ENG.TYPE 18V32CLK x 3SETS JOB.No. B220655 6200 kWe x 3SETS DIESEL GENERATING PLANT FOR CHI MEI CORPORATION, INSTRUCTION MANUALS DRAWING TITLE : INTAKE AIR FILTER “DRAWING No: P7943108A NIIGATA ENGINEERING CO., LTD POWER SYSTEMS DIVISION POWER PLANT ENGINEERING DEPARTMENTLocker Air-Maze Limited PO Box 17 Folly Lane ‘Warrington Cheshire WAS SNP Tel, (0925) 54321 Telex 628234 Fax: (0925) 414588 AUTOMAZE 600 EM INSTALLATION, OPERATION AND — MAINTENANCE INSTRUCTIONS IRB/AHM/12.84CONTENTS RECOMMENDED ADESIVE OILS OTL TANK CAPACITIES AUTOMAZE AIR FILTERS (ELBCERIC MOTOR DRIVE) ASSEMBLY & INSTALLATION INSTRUCTIONS. ‘Automaze Stages of Erection AUTOMAZE AIR FILTERS (ELBCTRIC MOTOR DRIVE) MAINTENANCE INSTRUCTIONS Maintenance Checking Drive Chain Tension Jammed Panels Oil Level Major Overhaul Overfill Conditions SERVICING INSTRUCTIONS Servicing of Filter Tank Servicing of Filter Panel ASSEMBLY AND PARTS LISTS Filter Panel Assenbly Upper Sprocket AssemblyRECOMMENDED ADHESIVE OILS ambient Temperature 10 deg.c to - 5 deg.c to +6 deg.c to +16 deg.cC to +28 deg.C to OLL ‘TANK CAPACITIES Width No. 3 (3'0" / Width No. 4 (4'0" / Width No. 5 (5'0" / (Larger units are multiples of the above) + 6 deg.c #16 deg.c +27 deg.c 438 deg.c 452 deg.c 930 mn) 1240 rm) 1540 mn) Oil Grade Shell Tellus R 10 Shell Tellus v 15 Shell Tellus 2 22 Shell Tellus R 37 Shell Tellus R100 125 litres 165 litres 205 litresAUIOMAZE ATR FILTERS (ELECTRIC MOTOR DRIVE) ASSEMBLY & INSTALLATION INSTRUCTIONS This information is intended to give the erector concise instructions for the proper installation and commissioning of Automaze Air Filters. The instructions indicate, by stages, the checks to be made in the course of assembly. Before proceeding with erection, the installation General Arrangement drawing and the product brochures should be studied carefully.Stages of Erection. 3. » 2) 3) 4) Bach Automaze casing or section must rest on a prepared level foundation so that, when the individual units are placed in position, they may be secured together, and fixed to the base without any distortion. This is extremely important. Any variation in the level of foundations must be rectified before the units are bolted together. Distortion in the casings may cause jamming of filter panels in the guide channels. On no account must the individual units be forced together on assembly. When Automaze casings have been placed in their final positions and bolted together, front and back, the assembled sections may be secured to the foundations. ‘The Automaze casings are now ready for final assembly. Remove all loose items that may have been packed in the Automaze casings. Check that panels have not jammed during transit. Connect electrical supply. Apply power, and check direction of rotation. The front panel curtain should move upwards. If downwards, reverse polarity immediately. The filter is not suitable to run in reverse. Fill tanks with adhesive oil to the indicated oil level only. DO NOT OVERFILL. Before starting equipment, allow filter to run for at least 24 hours to ensure panels are oil-coatedAUTOMAZE AIR FILTERS (ELECTRIC MOTOR DRIVE) MALNTENANCE INSTRUCTIONS. Maintenance. The Automaze filter is designed for continuous operation under the most arduous conditions, and the need for routine maintenance has been reduced to an absolute minimum. The following mechanical checks, however, should be made on a scheduled basis. By so doing, major "down time" may be eliminated. vy 2) Check that the securing bolts on the left and right hand tensioning plates are tight, and that correct tension is maintained in the panel chains. Care should be taken not to over-tighten. The panels should remain horizontal in operation. Loose tensioning plates will allow the chain to “trip a tooth" on the drive sprocket. The effect would be apparent by tilting and possible jamming of panels in the quides. This fault may be rectified by the following procedure: a) Remove access plates at lower left and right front guides and remove 'E' clips. b) Remove one or two filter panels, giving access to the motor drive chain. c) Remove motor drive chain to enable the curtain to be moved round to gain access to the upper sprocket tensioning plates. 4) Slacken the locking and tensioning screws on the tensioning plates.e) nore: £) a) A) Re-adjust chain, meshing in correct sprocket teeth to give horizontal panel positioning. Ensure that panel assembly cannot rotate inadvertently when motor drive chain is disconnected. Re-adjust tension and securely lock tensioning plates, observing the following procedure: The left and right hand chains should be fitted to the top and bottom sprockets and equally tensioned so that the panel attachment link located midway between the top and bottom sprocket just touches the inner face of the panel guide channel (see sketch). Replace panels and secure with 'E' clips. Replace access plates and secure with bolts.AUTOMAZC AIR FILTER GOO Em (ELECTRIC MOTOR CRIMI) leat cprings i Inside Face of ——| Channel Guide Panel Attachment ‘ Link 0 Direction of curtain movement Direction of Airflow ——e Checking drive chain tension (item 2c}Jammed Panels. Should the panels become jammed, do not attempt to release by forcing the curtain. The probable cause will be broken leaf springs, which are located inside the front left and right hand of the casing, close to the top sprockets. a) b) ce) a) e) Remove top front sheet metal cover plate Remove access plates. Remove one or two filter panels to remove motor drive chaii. This will allow movement of the filter panel curtain to unjam the affected panel and enable the panel curtain to be operated normally. CHECK LEAF SPRINGS. If springs are broken, it will be necessary to rotate the panels until access is gained to the leaf spring retaining rivets. Fit new leaf springs and re-assemble. Care mist be taken to ensure that the panel assembly cannot rotate inadvertently while the motor drive chain is disconnected.Oil Level. ‘the oil should be maintained to the level indicated by the plate inside the oil tank. The oil level should be checked periodically and topped up as necessary, using only an approved oil adhesive. The solid collected by the filter will be deposited in the tank and form a sludge which will tend to settle in the base of the tank. a) Remove sludge with scraper provided. t) Top up with clean adhesive oil to the indicated level.Major Overhaul. 9 Major overhaul periods will be determined by the atmospheric conditions encountered at the installation, but will not normally be required more frequently than every three years. ‘The overhaul will consist of a complete dismantling of the filter assembly, including panel chain and sprocket assemblies. A check should be made on the following components and assemblies for possible wear or mel function. a) b) ©) a) e) £) ‘Top sprocket assemblies, including bearings. Check for wear. Panel. drive chains and panel mounting lugs. Check that all lugs are securely riveted into the main links. Main drive shaft. Remove pins from panel drive sprockets. Remove nuts holding sprocket plates to side plate. Dismantle shaft from Automaze removing sprocket assemblies in the process. Bottom sprocket assenblies. Check for possible wear. Bearing bushes. These should be checked for wear and replaced if necessary. NOTE: When re-assembling, the tensioning plates positioned at the top of the unit should be adjusted with the drive shaft, sprockets and chains fitted, to ensure correct tension in the panel chains. Do not over-tension. Er sure that the tensioning plates are securely locked before re-inserting the panels. Electric motor drive assenbly. All units are fitted with pre-packed shielded ball bearings with an estimated life of 5,000 working hours, which can vary depending on operating conditions and temperature. We recomend replacing a noisy bearing, as re-greasing will not obviate this fault.g) h) il 10. In most cases, dismantling of the motor or gear box is a straightforward procedure. Carefully note the position of spring loading washers, shields, shims, etc. However, the commutator type motors require a suitable extractor to remove the armature from the main frame. Commutator alignment in relation to the brush gear should be observed to ensure the armature is replaced in the correct position. Comutator or collector motors require more maintenance than induction type, due to the accumulation of carbon dust in the brush gear area. This dust should be blown out periodically with a dry air supply, and only when the commutator surface is in a very blackened condition should it be lightly cleaned with "flour paper or similar (note - not emery paper). When replacing carbon brushes, (which may have a life of some 1000 hours depending on operating conditions) care should be taken to ensure these are a free fit in the holders. When dismantling, the brush gear should be marked to ensure it is replaced in the original position, and the pigtails, if any, are clearing the motor casing. Desludge. Thoroughly clean the oil tank. Clean Panels. If cleaning of panels is necessary, this should be carried out by soaking in kerosene or other suitable cleaning fluid. Blow out from the clean side of the media with compressed air. Check for clearance of solid from the media labyrinth by holding the panel up to the light. Clogged dirt will be denoted by areas of ‘blanking’ in the media. These should be cleared. Check panels for damage to frame or media. Damaged units should be renewed. Ensure correct rotation of filter curtain after re-assembly. Refill tank with clean oil adhesive. As specified by the filter manufacturer. Care should be taken not to overfill the tarks.SERVICING INSTRUCTIONS. nh. Servicing of Filter Tank. ‘The sludge which is deposited in the oil tank must be removed at regular intervals. The frequency of removal will depend upon lecal dirt conditions. The sludge should not be allowed to accumlate to a depth of more than 70 mm. When the filter is first installed, the tank should be inspected every two weeks to determine the rate at which sludge is being deposited. Some oil will be lost with the sludge, and must be replaced with fresh oil. The oil should be maintained at the oil level mark.Servicing of Filter Panel. 12. If it becomes necessary to remove any or all of the filter panels, for any reason, the procedure below should be followed. le Place the control box door switch in the ‘off" position. Unbolt the two access plates on the front of the Automaze guide channels. These plates are located 1 m up from the bottom of the filter. Remove the two wire snap rings from the panel support pins with Jong-nosed pliers. Slip the panel support pins from the conveyor chain lugs, freeing the panel. Remove the panel. Release lower drive shaft motor drive chain to allow manual movement of the filter panel curtain. Nore: Ensure that curtain cannot move inadvertently while motor drive chain is disconnected. Move the filter curtain up again by hand until the next panel is framed in the opening. Remove all panels in this manner. To replace the panels in the filter housing, reverse the process, being sure to replace the wire snap ring on the panel support pins. Spare snap rings are provided with each Automaze Assembly. Replace motor drive chain.AUIOMAZE ATR FILTER 600 EM (ELBCIRIC MOTOR DRIVE). FILTER PANEL ASSEMBLY AND PARTS LIST tem No. 1 2 3 4 5 Description Access Plate M6 Hex Nut Gme Dia. Flat Washer Pane "Clip Ret No. No off 0 3323 2 4 4 8.3350 Anderton Ref E3032 Per Panel PANEL ASSEMBLY TYPICAL BOTH SIDES OF CASEUPPER SPROCKET ASSEMBLY & PARTS LIST Description Clamping Plate Mé x 1 C'SK head set screw 12 mm long Plate & Stub Shaft Assy Roller Bearing Sprocket, MLO Hex Nut MLO Flat Washer M12 Hex Nut M12 Hed Hd Set screw 95 mm long Ref. No. paa71 20102 Hoffman Ref RXLS 14 caa72 No. off 1s.MAIN DRIVE ASSEMBLY ~ PARTS IDENTIPICATION LIST Ttem Description Ref. No. ty 1 Mounting Plate €20095 (5-33) 2 (10-66) 5) 2 Lower Sprocket Bearing pa4e3 2 3 2 BA Socket Head Cap Screw - 4 4. 0.312" Dia. Pin - 4 + Lower Sprocket Bearing (inner) caaea 2 6. Lower Sprocket - 2 7. Woodruff Key No. 90 - 2 8. Roll Pin - 4 9. Lower Drive Shaft - a 10. Clutch Assembly F0303002X il ll. Motor Drive Bracket 19766 a 12. Motor splsws 1 13. Chain Wheel p19151 a 14, Roller Chain 34 Links Renold 110-046 1 35. MG x 20 Hex Hd Screw - 4 16. M6 Washer - 10 17. MG Hex Nut - 10 18. MS x 10 Grubserew - 1eS © TIMER SWITCH CAPACITOR MOTOR TIMER, MOTOR MAU é 500 TON WIRING DIAGRAM