This document outlines the maintenance procedures for a Circular Collector H Drive, a crucial component in water treatment systems. The device is designed to facilitate the collection and removal of solids from clarifiers, ensuring efficient operation and water quality.
Function Description
The Circular Collector H Drive is a mechanical system that drives the movement of a circular collector mechanism within a clarifier. Its primary function is to continuously scrape the bottom of the clarifier, moving settled solids towards a central collection point for removal. This process is essential for maintaining the clarity of treated water and preventing the accumulation of sludge. The drive system consists of an electric motor, a primary reducer, worm and pinion gears, and a drive chain, all working in concert to provide the necessary torque and rotational speed for the collector. The system also includes various safety features and indicators to monitor its operation and ensure safe maintenance.
Important Technical Specifications
The H-Drive system comes in several models, including H30, H30A, H40, H40A, H40HD, H60, H60A, H60HD, H80, H80A, H90, H90A, and HD90A. Key technical specifications include:
- Ball Diameter: Varies by model, ranging from 1.00" (25.4 mm) to 1.50" (38.1 mm).
- Stop Block Gap: Ranges from 0.07" (1.778 mm) to 0.093" (2.362 mm).
- Maximum Stop Block Gap: Consistently 0.225" (5.715 mm) across all models.
- Gear/Housing Clearance: Consistently 0.25" (6.35 mm) across all models.
These specifications are critical for proper installation, operation, and maintenance, particularly for ensuring correct clearances and preventing mechanical interference.
Usage Features
The Circular Collector H Drive is designed for continuous operation in demanding water treatment environments. Key usage features include:
- Robust Construction: Built with durable components such as steel sprockets, worm gears, and roller bearings to withstand the rigors of continuous use.
- Load Monitoring: Equipped with a drive load dial indicator to monitor the operational load, allowing operators to detect potential issues early.
- Safety Mechanisms: Includes micro switches and stop blocks to prevent over-rotation and ensure safe operation. The stop blocks are crucial for preventing damage to the drive mechanism and clarifier structure.
- Lubrication System: Features multiple grease fittings, oil level plugs, and vent/fill plugs for easy lubrication and oil management, which is vital for extending the lifespan of the gears and bearings.
- Modular Design: Components like replaceable bearing races and removable access covers facilitate easier maintenance and part replacement.
Maintenance Features
Comprehensive maintenance is essential for the longevity and reliable operation of the H-Drive. The manual outlines various maintenance features and procedures:
- Safety Precautions: Emphasizes power source lock-out, proper handling of hazardous materials (grease, oil), and the use of personal protective equipment. It also highlights the importance of proper ventilation and fire safety.
- Routine Maintenance Schedule: Provides a detailed schedule for various tasks, categorized by daily, weekly, monthly, and semi-annually intervals.
- Surface Skimmer: Daily checks for smooth action and lock-out position. Semi-annual checks for loose connections, proper skimmer assembly, and spring loaded hinged guide.
- Worm Gear Subassembly: Weekly checks for oil level at sight gauge. Monthly checks for leaking shaft seals, proper oil level, and damaged components. Semi-annual checks for metal contaminants and overall condition. Seasonal oil changes are also recommended.
- Torque Overload Switches: Semi-annual inspection for signs of corrosion and proper microswitch operation.
- Drive Chain: Monthly checks for loose bolts, setscrews, keys, and proper tension. Semi-annual checks for excessive slack and sprocket alignment.
- Shear Pin Sprocket: Monthly checks for grease fitting, loose screws, and tooth wear. Semi-annual checks for chain and sprocket removal, cleaning, and regreasing.
- Final Drive Assembly: Daily checks for oil level. Monthly checks for oil condition (condensate, milky color, metal contaminants) and damaged dust shield. Semi-annual checks for stop blocks and seasonal oil changes.
- Bridge Components: Monthly checks for loose fasteners. Semi-annual inspection and verification of bridge base plate expansion connection.
- Scum Trough, Scum Baffles, Weirs: Semi-annual checks for consistent water depth, full rotation of skimmer assembly, and any binding.
- Scraper Arms: Semi-annual inspection for slime and sludge.
- Oil Flushing Procedure: Recommended for intermediate and final housings, involving lowering the sludge blanket, stopping and locking out the drive motor, draining existing oil, flushing with a mixture of Mobil System Cleaner and gear lube oil, and refilling with proper viscosity oil.
- Lubrication Summary: Provides detailed recommendations for Mobil SHC-630 (summer) and Mobil SHC-629 (winter) lithium-based grease for upper and lower housing, along with specific oil capacities for various H-Drive models. It also includes viscosity information for the recommended oils.
- Troubleshooting Guide: Offers solutions for common problems such as drive overheating (low oil level, condensation, low oil level in high speed gear case), broken shear pins or alarms (large debris, grout on tank floor, damaged/missing stop blocks, scraper making contact with tank floor, bridge being locked down), and skimmer not skimming properly (blade not adjusted correctly, build-up of material on beach).
- H-Drive Bearing Check Points: Provides a detailed diagram and instructions for checking the stop block gap and gear/housing clearance, which are critical for preventing damage and ensuring proper operation. It also specifies the procedure for addressing issues with stop blocks, including contacting an Evoqua Field Technician if a stop block is missing.
The manual emphasizes the importance of adhering to the recommended maintenance schedule and procedures to ensure the safe, efficient, and long-lasting operation of the Circular Collector H Drive.
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