CHECKUP PROFESSIONAL - Leistritz · 2020. 3. 23. · CHECKUP PROFESSIONAL Protocol to service on...
Transcript of CHECKUP PROFESSIONAL - Leistritz · 2020. 3. 23. · CHECKUP PROFESSIONAL Protocol to service on...
CHECKUP PROFESSIONAL
Protocol to service on 12.02.2019
S-40114028 / Call 2862
Technician: Leis Tritz
Customer: Customer XYZ
Machine type: ZSE 50 MAXXtorque - 44D
Serial no.: 03608
OVERALL EVALUATION
The extruder has at least one critical point, which has to be fixed
immediately.
page
1. OVERVIEW 3
2. BARREL MEASUREMENT 4
3. SCREW MEASUREMENT 6
4. DRIVE TRAIN 8
5. TEMPERATURE CONTROL 11
6. VACUUM PUMP 13
7. EXTRUDER (GENERAL) 13
8. SAFETY SHUTDOWNS 14
9. DOSING SYSTEM 15
10. SUMMARY 16
11. ATTACHMENT 17
11.1. CERTIFICATE
1. OVERVIEW
The vacuum pump works properly. Some points of the CheckUp are not
accepted and requires an action.
Some barrels already passed the accepted wear limit
and has to be exchanged. All points in scope of the CheckUp are
accepted.
Some screw elements already passed the accepted wear
limit and have to be exchanged.
All points in scope of the
CheckUp are accepted.
All points in scope of the CheckUp
are accepted.
BARREL MEASUREMENT
SCREW MEASUREMENT
CHECK OF THE DRIVE TRAIN
SAFETY SHUTDOWNS
VACUUM PUMP TEMPERATURE CONTROL
DOSING SYSTEM
Next CheckUp 02.2020
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2. BARREL MEASUREMENT
Wear on the following areas detected no signs of wear
main melting zone
after the sidefeeder
discharge section
immediately 6 months 12 months
Some barrels already passed the accepted wear limit and has to be
exchanged.
The barrels 02 & 03 in the main melting zone have passed the wear limit by far and constitue a
critical condition of the maschine. The barrels 05 & 08 have also reached the accepted wear limit. All
mentioned barrels have to be exchanged immediately.
Comment:
We recommend to exchange the
yellow marked barrels within the
following period
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Customer XYZ Type: ZSE 50 MAXXtorque - 44D Date: 12.02.2019 Serial no.: 03608 Version 01
page 5 of 17
50,5
51,0
51,5
52,0
52,5
53,0
53,5
54,0
54,5
3. BARREL MEASUREMENT
25.06.18 left 25.06.18 right
barrel 11 barrel 10 barrel 09 barrel 08 barrel 07 barrel 06 barrel 05 barrel 04 barrel 03 barrel 02 barrel 01
wear limit 53,20 mm
new condition 51,50 mm
ZSE 50 MAXXtorque - 44D; 03608 Operating hour13685 h
page 6 of 17
3. SCREW MEASUREMENT
Wear on the following areas detected no signs of wear
main melting zone
after the sidefeeder
discharge section
immediately 6 months 12 months
Some screw elements already passed the accepted wear limit and
have to be exchanged.
Comment:
Many elements have passed the accepted wear limit and have to be exchanged immediately.
We recommend to exchange the
yellow marked elements within the
following period
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Customer XYZ Type: ZSE 50 MAXXtorque - 44D Date: 12.02.2019 Serial no.: 03608 Version 01
page 7 of 17
48,5
49,0
49,5
50,0
50,5
51,0
51,5
GF
A-2
-36
-10
0-A
GF
F-2
-72-3
0-A
GF
F-2
-72-1
20
-MG
FF
-2-7
2-3
0-E
GF
A-2
-72
-60
GF
A-2
-72
-60
GF
A-2
-60
-30
GF
A-2
-60
-30
KB
-4-2
-30
-30-R
eK
B-4
-2-3
0-3
0-R
eK
B-4
-2-3
0-6
0-R
eK
B-4
-2-3
0-6
0-R
eK
B-4
-2-3
0-6
0-R
eK
B-4
-2-3
0-9
0K
B-4
-2-3
0-9
0G
FA
-2-7
2-6
0G
FA
-2-7
2-6
0G
FA
-2-7
2-6
0G
FA
-2-7
2-6
0G
FA
-2-7
2-6
0G
FA
-2-6
0-6
0G
FA
-2-6
0-6
0G
FA
-2-6
0-6
0K
B-4
-2-3
0-6
0-R
eK
B-4
-2-3
0-6
0-R
eK
B-4
-2-3
0-9
0K
B-4
-2-3
0-9
0K
B-4
-2-3
0-9
0G
FA
-2-6
0-3
0G
FA
-2-7
2-6
0G
FA
-2-7
2-6
0G
FA
-2-7
2-6
0G
FA
-2-6
0-6
0K
B-4
-2-3
0-6
0-R
eK
B-4
-2-3
0-6
0-R
eK
B-4
-2-3
0-6
0-R
eK
B-3
-2-3
0-9
0K
B-3
-2-3
0-9
0G
FA
-2-6
0-6
0G
FA
-2-4
5-6
0K
B-4
-2-3
0-9
0K
B-4
-2-3
0-9
0K
B-4
-2-3
0-9
0G
FA
-2-4
5-3
0-L
GF
A-2
-72
-60
GF
A-2
-72
-60
GF
A-2
-72
-60
GF
A-2
-60
-60
GF
A-2
-60
-60
GF
A-2
-60
-60
GF
A-2
-60
-60
28.08.2018
dia
mete
r (m
m)
ZSE 50 MAXXtorque - 44D; 036083. SCREW MEASUREMENT
new conditionGFA/GFF/GFM 51,00
KS/KB 50,80 mm
wear limit 49,20 mm
Operating hour13685 hScrew design 1A
page 8 of 17
4. DRIVE TRAIN
Check of the extruder speed set value actual value deviation / %
300 299 0,33
600 588 2,00
900 901 0,11
1200 1198 0,17
deviation limit < 3 %
Check of the screw shaft sealing
Oil level check
Oil filter of gear box exchanged
Check of the gearbox for visible leaks
Data of the gearbox cooling temperature 40 °C pressure 60 bar
Oil sample taken
All points in scope of the CheckUp are accepted.
Check of the gearbox output shafts for twist
and displacement
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Customer XYZ Type: ZSE 50 MAXXtorque - 44D Date: 12.02.2019 Serial no.: 03608 Version 01
page 9 of 17
Vibration measurement
Pos 1 Pos 2
Pos 3 Pos 4
measured position
1 2 2 1 2
1 0 600 0,106 --- ---
2 0 600 0,096 --- ---
3 0 600 0,085 --- ---
4 --- --- --- --- ---
A/B B/C C/D
estimated value/ mm/s
new condition
2,8 - 4,5
zone
limit value in mm/s< 1,4 1,4 - 2,7
---
---
1
0,076
0,054
0,064
RPM/ min-1
> 4,5
last measurement / mm/s
Measured position on gearbox
Pos 1
--- ---
Pos 4 ---
---
Pos 2 --- ---
Pos 3
---
ntrollkästch
Customer XYZ Type: ZSE 50 MAXXtorque - 44D Date: 12.02.2019 Serial no.: 03608 Version 01
page 10 of 17
Relevant machine data:
3
400
104
1591
624
gear reduction i = 2 assembly of Drive/Gearbox on rack in-flexible
coupling Drive to Gearbox flexible
Comments:
---
No abnormality
0,106
1
Evaluation of the vibration measurement
Possible root cause:
Measured postion:Estimated value:
Conspicuousness:
Technical data of the drive:
pole number
power frequency / Hz
nominal speed / min-1
nominal torque / Nm
Other data:
nominal capacity / kW
Technical data of the gearbox:
Customer XYZ Type: ZSE 50 MAXXtorque - 44D Date: 12.02.2019 Serial no.: 03608 Version 01
page 11 of 17
5. TEMPERATURE CONTROL
Check of the ZIK-cooling for leakages
Inlet pressure from the heat exchanger
Filter for heat-exchanger cleaned
Water sample taken for analysis
Melt-temperature sensor checked
Heating currents checked
Cooling capacity of the main feed barrel
Check of heating & cooling characteristics
Cause if not oknot specified
magnetic valves blocked/defective
non-return valves blocked
barrel cooling channels blocked
defective Heating cartridges
Some points of the CheckUp are not accepted and requires an
action.
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Customer XYZ Type: ZSE 50 MAXXtorque - 44D Date: 12.02.2019 Serial no.: 03608 Version 01
page 12 of 17
Customer XYZ Type: ZSE 50 MAXXtorque - 44D Date: 12.02.2019 Serial no.: 03608 Version 01
page 13 of 17
6. VACUUM PUMP
Check of sealing
Displayed (relative) vacuum on manometer 800 mbar
limit:
7. EXTRUDER (GENERAL)
Alignment of extruder checked
Check of the software version
General sight check for damages
Sight check electrical cabinet
Other equipment
Screw tip wrench existing
Screw mounting device existing
Screw extractor existing
Down-stream equipment
Functional check of the screen changer
Sight check of the die plate
Knifes or cutter of the pelletizer checked
Function check of strand drying device
ok
All points in scope of the CheckUp are
accepted.
The vacuum pump works properly.
< 400 mbar
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Customer XYZ Type: ZSE 50 MAXXtorque - 44D Date: 12.02.2019 Serial no.: 03608 Version 01
page 14 of 17
8. SAFETY SHUTDOWNS
PM 1 PLC shutdown
196 194 1,02
switch-off value 245 243 0,82
accep. tolerance for shutdown < 5 %
PM 2 PLC shutdown
1,02
switch-off value 1,02
accep. tolerance for shutdown < 5 %
PM 3 PLC shutdown
1,02
switch-off value
accep. tolerance for shutdown < 5 %
Proximity switch for safety clutch
Overload protection
Underload protection
Emergency switches
Comments:
deviation in %
actual value in
bar
displayed value
in bardeviation in %
actual value in
bar
displayed value
in bardeviation in %
actual value in
bar
displayed value
in bar
version without PLC shutdown
All points in scope of the CheckUp are
accepted.
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Customer XYZ Type: ZSE 50 MAXXtorque - 44D Date: 12.02.2019 Serial no.: 03608 Version 01
page 15 of 17
9. DOSING SYSTEM
Number of feeders: 1
Feeder 1 Type Brabender DDW - MD3 - DS28 - 20
Check of load cell with calibration weight
0,000 0,500 0,0
0,000 1,000 0,0
limit deviation: < 2 %
Set leverage factor (only Brabender) 0,999
Bellow + compensator available? available
Comments:
deviation / %
0,500 0,500
1,000 1,000
m_after
adjustment in
self weight
in kg
m_start in
kg
m_before
adjustment in
All points in scope of the CheckUp are
accepted.
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Customer XYZ Type: ZSE 50 MAXXtorque - 44D Date: 12.02.2019 Serial no.: 03608 Version 01
page 16 of 17
10. SUMMARY
Some barrels as well as some screw elements have passed the wear limit by far. This is a
critical condition for the machine and a counteraction is necessary.
Beside of that, a frozen polymer was between the screw and the output shaft of the gearbox and
caused an axial shift of the whole screw. This was noticed during the service because of the
grinding marks, which were visible on some elements.
The extruder has at least one critical point, which
has to be fixed immediately.
Customer XYZ Type: ZSE 50 MAXXtorque - 44D Date: 12.02.2019 Serial no.: 03608 Version 01
page 17 of 17
11. ATTACHMENT
Measuring equipments are checked and have been satisfied according to
the requirements of the DIN EN ISO 9001 :2015
Customer XYZ Type: ZSE 50 MAXXtorque - 44D Date: 12.02.2019 Serial no.: 03608 Version 01