OPERATING INSTRUCTIONS Omniscreen - … Voith/OS2B 22844.pdf · OPERATING INSTRUCTIONS Omniscreen...

O P E R AT I N G I N S T R U C T I O N S

Omniscreenwith conical shaft hub connection

OS2B-BR

Serial No.:

Codeword:

Date: 2000-07-28

1

Omniscreen

Copyright

Copyright by VOITH SULZER Stoffaufbereitung GmbH & Co. KG. All rights reserved. No part ofthis publication may be reproduced, stored in a retrieval system, or transmitted in any form or byany means, graphic, electronic, mechanical, photocopying, recording, taping, or otherwise with-out the prior permission of the copyright owner.

Manufacturer’s name and address

VOITH SULZER Stoffaufbereitung GmbH & Co. KG

Postfach 2120

D-88191 Ravensburg

Telephone: (0751) 8301

Telefax: (0751) 832280

Telex: 732901

OS2B-BR-GB

Omniscreen

Table of Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Explanation of warnings and symbols . . . . . . . . . . . . . . . 1-11.2 Numbering of pages, figures and tables . . . . . . . . . . . . . 1-21.3 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31.4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 2-12.2 Designated use of the machine . . . . . . . . . . . . . . . . . . . . 2-22.3 Organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . 2-22.4 Selection and qualification of personnel . . . . . . . . . . . . . . 2-52.5 Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52.6 Additional hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.2 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.3 Operating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.4 Drive data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

4 Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.2 Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.3 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Unpacking the machine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.2 Transporting the machine . . . . . . . . . . . . . . . . . . . . . . . . 5-15.3 Disposing of packing materials . . . . . . . . . . . . . . . . . . . . 5-15.4 Laying the foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25.5 Setting up and aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45.6 Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75.7 Checking the direction of rotation . . . . . . . . . . . . . . . . . . 5-115.8 Mounting and dismounting the belt pulleys . . . . . . . . . . 5-125.9 Mounting the belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145.10 Preparing for initial start-up . . . . . . . . . . . . . . . . . . . . . . 5-155.11 Dismounting the machine . . . . . . . . . . . . . . . . . . . . . . . . 5-16

OS2B-BR Table of Contents I

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6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 Safety instructions for operation . . . . . . . . . . . . . . . . . . . . 6-16.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26.3 Checks during operation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36.4 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46.5 Prolonged shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 Safety instructions for maintenance work . . . . . . . . . . . . . 8-18.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28.3 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48.4 Opening and closing the machine . . . . . . . . . . . . . . . . . . . 8-68.5 Removing and fitting the screen basket . . . . . . . . . . . . . . 8-88.6 Removing and fitting the rotor . . . . . . . . . . . . . . . . . . . . . 8-108.7 Removing and fitting the mechanical seal . . . . . . . . . . . 8-148.8 Removing and fitting the bearing unit . . . . . . . . . . . . . . . 8-168.9 Removing and fitting the bearings . . . . . . . . . . . . . . . . . 8-188.10 Cleaning the bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

9 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 Wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19.2 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

10 Main Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.1 Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210.2 Bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-410.3 Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-810.4 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1010.5 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1210.6 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1410.7 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1610.8 Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18

11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

12 Subcontractor Documentation . . . . . . . . . . . . . . . . . . 12-1

II Table of Contents OS2B-BR

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Figures

Fig. 2-1 Guards on the machine . . . . . . . . . . . . . . . . . . . . . . 2-4

Fig. 4-1 Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fig. 4-2 Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Fig. 5-1 Correct transportation of machine . . . . . . . . . . . . . . 5-1

Fig. 5-2 Foundation plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Fig. 5-3 Fastening the machine . . . . . . . . . . . . . . . . . . . . . . . 5-4

Fig. 5-4 Fastening the motor . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Fig. 5-5 Machine and motor grouting . . . . . . . . . . . . . . . . . . . 5-6

Fig. 5-6 Connecting dimensions . . . . . . . . . . . . . . . . . . . . . . 5-7

Fig. 5-7 Pressure gauge with damping characteristics . . . . . 5-9

Fig. 5-8 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Fig. 5-9 Replacing the belt pulleys . . . . . . . . . . . . . . . . . . . . 5-12

Fig. 5-10 Mounting and dismounting the belt pulleys . . . . . . . 5-13

Fig. 5-11 Guide values for tensioning . . . . . . . . . . . . . . . . . . 5-14

Fig. 8-1 Lubrication intervals . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Fig. 8-3 Opening the cover . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Fig. 8-4 Correct transportation of cover . . . . . . . . . . . . . . . . . 8-7

Fig. 8-5 Removing the screen basket . . . . . . . . . . . . . . . . . . 8-8

Fig. 8-6 Removing the screen basket out of the machine . . . 8-9

Fig. 8-7 Removing the rotor . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Fig. 8-8 Lifting the rotor out of the machine . . . . . . . . . . . . . 8-11

Fig. 8-9 Reference dimension . . . . . . . . . . . . . . . . . . . . . . . 8-12

Fig. 8-10 Fitting the mechanical seal . . . . . . . . . . . . . . . . . . . 8-14

Fig. 8-11 Removing the bearing unit . . . . . . . . . . . . . . . . . . . 8-16

Fig. 8-12 Removing the bearings . . . . . . . . . . . . . . . . . . . . . . 8-18

Fig. 10-1 Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Fig. 10-2 Bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Fig. 10-3 Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

Fig. 10-4 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

Fig. 10-5 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

Fig. 10-6 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

Fig. 10-7 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

Fig. 10-8 Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18

OS2B-BR Figures III

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IV Figures OS2B-BR

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Tables

Tab. 5-1 Parts for mounting the belt pulley . . . . . . . . . . . . . . 5-12

Tab. 5-2 Test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Tab. 5-3 Check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Tab. 7-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Tab. 8-1 Lubrication intervals and grease quantities . . . . . . . 8-3

Tab. 8-2 Bearing lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Tab. 8-3 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Tab. 8-4 Special tools for screen basket removal . . . . . . . . . . 8-8

Tab. 9-1 Wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Tab. 9-2 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Tab. 10-1 List of subassemblies . . . . . . . . . . . . . . . . . . . . . . . 10-2

Tab. 10-2 Main parts list for bearing assembly . . . . . . . . . . . . 10-5

Tab. 10-3 Main parts list for casing . . . . . . . . . . . . . . . . . . . . . 10-9

Tab. 10-4 Main parts list for accessories . . . . . . . . . . . . . . . . 10-9

Tab. 10-5 Main parts list for rotor . . . . . . . . . . . . . . . . . . . . . 10-11

Tab. 10-6 Main parts list for screen . . . . . . . . . . . . . . . . . . . . 10-13

Tab. 10-7 Main parts list for sealing . . . . . . . . . . . . . . . . . . . 10-15

Tab. 10-8 Main parts list for drive . . . . . . . . . . . . . . . . . . . . . 10-17

Tab. 10-9 Main parts list for guard . . . . . . . . . . . . . . . . . . . . 10-19

OS2B-BR Tables V

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VI Tables OS2B-BR

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These operating instructions are to familiarize the user with themachine. They contain a description of the machine‘s design and itsprinciple of operation. Following these operating instructions ensuresrapid and safe start-up and maintenance of the machine.

– denotes listings

Ö denotes cross-references to other pages, sections, figures, andtables

Æ denotes „task to be performed“

� denotes „monitoring task“

9 denotes „task completed“

ª denotes „result of a completed task“

1 Introduction

1.1 Explanation of warnings and symbols

DANGER

This symbol indicates an imminent hazard. If this hazardis not avoided, it will lead to death or serious injuries.

WARNING

This symbol indicates a potentially hazardous situation.If it is not avoided, it could result in death or seriousinjuries.

CAUTION

This symbol indicates a potentially hazardous situation.If it is not avoided, it could result in minor or moderateinjuries.

NOTICE This symbol indicates a potentially damaging situation.If it is not avoided, it could result in damage to the prod-uct or surrounding equipment.

This symbol indicates special hints for the user and otherparticularly useful information. It is not a signal word for ahazardous or damaging situation.

OS2B-BR-GB Introduction 1-1

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Pages

The pages are numbered consecutively throughout each individualsection.

Figures

The figures are numbered consecutively throughout each individualsection.

Cross-references to figures

Tables

The tables are numbered consecutively throughout each individualsection.

Cross-references to tables

1.2 Numbering of pages, figures and tables

2 - 1

page 1

section 2

figure 1section 4

Fig. 4 - 1

figure 1section 4

Fig. 4 - 1 / 3

item 3

table 1section 3

Tab. 3 - 1

table 1

section 3

Tab. 3 - 1 / 3

column 3

1-2 Introduction OS2B-BR-GB

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Sec. Section

Fig. Figure

Tab. Table

Cont‘d Continued

Unless specified otherwise, all dimensions are in mm.

1.3 Abbreviations

1.4 Dimensions

OS2B-BR-GB Introduction 1-3

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1-4 Introduction OS2B-BR-GB

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For operation of the machine, the local safety and accident preventionrules and regulations are in any case binding.

State of the art

This VOITH SULZER stock preparation machine has been built inaccordance with state-of-the-art standards and the recognized safetyrules. Nevertheless, its use may constitute a risk to life and limb of theuser or of third parties, or cause damage to the machine and to othermaterial property, if:

– the machine is not used as designated,

– the machine is operated by untrained personnel,

– the machine is modified or converted improperly and/or

– the safety instructions are not observed.

Therefore, every person involved in erecting, operating, inspecting,maintaining, servicing and repairing the machine must read, under-stand and observe the complete operating instructions, particularlythe Safety Instructions.

Preconditions for using the machine:

The machine may only be used:

– in perfect technical condition,

– as designated,

– according to the instructions set out in the operating manual, andonly by safety-conscious persons who are fully aware of the risksinvolved in operating the machine,

– if all safety devices and emergency shut-off components are fittedand operative.

Any functional disorders, especially those affecting the safety of themachine, must therefore be rectified immediately.

2 Safety Instructions

2.1 General safety instructions

OS2B-BR-GB-A Safety Instructions 2-1

Omniscreen

The intended field of application of the Omniscreen is in screening orapproach-flow systems ahead of paper and board machines where itcan be used for the continuous removal of contaminants from pulpsuspensions.

The Omniscreen is designed exclusively for removing contaminantsfrom paper stock suspensions. Admissible contaminants are plasticgranules and films, knots, fibre bundles, shives, hair, flakes and simi-lar particles.

Liability for non-designated use

Using the machine for purposes other than those mentioned above isconsidered contrary to its designated use. VOITH SULZER Stoffauf-bereitung GmbH & Co. KG cannot be held liable for any resultingdamage. The risk of such misuse lies entirely with the user.

Availability of operating instructions

The operating instructions must be available wherever the machine isin use.

Additional regulations

In addition to the operating instructions, observe all other generallyapplicable legal and other mandatory regulations relevant to accidentprevention and environmental protection and instruct the personnel tocomply with them.

Additional instructions

Supplement the operating manual by instructions covering the dutiesinvolved in supervising and notifying special organizational features,such as job organisation, working sequence or the personnelentrusted with the work.

Checks

Check regularly whether the personnel carries out the work in compli-ance with the operating instructions and whether they pay attention torisks and safety factors.

2.2 Designated use of the machine

2.3 Organizational measures

2-2 Safety Instructions OS2B-BR-GB-A

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Protective equipment

Use protective equipment wherever and whenever required.

Safety instructions and warnings

Observe all safety instructions and warnings attached to the machine.Make sure that these signs are legible and replace damaged andillegible plates.

Modifications or changes in operating conditions

In the event of safety-relevant machine modifications or changes inoperating conditions, stop the machine immediately and report themalfunction to the person responsible for the machine.

Rebuilds or modifications

Never make any unauthorized rebuilds and modifications which mightimpair safety. Any verbal agreements with the manufacturer or thedesign engineer require written confirmation.

Replacing damaged parts

Parts of the machine that are not in perfect working order must bereplaced immediately with original spare parts (Ö Sec. 9, Spare partson page 9-1).

Use only original spare and wearing parts from VOITH SULZER Stof-faufbereitung GmbH & Co. KG! Unauthorized parts provide no guar-antee that they have been designed and manufactured according tothe application. Danger of accidents!

Checks and maintenance

Adhere to prescribed intervals or intervals specified in the operatinginstructions for routine checks and maintenance work.

Working with hazardous substances

Make sure that dangers to the environment caused by hazardoussubstances are precluded when working on lubricating systems anddevices and when cleaning the machine with solvent-containingdetergents.

Lifting gears

Make sure that the lifting capacity of the lifting gears to be properlyinstalled is at least equal to the weight of the machine or of the partsto be lifted (Ö Sec. 3.2, Weights on page 3-1 ).


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Guards

Guards must be removed only after the machine has been shut downand secured against restart.

Ensure that all guards have been fitted again before starting orrestarting the machine.

1 V-belt guard

Fig. 2-1 Guards on the machine

11 1


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Qualification of personnel

Any work on the machine must be executed only by trained andinstructed personnel authorized by the owner.

Responsibilities

Responsibilities in the operation of the machine must be clearlyestablished and observed, so that no unclear competences mightimpair safety.

Instructions contrary to safety

Give the operator the authority to refuse instructions by third partiesthat are contrary to safety.

Maintenance and repair

Maintenance and repair demand special knowledge and may only becarried out by trained technical specialists.

Depending on the operating conditions, place of installation, piperuns, and other unit parts, the machine may produce a noise levelwhich exceeds 80 dB (A).

Therefore, wear appropriate ear protection when working in the imme-diate vicinity of the machine in operation.

In general, the machine is operated/controlled from a sound-proofoperating room.

2.4 Selection and qualification of personnel

2.5 Noise protection


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Entanglement, crushing and cut/sever hazards due to:

– moving machine parts left exposed by removing covers for inspec-tion, sampling, etc.,

– running and exposed shafts, cylinders, drums, or belts,

Burning or scalding hazards when

opening or keeping open function-check and/or sampling openings onequipment operating at high temperatures (above 40°C).

2.6 Additional hazards


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3 Technical Data

3.1 Machine data

Siebkorb C-3.5-V

Serial No. 22844

Year of construction 2000

3.2 Weights

Casing, empty, without attachment parts t 0.47

Bearing assembly t 0.11

Rotor t 0.07

Screen basket up to t 0.06

Cover t 0.08

Empty weight with V-belt pulley t 0.705

3.3 Operating data

Rotor speed, max. rpm 1475

Motor rating, max. kW 55

Pressure drop, max. bar 0.3

Operating pressure, max. bar 5

Outlet pressure, required minimum bar 0.5

Moment of inertia J kgm2 2.4

OS2B-BR-GB Technical Data 3-1

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Motor data

Belt data

3.4 Drive data

Protection — IP 54

Frame — V 5

Size — 225M

Motor rating kW 55

Motor speed rpm 1500

Mains frequency Hz 50

Type — SPB

Distance between pulley centres mm 942

Belt length mm 3000

Number of belts z — 4

3-2 Technical Data OS2B-BR-GB

Omniscreen

The intended field of application of the Omniscreen is in fine-screen-ing or approach-flow systems ahead of paper and board machineswhere it can be used for the continuous removal of contaminants frompulp suspensions.

The Omniscreen is designed exclusively for removing contaminantsfrom paper stock suspensions. Admissible contaminants are plasticgranules and films, knots, fibre bundles, shives, hair, flakes and simi-lar particles.

4 Technical Description

4.1 Use

OS2B-BR-GB Technical Description 4-1

Omniscreen

The Omniscreen is an enclosed pressurized screening machine.

The paper stock suspension is pumped tangentially into the machinethrough the inlet (Fig. 4-1/1).

Due to their small size, the fibres pass through the screen basket(Fig. 4-1/4) and leave the machine as accepted stock.

As a result of their shape or size, the contaminants are retained at thescreen. From there, the flow carries them to the rejects collectingchamber where they are continuously discharged.

The rotor (Fig. 4-1/3) has the function to produce pressure pulses thatlift the fibre mat off the screen basket and to clean the screen perfora-tion.

The fibres discharged together with the contaminants are recoveredin a post-screening system.

4.2 Principle of operation

1 Inlet socket 3 Rotor 5 Reject socket

2 Screening zone 4 Screen basket

Fig. 4-1 Principle of operation

Inlet

Accepts

Rejects

1

3

4

2

5

Deaeration

Junk trap

4-2 Technical Description OS2B-BR-GB

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4.3 Design

1 Motor 4 Bearing assembly 7 Sealing unit

2 Belt drive 5 Casing 8 Screen basket

3 Guard 6 Rotor

Fig. 4-2 Subassemblies

1 3 52 4 76 8

OS2B-BR-GB Technical Description 4-3

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4-4 Technical Description OS2B-BR-GB

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Æ Loosen machine fixing.

Æ Check consignment against delivery note for completeness.

Æ Check consignment for transport damage.

Æ Report any transport damage immediately to the Voith Sulzer Stoffaufbereitung GmbH& Co. KG.

The transport weight of the empty machine is approx. 0.7t.

Fig. 5-1 Correct transportation of machine

Æ Dispose of the packing materials in an environmentally soundmanner.

Æ Recycle packing materials.

� Observe the applicable regulations.

5 Installation

5.1 Unpacking the machine

5.2 Transporting the machine

WARNING

Ensure that the ropes and the lifting equipment are suita-ble for the empty weight of the machine.

Only use undamaged ropes and lifting equipment.

Only attach the ropes to the intended and marked posi-tions.

5.3 Disposing of packing materials

OS2B-BR-GB Installation 5-1

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Fig. 5-2 Foundation plan

5.4 Laying the foundations

740

( 400 )

( 1140 )

480 330

710 3

45

170

ø 25 ,Z=4

( 39

5 )

150 130

50

50

( 28

0 )

225

1000

325

1140

640

210

470

365

810

ø 18 ,Z=8

125

240

15000 N

5700 N

225

370 370

Chemical anchor M 20

Chemical anchorM 16

incl. 50% dyn. allowance

incl. 50% dyn. allowance

5-2 Installation OS2B-BR-GB

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General

The foundations are to be laid by the customer.

The foundation plan contains all dimensions necessary to lay thefoundations.

Preconditions

9 Location known and accessible.

9 Load capacity of the substructure is sufficient.

9 The reinforcement plan is available.

Preparations

Æ Set up boarding as shown in the foundation plan (Ö Fig. 5-2,Foundation plan on page 5-2).

Æ Make and lay reinforcements.

Æ Fill foundation recesses with filling materials.

Concreting

Æ Mix and pour concrete, allow to set.

Finishing work

Æ Remove boarding.

Æ Remove filling materials.

Æ Clean recesses.

NOTICE Do not use thinners otherwise the grout will not harden.


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Preconditions

9 Foundations are laid.

Preparations

Æ Remove screen basket before setting the machine up (Ö Sec. 8.5,Removing and fitting the screen basket on page 8-8) and close themachine again.

Æ Store screen basket in a safe place until start-up.

Machine

The installation of the chemical anchors is described in Sec. 12, Sub-contractor Documentation on page 12-1. The dimensions are speci-fied in foundation plan (Ö Fig. 5-2, Foundation plan on page 5-2).

Æ Hook machine (Fig. 5-3/1) on a crane (Ö Sec. 5-1, Correct trans-portation of machine on page 5-1).

Æ Position flat steel (Fig. 5-3/5).

Æ Lower machine over threaded rods (Fig. 5-3/4) on flat steel.

Æ Position machine as shown in foundation plan.

Æ Horizontally align machine using the setscrews (Fig. 5-3/3).

Æ Mount and slightly tighten nuts (Fig. 5-3/2).

5.5 Setting up and aligning

1 Machine 4 Threaded rods, 4 x

2 Hex. nut 5 Flat steel

3 Setscrew

Fig. 5-3 Fastening the machine

min

. 30

mm

4

321

5


Omniscreen

Motor

The installation of the chemical anchors is described in Sec. 12, Sub-contractor Documentation on page 12-1. The dimensions are speci-fied in foundation plan (Ö Fig. 5-2, Foundation plan on page 5-2).

Æ Hook motor on crane.

Æ Position flat steel (Fig. 5-4/5).

Æ Lower slide rails (Fig. 5-4/1) over threaded rods (Fig. 5-4/4) on flatsteel (Fig. 5-4/5).

Æ Align slide rails (Fig. 5-4/1) rectangular to the longitudinal axis ofthe machine and centric to the foundation recesses (Ö Fig. 5-3,Fastening the machine on page 5-4).

Æ Horizontally align slide rails (Fig. 5-4/1) using the setscrews(Fig. 5-4/3).

Æ Mount and slightly tighten nuts (Fig. 5-4/2).

1 Slide rail 4 Threaded rods, 4 x

2 Hex. nut 5 Flat steel

3 Setscrew

Fig. 5-4 Fastening the motor

min

. 30

mm

4 5

321


Omniscreen

Machine and motor grouting

Æ Set up boarding for grout.

Æ Mix and pour grout (Fig. 5-5/2) and allow to set.

Æ Remove boarding.

Æ Tighten hex.nuts (Fig. 5-5/1).

Æ Lower motor onto slide rails and fasten it.

1 Hex. nut 2 Grout

Fig. 5-5 Machine and motor grouting

1 2 12


Omniscreen

Fig. 5-6 Connecting dimensions

5.6 Connecting

127

2

283

425 425 9

15

595

200

453

385

199

14 P9 53.

5

173

ø 2

95ø

295

195

283

ø 355

ø 180

ø 160ø 180

ø 450

740

610

460

275 114

ø 110

Test Grease

Top Bottom Top Bottom

b

s

øDøk

øg

øl

øC d i

Overview of all flange dimensions

A B C D E F

DN 200 200 100 80 40 100

∅D 340 340 220 200 150 220

∅k 295 295 180 160 110 180

∅g 268 268 158 138 88 158

∅C 212 212 110 90 54 110

di 200 200 100 80 40 100

s 2.5 2.5 2.5 2.5 2.5 2.5

∅l 23 23 18 18 18 18

b 24 24 18 20 16 18

Earthing of machineAlign machine and soleplates and grout in with concrete

Reject dilution (flushing) F

Dilution-water connection E

Deaeration valve 1 1/2"

Inlet A

Accepts B

Reject C

Bearing

Lube connectionsShock-pulse gauging lines Junk

trap D

Bearing

942


Omniscreen

Preconditions

9 Machine and motor are completely fixed on foundations.

Machine

Pipework

The inlet and outlet circuits can be positioned more or less asrequired. To avoid disturbing deposits, for example in dead corners,the flange connections between the single pieces of the pipeworkmust be exactly concentric.

Sampling ports

Sampling valves must be fitted in all stock-conducting pipes by thecustomer on site.

NOTICE Destruction of the machine!

When the screen runs empty, the mechanical seal mightbe destroyed during restart.

The pipes must be routed so that the screen cannot runempty during short-term shutdown. If this is not possible,the regulating and control valves must prevent the screenfrom running empty.

NOTICE All pipework must be connected completely free of ten-sion.

Do not join with force using the fastening screws.

Support and suspend pipework so that it does not swingor affect the machine during operation, for examplethrough pipework expansion caused by heat.


Omniscreen

Pressure gauges

Fit one pressure gauge each in the inlet and accepts branch of themachine to monitor the differential pressure.

The pressure gauges have:

– a pressure range of 0 … 6 bar and

– damping characteristics.

They are also fitted with the required connecting lugs (Ö Fig. 5-7,Pressure gauge with damping characteristics on page 5-9).

Fig. 5-7 Pressure gauge with damping characteristics

Locate the pressure gauges at the same height. If this isnot possible, take differential pressure into account.

∅101

30°30°

∅70∅85

∅50∅60

∅90

2218

∅70

6xM6

5068

31

∅59

∅48

17

23

6

2

∅7

7

Shown offset through 30°

Counterflange or lug is to bepurchased by the customer

Steel or copper tube

Seal ring


Omniscreen

Shut-off valves

Install one shut-off valve each in the inlet and the accepts branch.

These valves are required for:

– shutting down a single machine in systems where severalmachines are arranged in parallel.

– avoiding stock return flows during repair work.

Regulating valves

If you install the Omniscreen and the post-screening machine at thesame level, connect the rejects regulating valve directly to the Omni-screen as shown in Fig. 5-8, Valves on page 5-10.

It is also possible to locate the post-screening machine ata higher level than the Omniscreen. We recommend thatyou install the regulating valve (Fig. 5-8/1) at the rejectspipe end to ease plant control.

The rejects branch has a connecting lug (Fig. 5-8/2) topermit complete discharge of the Omniscreen. The usercan install a drain valve (Fig. 5-8/4). It is advisable to con-nect a water supply line (Fig. 5-8/3) to flush the Omni-screen.

1 Rejects regulating valve 3 Water connection with valve

2 Connecting lug 4 Drain valve

Fig. 5-8 Valves

1

2

3

4


Omniscreen

Motor

Preconditions

9 Motor is mounted.

Connecting the motor

Connect motor according to the VDE rules VDE/0100 and 0113 or thelocally applicable rules and regulations.

Æ Connect motor electrically.

� Check connections (Ö terminal diagram of motor supplier).

Emergency stop switch

Æ Install emergency stop switch in the vicinity of the machine.

Preconditions

9 Motor is connected.

Checking the direction of rotation

Æ Switch motor on for a short time.

� The direction of rotation of the motor must be anticlockwise whenviewed towards drive journal.

Æ Shut motor off.

For safety reasons, we recommend to install a lockable3-pole safety main switch with padlock.

The power supply circuits are to be routed in such a waythat the entire adjusting range of the motor can be cov-ered without disconnecting the lines.

5.7 Checking the direction of rotation

WARNING

Check the direction of rotation only after belt has beenremoved.

Possible danger of injury due to the dismounted beltguard.

If the machine is not disconnected, the shaft seal couldrun dry and thus be damaged.


Omniscreen

Preconditions

9 Main switches of machine and pump are switched off and securedagainst unintentional restart.

9 Belt is dismounted.

Parts required

5.8 Mounting and dismounting the belt pulleys

1 Supporting elements

Fig. 5-9 Replacing the belt pulleys

Qty. Designation Dimensions

1 V-BELT PULLEY SPB DW 355, 4 GROOVES

1 TAPER LOCK CLAMPING BUSH NO. 3535

D50

1 V-BELT PULLEY SPB DW355, 4 GROOVES

1 TAPER LOCK CLAMPING BUSH NO. 3535

D65

Tab. 5-1 Parts for mounting the belt pulley

3 m

m

1


Omniscreen

Mounting

Æ Clean shaft, hub bore (Fig. 5-10/2) and Taper-Lock bush (Fig. 5-10/1), remove varnish or oil.

Æ Insert bush in tapered bore so that screw holes line up and placescrews (Fig. 5-10/ 3) loosely in holes.

Æ Fit hub and bush to shaft as one unit, locate in position and tightenscrews alternately with uniform force.

� Tightening torques of screws are:

– 115 Nm on motor side

– 115 Nm on machine side

� Remember that bush will nip the shaft first and then hub will beslightly drawn on to the bush.

Æ Align motor and machine belt pulleys.

Dismounting

Æ Loosen screws by several turns.

Æ Screw one of the screws into one of the provided jackscrew hole (Fig. 5-10/4).

Æ Tighten screw until bush is loosened in hub.

Æ Remove assembly from shaft.

1 Taper-Lock bush 3 Socket head cap screw

2 Hub bore 4 Jackscrew hole

Fig. 5-10 Mounting and dismounting the belt pulleys

Jacking offTightTightening

431 2

NOTICE Do not mount belt pulleys without positioning the support-ing elements.

The belt pulleys might be damaged when slipping fromthe journal.


Omniscreen

Preconditions


9 The belt pulleys are mounted to motor and machine.

To install belts

Æ Adjust minimum centre distance between motor journal and rotorshaft for belt mounting.

Æ Install belts.

To tension belts

Æ Tension belts with correct initial tension (Ö Fig. 5-11, Guide valuesfor tensioning on page 5-14 and Tab. 5-2, Test data on page 5-14).

Æ Turn drive several times so that the tension is distributed uniformlyamong all belts.

Fig. 5-11 Guide values for tensioning

5.9 Mounting the belts

NOTICE Loose belts result in lower power input and higher wear(smell of burning rubber) or even screen plugging.

The belts must be retensioned after several hours of oper-ation.

Motor belt pulley dia. dk mm 355

Machine belt pulley dia. dg mm 355

Centre distance e mm 942

Deflection force F per belt N 75

Deflection Ea mm 23

Tab. 5-2 Test data

e2

Ea

dk

dg

e

F


Omniscreen

Preconditions


Flushing

Æ Thoroughly flush inlet piping.

Æ Close inlet valve.

Æ Open machine (Ö Sec. 8.4, Opening and closing the machine onpage 8-6).

Æ Thoroughly wash down machine with hose.

Æ Remove any heavy particles which have been flushed into themachine.

Æ Install screen basket (Ö Sec. 8.5, Removing and fitting the screenbasket on page 8-8).

Lubrication

Æ Check grease lubrication for bearings (Ö Sec. 8.2, Lubrication onpage 8-2).

Check list

Æ Close machine.

The machine is ready for operation when all items on the check listhave been checked.

5.10 Preparing for initial start-up

Components Target Checked

Connections – Mounting correct– Screws tight

Screen basket – Mounting position cor-rect

– Perforation correct

Rotor freely rotating

Guards Mounting correct and com-plete

Emergency stop switch Location known

Sealingwater pressure 1 bar above operating pres-sure

Tab. 5-3 Check list


Omniscreen

Æ Shut machine down (Ö Sec. 6.4, Shutdown on page 6-4).

Æ Prepare machine for long-term shutdown (Ö Sec. 6.5, Prolongedshutdown on page 6-4).

Æ Dismount all pipework.

Æ Disconnect supply piping flanges.

Æ Remove belt guard and belts.

Æ Loosen foundation fastening.

The machine is now ready for transport.

5.11 Dismounting the machine


Omniscreen

Safety devices

Rotating parts, such as V-belts, couplings, shafts, rotors, etc. mayseize loose clothes, long hair, jewellery or limbs.

You might get seriously injured or killed.

The machine must never be used without the required safety devices.

Protection of persons

Unplanned incidents may result in personal injury.

To ensure rapid reaction, always check where the emergency stopswitch is installed and whether it works properly before putting themachine into operation.

Safe operation

This machine is operated under pressure. Therefore, it must bechecked whether all housing covers, inspection ports, windows, etc.are properly locked with undamaged, reliable fasteners.

Covers bursting open can lead to serious injuries and scalding.

The machine must never be used at pressures exceeding the maxi-mum permissible operating pressure (Ö 3.3, Operating data onpage 3-1).

This can occur when:

– the stock flow is interrupted; therefore the accepts and rejectsvalves must be open.

– sudden pressure surges when the shut-off elements are shut tooabruptly.

– air collects inside the machine, that means the venting valve mustalways be slightly open.

6 Operation

6.1 Safety instructions for operation

OS2B-BR-GB Operation 6-1

Omniscreen

Preconditions

9 The preparations for initial start-up must have been completed(Ö Sec. 5.10, Preparing for initial start-up on page 5-15).

9 The main switch is switched off and secured against unintentionalrestart.

Preparations

Æ Open sealing water below rotor.

Æ Open inlet valve.

Æ Close accepts valve.

Æ Close rejects valve.

Æ Open venting valve.

Starting the machine

Æ Fill machine with water.

Æ Switch main switch on.

Æ Put control system to ON.

Æ Slightly open accepts valve.

Æ Slightly open rejects valve.

Æ Start machine.

Æ Switch pump on.

Æ Operate machine with water.

Æ Open stock inlet.

Æ Optimise valve adjustments.

� Operating pressure at accepts branch must be ≥ 0.8 bar.

Æ Adjust accepts and rejects valves accordingly.

Æ Adjust vent valve.

6.2 Start-up

NOTICE According to the pressure vessel regulation, it must beensured that the machine is continuously vented and thatno air or gas accumulates in the casing.

6-2 Operation OS2B-BR-GB

Omniscreen

Æ Take stock samples from inlet, accepts and rejects flows to assurea consistent quality.

Æ Check venting.

Æ Check operating pressure on accepts branch.(Ö Sec. 3.3, Operating data on page 3-1)

Æ Check sealing water pressure.(Ö Sec. 3.3, Operating data on page 3-1)

Æ Observe differential pressure between feed flow and accepts flow.If differential pressure increases Ö Sec. 7, Troubleshooting onpage 7-1.

Æ Observe power consumption of machine.If power consumption increases Ö Sec. 7, Troubleshooting onpage 7-1.

Æ Pay attention to noises and vibrations.In the event of unusual noises and vibrations Ö Sec. 7, Trouble-shooting on page 7-1.

Switch from water to stock supply as early as possible,since the machine absorbs much more power when oper-ated with water.

Depending on the contamination level, the rejects regulat-ing valve must be so adjusted that 15…35 weight% of thefeed flow are supplied to the post-screening system.

6.3 Checks during operation

OS2B-BR-GB Operation 6-3

Omniscreen

Æ Interrupt stock feed flow.

Æ Continue to operate machine with water for a short time.

Æ Switch pump off.

Æ Switch machine off.

Æ Close sealing water.

Æ Interrupt stock feed flow.

Æ Continue to operate machine with water for a short time.

Æ Switch pump off.

Æ Switch machine off.

Æ Close sealing water.

Æ Drain machine.

Æ Carefully wash down machine inside and outside.

6.4 Shutdown

During short-term shutdowns, the machine is not drainedso that the machine remains filled with water.

6.5 Prolonged shutdown

CAUTION

Danger of eye injuries and/or scalding when usingsteam-jet cleaners.

Wear goggles and safety gloves during cleaning.

NOTICE Do not use benzine or other easily flammable substancesfor cleaning.

Never expose electric lines and sealing components tosteam jet. Protect these parts with a cover before clean-ing.

6-4 Operation OS2B-BR-GB

Omniscreen

7 Troubleshooting

Fault Possible cause Fault clearance Remarks

Increase in differen-tial pressure and power consumption

Screen blinding due to:

– Excessive stockconsistency,

– Excessivethroughput,

– Insufficient rejects flow

– Insufficient dilu-tion water volume below rotor

Compare adjust-ments with that of order specification and readjust.(Ö Sec. 3.3, Operat-ing data on page 3-1)

Throttle inlet valve for a short time; usu-ally the rotating blades clear the screen perforation; If the fault cannot be eliminated this way: clean the machine(Ö Sec. 6.5, Pro-longed shutdown on page 6-4)

Rotor blocked due to loose or wet V-belt

Clean, dry V-belts, adjust correct belt tension

Ö Fig. 5-11, Guide values for tensioning on page 5-14 and Tab. 5-2, Test data on page 5-14

Wrong belt tension Adjust correct belt tension


Worn screen basket Install new screen basket

Ö Sec. 8.5, Remov-ing and fitting the screen basket on page 8-8

Reduced throughput and increased rejects consistency or rejects flow

Worn screen basket Install new screen basket


Tab. 7-1 Troubleshooting

OS2B-BR-GB-A Troubleshooting 7-1

Omniscreen

Machine switched off by motor cir-cuit-breaker

Screen plugging due to:

– Excessive stockconsistency

– Excessivethroughput

– Insufficientrejects flow

– Excessive auto-matic intervals

Clean machine

Then compare adjustments with that of order specification and readjust.(Ö Sec. 3.3, Operat-ing data on page 3-1)

After cleaning, check screen basket for damage.

Rotor blocked due to loose or wet V-belt

Clean, dry V-belt and adjust correct belt tension


Wrong belt tension Adjust correct belt tension


Worn rotor Check rotor and replace or repair if necessary

Ö Sec. 8.6, Remov-ing and fitting the rotor on page 8-10

Worn screen perfora-tion

Replace screen bas-ket



Tab. 7-1 Troubleshooting (Cont’d)

7-2 Troubleshooting OS2B-BR-GB-A

Omniscreen

Noises, vibrations High amount of air in stock or insufficient venting

Open vent

Foreign matter in the area of rotor rotation

Clean rotor and rotor rotation area

Deformed screen basket

Replace screen bas-ket


Bearing damage Replace bearings Ö Sec. 8.9, Remov-ing and fitting the bearings on page 8-18

Rotor unbalance Dismount rotor(Ö Sec. 8.6, Remov-ing and fitting the rotor on page 8-10).

May be caused by contaminants built-up under the rotor due to insuffi-cient pre-cleaning of stock(Ö Sec. 8.6, Remov-ing and fitting the rotor on page 8-10).


Tab. 7-1 Troubleshooting (Cont’d)

OS2B-BR-GB-A Troubleshooting 7-3

Omniscreen

7-4 Troubleshooting OS2B-BR-GB-A

Omniscreen

Guards

Ensure that all required guards have been fitted again after comple-tion of all maintenance work.

Protection of persons

Ensure that the main switches of the machine and all upstream ordownstream equipment are switched off and secured against uninten-tional restart prior to any maintenance work.

Make sure that the machine and all stock pipes to the machine havebeen emptied and depressurised.

Safe operation

To ensure safe operation after completion of maintenance and repairwork, use only new and undamaged fasteners (screws, bolts, wash-ers, locking elements, nuts, etc.) and new seals for reassembly.

8 Maintenance

8.1 Safety instructions for maintenance work

OS2B-BR-GB Maintenance 8-1

Omniscreen

Fig. 8-1 Lubrication intervals

8.2 Lubrication

every month

Interval

ever

y m

onth

2

1

Test Grease

Bearing BearingTop Bottom Top Bottom

8-2 Maintenance OS2B-BR-GB

Omniscreen

Bearings

Grease pan

The used grease which is forced out of the bearings during regreasingis collected in a grease pan located below the machine base plate. Ifthe specified grease quantities are used, this pan must be emptiedevery 6 months.

The Omniscreen is supplied with lubricated bearings andfilled grease pipes. Prior to initial start-up, grease bear-ings with half the quantities specified in Tab. 8-1, Lubrica-tion intervals and grease quantities.

Use a grease grade which is also recommended for cen-tralized lubrication systems.

No. Lubricationinterval

Lubrication type

Component Lubrication point

Lubricant Quantity/point

1

every month

Forced-feed lubri-cation

Top bearing(deep-groove ball bearing)

Lube nipple

Grease

10 g

2Bottom bearing(angular-contact ball bearings)

Lube nipple 10 g

Tab. 8-1 Lubrication intervals and grease quantities

NOTICE The use of inappropriate grease grades considerablyreduces bearing life.

Use a lubricant as specified in the following table.

Designation Thickener Temperature range in °C

Worked penetration

DIN 51825K2K

Lithium soap …120 265…295

Tab. 8-2 Bearing lubricants


Omniscreen

Fig. 8-2 Checks

8.3 Checks

every 6 months

Interval

ever

y 6

mon

ths

1

2

5

434


Omniscreen

General

The operating conditions determine the schedule for machine mainte-nance. Nevertheless, the rotor and the screen basket have to beinspected at least 2 times a year.

Preconditions

9 Machine is flushed and drained (Ö Sec. 6.5, Prolonged shutdownon page 6-4).


No. Interval Compo-nent

Check Action Remark

1 Every 6 months

Rotor Check for damage and/or wear

Remove and replace (Ö Sec. 8.6, Remov-ing and fitting the rotor on page 8-10)

2 Screen basket

Check for damage and/or wear

Remove and replace (Ö Sec. 8.5, Remov-ing and fitting the screen basket on page 8-8)

3 Belts Check for damage and/or wear

Remove and replace (Ö Sec. 5.9, Mount-ing the belts on page 5-14)

4 Belt pulley

Check for damage and/or wear

Remove and replace (Ö Sec. 5.8, Mount-ing and dismounting the belt pulleys on page 5-12)

5 Splash guard

Check for increased grease deposits

Clean splash guard from excess grease

(Ö Sec. 8.8, Remov-ing and fitting the bearing unit on page 8-16)

Tab. 8-3 Checks


Omniscreen

Preconditions

9 Main switch is switched off and secured against unintentionalrestart.

9 Machine is flushed and drained (Ö Sec. 6.5, Prolonged shutdownon page 6-4).

9 Inlet valve, accepts valve and rejects valve are closed.

9 Venting valve is opened.

� Pressure gauge shows no pressure.

9 Pump is switched off.

9 Sealing water is switched off.

Opening the machine

Fig. 8-3 Opening the cover

Æ Slacken all screws.

Æ Remove vent line.

Æ Suspend cover (Ö Fig. 8-4, Correct transportation of cover onpage 8-7).

8.4 Opening and closing the machine

Do not remove screws from cover screwholes to preventthem from falling into the machine.


Omniscreen

Fig. 8-4 Correct transportation of cover

Closing the machine

Æ Insert new O-Ring into casing groove.

Æ Position lifted cover.

Æ Lower cover.

Æ Tighten screws with a tightening torque of 210 Nm.

Æ Mount vent line.

WARNING

Remove cover using the lifting equipment (Ö Sec. 3.2,Weights on page 3-1).

Stand clear when parts are being lifted.

DANGER

Always tighten all cover screws.

If this is not done, the cover might work loose and getthrown off due to the pressure within the machine.

This can cause serious injuries.

300

0 - 30°

300

0 - 30°


Omniscreen

Special tools required

Preconditions


9 Machine is open.

8.5 Removing and fitting the screen basket

1 Socket head cap screw 4 Screen Basket

2 O-ring 5 Hex. nut

3 Threaded rod 6 Lift-out device

Fig. 8-5 Removing the screen basket

Designation Use

Lift-out device Removing the screen basket

Tab. 8-4 Special tools for screen basket removal

2

1

3

4

6

5


Omniscreen

.

Fig. 8-6 Removing the screen basket out of the machine

Removal

Æ Loosen socket head cap screws (Fig. 8-5/1) on screen basket(Fig. 8-5/4).

Æ Screw lift-out device (Fig. 8-5/6) to screen basket retainer ring(Fig. 8-5/4).

Fitting

Æ Clean seats.

Æ Check screen basket position.

Reverse removal sequence when installing the screen basket.

� The tightening torque for the fastening screws on the screen bas-ket retainer ring is 60 Nm.

WARNING

Lift screen basket by means of lift-out device and liftingequipment (Ö Sec. 3.2, Weights on page 3-1 andFig. 8-6, Removing the screen basket out of the machineon page 8-9).

Stand clear when parts are being lifted.

appr

ox. 9

00 m

m

rem

oval

hei

ght


Omniscreen

Preconditions


9 Machine is open.

9 Screen basket is removed.

8.6 Removing and fitting the rotor

1 Locking washer 6 Eyebolt

2 Lock nut 7 Key

3 Screw 8 Seal

4 Cover 9 Washer

5 Seal

Fig. 8-7 Removing the rotor

1 32 4 65 7 8 9


Omniscreen

Fig. 8-8 Lifting the rotor out of the machine

Removal

Æ Loosen screws (Fig. 8-7/3) and remove them with cover(Fig. 8-7/4).

Æ Remove lock nut (Fig. 8-7/2) and locking washer (Fig. 8-7/1)

Æ Remove seal (Fig. 8-7/5).

Æ Screw eyebolt (Fig. 8-7/6) into the rotor hub.

Æ Fasten rotor to crane hook.

Æ Lift rotor out of machine carefully.

ø 414

appr

ox. 7

50

min

. 50

420


Omniscreen

Fitting

Fig. 8-9 Reference dimension

Æ Clean seats.

Æ Measure clearance between upper shaft edge and upper edge ofrotor hub.

ª You obtain the reference dimension (Ö Fig. 8-9, Reference dimen-sion) for the correct rotor fitting.

Æ Remove rotor from the shaft.

Æ Apply fine oil on shaft and hub.Do not use materials forming thick layers, such as grease, Moly-cote or the like.

Æ Install washer (Fig. 8-7/9), seal (Fig. 8-7/8) and key (Fig. 8-7/7).

Æ Install rotor.

Æ Measure clearance between upper shaft edge and upper edge ofrotor hub.

� The measured value must be equal to the reference dimensionpreviously obtained.

Æ Install new seal.

Æ Reverse removal sequence when fitting the cover.

NOTICE Conical shaft hub connection.

To ensure the correct seating of the rotor on the shaft, thesurface of the shaft cone must perfectly fit the form of theconical rotor hub.

Therefore, first mount the rotor on the shaft without insert-ing the key (Fig. 8-7/7), seal (Fig. 8-7/8) and washer(Fig. 8-7/9).

Reference dimension


Omniscreen

Notes


Omniscreen

Preconditions


9 Machine is open.

9 Rotor is removed.

General

The shaft of the Omniscreen is sealed with a mechanical seal.

The mechanical seal (Fig. 8-10/1) is supplied as one unit (cartridge)and can be replaced as a whole. The exact installation position issecured by two threaded pins (Fig. 8-10/4).

8.7 Removing and fitting the mechanical seal

1 Mechanical seal 4 Threaded pin

2 Cover 5 Shaft sleeve

3 Flinger ring (top) 6 Mechanical seal flange

Fig. 8-10 Fitting the mechanical seal

NOTICE Make sure that the distance between top edge of cover(Fig. 8-10/2) and flinger ring (Fig. 8-10/3) is within the tol-erance range 41.5±0,5 mm.

4

5

6

12

3


Omniscreen

� Fitting dimension must be 41.5±0,5 mm (ÖFig. 8-10, Fitting themechanical seal).

� Make sure that the shaft sleeve (Fig. 8-10/5) is flush with the sur-face of the flinger ring (Fig. 8-10/3).

Æ Fix threaded pins (Fig. 8-10/4) on the shaft.

Ö Sec. 12, Subcontractor Documentation on page 12-1Burgmann instruction manualType HRN-S20/70-E1

NOTICE Never use sealing compound for assembly!

Never apply sealing compound between mechanical sealflange (Fig. 8-10/6) and cover (Fig. 8-10/2).


Omniscreen

8.8 Removing and fitting the bearing unit

1 Water piping 4 Screw

2 Splash guard 5 Screw

3 Eyebolt

Fig. 8-11 Removing the bearing unit

2

3

4

5

1ap

prox

. 950

mm

rem

oval

hei

ght


Omniscreen

Preconditions


9 Machine is open.

9 Screen basket is removed.

9 Rotor is removed.

9 Belts are removed.

9 Belt pulley is removed.

9 Mechanical seal is removed.

Removal

Æ Remove splash guard (Fig. 8-11/2).

Æ Dismount lube pipes.

Æ Remove bearing monitoring lines.

Æ Remove water piping (Fig. 8-11/1).

Æ Remove screws (Fig. 8-11/4) and (Fig. 8-11/5).

Æ Screw eyebolt (Fig. 8-11/3) into the shaft.

Æ Hook bearing unit on a crane.

Æ Carefully lift bearing unit out of the machine.

Fitting

Reverse removal sequence when fitting the bearing unit.


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8.9 Removing and fitting the bearings

1 Flinger ring (top) 8 Bearing housing (bottom)

2 Bearing cover (top) 9 Ring

3 Deep-groove ball bearing 10 Shaft seal

4 Bearing housing (top) 11 Cover

5 Flinger ring (bottom) 12 Locking washer MB16

6 Bearing cover (bottom) 13 Locknut KM16

7 Angular-contact ball bearings

Fig. 8-12 Removing the bearings

1

2

3

4

5

6

7

8

9

10

11

1213


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Preconditions


9 Machine is open (Ö Sec. 8.4, Opening and closing the machineon page 8-6).

9 Rotor is removed (Ö Sec. 8.6, Removing and fitting the rotor onpage 8-10).

9 Screen basket is removed (Ö Sec. 8.5, Removing and fitting thescreen basket on page 8-8)

9 Bearing unit is removed (Ö Sec. 8.8, Removing and fitting thebearing unit on page 8-16).

Removal

Æ Remove bearings (Ö Fig. 8-11, Removing the bearing unit onpage 8-16).

Fitting

Æ Fill cleaned bearings completely with grease.

Æ Rotate bearings a number of times in both directions.

Æ Fit bearings.

Æ Fill bearing housing space above bearing completely with grease.

Æ Fit bearing unit (Ö Sec. 8.8, Removing and fitting the bearing uniton page 8-16).

NOTICE Damage of bearings!

Always replace all machine bearings.

Use paired angular-contact ball bearings (ÖFig. 8-12/7)of type 7311 BECBM only.


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Preconditions


9 Machine is open (Ö Sec. 8.4, Opening and closing the machineon page 8-6).

9 Rotor is removed (Ö Sec. 8.6, Removing and fitting the rotor onpage 8-10).

9 Screen basket is removed (Ö Sec. 8.5, Removing and fitting thescreen basket on page 8-8)

9 Bearing unit is removed (Ö Sec. 8.8, Removing and fitting thebearing unit on page 8-16).

9 Bearings are removed (Ö Sec. 8.9, Removing and fitting the bear-ings on page 8-18).

Cleaning

Æ Remove stock and old grease residues from the bearings.

Æ Remove stock and old grease residues from all other parts of thebearing unit.

Æ Fill cleaned bearings completely with grease.

Æ Rotate bearings a number of times in both directions.

Æ Fit bearings.

Æ Fill bearing housing space above bearings completely withgrease.

Æ Fit bearing unit (Ö Sec. 8.8, Removing and fitting the bearing uniton page 8-16).

8.10 Cleaning the bearings

NOTICE Dismount the entire bearing assembly after four years ofcontinuous operation at the latest and clean the bearings.


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9 Spare parts

We recommend storing spare parts in good time becauselong delivery times cannot always be avoided.

Use the preprinted order form for spare parts(Ö Sec. 11, Appendix on page 11-1).

The following position numbers refer to the drawings inSection 10.

9.1 Wearing parts

Pos.No.

Qty. Designation Dimensions Part No.

403 1 SCREEN BASKET OS2 D 540 X 495 4017739

3 1 ROTOR SHELL OS2B BR D 427 X 365 4045562

Tab. 9-1 Wearing parts

OS2B-BR-GB Spare parts 9-1

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9.2 Replacement parts

NOTICE Rapid bearing wear!

Plastic cages can be deformed by major temperature vari-ations so that the rollers might edge up.

Use rolling bearings with metal cages only.

NOTICE Damage of bearings!

Not paired bearings wear early!

Allways use paired angular-contact ball bearings of typeBECBM only.

Pos.No.


105 1 LOCKNUT DIN981 KM 9 M 45 X 1,5 0886105

106 1 LOCKING WASHER DIN5406 MB 9 0886305

108 1 SEALING PLATE D 108 X 1,5 0550115

110 1 SEAL D 75 X 8 4017653

116 1 DEEP-GROOVE BALL BEARING (SKF)

D 130/60 X 31, 6312J/C3 4017656

123 2 ANGULAR-CONTACT BALL BEARING (SKF)

D 120/55 X 29, 7311BECBM

4017659

126 1 LOCKNUT DIN981 KM 11 M 55 X 2 0886107

127 1 LOCKING WASHER DIN5406 MB 11 D 55 0886307

205 1 O-RING 591 X 6 4029087

2 1 ROTOR HUB OS2B BR/LR D 365 X 90 CONICAL 4039338

504 1 MECHANICAL SEAL CARTRIDGEHRN-S20/70-E1

4060997

911 4 V-BELT SPB LW 3000 4011027

Tab. 9-2 Replacement parts

9-2 Spare parts OS2B-BR-GB

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General

The main parts list permits to identify the parts in a general arrange-ment drawing and the corresponding list.

10 Main Parts List

OS2B-BR-GB Main Parts List 10-1

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Fig. 10-1 Subassemblies

10.1 Subassemblies

Pos.No. Qty. Designation Dimensions Part No.

1 1 DRIVE OS2 ASSEMBLY 4032792

2 1 GUARD OS2B, ASSEMBLY 4039077

3 1 ROTOR OS 2 -BR CON. ASSEMBLY 4045576

4 1 SCREEN OS2 ASSEMBLY 4032583

5 1 CASING OS2B, ASSEMBLY 4052130

6 1 SEALING UNIT OS2B ASSEMBLY 4060996

7 1 BEARING ASSEMBLY OS2, ASSEMBLY 4054567

Tab. 10-1 List of subassemblies

1 2 3 54 76

10-2 Main Parts List OS2B-BR-GB

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Notes


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Fig. 10-2 Bearing assembly

10.2 Bearing assembly


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— 1 BEARING ASSEMBLY OS2, ZUSAMMENBAU 4054567

102 1 SHAFT D 75 X 776 4054740

103 1 KEY 14 X 9 X 71 4032432

104 1 KEY 14 X 9 X 70 4041957

105 1 LOCK NUT DIN981 KM 9 M 45 X 1,5 0886105


107 1 ROTOR CAP D 108 X 38 4041958

108 1 SEALING PLATE D 108 X 1,5 0550115

109 3 SOCKET HEAD CAP SCREW DIN912

M 8 X 40 0286110

110 1 SEAL D 75 X 8 4017653

111 1 WASHER D 90 X 3 4041509

112 1 FLINGER RING (TOP) D 115 X 20 4060534

113 1 LOCKING WASHER DIN471 D 58 X 2 4017654

114 1 BEARING HOUSING (TOP) D 235 X 70,5 4017655

115 4 HEX. SCREW DIN933 M 12 X 40 0227516

116 1 DEEP-GROOVE BALL BEARING (SKF)

D 130/60 X 31, 6312J/C3

4017656

117 1 BEARING COVER (TOP) D 165 X 38 4017657

118 12 HEX. SCREW DIN933 M 10 X 30 0227484

119 1 FLINGER RING (BOTTOM) D 142 X 42 4041960

120 2 THREADED PIN DIN913 M 8 X 16 0269111

121 1 BEARING COVER (BOTTOM) D 235 X 76.5 4054745

122 4 HEX. SCREW DIN933 M 12 X 45 0227517

123 2 ANGULAR-CONTACT BALL BEARING (SKF)

D 120/55 X 29, 7311BECBM

4017659

124 1 BEARING COVER (BOTTOM) D 160 X 45 4054568

125 1 COVER D 160 X 13 4054569

126 1 LOCKNUT DIN981 KM 11 M 55 X 2 0886107


128 1 SPLASH GUARD D 380 X 25 4057368

129 4 SPACER D 15/10 X 32 4017662

130 4 HEX. SCREW DIN931 M 8 X 40 0227458

131 1 HP HOSE DN6/1SN X 730 4048887

132 1 HP HOSE DN6/1SN X 430 4048888

133 4 HEX. SCREW DIN933 M 8 X 25 0227455

134 2 SHAFT SEAL A 65 X 85 X 10 4024822

135 2 SHAFT PROTECTION SLEEVE D 65 X 20 4047306

136 1 RING D 65/55 X 23 4054851

Tab. 10-2 Main parts list for bearing assembly


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137 2 AMP ACCELERATION SENSOR TYP 8000 ST 4038328

138 2 BNC ADAPTERS BARREL COUPLER 4038331

139 2 AMP BNC CONNECTIONS CAP FOR COUPLER WITH CHAIN

4038330

140 2 HEX. SCREW DIN933 M 2,5 X 5 4030109

— 2 FLAT LUBE NIPPLE DIN3404 A G 1/8A 0875503

— 12 WASHER DIN125 10,5 0331020


Tab. 10-2 Main parts list for bearing assembly(Cont’d)


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Notes


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Fig. 10-3 Casing

10.3 Casing


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Pos.No.


— 1 CASING OS2B 4052130

202 1 CASING D 690 X 780 4052131

203 1 CASING COVER D 690 X 128 4031845

204 20 HEX. SCREW DIN933 M 20 X 60 4031853

205 1 O-RING 591 X 6 4029087

206 4 SUPPORT 165 X 165 X 310 4039051

207 16 HEX. SCREW DIN933 M 12 X 30 0227514

208 16 WASHER DIN125 13 0331021

209 1 WEARING RING TOP D578/495 X 25 4052132

210 1 WEARING RING BOTTOM D526/486 X 15 4052180


M8 X 20 0286105

Tab. 10-3 Main parts list for casing

Pos.No.


— 1 ACCESSORIES OS2B 4039075

002 4 CHEMICAL ANCHOR CAPSULE UKA3; M 20 0212320

003 2 THREADED ROD DIN975 M 20 X 1000 4020847

004 1 ARROW PLATE 74 X 16 X 1 0887002

005 1 RATING PLATE „VSR“ 105 X 74 X 2.5 0888610

006 1 NAMEPLATE „VSR“ 328 X 40 X 5; H= 25 0888510

007 4 BLIND RIVET DIN7337 A4 X 12 0374070

008 6 BLIND RIVET DIN7337 A 3 X 10 0374065

009 4 HEX. NUT DIN934 M20 0311020

010 4 WASHER DIN125 B 21 0331024

Tab. 10-4 Main parts list for accessories


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Fig. 10-4 Rotor

10.4 Rotor


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Pos.No.


— 1 ROTOR OS 2 -BR CON. ASSEMBLY 4045576

2 1 ROTOR HUB OS2B BR/LR D 365 X 110,5 CONICAL 4039338

3 1 ROTOR SHELL OS2B D 427 X 365 4045562


M 10 X 25 0286124

5 4 THREADED PIN DIN916 M 10 X 16 4039011

Tab. 10-5 Main parts list for rotor


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Fig. 10-5 Screen

10.5 Screen


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Pos.No.


— 1 SCREEN OS2 ASSEMBLY 4032583

402 8 HEX. SCREW DIN933 M 12 X 25 0227512

403 1 SCREEN BASKET OS2 D 540 X 495 4017739

Tab. 10-6 Main parts list for screen


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Fig. 10-6 Sealing

10.6 Sealing


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Pos.No.


— 1 SEALING OS2B ASSEMBLY 4060996

502 1 COVER D 290 X25 4056862

503 ? SOCKET HEAD CAP SCREW ISO4762

M 10 X 30 0286125

504 1 MECHANICAL SEAL CARTRIDGEHRN-S20/70-E1

4060997

509 1 DILUTION-WATER PIPING 480 X 370 X 180 4034868

510 2 PIPE NUT DIN431 B G 1 4063262

511 1 CONNECTING PLATE „D“ 200 X 100 X 20 4039224

512 3 HEX. SCREW ISO4017 M 8 X 20 0227453

513 2 O-RING 35 X 2,5 0830526

514 2 O-RING 33 X 3 4550729

— 1 FLAT STEEL 40 X 6 X 80 0115612

Tab. 10-7 Main parts list for sealing


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Fig. 10-7 Drive

10.7 Drive


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Pos.No.


— 1 DRIVE OS2 ASSEMBLY 4032792

903 1 MOTOR BRACKET 800 X 600 X 460 4018086

904 2 TENSIONING RAIL 630, 710 X 100 X 65 4010931

905 8 CHEMICAL ANCHOR CAP-SULE, UKA3

M 16 0212316

906 2 THREADED ROD DIN975 M16 X 1000 0866650

907 1 V-BELT PULLEY SPB DW355, 4 GROOVES 4018099

908 1 TAPER-LOCK CLAMPING BUSH NO. 3535, D 50 4018091

909 1 V-BELT PULLEY SPB DW355, 4GROOVES 4018099

910 1 TAPER-LOCK CLAMPING BUSH NO. 3535, D65 4013082

911 4 V-BELT SPB LW 3000 4011027

— 8 HEX. NUT DIN934 M16 0311016

— 8 WASHER DIN125 17 0331022

Tab. 10-8 Main parts list for drive


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Fig. 10-8 Guard

10.8 Guard


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Pos.No.


— 1 GUARD OS2B, ASSEMBLY 4039077

002 1 COVER PLATE 280 X 300 X 630 4015842

003 2 COVER PLATE 2 X 480 X 530 4015880

004 1 COVER PLATE 2 X 480 X 630 4015895

005 1 COVER PLATE 2 X 100 X 200 X 540 4015901

006 18 SPACER D 15 / 10 X 10 4021943

007 20 HEX. SCREW DIN 933 M 8 X 20 0227453

008 1 COVER PLATE 2 X 440 X 500 4038660

Tab. 10-9 Main parts list for guard


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The appendix includes:

– 3 Order Forms for Spare Parts

11 Appendix

OS2B-BR-GB Appendix 11-1

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11-2 Appendix OS2B-BR-GB

VOITH SULZERStoffaufbereitungGmbH & Co. KGPostfach 2120D-88191 Ravensburg

Fax: 0751/83 22 80

Customer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Address: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepared by: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dept. / Tel.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Order No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Codeword: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Order No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine designation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type / Size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Requested delivery date: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Requested shipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Firm stamp: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date, signature: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Order Form for Spare Parts

Part No. Quantity Designation

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VOITH SULZERStoffaufbereitung GmbH & Co. KGPostfach 2120D-88191 Ravensburg

Fax: 0751/83 22 80

Customer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Address: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepared by: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dept. / Tel.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Order No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Codeword: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Order No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Type / Size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Firm stamp: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date, signature: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Sen

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VOITH SULZERStoffaufbereitungGmbH & Co. KGPostfach 2120D-88191 Ravensburg

Fax: 0751/83 22 80

Customer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Address: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepared by: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dept. / Tel.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Order No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Codeword: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Order No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Type / Size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Firm stamp: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date, signature: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Sen

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Contents:

– 1 Upat documentation:Upat-UKA 3 chemical anchor with mortar capsule EAP

– 1 Instruction manual for Desch Taper Bushes

– 1 Burgmann instruction manual for mechanical seal

12 Subcontractor Documentation

OS2B-BR-GB Subcontractor Documentation 12-1

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12-2 Subcontractor Documentation OS2B-BR-GB

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OS2B-BR-GB Subcontractor Documentation 12-3

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12-4 Subcontractor Documentation OS2B-BR-GB

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