mechanical separator operation and maintenance manual - osprey€¦ · 1.1 osprey mechanical...

Rev. 0 - June 2016

Mechanical Separator Operation and Maintenance Manual

www.ospreyfilters.com (404) 321-7776

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Table of ContentsTable of Contents ......................................................................................iii

Chapter 1 Introduction ............................................................................1-11.1 Osprey Mechanical Separator (MS) Overview ..................................................................................1-3

Component Identification .................................................................................................................1-3Theory of Operation .........................................................................................................................1-4

Exiting Air ......................................................................................................................................1-4Exiting Material .............................................................................................................................1-4Negative Pressure ........................................................................................................................1-4

Typical Installation ...........................................................................................................................1-6Pressure Sensors ............................................................................................................................1-6Control Panel ...................................................................................................................................1-6Service .............................................................................................................................................1-6

1.2 Specifications ....................................................................................................................................1-6

Chapter 2 Safety ......................................................................................2-12.1 Safety Precautions ............................................................................................................................2-3

Notes, Notices, Cautions, Warnings, and Dangers Definitions ........................................................2-32.2 General Warnings and Notices .........................................................................................................2-42.3 Warning Labels .................................................................................................................................2-52.4 Limits of Machinery ...........................................................................................................................2-6

Use Limits ........................................................................................................................................2-6Space Limits ....................................................................................................................................2-6Time Limits .......................................................................................................................................2-6Other Limits .....................................................................................................................................2-6Potential Misuse ..............................................................................................................................2-6

2.5 Noise Emission Data .........................................................................................................................2-72.6 Data Plate .........................................................................................................................................2-72.7 EC Declaration of Conformity............................................................................................................2-8

Chapter 3 Installation ..............................................................................3-13.1 Unit Inspection ..................................................................................................................................3-33.2 MS Installation...................................................................................................................................3-43.3 Electrical Connections.......................................................................................................................3-53.4 Initial Checks and Run-In ..................................................................................................................3-6

Chapter 4 Operation ................................................................................4-14.1 MS General Information ....................................................................................................................4-3

Control Panel ...................................................................................................................................4-3Typical Control Panel Buttons ..........................................................................................................4-3Control Theory .................................................................................................................................4-3

4.2 System Operation .............................................................................................................................4-4Manual Start ....................................................................................................................................4-4Motor Speed Adjustment .................................................................................................................4-5Manual Stop .....................................................................................................................................4-5


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Table of Contents (contd.)

Chapter 5 Maintenance ...........................................................................5-15.1 Maintenance Schedule .....................................................................................................................5-35.2 Air Lock and Wiper Blade Seal Adjustment or Replacement ............................................................5-4

About the Air Lock and Wiper Blade Seals ......................................................................................5-4Seal Adjustment ...............................................................................................................................5-5Seal Replacement ...........................................................................................................................5-5

Seal Removal ...............................................................................................................................5-5Seal Installation ............................................................................................................................5-5

5.3 Screen Replacement.........................................................................................................................5-6Screen Removal ..............................................................................................................................5-6Screen Installation ...........................................................................................................................5-6

5.4 Motor Replacement ...........................................................................................................................5-7Motor Removal ................................................................................................................................5-7Motor Installation .............................................................................................................................5-7Motor User’s Manual Citation ..........................................................................................................5-9

Chapter 6 Troubleshooting .....................................................................6-16.1 Troubleshooting ................................................................................................................................6-3

High Differential Pressure Across the Screen ..................................................................................6-3Air Pulled into MS Enclosure from Air Lock .....................................................................................6-3Particles/Fibers Escaping from MS Enclosure .................................................................................6-3Excessive Material Passing through the MS Screen .......................................................................6-4Jammed Air Lock or Wiper Blade Shaft ...........................................................................................6-4HMI Displays a Rotation Sensor Fault .............................................................................................6-4Gear Motor Circuit Breaker Tripped or Gear Motor Drive (VFD) Displays a Fault ...........................6-5MS Operating Under Positive Pressure Inside the Enclosure .........................................................6-5Excessive Material Buildup Inside the Outlet Transition ..................................................................6-5

Chapter 7 Spare Parts .............................................................................7-17.1 Spare Parts .......................................................................................................................................7-3

Ordering ...........................................................................................................................................7-3Contact Information .........................................................................................................................7-3MS Spare Parts ...............................................................................................................................7-4

Chapter 8 Osprey Warranty ....................................................................8-1


1-1

Chapter 1 Introduction ............................................................................1-11.1 Osprey Mechanical Separator (MS) Overview ..................................................................................1-3

Component Identification .................................................................................................................1-3Theory of Operation .........................................................................................................................1-4

Exiting Air ......................................................................................................................................1-4Exiting Material .............................................................................................................................1-4Negative Pressure ........................................................................................................................1-4

Typical Installation ...........................................................................................................................1-6Pressure Sensors ............................................................................................................................1-6Control Panel ...................................................................................................................................1-6Service .............................................................................................................................................1-6

1.2 Specifications ....................................................................................................................................1-6

Chapter 1 Introduction


1-3

1.1 Osprey Mechanical Separator (MS) OverviewThe Osprey MS separates pneumatically conveyed material from a conveying air stream. Typical material applications include the following:

• Bulk fiber• Poly leg cutouts• Bagtails• Reject diapers• Skeletons• Reclaimed products

Several MS models are available. The models vary in size based on a combination of total airflow (cmh, cfm) through the unit and the total rate of material processed (kg/hr, lb/hr) through the unit.

This manual applies to all Osprey MS units.

Component Identification

Conveying air and material inlet

Figure 1-1 Osprey Mechanical Separator (MS) Components

Access door

Junction box

Material discharge

Access door safety switch

Air outlet

Sprinkler enclosure

Rotation sensors

Air lock motor

Wiper blade motor


1-4


Theory of OperationSee “Figure 1-2 Flow of Air and Material through the MS” on page 1-5. The material and conveying air enter the MS at the top of the machine. The conveying air passes through an internal screen that has openings in it small enough to prevent the material from passing through. After passing through the screen, the air exits the MS on the back side of the machine. A rotating mechanical wiper blade cleans the screen by wiping material from the screen surface. The separated material exits the bottom of the machine through a rotating air lock. The rotating wiper blade and air lock are driven by AC motors and are variable-frequency drive (VFD) controlled.

Exiting AirThe air that exits through the back side of the MS still contains some fine dust and contaminants. The amount of contamination varies depending on the type of material being conveyed and the type of internal screen. In most applications, the exiting air is sent to a drum filter or other filtration device.

Exiting MaterialMaterial exits the MS through a rotating air lock at the bottom of the unit. This air lock allows the material to drop out of the machine and free-fall into the equipment below it, without allowing the conveying air to blow out.

Negative PressureThe MS is designed to operate under a negative pressure so that air is pulled into, and through, the machine. The MS is not designed to operate under a positive pressure because (1) dust could escape from the machine into the plant environment and (2) the machine could plug or jam.


1-5

Figure 1-2 Flow of Air and Material through the MS

Air and material entering the top of the MS

Air and dust passing through the screen and exiting the MS

Wiper blade

Air lock scrolls

Material dropping out of the air lock at the bottom of the MS

Theory of Operation (continued)

Scre

en

= Air= Material

Air and material entering the top of the MS

Material dropping out of the air lock at the bottom of the MS

Air and dust passing through the screen and exiting the MS


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1.2 SpecificationsItem MS-2 MS-4 MS-8 MS-10 MS-12

Overall dimensions (width x height x depth)

1.5 x 1.2 x 1.0 m (61 x 49 x 41 in.)

1.9 x 1.2 x 1 m (73 x 49 x 41 in.)

1.5 x 1.6 x 1.4 m (61 x 64 x 56 in.)

1.9 x 1.6 x 1.4 m (73 x 64 x 56 in.)

2.2 x 1.8 x 1.4 m (85 x 70 x 56 in.)

Weight 499 kg (1,100 lb)

567 kg (1,250 lb)

658 kg (1,450 lb)

726 kg (1,600 lb)

1,134 kg (2,500 lb)

Maximum air flow 1,176 cmh (2,000 cfm)

2,352 cmh (4,000 cfm)

4,704 cmh (8,000 cfm)

5,880 cmh (10,000 cfm)

7,056 cmh (12,000 cfm)

Maximum material throughput

909 kg/hr (2,000 lbs/hr)

1,818 kg/hr (4,000 lb/hr)

3,636 kg/hr (8,000 lbs/hr)

4,545 kg/hr (10,000 lb/hr)

5,454 kg/hr (12,000 lb/hr)

Maximum allowable pressure/vacuum

-2,000 Pa (-8 inH2O)

-2,000 Pa (-8 inH2O)

-2,000 Pa (-8 inH2O)

-2,000 Pa (-8 inH2O)

-2,000 Pa (-8 inH2O)

Typical InstallationThe MS is typically installed over static material collection bins, or over operating machinery such as bale presses, conveyors, or compactors. The MS can be mounted directly on the receiving equipment, or it can be mounted on a separate support stand and connected to the equipment with steel outlet transitions.

Because the MS is designed to operate under a negative static pressure, the conveying air is pulled into and through the machine. This pull-through air is supplied by a conveying fan that is connected to the air outlet of the MS. This fan is separate from the MS unit, not integrated, and may be ordered with the unit or customer-supplied. In some applications, the MS operates in a push/pull scenario where there is a fan pushing air into the unit, but the unit is balanced so that the pull-through fan keeps the unit under a negative pressure. The push/pull system is required if the MS is located a long distance from the material pickup point.

Pressure SensorsThe MS includes two pressure sensors. The purpose of one sensor is to measure the air inlet pressure to verify that the entire MS operates under a negative pressure at all times. The purpose of the second sensor is to measure the differential pressure across the screen to verify that the screen is not dirty or clogged and thus does not need to be cleaned or replaced.

Control PanelThe MS is operated manually or automatically through control devices located in various electrical control panels, such as a cull system panel or a vertical hopper panel. A typical control panel for controlling an MS is shown in the Operation chapter.

Osprey manufactures control panels specific to each application. Control panel layout drawings and an electrical schematic are provided with the equipment and are also placed inside the control panel.

ServiceAn access door on the front of the unit is equipped with a safety switch to prevent the unit from running when the door is open. The door allows service access to the upper screen wiper or the material air lock.

Theory of Operation (continued)


2-1

Chapter 2 Safety

Chapter 2 Safety ......................................................................................2-12.1 Safety Precautions ............................................................................................................................2-3

Notes, Notices, Cautions, Warnings, and Dangers Definitions ........................................................2-32.2 General Warnings and Notices .........................................................................................................2-42.3 Warning Labels .................................................................................................................................2-52.4 Limits of Machinery ...........................................................................................................................2-6

Use Limits ........................................................................................................................................2-6Space Limits ....................................................................................................................................2-6Time Limits .......................................................................................................................................2-6Other Limits .....................................................................................................................................2-6Potential Misuse ..............................................................................................................................2-6

2.5 Noise Emission Data .........................................................................................................................2-72.6 Data Plate .........................................................................................................................................2-72.7 EC Declaration of Conformity............................................................................................................2-8


2-3

2.1 Safety Precautions

Notes, Notices, Cautions, Warnings, and Dangers DefinitionsThroughout this guide NOTE, NOTICE, CAUTION, WARNING, and DANGER will be used. Please observe these NOTES, NOTICES, CAUTIONS, WARNINGS, and DANGERS; be aware that servicing the equipment requires mechanical skill and a regard for conditions that may be hazardous. Improper service or repair may damage the equipment or render it unsafe.

N O T EAddresses practices not related to personal injury.

NOTICEIndicates a situation which, if precautions are not complied with, may result in equipment or property damage.

Indicates a hazardous situation which, if not avoided, may result in minor or moderate personal injury.

C A U T I O N

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

W A R N I N G

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

DANGER

BEFORE you attempt to operate this equipment, read and study the following safety information. In addition, MAKE SURE that every individual who operates or works with this equipment is familiar with these safety precautions. The OPERATOR’S MANUAL AND SAFETY SIGNS on the machine itself warn you of dangers and SHOULD BE READ AND OBSERVED CLOSELY.Failure to follow these precautions could result in death or serious injury.


2-4


2.2 General Warnings and Notices

Care must be taken when performing maintenance. Appropriate personal protection equipment must be worn. Failure to comply could result in personal injury or death.

W A R N I N G

Bolted guards or transitions must be in place to prevent operators from reaching into the MS during operation. Failure to comply could result in a crush injury to hands.

W A R N I N G

Do not place hands inside the MS while it is running. Failure to comply could result in a crush injury to hands.

W A R N I N G

Prevent injury from fires when working near the MS:• The maximum surface temperature must not exceed 55 °C (122 °F) to avoid creating a

possible ignition source.• To avoid possible overheating, do not apply excessive loads to the gear motors.• Make sure the rotation sensor is properly rated and wired correctly to avoid creating a

possible ignition source.• Prevent any ignition source outside the MS unit from entering the MS unit through an

inlet duct.• Magnets, screens, etc., must be in place to prevent all foreign materials, including

tissues, nuts, bolts, tools, etc., from entering the filter enclosure.• To reduce the possibility of static electricity discharge creating an ignition spark,

ensure that the metal enclosure is grounded.

W A R N I N G

NOTICEEnsure that the air lock and wiper blade clearances are checked as described in the installation chapter.


2-5

2.3 Warning LabelsWarning labels indicate special hazards in and around the MS. Read all warning labels and follow the instructions on them. Following are the warning labels you may observe while working on the MS.

Rotating parts and shaft can cause severe injury. Lock out power and allow machine to stop before opening.

W A R N I N G

Rotating parts can crush and cut. Do NOT operate with guards removed. NEVER touch or lean in machine without following lockout procedures.

DANGER

HAZARDOUS VOLTAGE. Contact may cause electrical shock or burn. Lockout/tagout before servicing.

W A R N I N G


2-6


2.4 Limits of Machinery

Use Limits• The MS is intended to be used as part of a larger, Osprey approved, material handling system.• The MS is intended to be operated in an automatic mode by a control panel/program provided by

Osprey, or in some cases, the end user.• The MS is intended to operate under a negative pressure [-1,500 Pa to -2,000 Pa (-2 inH2O to

-8 inH2O)] at all times.• The MS is intended to handle a dry air stream and to operate in an environment with 50% relative

humidity or less.• The MS is generally used to process small pieces of the following materials, although other types of

material could be processed: - Textiles - Pulp and paper (cellulose) - Plastics - Nonwovens

• Refer to “1.2 Specifications” on page 1-6 for material and air flow throughput limits.• Maximum motor speed is 300 rpm.• Maximum operating temperature is 49 ºC (120 ºF).

Space Limits• The MS is intended for use in an indoor industrial environment.• A minimum of 0.9 m (3 ft) around all sides of the MS must be kept clear for maintenance.• The MS must be bolted securely to a rigid base or stand.• The bottom of the MS must be enclosed or protected to prevent injury from the rotating air lock.

Time Limits• With proper maintenance, the MS can last 20 or more years. Refer to the maintenance chapter for

specific service intervals.

Other Limits• The MS is intended for professional use in an industrial application.• The MS is intended to be used by a qualified operator who has been trained to operate the machine.• The MS is intended to be maintained by a skilled and qualified operator following the instructions in the

operating manual.

Potential MisuseThe following examples constitute misuse of the MS:

• Operating the MS at a positive pressure or outside any of the other specified parameters.• Feeding long strips of material to the MS that can get tangled or wrapped around the rotating

components.• Operating the MS when seal strips on the rotating components are worn or misaligned.• Operating the MS with a clogged screen.


2-7

2.5 Noise Emission Data1. The sound pressure level is based on six points measured at a distance of 1 m (3.3 ft) from the

surface of the machinery and at a height of 1.6 m (5.2 ft) from the floor.2. The A-weighted sound power level emitted by the MS does not exceed 105 dB(A).3. The peak C-weighted instantaneous sound pressure level of the MS does not exceed 63 Pa (130 dB

in relation to 20 microPA).

2.6 Data PlateThe data plate is located on the side of the MS. The data plate contains the model and serial numbers, the unit weight, and the manufacturing date for that particular MS.


2-8


2.7 EC Declaration of Conformity

DECLARATION OF CONFORMITYHerewith we declare that the equipment designated below, on the basis of its design and construction, in the form brought on to the market by us, is in accordance with the relevant safety and health requirements of the EC Council Directives listed. We further declare that the equipment identified below may be intended to be assembled with other equipment / machines to constitute machinery, which shall not be put into service until the assembled machinery has been declared in conformity with the following provisions of these EC Council Directives and Standards:

Directives: Machinery Directive 2006/42/EC

Low Voltage Directive 2006/95/EC

Electromagnetic Compatibility Directive 2004/108/EC

Standards: EN 12100:2010, EN 60204-1:2006, EN 61439-1:2011

Manufacture: Osprey Corporation 1835 Briarwood Road Atlanta, Georgia 30277 U.S.A.

EU Representative: Christoph Ritter 13 Mont’ee des Lauzières 04160 Chateau-Arnoux France

Importer’s Name: —

Equipment Type: Material Separator

Model Number: — Project Number: —

Serial Number: — Year of Manufacture: —

Signature: _________________________Name: _________________________

Position: _________________________Date: _________________________


3-1

Chapter 3 Installation ..............................................................................3-13.1 Unit Inspection ..................................................................................................................................3-33.2 MS Installation...................................................................................................................................3-43.3 Electrical Connections.......................................................................................................................3-53.4 Initial Checks and Run-In ..................................................................................................................3-6

Chapter 3 Installation


3-3

3.1 Unit Inspection1. Remove the MS from the shipping crate and inspect it for any obvious sign of shipping damage.2. Open the access door (1).3. Rotate the wiper blade (2) by hand to ensure it turns freely.4. Inspect the wiper blade seals to ensure they are making full contact with the screen across its entire

length. If adjustment is needed, refer to “Seal Adjustment” on page 5-5. Return here to continue.

Figure 3-1 Inspecting the Wiper Blade and Seals

Figure 3-2 Inspecting the Air Lock and Seals

5. Rotate the air lock (3) by hand to ensure it turns freely.6. Inspect the air lock seals to ensure they are making full contact with the air lock housing across

its entire length. If adjustment is needed, refer to “Seal Adjustment” on page 5-5. Return here to continue.

3

1

2

Seal/screen contact

Seal/scroll contact


3-4


3.2 MS Installation1. Use the lifting eyes (1) on the top of the MS to move the unit into position.2. Anchor the MS to a platform or base. If the platform or base is customer-supplied, it must be

structurally sound enough to withstand the dynamic load required by the MS.3. Attach any guards or square-to-round transitions (2) and required ducting to the MS. Use gasket tape

or caulk to ensure an air-tight seal.

Use caution when connecting the water supply: one sprinkler head is open/manual and one is fused/automatic (heat-operated).

C A U T I O N

4. Connect a water supply to the two sprinkler heads (3) located on the top of the MS (1/2 NPT thread size).

Figure 3-3 Installing the MS

31

2

1/2 NPT

N O T ETo ensure that material does not back up into the rotating air lock from below, Osprey Corporation recommends configuring bins or equipment located below the MS with level sensors

Before the MS is put into service, guards or inlet and outlet transitions must be installed to prevent access to the rotating components.

W A R N I N G


3-5

3.3 Electrical Connections

Lock out the electrical supply to the MS and ensure that the air lock is inaccessible (guarded by the material discharge transition).

W A R N I N G

1. Disconnect and lock out the electrical supply to the MS.2. Refer to the Osprey-supplied electrical schematics to wire the MS motors, rotation sensors, pressure

sensors, and door switches through the junction box located on the drive-side panel (1).3. Remove the lockout from electrical supply.

Before applying power to any drive system, ensure that all guards are in place and that there are no obstructions that could damage the equipment while it is moving.

W A R N I N G

4. Momentarily supply power to the air lock and wiper blade motors to ensure the correct direction of rotation. Rotational arrows (2) are located on the drive-side panel. If the direction of rotation is incorrect, reverse the motor wiring connections.

Figure 3-4 Location of the Junction Box and Motor Rotation Arrows

1

2


3-6


3.4 Initial Checks and Run-In

Carefully perform all checks and adjustments prior to operating the MS. Failure to perform the necessary checks and adjustments prior to startup can damage the equipment.

C A U T I O N

1. Ensure that:• All electrical connections are tight.• The MS is securely mounted on its base• All duct connections are tight.• The inside of the MS is free of any foreign objects (screws, tools, etc.).

2. Run the MS at full speed for 60 seconds; observe and listen for unusual operation or sounds.3. Operating at nominal frequency and voltage (380V/50 Hz and 460V/60 Hz), the MS motors rotate at

approximately 200 rpm. To maximize the lifetime of the air lock and wiper blade seals, make the air lock and wiper blade rotational speeds as slow as possible without creating jams inside the MS.To do this, feed material into the MS at the expected loading rate and adjust the speed of the air lock and wiper blade motors to the slowest speed that does not create jams inside the MS.

If you experience any installation issues, contact Osprey Corporation.

N O T ESmall imperfections in the rotation of the shaft can create oscillations of the gear motor when a torque-arm mounting arrangement is used. This is a normal occurrence and will not negatively affect the performance or life expectancy of the MS.

N O T EAll MS units are tested at Osprey for multiple hours and inspected by our Quality Control department before being shipped.


4-1

Chapter 4 Operation ................................................................................4-14.1 MS General Information ....................................................................................................................4-3

Control Panel ...................................................................................................................................4-3Typical Control Panel Buttons ..........................................................................................................4-3Control Theory .................................................................................................................................4-3

4.2 System Operation .............................................................................................................................4-4Manual Start ....................................................................................................................................4-4Motor Speed Adjustment .................................................................................................................4-5Manual Stop .....................................................................................................................................4-5

Chapter 4 Operation


4-3

4.1 MS General InformationThe MS is designed to operate in AUTO (automatic) mode so that it is controlled by remote machines and systems. The interface of these units is described in manuals from Osprey or other manufacturers. This chapter explains the manual operation of the MS through the control panel. The MS should be operated in MANUAL mode only for maintenance and troubleshooting purposes.

Control PanelThe control panel can be located anywhere that is convenient for the operator. The MS is electrically wired to the control panel as shown on the electrical diagrams provided with the equipment. Osprey Corporation recommends installing the control panel as close to the MS as possible to reduce the length of the connecting wires.

Typical Control Panel Buttons• AUTO places the system, including the MS, into the AUTO mode.• MANUAL places the system, including the MS, into the MANUAL mode.• MOTORS accesses the following for the MS motors:

- Motor speed settings - Manual start and stop

Control Theory• The MS drive motors will start only when the access door is closed.• If the rotation of either shaft stops when the MS is running, a warning is triggered and the MS and

balance fan are shut down.• If the MS is discharging material to another automatic unit (such as a baler), that unit must supply a

READY signal before the MS will be ready to start.• The MS unit must be started before starting the fan/mechanism that delivers material to the MS.• If a balance fan is installed downstream of the MS, the balance fan must be started before the fan/

mechanism that delivers material to the MS.

Figure 4-1 Typical Osprey SYSTEM Control Panel (with MS Controls Included)


4-4


4.2 System OperationTypically, the MS is part of a larger system and is started and stopped automatically. Procedures for manually starting and stopping the MS or manually adjusting the motor speeds are provided below. The MS should be operated in MANUAL mode only for maintenance and troubleshooting purposes.

N O T EMANUAL mode operation is intended for maintenance or troubleshooting purposes only. For production purposes, always operate the MS in AUTO mode.

Manual StartSee Figure 4-2.

1. Using the control panel HMI (see Figure 4-1), press MANUAL to place the system into the MANUAL mode.

2. Press MOTORS to navigate to the Motors page.3. Press START for the air lock motor.4. Press START for the wiper blade (paddle) motor.5. Press MAIN to exit.

Figure 4-2 Osprey MS Control Panel MOTORS Page

Motor status indication

Motor START and STOP buttons

Motor Speed control buttons


4-5

Motor Speed AdjustmentSee Figure 4-3.

1. Using the control panel HMI (see Figure 4-1), press MOTORS to navigate to the Motors page.2. Press MOTOR SPEED and adjust up or down as necessary using the Motor Speed keypad window.3. Press MAIN to exit.

N O T EThe motor speed can be adjusted in either MANUAL or AUTO mode.

N O T EThe typical operating speed of an MS is 200 rpm for the air lock and the wiper blade motors, but this can vary for different applications. Each application requires fine-tuning during startup.

Figure 4-3 Adjusting the Motor Speed

Manual StopSee Figure 4-2.

1. Using the control panel HMI (see Figure 4-1), press MOTORS to navigate to the Motors page.2. Press STOP for the air lock motor.3. Press STOP wiper blade (paddle) motor.


5-1

Chapter 5 Maintenance ...........................................................................5-15.1 Maintenance Schedule .....................................................................................................................5-35.2 Air Lock and Wiper Blade Seal Adjustment or Replacement ............................................................5-4

About the Air Lock and Wiper Blade Seals ......................................................................................5-4Seal Adjustment ...............................................................................................................................5-5Seal Replacement ...........................................................................................................................5-5

Seal Removal ...............................................................................................................................5-5Seal Installation ............................................................................................................................5-5

5.3 Screen Replacement.........................................................................................................................5-6Screen Removal ..............................................................................................................................5-6Screen Installation ...........................................................................................................................5-6

5.4 Motor Replacement ...........................................................................................................................5-7Motor Removal ................................................................................................................................5-7Motor Installation .............................................................................................................................5-7Motor User’s Manual Citation ..........................................................................................................5-9

Chapter 5 Maintenance


5-3

5.1 Maintenance ScheduleTask Period Inspection Step Possible Action

Air lock and wiper blade shaft bearing inspection

Monthly Not applicable Re-lubricate bearings. Do not over-lubricate.

Air lock and wiper blade gear reducer inspection

Monthly Check the reducer oil level.

Refill if needed according to manufacturer’s instructions.

Air lock and wiper blade gear reducer oil change

As required Not applicable The reducer oil must be changed at regular intervals. Refer to manufacturer’s instructions.

Air lock and wiper blade seal inspection

Monthly Inspect the seals to ensure full contact with screen/air lock scroll.

Replace or adjust if needed. Refer to “About the Air Lock and Wiper Blade Seals” on page 5-4.

Screen inspection Monthly Visually inspect the screen for damage and signs of being clogged.

Clean or replace if needed. Refer to “5.3 Screen Replacement” on page 5-6.

MS inlet pressure inspection

Weekly Check the inlet pressure to ensure it is negative.

Clean the screen or increase the balance fan speed. Refer to “5.3 Screen Replacement” on page 5-6.

Screen differential pressure inspection

Monthly Check the differential pressure across the screen to ensure it is less than 3 in. w.c.

Clean or replace the screen. Refer to “5.3 Screen Replacement” on page 5-6.


5-4


5.2 Air Lock and Wiper Blade Seal Adjustment or Replacement

About the Air Lock and Wiper Blade SealsThe MS has two wiper blade seals (1) and six air lock seals (3).

The wiper blade seals make contact with the screen (2).

The air lock seals make contact with the front and rear air lock scrolls (4).

The wiper blade and air lock seals must maintain full contact with the screen or air lock scrolls along their entire length. There should be approximately 6 mm (1/8 in.) of contact between the seals and the screen or air lock scrolls. If the seals are not making full contact with the screen or air lock scrolls, they can be adjusted a limited amount.

2

3

4

1


5-5

Seal AdjustmentEach seal has slotted holes that allow it to be clamped to the air lock and wiper blades.

1. To adjust the seals, loosen the bolts on the air lock and wiper blades and pull the seal out until the correct amount of contact with the air lock scrolls and screen is achieved.

2. Tighten the bolts on the air lock and wiper blades.

N O T EThe seals can be adjusted a limited number of times before there is not enough seal material left to make full contact with the air lock scrolls and screen. When that point is reached, the seals must be replaced.

Seal Replacement

Seal Removal1. Completely remove the air lock and wiper blade

bolts.2. Remove the existing seals and discard.

Seal Installation1. Place new seals on the air lock and the wiper

blades between the seal clamps.2. Loosely tighten the bolts and then adjust the seals

until approximately 6 mm (1/8 in.) of contact with the air lock scrolls and screen is achieved.

3. Fully tighten all bolts.

Do not service the MS when the power is on. Shut off and lock out the system disconnect before performing any service procedures.

W A R N I N G


5-6


5.3 Screen ReplacementThe screen in the MS is made of either wire mesh or perforated steel, depending on the application. Over time, the screen can become clogged or damaged. If the screen is clogged, blowing it down with compressed air may resolve the issue. If it does not, the screen must be removed and cleaned manually or replaced.

During screen cleaning or replacement, wear a dust mask to prevent inhalation of dust.

W A R N I N G

Screen Removal1. Open the access door and remove the bolts (1) on

the upper and lower flange of the screen.At this point the screen should be completely unbolted.

2. Remove the screen (2) by pulling the bottom flange towards the access door and rotating the screen around the wiper blade.

Screen Installation1. Insert the upper flange (3) of the screen into the MS

below the wiper blade shaft.2. Rotate the screen (4) around the wiper blade while

simultaneously pushing the screen into the MS.3. Loosely bolt the upper and lower screen flanges in

place.4. When the screen is properly positioned, fully tighten

all bolts.3

1

4

2


5-7

5.4 Motor Replacement

N O T EThe information in this Appendix was excerpted and adapted from the SEW Eurodrive “TorqLOC” product manual and is provided for convenient reference. Refer to the “TorqLOC” manual for all other information related to the motors. Refer to “Motor User’s Manual Citation” on page 5-9 for a full source citation.

Motor Removal1. Remove the bolts that secure the shrink disc to the

motor.2. Remove the shrink disc, steel bushing, torque-arm

bolt, motor, clamping ring, and bronze bushing.

Motor InstallationRefer to the corresponding illustration for each numbered step.

1. Clean the shaft with a cleaning solution.2. Install the clamping ring and bronze bushing on

the shaft. Apply NOCO-Fluid® to the outside of the bronze bushing. Refer to the SEW manual for additional information.

3. Install the replacement motor on the shaft.

4. Place the motor torque arm inside the torque-arm bracket and loosely secure it with a hand-tightened nut and bolt.

5. Push the bronze bushing into the motor bore.

Figure 5-1 Motor Removal


5-8


5.2 Motor Replacement (continued)

6. Fully tighten the torque-arm nut and bolt.7. Push the clamping ring into its groove in the bronze bushing and then tighten the clamping ring to

18 N•m (13 ft-lb).8. Install the shrink disc on the shaft.9. Insert the steel bushing into the shrink disc.10. Use a rubber mallet to force the steel bushing further into the shrink disc.11. Verify that the face of the steel bushing is parallel to the face of the shrink disc.


5-9

12. Hand-thread the motor bolts into the shrink disc, ensuring that the shrink disc plates remain parallel.13. Use a criss-cross pattern to tighten the motor bolts to 12 N•m (9 ft-lb).14. Check gap “a:” Gap “a” must be no less than 5 mm (0.197 in.) and no more than 7.6 mm (0.299 in.).

Adjust as necessary.

5.2 Motor Replacement (continued)

Motor User’s Manual CitationSEW-Eurodrive (2003). TorqLOC. Bruchsal, Germany: SEW-Eurodrive; Edition 10/2003, 11236116/EN.


6-1

Chapter 6 Troubleshooting .....................................................................6-16.1 Troubleshooting ................................................................................................................................6-3

High Differential Pressure Across the Screen ..................................................................................6-3Air Pulled into MS Enclosure from Air Lock .....................................................................................6-3Particles/Fibers Escaping from MS Enclosure .................................................................................6-3Excessive Material Passing through the MS Screen .......................................................................6-4Jammed Air Lock or Wiper Blade Shaft ...........................................................................................6-4HMI Displays a Rotation Sensor Fault .............................................................................................6-4Gear Motor Circuit Breaker Tripped or Gear Motor Drive (VFD) Displays a Fault ...........................6-5MS Operating Under Positive Pressure Inside the Enclosure .........................................................6-5Excessive Material Buildup Inside the Outlet Transition ..................................................................6-5

Chapter 6 Troubleshooting


6-3

6.1 TroubleshootingThe MS is designed to provide consistent, trouble-free operation. In the event the MS ceases to operate, or operates inconsistently, refer to the following troubleshooting guide for assistance in correcting the problem.

Before attempting to troubleshoot the MS, read and understand all the information in the Safety chapter.

W A R N I N G

High Differential Pressure Across the ScreenProblem/Symptom Possible Causes Possible Solutions

High differential pressure across the screen

Clogged screen Blow-down the screen with compressed air.Remove the screen and clean it manually.Replace the screen.

Wiper blade seals not clearing material from the screen

Adjust the seals to achieve approximately 6 mm (1/8 in.) between the seals and the air lock scrolls and screen.Replace the seals when they cannot be adjusted further.

Screen wiper blade rotating too slowly to properly clean screen

Check the motor speed for the wiper blade motor. Increase the speed if needed.

Air Pulled into MS Enclosure from Air LockProblem/Symptom Possible Causes Possible Solutions

Air pulled into MS enclosure from air lock

Air lock seals not maintaining contact with air lock scrolls

Adjust the seals to achieve approximately 6 mm (1/8 in.) between the seals and the air lock scrolls and screen.Replace the seals when they cannot be adjusted further.

Particles/Fibers Escaping from MS EnclosureProblem/Symptom Possible Causes Possible Solutions

Particles/fibers escaping from MS enclosure

MS being operated with a positive pressure inside the MS enclosure

Refer to “MS Operating Under Positive Pressure Inside the Enclosure” on page 6-5.


6-4


Excessive Material Passing through the MS ScreenProblem/Symptom Possible Causes Possible Solutions

Excessive material passing through the MS screen

Large hole or cut in screen Inspect the screen for damage and replace if necessary.

Screen mesh too large for application Replace the existing screen with a finer mesh screen.

Jammed Air Lock or Wiper Blade ShaftProblem/Symptom Possible Causes Possible Solutions

Jammed air lock shaft or wiper blade shaft

Material jammed between wiper blade and screen or between air lock and air lock scrolls

Remove jammed material. Reduce throughput if necessary.

Material jammed between wiper blade side plate and MS enclosure

This type of jam is typically caused by long, stringy material wrapping around the shaft. Remove the jam and reduce the length of the incoming material if necessary.

Material jammed between air lock side plate and MS enclosure

This type of jam is typically caused when the MS begins operating under positive pressure and pushes material out of the small crevices near the air lock shaft. Remove the jam and prevent the MS from operating under positive pressure.

Worn air lock seals causing discharged material to be pulled back into air lock

Adjust or replace the air lock seals. Refer to “5.2 Air Lock and Wiper Blade Seal Adjustment or Replacement” on page 5-4.

HMI Displays a Rotation Sensor FaultProblem/Symptom Possible Causes Possible Solutions

HMI displays a rotation sensor fault

Nuisance fault triggered Reset the alarm by pressing the alarm reset button on the control panel or HMI. Check to see if the fault recurs.

Rotation sensor not properly aligned Check for proper alignment of the rotation sensor and adjust if necessary.

Jammed air lock or wiper blade shaft Refer to “Jammed Air Lock or Wiper Blade Shaft” on page 6-4.


6-5

Gear Motor Circuit Breaker Tripped or Gear Motor Drive (VFD) Displays a FaultProblem/Symptom Possible Causes Possible Solutions

Gear motor circuit breaker tripped or gear motor drive (VFD) displays a fault

Motor wiring incorrect Check the motor wiring. Refer to the electrical section of the installation chapter.

Circuit breaker setting incorrect Confirm that the circuit breaker setting matches the setting shown on the Osprey-supplied electrical schematics. Adjust if necessary.

Gear motor VFD parameter settings incorrect

Confirm that the gear motor VFD parameter settings for the MS match the parameter settings provided by Osprey. Adjust if necessary.

MS motor faulty Replace the motor. Refer to “5.4 Motor Replacement” on page 5-7.

MS Operating Under Positive Pressure Inside the EnclosureProblem/Symptom Possible Causes Possible Solutions

MS operating under positive pressure inside the enclosure

Clogged screen Refer to “High Differential Pressure Across the Screen” on page 6-3.

Balancing fan not providing enough negative pressure

Increase the balancing fan motor speed.

During startup, shutdown, or process change, sequence or timing of starting and stopping equipment not properly programmed, leading to momentary instances of positive pressure inside MS

Update the programming to ensure that the MS always operates under a negative pressure.

Transition or ducting partially blocked Locate and remove any blockages.

Excessive Material Buildup Inside the Outlet TransitionProblem/Symptom Possible Causes Possible Solutions

Excessive material buildup inside the outlet transition

Total air flow (air volume) through system too low

Increase the air flow through the system.


7-1

Chapter 7 Spare Parts .............................................................................7-17.1 Spare Parts .......................................................................................................................................7-3

Ordering ...........................................................................................................................................7-3Contact Information .........................................................................................................................7-3MS Spare Parts ...............................................................................................................................7-4

Chapter 7 Spare Parts


7-3

7.1 Spare Parts

OrderingSpare parts may be ordered from the Parts Department at Osprey Corporation by either phone or fax.

When ordering spare parts, have the following information available.

• Part number• Complete description of part• Equipment model number• Equipment serial number (if applicable)• Quantity needed• Shipping address and method• Customer order number

Contact InformationOsprey Corporation

1835 Briarwood Road, NEAtlanta, GA 30329Tel: 404-321-7776Fax: 404-634-1401

www.ospreyfilters.com

Table 6-1 lists the spare parts recommended by Osprey to minimize downtime.

N O T EActual spare parts list may differ from the list provided. Consult the documentation that is shipped with the equipment before ordering.


7-4


Figure 7-1 MS Spare Parts

3

1

9

4

2

4

6, 7, 8

5

5

MS Spare Parts


7-5

Table 7-1 MS Spare Parts

Item No. Part Name

Qty. Required

MS-4 Part Number

MS-10 Part Number

MS-12 Part Number

1 Wiper Blade Seal 1 3504L0014 3504M0023 3504M0010

2 Air Lock Seal 1 3504L0014 3504L0056 3504L0025

3 Gear motor 2

DRVRED23302 (400/50)

DRVRED22901 (460/60)

DRVRED23302 (400/50)

DRVRED22901 (460/60)

DRVRED23302 (400/50)

DRVRED22901 (460/60)

4 Bearing 4 DRVBRG22155 DRVBRG21321 DRVBRG21321

5 Rotation Sensor 2 ELCMSC12525 ELCMSC12525 ELCMSC12525

6 Door Safety Sensor 1 ELCMSC23220 ELCMSC23220 ELCMSC23220

7 Door Safety Actuator 1 ELCMSC23221 ELCMSC23221 ELCMSC23221

8 Door Safety Sensor Cable 1 ELCMSC23222 ELCMSC23222 ELCMSC23222

9 Screen 1 Note A Note A Note A

NOTE A: Screens are available in several mesh sizes. Refer to the job documentation for the part number and the screen size and mesh details.

MS Spare Parts (continued)


8-1

Chapter 8 Osprey Warranty ....................................................................8-1

Chapter 8 Osprey Warranty


8-3

Chapter 8 Osprey Warranty

Osprey Corporation provides a warranty for their equipment in accordance with the terms of sale and payment, unless otherwise agreed upon. The Purchaser should refer to the sales agreement for specifics of their warranty.Following summarizes a typical warranty agreement:Osprey warrants the equipment to be free of any defects in parts and workmanship for one year from shipment, if properly installed, maintained, and operated in accordance with the operations manual.Upon receipt of the equipment, should the Purchaser find any missing/wrong parts after delivery, the remedy of the Purchaser under this warranty is Osprey’s obligation to deliver/replace the parts at no cost to the Purchaser provided the Purchaser notifies Osprey of any missing/ wrong part within thirty days from receipt of the equipment. In the event the Purchaser does not notify Osprey of any missing/ wrong part within thirty days of delivery, Osprey will not deliver/replace the part(s) at no cost.This warranty does not cover parts that:• Wear out from normal use• Have been modified• Have been used incorrectly• Have not been properly maintained

Osprey shall have no liability to Purchaser for direct, consequential, or incidental damages of any kind whatsoever, including, but not limited to:• Personal injury• Property damages• Lost profits• Lost production• Economic loss due to defect in the equipment• Any use or inability to use the equipment• Any other breach by Osprey of this agreement

Osprey shall have no liability to Purchaser, remote Purchasers, or other users of the equipment for any liability concerning the use of the equipment, or for the omission of any caution or warning.

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