Sulzer 114665-1-11 Operation And Maintenance Manual Download

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OPERATION and MAINTENANCE MANUAL

THERMAL 4 LLC

MONSTER INDUSTRIAL GRINDER

Model 7-SHRED-1-H-4000

Serial No. 114665-1-11

Contractor

Manufacturer/Local Rep

Thermal 4 LLC

JWC Environmental

790 South Ivy Street

2600 South Garnsey Street

Canby, OR 97013

Santa Ana, CA 92707

Ph:Alexandria, IN 46001-8649

Ph: 800-331-2277

Ph: 765-724-3554

Summary of Contents for 114665-1-11

Page 1: ...IAL GRINDER Model 7 SHRED 1 H 4000 Serial No 114665 1 11 Contractor Manufacturer Local Rep Thermal 4 LLC JWC Environmental 790 South Ivy Street 2600 South Garnsey Street Canby OR 97013 Santa Ana CA 92707 Ph Alexandria IN 46001 8649 Ph 800 331 2277 Ph 765 724 3554 ...

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Page 3: ...uffin Monster Channel Monster Mini Monster Macho Monster and Sludge Monster are registered trademarks of JWC Environmental LLC JWCE s Santa Ana and Costa Mesa California facilities are registered by UL to ISO9001 2008 10001313 QM8 JWC International Congleton UK is registered by QAS to ISO9001 2008 File A13056 U S patents apply 4 919 346 5 060 872 5 320 286 5 333 801 5 354 004 5 478 020 5 505 388 5...

Page 4: ...HALL THE SELLER BE LIABLE FOR LOST PROFITS OR OTHER SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES EVEN IF THE SELLER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES THE TOTAL LIABILITY OF THE SELLER TO BUYER AND OTHERS ARISING FROM ANY CAUSE WHATSOEVER IN CONNECTION WITH BUYER S PURCHASE USE AND DISPOSITION OF ANY PRODUCT COVERED HEREBY SHALL UNDER NO CIRCUMSTANCES EXCEED THE PURCHASE PRICE PAID F...

Page 5: ...e Man Hours x Reduce Your Life Cycle Ownership Costs x Reduce Your Parts Inventory 2 Cutter Cartridge Exchange Another option is the Cutter Cartridge Exchange Program Muffin Monster owners can order a factory reconditioned cutter cartridge in exchange for their unit requiring reconditioning Subject to availability the replacement cartridge will be shipped in response to a user s request The factor...

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Page 7: ...2 3 1 3 Grinder Cutter Stack and Seal Cartridges 3 2 3 1 4 Grinder Drive Gears 3 2 3 2 LUBRICATION 3 2 3 2 1 Motor 3 2 3 2 2 Speed Reducer 3 2 3 2 3 Grinder Drive Gears 3 2 3 3 LONG TERM AND PERMANENT SHUTDOWNS 3 3 3 3 1 Long Term Shutdown 3 3 3 3 2 Permanent Removal 3 3 SECTION 4 TROUBLESHOOTING SECTION 5 REMOVAL AND REPLACEMENT 5 1 GRINDER 5 1 5 2 GRINDER COMPONENT REMOVAL AND REPLACEMENT 5 1 5 ...

Page 8: ...OF FIGURES FIGURE 5 1 CUTTER ORIENTATION 5 3 LIST OF TABLES TABLE 1 1 SPECIFICATIONS 1 2 TABLE 1 2 MATERIALS 1 2 TABLE 3 1 INSPECTION AND LUBRICATION SCHEDULE 3 1 TABLE 3 2 RECOMMENDED LUBRICANTS 3 1 TABLE 4 1 TROUBLESHOOTING 4 1 ...

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Page 11: ...ust be in compliance with all applicable local federal and area safety rules regulations and guidelines 1 2 DESIGN COMPLIANCE The grinder satisfies the design criteria for same and or similar types of equipment JWCE considers that the buyers and users of the grinder comply and ensure compliance with the warnings and cautions used in this manual to avoid the potential for personal injury and or equ...

Page 12: ...pport Department or a local sales service representative for answers to service questions JWCE Customer Service Center Toll Free 800 331 2277 Local 949 833 3888 Fax 714 549 4007 Reducer Ratio 59 1 Estimated Weights Grinder 5975 lbs Stand 600 lbs Hopper 350 lbs TABLE 1 2 MATERIALS Housings Covers Side Rails Ductile iron Cutters Spacers 17 tooth 4130 alloy steel Seal Faces Buna N Hopper Frame Grinde...

Page 13: ...riate supply power if unable to rotate drives manually If required lubricate the motor per Paragraph 3 2 1 if equipment is stored or idle for more than 12 months 2 3 SPARES A complete set of spare fuses is included in JWCE provided control panels No spares were ordered or provided with the equipment 2 4 INSTALLATION No special equipment is needed for installation Standard lifting and handling devi...

Page 14: ...Attach lifting equipment capable of supporting the hopper weight Lift and lower the hopper on to the grinder inlet Verify the hopper is in the desired position refer to the general arrangement drawing in Section 6 If required for larger hoppers weld the hopper to the hopper frame as required If required connect the hopper spray wash ball valve to the wash water supply Refer to the spray wash assem...

Page 15: ...er stack Every 3 months Paragraph 3 1 1 Inspect grinder drive assemblies and couplings Every 12 months Paragraph 3 1 2 Inspect seal cartridges Every 12 months Paragraph 3 1 3 Inspect grinder drive gears Every 12 months Paragraph 3 1 4 Replace motor grease 25 50Hp every 7 400 operating hours 60 100Hp every 3 500 operating hours Paragraph 3 2 1 Service oil filled speed reducer Every 6 months Paragra...

Page 16: ... to Table 3 1 for lubrication intervals and Table 3 2 for lubricants Remove power from the grinder motor before lubrication Always use new lubricant do not reuse removed lubricant Avoid mixing brands and or types of lubricants 3 2 1 Motor Refer to the motor data sheet in Section 6 for the motor used in this application The lubrication requirements depends on the motor size and the service conditio...

Page 17: ...emporarily apply appropriate supply power if unable to rotate drive manually If storing the grinder for over 12 months Using a container capable of holding three gallons remove the drain plug and allow the speed reducer to drain Discard the removed oil do not reuse Replace the drain plug Open the breather valve plug Completely fill the reducer with a rust preventative oil Shell VSI Circulating Oil...

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Page 19: ... start Power disconnect open Check that any power disconnect provided by others is not open Open fuse Check control panel for any open fuses PLC module not working Check the control panel PLC indicators Contact JWCE for any PLC faults in factory provided panels Motor freewheeling Check drive couplings Solids not being reduced Debris buildup on cutters and spacers Grinder rotating in reverse agains...

Page 20: ...equired Replace any worn damaged cutters Grinder reverses excessively but continues to run Excessive solids loading or duty cycle Reduce solids loading or decrease duty cycle Control panel current sensor reverse threshold set too low Contact JWCE for assistance Grinder cutters worn or damaged Inspect cutters Replace any worn damaged cutters Drive gears not properly greased or worn broken Inspect d...

Page 21: ...oval Verify the grinder is isolated and supply power is removed from the grinder motor Disconnect all grinder motor wiring Attach lifting fixtures and slings around the grinder Remove any hardware securing the grinder to the stand or site Lift the grinder Place grinder upright on blocks on a secure level surface for component removal or on blocks with the top and bottom cover accessible for seal a...

Page 22: ...le from the shafts A gear puller may be required if the couplings can not be removed by hand Proceed to the next step if removing the spool Remove hardware securing the adapter spool to the top cover Slowly lift the equipment adapter spool from the unit top cover and place it on a clean flat work surface Remove the spool to top cover gasket replace if damaged 5 2 2 Top Cover Remove the drive assem...

Page 23: ...ection 6 for the cutter stack configuration during stacking Stack cutters and spacers as follows A Remove shaft clamp Install a normal sized cutter on the taller drive shaft index mark at position 1 B Install a spacer on the driven shaft then on the drive shaft C Install a normal sized cutter on the driven shaft index mark at position 1 D Install a cutter on the drive shaft index mark at position ...

Page 24: ... cover 5 2 10 Bottom End Housing Remove the top cover drive driven gears top end housing side rails cutters and spacers and bottom cover 5 2 10 1Bottom End Housing Seal Assemblies Remove the hardware securing the seal cartridge assembly Handle end housings with care avoiding any contact with seal cartridge surfaces Replace the entire seal cartridge assembly if contaminants have leaked into the end...

Page 25: ...for the grinder include Grinder General Arrangement if part of a system Grinder Assembly Parts List Grinder Configuration Parts List Grinder Drive Assembly Parts List Motor Data Cutters and Spacers Hopper Assembly Parts List Motor Support Assembly Parts List Stand Assembly Parts List ...

Page 26: ...7 SHRED 1 H GRINDER 6 2 This page intentionally left blank ...

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Page 34: ...ket CEM4314T 60HP 1780RPM 3PH 60HZ 364TC 1462M TEFC Copyright All product information within this document is subject to ABB Motors and Mechanical Inc copyright protection unless otherwise noted JWCE PN 60010 0004 page 1 of 9 ...

Page 35: ...Class and Group None XP Division Not Applicable Agency Approvals CCSA US CSA EEV Auxillary Box No Auxillary Box Base Indicator Rigid Bearing Grease Type Polyrex EM 20F 300F Current Voltage 136 000 A 230 0 V 68 000 A 460 0 V Design Code B Feedback Device NO FEEDBACK Heater Indicator No Heater Insulation Class F Inverter Code Inverter Ready KVA Code G Lifting Lugs No Lifting Lugs Motor Lead Quantity...

Page 36: ...Page 3 of 11 Product Information Packet CEM4314T 60HP 1780RPM 3PH 60HZ 364TC 1462M TEFC Drip Cover No Drip Cover Duty Rating CONT Thermal Device Bearing None Thermal Device Winding None ...

Page 37: ...0 AMPS 136 68 VOLTS 230 460 DESIGN B FRAME 364TC RPM 1780 HZ 60 AMB 40 SF 1 15 DRIVE END BEARING 65BC03J30X PHASE 3 DUTY CONT INSUL CLASS F OPP D E BEARING 65BC03J30X TYPE P ENCL TEFC CODE G SER NO POWER FACTOR 87 NEMA NOM EFFICIENCY 95 SUIT FOR 208V 149 AMPS MAX CORR KVAR 10 GUARANTEED EFFICIENCY 94 1 NEMA NOM CSA QUOTED EFF MOTOR WEIGHT 915 ...

Page 38: ...ODE LETTER ENCLOSURE E S ROTOR TEST S O TEST DATE STATOR RES 25 C OHMS BETWEEN LINES A C MOTOR PERFORMANCE CURVES REMARKS DR BY CK BY APP BY DATE ISSUE DATE AMPERES SHOWN FOR AMPERES WILL VARY INVERSELY WITH THE RATED VOLTAGE VOLT CONNECTION IF OTHER VOLTAGE CONNECTIONS ARE AVAILABLE THE 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 Rotext2 0 0 1 22345 632 0 113 32 57 4 183092 5 2 18309...

Page 39: ...EFF 94 5 D M BYRD J P TSAO A36WG0216 R002 J P TSAO 10 10 91 12 14 10 Printed on 4 18 16 14 42 bengap01 baldor com REL S O FRAME HP TYPE PHASE HERTZ RPM VOLTS AMPS DUTY AMB C INSUL S F NEMA DESIGN CODE LETTER ENCL E S ROTOR TEST S O TEST DATE STATOR RES 25 C OHMS BETWEEN LINES PERFORMANCE LOAD HP AMPERES RPM POWER FACTOR EFFICIENCY NO LOAD 1 4 2 4 3 4 4 4 5 4 SPEED TORQUE RPM TORQUE FULL LOAD TORQU...

Page 40: ...MA DESIGN CODE LETTER ENCLOSURE E S ROTOR TEST S O TEST DATE STATOR RES 25 C OHMS BETWEEN LINES A C MOTOR PERFORMANCE CURVES DR BY CK BY APP BY DATE ISSUE DATE AMPERES SHOWN FOR AMPERES WILL VARY INVERSELY WITH THE RATED VOLTAGE CONNECTION IF OTHER VOLTAGE CONNECTIONS ARE AVAILABLE THE Rotext2 0 0 12 0 12 3 43 453 3643 43 6 7 3 36 3 3 37 1088 9 0 3 3 6 2 01 2 1 3 3 6 8 9 6 3 6 3 6 7 5 3 33 180 8 6...

Page 41: ...7 21 67 521 216758 7 21 5 0 6 7 7 1 2685 727 1 26 02817 1 227 22 1 1 22 0 080 3 50 66 6 7 581287 1 0 685 7 1 2 67 6 7 7 16 21 6 7 5 83 72 1 1 8 1 1 7 5 72 1 7 6 7 7 02725 76 0 9 5 3 1 1 8321 5 7 1 17 5 2 5 9 7 7 9 5 1 520 17 5 0 6 7 7 7 6 5 9 6 5 9 5 9 6 02 12 9 56 21 7 5 5 2 5 66 86720 5 6 5 63216 25 7 50 1 1 7 7 25 6 352 8 7 3 5 250 68 7 1 7 17 1 33 7 21 ...

Page 42: ...Page 9 of 11 Product Information Packet CEM4314T 60HP 1780RPM 3PH 60HZ 364TC 1462M TEFC ...

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