conditions must be avoided at all times. “Short periods” means a few days and less than a week. resonances and faults of assembly before any major problem occurs.8 . Should it do so. 4. Intensity (mm/s) <1.8 1.5 mm/s. The normal vibration value must be set. NOTE The vibrations measured out of the frequency range 3 to 1000 Hz must not be considered vibrations coming from the machine. 8 Machine vibrations probe Vibration sensor 2 Bearings condition probe When you start up the machine for the first time (see section 4) you must check the vibrations to identify the tensions. given that parts of the machine may suffer irreversible damage in minutes. 12/47 . Under these conditions the machine may be used temporarily for short periods.

The treatments are the following: – Do not clean or use solvents. – Vibrations must also be strictly monitored. WARNING Internal damage. – It must remain free of dust and dirt. ECUTEC supplies the machines with ceramic components that require more rigorous care than the steel components. – Sharp changes in temperature are not recommendable for the ceramic parts. Never exceed the maximum rotor speed. 13/47 . Polyurethane parts These are used for abrasive materials with low abrasiveness. – All the surface coated with ceramic must be checked and repaired with Epoxy cement. – During the rotor assembly process. Motor In some applications. Machine breakage. the machine must be balanced more frequently. – The machine may never function if this fan is off. For these cases. we recommend you have a replacement ceramic rotor due to its fragility. You must take into consideration: – This must be switched on at the same time as the motor. – Due to the abrasive power of these products. – The maintenance and revisions must be increased with respect to the steel parts (see the maintenance list in point 6. if possible. so the interruption of the production process is kept to a minimum. 2. so we recommend you analyse the condition of the rotor and. you must take extreme care that the rotor does not come into contact with the other parts.3 Classifier options Rotor and ceramic coatings Some materials must be processed with ceramic parts due to their high abrasiveness. rebalance.3). – In addition. – Do not allow high temperatures. – Ceramic is brittle so it should never be hit. it is necessary to connect a supplementary fan to cool the motor.Description of the particle classifier ALPHA 700 A very large increase in vibrations in a very short period may mean it is off-balance. Please contact ECUTEC staff regarding any queries you may have. as they work at a low rpm.

The cooling circuit system will be comprised of a 100litre oil tank. 9 Oil discharge from the bearing casing Oil collector 2 4 Oil injection into the bearing casing Air cooler pump Oil collector/pump suction discharge Cooling system 14/47 .Description of the particle classifier ALPHA 700 2.4 Classifiers with cooling system Introduction Depending on the product to be treated and the working and environmental conditions. certain classifiers may be supplied with an air-oil cooling system for the bearing casing. 1 2 3 4 5 1 3 5 Fig. an air cooler and the flexible hoses needed for the connection to the various elements. All the screwed connections will use 1" BSP screws. a suction pump.

Circuit regulated by the temperature of the bearings: The temperature of the bearings is compared to a pre-set setpoint and when the temperature exceeds the setpoint the cooling system connects. This oil has been designed for most of the industry. Option 2 . depending on the complexity required. but in the event of special requirements please contact our staff before performing start-up. During the start-up operation the cooling system connects in parallel with the classifier motor. 15/47 .Description of the particle classifier ALPHA 700 Operation of the cooling system There are different ways to operate the cooling system. Type of oil ECUTEC recommends the use of KLUBER AIRPRESS 15 oil. The cooling system continues to operate in this way until a minimum disconnection temperature value is reached. which has obtained the best results in the tests performed on the machinery.Circuit always in operation: Cooling of the bearings is forced regardless of their temperature. Option 1.

For this reason. ATTENTION Falling objects.1 Transport Due to the weight of the particle classifier and its respective parts. the transport and assembly imply significant risks. only use the existing fixing points. – Due to the weight. Lifting the motor casing part 16/47 . only use suitable lifting machinery that has been officially checked and approved for transport and assembly. Transport and assembly 3. all the individual parts that cannot be moved manually due to their weight or shape are provided with fixing elements.Transport and assembly ALPHA 700 3. – When lifting individual parts. Risk of crushing and blows.

Transport and assembly ALPHA 700 Lifting the fines output part Lifting the coarse output part 17/47 .

Transport and assembly ALPHA 700 3.2 Work prior to assembly All the brackets must be cleaned of the accumulated grease and dirt. The use of an industrial solvent is recommended. All the bolts must be fixed with Loctite 2701.8 quality or higher.5 M20 M24 M24x2 M30 M30x2 M36 M36x3 M42 M48 M48x3 Quality of fastener 8. The tightening torques are indicated in the following table.3 Tools necessary for assembly. Metric M5 M6 M8 M10 M12 M14 M16 M16x10.9 Torque Nm 6 10 25 49 86 135 210 225 325 410 710 780 1450 1600 2450 2650 4070 6140 6213 8.5 14 35 69 120 190 295 315 460 580 1000 1100 2000 2250 3560 5720 8640 3. Always use fasteners of 8. disassembly and maintenance – Socket wrenches for hexagon screws between M8 and M24 – Double ended spanners between M8 and M24 – Set of spanners for bolts DIN 912 – Extractor for bearings with outer diameter of 100 mm. inner diameter of 50 mm – Grease pump – Rubber mallet 18/47 .8 10.5 M18x10.

which must be assembled before their final positioning. Orient and place the casing containing the rotor and the bearing support. The first step is to place the body containing the fines output on a base that is stable and capable of resisting the weight of the machine. NOTE – The transporting of each machine element must only be done by personnel authorised to handle the corresponding transport devices. Assembly Add and spread silicon or polyurethane on the flange to seal the inside of the machine from the outside. – The particles classifier must be installed on a horizontal. the machine shall be delivered in three parts. 19/47 . For example Loctite 5910. level surface that is resistant enough to bear the total weight of the equipment.Transport and assembly ALPHA 700 3. In general. The orientation depends on the customer's needs and it has different positions.4 Assembly The three assemblies of the particle classifier may be pre-assembled on the ground or assembled directly at the operation site.

you must open the door and place the following elements through the lower part of the sealing flange: o Hexagonal bolt M16x30 DIN 933 (8 units) o Spring washer 16 DIN 127 (8 units) 20/47 . 10 Assembly 1: Fitting the motor casing Once the two parts are in the correct position. 1 3 5 Area to apply silicon Spring washer 12 DIN 127 Sealing flange 2 Hexagonal bolt M16x50 DIN 933 4 Hexagon nut Fig. use the following components to fix the two parts: o Hexagonal bolt M16x50 DIN 933 (16 units) o Spring washer 16 DIN 127 (32 units) o Hexagon nut (24 units) To do the following step.Transport and assembly ALPHA 700 Add and spread silicon or polyurethane on the flange that joins the seal with the closure of the fines output.

Transport and assembly ALPHA 700 Assembly 2 1 3 Area to apply silicon Spring washer 16 DIN 127 2 Hexagonal bolt M16x45 DIN 933 4 Hexagon nut Fig. as with the others. place the temperature probes if they are not installed and those of vibrations if they have been supplied (optional). 11 Assembly 2: Fitting the motor casing Then place the casing containing the coarse material output and. add silicon and the corresponding fasteners: o Hexagonal bolt M16x45 DIN 933 (28 units) o Spring washer 16 DIN 127 (56 units) o Hexagon nut (28 units) Once assembled. 21/47 .

5 Work after assembly Once all the parts are joined and correctly tightened.Transport and assembly ALPHA 700 3.2 mm. 1 Fig.5 .1. 12 Labyrinth seal Checking the seal 22/47 . you must check the tolerance between the moving and fixed parts. you must open the door and verify that the space between the rotor and the seal is 0. To do this.

During commissioning or after changing the bearings. This operation should take approximately 6 hours. you must check the following points: – Check the power. the fins are OK). ECUTEC recommends starting the machine by increasing the revolutions in 2 or 3 steps up to the maximum number of revolutions. Start-up 4. • Check the belts. • Check the lubrication.5 and 1. 23/47 . – The commissioning of the machine should be carried out by ECUTEC personnel. NOTE During the commissioning of the machine. Machine breakage. If the client decides to dispense with ECUTEC staff. 4. the 2 lubrication points in the bearings must be greased with approximately 15 g of grease (ISOFLEX NBU 15 from KLÜBER).1 Commissioning Before commissioning the classifier for the first time you have to check the following: • Check the condition of the rotor (the rotor turns without problems.Start-up ALPHA 700 4.2 Ignition period WARNING Internal and/or external damage. the company can decide to cancel the warranty and all personal harm or material damage shall be the client's responsibility. – Check that it turns gently.2 mm). • Check the distance between the rotor and the labyrinth seal (the space between the rotor and labyrinth seal must be between 0.

Start-up ALPHA 700 – Verify the rotation direction. 24/47 . 13 Rotation direction – Verify the vibrations and that the temperatures do not exceed the standard values (max. 95ºC) It is advisable to grease the machine after the first 30 hours of operation. Fig.

2. Turn on the suction fan. Turn on the rotary valve for feed. 6. 3. 4. 25/47 .Operation ALPHA 700 5. 14 Commissioning a plant 2 Feed silo 4 Particle classifier 6 Filter 8 Butterfly valve To commission a plant the following order must be respected: 1.1 Commissioning a plant 2 4 6 3 8 9 1 7 1 Flow regulation valve 3 Rotary valve for feed 5 Rotary valve for coarse material output 7 Rotary valve for fines output 9 Suction fan Fig. Turn on the classifier cooling fan and motor. Adjust the input butterfly valve to regulate the air flow. Open the butterfly valve to create a circulation of air between the classifier and the filter. Turn on the valves for coarse and fine output to empty the respective silos. Operation 5. 5.

you will obtain a coarser product and production will increase. you will obtain a coarser product and production will increase. the cut point is less close and. – Before starting up the machine. – With a greater feed. – With a greater air flow.2 Settings during operation The general rules to be able to configure the machine are the following: – At higher speeds. ECUTEC may decide to terminate the warranty of the machine and all personal harm or material damage shall be the client's responsibility. – Keep limbs away from rotating elements such as fans or shafts. the cut point is less close and. – The maximum speed indicated in the table of characteristics is the maximum working speed. including risk of death. as such. – If the client exceeds this working speed. as such. 5. you will obtain a finer product but with less quantity. the cut point is closer and.Operation ALPHA 700 DANGER Machine in movement. as such. verify that the frequency adjuster has been limited so the machine cannot exceed the maximum rotation speed. Serious injury or death. This speed should not be exceeded under any circumstances due to the high risk of material damage or personal injury. 26/47 .

burred or panelled pieces. Alternatively. – Make sure fans and moving parts have come to a full stop before starting maintenance procedures. – If there are sharp. – If there is more than one power source. for example Vogel type. – Use lockout devices and the corresponding warnings signs in order to prevent the machine from being started up accidentally. ensure that they are all switched off. – If there are blocked elements. You must consider the ambient conditions to be able to increase or decrease the periods between lubrications. CAUTION Blows and cuts on limbs. If you wish to use another grease. 27/47 . which may lead to the shaft dilating excessively and therefore increasing the probability of breakage. ECUTEC personnel must confirm its use.1 Standard maintenance The following inspections and maintenance work must be performed regularly. Repair if not in optimum condition. ECUTEC tests the machines with Isoflex NBU 15 grease from Klueber so we recommend you use this grease. use the proper tools and lubricants to release these. An increase in temperature at constant operating conditions may indicate insufficient grease. – Maintenance tasks may only be carried out on machines which have been disconnected from the mains or with the power supply sectioned off. – Do not proceed to make any adjustments or cable connections with the power supply switched on. it is mandatory to use Isoflex NBU 15 grease. Maintenance DANGER Electrocution and/or cuts on limbs. Using unsuitable greases or applying grease excessively can cause high temperatures. – The warranty may be cancelled in the event of not complying with this requirement. use protective gloves. Serious injury or death.7. – Regular reviews must be carried out on the status of the earth to ensure its integrity. Minor injuries. NOTE – During the commissioning period. Lubrication It is advisable to install a central greasing unit.Maintenance ALPHA 700 6. 6. some equivalents are listed at the end of section 6.

if possible. Bearings breaking very frequently may indicate bad greasing.000 h. insufficient balancing or defects in some parts. an increase in particles in the fine product may indicate this part is excessively worn. The service life of the bearings may be longer or shorter. depending on the operating conditions (product. from one of the following manufacturers: SKF. you must change them for the types that ECUTEC indicates and. 28/47 . In addition. NOTE If coarse particles are found in the labyrinth joint. This must be between 0. Whenever you replace bearings. It is very important to check the distance between the labyrinth seal and the rotor. this seal must be kept perfectly clean so it can do its job. NSK or FAG.3) must be used as an indicator of the condition of the bearings. Therefore. Belts Do not over-tension the belts as this may cause excessive tensions in the shafts of the machines. Bolted joints The bolted joints must be checked every 10. contact the manufacturer. The replacement period of this element must be adapted to the characteristics of material to classify.2 mm. The history of measurements from the monitoring system (see section 2.Maintenance ALPHA 700 Bearings and seals The bearings must be changed regularly. humidity. Labyrinth seal The labyrinth seal is the element that allows you to keep the area of material to classify separate from the area of fine material. Excessive temperatures in the bearings may indicate excessive tension. temperature). Electric motor See the manual from the supplier.5 mm and 1.

2 mm. follow these steps: – Lift the rotor. etc. – Finally remove the distorted object and measure its thickness after being distorted. points where the material hits directly. The verification must centre. – Unscrew and lift the rotor.). etc. 29/47 . We recommend the disassembly of the different bodies for this verification. the design of the seal has been modified to lengthen its lifetime. on the points where the most wear occurs. If some of the parts that cover the casing have come off.2 Special maintenance (for ceramic particle classifiers only) Labyrinth seal In these classifiers. above all.Maintenance ALPHA 700 6. they must replaced with new parts. The distance between the rotor must be observed. In this case you must check it by placing a material that can be distorted between the rotor and seal. – Place a material that can be deformed (chewing gum.5 and 1. as with the standard classifiers at between 0. such as union elbows. always using Epoxy adhesives. Condition of the ceramic At intervals of a certain number of hours. plasticine. To do so. – Lower the rotor and bolt it. check the condition of the ceramic.

Maintenance ALPHA 700 6. Once the pulleys are out. you must loosen the belts and remove them. 15 Tensing system Loosening the belts 2 Belt protector Step 2 Step 3 Step 4 The remove the tightening bolts of the pulley and move it towards the lower part of the machine using a rubber mallet. Once this has been removed. 30/47 . You can use the holes made in the ribs of the bearing support to lift the rotor. remove the M12x25 bolts and use the elevation screws to lift the rotor.3 Removing the rotor Step 1 Start the process of dismantling the rotor by removing the belt protector. 1 Fig.

01.10) and the radial seal (pos. also remove the upper bearing (pos. 31/47 . Remove the inner hexagonal bolts and lock washers (pos.01.01.Maintenance ALPHA 700 1 3 Fig. Along with the casing. follow these steps: Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Remove the screw and washer from the block (pos. 16) using a bearing extractor. 38.14 and 15) Remove the cover that protects the bearings (pos. pos. 16). 38.09) and the lower bearing (pos. Remove the spacer between bearings (pos. 21 and 20) Remove the bearings casing (pos. Remove the inner hexagonal bolts and washers from the block (pos. 38.01) using a large extractor. 13). 16 Tightening bolts M12x25 bolts Extracting the pulleys 2 Elevation screws To perform the maintenance of the bearings. 12. 17).

retighten the belt.04). 38. 17 Extracting the bearings Table of classifier maintenance for non-abrasive materials: Parts to check Bearings Radial seals Balancing Tensioning Labyrinth seal Distance between rotor and seal Greasing Change (hours) 10000 10000 Revision (hours) 15000 6000 6000 6000 10000 500-1000 Table of classifier maintenance for abrasive materials: Parts to check Bearings Radial seals Balancing Tensioning Labyrinth seal Distance between rotor and seal Greasing Ceramic lining Rotor NOTE Change (hours) 10000 10000 Revision (hours) 6000 6000 6000 10000 6000 2500 2500 500-1000 500 500 32/47 Once it is assembled.01. 24) and lower protective cover (pos. 38 38 38 38 38 38 38 Fig. .Maintenance ALPHA 700 Step 7 Finally remove the radial seal (pos.

132 140 .016 The tensioning force authorised is selected according to the following table depending on the type of section and the diameter of the smallest transmission pulley.20 20 .315 224 .140 100 .355 375 .120 33/47 . Check the tension of the belts in the following way: a t Fig. follow the same steps in reverse order as for removing it.50 50 .35 35 . 18 Distance between shafts Tensioning depth Tensioning the belts F Tensioning force The tensioning depth is calculated using the formula: t = a x 0.200 160 . you must tension the trapezoidal belts using the tensioning system incorporated next to the motor.27 28 .4 Assembling the rotor To assemble the motor.15 15 .5 Tightening the trapezoidal belts Once you have assembled the rotor. Type of profile SPZ SPA SPB SPC Effective Ø of the small pulley (mm) 67 .560 Tensioning force (N) 10 .224 236 .65 60 . 6.Maintenance ALPHA 700 6.95 100 .90 90 .

050 mm x 0. 38.01.01.01. with a tensioning depth of 17 mm.01. it has a tensioning force of between 50 and 65 N. calculate the tensioning depth. The name of the belt is SPB. The tension of the belt is optimum when. 6.01.01 38.Maintenance ALPHA 700 Example of tightening: In the machine.11 12 13 14 Name Bearings casing Rotor Lower protector Spacer Upper protector Upper ring Lock washer Lock washer Inner hexagonal bolt DIN 912 M8x20 34/47 . t= 1.6 Spare parts lists Spare parts list 1 38 38 38 38 38 38 38 Fig. Using the distance between shafts.00 38. the tensioning force must be between 50 and 65 N. and an effective diameter of the small transmission pulley of 250 mm.050 mm. you have to measure the distance between shafts of 1. 19 Spare parts list 1 Pos.01.07 38.09 38.8 mm P 17 mm According to the table.10 38.016 = 16.

(no image) Ceramic seal (ceramic version only) Vibration sensor (version with vibration analysis only) List of spare parts table 2 35/47 .08 15 16 17 20 21 23 24 26 38.00. 2 Name Seal Motor 225M Pulley SPB 17/B d=350 Belts DIN 2215 B/17 Lw=3550 Pulley SPB 17/B d=315 RPM sensor (no image) Ceramic coating (ceramic version only). 1 Lower ring Lock washer A8 DIN 127 Bearing 23024 CC/W33 C3 Radial seal CR135x160x15 CRSA1 Inner hexagonal bolt DIN 912 M10x25 Lock washer A12 DIN 127 PT 100 M8x25 (no image) Balance weight (no image) Grease Isoflex NBU 15 (no image) Ceramic rotor (ceramic version only) List of spare parts table 1 Spare parts list 2l 38 Fig.01.01.01 12 13 14 15 46 59 38. 38.Maintenance ALPHA 700 38. 20 Spare parts list 2 Pos.00.02 CD Tab.01 CD 60 Tab.

3 Table of recommended greases 36/47 .Maintenance ALPHA 700 6. If possible. – During the commissioning period. ECUTEC recommends the ISOFLEX NBU-15. in hotter countries the regreasing period must be shorter. ECUTEC personnel must confirm its use. 21 Lubrication holes Location of lubrication holes 2 Release of grease NOTE – ECUTEC recommends regreasing the bearings every 500-1000 hours for locations with environmental temperatures between 20 ºC and 35 ºC. – The machine is delivered with lubricant but it is advisable to regrease after the first 30 hours of running. These are in the upper part of the machine. 1 Fig. it is mandatory to use Isoflex NBU 15 grease. ECUTEC advises that you check the grease holes and look for possible obstructions. . – When you change the bearings. Product Type Isoflex NBU-15 Beacon 325 Mobilgrease 28 Berulub FR 16 Tab. The system is designed to be greased by a manual pump or an automatic greasing system.7 Lubrication The machine has two lubrication points. use the grease suggested by KLÜBER. If you wish to use another grease. – The warranty may be cancelled in the event of not complying with this requirement. The machine has some holes for releasing the excess grease.

Fault search ALPHA 700 7. Fault search Fault Rotor clogged Cause • particles too large • transmission shaft dilated Solution • check the size of the feed • monitor the bearings Fine material does not correspond to the setting • rotor diameter is not • change the rotor correct • input butterfly valve • adjust the input butterfly changed valve • length of seal between the rotor and the stator too long • change the labyrinth seal Length of seal between the rotor and the stator too long Bearings noisy The rotor shaft cannot be moved Excessive temperature in the bearings High vibrations • wear or deformity • change the labyrinth seal • bearings broken • bearings broken • excessive tensioning • bearings damaged • insufficient grease • bearings damaged • rotor out-of-balance • change the bearings • change the bearings • loosen • bearing change • grease • bearing change • rebalance 37/47 .

it must be impossible to operate the machine. an emergency stop switch or disconnector switch must be installed at a distance of less than 2 metres from the machine.1 Electrical appendix Components necessary for the functioning of the machine • The machine is configured by modifying the speed. • The protection systems of the motors must be installed and.Appendices ALPHA 700 8. depending on the motor. • There must be outputs and inputs for vibration probes. 38/47 . • It must have a general ammeter and voltmeter and ones for the classifier and main fan. Requirements of the control panel • The classifier must have a frequency converter that allows you to monitor the speed. but do reflect the way of operation. for which the use of a frequency converter is required. • During machine maintenance. Appendices 8. • ECUTEC recommends the use of a PLC to check the components. • The machine has 3-wire temperature probes to monitor the temperature so it is necessary to install displays for two probes. • Below some examples are shown. • ECUTEC supplies a speed sensor and a display that must be installed in the control panel. • There must be outputs and inputs for PT-100 temperature probes. Therefore. The sensor is PNP type. they are delivered with PTC or PT-100. These do not reflect the real powers.

x) Appendices ALPHA 700 BREAKING RESISTOR THERMISTOR PROTECTION RELAY 90M Fig.1 +(24VDC) 18(230V) 19(230V) PE /3. 22 1 3 5 2 6 4 /4.BROWN GREEN WHITE 89 84 85 86 87 83 RRx Xx Ux Wx PE Vx VW3-A66704 RRx PCx QPx 10KOh 10Rounds Mx 3 M ~ xKW-xA THERMISTOR LOAD INDICATOR POTENTIOMETER FOR VELOCITY ALPHA 700 (POS.3 BROWN WHITE 37KW READY PE W PE PB COM AO1 PE U V PA +10 AI1 PE 83 KMx 7.1 L1 L2 L3 +(24VDC) 18(230V) 19(230) PE L1 /3.1 /4.1 /4.1 QSx NSxxxA TIx 80 4.1 L2 /3.1 L3 /3.1 13 14 Xx 90 91 39/47 .1 81 E0000 PAx x/5A x/5A Examples of circuit diagrams General electric circuit A AMMETER 88 UCFx R1C R1B R1A L1 R1B R1C R2C R1A R2A R2C R2A FTx A1 +24V START 95 96 97 98 L2 L3 A2 T1 T2 LI1 4.

x ANALOGICS INPUTS .FSSP-1..x) RACK x/SLOT x IWx.x) PT100 BEARING DOWN TEMPERATURE (POS.8/ 8.x) BDx s X IWx TERMINAL N§ BIT SENSOR SPEED 4-20mA (POS. 23 PT100 BEARING UP TEMPERATURE (POS.8/ PE +(24VDC) -(0V) EA0004 x(M-) IWx x(M+) x(S-) x(M-) - EA0005 EA0025 EA0035 EA0006 x(M+) BROWN EA0026 x(S-) IWx SLOT x x(I+) GREEN EA0006M Analogue inputs circuit 1 24VDC 4 ANALOGIC OUTPUT 4-20mA 11 12 5 202 40/47 BTx BTx XX x(I+) IWx x(M-) + - Fig..Appendices ALPHA 700 200 201 UAx 7 14 13 15 PULSE INPUT FREQUENCY VOLTAGE CURRENT CONVERTER P&F KFU8.0 EA0025 EA0026 EA0026 EA0025 EA0035 EA0005M EA0036 EA0036 x(M-) WHITE GREEN WHITE BROWN BROWN 7.

8/ PE BROWN Analogue inputs circuit 2 EA0002M /6.8 /5.x) 41/47 .8 /6.8 EA0000 EA0020 EA0000M EA0001 EA0021 EA0001M EA0002 EA0022 WHITE /6.x) CONTROL VIBRATION BEARING DOWN WARNING 4-20mA (POS.8 /6.8 Fig.8 WHITE BROWN BROWN WHITE 6.1 EA0001 x(I+) IWx x(M-) EA0000 EA0020 EA0021 EA0002 x(I+) IWx EA0022 x(M-) x(I+) IWx x(M-) SLOT x x(I+) x(M-) IWx TERMINAL N§ BIT RACK x/SLOT x IWx.8 /5... 24 PE /9.8 /6./5.8 /6.x ANALOGICS INPUTS Appendices ALPHA 700 CONTROL VIBRATION WARNING 4-20mA (POS.x) CONTROL VIBRATION BEARING UP WARNING 4-20mA (POS.

1 /5.8/ PE 18(230V) 19(230V) +(24VDC) PE /5.8/ 3.1 E0000 2.8/ /5..x) RACK x/SLOT x x.3 230V L N PE 31 32 Digital inputs circuit 1 Xx E0000 + 18 19 PE E0001 x.x) THERMISTOR RELAY FAULT ALPHA 700 (POS.x) SENSOR MAX.8/ 2.x) THERMIC COOLER (POS.2 E0000 E0003 x.. 25 BNx QGx 3.3 SLOT x x.1 2.0 BIT TERMINAL N§ READY ALPHA 700 (POS.1 /5.4 2.3 DIGITALS INPUTS .0.Appendices ALPHA 700 42/47 FTx 2.7 98 97 Fig.1 18(230V) 19(230V) +(24VDC) E0002 x. LEVEL ALPHA 700 (POS.

1 +(24VDC) /7. 26 BLANCO MARRON EA0001 EA0021 EA0001M EA0002 EA0022 EA0002M /8.x) CONTROL VIBRATION BEARING DOWN WARNING (POS..9 E0008 x.11 SLOT x BIT TERMINAL N§ RACK x/SLOT x Appendices ALPHA 700 CONTROL VIBRATION BEARING UP WARNING (POS.8/ E0009 Digital inputs circuit 2 4-20mA OUT1 4-20mA OUT2 ALARM WARNING ALARM WARNING 230V + + L N PE + + BMxx Xx E0008 18 + 19 PE EA0002M Fig.x) x.5 /8.4 /8.8.5 /8.BLANCO MARRON /8.8/ 5.1 5.11 DIGITALS INPUTS 43/47 .x) CONTROL VIBRATION BEARING DOWN ALARM (POS..6 E0010 E0011 PE /8.8/ 5.x) CONTROL VIBRATION BEARING UP ALARM (POS.8/ PE 18(230V) 19(230V) +(24VDC) E0009 x.4 EA0021 EA0001 EA0021M EA0002 EA0022 Xx 5.10 E0011 x.3 /8.8 E0010 x.

.1 /6.4.x) x.8/ 4.1 18(230V) 19(230V) +(24VDC) E0007 x.Appendices ALPHA 700 EA0000 EA0020 Xx BMx 4-20mA WARNING ALARM 4. 27 230V + + L N PE EA0000 EA0020 EA0000M /8.7 SLOT x x..8/ PE 18(230V) 19(230V) +(24VDC) E0006 x.5 x.1 4.4 BIT TERMINAL N§ RACK x/SLOT x CONTROL VIBRATION WARKING (POS.8/ 4.6 PE /6.8/ E0007 Digital inputs circuit 3 EA0000M 44/47 WHITE BROWN /8.2 Fig.x) CONTROL VIBRATION ALARM (POS.1 /8.1 /6.2 Xx E0006 + 18 19 PE /6.7 DIGITALS INPUTS .

28 6../9.03 START COOLER SLOT x ) Fig.2 KMx S0000 4 x..00.1 +(24VDC) 44 43 -E(0V +(24VDC) QGx 300 A2 A1 3.03 x.8/ Digital outputs circuit Appendices ALPHA 700 45/47 .01 1 x.00 TERMINAL N§ BIT 1L DIGITALS OUTPUTS RACK x/SLOT x x.02 3 2 x.

8/ 2.1 2 4 6 2.1 xA 2.7 1 5 6 2 4 3 x-xA QGx KMx 7. 29 7.8/ L1 L2 L3 Motor cooling circuit 4.1 Xx Ux Vx Wx PE Mx 3 M ~ xKW-xA COOLER (POS.x) .Appendices ALPHA 700 46/47 1 43 31 32 44 3 5 2.8/ PE PE /4.8/ Fig.

for example if the classifier stops.) • Finally.) • If the motor has a cooling fan. start the feed. Never connect the feed rotary valve first (10 s.). this is the moment to open the butterfly valve that is between the filter and the fan and that closes the circuit. • If the cooling fan is not connected. • Any PTC or thermal signal must stop the components for their safety. • The temperature probes of the machines must be configured with an alarm at 85 ºC and a machine shutdown at 95 ºC. (30 s. fan and filter must be stopped. approx. the valve. Cuts and personal injuries. this must be connected at the same time as the motor. (15 s. approx. approx. the machine or quality. • The vibration systems must have an alarm configured at 7 mm/s and a machine shut down at 11 mm/s. approx. approx. then connect the fan.) • When the classifier and the fan are in full operation. • The first element to be connected is the classifier. (10 s. you must stop all the elements that are behind this. • Whenever an alarm is triggered in any of the elements. you cannot continue with the sequence. First connect all the output rotary valves (filter and classifier). • The following element is the connection of the system for cleaning the filter. you must follow the instructions below: ATTENTION Rotating element. (60 s. 47/47 .Appendices ALPHA 700 Configuration of the process operations To achieve the quality and quantity established by ECUTEC in addition to the protection of the components and staff. thus it protects against coarse product getting into the area of fine product.) • Once all the systems that ensure the accumulated product output in the different elements are connected. Rules for stopping the machine The following rules must be followed to protect people.