AMD 0001 W912ER22R0038 Bidder Descriptions.pdf

Owner Manual

HD-18.1

Horizontal, Belt-Driven

Balancing System

Balancer Models:

HD-18.1 & HD-18.1J

Owner Reference Information Please use this sheet to keep reference information for this balancing system.

Balancer data:

Machine Manufacturer: American Hofmann Corporation

Machine Model: ___________________________________________

Serial Number: ____________________________________________

Owner: __________________________________________________

Installation Date: __________________________________________

Contacts, references, and notes:

AHC, Service & Sales: 1.800.446.0997 or 1.434.522.0300

HD-18.1

Horizontal, Belt-Driven Balancing System

Balancer Models:

HD-18.1 & HD-18.1J

Owner Manual

Technical Manual Identification:

PD-HD-18.1

Issue Date: 2005-04-20

American Hofmann Corporation Precision Balancing Systems

3700 Cohen Place Lynchburg, VA 24501 USA

Voice: 1.434.522.0300 • 1.800.446.0997 Fax: 434.846.1340

Email: Sales@americanhofmann.com Service.Dept@americanhofmann.com

Website: http://www.americanhofmann.com

© 2005 American Hofmann Corporation All Rights Reserved.

Printed in the United States of America.

This manual contains general instructions for the operation of an American Hofmann Corporation balancing system. If there are any questions, please contact American Hofmann Corporation at

1.800.446.0997. Included with this balancing system is American Hofmann Corporation proprietary software. Purchase of this system includes license to use this software but all rights to the software remain the property of American Hofmann Corporation.

No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any form by any means without the express written consent of American Hofmann Corporation. This work may be copied or printed without modification when provided by American Hofmann Corporation to its customer as support for equipment sold, but only when used solely for that purpose.

American Hofmann Corporation makes no representations or warranties with respect to the contents or use of this manual and specifically disclaims any express or implied warranties of merchantability or fitness for any particular purpose. Information in this document is subject to change without notice and does not represent a commitment on the part of American Hofmann Corporation.

American Hofmann Corporation Model HD-18.1 and HD-18.1J Balancing System, Owner Manual

Contents Section and Title Page How to Use This Manual ......................................................................................a

Who Should Use This Manual .......................................................................................a Content and Organization...............................................................................................a Text and Graphical Conventions................................................................................... b Related Documentation ..................................................................................................c

Test Report................................................................................................................c Safety ...................................................................................................................... e

Preventing Accidents and Injury ....................................................................................e If You Operate or Maintain the Machine..................................................................e Others Close to the Machine.....................................................................................e Specific Safety Practices........................................................................................... f

Safety Symbols in This Manual .................................................................................... g 1, Getting to Know the Balancing System........................................................1-1

Balancer Overview..................................................................................................... 1-1 Unbalance Measure............................................................................................... 1-1 Operational Design ............................................................................................... 1-2

Support/Measure Assembly ....................................................................................... 1-5 Belt Drive System ...................................................................................................... 1-4 Control Cabinet .......................................................................................................... 1-5 HD Electronic: Operator Interface and Control ........................................................ 1-6

HDplus Electronic Specifications ......................................................................... 1-6 Technical Specifications, HD-18.1 Balancer for Standard Applications ................... 1-7 Technical Specifications, HD-18.1J Balancer for Turbine Applications ................... 1-9 Identifying Your Balancing System......................................................................... 1-11

2, Operating the Machine ..................................................................................2-1 Operator Controls....................................................................................................... 2-2

Control Panel ........................................................................................................ 2-2 Power Controls...................................................................................................... 2-3 HD Electronic Controls......................................................................................... 2-3

Powering On and Shutting Down............................................................................... 2-4 Setting Up for Operation ............................................................................................ 2-5

Adjusting the Work Support Pedestals ................................................................. 2-5 Mounting and Securing the Rotor......................................................................... 2-7 Connecting the Belt Drive..................................................................................... 2-9 Photocell Setup and Calibration.......................................................................... 2-10

Operating Procedures ............................................................................................... 2-12 3, Preventive Maintenance ...............................................................................3-1

Maintenance Schedule ............................................................................................... 3-1 Frequency of Maintenance.................................................................................... 3-1 Keeping Records................................................................................................... 3-2

Contents i

Model HD-18.1 and HD-18.1J Balancing System, Owner Manual American Hofmann Corporation ii Contents

Contents – Continued Section Title Page 3, Preventive Maintenance – Continued

Daily Maintenance ..................................................................................................... 3-2 Visual Inspection .................................................................................................. 3-2

Weekly Maintenance.................................................................................................. 3-3 Visual Inspection .................................................................................................. 3-3 Lubrication............................................................................................................ 3-3

Monthly Maintenance ................................................................................................ 3-4 Dust Buildup on Electrical Components............................................................... 3-4 Performance Tests................................................................................................. 3-4 Cleaning the Machine ........................................................................................... 3-5 Cleaning Inside the Cabinets ................................................................................ 3-6

4, Troubleshooting............................................................................................. 4-1 A, Customer Support ........................................................................................A-1

Customer Service ...................................................................................................... A-1 Technical Assistance................................................................................................. A-2

Technical Phone Support ..................................................................................... A-2 Maintenance Contracts ........................................................................................ A-2

Returning Material .................................................................................................... A-3 Ordering Spare and Replacement Parts..................................................................... A-4

Using the Parts List.............................................................................................. A-4 How to Contact AHC................................................................................................ A-5

B, Warranty .......................................................................................................B-1 Warranty A.................................................................................................................B-1 Warranty B.................................................................................................................B-3

C, Balancing Overview......................................................................................C-1 Introduction................................................................................................................C-1 Rotor Characteristics..................................................................................................C-2

Axis and Center of Mass.......................................................................................C-2 Types of Rotor Unbalance ....................................................................................C-4

Factors that Influence Unbalance...............................................................................C-6 Balancing Speed ...................................................................................................C-6 Rotational Forces ..................................................................................................C-6 Resonance .............................................................................................................C-7

Unbalance Calculation ...............................................................................................C-8

How to Use This Manual

Contents Who Should Use This Manual ............................................................................................a Content and Organization....................................................................................................a Text and Graphical Conventions ........................................................................................ b Related Documentation .......................................................................................................c

Test Report .....................................................................................................................c

Who Should Use This Manual This manual describes your American Hofmann Corporation precision balancing system.

It is intended to assist two types of users in understanding and operating the system:

• Those who run the machine during production balancing

• Those who set up and maintain the machine

To effectively use this manual, all readers should be experienced or previously trained in operating and maintaining industrial balancing machines.

Content and Organization The manual is organized into the sections described below.

Contents, serves as an outline and locator of the information provided in this manual.

How to Use This Manual provides an overview of the manual’s purpose, structure, content, and text conventions. Includes a list of related documents.

Safety Precautions provides an overview of safety practices and guidelines that must be observed when operating the balancing system.

Section 1, Getting to Know the Balancing System, describes your balancing system hardware design, operational features, and technical specifications.

Section 2, Operating the Machine, covers system startup, operation, setup and adjustments, and parts replacement needed for operating the balancing system.

Section 3, Preventive Maintenance, provides recommended upkeep and inspection routines to help you take care of your machine.

Section 4, Troubleshooting, helps you determine and fix some machine malfunctions.

Appendix A, Customer Support, describes technical support services provided by AHC, parts ordering instructions, and contact information.

How to Use This Manual a

Appendix B, Warranty Information, provides American Hofmann Corporation’s warranty for both domestic and international purchases.

Appendix C, Balancing Overview, provides a brief overview of the theory of balancing, to be used as reference.

Text and Graphical Conventions To make the content easier to understand, this manual uses specific text conventions.

Convention Meaning

Numbered list Procedural steps that you must follow in the order noted (for example, 1, 2, 3)

Alphabetized list Procedural substeps (of numbered steps) that you must follow in the order noted (for example, a, b, c)

Bullets (•) Related items or procedures, but the order does not matter

Indicates that a procedure follows.

Arial When describing software, indicates a file or directory name Arial Bold When describing software, indicates the actual command or option that is shown on a menu or dialog box

Additionally, specific symbols and words are used to indicate safety conventions or draw attention to a condition that you should observe (refer to the Safety Precautions section of this manual).

All drawings and screen shots are intended as examples of a concept or application, but may differ slightly for your specific system b How to Use This Manual

How to Use This Manual c

Related Documentation AHC provides support documentation for its balancing systems on a CD as PDF files (Adobe® portable document format). In addition to this technical manual, the following documents also apply to your balancing system and may assist in understanding or providing reference information:

• HD Electronic User Guide

• Receiving, Storage, and Installation Guidelines (document number PD-1001)

• Parts List (Bill of Material Tree)

• Floor and Foundation Plan Drawings (if provided)

• Assembly Drawings

• Wiring Diagrams

• Printed Wiring Board Drawings

Test Report AHC sets up and calibrates each balancing system to meet customer specifications before shipping it to the jobsite. Service technicians then fine-tune this machine during commissioning, making it ready for operation. AHC records the setup values for your specific part in a Test Report, which is provided with your machine when shipped.

d How to Use This Manual

User Notes:

American Hofmann Corporation Precision Balancing Systems

Safety Precautions

Contents Preventing Accidents and Injury .........................................................................................e

If You Operate or Maintain the Machine .......................................................................e Others Close to the Machine ..........................................................................................e Specific Safety Practices ................................................................................................ f

Safety Symbols in This Manual ......................................................................................... g

Preventing Accidents and Injury American Hofmann Corporation (AHC) balancing systems are very safe to operate and maintain when all safety guidelines are followed. However, any machine can be dangerous if precautions are not observed at all times.

If you have any questions about the safe operation of this machine, contact AHC’s Technical Phone Service at 1.800.446.0997, press 4 or + 1.434.522.0300, press 4 (refer to Appendix A).

If You Operate or Maintain the Machine To prevent accidents and injury, any person operating or maintaining the balancing system must be alert, careful, and strictly observe all safety precautions at all times.

These precautions include:

• Practices and guidelines learned by persons professionally trained in electrical and mechanical safety practices

• All precautions noted in this manual, on the machine, and in the area of the machine

• “Common sense” safety practices

Others Close to the Machine Anyone close to a machine that is running or simply powered on is responsible for understanding and observing applicable safety precautions. These include:

• Be aware of the potential dangers of mechanical and electrical equipment. Maintain a safe distance and not touch any part of a running machine, including cabling.

• Whether power is on or off, do not touch cabling, cable connections, or anything inside the machine.

• Do not distract or interfere with operators or maintenance personnel in a way that may distract them from observing safety precautions.

Safety Precautions e

Precision Balancing Systems American Hofmann Corporation

Specific Safety Practices

• Know the Machine. Make yourself aware of potential hazards while around the machine. It is extremely important that no person operates, attempts to operate, services, or attempts to service the machine before becoming thoroughly familiar with the machine.

• Avoid Pinch Points. Because of the nature of the machine, many pinch points cannot be marked. Do not leave the operator console until the machine has been disengaged and the power turned off.

KEEP AWAY FROM ALL PINCH POINTS. Serious injury will occur if fingers, hands, feet, or any other body part are placed between pinch points. Do not place hands, feet, or clothing near pinch points during machine operation or while power is on.

• Be Aware of Shock Hazard. This machine is operated by a high voltage electrical supply, which presents an electrical risk if precautions are not strictly followed.

SEVERE SHOCK HAZARD. To avoid serious or fatal injury caused by contact with high voltages, do not open electrical cabinets while the power supply is connected.

Disconnect power and compressed air (if applicable) before attempting to inspect or service the machine.

The electronic cabinet contains high voltage circuits and sensitive electronic equipment. To prevent personal injury or expensive damage to computer systems, allow only trained maintenance personnel access to the cabinet.

• Maintain the Work Area. To prevent accidents, the working area in and around the machine must be properly maintained. You must immediately correct any substance that could create a slippery or cluttered condition.

• Observe Rotor Safety. Some rotors must be balanced, then tested at or above their service speed, which may increase the risk or danger of a rotor accident. It may be necessary to provide an enclosure to retain the rotor in case of rupture

When operating the machine, use the following safety precautions:

• Do not operate machine unless you have been instructed in its use and are thoroughly familiar with its operation.

• Do not operate machine with any of the guards or safety interlocks removed.

• Keep clear of machine when it is running. Constrain long hair, loose clothing, and dangling jewelry or accessories while in the area of operation. Do not reach into the running machine for any reason.

f Safety Precautions

• While machine is balancing, the operator should stand back at a safe distance from the rotating rotor, but within reach of the Start and Stop buttons on the Control Station.

• Be aware that fatal voltages are present in the control cabinets. Always shut off air, oil, and electricity before working on the machine.

In case of emergency, immediately stop the machine by pushing the Stop button.

Safety Symbols in This Manual Before operating or maintaining the balancing system, read the procedures in this manual, carefully. Note all safety alerts and practices. These are identified by symbols and words, as follows.

WARNING

Alerts you to a situation or practice that can seriously injure or kill a person if safety practices and all precautions are not strictly followed. In color-enabled media, an orange background is used to additionally flag the word WARNING.

CAUTION

Alerts you to a situation or practice that can injure a person or damage the machine and equipment if safety practices all precautions are not strictly followed. In color-enabled media, a yellow background is used to additionally flag the word

CAUTION.

Alerts you to WARNINGs or CAUTIONs when a more specific symbol is not available for the type of alert.

Alerts you to an electrical WARNING.

Alerts you to a pinch-point WARNING.

Note Highlights a condition or procedure that is important, but not associated with safety or damage.

Safety Precautions g h Safety Precautions

1 Getting to Know the Balancing System

Contents Balancer Overview .......................................................................................................... 1-1

Unbalance Measure .................................................................................................... 1-1 Operational Design..................................................................................................... 1-2

Support/Measure Assembly............................................................................................. 1-4 Belt Drive System ........................................................................................................... 1-5 Control Cabinet ............................................................................................................... 1-5 HD Electronic: Operator Interface and Control ............................................................. 1-6

HDplus Electronic Specifications .............................................................................. 1-6 Technical Specifications, HD-18.1 Balancer for Standard Applications ........................ 1-7 Technical Specifications, HD-18.1J Balancer for Turbine Applications ........................ 1-9 Identifying Your Balancing System .............................................................................. 1-11

Balancer Overview

Unbalance Measure (Refer to Figures 1-1 and 1-2.) The models HD-18.1 and HD-18.1J Balancing Systems are horizontal, floor-mounted machines designed for one or two-plane measurement of unbalance in mechanical components and assemblies. Both models incorporate the same basic design and operation. However, the “18.1” is used for standard applications, while the “18.1J”meets ARP specifications for turbine applications (see Technical Specifications).

Both machines use the force-measuring method for calculating the amount and location (angle) of unbalance. During the measure cycle, the rotor rests on the roller bearings (or optional V-blocks or half-shells) of force-measuring, hard-bearing supports. When the rotor spins, the unbalance creates forces that are directly proportional to the amount (the greater the unbalance, the greater the force). Transducers within the supports sense the force and convert it to alternating electrical voltages (signals).

A separate, industrial-rated control cabinet houses the HDplus Electronic Measuring Instrument (the HD Electronic), which is the computer that provides processing, memory, program storage, and operator interface programs. It communicates with the other system components to achieve intelligent and automated system control. Operating parameters and settings are customized and fine-tuned in the setup and maintenance process for each different application.

When the rotor spins, the unbalance creates forces that are directly proportional to the amount (the greater the unbalance, the greater the force). The transducers sense the force and convert it to alternating electrical voltages (signals). These signals are transmitted through shielded cables to the HD Electronic.

Getting to Know the Balancing System 1-1

The machine calculates amount of unbalance correction as weight to be either added or removed at the selected correction planes. It determines the location of correction in relation to a reference point, and displays the results on the HD Electronic screen as both polar-graphic and digital readings.

The belt drive system is a standard, self-adjusting design that efficiently turns the rotor without slippage or strain to ensure accurate force-measurement by internal pressure-sensing devices. The belt is mounted in an interlacing configuration on a set of pulleys and over the rotor, then tightened by the pneumatic belt tension regulator. The belt drive motor moves the belt, which then turns the rotor. The large area of contact

For each design, the rotor rests on the roller bearings of adjustable force-measuring supports. These balancing system components are described in more detail below.

Operational Design The HD-18.1 and HD-18.1J balancing systems physically consists the following main components (see Figure 1-2):

• Support/Measure Assembly holds the rotor and includes the measuring devices (photocell assembly and internal pressure-sensing devices). Rigid, hard-bearing supports ensure high precision, eliminating the need to calibrate for each rotor type.

These easily adjust or change-out to fit different rotor lengths and journal diameters within a defined range.

• Belt Drive System consists of a motor, pulleys, and belts in an interlacing, configuration that can operate variable speeds.

• Control Cabinet contains the HD Electronic, operator controls, and electrical control components. The HD Electronic is the computer that provides processing, memory, program storage, and operator interface programs.

Electrical Control Cabinet Measure Assembly

D at a

I/O

C on tro l

Control

Data

Control

HD

Electronic

Electrical & Operator Control

Force Measuring Components

Belt Drive System

Drive Motors & Components

Figure 1-1. Simple Functional Block Diagram of Balancing System

1-2 Getting to Know the Balancing System

Electrical Control Cabinet

Operator Control Panel

HD Electronic

Printer Shelf

Main Power Disconnect Switch (on back, outside).

Belt Drive Motor

Pedestal Lock Handle

Negative Load (Safety) Arm

Belt Roller

Roller Bearings (can also hold V-Block)

Force-Measuring Pickups Inside

Work Support Pedestal

Pneumatic Belt Tension Adjustor

Pedestal Adjustment Wheel

Photocell Support Rod

Machine Bed

End ThrustEnd Thrust

Keypad

Figure 1-2. HD-18.1 Balancer with Roller Bearing Type Work Supports

Getting to Know the Balancing System 1-3

Support/Measure Assembly (Refer to Figure 1-2.)

Work Support Pedestals – A set of two sturdy work support pedestals mount onto the machine bed rails. By loosening the lock bolts, these can be adjusted (moved) along the rails for rotors of different lengths. Each pedestal includes the following components:

• Roller bearings for holding rotors with journal diameters from 1.18 inches to 3.14 inches. (30 mm to 80 mm) in diameter

• Optional set of V-blocks for standard (non-turbine) applications

• Negative load arm, which is a safety arm with negative load rollers (hold down bars) to keep the rotor down firmly on the roller bearings

• End thrust assembly, which keeps the rotor from moving horizontally on the roller bearings

• Force-measuring pickups, located inside the pedestal and covered by a plate

Half Shell Supports (Option) – (Refer to Figure 1-3). Set of saddle bearings (one for each pedestal) for mounting some types of rotor assemblies. The bearings can include stuffers to a customer-specified bore.

Machine Bed – Precision-machined steel base or (optional) cast iron base provides a sturdy foundation to the Support/Measure Assembly, preventing vibration from affecting the unbalance readings in the part being balanced. The bed can be anchored to the floor.

Options to increase bed length include bed extensions or a separate short bed placed at any axial distance from the main bed.

Photocell Assembly – Used for monitoring the rotor rpm and angle reference. This assembly mounts onto the support with mounting brackets.

Figure 1-3. Measure Assembly with Half-Shell Type Work Supports

1-4 Getting to Know the Balancing System

Belt Drive System (Refer to Figure 1-2.) The belt drive system includes the following:

Belt Drive Motor – Supplies the rotational power to the drive system by moving the belt (Refer to Technical Specifications for motor type.) The operator regulates motor speed using the Speed dial on the control panel.

Belt Rollers (Pulleys) – A belt is mounted in an interlacing configuration on the set of pulleys.

Drive Belt – Flat, endless belt interlaces over the drive motor pulley (which is covered by a guard), as well as the rotor and pulleys in the Support/Measure Assembly. When the belt is tightened onto the pulleys, the turning motor drives the pulleys, which move the belt, spinning the rotor. An optional underdrive belt arrangement is available.

Pneumatic Belt Tension Adjustor – Driven by air pressure and activated from the operator control panel, this device moves the bottom belt pulleys, automatically removing slack from the drive belt. This eliminates the need to manually adjust the belt tension.

Air Pressure Regulator – Air supply connection and pressure control, used to regulate pressure of air supplied to pneumatics.

Control Cabinet (Refer to Figure 1-2.) The cabinet is a steel enclosure that houses the following:

Electrical Control Components – Balancing system’s control circuitry, I/O wiring, and power distribution components, including fuses.

Main Disconnect (Power) Switch – A manually controlled on/off switch, usually located on the outside back of the cabinet, connecting the incoming source power to the balancing system. In the On position, power flows to all system components; the Off position disconnects source power from all components.

SEVERE SHOCK HAZARD. To avoid serious or fatal injury caused by contact with high voltages, do not open electrical cabinets while the power supply is connected. Disconnect power and compressed air (if applicable) before attempting to inspect or service the machine.

The electronic cabinet contains high voltage circuits and sensitive electronic equipment. To prevent personal injury or expensive damage to computer systems, only trained maintenance personnel should access the cabinet.

HD Electronic – See the following section, HD Electronic: Operator Interface and Control.

Operator Control Panel – Contains the manual operator controls for running the balancing system (refer to Section 3).

Getting to Know the Balancing System 1-5

HD Electronic: Operator Interface and Control The is HDplus Electronic Measuring Instrument (the HD Electronic) is the computer that provides processing, memory, program storage, and operator interface programs. It communicates with the other system components to achieve intelligent and automated system control. Operating parameters and settings are customized and fine-tuned in the setup and maintenance process for each different application.

The HD Electronic is extremely flexible and accurate. Its standard software features meet both typical and specific balancing needs. Optional features provide additional benefits that may be preferred by the customer for their application.

Refer to the HDplus Electronic technical manual (User Guide) for information about using the electronic, including both standard and optional features.

HDplus Electronic Specifications Measuring Range Options:

36 – 3600 rpm 60 – 6,000 rpm 600 – 6,000 rpm 360 – 10,000 rpm 360 – 25,000 rpm

Display:

Type: 13-inch, color CRT

Resolution: High, 5-digit, auto-ranging

Reading: Digital & polar graphic display of unbalance amount & location (0° to 359°), balancing speed (in rpm), intolerance indication, setup screens

Data Storage: Type: Collected data is stored in random-access memory (RAM), providing rapid updates

Capacity: 50 rotor memories containing all rotor parameters and unique calibration

Electrical Characteristics:

110 V, single phase, 60 Hz

1-6 Getting to Know the Balancing System

Technical Specifications, HD-18.1 Balancer for Standard Applications

Weight of rotor: Maximum: 550 lb (250 kg) Maximum per pedestal: 275 lb (125 kg) Minimum: 1 lb (.5 kg)

Rotor diameter (maximum):

Over belt tensioner: 25 in (635 mm) Over rest of bed: 40 in (1016 mm)

Rotor length between center of bearings:

Maximum: 75 in (1905 mm) Minimum: 5.5 in (139 mm)

Bearing journal diameter options:

.23 in to .98 in ( 6 – 25 mm) .39 in to 1.57 in (10 – 40 mm) .78 in to 2.36 in (20 – 60 mm)

1.18 in to 3.14 in (30 – 80 mm)

3.14 in to 5.51 in (80 – 140 mm)

V-block option: 1.00 in to 6.00 in (25 – 152 mm)

Half-shell option, set: Max. bore diameter: 6.00 in (152 mm) Set stuffers: To specified bore

Balancing speeds: Infinitely variable, dependent on drive diameter of rotor

Machine base length: Standard: 80 in. (2032 mm) Bed extension options: 20 in (508 mm) increments Separate short bed option: 20 in (508 mm)

Test rotor (optional): 56 lb (25.4 kg) with test weights, driveshaft adaptation, journal diameter 1.45” (36.83 mm), storage container, and certification

Sensitivity (displace-ment of C.G.):

≤4 microinch

WN2: 1525 × 106 × rpm2 Unbalance reduction ratio (URR):

95%

Voltage: 60 Hz: 230 or 460 V ac, 3-phase 50 Hz: 380 – 440 V ac, 3-phase or 220 V ac, 1-phase

Electrical requirements:

Power consumption: 1.5 kW Approximate full current load: 7 A @ 230 V, 4 A @ 460 V

Air requirements: 1 SCFM per cycle

Getting to Know the Balancing System 1-7

HD-18.1 Technical Specifications – Continued:

Drive options: Drive motor: 2 hp ac, infinitely variable, ac frequency, dynamic braking Belt drive: Enlacing arrangement with pneumatic tensioning.

Belt drive option: Underdrive arrangement, maximum diameter over belt tensioner = 21 in (533.4 mm) Belt options: ¾ in x 90 in; ¾ in x 98 in; ¾ in x 106 in Drive pulley diameter:

– Large: 5.25 in (133 mm)

– Small: 2.5 in (63 mm)

Shipping dimensions (estimated):

Length = 90 in (2286 mm) Width = 60 in (1524 mm) Height = 65 in (1651 mm)

Weight (estimated): 3000 lb (1360 kg)

Note Refer to the machine drawings to identify the options that apply to your balancer.

1-8 Getting to Know the Balancing System

Technical Specifications, HD-18.1J Balancer for Turbine Applications

Standards: Meets or exceeds SAE ARP 4048 Specifications for Horizontal Machine Class 300

Weight of rotor: Maximum: 550 lb (250 kg) Maximum per pedestal: 275 lb (125 kg) Maximum at 900 rpm: 550 lb (250 kg) Minimum: 1 lb (.5 kg)

Rotor diameter (maximum):

Over belt tensioner: 35 in (889 mm) Over bed: 50 in (1270 mm)

Rotor length between center of bearings:

Maximum: 75 in (1905 mm) Minimum, belt drive inboard of supports: 5.5 in (140 mm) Minimum, belt drive outboard of supports: 3.0 in (76 mm)

Bearing journal diameter options:

.39 in to 1.57 in (10 – 40 mm)

1.18 in to 3.14 in (30 – 80 mm)

3.14 in to 5.51 in (80 – 140 mm)

Half-shell option, set: Max. bore diameter: 4.00 in (102 mm) or 6.00 in (152 mm) Set stuffers: To specified bore

Balancing speeds: Infinitely variable, 60 – 2400 rpm

Machine base length: Standard: 80 in. (2032 mm) Bed extension options: 20 in (508 mm) increments

Proving rotor (optional):

50 lb (22 kg) with test masses to ARP 4162, storage container, and certification

Sensitivity (displace-ment of C.G.):

≤4 microinch

WN2: ≥1000 × 106 × rpm2 Unbalance reduction ratio (URR):

95%

Voltage: 60 Hz: 230 or 460 V ac, 3-phase 50 Hz: 380 – 440 V ac, 3-phase

Electrical requirements:

Power consumption: 1.5 kW Electrical service: 30 A Approximate full current load: 7 A @ 230 V, 4 A @ 460 V

Air requirements: ≥80 psi @ 20 SCFM per cycle Pedestal option: To accommodate swing diameter of 63 in (1600 mm)

Getting to Know the Balancing System 1-9

HD-18.1J Technical Specifications – Continued:

Drive options: Drive motor:

– Standard: 2 hp ac, infinitely variable, ac frequency, bidirectional, dynamic braking, 1750 rpm base speed, timed acceleration ±1%

– Options: 5 hp ac or 10 hp dc Belt drive: Enlacing arrangement with pneumatic tensioning.

Belt drive option: Underdrive arrangement, maximum diameter over belt tensioner = 21 in (533.4 mm) Belt options: ¾ in x 90 in; ¾ in x 98 in; ¾ in x 106 in Drive pulley diameter:

– Large: 5.25 in (133 mm)

– Small: 2.5 in (63 mm)

Shipping dimensions (estimated):

Length = 90 in (2286 mm) Width = 60 in (1524 mm) Height = 65 in (1651 mm)

Weight (estimated): 3000 lb (1360 kg)

Refer to the machine drawings to identify the options that apply to your balancer.

1-10 Getting to Know the Balancing System

Identifying Your Balancing System A balancing machine’s model number is structured in a way that identifies the basic configuration, independent of customer options. This includes type of measuring system, correction station (if included), and Electronic (see Figure 1-4).

AHC also assigns a unique serial number to each customer project. This number is required when you contact AHC because it identifies your machine model plus any additional custom engineering.

You can find the balancing system’s model and serial numbers on both the machine nameplate and parts list. Additionally, the PC Balancer program’s Help menu includes the serial number and identifying information about your software version and special options.

aaa b- ### .# c (no spaces between nos. & letters)

Type of Electronic (2 or 3 letters)

F = flat spring table R = round spring table S = side spindle V = vertical T = turbo

Size of machine (1 to 3 nos.);

colon separates nos. if 2 different size work supports

.1 = belt drive on horizontal machine single plane on vertical machine single axis on moment scale .2 = belt/end drive on horizontal machine 2-plane on vertical machine .3 = air drive dual axis on moment scale No no. = end drive on horizontal machines

ALT = alternator C = computer (disk drive) CB = core balancer CW = compression wheel D = drill correction G = gyro balancer IP = industrial power J = jet application M = mill correction N = nibbler SP = special feature W = woodworking WS = wheel & shaft

Figure 1-4. Machine Identification (Model Number) Conventions

Getting to Know the Balancing System 1-11

1-12 Getting to Know the Balancing System

2 Operating the Machine

Contents Operator Controls ............................................................................................................ 2-2

Control Panel.............................................................................................................. 2-2 Power Controls........................................................................................................... 2-3 HD Electronic Controls.............................................................................................. 2-3

Powering On and Shutting Down.................................................................................... 2-4 Setting Up for Operation ................................................................................................. 2-5

Adjusting the Work Support Pedestals....................................................................... 2-5 Mounting and Securing the Rotor .............................................................................. 2-7 Connecting the Belt Drive.......................................................................................... 2-9 Photocell Setup and Calibration............................................................................... 2-10

Operating Procedures .................................................................................................... 2-12

Note Read all instructions in this section before operating this machine

To balance a rotor on the HD-18.1 and HD-18.1J machines, an operator should be thoroughly familiar with the machine (see Section 1), all operator controls, and correct power on and off procedures. Additionally, the operator must perform two main procedures:

• Mechanically set up the machine

• Run the balancing operation

Figure 2-1 provides a simple block diagram of these procedures.

Adjust Work

Supports

Mount & Secure Rotor

Connect Belt

Drive

Set Up, Calibrate Photocell

Mechanical Setup

Measure (Control Panel, Electronic)

HD

Electronic

Setup

Operating Procedures

Correction

Figure 2-1. Simplified Block Diagram of Balancing Operation

Operating the Machine 2-1

Operator Controls Control Panel The control panel contains controls and indicators used to operate the balancing system.

The configuration, type, and function of these devices depends on the balancer options selected by the customer and their operation requirements.

The following section defines controls that may be included on your balancer. The nameplate above or below each control panel item identifies its function.

Standard controls (refer to Figure 2-2):

• Start pushbutton. Begins the balancing cycle. When pressed, starts the motor, which then starts the belt and rotor rotation.

• Stop pushbutton. When pressed, stops the motor, which then stops the belt and rotor rotation.

• Belt Tension (On or Off) selector switch. Position turns on or off the pneumatic belt tension adjustor, which automatically tightens the belt.

• Speed dial. Dial setting selects the motor speed for a measure, which determines how fast the rotor spins. You should start off at a slow speed and gradually increase it until the desired measuring speed is reached.

• Fault Reset lighted pushbutton. On (lit) when a drive fault occurs. When pressed, resets the drive fault signal to the electronic, allowing the motor to be restarted.

Figure 2-2. Example of Standard Control Panel

Optional controls:

• Fwd/Rev (forward/reverse) selector switch. Position sets the direction of motor rotation, which determines the direction that the belt and rotor spins. Used in systems with bidirectional drive motors.

• Fault Reset pushbutton and Fault light. Option used instead of single Fault Reset “lighted” pushbutton. Light turns on when a drive fault occurs. Pressing the Fault Reset pushbutton resets the drive fault signal (allowing the motor to be restarted) and turns off the Fault light.

2-2 Operating the Machine

A drive fault can be caused by any detected problem with the belt drive motor, such as pulling too much power or inability to reach desired speed. A drive fault stops the motor.

Power Controls These controls power on (apply power to) the balancer’s electrical and electronic components.

• Main Disconnect switch. Power switch for the balancing machine, including the control panel, located on the electrical cabinet.

• On/Off switch. Switch turns power on and off to the HD electronic; normally located on the back of the electronic.

Note For these controls to function, the power cable must be connected to a power source of the correct rating.

HD Electronic Controls The HD Electronic provides menus and selectable options used to set up parameters for the balancing operation. It includes the following operator controls:

• Keyboard. Located below the monitor. Includes alphabetical, numeric, and function keys used to access menus and enter setup and parameter values in the HD electronic.

• Security key. Located next to the keyboard. Three positions provide security access for balancer operation and maintenance functions (see Figure 2-3):

– Program. Only used to disable and edit ladder logic and allow saving of rotor memories to memory slots.

– Setup. Allows full access to all functions of the HDplus electronic.

– Operate. Allows use of the Make Setup and Recall Setup keys, editing, printing, and performing measuring and correction functions. Does not allow access to programming (Program) and some Setup functions.

Refer to the HDplus Electronic technical manual (User Guide) for information about using the keyboard and security key.

Security Key Slot

Keyboard

Monitor

HD Electronic (no base)

Figure 2-3. HD Electronic Controls

Operating the Machine 2-3

Powering On and Shutting Down Note Do not power-on the machine unless setup has been completed, or you are directed to turn on power during the setup procedure.

The input power cabling should already be connected to the machine, which was prepared for operation during commissioning.

To power on the machine, do the following:

1. Turn the Main Disconnect (Power) Switch (located on the electrical cabinet) to the On position. This provides power to the belt drive motor and control cabinet.

Note The motor is powered up, but not running.

2. Turn the On/Off Switch (on the back of the HD Electronic) to the On position. This powers on the Electronic and starts up the program.

The balancing system is now ready for operation (refer to Setting Up for Operation).

To power off (shut down) the machine, do the following:

1. If the drive motor is running, press the Stop pushbutton.

2. Turn the On/Off Switch to the Off position. This powers off the Electronic, closing the program.

3. Turn the Main Disconnect Switch to the Off position.

2-4 Operating the Machine

Setting Up for Operation Before you can run a production cycle on the balancing system, you must make sure that the following mechanical areas are set up as needed for the rotor type:

1. Work Support Pedestals are adjusted to fit the rotor

2. Rotor is mounted onto the supports and secured by the safety arms and end thrusts

3. Belt is correctly threaded through the pulleys and tightened around the rotor

4. Photocell assembly is correctly positioned and calibrated (remote angle set up)

Adjusting the Work Support Pedestals Note At this point in the Mechanical Setup procedure, the rotor should not be loaded or resting on the balancer.

Adjust the work supports to fit rotor length, as follows:

1. Loosen the pedestal lock handles on each side of both work support pedestals and the lock bolt on the belt roller (see Figure 2-4).

2. Turn the pedestal adjusting wheels to move the work support pedestals along the machine bed. The distance between them should fit the mounting points of the rotor to be balanced.

3. Turn the belt roller adjusting wheels to move the belt roller assembly to the correct position for mounting the belt.

4. Tighten all pedestal lock handles and lock bolts.

Pedestal Lock Handle

Pedestal Lock Handle

Pedestal Adjusting Wheel

Work Support PedestalBelt Roller

Adjusting Wheel

Photocell Mounting Rod attached herePedestal Adjusting Wheel

Work Support Pedestal

Figure 2-4. Adjustments for Work Support Pedestals

Operating the Machine 2-5

Adjust the height of the roller bearings to accommodate the diameter of the rotor, as follows:

1. On one work support assembly, loosen the four tensioning bolts on the roller bearing plate (see Figure 2-5). These are located on the “outside” of the work support, not the “inside” where the rotor is mounted.

2. Turn the support (height adjustment) screw to move the roller bearings up or down, as needed. Use the adjustment guide ruler as a reference.

3. Make sure the roller bearings are level, then re-tighten the tensioning bolts.

4. Repeat steps 1 through 3 for the other work support.

You are now ready to mount the rotor, as described below.

Tensioning Bolts

End ThrustRoller Bearing

Support (Height Adjustment ) Screw

Figure 2-5. Roller Bearing Adjustments (Outside View of Work Support)

2-6 Operating the Machine

Mounting and Securing the Rotor Mount and secure the rotor, as follows:

1. Move the rotor to the Support/Measure Assembly, using a means appropriate to the rotor size and weight.

Be alert and careful when handling the rotor. The rotor is heavy and can cause serious injury if dropped or swung against a person. Before moving the rotor, make sure that it is well-secured and stable. Move it slowly to maintain safe control.

Avoid pinch points. Keep fingers, hands, or any other body part safely away from the rotor end and roller bearings when lowering it onto the onto the bearings.

2. Slowly lower the rotor down in the mounting position, but stop before it touches the roller bearings. Leave enough space for slipping the drive belt over the end.

3. Loop the drive belt over one end of the rotor, then slowly lower the rotor so that the rotor journals rest securely in position on the roller bearings.

4. There is an end-thrust assembly on each work support pedestal to prevent the rotor from drifting horizontally. Adjust the two assemblies to barely touch the center of the rotor shaft , as follows (see Figure 2-6):

a. On one end of the rotor, position the end thrust bracket in the appropriate mounting holes to fit the length of the rotor shaft.

b. Loosen the end thrust adjustment handle, position the end thrust at the center of the shaft, then retighten the handle.

c. Repeat steps a and b for the other end of the rotor.

You are now ready to adjust the negative load rollers, as described below.

Adjust the negative load rollers as follows:

1. There is a negative load (safety) arm at each end of the Support/Measure Assembly to prevent the rotor from moving vertically off its support. For both ends of the machine, pull down the safety arm and secure the lock (see Figure 2-6).

2. Adjust the negative load roller on each safety arm, as follows:

a. Loosen the height adjustment bolt.

b. Move the roller up or down until it is positioned to 1/16 inch (1.59 mm) above the rotor journal.

c. Tighten the height adjustment bolt.

You are now ready to connect the belt drive, as described below.

Operating the Machine 2-7

Rotor

End Thrust Adjustment Handles

Negative Load Roller

Negative Load Roller Height Adjustment Bolt

Negative Load Roller

Safety Arm Lock

Safety Arm Safety Arm

End Thrust against Rotor Journal

End Thrust

Rotor Journal resting on Roller Bearings

Roller Bearing

Figure 2-6. Negative…