Installation Guide for Decanter Centrifuge

Installation of Mechanical Parts

The centrifuge must be placed on a horizontal and solid base. The installation diagram provided by our company only explains the dimensions of the plane layout, and the concrete foundation with pre-embedded parts should be poured according to the installation diagram provided, and the structural strength of the foundation should be considered by the user according to the load condition, and it should be able to withstand the total weight of the centrifuge and the running dynamic load the vertical dynamic load should be calculated as 1.5 times the static load, and the horizontal dynamic load should be calculated as 0.5 times the static load. The centrifuge should also be isolated from vibrations generated by other equipment.

Upon delivery of the machine, adjust its position according to the requirements, and weld the shock absorber mounting plate under the machine body to the corresponding pre-buried parts. Users can also use steel structure or other forms of foundation according to the needs. However, when using a steel structure foundation, special attention should be paid to the fact that even if the steel structure foundation is strong enough, when the vibration frequency of the centrifuge is the same as the intrinsic frequency of the steel structure, resonance and other phenomena will be generated, so it is recommended to avoid using this method, if a steel structure must be used, the supporting feet of the steel structure must be below the vibration damper of the centrifuge. When installing centrifuges on the basis of elevated steel structures, sufficient reinforcement should be added. When multiple centrifuges are installed on a steel structure, it should be ensured that the steel frame of the single centrifuge is in an independent state and the steel foundations must not be connected together to prevent resonance problems of the equipment. The level of the shock absorber for both concrete and steel structure foundations should be maintained within 1mm/m.

Installation of Equipment

  • Necessary lifting equipment that meets the lifting requirements should be installed, and easy maintenance should be considered;
  • When lifting, securely connect the sling to the sling bag ring and the special ring on the base. Do not hang the sling on other parts, and ensure that the angle between two slings does not exceed 90°.
  • All coupling parts of the machine, valves, etc., should be carefully considered for safe and easy operation. There should be sufficient reserved space or access around the equipment. In particular, there should be enough space around the drum assembly and spiral assembly to facilitate disassembly and placement; and around the centrifuge to ensure that there is space to pull out the feed tube.
  • The centrifuge will be placed on the base according to the correct position, adjust the centrifuge and the auxiliary equipment, pipeline interface position, to be checked according to the relevant technical requirements are correct, you can weld the base plate of the shock absorber and the relevant embedded parts (can be welded a few sections can be), see the shock absorber and the foundation of the embedded parts of the welded schematic diagram.
  • Equipment operating environment temperature should be controlled between 5 ℃ ~ 40 ℃, to avoid contact with strong corrosive substances, should try to use indoor layout.
  • When checking the level of the machine, the upper plane of the machine base (guide rail) should be used as the standard, and the level is required: the length direction should not exceed 0.2mm/m, and the width direction should not exceed 0.2mm/m. If the standard is exceeded, the connecting bolts between the machine base and the shock absorber can be loosened, the machine can be lifted up, and the adjusting shims can be appropriately added or subtracted to the top of the shock absorber to realize the level.

Connection to Process Piping

Centrifuge is a high-speed rotating equipment, with a certain vibration amplitude, any external influence will deteriorate the working condition of the machine. It is required that all pipelines and facilities to be connected with the machine should be connected in a flexible way that can be extended and retracted near the machine body.

Connection of Feed Pipe

It is preferred that the feed for the centrifuge be conveyed by a volumetric pump (1 to 1 mode is required, i.e., 1 feed pump controlling 1 centrifuge, controlled by a frequency converter). The start and stop of the feed pump must be interlocked with the centrifuge control, the pressure at the inlet of centrifuge feed pipe is about 0.05 ~ 0.3 MPa (related to the feed volume), and a flow meter is set up on the centrifuge inlet feed pipeline in order to confirm and control the flow rate. And equipped with washing water pipeline, washing centrifuge drum and spiral, as well as the inner cavity of the seat, the number of washing water pipeline according to the characteristics of the material, process requirements are different, see the centrifuge installation foundation diagram.

The feed pipe should be connected to the process feed line by a hose connector with a metal mesh, and there should be space for disassembling the feed pipe.

Solid Phase Outlet Connection

Can use the randomly fitted flange (square), mounted on the body, the lower end of the flexible connector and slag storage tank (or screw conveyor and other conveying equipment such as the inlet) connection, can also be used non-contact open-end type of receiving materials.

Liquid Phase Port Connection

Can be used randomly with liquid collection bucket, the site according to the liquid collection bucket installation location for pipe laying, pipe diameter size to ensure smooth drainage, to avoid right-angle bends, through the soft connector and the liquid discharge pipe connected to the pipe diameter and installation slope must meet the requirements of the machine's maximum handling capacity.

All other piping connected to the machine should have a flexible connection near the body.

Acceptance of Installation Work

After the end of the installation project, the relevant personnel should be organized in accordance with technical standards and agreements, the entire project carefully checked and accepted, and those that do not meet the requirements should be thoroughly rectified until qualified. The inspection mainly includes the following aspects:

  • Whether the installation is correct (including: fixing method, levelness, installation position, etc.);
  • Whether the conveying method is reasonable;
  • Before starting the centrifuge, check whether the centrifuge transportation support bolts (2 in total) are removed, the installation position of the support bolts is located in the upper part of the bearing housing, and replace them with the bolts (M 16, the length of which must not be more than 40mm) that are supplied with the centrifuge;
  • Whether the connection between the centrifuge and each system is safe and reliable, and whether the imports and exports of the centrifuge adopt soft connection;
  • Whether the slag outlet and liquid outlet are unobstructed;
  • Drive belt and safety cover are installed correctly;
  • Is the motor steering correct, the drum rotates counterclockwise when viewed from the input shaft end of the differential, or can be determined by the rotating pointing plate on the machine;
  • Are lubricants, grease, and grease guns fully equipped;
  • Is the setting of each parameter value, etc. of the electrical system correct?
  • Whether each protection and detection device of the equipment (if equipped with vibration sensors, bearing temperature sensors, etc.) is connected, reliable and effective;
  • Centrifuge auxiliary equipment interlock control is perfect, for example: feed pump start and stop and centrifuge interlock (when the centrifuge stops, the feed pump automatically stops feeding); rinse water valve switch and centrifuge interlock (when the centrifuge stops, the rinse water valve is automatically opened) and so on.

Installation of Electrical Parts

Warning! This control cabinet is energized by a strong 380V / 220V power supply, therefore installation is only permitted by qualified technicians, otherwise there is a risk of electric shock!

Please read these installation instructions carefully before installation, as ignoring these instructions may result in equipment damage or personal injury!

The control cabinet has been reasonably designed for the controlled equipment, therefore, without the consent of ZK SEPARATION, it is not permitted to use the centrifuge control cabinet to control equipment outside the scope of the design, so as to avoid unnecessary damage, otherwise ZK SEPARATION will not be responsible for the damage caused to the equipment and reserves the right to pursue the relevant responsibilities.

Installation Environment of Control Cabinet

In order to ensure the stable and reliable operation of the components in the control cabinet, there are the following specific requirements for control cabinet installation:

  • Installation should be done in an area that can support the weight of the control cabinet, otherwise there is a risk of injury or damage if dropped.
  • It is strictly prohibited to install in the water pipe and other occasions that may produce splashing water droplets, otherwise there is a risk of injury or damage.
  • Avoid installations with oil mist, metal dust and dusty areas.
  • Avoid installation in hazardous gases, liquids, and corrosive situations.
  • Non-explosion-proof type control cabinets should be installed in non-explosion-proof areas.
  • Do not install in direct sunlight.
  • Do not drop drilling residues inside the control cabinet during installation work, especially inside the components inside the control cabinet (e.g. frequency converter, PLC, air switch, etc.), otherwise there is a danger of damaging the devices or even electric shock.
  • Please install the control cabinet vertically and keep the environment of the site well ventilated to facilitate the heat dissipation of the inverter in the control cabinet. It is recommended to install cooling fans or air conditioners on site to prevent the ambient temperature from rising above 45℃.
  • Install in a location where vibration is less than 5.9m/s2 (0.6g).

Control Cabinet Handling

When handling, do not stress the control cabinet panel or risk injury or damage if dropped.

When lifting, connect the sling with the control cabinet ring (diagonal ring) firmly, do not hang the sling on other parts, the angle between two slings shall not be greater than 90°, the lifting process requires a smooth, light lifting and placing, there shall be no vibration and rubbing phenomenon, please refer to the control cabinet lifting schematic diagram.

Safety Notes:

  • When lifting the equipment, please lift it according to the specified position and use a large enough spreader and crane to lift it;
  • Do not stand under the boom!

Installation of Electrical Systems

  • Motor wiring should fully consider the motor's starting current and full-load current on the requirements of the wire, select the appropriate wire diameter for configuration. And at the same time take into account the wire around the environment on the wire whether there are special requirements;
  • The installation of the control cabinet should follow the principles of easy operation, easy observation and easy maintenance. The arrangement of all devices in the cabinet should be carried out in strict accordance with the specifications. Before connecting, it should be carefully checked against the electrical control diagram, and it should be connected only after two or more people confirm that there is no error;
  • All parts that may come into contact with the human body (or are required by design) shall be provided with a reliable earth protection device;
  • It is not permitted to disassemble or adjust the machine without disconnecting the power supply;
  • For other requirements, please refer to “Electrical Control Instruction Manual” as well as national technical standards and technical specifications on electrical aspects are suitable for this machine.

Acceptance of Installation Work

After the completion of the installation project, relevant personnel should be organized in accordance with technical standards and agreements, the entire project carefully checked and accepted, and those that do not meet the requirements should be thoroughly rectified until qualified. The construction department should provide complete completion information to the using department. The inspection mainly includes the following aspects:

  • Is the mounting position correct;
  • The cables are in compliance with the requirements;
  • Is the motor wiring reliable, and has the motor cable entry hole been sealed with rubber cement or grease to prevent water from entering the junction box;
  • Have the cables been marked as required and is the lettering clear;
  • Check that the voltage and frequency correspond to the indicator marks on the motor and other electrical equipment.