30” Rotary Drum Washer
JenFab Job Number: 11923
Built by:
Jensen Fabricating Engineers, Inc.
555 Wethersfield Road
Berlin, CT 06037
Telephone: 860-828-6516
Fax: 860-828-0473

Project Engineer / Mechanical: Jim Lester
Project Engineer / Electrical: Matt Christopher

Safety Instructions

Installation

This section covers the basics in setting up the machine.

Level Surface

Set up machine on a level, properly supported surface. If machine requires leveling, place shims under the main machine frame. The machine should be level so that counter-flows and overflow drains operate properly.

Drum Rings

Inspect drum support rings to assure that they are properly positioned on the load runner bearings. Rough handling during shipping can cause the drum to move. Check by removing covers and inspecting load runners at each end of the machine.

Tanks

Check to see if there are any foreign objects in the tanks and that the pump screens are in place.

Connections

The following deal with machine hook-ups:

Power Sources

Check that the voltage on the schematics is the same as that of the plant utilities. Most systems have 480volts, 60cycles, and 3phase with an 110volt control circuit. When connecting power to the main disconnect, verify that all motors are rotating in the proper direction (phased). Normally, the machine is phased before it is shipped.

Drains and Overflows

Before hooking-up drains and overflows, refer to the drawing for their locations.

Water Level Controls

Normally, there is a main connection for water unless the customer requests otherwise. Connection and size are noted on the drawing supplied. Read specific instructions furnished for the type of level control on the machine.

Emergency Stop

If necessary, use the emergency stop to remove all control power. Press Power On button “ON” for restoring power to machine.

Machine Storage

Empty and clean the tanks and drum. Drain all piping including filters and steam piping, and grease all bearings on drum and dryer blower.

Maintenance

JenFab recommends a regular maintenance schedule. Below presents the assemblies that to be checked on a routine basis:

Components1 / Routine Maintenance / How Often
Drive
Drum Rings / Grease lightly. Grease fittings located on back of washer drum enclosure at each end of machine. / Weekly
DrumLoad Runners / Check for wear. / Periodically
Dryer Blower Bearings / Grease lightly. Grease fittings on blower shaft. / Weekly
Drum Drive Chain / Inspect and oil drive chain. / Monthly
Drive Chain / Check tension and adjust if required. / Every six months
Drum Gear Reducer / Check oil level. Not applicable on machines with Bodine gearmotors. / Every three months
Spray Pump Motors / Grease lightly. / Every six months
Spray
Spray Headers and Nozzles / Remove spray headers and clean spray nozzles. / Periodically (Every six months)
“In-Tank” Pump Screens / Clean and check. (not applicable on LJ machines) / Daily, or when applicable
Drum
Perforations / Inspect for foreign particles. / When draining and recharging the tanks
Exterior / Clean and rinse down. / When draining and recharging the tanks
Exterior and Interior / Check and inspect for excessive wear or cracks. / Every six months
Solution Heating
Temperature Controls / Check temperature controls for accuracy. / Every six months
Tank Heaters / Check for salts build-up (these have a tendency to cause overheating at heater interface and cause burn-out). / When draining and recharging the tanks
Conductivity Meter and Rinse-Tank Controller
Inspect probes. / Weekly
Clean. / As required
1Detailed information supplied in the back of this manual.

Operating Procedure

  1. Check tanks to be sure they are full of solution.
  2. Press “POWERON RESET”and “TANK OVERTEMP HEAT RESET” buttons and turn on “TANK HEAT” and “DRYER HEAT” allow tanks to heat up to operating temperature. The dryer blower will turn on when the “POWERONRESET” button is pressed.
  3. When tanks reach operating temperature press “START” button this will start the pumps and drum rotation. Allow dryer temperature and solution temperatures to reach operating temperatures.
  4. Check pressure gauges to be sure pumps are working.
  5. Look in unload sight hole to see that sprays are working.
  6. Start loading parts to be cleaned.
  7. To shut down machine and leave the tank heat on; press the “STOP” button.
  8. To shut down machine and tank heat; press the “EMERGENCY-STOP” button.

Changing Tank Solution

  1. Turn off and lockout electrical supply.
  2. Close all ball valves to tanks on the water header so automatic make-up valves will not add water while draining the tanks
  3. Open drain valves at the bottom of the tanks you wish to drain and allow tanks to drain. Spray tanks with a hose to rinse dirt from the sides of the tanks as the tanks drain.
  4. Clean out any residue in the tank with a brush or mop if needed.
  5. Inspect the tank heaters for build up of solution or salts and clean if needed.
  6. Inspect pumps to be sure there isn’t anything blocking the inlet to the pump.
  7. If the machine has pump screens or chip baskets these should be cleaned at this time.
  8. If the machine has filters they should be changed at this time.
  9. If the machine has an oil separator it should be cleaned at this time.
  10. Rinse tanks completely with clean water and allow all water to drain.
  11. Close all drain valves and open manual fill valves to all tanks that were drained. Allow tanks to fill to about 6” from the top of the tanks and turn off manual fill valves. Open valves to automatic water make-up.
  12. Add required chemistry to tanks. Follow all instructions and precautions from chemical supplier.
  13. Turn power to machine on and automatic level controls will finish filling the tanks.
  14. Allow tanks to heat up to operating temperature. When tanks reach operating temperature turn on pumps and check solution temperatures again, temperatures may change due to uneven heating, allow tanks to reach operating temperatures.
  15. Machine is ready to run proceed to operating procedure section.

Installing or Replacing Filter Cartridges

When it is necessary to replace a filter cartridge and before the limiting differential pressure is reached (5-10 psi), follow these steps:

  1. Turn off spray pump and close valves located immediately upstream and downstream from filter housing.
  2. Open the drain and top vent valves to depressurize the filter housing.Opening the drain releases any remaining liquid in the housing. If the filter drain is not connected to a drain system be prepared to catch the solution
  3. Loosen the wing nuts on the cover, rotated the two bolts with slots down, and swing cover open.
  4. Remove the perforated basket with the filter bag inside. Some solution will drip off the bag.
  5. Wipe all parts of the filter housing with a clean cloth. Inspect all parts of the filter housing, particularly the O-ring, for possible damage and/or excessive wear and corrosion. Replace any damaged or worn parts.
  6. Install filter bag inside perforated basket spreading it out as much as possible.
  7. Check that the O-ring is in place on the housing.
  8. Swing cover on top of housing, be careful not to damage the O-ring. Rotate the two bolts into the slots on the cover. Tighten the three wing nuts alternating between the so that they are all tightened evenly.
  9. Close the drain valve.
  10. Open the valves upstream and downstream from filter slightly, turn spray pump on. (be sure there is water in the tank) Check filter housing for leaks then slowly open the valve to operating position while checking for leaks.
  11. Allow run run a short time to release any air in the housing then close the vent valve on the top of the housing.
  12. Check pressure gauges for differential pressure.

Parts List

ITEM / Qty / DESCRIPTION / SUPPLIER
* (asterisk) denotes spare part recommendation.
Tanks
*Tank Heat
Wash Tank / 1 / #12HSL84455X-R32S-PLII, Twelve element over the side stainless steel immersion heater. 84 kw, 480volt, 55” high straight riser
Vendor-INFO\Protech\ele heat install.pdf Vendor-INFO\Protech\install-maint.pdf / Process Technology
*Temperature Control / 1 / #1603-11030, Digital Temp Control, 1/16 DIN
Vendor-INFO\Chromalox\Chromalox-1603 manual.pdf / Chromolox
*Temp. Probe Rinse and Dryer / 1 / #G918RTDAL, 18” long probe / G. I. C.
*Float Switches / 1 / #209755, Single-switch, stainless steel rod & float
Vendor-INFO\Gems\FloatSwitch.pdf / Gems
Sprays
*Pump Wash Tank / 1 / #11019A-VD-B, stainless steel, 5 hp, 5"impeller, 240/460/3/60
Vendor-INFO\Gusher\7800-new.pdf / Gusher
Nozzles / 28 / 1/8F2520, T304SS, ⅛"NPT flat “V”, 25°, 2gpm @40 psi / BEX
Filter Housing / 1 / #1DFN2B2, DuoFlo Stainless Steel housing / Cuno
*Filter Bag / 1 / #DFG050PP2C, DuoFlo element, Polypropylene, 50 micron, other micron sizes available / Cuno
Pressure Gauge / 2 / 0-60 psi gauge with protective diaphragm seal, ¼” npt connection / Ashcroft
Drum
*Gear Reducer / 1 / Model 384, 60:1 ratio, style A, for 145TC motor
Vendor-INFO\HubCity\Red Lube & Ins.pdf / HubCity
*Motor / 1 / #CDP3585, 2 hp, 1750 rpm, 145TC frame, 180vDC
Vendor-INFO\Baldor\Baldor DC.pdf / Baldor
*DC Speed Control / 1 / #B161 Bronco Series
Vendor-INFO\SECO\BroncoII.pdf / SECO
Sprocket (Motor) / 1 / #H80P16, 80 pitch, 16 teeth, with Px 1-1/2”bore split taper bushing / Browning
Sprocket (Drum) / 1 / #80A112 with 31” bore / Browning
*Load Runner / 4 / #PLR-4Plain / Osborn
*Cam Follower / 2 / #CCFD2-1/2”SB, 2 ½” crowned cam follower / McGill
Chain Tensioner / 1 / #SE38 / LoveJoy/ Rosta
Sprocket, Tensioner / 1 / #80BB12 / Love/Joy Rosta
Chain / 10' / #80 riveted roller / US Tsubaki
Dryer
*Fan / 1 / Size 18 ¼” SQA, SISW, CCWUB rotation/outlet,
Arrangement 9SR, slip inlet, flanged outlet, housing drain, shaft cooler, with 5 hp motor, sheaved for 6000 cfm at 1.5”sp & 200ºF
Vendor-INFO\ChicagoBlower\ChicagoManual.pdfVendor-INFO\ChicagoBlower\chicago-02.dwg / Chicago Blower
*Motor, Fan / 1 / 5 hp, 1800 rpm, 3/60/230/460, 182T frame, TEFC Vendor-INFO\ChicagoBlower\416820-1.pdfVendor-INFO\ChicagoBlower\611795-22.pdfVendor-INFO\ChicagoBlower\PD18-G4903.pdf / Reliance
*Temperature Control / 1 / #1603-11030, Digital Temp Control, 1/16 DIN
Vendor-INFO\Chromalox\Chromalox-1603 manual.pdf / Chromolox
*Temp. Probe / 1 / #G912RTDAL, 12” long probe / G. I. C.
High Limit Temp. Control / 1 / ARC-519
Vendor-INFO\Chromalox\ARC-519 HiLimit.pdf / Chromalox
*Heat Elements / 9 / #KXF99GL3012-01, finned tubular 3350kw @ 277V / Caloritech
Oil Coalescer
*Pump / 1 / Model E285J, ½ hp, iron, Horizontal Centrifugal PumpVendor-INFO\Gusher\7800-new.pdf / Gusher Pumps
*Tube Bundle / 1 / 24”x24”x18” Polypropylene Tubes / AFL
*Float Valve / 1 / #124G-01A, ½” stailess steel valve with stainless steel ball and float
Vendor-INFO\Cla-Val\QuickMan.pdf Vendor-INFO\Cla-Val\TechMan.pdf / Clayvalco
Electrical
*Fuse / a/r / #TR-*-R; 250V
#AJT, #ATQR; 600V / Shawmut

COALESCING OIL SEPARATOR

MAINTENANCE PROCEDURE

1.TURN OFF OIL COALESCER.

2.TURN OFF BALL VALVE TO CLAYTON LEVEL CONTROL WHICH IS LOCATED AT THE PUMP COMPARTMENT ON THE TOP RIM OF THE TANK.

3.OPEN ALL BOTTOM DRAIN VALVES OF THE OIL SEPARATOR IN ORDER TO DRAIN ALL THE COMPARTMENTS.

4.REMOVE THE SLOTTED OIL DRAIN PIPE BY ROTATING IT COUNTERCLOCKWISE OUT OF ITS FITTING.

  1. REMOVE THE TUBE BUNDLE HOLD DOWN BARS WHICH ARE LOCATED IN THE CENTER COMPARTMENT.
  1. LIFT EACH POLYPROPYLENE TUBE BUNDLE UP AND OUT OF ITS COMPARTMENT FOR CLEANING.
  1. CLEAN OUT ALL THREE COMPARTMENTS, CLEAN THE PERFORATED PARTITIONS.
  1. CLOSE THE BOTTOM DRAIN VALVES.
  1. TURN ON BALL VALVE TO CLAYTON LEVEL CONTROL AND REFILL PUMP COMPARTMENT.
  1. REINSTALL THE TUBE BUNDLES, HOLD DOWN BARS AND SLOTTED OIL DRAIN PIPE TO THEIR ORIGINAL POSITIONS.
  1. REFILL MAIN CLEANER TANK TO OVERFLOW WEIR IF NECESSARY AND START SKIMMER PUMP IF SOLUTION LEVEL IS AT HIGH SET POINT OF THE FLOAT VALVE.
  1. THE SYSTEM WILL ATTAIN ITS OWN SOLUTION LEVELS WITH THE RECIRCULATING PUMP OPERATING CONTINUOUSLY IN A SHORT PERIOD OF TIME.

BASIC OPERATION

1. FILL ALL TANK COMPARTMENTS TO THE OPERATING LEVEL.

  1. PUMP COMPARTMENT SHOULD HAVE OPERATING LEVEL AT 2”-3”: ABOVE PUMP INLET.

B. MAIN CLEANER TANK IN WASHER SHOULD HAVE SOLUTION LEVEL AT THE OVERFLOW WEIR.

C.ADJUST CLAYTON FLOAT CONTROL TO FILL PUMP COMPARTMENT 2-3” OVER PUMP HEAD AND TO SHUT OFF WHEN FILLED 4-5” OVER PUMP HEAD. THE REST OF THIS EMPTY COMPARTMENT SERVES AS A SURGE RESERVOIR.

2. IF A ROTARY DRUM MACHINE: TURN ON DRUM DRIVE AND SPRAY PUMP IN WASHER.

3. LOAD WASHER WITH PARTS TO BE PROCESSED.

4. REFILL MAIN CLEANER TANK TO OVERFLOW WEIR IF SOLUTION LEVEL HAS DROPPED.

5. OPEN INLET VALVE TO SKIMMER PUMP.

6. PRESS SKIMMER PUMP START BUTTON LOCATED AT THE MAIN CONTROL PANEL.

7.OPEN VALVE ON DISCHARGE OF PUMP.

  1. VALVE SHOULD BE APPROXIMATELY 1/3 OPEN FOR NORMAL OPERATION.

B.THE FLOW RATE SHOULD BE AS MINIMAL AS POSSIBLE (8-10 GPM).

FLOW SHOULD BE SUFFICIENT ENOUGH TO SKIM THE SURFACE OF THE MAIN CLEANER TANK AND OVERFLOW THE WEIR.

9.ADJUST THE SLOTTED OIL RETURN PIPE IN THE CENTER COMPARTMENT BY ROTATING IT TO ACHIEVE DESIRED OIL SKIM LEVEL. THE HIGHEST POSITION OF THE SLOT IS BEST FOR INITIAL START-UP.