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.

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

page 3 of 17

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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

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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

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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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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

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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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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

---

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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:


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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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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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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


PM 3 PLC shutdown

1,02

switch-off value


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


accepted.

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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


accepted.

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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.


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11. ATTACHMENT

Measuring equipments are checked and have been satisfied according to

the requirements of the DIN EN ISO 9001 :2015


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