Refinador Beloit

8/11/2019 Refinador Beloit

1/86

2001-2005GL&VInc.

Installation, Operation and Maintenance ManualDD3000 Refiner

GL&V USA Inc. 141 Burke Street Nashua, New Hampshire 03061 Telephone: 603-882-2711 Fax: 603-595-0035


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Customer Information

Customer: Customer Name goes here

Location: Customer location goes here

Serial Nos.: enter the serial number here

S.O. No.: The S.O. number goes here

Account No.: Enter the Account number here

DRAWING LIST

Drawing 1 goes here

Drawing 2 goes here

Drawing 3 goes here

Drawing 4 goes here

VENDOR DATA

Vendor data goes here




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Preface

This instruction manual provides installation

and maintenance information for the equip-

ment supplied by GL&V Inc. Illustrations

used are typical and are intended to show

the principal design features. The specific

drawings supplied for the unit should be

consulted for more accurate detail. There is

no intent to state or imply any warranties or

guarantees of process or performance. Any

contractual obligations of GL&V are stated

in the terms of the Sales Agreement.

The contents of this manual should be

studied carefully by all Engineering, Su-

pervisory, Operation and Maintenance

personnel before any attempt is made to

install, operate or maintain the equipment.

Although every effort has been made to

provide comprehensive instructions, this

manual may not provide for every contin-

gency which may arise during installation,

operation and maintenance. Should fur-

ther information be desired, or should you

have questions, contact GL&V USA Inc.,

Nashua, NH, U.S.A., Customer Support

Group, telephone 603-882-2711, fax 603-

595-0035. Please be sure to include the

specific serial number of the machine in-

volved when making informational inquiries

or requests for spare parts.

GL&V can provide field service if mills re-

quire support for installation, mechanical

checking or maintenance/repair service. For

further details contact the Customer Sup-

port Group at the numbers listed previously.

WARNINGDo not attempt to install, operate or

perform any work on this equipment

until you have read and fully understoodthe instructions in this manual. Serious

injury can result.

Preface


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Table of Contents

PREFACE 5

SAFETY INFORMATION 11

SAFETY FIRST .......................................................................................................................................12

RECOGNIZE SAFETY INFORMATION ...................................................................................................12

UNDERSTAND SIGNAL WORDS ...........................................................................................................12

SAFETY WARNINGS AND PRECAUTIONS ...........................................................................................13

REFINING PROCESS SCHEMATIC .......................................................................................................19

DECAL LOCATIONS ...............................................................................................................................20

DESCRIPTION 23

GENERAL MACHINE DESCRIPTION ....................................................................................................24

PRINCIPLE OF OPERATION ..................................................................................................................24

DESCRIPTION OF COMPONENTS .......................................................................................................25

Base ..................................................................................................................................................25

Adjusting Mechanism ........................................................................................................................26Bearing and Rotating Assembly ........................................................................................................26

Packing Assembly .............................................................................................................................27

Rotor .................................................................................................................................................28

Electrical Components ......................................................................................................................28

Controls .............................................................................................................................................28

TYPE OF INSTALLATION .......................................................................................................................28

ADDITIONAL COMPONENT INFORMATION .........................................................................................29

Synchronous Motor Torque Data ......................................................................................................29

Motor Data ........................................................................................................................................29

Sliding Head Movement & Old Style Gearmotor Information ............................................................29

Sliding Head Movement & XL Gearmotor Information ......................................................................30

WEIGHTS AND LIFTING 31

MAJOR ASSEMBLY AND COMPONENT WEIGHTS ..........................................................................32

LIFTING ..................................................................................................................................................33

Lifting the Entire Machine ................................................................................................................33

Lifting the Disks and Rotating Head .................................................................................................34

Lifting the Rotating Assembly ............................................................................................................34


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Table of Contents

RECEIVING AND STORAGE 35

SHIPPING PREPARATIONS ...................................................................................................................36

LONG TERM STORAGE PREPARATIONS AND CONDITIONS ............................................................36

STORAGE MAINTENANCE ....................................................................................................................37

Every Three Months ..........................................................................................................................37

Every Two Years ................................................................................................................................37

VENDOR SUPPLIED DRIVES AND OTHER EQUIPMENT ..................................................................37

INSTALLATION 39

FOUNDATION AND LEVELING ..............................................................................................................40

Installing the Refiner to the Foundation without a Sole Plate ..........................................................40

Installing the Refiner to the Foundation with a Sole Plate (Optional) ..............................................40

MOUNTING .............................................................................................................................................41

INSTALLATION OF COUPLING ..............................................................................................................41

SETTING DRIVE .....................................................................................................................................42

PIPING AND WIRING .............................................................................................................................43

Piping Installation ..............................................................................................................................43

Mono-Flow Piping .............................................................................................................................43

Two-Pipe Duo-Flo Piping...................................................................................................................44

Packing Box Piping ...........................................................................................................................44

Transmitter Signal Lines ....................................................................................................................45

Electrical Wiring ................................................................................................................................45

MODELS WITH AIR LOCK (OPTIONAL) ................................................................................................45

OIL CIRCULATION SYSTEM (OPTIONAL) ............................................................................................46

Description ........................................................................................................................................46

Installation .........................................................................................................................................47

OPERATION 49

PRE-STARTUP CHECK ..........................................................................................................................50

STARTUP AND OPERATION (TYPE 2) REFINER LOADING STATION ................................................50

SHUTDOWN ...........................................................................................................................................51

CONTROLS .............................................................................................................................................51


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Table of Contents

MAINTENANCE 53

GENERAL ...............................................................................................................................................54

LUBRICATION .........................................................................................................................................54

Bearings ............................................................................................................................................54

Recommended Lubricants: ...............................................................................................................54

Adjusting Mechanism ........................................................................................................................55

Recommended Lubricant ..................................................................................................................55

Pressure Fittings At Keyways ............................................................................................................55


Coupling ............................................................................................................................................55


Gearmotor .........................................................................................................................................56

Circulating Oil System .......................................................................................................................56

Oil cleanliness ...................................................................................................................................56

TROUBLE SHOOTING ............................................................................................................................57

DISMANTLING AND REASSEMBLY OF MACHINE ...............................................................................58

Disk Replacement .............................................................................................................................58

Segmental Disks ...............................................................................................................................58

Segmental Disk Removal ..................................................................................................................58

Segmental Disk Installation ..............................................................................................................59

Adjusting Mechanism .......................................................................................................................59

One-Piece Disks ...............................................................................................................................60

DISASSEMBLY OF ROTATING AND PACKING ASSEMBLY ..................................................................63

Refiners with Coupled Motors ...........................................................................................................63

DISASSEMBLY OF ROTATING AND PACKING ASSEMBLY ..................................................................64

Refiners with Integral Motors ............................................................................................................64

DISASSEMBLY OF INTEGRAL MOTOR AND STATOR .........................................................................64

DISASSEMBLY OF ROTOR COUPLED UNITS ......................................................................................64

REMOVAL OF INBOARD BEARING .......................................................................................................65

34 and 42 inch model refiners with coupled and integral motors ......................................................65

REMOVAL OF OUTBOARD BEARING ...................................................................................................66

34 and 42 inch model refiners with coupled motors ..........................................................................66

REMOVAL OF INBOARD AND OUTBOARD BEARINGS .......................................................................66

For 20 and 26 inch model refiners ....................................................................................................66

REMOVAL OF INBOARD AND OUTBOARD BEARINGS .......................................................................67


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54 inch model refiner ........................................................................................................................67

INBOARD AND OUTBOARD BEARING REASSEMBLY ........................................................................67

All refiners .........................................................................................................................................67

REMOVAL AND REPLACEMENT OF PACKING SLEEVE .....................................................................68

Cleaning ............................................................................................................................................68

Assembly of Packing Sleeve .............................................................................................................68

GENERAL INFORMATION ON LOCTITE ...............................................................................................69

CURING: .................................................................................................................................................69

PACKING BOX ASSEMBLY .....................................................................................................................70

SHEAR PIN REPLACEMENT .................................................................................................................70

SIER-BATH COUPLING INFO ................................................................................................................70

GOOD PACKING PRACTICES FOR ROTATING SHAFTS .....................................................................71

Compression Packing Installation And Maintenance ........................................................................71

SLEEVE INSTALLATION USING LOCTITE RETAINING COMPOUND ..................................................73

APPENDIX 75

SUGGESTIONS FOR THE CARE AND USE OF STAINLESS STEEL EQUIPMENT ............................76

Introduction .......................................................................................................................................76

Precautions .......................................................................................................................................76

Cleaning Procedure ..........................................................................................................................77

RECOMMENDED TIGHTENING TORQUE FOR CAP SCREWS (INCH)...............................................78

RECOMMENDED TIGHTENING TORQUE FOR CAP SCREWS (METRIC)..........................................79

PROCEDURE FOR APPLYING POLYESTER SIGNS ............................................................................80

SPARE PARTS 81

DRAWINGS 83

VENDOR DATA 85


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Safety InformationThe safety labels shown in this manual and on the equipment are for

personnel protection. Replacement safety labels can be obtained at no cost

by contacting the Customer Support Group at:

GL&V USA Inc.141 Burke Street

Nashua, NH 03061

Telephone: 603-882-2711

Fax: 603-595-0035


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Safety Information

DANGER

WARNING

CAUTION

SAFETY FIRST

Safety is the primary concern for the pro-

tection of both personnel and the equipment.

All personnel must thoroughly understand all

safety precautions before operating or doing

any maintenance work on this equipment.

RECOGNIZE SAFETY INFORMATION

This is the safetyalert symbol.

When you see this symbol on your

equipment or in the manual, be

alert to the potential for personal

injury. Be sure to follow all recommended pre-

cautions and safe operating practices.

UNDERSTAND SIGNAL WORDS

A signal word DANGER, WARNING, or

CAUTION is used with the safety alert

symbol. All personnel must understand the

DANGER, WARNING, CAUTION andNOTICE

used throughout the text of this manual, and

on the safety labels located on the equipment.

Danger indicates an imminently haz-

ardous situation which, if not avoided,

will result in death or serious injury.

Warning indicates a potentially haz-


could result in death or serious injury.

Caution indicates a potentially haz-


may result in minor or moderate injury.

Caution used without the safety alert

symbol indicates a potentially hazardous

situation which, if not avoided, may re-sult in property damage.

Notice is used to notify people of installation,

operation, or maintenance information which

is important but not hazard related.

DANGER

WARNING

CAUTION

NOTICECAUTION

CAUTION


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Safety Information

The following safety precautions and all

mill safety procedures must be observed

during the installation, operation andmaintenance of this equipment to prevent

injury to personnel or damage to

equipment.

PS00091 Rev. A

Failure to follow these instructionscan cause severe injury or death.

Read Operation and Maintenancemanuals supplied with this equipmentbefore operating and servicing.

Follow all mill safety proceduresduring operation and servicing of thisequipment.

WARNING

1. The operator or millwright should use

common sense and good working

practice while operating and main-

taining this equipment.

2. Servicing and maintenance should

be done by qualified personnel, ad-

equately trained and equipped with

the proper tools.

WARNING 3. Do not remove guards prior to or

during operation of machine.

Contact with rotating equipment

can cause severe injury or death.

Listed below are areas that have been

guarded, accompanied by the asso-

ciated warning.

Main Drive Coupling

Rotating coupling.Can cause severe injury.

Do not operate with guardremoved.

PS00121 Rev. A

WARNING

SAFETY WARNINGS AND PRECAUTIONS


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Safety Information

WARNING

4. Do not operate this machine

at pressures exceeding 690 kPa

(100 psig). Overpressurizing the

refiner can cause sudden rupture

of the refiner casing. This can result

in serious injury or death. A refiner

can become overpressurized due

to several factors.

Incorrect refiner application,

Incorrect process control,

Closed or plugged stock lines,

Unusual process conditions.

WARNING

5. Do not operate this machinewithout all of the safety interlocks

in place. These interlocks are

designed to alert the operator

about the low flow and high

pressure conditions that

lead to overpressurization.

Overpressurization can cause

sudden rupture of the refiner

casing. This can result in serious

injury or death.

WARNING

6. Do not work on, climb on or enter

this machine until the following

procedures have been performed.Severe injury or death can result

if these minimum precautions are

not followed.

a. Follow mill Lockout/Tagout pro-

cedures prior to servicing this

machine.

b. Mechanically disconnect the mo-

tor from the driven components

before working on this machine.

c. Isolate the machine from the

process. Close, lock and tag all

valves on all inlet and discharge

lines.

d. Completely drain the machine.

Allow it to cool down to room tem-

perature before performing any

work on it. Hot pulp and liquor can

cause severe burns.

e. Use caution when removing any

access covers. Gaskets maystick, retaining hot pulp or liquor.

f. Completely wash all stock and

liquor off the machine before start-

ing any work on the machine.

PS09591

WARNINGMaximum operating pressure is 100 psi(690 kPa).

Over pressurizing can cause suddenrupture, severe injury or death.

Operate refiner below 100 psi and with alldoor bolts installed. Leave area if warningsignals start.

SAFETY WARNINGS AND PRECAUTIONS(CONT.)


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Safety Information

b. When Stock Pressure (Inlet

or Outlet) Reaches 620 kPa

(90 PSI)

Actuate the gear motor in fast

open mode to completely open

the refiner plates, i.e. to com-

pletely unload the refiner motor.

c. When Stock Pressure (Inlet or

Outlet) Reaches or Exceeds

690 kPa (100 PSI)

If, after execution of 2b the re-

finer pressure (inlet or outlet)

continues to increase to 690 kPa

(100 PSI):

Shut down the refiner drive motor.

Give an audio/visual signal near

the refiner and at the control

room to indicate this condition.

d. Stock Pressure Measuring

Equipment

Reliable stock pressure measur-

ing equipment (pneumatic or

electronic) must be installed and

properly maintained in the stockpipe line immediately before (in-

let) and after (outlet) the refiner,

with a measuring range of 0 to

860 kPa (0 to 125 PSI).

e. Pneumatic Stock Pressure Mea-

suring Equipment

The pressure measuring range

of pneumatic stock pressure

measuring equipment is limited

by the mill instrument air supply

pressure.

If the instrument air supply pres-

sure at the refiner location is, for

instance, only 550 kPa (80 PSI),then the highest stock pressure

that can be reliably measured

is 515 kPa (75 PSI). In such a

case, the stock pressure values

given under 2b and 2c must be

reduced accordingly.

EXAMPLE:

For instrument air supply at the

refiner of 550 kPa (80 PSI):

When stock pressure (inlet or out-

let) reaches 450 kPa (65 PSI):

Actuate gear motor in fast open

mode to completely open the

refiner plates, i.e. to completely

unload the refiner drive motor.

Give an audio/visual signal to

indicate this condition.

When stock pressure (inlet or out-

let) reaches or exceeds 515 kPa

(75 PSI):

Shut down the refiner drive motor.

Give an audiovisual signal near

the refiner and at the control

room to indicate this condition.

SAFETY WARNINGS AND PRECAUTIONS(CONT.)


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Safety Information

d. Mechanical Minimum Process

Flow Limit (F1)

If an electronic process flow in-

terlock (3.1) is not feasible, then

a mechanical restriction should

be provided to prevent the, valve

from closing completely while

the refiner is running. Recom-

mended minimum valve opening

is 15 to 20%.

e. Net Specific Refining Energy

Control (NHPD/T or NkWh/T)

The primary purpose of this

function is to provide uniform

refining as the demand for pro-

cess flow F1 changes. It will,

however, also provide additionalsafety to prevent over-pressur-

ization since excessive heat and

resulting pressure buildup can

be avoided for low process flow

(F1) demands.

SAFETY WARNINGS AND PRECAUTIONS(CONT.) Allocate refiner power (HP, kW)

proportionate to fiber flow

(gpm x % Consistency x Con-

stant) or (lpm x % Consistency xConstant).

f. Stock Inlet Pressure Control

(kPa or PSI)

This feature will maintain a con-

stant stock inlet pressure (kPa

or PSI) over the entire process

flow range F, (lpm, gpm). This, in

turn, will prevent the outlet stock

pressure (kPa or PSI) from ris-

ing excessively when refiners

are used in series under low

process flow conditions.


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Safety Information

REFINING PROCESS SCHEMATIC

P PUMPR1, R2 REFINERS

F1 PROCESS FLOW, (GPM, LPM)

F2 RECIRCULATION FLOW, (GPM, LPM)

F3 REFINER FLOW, F3=F1+F2 (GPM, LPM)

FM FLOW TRANSMITTER

CS CONSISTENCY TRANSMITTER

CC CONSISTENCY CONTROL

DIL DILUTION WATERLIC LEVEL CONTROL

FIC REFINER/RECIRCULATION FLOW CONTROL, (GPM, LPM)

PIC INLET PRESSURE CONTROL

NREC NET REFINER ENERGY CONTROL, (NHPD/T, NKWH/T)

P1 STOCK INLET PRESSURE (PSI, kPa)

P2 STOCK OUTLET PRESSURE (PSI, kPa)


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Safety Information

PS0969Z

NOTICE

Use AGMA No. 8 EP premium grade gear oil with

EP additives and viscosity of 2837-3467 SSU at100F. Drain, flush and renew every three (3)months.

PS09591


Over pressurizing can cause suddenrupture, severe injury or death.

Operate refiner below 100 psi and with alldoor bolts installed. Leave area if warningsignals start.

Hazardous voltage.Can cause severe injury or death.

Disconnect power before servicing.Lockout/Tagout machine.

PS1030Z

WARNING

NOTICE

PS0971Z

Use NLGI #0 premium

grade multi-purpose non-soap grease with EPadditives, for pressurefittings.

PS0970Z

Under 66C (150F) Use AGMA No. 3premium grade rust & oxidation inhibitiveanti-wear oil with viscosity of 417-510

SSU (91-112 CST) at 38C (100F)Drain, flush and renew every (3) threemonths .

Over 66C (150F) Same as aboveexcept use AGMA No. 5 gear oil withviscosity of 918-1122 SSU (202-247)at 38C (100F). Drain, flush and renewevery (3) three months.

NOTICE

PS0713Z

Use NLGI no. 2 premiumgrade multi-purpose

lithium-complex, soap-base grease with EPadditives. Removecovers, flush out greaseand renew every six (6)months.

NOTICE

PS0969Z

NOTICE

Use AGMA No.8 EP premium grade gear oil withEP additives and viscosity of 2837-3467 SSU at100F.Drain, flush and renew every three (3)months.

PS09591


Overpressurizingcancausesuddenrupture,severe injury or death.

Operaterefinerbelow100psiandwithalldoorboltsinstalled.Leaveareaifwarningsignalsstart.

Hazardous voltage.Can cause severe injury or death.

Disconnect power before servicing.Lockout/Tagout machine.

PS1030Z

WARNING

NOTICE

PS0971Z

Use NLGI #0 premiumgrademulti-purposenon-soap grease with EPadditives, for pressurefittings.

PS0970Z

Under66C(150 F)UseAGM ANo.3premiumgraderust&oxi dationinhibi tiv eanti-wear oilwith viscosi tyof 417-510SSU(91-112 CST) at38C(100 F)Drain,flush and renew every ( 3)threemonths .

Over 66C(150F)Sameasaboveexcept useAGMA No.5gearoi lwi thv iscosity of918-1122 SSU (202-247)at38C(100F).Drain,flushandr enewevery (3)three months .

NOTICE

PS0713Z

Use NLGIno.2 premiumgrade multi-purposelithium-complex, soap-base grease with EPadditives.Removecovers, flush out greaseand renew every six (6)months.

NOTICE

NOTICE

PS0971Z

Use NLGI #0 premiumgrademulti-purposenon-soap grease with EP

additives, for pressurefittings.

RE002

4-002

DD 3000 Side View

DECAL LOCATIONS


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Safety Information

DECAL LOCATIONS(CONTINUED)

DD 3000 Coupled End View

PS05542

Rotating shaft.Can cause severe injury.

Stay clear when operating.

WARNING

NOTICE

PS0971Z

Use NLGI #0 premiumgrade multi-purpose non-soap grease with EPadditives, for pressurefittings.

PS0970Z

Under 66C (150F) Use AGMA No. 3premium grade rust & oxidation inhibitive

anti-wear oil with viscosity of 417-510SSU (91-112 CST) at 38C (100F)Drain, flush and renew every (3) threemonths .

Over 66C (150F) Same as aboveexcept use AGMA No. 5 gear oil withviscosity of 918-1122 SSU (202-247)at 38C (100F). Drain, flush and renewevery (3) three months.

NOTICE

PS0713Z

Use NLGI no. 2 premiumgrade multi-purposelithium-complex, soap-base grease with EP

additives. Removecovers, flush out greaseand renew every six (6)months.

NOTICEPS05542

Rotatingshaft.Cancausesevereinjury.

Stayclearwhenoperating.

WARNING

PS0970Z

Under 66C (150F) Use AGMA No.3premiumgraderust&oxidationinhibitiveanti-wear oil with viscosity of 417-510

SSU (91-112 CST) at 38C (100F)Drain, flush and renew every (3) threemonths .

Over 66C (150F) Same as aboveexcept use AGMA No.5 gear oil withviscosity of 918-1122 SSU (202-247)at38 C(100F).Drain,flushandrenewevery (3) three months.

NOTICE

NOTICE

PS0971Z

Use NLGI #0 premiumgrademulti-purposenon-soap grease with EPadditives, for pressurefittings.

PS0713Z

Use NLGIno.2 premiumgrade multi-purposelithium-complex, soap-base grease with EPadditives.Removecovers, flush out greaseand renew every six (6)months.

NOTICE


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23B324 DD 3000 Refiner - Rev. 00 05/01

Description


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24B324 DD 3000 Refiner - Rev. 00 05/01

Description

GENERAL MACHINE DESCRIPTION

The DD-3000 is a pressurized four-disk

refiner. The recommended minimum oper-

ating pressure is 20 PSI (1.4 kg/cm2). Themaximum operating pressure is 100 PSI

(7.0 kg/cm2). It is a compact, precision built

unit in which two rotating elements and one

of the non-rotating elements move axially to

vary the pressure applied to the stock pass-

ing through the refining areas. The rotating

element is free to locate its own center be-

tween the two stationary elements so the

need for a thrust bearing is eliminated.

The inlet and outlet are smooth transitions

with no sharp corners to build up stock or

plug the passages. Refiners are manufac-

tured of materials to suit specific mill condi-

tions. Standard construction has stainless

steel lining in all areas in contact with stock.

As with the DD-2000 and DD-4000 Series

designs, this unit can be operated either in

Mono-Flo or two-pipe Duo-Flo. In operation,

the free floating rotor and disks are prevent-

ed from contacting either of the non-rotating

disks during start-up by a locking device.

This device is mounted on the rotating as-

sembly and consists of a pair of air-operat-

ed diaphragms for coupled motor assembly

and a single air-operated diaphragm for

integral motor assembly.

Prior to entry of stock into the refiner, the

diaphragms are inflated, positioning the

rotating assembly against a stop. The stop

maintains the rotor in a pre-set neutral posi-

tion between the disks.

PRINCIPLE OF OPERATION

Most refining is carried out using the prin-

ciple of a rotor with bars operating in close

proximity to a starter which also contains

bars. While some amount of useful fiber de-

velopment can be obtained on the flat bar

surface with a relatively large gap between

refining elements, a major portion of the

fiber development takes place at the bar

edges when the bars are in close proximityso that only the fiber film is keeping the re-

fining elements apart.

The patented spoked rotor provides

Duo-Flo operation with only one inlet and

one outlet pipe. Flow is split inside the Re-

finer.

The floating rotor utilizes the basic stock

film principles which keeps a precise rela-

tionship between the rotating and non-ro-

tating disks. In this way, uniformity of fibertreatment is accomplished with a minimum

of power.


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Description

DESCRIPTION OF COMPONENTS

Base

The base contains the refining cavity, the

bearing pedestal, the top outlet, the drainand the support for the adjusting mecha-

nism hinge. Sizes 20" and 26" have inboard

and outboard bearing guides in the base.

Refining Cavity Lining

The refining cavity is protected

with a stainless steel 304L liner as

standard equipment. Stainless steel

316L can be supplied at extra cost.

The lining is machined and fastened

in place.

Top Outlet Cover

A stainless steel top outlet cover is

supplied when the unit is arrangedfor Mono-Flo operation. For two-

pipe Duo-Flo operation, this cover is

omitted and the discharge opening

in sliding head for Mono-Flo opera-

tion is covered.

Drain Cover

A stainless steel, 3" blind flange

cover is furnished with a 2" NPT (2"BSPT Adapter supplied for metric)

in its center for use as a drain con-

nection. This offers the customer

the option of selecting his own type

drain valve.

DD 3000 Refiner

GEARMOTOR

ADJUSTINGMECHANISM

LIMIT SWITCHADJUSTMENT

SLIDINGHEAD

HINGE

INBOARDBEARING

BASE

AIROPERATEDLOCK

COUPLING

OUTBOARDBEARING

SLEEVE

PACKINGBOX

INLET FORMONOFLOOR DUOFLO

REFININGCAVITY

DUOFLOOUTLET

ROTORROTORHUB

MONOFLOOUTLET

RE0024-006FHT


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Description

Adjusting Mechanism

The DD-3000 unitizes the adjusting mecha-

nism housing and permits the thrust load tobe transmitted directly to the door. The ba-

sic worm and worm gear is of our standard

design and the worm and adjusting screw

are immersed in oil at all times. The adjust-

ing screw housing is sealed by the use of

O rings and lip-type seals are used on the

worm shaft. A large oil fill pipe plug is lo-

cated above the adjusting screw and a drain

pipe plug is located beneath the worm. An

air vent breather is located high on the gear

case cover.

The sliding head has a stainless steel liner

at the outside diameter which provides

non-corrosive sliding surface for the lip

seals. Four grease lubricated pads, two with

keyways, guide the sliding head in place,with the keys serving as anti-rotation stops.

The sliding head is joined to the adjusting

screw by flange mounting, and the adjust-

ing mechanism housing is hinged to the

Refiner base to facilitate disk inspection and

replacement.

Bearing and Rotating Assembly

The shaft is mounted on double row ta-

pered roller bearings and the bearings have

been designed to provide sufficient axialtravel to permit the use of cast disks and

the thicker machined stainless steel disks.

Sizes 34" and 42" DD-3000 refiners have

inboard and outboard bearings assembled

in separate bearing housings. The rotating

assembly slides (floats) axially on bearing

housings, inside the guide bores. A key in

each bearing housing O.D. prevents it from

rotating.

Sizes 20", 26" and 54" DD-3000 refiners

have a common bearing housing (quill) for

inboard and outboard bearings. The com-

plete rotating assembly slides axially on

quill O.D. A key on outboard end prevents it

from rotating.

A rubber excluder located against the in-

board bearing end cover prevents water,

which seeps from packing box, from enter-

ing the bearing assembly.

DESCRIPTION OF COMPONENTS (CONTINUED)


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Description

Packing Assembly

The water lubricated packing box is located

in the flanged inlet. It must be removedthrough the refining cavity. Adjustment and

DESCRIPTION OF COMPONENTS (CONTINUED) component replacement is accomplished

from the backside of the refining chamber.

See "Good Packing Practices for Rotating

Shafts" in the Maintenance section for ad-ditional information. The packing sleeve on

PACKING WEEP HOLES

TO PRESSURE GAUGE(PACKING INLET BOX)

STUD AND ELASTICSTOP NUT

CLEAR WATER SUPPLY(PACKING WATER INLET)

PACKING GLAND

PACKING BOX

LANTERNRING

PACKING

SET

RE0024-007FHT

Packing Box Assembly

the main shaft is replaceable. See "Sleeve

Installation" in the Maintenance section for

additional information.


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Description

Rotor

There are two designs of rotor and rotor

mounting hub: one for Mono-Flo applicationand one for two-pipe Duo-Flo application.

Electrical Components

Two pressure switches are mounted on

the side of the refiner. One switch receives

its signal from the inlet stockline pressure

transmitter. When stockline pressure drops

below a preset value, the pressure switch

contacts energize the outfast contactors of

the gearmotor starter package. This action

moves the disks out of refining position at

high speed. The other switch receives its sig-

nal from packing gland water piping. When

water pressure is lost, switch energizes an

alarm. Both switches are prewired and termi-

nate in a conduit box on side of refiner.

Controls

There are a variety of controls available

for the DD 3000 Refiner. They range from

manual controls like the "T" series to the

programmable series of PRC controllers.

Contact GL&V for more specific information.

DESCRIPTION OF COMPONENTS (CONTINUED) TYPE OF INSTALLATION

Primary types of installations are Mono-Flo

and two-pipe Duo-Flo. Low stock flow ap-

plications require recirculation from outlet ofrefiner to pump suction.


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Description

ADDITIONAL COMPONENT INFORMATION

Synchronous Motor Torque Data

Percent Starting Pull In Pull Out

Full Load Torque 50 50 150

Motor Data

Model 20" Size 26" Size 34" Size 42" Size 54" Size

WR2Effect 89 lbs. - ft.2 420 lbs. - ft.2 1300 lbs. - ft.2 4000 lbs. - ft.2 10,200 lbs. ft.2

Sliding Head Movement & Old Style Gearmotor Information Motor Output High Low HandModel Motor HP Speed Speed Speed Speed Wheel

Frame RPM RPM in. / min. in. / min. in. / min.

20" 7430RC .5/.08 1620/270 35/5.9 .280 .0472 .008

26" 204RC 1/.166 1620/270 35/5.9 .280 .0472 .008

34" 225RC 1.5/.25 1620/270 11/1.8 .297 .0486 .027

42" 254RC 3/.5 1620/270 22/3.7 .2992 .050 .013654" 254RC 3/.5 1620/270 15/2.5 .30 .050 .020


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Description

Sliding Head Movement & XL Gearmotor Information

Motor Output High Low HandModel Motor HP Speed Speed Speed Speed Wheel

Frame RPM RPM in. / min. in. / min. in. / min.

12" M48WG12F .12 1140 29 - .116 .004

20" T56CG16F .5/.12 1725/450 20/5 .160 .040 .008

26" 204RC 1/.166 1725/450 20/5 .160 .040 .008

34" 225RC 1.5/.25 1750/440 7/1.7 .191 .046 .027

42" 254RC 3/.5 1750/440 11/2.8 .150 .037 .013654" 254RC 3/.5 1750/440 11/2.8 .220 .056 .020

ADDITIONAL COMPONENT INFORMATION

(CONTINUED)


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Weights and Lifting


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Weights and Lifting

MAJOR ASSEMBLY AND COMPONENT

WEIGHTS

Servicing the DD 3000 Refiner may require

the removal of heavy sub-assemblies orcomponents. The weights listed are to be

used to select the proper lifting equipment.

DD 3000 MAJOR COMPONENT WEIGHTS

20 26 34 42 54

lbs kgs lbs kgs lbs kgs lbs kgs lbs kgsComplete Refiner 5,000 2273 6,500 2955 13,500 6136 25,000 11364 40,000 18182

Rotating Assembly 875 398 1,850 841 1,600 727 1,980 900 8,000 3636

Rotating Head w/Disks 300 136 750 341 1,110 505 2,250 1023 3,820 1736

Each Disk 66 30 180 82 200 91 490 223 640 291


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Weights and Lifting

LIFTING

Lifting the Entire Machine

1. The hoisting system required will vary

based on the size of the refiner in-volved. See the Major Assembly and

Component Weights Chart for weight

information about the specific size

refiner being lifted. Weights range

from 2275 kg (5000 lbs) to 18182

kg (40,000 lbs).

2. The accompanying illustration shows

the recommended method for lifting

the entire dry machine. The lift requires

a four hook slign of the proper size.

CAUTION

Do not attach any lifting

equipment to the refiner shaft.

Lifting the refiner by the shaft can

damage the refiner.

Lifting the DD 3000 Refiner

4 HOOK SLING

RE0024-008FHT


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Weights and Lifting

Lifting the Rotor

PLATES

HUB

ROTOR

LIFTING BRACKET

COMPLETE ROTOR WITHLIFTING BRACKET

RE0020-008

LIFTING (CONTINUED)

Lifting the Disks and Rotating Head

A special lifting bracket is used to remove

one-piece disks and the rotating head. Abracket can be purchased with each refiner.

Lifting the Rotating Assembly

CAUTIONDo not allow lifting cables or chains to come in

contact with the finished diameter of the shaft.

Use nylon lifting slings or other padded lifting

equipment for lifting the rotating assembly.

Do not allow any lifting equipment to come in

contact with the packing sleeve.


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Receiving and Storage


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Each machine is carefully packed to prevent

damage in transit. When the shipment ar-

rives, carefully inspect each item listed on

the shipping papers to assure that no dam-age or loss has occurred in transit. If loss or

damage is detected, notify the carrier immedi-

ately and file claim with the carrier.

All DD Series Refiners are shipped as a

complete assembly. Several components

are boxed separately. They are to be as-

sembled at the customers facility. These com-

ponents are:

1. The motor half of the coupling.

2. The lifting bracket for the disks and

the rotating head.

3. The controls.

SHIPPING PREPARATIONS

Under ordinary conditions, the normal shipping

preparations below will protect the machine

in storage for three months. For severe con-

ditions or longer periods, see Long Term

Storage Preparations and Conditions.

Prior to shipment the equipment is thoroughly

cleaned and prepared as follows:

1. All exposed machined surfaces arecoated with rust inhibitor.

2. Lubricant compatible rust inhibitors

are used with greases and oils during

assembly and testing. These protect

the bearings, seals and internal sur-

faces of lubricant chambers.

3. All ports and openings are coveredwith plywood or other suitable material

to prevent entry of any foreign mate-

rial.

4. Depending on the method of ship-

ment the equipment may be covered

or not covered during shipment. Pro-

tective shipping covers may consist

of various materials such as poly-

ethylene shrink wrap, polyethylene

sheets, tarpaulins, etc. Note that

these coverings may not be appropri-

ate for long term storage purposes.

LONG TERM STORAGE PREPARATIONS AND

CONDITIONS

1. To permit shaft rotation during storage,

remove any blocking which mightinterfere.

2. Special care must be taken to main-

tain the rust inhibitor coating on ex-

posed machined surfaces. Renew as

necessary using a rust inhibitor (Spec.

S8310 or equivalent).

3. Store the machine in a weather-tightwarehouse. Controlled atmospheric

conditions are preferred. If this is not

possible, the machine must be shel-

tered completely from the weather.

It must be kept out of direct sunlight.

Ultraviolet rays have an adverse af-

fect on seal materials and any polyeth-

ylene covering used.

4. The machine must not be exposed

to extremes in temperature or rapid

changes in temperatures.


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5. The machine should be protected from

foreign material. Polyethylene sheetmaterial should be applied over a

framework that is large enough to

allow free circulation of air around the

machine. It should also allow access

for any necessary maintenance. Any

wood used on the machine or in the

framework, must be kiln dried.

6. If the machine is stored in a closed

container, a desiccant must be pro-

vided to control the humidity inside

the container. The desiccant must be

accessible for periodic renewal.

STORAGE MAINTENANCE

To assure maximum protection during long

term storage, the following maintenance must

be performed.

Every Three Months

1. Rotate the shaft several revolutions

by hand. This will ensure that the

rust inhibitor thoroughly coats the

bearings and internal surfaces.

2. Inspect all exposed external machined

surfaces for integrity of the rust in-hibitor coating. Renew as necessary.

3. Inspect integrity of cover material.

LONG TERM STORAGE PREPARATIONS AND

CONDITIONS (CONTINUED)

Every Two Years

1. Purge all greases and rust inhibitors

from the machine. Renew all lubri-

cants using lubricants specified in theLubrication Sectionof this manual.

2. Renew rust inhibitor coating on all

exposed machined surfaces as speci-

fied previously.

3. Carefully inspect the cover material

and its framework. Replace as nec-

essary.

VENDOR SUPPLIED DRIVES AND OTHER

EQUIPMENT

For special long term storage instructions for

items not made by GL&V, see the vendor

instructions.


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Installation


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Installation

WARNING

Follow all mill lockout/tagout proceduresbefore working on this machine.

Unexpected machine operation can

cause property damage, serious injury

or death. All energy sources including

process piping must be properly locked

out and tagged before any repair work

or maintenance is done. Read and follow

all safety precautions in the Safety

Section of this manual.

FOUNDATION AND LEVELING

The size of the foundation is shown on the

Certified General Arrangement Drawing.

The drawing also shows the size, number

and location of the foundation bolt holes.

Note that the distance from the center of the

outlet port on the casing to the end of the main

motor shaft is critical. Particular care must be

used to ensure that this dimension is correct

when installing the foundations.

The refiner must be leveled to within .26

mm per meter (.003" per foot).

Installing the Refiner to the Foundation

without a Sole Plate

1. Use the machined surface of the

casing outlet as the leveling surface.

2. Build shims under the base at all

anchor bolt locations. Use the mini-

mum number of shims possible.

3. Tighten the nuts on the anchor bolts.

Recheck the refiner for level.

4. Grout under base with non-shrinkgrout. Do not overlap onto the re-

finer base.

WITHOUT SOLE PLATE WITH SOLE PLATE (OPTIONAL)

GROUT

REFINER BASE

SHIMS

ANCHORBOLTS

FOUNDATION

CAP SCREWS

SHIMS

ANCHORBOLTS

FOUNDATION

REFINER BASE

SOLEPLATE

GROUT

RE0020-009

Foundation Requirements

Installing the Refiner to the Foundation

with a Sole Plate (Optional)

Sole plates may be one-piece or multi-piece.

This is determined by the size of the refiner.

1. Use the machined surface of the sole

plate(s) as the leveling surface. If the

sole plate is a multi-piece, the pieces

must also be level to each other.

2. Build shims under the sole plate(s)

at all anchor bolt locations. Use the

minimum number of shims possible.


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Installation

3. Tighten the nuts on the anchor bolts.

Recheck the sole plate(s) for level.

4. Grout under the sole plate(s) with

non-shrink grout.

5. Mount the refiner to the sole plate(s)

after the grout has set.

MOUNTING

Prepare Refiner location (use care and

follow foundation dimensions shown onGeneral Arrangement and Installation

Drawings).

Locate Refiner on foundation. Level the Re-

finer with .003 inch (.08 mm) per foot. Use

machined surface of casing outlet as level-

ing pad. Build up shims under base at all

anchor bolts. Use the minimum number of

shims possible.

Tighten nuts on anchor bolts.

Check level in all directions at casing outlet

(machined surface). Level should be within

.003 inch (.08 mm) per foot.

If desired, nuts could be tack welded to an-

chor bolts.

Grout concrete under base; use care not tooverlap onto base of Refiner.

INSTALLATION OF COUPLING

Motor half coupling is supplied by GL&V

and may be mounted by the motor manu-

facturer, by GL&V or in the field in accor-

dance with the following:

1. Insert key on motor shaft.

2. Slide coupling sleeve and O Ring

over shaft.

FOUNDATION AND LEVELING(CONTINUED)

Motor Half Coupling - Type "HM" - "FMS"

RE0024-009TABLE.TIF

RE0024-009-TIF


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Installation

3. Lubricate shaft with anti-gallant.

4. Heat coupling hub in hot oil, oven orwith torch, to approximately 300F

(149C).

CAUTION

If torch is used, be careful and

prevent flame from coming into

contact with hub teeth.

5. Use suitable handling equipment

and install hub onto shaft quickly so

as not to lose its expansion. Take

care when installing to be sure it isin alignment. Hub must be mounted

with teeth away from motor to pro-

vide for part of travel in coupling.

NOTICE

End of coupling hub must be flush

with end of shaft.

SETTING DRIVE

Drive motor should be mounted and leveled

on a separate sole plate. Take particular care

in setting the distance between drive shaft

and Refiner shaft. Refer to General Arrange-

ment Drawing for dimension from center of

casing outlet port to end of motor shaft.

1. With motor set in place with re-

spect to the Refiner, check angular

alignment with dial indicator set on

Refiner coupling hub and read-off

vertical face of motor coupling hub.

Maximum allowance is .002 inch

INSTALLATION OF COUPLING (CONTINUED)

No. 8 Slide Coupling for 54" Refiner

(.05 mm) between readings taken

every 90 degrees.

2. Check offset alignment by settingindicator on O.D. of Refiner coupling

hub and reading off O.D. of motor

hub. Rotate shaft and take readings

90 degrees apart. Relocate motor

on mounts until the angular align-

ment is within .002 inch (.05 mm)

total indicator reading.

3. After motor and coupling are prop-erly aligned, dowel motor to sole

plate. This will facilitate replacement

if for any reason the drive has to be

removed.

NOTICE

Be sure adjusting mechanism is

closed and bolted to base before align-

ing coupling.

4. Make sure coupling flanges are thor-

oughly clean, then insert gaskets and

stop plate.

RE0024-010.TIF


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Installation

5. Secure flanges together with bolts,

lockwashers and nuts.

6. This coupling is oil lubricated. Use pre-

mium quality oil, having a viscosity of

2837-3467 SSU at 100F (38C) and

extreme pressure additive package

containing no lead.

Rotate the coupling until the oil holes

in the Refiner half are at 45 degree

and 225 degree positions. Removeboth plugs. Fill the coupling half with oil

through the upper (45 degree) hole un-

til oil flows out the lower hole. Replace

plugs. Repeat for motor half coupling.

The following table indicates coupling oil

capacities:

Coupling Oil CapacitySize No. (Pints)

3.5 3/4

4 1

4.5 1 1/4

5 1 3/4

5.5 2 3/4

6 3 3/8

7 4 3/4

8 5 1/2

PIPING AND WIRING

Piping Installation

Piping system layout is left to the discretion

of the customer. In cases of either Mono-Flo or Duo-Flo (specified on Certification

Sheet), customers to supply a two inch

flush-out line at the Refiner inlet with neces-

sary gage and check valves. Refiners are

supplied with stockline pressure transmit-

ters which customers install in inlet and out-

let stocklines.

Mono-Flow Piping(Refer to applicable General Arrangement

and Installation Drawing)

It is recommended that the customer install

a stock shut-off valve on the inlet pipe near

the refiner to permit wash-up or bypass.

The inlet stockline pressure transmitter

is installed down stream from the shut-

off valve. Top center opening in refiner is

sealed off.

On the discharge outlet in the sliding head,

customer should install an elbow, a pres-

sure transmitter and then a throttling valve.

Next, a flexible outlet hose, approximately

SETTING DRIVE(CONTINUED)


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Installation

60 inches long, should be connected.

Hose must be capable of supporting 150

psi working pressure and 150 F operat-ing temperature. For a higher temperature

refining, the flexible connection should be

selected to withstand 250 F.

Drain connection located at the bottom

center of the refiner is threaded for a two

inch NPT connection. A two inch valve is

recommended to permit adequate refiner

flush-out. Drain installation is left up to thecustomer's discretion.

Two-Pipe Duo-Flo Piping

(Refer to applicable General Piping Ar-

rangement Drawing).

It is recommended that the customer install

a stock shut-off valve on the inlet pipe near

the Refiner to permit wash-up or by-pass.

The inlet stockline pressure transmitter is in-

stalled down stream from the shut-off valve.

Top center opening is the discharge port.

Drain connection located at the bottom

center of the Refiner is threaded for a two

inch NPT connection. A two inch valve is

recommended to permit adequate Refinerflushout. Drain installation is left up to the

customers discretion.

PIPING AND WIRING (CONTINUED) Packing Box Piping

To ensure proper packing box operation,

the mill must regulate fresh filtered water

to the packing box at a rate of 1-1.5 GPM(3.8-15.7 lpm) with a supply pressure of 15

PSI (1.05 kg/cm2) above stock inlet pres-

sure. See illustrations "Packing Box Assem-

PACKING WEEP HOLES

TO PRESSURE GAUGE(PACKING INLET BOX)

STUD AND ELASTICSTOP NUT

CLEAR WATER SUPPLY(PACKING WATER INLET)

PACKING GLAND

PACKING BOX

LANTERNRING

PACKINGSET

RE0024-007FHT

Packing Box Assembly


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Installation

bly" and "Packing Box Piping Schematic"

for complete piping arrangements.

PIPING AND WIRING (CONTINUED)

FRESH MILLWATER SUPPLY

VALVE, GUAGE AND OPTIONALFLOW METER BY CUSTOMER

GAUGE, PRESSURE SWITCHAND VALVE BY GL&V

TODRAIN

PACKING BOX

FM

G1

G1 PS-2

V-2

NOTES:

1. Set packing box inlet flow to approximately 1-1.5 gpm (3.8-5.7 lpm) at 15 psi (1.05 kg/cm2) above stock

inlet pressure by adjusting valve V-1.

2. Set packing gland water pressure alarm switch (PS-2) to 3 - 5 psi (0.21-0.35 kg/cm2) below stock inletpressure.

3. Set packing box outet pressure (G-2) to 10 psi (0.7 kg/cm2) above stock inlet pressure by adjustingoutlet needle valve (V-2). Do not close valve completely.

Packing Box Piping Schematic

Transmitter Signal Lines

Connections to stockline transmitters

should be made in accordance with stock-

line pressure system.

Electrical Wiring

All internal refiner wiring is complete and

terminates at the conduit boxes. The bal-

ance of the wiring must be accomplished

in accordance with existing local Electri-

cal Codes and applicable Refiner Control

Manual.

MODELS WITH AIR LOCK (OPTIONAL)

Mill should provide clean, dry air to the

pneumatic cylinder of at least 60 psi (4.2

kg/cm2).


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Installation

OIL CIRCULATION SYSTEM (OPTIONAL)

Description

A separately mounted, complete oil lubri-

cation system may be supplied to providelubrication for the bearings on the rotating

shaft of the Refiner.

The lubrication system will contain the fol-

lowing components:

(1) oil reservoir with level gauge, ther-

mometer, filler-breather, drain, dump

strainer and return port.

(1) or (2) Oil pump and motor

(1) oil filter

(1) water cooled heat exchanger

(1) water temperature controller for heat

exchanger

(1) thermometer for oil at heat exchang-

er outlet

(1) pressure gauge

(1) immersion oil heater

(2) flow control needle

valves*

(2) flow switches*

(1) load switch*

* These are included in the

Flow Control Unit mounted

on the Refiner.

The exact specifications of each compo-

nent of the lube system will depend on

the manufacturer. The literature supplied

by the manufacturer with reference to the

maintenance, specifications and service

of the circulation system is located in a

separate manual.


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Installation

Installation

The circulating system should be locatedwithin 10 feet of the Refiner, allowing the

most direct routes for the oil feed and return

lines. Once the unit is located, it should be

securely anchored.

An oil feed line supplied by the customer

should be installed between the Flow Con-

trol Unit on the Refiner and the outlet con-

nection on the lube system.

An oil return line (minimum 3/4" (20mm) I.D.)

should be installed between oil outlet on the

Refiner and the oil return port on the circu-

lating system. This return line is supplied by

the customer and may be hose, tubing or

pipe with a minimum slope of 1/2" (13mm)

per foot of run. An oil sight indicator in thisline is helpful but not essential.

The next step is to make the electrical con-

nections. The oil pump and oil immersion

heater should be wired to appropriate pow-

er supplies as indicated on their respective

name plates. The pump rotation should be

checked and must be as indicated by the

arrow on the housing or motor. All electrical

components and wiring other than thosesupplied with the system are the responsi-

bility of the customer.

Once all connections are made, the oil sys-

tem must be checked for operation and per-

formance prior to Refiner start-up. At this

time, the oil reservoir should be filled.

Use AGMA #2 premium grade rust and oxi-dation inhibited anti-wear oil with viscosity

of 284-347 SSU at 100 F. Drain, flush and

renew every three (3) months. Use SHELL

TELLUS #68 oil or equivalent or see Ven-

dor's specs in separate manual, if supplied.

Fill reservoir to level indicated on side of

tank. Turn on the immersion heater and al-

low the oil to warm up to 100F (38C) be-

fore proceeding.

To check the system, it is necessary to dis-

connect the supply lines at the Refiner and

measure the flow rates. When the oil is up

to temperature and the lines are discon-nected, start the pump. Collect the oil in an

appropriate container and measure the flow

rates. At 25 psi (1.8kg/cm2) oil pressure, the

flows should be 1 pint/minute/ bearing (.47

liters/min/bearing).

If a flow is incorrect, adjust the flow control

needle valve and the pressure relief valve

to give the correct oil flow rate at an oilpressure of 25 psig (1.8kg/cm2).

When the proper flow is set, check the flow

and pressure switches for proper operation.

This can be done by checking for continu-

ity across each switch when the flow and

pressure are reduced by slowly opening the

pressure relief valve. Both switches should

open at about 75% of their recommended

set point. The pressure switch may be ad-

justed if it is set improperly; however, the

flow switch has a fixed set point and must

be returned for replacement if it is not oper-

ating properly.

OIL CIRCULATION SYSTEM(OPTIONAL)

(CONTINUED)


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Operation


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Operation

PRE-STARTUP CHECK

Prior to startup, make sure all piping con-

nections are secure and that any electrical

connections are complete and covered.

CAUTIONThe Refiner main shaft bearings are

designed to be used with oil lubrication.

Use of alternative lubrication will void

the warranty.

Do not make any attempt to start Refiner

without checking oil level. Refer to "Lubri-

cation" in the "Maintenance Section" of this

manual for proper lubricants.

NOTICEThe Refiner is shipped with preservative oil.

This must be drained and replaced prior to

Refiner start-up.

Prior to actual Refiner operation, the op-

erator must ascertain that clearance exists

between the disks. Generally, a minimum

of 3/32" (2.4 mm) is set on each side of the

rotor head. To determine proper minimum

clearance, refer to Limit Switch Setting in

Maintenance Section.

Set pressure switches as follows:

Low stockline pressure alarm switch is set

at 10 psi.

Packing gland pressure switch is set at a

valve 20% below stock inlet pressure.

STARTUP AND OPERATION (TYPE 2) REFIN-

ER LOADING STATION

1. Turn on packing box water. Check

to see that water is visible around

the refiner shaft. If it is not, loosen

the elastic stop nuts retaining the

packing gland.

2. Energize control panel.

3. Start main Refiner motor.

4. Adjust packing gland using elastic

stop nuts so water drips from pack-

ing gland but does not sling off re-

finer shaft. Check water pressure

gauge reading, it should be at least

10% below normal operating stock

inlet pressure. If pressure is incor-rect, adjust valve located below

gauge to correct.

NOTICE

Final water flow to packing box

should be 1-1.5 GPM (3.8-5.7 lpm)

5. Open stock outlet valve at least

25%, then open stock inlet valve

and/or start stock pump.

6. Position gearmotor selector switch

on FAST and rotate gearmotor

control IN.

7. Sliding head starts forward at high

speed. Note ammeter or wattmeter

for power level to begin to rise, then

switch gearmotor selector switch to

SLOW speed and adjust final set-

ting to obtain desired power level.


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Operation

8. For refiners piped for Mono-Flo

operation, open or close stock con-trol valve as necessary until outlet

pressure is approximately 2 to 5 psi

lower than inlet pressure (when the

desired power level is reached at

that pressure differential, the refiner

will continue to operate smoothly

provided stock consistency and

through-put rate are maintained

consistently).

CAUTION

Gearmotor will overheat if

allowed to operate more than

thirty minutes.

SHUTDOWN

1. Turn selector switch to UNLOAD.

Alarm light in panel will illuminate

and gearmotor will start in reverse

at high speed.

2. Gearmotor will continue to oper-

ate until sliding head trips the limit

switch which shuts gearmotor off.

3. Shut off stock flow by either closing

inlet valve or stopping pump.

CAUTION

Do not close stock discharge line

valves before stopping the stock

feed pump. It will cause pressurerise in the refining cavity and

may ultimately result in damage

to Refiner (burst) and injury to

personnel.

4. After stock flow stops, flush out Re-

finer by means of the two inch flush-

out line and/or drain valve.

5. Stop the Refiner motor.

CONTROLS

Consult the applicable Control Manuals for

complete information concerning any par-

ticular Refiner control system.

STARTUP AND OPERATION (TYPE 2) REFIN-

ER LOADING STATION(CONTINUED)


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Operation


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Maintenance


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54B324 DD 3000 Refiner - Rev. 00 05/01

Maintenance

WARNING

Follow all mill lockout/tagout proceduresbefore working on this machine.

Unexpected machine operation can

cause property damage, serious injury

or death. All energy sources including

process piping must be properly locked

out and tagged before any repair work

or maintenance is done. Read and follow

all safety precautions in the Safety

Section of this manual.

GENERAL

Proper maintenance practice will promote

trouble-free operation and ensure better

machine performance.

Care should be exercised during disassembly

to place removed parts in clean, dry and pro-

tected locations. A high quality light oil should

be applied to all parts to prevent corrosion. If

machine is to be left disassembled for a period

of time, openings should be protected to pre-

vent entrance of foreign material.

During reassembly, all new replaced parts

should be checked carefully prior to installation

to ensure that they are proper for that particu-

lar location. Use of proper tools and equipmentfacilitate performance of fine quality work.

LUBRICATION

Bearings

All bearings and gearing require lubrication

at regular intervals.

Main shaft bearings are tapered roller bear-

ings and are lubricated by oil bath.

CAUTIONThe Refiner main shaft bearings are

designed to be used with oil lubrication.

Use of alternative lubrication will void

the warranty.

NOTICERefiner is shipped with a preservative oil.

This must be drained and replaced with

proper oil prior to start-up.

Recommended Lubricants:

1. For operation under 150F (66C)

use AGMA #3 premium grade rust and

oxidation inhibited gear oil with viscos-ity of 417-510 SSU at 100F (38C).

2. Drain, flush and renew oil after ten

days to two weeks of operation; there-

after, every three (3) months or when-

ever there is an indication of sludging.

Use SHELL TELLUS #100 oil or

equivalent.

3. For operation over 150F (66C) use

AGMA #5 premium grade rust and oxi-

dation inhibited gear oil with viscosity

of 918-1122 SSU at 100F (38C).

4. Drain, flush and renew every three (3)

months.

Use SHELL TURBO #220 oil or equiv-

alent.

5. See Oil Circulating System if appli-

cable.


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Maintenance

Adjusting Mechanism

The adjusting mechanism assembly in-

cludes tapered roller bearings, large Acmescrew, worm gear and worm. These are lu-

bricated by oil bath.

Recommended Lubricant

Use AGMA #8 premium grade gear oil

with EP additives and with viscosity of

2837-3467 SSU at 100F (38C).

Drain, flush and renew every three (3) months.

Use SHELL OMALA #680 or equivalent.

Pressure Fittings At Keyways

Sliding head to adjusting mechanism hous-

ing. On new models, the grease fittings are

brought to one central block mounted on

the sliding head. These should be lubricat-

ed every six (6) months.


Use premium quality multi-purpose

non-soap grease of NLGI No. 0 consistency

with good load carrying ability.

Use SHELL DARINA-EP O or equivalent.

Coupling

Is of the gear type and uses O-Ring seals.The two halves are separated by a steel

plate and each half must be oiled sepa-

rately. Rotate the coupling until the oil holes

in the Refiner half are at 45 degree and 225

degree positions. Remove both plugs. Fill

the coupling half with oil through the upper

(45 degree) hole until oil flows out the lower

(225 degree) hole.


This coupling is oil lubricated.

Use premium quality oil, having a viscosity

of 2837-3467 SSU at 100F (38C) and ex-

treme pressure additive package containing

no lead.

Drain, flush and renew every three (3)

months.

Use SHELL OMALA-680 or equivalent.

Coupling Oil Capacity

Size No. (Pints)

3.5 3/4

4 1

4.5 1 1/4

5 1 3/4

5.5 2 3/4

6 3 3/8

7 4 3/4

8 5 1/2

LUBRICATION (CONTINUED)


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Maintenance

Gearmotor

Lubrication is extremely important for sat-

isfactory operation. Proper oil level mustbe maintained in the gearcase at all times.

The correct level is indicated by the red

plug. Frequent inspections with the unit not

running (preferably when warm), should be

made by removing this plug to see that the

level is being maintained. If low (without re-

placing oil level plug), add lubricant through

one of the upper openings until it comes

out of the oil level hole. Replace the oil levelplug securely.

Lubricant should be drained and the

gearcase refilled after the first 250 hours

of operation; then every 1500 hours or six

months thereafter, whichever occurs first.

Use only recommended lubricants.

All bearings above the operating oil level

that are provided with a plug, lubricate with

a good grade of ball bearing grease when

changing lubricant.

NOTICE

Do not over lubricate grease packedbearings.

For recommended lubricants, see Man-

ufacturers (Reliance Electric) Instruction

Manual E-3614-8 for master XL gearmotors

in the "Appendix" of this Manual.

Circulating Oil System

See Vendors specs in separate manual.

Oil cleanliness

It is important that the oil be kept clean at

all times.

1. Drain and change oil after first two

(2) weeks of operation. Thereafter,

as indicated.

2. Clean tank carefully once a year

to remove any sludge. Open drain

valve and remove all oil.

3. Replace filter elements (see Specifi-

cation). Clean or replace strainer.

4. Check and clean vent and filler cap

screen. Check and service all other

parts for proper operation (motor,

pump, etc.).

LUBRICATION (CONTINUED)


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57B324 DD 3000 Refiner - Rev. 00 05/01

Maintenance

TROUBLE SHOOTING

Problem Cause Solution

Bearing overheating Oil level too low or too high. Correct oil level.

Improper oil. Replace with proper lubricant.

Thrust load. Check clearances.

Excessive vibration

Misalignment of coupling. Check alignment.

Bent shaft. Straighten.

Cracked shaft. Replace.

Excessive disk imbalance. Balance disks.

Unusual filling wear Uneven stock consistency. Correct variations of consistency in chest.

Burn through. Raise consistency.

Use less power.

Sliding head wont move, gearmotor runs. Broken shear pin. Replace shear pin.

Sticking sliding head. Lubricate pads, check sliding head seal.

Sliding head wont move, gearmotor wont run. Stock pressure too high. Reduce pressure.

Rotor wont float. Worn packing sleeve. Replace sleeve.

Coupling. Clean and lubricate.

Bearing sticking. Check clearances and adjust.


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Maintenance

DISMANTLING AND REASSEMBLY OF MA-

CHINE

Disk Replacement

Disks are available in one-piece or in seg-ments.

NOTICEWhen installing refining disks, do notuse

an air or electric impact wrench to tighten

to the prescribed maximum torque. The

action of the wrench causes galling onthe threads. However, the impact wrench

may be used to tighten the collar bolts to

an intermediate value (approximately 80

Ft.-Lbs.) (27 KPM), after which the collar

bolts are tightened manually to required

torque value using a hand torque wrench.

See the "Appendix" of this manual for

recommended torque values.

Segmental Disks

Segmental Disks are packed in a box which

contains one set of segments ground to-

gether and should be mounted as a com-

plete disk.

NOTICEIf the disks are match marked in a given

set, they should be assembled in the

proper order per the match marking. Each

segment is marked on the back with the

pattern number designated. Mount this

set of segments in position number as

indicated on instructions included with

shipping material.

Segmental Disk RemovalRemove disk segments from the Refiner as

follows:

1. Place main motor and control panel

electric power switches in the OFF

position and LOCK.

2. Tag switches to prevent personnel

from using.

3. On Mono-Flo piping installation,

disconnect piping from adjusting

mechanism end of Refiner.

4. Remove retaining bolts from ad-

justing mechanism end mounting

flange, then swing open Refiner.

The disk which can be seen boltedto the sliding head is No. 4. The disk

mounted on rotating head is No. 3.

5. Remove No. 4 disk segments by un-

screwing collar bolts. Segments may

be easily carried to an appropriate

location.

6. Remove one segment of the No. 3disk and install the applicable rotor

lifting bracket.

NOTICE

A lifting bracket is recommended

and can be purchased from GL&V.

7. Attach lifting bracket to overhead

sling and take up slack. Unscrew the

eight retaining screws to free the ro-

tating head (containing No. 2 and 3

disks) from the rotating hub.


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Maintenance

NOTICE If rotating head disassembly is

difficult, use two jack screws in

holes in head to facilitate separation.

8. Carefully extract the rotating head

unit from the refiner cavity. Place in

clean location and continue the disk

segment removal.

9. Now the No. 1 disk is accessible and

its segments may be removed.

NOTICE

If disks are to be retained for

future use, clean and inspect all

segments. Keep segments of each

set together, do not intermix. Prior

to storing, be sure to mark their

position identity on them.

Segmental Disk Installation

If the disks to be installed are new (from

GL&V), follow the instruction sheet shipped

with them. For disk identity, refer to Identifi-cation paragraph. If disks have been used

before, identify their proper installation

position from the identity that was marked

on the disks at time of their removal. Care

must be exercised in replacing the disks to

make certain all contact surfaces are clean

and free from burrs.

When replacing the segments, push thesegment radially outward until the two (2)

bosses on the outside diameter of the seg-

ments are seated against the retaining ring.

Then tighten the mounting screws. Torque

to recommended torque values listed in the

"Appendix" of this manual.

Reassemble the rest of the Refiner in re-

verse order of disassembly. Then set ad-

justing mechanism in accordance with the

next paragraph.

Adjusting Mechanism

Setting

NOTICE It is necessary to disengage

gearmotor by moving clutch handle

before rotating handwheel.

1. Rotate handwheel until sliding head

closes up all clearance between

disks. Be sure disks are firmly in

contact.

NOTICE

To ensure disks are in firm contact,

remove center outlet cap or

connection and visually inspect.


CHINE (CONTINUED)


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60B324 DD 3000 Refiner - Rev. 01 04/03

Maintenance

2. Adjust the bolts at the air diaphragms

to obtain a clearance of 3/32 of an inch(2.4 mm) between bolts and frame.

This provides a minimum of 3/32 inch

(2.4 mm) disk clearance whenever air

diaphragms are inflated.

3. Now rotate handwheel to back off

sliding head 3/16" (5 mm). Use fol-

lowing table to determine number of

turns required.

4. Set limit switch adjusting rod in ac-

cordance with the paragraph entitled

Setting Limit Switch.

5. After completing limit switch ad-

justment, remove tags and return

switches to normal.

One-Piece Disks

Identification

1. One-piece disks are marked in one

of the following methods:

a. Number consisting of a digit

followed by a dash, then three

more digits. The first digit des-

ignates disk position, the lastthree digits refer to GL&V draw-

ing number.

b. Letter R or S then dash and

three digits. R indicates rotat-

ing disk for positions 2 and 3.

S indicates stationary disk for

positions 1 and 4. Digits refer to

GL&V drawing number. See il-lustration.


CHINE (CONTINUED)

#1-STATIONARY DISK

#2-ROTATING DISK

#4-STATIONARY DISK

#3-ROTATING DISK

RE0024-013

Refiner Model 20 26 34 42 54

Sliding Head Movement - Inches .0083 .0083 .027 .0136 .020

(mm) (.20mm) (.20mm) (.70mm) (.35mm) (.52mm)

(Per One Revolution of Wheel

Number of Revolutions required 24 24 7 14 10

to Obtain 3/16" (5 mm) Backout

Clearance

Disc Positions


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Maintenance

One-Piece Disk Removal

1. Repeat steps 1 through 4 in preced-ing paragraph entitled Segmental

Disk Removal.

2. If refiner was piped for Mono-Flo op-

eration, remove rotating head cover.

3. Remove upper two retaining screws

from No. 4 disk (disk inside hinged

housing). Install two threaded 5/8"(16mm) diameter rods about 12"

(305 mm) long into upper two retain-

ing screw holes. For 20" DD Refin-

ers, use 1/2" (12mm) rods.

4. Unscrew rest of retaining screws;

dis

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