Broadbent Machine MH97177 C46MT 55 X 45

Operating Manual for C46MT Batch Centrifuges MH97177-8 Page 1
Thomas Broadbent and Sons Limited
OPERATING MANUAL
C46MT (5545) BATCH

SUGAR CENTRIFUGES
Serial Numbers
H97177-8
Belle Vue
Mauritius
Thomas Broadbent & Sons Ltd

Queen Street South
Huddersfield
HD1 3EA
ENGLAND
© May 2009 Thomas Broadbent & Sons Ltd

Written/Modified Checked
By Date By Date
Mechanical KK 29.04.09 GH 07.05.09
Electrical GH 06.05.09 KK 07.05.09

IMPORTANT INFORMATION
This instruction manual must be studied carefully before attempting to Install, Operate or
Maintain the equipment. Particular attention is drawn to the installation, monitoring, and
protection requirements together with start-up and shut-down procedures.
It should be noted that Thomas Broadbent & Sons Ltd will not accept liability for direct or
consequential damage, loss or injury that may arise from any failure to comply strictly to the
instructions contained in this manual and good engineering practice as covered by the
Standards, Regulations and Codes of Practice referenced in this manual or applicable in
the country of installation.
It is recommended that the installer and user consider the employment of the experienced
Service Personnel of Broadbent Ltd to assist with the installation, commissioning and
maintenance of the equipment. A member of our Service Department will be pleased to
discuss your requirements in this respect. Contact details are given below.
The provisions of the equipment, process or other guarantees may be invalidated if the
equipment is not installed, started, stopped, operated and maintained strictly in accordance
with this manual using trained and qualified personnel. It is a condition of the guarantee
that formal records are maintained by the installer and user detailing:
1)Tests or checks carried out on the equipment and its associated monitoring and
protection systems during installation and commissioning.
2)Maintenance undertaken during the life of the equipment.
3)Tests and checks carried out on the equipment and its associated monitoring and
protection systems during the operational life of the equipment to ensure their
correct functioning.
4)Any defects encountered in the operation, installation or maintenance of the
equipment.
5)Training of personnel operating and maintaining the equipment.
These records must be made available to Broadbent Ltd upon request.
If in doubt regarding any aspect of these instructions or if requiring additional information

assistance should be sought from Broadbent Ltd before operating the equipment. In all
communications please state the equipment serial number detailed on the equipment
nameplate.
Contact details:
Thomas Broadbent & Sons Ltd Broadbent Incorporated
Queen Street South 2509 Gravel Drive
Huddersfield PO Box 185249
West Yorkshire Fort Worth, Texas 76118
UK USA
Tel: +44 (0)1484 477200 Tel: +1 (817) 595 2411
Fax: +44 (0)1484 423159 Fax: +1 (817) 595 0415
E-mail: sugar@broadbent.co.uk E-mail: broadbent.inc@att.net

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CONTENTS


CONTENTS
INTRODUCTION
SAFETY
CENTRIFUGE
1 DESCRIPTION
2 TECHNICAL DATA
3 INSTALLATION
4 OPERATION
5 MAINTENANCE
6 FAULT DIAGNOSIS
7 PART LISTS
APPENDIX A CONTROL PROGRAM
APPENDIX B BASKET INSPECTION
APPENDIX C PNEUMATIC CIRCUIT
APPENDIX D PROCESS PERFORMANCE
REFERENCE DRAWINGS

INTRODUCTION


INTRODUCTION
This manual applies to the Broadbent C46MT Fully Automatic Pendulum
Suspended Batch Centrifuge.
This manual covers the basic centrifuge unit. A set of reference drawings is included.
NOTE: ILLUSTRATIONS IN THIS MANUAL MAY DIFFER IN DETAIL

FROM THE EQUIPMENT SUPPLIED. ALWAYS REFER TO THE
REFERENCE DRAWINGS LISTED IN SECTION 2 AS THE DEFINITIVE
VERSION.

SAFETY


SAFETY
A safety information plate is attached to the centrifuge casing. It contains important advice
essential to the safe installation and use of the machine. The notice is reproduced below for
information.
DANGER
IMPORTANT SAFETY INFORMATION
For SAFE and RELIABLE OPERATION, this equipment MUST be installed, operated
and maintained by trained personnel in accordance with safe engineering practice and
the current edition of the instruction manual issued by Thomas Broadbent & Sons Ltd.
The equipment should only be used for purposes agreed at the time of sale and notified
at such time to Thomas Broadbent & Sons Ltd. It must NOT be used for any other
purpose without the written approval of Thomas Broadbent & Sons Ltd or otherwise
authorised and qualified personnel.
Guards and Interlocks are designed and fitted in the interests of safety and UNDER NO
CIRCUMSTANCES should the equipment be operated with Guards removed or Interlock
switches overridden.
In the event of MALFUNCTION the equipment should be SWITCHED OFF and (where
appropriate) disconnected. It should then be inspected and repaired by a suitably
qualified technician before attempting to use the equipment.
FAILURE TO COMPLY WITH THIS PROCEDURE COULD RESULT IN SEVERE OR

FATAL INJURIES.
In case of doubt or continuing difficulty concerning the installation or operation of this

equipment, contact
BROADBENT CUSTOMER SERVICES LTD

Huddersfield, HD1 3EA, England
Telephone: 01484 477200 Telex: 51515 TBS G Fax: 01484 516142
Outside Normal Office Hours: Telephone 01484 424660

1 DESCRIPTION

1 DESCRIPTION
1.1 PRINCIPLES OF OPERATION
1.2 BASKET
1.3 MAIN DRIVE MOTOR
1.4 SPINDLE AND BEARING HOUSING
1.5 CASING AND SUPPORT FRAME
1.6 COOLING AND ANTI-PRECESSION SYSTEMS
1.7 BRAKING SYSTEM
1.8 FEED SYSTEM
1.9 FEED LIMITER
1.10 PLOUGH DISCHARGER
1.11 DISCHARGE VALVE
1.12 PROCESS FITMENTS
1.13 DRIVE PANEL (INVERTER)
1.14 CONTROL PANEL (PLC)
1.15 MACHINE ELECTRICAL EQUIPMENT
1.16 CONTROL FUNCTIONS

1 DESCRIPTION
Broadbent C46MT Batch Centrifuges are filtration machines used to separate sugar
massecuite into its constituent crystals and mother liquor, under the action of centrifugal force.
The product is processed in a cylindrical perforated basket fitted with filtering screens, which
is hung on the bottom end of a long spindle. The spindle is suspended from a resilient buffer,
which allows the rotating assembly to swing slightly to find its own balanced axis of rotation,
thus reducing transmission of vibration to the support platform. The centrifuge is driven by an
electric induction motor running off a variable frequency supply, from a solid state inverter,
which allows a continuously variable running speed. All mechanisms used for feeding and
discharging product are pneumatically actuated, and the whole machine cycle is controlled by
a programmable logic controller (PLC).

The centrifuge processes batches of product in a cyclic manner as follows,
The centrifuge accelerates to a low speed. The butterfly feed control valve and a flap
valve open, allowing product to flow down a feeding chute, onto a flinger disc attached
to the spindle. This throws the product onto the inside of the basket, where it flows
under centrifugal force to form a uniform wall. Liquor starts to flow out through the
filtering screens and basket perforations, and is collected in the outer casing and
discharged down pipework under the machine. The product thickness builds up inside
the basket until the feed detector trips, causing the feed control valve to close. The
inside of the feed chute is sprayed with water, and after a short delay the flap valve
closes to prevent any remaining dark coloured product dripping onto the product inside
the basket. The feeding rate depends on how far the feed valve opens and this can be
manually or automatically controlled.
On completion of feeding, the centrifuge accelerates to a medium speed hold point to

await operator or sequence permission to proceed. The centrifuge then accelerates to its
maximum spin speed. During this time, purging of liquor from the product cake
continues, water and steam can be sprayed on to remove the final traces of mother
liquor from the crystals. The purity of the run off liquor rises and a classification valve
system can be used to direct this liquor down a different discharge pipe. The centrifuge
pauses at spin speed for a preset time to dry the crystal cake to the desired level.
On completion of spinning, the centrifuge decelerates to a very low speed. A discharge

valve plate under the bottom of the basket opens. A plough blade cuts into the top of the
cake and moves slowly down the basket screens, discharging dried crystals through the
basket bottom and down a chute onto a conveyor running beneath the casing. The
plough blade moves back to its parked position, the discharge valve shuts, and the
machine accelerates to feed speed to begin another cycle. During acceleration, the
filtering screens can be sprayed with a small amount of water to remove any remaining
crystals, and thus prevent clogging.

Figure 1.1 General Arrangement of Centrifuge
Coolong Fan Anti-Precession

and Filter Damping Springs
Cowl enclosing
Drive Motor
Out of Balance
Switch and
Vibration Monitor
Motor Terminal
Box MTB
Auxiliary Terminal
Box ATB
Upper Frame
Plough
Emergency/Parking
Mechanism
Disc Brake
Operator
Interface
Flap Drip Valve Guard enclosing
Spindle
Pan Top
Feed Limiter
Outer Casing
Electro-Pneumatic
enclosing Basket
Panel EP
Floor Level
Control Terminal
Box CTB (at rear)
Sugar Liquor
Discharge Classification
Chute System

Figure 1.2 Sectional Arrangement of Centrifuge
Cooling Fan
and Filter Anti-Precession
Damper Assembley
Cyclic Duty
Induction Motor Out of Balance
Stator and Rotor Switch and
Vibration Monitor
Motor
Motor Cowl
Terminal
Box MTB
Torque Reaction
Conical Rubber Arms
Suspension Buffer
Grease Lubricating
Emergency/Parking Bearing Assembly
Disc Brake
Assembly
Upper
Frame
Pan Top Discharge Valve

Actuator Assembly
Outer Casing
Discharge
Valve
Feed Pushrod
Distributor
Flinger Floor Level
Hooped and Pushrod Seal

Perforated Assembly
Basket
Discharge
Liquor Sugar Discharge Valve Cone
Gutter

Figure 1.3 Upper Sectional Arrangement of Centrifuge
Upper Roller Bearing

Damper Plate with
Lower Roller Bearing

Inner Distance Piece
Inner Spacer Ring
Friction Liner
Centering Ring
Motor Rotor
Damper
Top Collar
Damper
Spring
Spindle
Ducting
Fan
Split Taper Hub

Bottom Collar
Dicharge Valve
Air Cylinder
Upper Spindle
Brake Disc
Bottom
Spacer
Grease
Sleeve
Flinger
Flexible Hose
Oil Wetted Filter
Rotating
Union
O Ring
Motor Stator
Cooling Fan
Flexible Leads
Centrifugal
Top Bearing Cap

Fan Drive
Contact Thrust Ball

Motor
Outer Spacer Ring
Bottom Bearing Cap

4 Point Angular
Lower Grease Cup

Upper Grease Cup
Spring On / Air Off

Bearing Housing
Brake Support Bracket
Break Caliper
Bearing
1.2 BASKET
The basket is a high integrity fabrication made from materials appropriate to the product
being processed. The shell is rolled from plate, seam welded, and perforated. Because of
the operating speed and density of the product, the shell is reinforced by shrink fitted,
high tensile, seamless rolled hoops. The basket bottom includes a hub for attachment to
the spindle and a spoked opening with integral seal, for product discharge. The basket
top is an annular disc whose inside diameter or 'lip' determines the maximum possible
product cake thickness which can be accommodated.

Figure 1.4 Lower Sectional Arrangement of Centrifuge

See Specific Sectional Arrangement for actual details.
15 - 25 mm
Basket Bottom
Clearance
to Casing
Feed Distributor
Flinger Cone
Pushrod Seal
Discharge Valve
Guide Bush
Pushrod Joint
Housing
Spindle
Spring
Collar/Puller
Retaining
Valve Cone
Discharge
Basket Reinforcing
Perforated Basket
Basket Top
Hoops
Shell
Tension Indicators
Basket Bolts with
Bump Ring
Curb Ring
Basket Hub
Basket Spokes
Casing
Basket
Basket Bottom
Assembly
Spindle
Sleeve
The perforated shell of the basket is lined with 3 screens. The innermost 'working' screen
is made from thin metal plate which has many fine perforations, and acts as the filter
medium. The 'intermediate' screen is fine woven mesh, and the 'backing' screen is
coarse woven mesh. The system is designed to optimise support of the working screen,
whilst allowing easy dispersion of the liquor filtrate.

1.3 MAIN DRIVE MOTOR

The cyclic duty induction motor is an induction motor specially designed for high torque
variable speed duty. It operates from a variable frequency supply, and has much lower
headroom requirements than an equivalent conventional motor. The stator is a 3 phase
winding in a laminated core with skewed slots to minimise harmonics. The stator frame
is of fabricated construction and bolts directly to the spindle bearing housing. The rotor
has a low resistance cage in a laminated core and is fitted on a fabricated spoked hub
which is attached directly to the spindle.
The motor is enclosed by a cowl which provides EMC and noise shielding, and includes
air ducts to allow cooling air to escape. The motor cowl also includes the main motor
terminal box.
The motor is force ventilated from above by a separate electric motor driven centrifugal
fan unit. The air delivered by the cooling fan is drawn through an oil wetted filter, to
prevent any dust or debris being fed into the internal motor assembly.
A rotating baffle on the top of the rotor splits this cooling air flow, so that some passes
directly across the upper end windings, whilst the remainder passes down the inside of
the rotor and across the lower end windings.
1.4 SPINDLE AND BEARING HOUSING

The spindle is a long tubular shaft with the basket attached at the bottom, and the motor
at the top. The spindle is suspended in a bearing housing just below the motor. The
spindle is located radially by two cylindrical roller bearings and vertically by a 4 point
angular contact ball thrust bearing, which are all retained in a cast bearing housing. All
bearings are grease lubricated and rated for long life.
Just beneath the bearing housing is a disc brake for parking and emergency duties, (In
normal operation, the centrifuge is decelerated by regeneration in the inverter). The
disc is attached to the spindle by a split taper collar. The caliper is mounted on a bracket
attached to the lower bearing cap. The disc and brake shoes are surrounded by a
substantial guard. Lower down the spindle is a conical flinger disc to aid distribution of
product in the basket.
1.5 CASING AND SUPPORT FRAME

The spindle bearing housing is flexibly supported in a conical elastomer bush or 'buffer'
which allows the whole rotating assembly to swing slightly. The buffer rests in a conical
seating in the top of a rigid support frame, which has splayed legs fabricated from square
hollow tube. The frame is in turn supported from the casing with intermediate packing
plates, whose thickness can be changed to adjust the vertical position of the basket.
The casing is a fabricated assembly comprising a central cylinder with boxed sides. The
cylindrical section surrounds the basket to catch the spun off liquor, and incorporates a
bottom gutter and bump ring to restrict the lateral motion of the basket. The side frames
transfer loads from the upper support frame direct to the supporting foundations.
1.6 COOLING AND ANTI-PRECESSION SYSTEMS

The motor cowl supports an auxiliary motor driven fan and filter unit, which directs
cooling air via a duct into the top of the main drive motor.
An anti-precession system is fitted to control gyration of the rotating assembly during
feeding, and to prevent gyroscopic precession at high speed. This comprises a damper
plate with a friction lining, which is pressed down onto the motor top by 3 springs
mounted on the motor cowl. The damper plate is held centrally by a rubber ring, which
is a tight fit on the cooling air duct. When the rotating assembly swings, the motor top is
forced to slide against the damper plate, giving rise to frictional damping.
1.7 BRAKING SYSTEM

In normal operation, the centrifuge is decelerated only by regeneration by the inverter in
the Drive Panel. A disc brake is provided as a parking brake, and for emergency
purposes such as inverter failure or loss of air pressure. Note if the inverter isolator is
switched off, or the power disconnect pushbutton is pressed whilst the machine is
running, the centrifuge will stop by means of the emergency brake only. This will cause
the stopping time to be considerably increased.
The brake caliper has a pair of floating shoes, and is supported off a bracket mounted on
the lower bearing housing cap. The caliper has a spring on - air off actuator. The brake
disc is attached to the spindle by a split taper hub.
1.8 FEEDING SYSTEM

Product is fed into the centrifuge via a flow control valve, streamlined feed spout and
secondary anti-drip valve. The product falls onto a conical distributor disc or 'flinger'
attached to a flange on the spindle sleeve. This throws the product onto the basket inner
wall approximately halfway up, from where it flows to form a product wall under
centrifugal action.
The flow control valve is a butterfly valve with a double acting actuator, controlled from
an integral electro-pneumatic positioner, which responds to a 4-20 mA signal from the
PLC. The flow control valve is mounted as close as possible to the mixer tank to avoid
plugging.
To avoid unsightly drips of coloured feedstock onto spun product, a secondary valve is
mounted directly onto the casing top. The secondary valve is a flap pulled up onto a soft
seating under the spout outlet by a pair of double acting pneumatic cylinders.
Mounted locally is an air reservoir, with sufficient capacity to allow emergency closing
of both valves in the event that the main pneumatic supply fails.

1.9 FEED LIMITER

A mechanical feed limiter unit initiates closing of the feed valve, when the build-up of
product cake inside the basket reaches the desired thickness. This comprises a slipper
arm inside the basket, connected via a rod to a control box on the casing top. The
control box contains a pneumatic cylinder and spring loaded linkages.
Figure 1.5 Feed Limiter
Just before feeding, the cylinder pushes the slipper close to the basket wall. As the
product cake thickens, the slipper rides on the cake surface under spring pressure, until
the lever arms in the control box move sufficiently to trip a proximity switch. This sends
a signal to close the feed valve, and releases the cylinder in the control box, so that the
slipper arm moves well away from the product for the remainder of the cycle. The rod
from the slipper arm extends through to a handle on the top of the control box, which
can be used as a manual override to terminate feeding. The desired product cake
thickness is adjusted by rotating the whole assembly on the casing top.

1.10 PLOUGH DISCHARGER

Product is ploughed from the basket by a blade which remains within the basket at all
times. Its parked position is close to the spindle, near the top of the basket. For
discharging, the blade lifts slightly, moves horizontally to cut into the top of the cake,
pauses, moves slowly vertically down the basket screens, pauses, moves vertically up,
moves horizontally back to the spindle, and finally drops slightly into the parked
position. All ploughing motions take place with the basket rotating at very slow speeds.
The actuating mechanism is mounted to the right of the main support frame, and is
connected to the blade by an 'L' shaped arm, which passes through a curved slot with a
sliding cover in the casing top. The heart of the mechanism is a vertical circular shaft, on
which the carriage supporting the plough arm slides vertically, under the action of a
double acting pneumatic cylinder, mounted in parallel with an oil filled dashpot unit. The
dashpot allows a slow, adjustable speed downwards during ploughing, and a fast
upwards motion when returning to the parked position. The horizontal motion is
obtained by a second double acting pneumatic cylinder, pushing on a lever arm attached
to the bottom of the plough shaft, which rotates the shaft and carriage in bushes at the
casing top, and at the top of the upper frame. Rollers in the end of the lever arm move
the plough arm. The geometry in plan view is such that under cutting action, the blade
naturally 'castors' to about half the maximum cake thickness. When first pushing the
blade into the cake, the horizontal cylinder operates at full pressure but once on the
screens, the pressure is reduced, to gently hold the blade lightly against the basket, to
ensure that all traces of product are removed from the filtering screens.
A spring loaded pin engages in cutouts in a locking plate, rigidly attached to the plough
shaft, to hold the mechanism either out towards the screens. So that the blade cannot
touch the flinger during ploughing, or in the parked position, close to the spindle during
the rest of the cycle. At appropriate points in the sequence, this pin is lifted out of
engagement by a lifting ridge on the carriage. When parked, a lug on the carriage rests
on a lug on the bracket, supporting the upper plough shaft bush. This bracket also
supports the proximity switches which sense the position of the mechanism.
The solenoid valves controlling the actuators are spring return units, and are connected
in such a way that if the electrical power fails during ploughing, the plough will naturally
tend to return up and in to the spindle, towards the parked position.

Figure 1.6 Plough Discharger (Typical Only)
Frame Bracket
Upper Support
Bracket
Sliding Cover
Plough Blade OUT

(Parked Position)
Plough Blade IN
(Ploughing Position)
Plough Shaft
Latching
Pin
Locking
Plate
Proximity
Switches
Plough Carriage
Plough Arm
Lever Arm
B C Vertical
Vertical Horizontal
F Dashpot
A Cylinder Cylinder
Damper
A Parked and Latched Out

B Out, Up and Unlatched
C In, Up and Latched In (Ploughing)
E D D In, Down and Latched In (Ploughing)
E Return, Down and Latched In (Retracting)
F Return, Up and Unlatched (Retracting)

1.11 DISCHARGE VALVE

The discharge valve is a cone, which is normally pulled up hard against the underside of
the spoked opening in the basket bottom, against a elastomeric seal. This cone is
lowered away from the seal during ploughing.
The discharge valve actuating mechanism is housed within the hollow spindle. It
comprises a central pushrod, surrounded by a long coil spring, which is housed within a
tubular hanger attached to the spindle. Spring pressure normally pulls up the pushrod to
hold the discharge valve against the basket bottom seal. A single acting cylinder is
mounted above the spring hanger, which can compress the spring to depress the
pushrod, and open the discharge valve. The cylinder air supply is via a rotary union and
a flexible hose to the cooling fan duct. To aid assembly the pushrod can be split into two
pieces at a joint just below the spring hanger. A sealing plate assembly attached beneath
the basket bottom incorporates a bush to guide the pushrod, and a lip seal to protect the
mechanism against ingress of product.
1.12 PROCESS FITMENTS

A static hot water spray pipe, protruding into the basket from the casing top, allows the
screens to be rinsed after ploughing, and the product to be washed during spinning. The
pipe is short to prevent 'dragging' in the product during ploughing. The spray nozzle
sizes, positions and angles have been carefully selected to provide an even wash
distribution. The wash is controlled by a pneumatically actuated ball valve attached to
the end of the wash pipe.
A steam injection pipe, protruding into the basket from the casing top allows steam to be
added, to help dry the product cake. The steam injection is controlled by a pneumatically
actuated ball valve attached to the end of the steam pipe.
A liquor classification unit is attached to the rectangular liquor outlet under the casing.
This allows separation of the initial low purity mother liquor, spun off immediately after
feeding, from the wash water containing dissolved product, spun off later. It comprises a
‘Y’ splitter box, with a pair of pneumatically actuated butterfly valves on the two
outlets. The controls are organised such that both valves are never shut simultaneously.

1.13 DRIVE PANEL (INVERTER)

The centrifuge main drive motor is an induction motor and runs just below the
synchronous speed, which is determined by the number of poles in the winding, and by
the frequency of the electrical supply. The motor speed can therefore be changed by
varying the frequency of the electrical supply to it. This function is performed by the
Drive Panel, which is a solid state electronic frequency converter (inverter). The fixed
frequency alternating current supply to the Drive Panel is first rectified to a direct
current, which is then electronically switched on and off to construct an output
alternating current at the desired frequency. Further details can be found in the Inverter
Manual.
The inverter is housed in a remote cabinet, with a door mounted keypad and display, for
use during setup and fault finding. In normal use, there is no need to use this keypad.
1.14 CONTROL PANEL (PLC)

The whole production cycle of the machine, including operation of the inverter, feed
valves, plough, discharge valve and process fitments is controlled by an electronic
Programmable Logic Controller (PLC). The PLC together with its interface devices and
auxiliaries is housed in a remote Control Panel cabinet. An isolator, 'Power On'
indicator and 'Machine Running' indicator are mounted on the outside of the door.
Components inside include,
1.14.1 Central Processor Unit (CPU)
The CPU is a solid state device consisting of a microprocessor and its support
system. It contains the operating program for the machine within its EPROM
memory. The program cannot normally be corrupted but changes can be made
when required by a suitably qualified and experienced person using a special
programming unit.
The CPU scans the inputs to the PLC from the various sensors on the centrifuge,
acts upon these inputs as determined by the program, and then turns on the
appropriate outputs to the inverter and centrifuge actuators in a cyclic manner. A
series of indicating LEDs are incorporated on the front of the unit to show the
operating status of the unit.
1.14.2 Power Supply Unit (PSU)

This separate unit supplies a low d.c. voltage to the input/output module mounted
on the rack. A light on the PSU indicates when the power supply is active
1.14.3 Input Modules

The input modules are all 16 way, low voltage d.c. optically isolated positive logic
units. Each input has an associated Light Emitting Diode (LED) on the front of the
unit to indicate its status (ON or OFF).

1.14.4 Output Modules

The output modules are all 16 way, low voltage d.c. optically isolated positive
logic units. Each output has an associated LED on the front of the unit to indicate
its status (ON or OFF).
1.14.5 Speed Monitoring System

The speed of the machine is measured by impulses from two proximity sensors
mounted above a series of holes through the brake disc. To guard against faulty
speed control, two entirely independent speed monitoring systems are fitted.
In the main system, the impulses from one of the sensors are sent directly to the
main PLC, which uses a pulse counting routine to measure the speed.
In the secondary system, the impulses from the second sensor are fed directly to a
secondary programmable logic controller (PLC2) which is of a different
type and manufacture to the main PLC. PLC2 is basically a pulse counting unit
and is configured to operate 6 sets of contacts corresponding to different speeds.
The main PLC continuously scans the status of these contacts and compares these
for consistency with its own measurement of speed. If a discrepancy is detected, a
fault condition occurs.
As a further protection against faults in the main PLC and/or the inverter causing
random uncontrolled actions, some of the contacts in PLC2 are hard wired via
relays to inhibit dangerous conditions. One set of contacts isolates the plough
actuators to prevent the plough deploying above low speed. Another set of
contacts isolates the feed valve actuators to prevent feeding above medium speed.
A particularly dangerous situation is overspeeding the centrifuge. The main PLC is

set with a software limit on maximum speed, and the inverter is preset with a
software limit to the output frequency. In the unlikely event of faults in both these
systems occurring simultaneously, two sets of contacts in PLC2 are used as a final
protection against overspeeding. The first set removes the inverter enable signal
and the second, higher speed, set trips the inverter input contactor and disconnects
power.

1.15 MACHINE ELECTRICAL EQUIPMENT

The following control equipment is mounted on the centrifuge,
1.15.1 Operator Interface
The Operator Interface is mounted on the front of the centrifuge frame. This
incorporates a touch sensitive panel with pushbuttons and indicators. It allows
operators to monitor and control the machine via the PLC in the Control Panel.
The interface allows displays of machine status, interaction with the production
cycle, and modification of process parameters. Details are given in section 4.
1.15.2 Terminal Boxes

Motor Terminal Box MTB is located on the top frame near the main drive
motor. The short, flexible trailing leads from the stator winding are terminated in
MTB for connection to rigid cabling back to the Drive Panel.
Electro-Pneumatic Panel EP is located on the front of the casing beneath the

Operator Interface. This contains all the solenoid valves for the brake, feed,
plough, discharge, and process fitment pneumatic actuation systems. Control wires
come into EP from CTB.
Control Terminal Box CTB is located on the back of the casing. This is the
termination point for all controls on the machine for connection back to the
Control Panel via multicore cables.
Auxiliary Terminal Box ATB is located on the rear upper centrifuge frame and
is used to marshal all proximity switch cables from the upper half of the machine
for connection to CTB via a multicore cable.
1.15.3 Electro-Pneumatic System

The brake, feed, plough, and discharge mechanisms are all actuated by pneumatic
cylinders controlled from solenoid operated valves inside the Electro-pneumatic
Panel EP. Appendix C details the operation of the pneumatic circuits. The circuits
are designed for lubrication-free operation, providing an almost maintenance-free
and hygienic actuating system suitable for use in the production of all grades of
sugar.
Optimum design pressure from the site air supply can be controlled by an
independent regulator, located on the rear of the casing. In order to avoid
extended cycle times, and to ensure safe operation, a low air pressure interlock
switch inside the pneumatic control panel prevents the machine from operating
should the air pressure fall below the minimum value.

1.15.4 Instrumentation
Position Sensing of the brake, feed, and plough mechanisms is by means of
non-contact inductive proximity switches, which are connected back to the
Control Panel, via the Auxiliary and Control terminal boxes ATB and CTB.
Machine speed is measured by impulses from a pair of non-contact inductive

proximity sensors mounted above a series of holes drilled through the brake disc.
These are fed to the main and secondary speed monitoring systems in the Control
Panel. See section 1.14.5.
Out Of Balance in the basket causes the rotating assembly to tilt and this is
monitored by two independent systems.
A mechanical out of balance switch trips if the top of the motor moves
radially by a preset amount. This is used to detect large movements at low
speed. Examples are excessive swinging due to poor product distribution
during feeding or slow gyroscopic precession while the rotating assembly is
spinning at high speed.
A vibration accelerometer unit comprising piezoelectric transducer and

built in amplifier and filter is fitted to the periphery of the stator and outputs
an analogue 4-20 mA signal to the Control Panel. This is used to detect
large forces at high speed. This can be caused by excessive out of balance in
the dried product cake, giving rise to vibration at machine speed. Two levels
of trip are preset - "High OOB" and "High High OOB".
Motor Winding Temperature is detected by thermistors embedded in the

windings of the main drive motor, which are connected to an overload relay in the
Control Panel.

1.16 CONTROL FUNCTIONS

1.16.1 Normal Operation
The normal feed-spin-plough cycle of the centrifuge is controlled entirely by the
ladder logic program in the PLC in the Control Panel. The program flowchart is
detailed in Appendix A. The PLC scans the relevant inputs at the Operator Panel
to determine which operating modes and options have been selected by the
operator. The PLC checks the inputs from the machine instrumentation, to ensure
that all the components and mechanisms are at their expected status. In
accordance with the program, the PLC outputs instructions to the Drive Panel,
and to the actuators on the machine, at the same time changing the status display
on the Operator Panel.
Various options for controlling the cycle speed and the feed valves are available.
These are described in detail in section 4.
1.16.2 Protection Functions

Hard wired push buttons are provided on the Operator Panel for manual initiation
of emergency stops and feeding termination. In addition, the control system
includes a number of automatic protection features;
Main Motor Overheating. An overload relay is fitted into the starter for the
cooling fan motor, thermistors are fitted in the windings of the main drive motor.
These interlocks are connected in series to stop the centrifuge and provide fault
indications.
Ploughing Speed. If the machine speed during ploughing falls outside a fixed
range, the plough is withdrawn from the cake and fault indications provided.
Overspeeding could damage the plough mechanism and underspeeding could be
the result of some obstruction.
Feeding Faults. If the feeding time exceeds the feeding time on the previous
cycle by more than a fixed margin, feeding stops, a fault indication is given and the
machine pauses at the end of the cycle. This guards against faults in the feed valve
and feed limiter or changes in product feedstock quality.
Cycle Insurance. If any step (except spinning and sequence steps) lasts more
than 1 minute, a fault indication is given. This guards against malfunctions of any
part of the centrifuge.
Speed Monitoring System Faults. The speeds from the main and secondary
speed monitoring systems are continuously compared and any discrepancy initiates
a fault condition and stops the centrifuge. Running at the incorrect speed can
cause severe mechanical damage at any point in the cycle.

Out Of Balance. Both the low speed switch and the high speed vibration
monitor initiate fault indications and actions depending on the point in the cycle
they occur. The trip levels, durations, and actions are selected to avoid unsafe or
mechanically damaging operation, while avoiding dumping wet product
unnecessarily.
Pneumatic Air Pressure. A pressure switch stops the machine and provides
fault indications if the supply pressure drops below a fixed level. This ensures that
the pneumatic cylinders can provide sufficient force to operate the various
mechanisms and guards against extended cycle times.
Details of these protection systems are given in section 6.

2 TECHNICAL DATA

2 TECHNICAL DATA
2.1 GENERAL
2.2 MECHANICAL REFERENCE DRAWINGS
2.3 ELECTRICAL REFERENCE DRAWINGS
2.4 CENTRIFUGE SPECIFICATION
2.5 PERFORMANCE
2.6 PROCESS AND CONTROL PARAMETERS
2.7 WEIGHTS
2.8 FASTENER TIGHTENING TORQUES
2.9 CONVERSION FACTORS

2 TECHNICAL DATA
C46MT (5545) Batch Sugar Centrifuges
Serial Numbers H97177-8
Belle Vue, Mauritius
2.1 GENERAL
Broadbent Designation Broadbent C46MT - 5545YC/1122
Design and Construction Standards British Standard BS 767
European Standard BS EN 12547
Type Fully automatic vertical axis pendulum
suspended batch centrifuge
MECHANICAL REFERENCE DRAWINGS

General Arrangement 51241-013
Sectional Arrangement 50251-018
Brake Caliper Details Mk2 22181-003
Casing Top Arrangement 56151-001
Feed Limiter Arrangement 54750-005
Plough Discharger Arrangement 57241-027
Wash Pipe Arrangement 47040-112
Pneumatic Schematic - Pneumatic Panel 58431-019
Pneumatic Schematic - Machine 58431-020

2.2 ELECTRICAL REFERENCE DRAWINGS

Control (PLC) Panel General Arrangement 56210-098
Layout 54511-119
Schematic 58051-085
Auxiliary Terminal Box (ATB) Layout 55861-018
Schematic 58051-082
Control Terminal Box (CTB) General Arrangement 55861-020
Layout 55861-019
Schematic 58051-080
Electro- Pneumatic Panel (EP) General Arrangement 56210-083
Schematic 58050-194
Operator Interface Layout 54511-120
Schematic 58051-081
Machine Hookup 59511-070

2.3 CENTRIFUGE SPECIFICATION

Basket Basket Designation 5545P12HSSS Mk3
Part Number 46061-029
Diameter 1400 mm
Height 1150 mm
Cake Thickness 220 mm
Maximum Permitted Speed 1150 rpm
Basket Bottom Stainless steel, stainless steel hub
Basket Shell Austenitic stainless steel
Basket Hoops High tensile carbon steel
Basket Top Austenitic stainless steel
Nominal dimensions for Annual Safety Inspection purposes
Top thickness st 12 mm
Shell thickness ss 8 mm
Perforation diameter d 6 mm
Number of Hoops 13
Hoop width x 30 mm
Hoop depth y 25 mm
Screens Working screen Stainless steel perforated sheet

0.6 mm diameter holes, 20% open area
Intermediate screen Stainless steel No 7 woven mesh
Backing screen Stainless steel No 4 woven mesh
Rotating Carbon steel tubular spindle

Assembly Cast iron bearing housing
Cylindrical roller upper and lower radial bearings
4 point angular contact ball thrust bearing
Lubrication by mineral oil/lithium soap grease NLGI grade 2 or 3
e.g. Shell Albida RL2.
Spring-on/air-off disc type parking brake
Drive Motor Broadbent 75/58-25-R2 Cyclic Duty Induction Motor

Rotor mounted directly on spindle
Stator mounted directly on bearing housing
3 phase, 380 V, 0-57.5 Hz
6 pole winding with torque-speed characteristic to suit cyclic duty
Housed in carbon steel cowl giving IP21 containment
Open circuit forced air ventilation by separate cooling fan,
Fan capacity 3000 ft3/minute at 0.45”WG
Fan drive motor 2.2kW - 3 phase - 380 - 415 V - 50 Hz
Filter Oil wetted wire mesh

Suspension Pendulum type self balancing suspension incorporating,

System Carbon steel square hollow section pyramid frame
Elastomer conical support buffer
Spring loaded friction pad gyration/precession damping system
Torque reaction rods with spherical jointed ends
Swing Resonance at 120 rpm (basket full) to 160 rpm (basket empty)
Monitor Stainless steel cylindrical chamber with carbon steel wings

Casing Liquor outlet at rear
Inspection panels at rear
Stainless steel pan top and steaming covers
Massecuite Fully enclosed feed chute with facility for internal spray washing
Feeding controlled by pneumatically actuated ball valve
System Feed Control Valve 300 mm Butterfly valve
Double acting pneumatic actuator
Electropneumatic positioner
Secondary Drip Valve Broadbent type Flap valve
Two double acting pneumatic actuators
Feed distributor disc (flinger) attached to spindle
Process Water Wash Internal static spray pipe with

Fitments Pneumatically actuated ball valve
Steam Wash Internal static injection pipe with

Pneumatically actuated ball valve
Feed Chute Wash Feed Chute Wash Nozzle with

Pneumatically actuated ball valve
‘T’ splitter box beneath monitor casing
Liquor Classification 1 x 200 mm butterfly valve
Double acting pneumatic actuator
Sugar Plough Discharger Fully floating internal beam type with

Discharge castoring geometry
Pneumatically actuated motions with
hydraulic damping and speed control
Discharge Valve Conical plate valve under basket hub
Spring closed/pneumatically opened by
Mechanism fitted inside spindle

Inverter Siemens Sinamics S150 200kW AFE - 6SL3710-7LE33-8AA0-Z

Drive Panel 3 phase 380V - 480V ± 10%, 50/60 Hz ± 5%, Containment IP54
Ambient Temperature range 0oC to 40oC
Relative Humidity less than 95% non-condensing
Control Allen Bradley SLC500 Programmable Logic Controller with EEPROM

(PLC) Panel memory, Containment IP54
Operator Touch sensitive programmable graphic screen with indications of

Interface centrifuge and cycle status.
24 V dc Supply, DH485 communications to PLC, Containment IP65

2.4 PERFORMANCE
Product Processed Sugar Massecuite
Maximum Specific Gravity at Feed 1.5
Maximum Specific Gravity at Spin 1.2
No impervious materials
Nominal Basket Capacity 1500 kg Massecuite (including spin off during feeding)
Operating Duty 20 to 22 cycles/hour at 1100 rpm spin speed
Separating Effect 950 ‘G’ at 1100 rpm
The following table summarises the estimated process performance for this particular
application. Actual performance will depend on the actual massecuite conditions and
required sugar quality and dryness.
Serial Numbers H97177-8

Massecuite ‘A’ Massecuite
60oC to 70oC recommended
See contract details for capacity.
Water Filtered and Strained mandatory
3 to 5 bar g mandatory
Peak Flow 170 litre/minute
Mean Consumption 19 litre/minute
Steam Filtered and Strained mandatory
2 to 3 bar g mandatory
Peak Flow 90 kg/minute
Mean Consumption 550 kg/hour
Compressed Air Clean, Dry, Unlubricated mandatory
4 bar g to 6 bar g mandatory
5.5 bar g optimum
Peak Flow 140 litre/minute free air
Mean Flow 70 litre/minute free air
Water, steam, and air must be supplied at the conditions indicated above at the
connections to the centrifuge.
The following are typical sound pressure level measurements during works testing at 1
metre from the front of the casing at 1.6 metre above the working platform. Noise levels
in service will depend on the environment and modes of operation.
Minimum sustained SPL 76 dBA (during feed and plough)

Maximum sustained SPL 86 dBA (during acceleration and deceleration)
Equivalent Continuous SPL Leq 85 dBA (integrated over cycle)

2.5 PROCESS AND CONTROL PARAMETERS

The various parameters used in the centrifuge control system are summarised in the
tables below. Refer to section 4 for explanations of what the parameters are and to
Appendix A for details of their use.
Operator Controllable Parameters can be changed by the operator to optimise

process performance. The limits set on all parameters by the control system are given in
the table below. Also given are recommended initial settings which can be used during
commissioning.
Operator Controllable Parameters

Ref Description Limits Initial
Setting
NF Feed Speed (rpm) 150 to 450 250
VP Valve Opening Preset in Preset Feed Mode (%) 0 to100 20
TFT Target Feed Time in Calculate Feed Mode (seconds) 5 to 40 20
TFF Fail Feed Time (seconds) 5 to 40 25
TCR Feed Chute Rinsing Time (seconds) 0 to 10 1
TCS Cake Settling Delay Time (seconds) 0 to 60 0
NWA Speed for Primary Wash to start (rpm) 250 to 1100 650
TWA Duration of Primary Wash (seconds) 0 to 30 5
TWF Liquor Classification Changeover Delay (seconds) 0 to 999 10
NWB Speed for Secondary Wash to Start (rpm) 250 to 1100 800
TWB Duration of Secondary Wash (seconds) 0 to 30 5
TSW Time for Wash C to start after start of spin (seconds) 0 to 999 5
TWC Duration of Wash C (seconds) 0 to 30 0
TSS Time for Steaming to start after start of spin (seconds) 0 to 999 5
TSD Duration of Steaming (seconds) 0 to 30 5
NS Spin Speed (rpm) 1000 to 1150 1100
TS Spin Time (seconds) 0 to 999 25
NP Ploughing Speed (rpm) 40 to 60 45
TPT Plough Dwell Time in Top of Basket (seconds) 0 to 10 1.5
TPB Plough Dwell Time in Bottom of Basket (seconds) 0 to 10 2

Fixed Parameters are embedded in the PLC program and cannot be changed by the
operator. They depend on the mechanical design of the centrifuge.
Fixed Parameters
Ref Description Value
NH Holding Speed before acceleration to spin (rpm) 500
ND Discharge Valve Opening Speed (rpm) 100
TCD Drain Delay after Feed Chute Rinse (seconds) 3
N1 PLC2 Running Check Speed (rpm) 50
N2 PLC2 Plough Inhibit Speed (rpm) 100
N3 PLC2 Feed Inhibit Speed (rpm) 600
N4 PLC2 Speed Check (rpm) 900
N5 PLC2 Overspeed 1 - Remove Inverter Enable Signal (rpm) 1175
N6 PLC2 Overspeed 2 - Trip Inverter Input Contactor (rpm) 1200
V1 High Vibration Trip Level (G rms) 0.45
TV1 High Vibration Trip Delay (seconds) 3
V2 High High Vibration Trip Level (G rms) 0.6
TV2 High High Vibration Trip Delay (seconds) 10
PMIN Low Air Pressure Trip Level (bar g) 3.5
TPMIN Low Air Pressure Trip Delay (seconds) 10

2.6 WEIGHTS
Basket and Screens (Empty) 1500 kg
Main Drive Motor Stator 600 kg
Main Drive Motor Rotor 400 kg
Spindle and Bearing Housing with Discharge Valve Assembly 1050 kg
Motor Cowl 200 kg
Motor Cowl Cover 170 kg
Cooling Fan and Filter 80 kg
Upper Frame 650 kg
Casing 1750 kg
Casing Cover 250 kg
Total Weight of Empty Centrifuge 7200 kg
Incoming Panel 250 kg
Drive Cabinet 950 kg
Control Cabinet 200 kg

2.7 FASTENER TIGHTENING TORQUES

WARNING: For safe and reliable operation of the centrifuge,
fasteners on the rotating assembly must be torque tightened and
locked as specified below
Fasteners should be cleaned and smeared with fresh thread locking compound before
reassembly. Where several fasteners are fitted, they should be tightened evenly in
diagonal pattern to the torques specified.
Fastener Tightening Torques

Ref Location Type Torque
A Basket to Spindle M24 Hexagon Head HTS Note A
B Flinger Hub to Flinger M16 Hexagon Head HTS 250 Nm
C Brake Hub to Brake Disc M16 Hexagon Head HTS 250 Nm
D Lower Bearing Cap to Bearing Housing M12 Hexagon Head HTS 100 Nm
E Top Bearing Cap to Bearing Housing M12 Hexagon Head HTS 100 Nm
F Motor Rotor to Spindle M16 Socket Head HTS 250 Nm
G Discharge Assembly to Motor Rotor M12 Hexagon Head HTS 100 Nm
H Joint in Discharge Pushrod M36 Threaded Joint 250 Nm
J Discharge Rod Seal Plate to Basket M16 Hexagon Head SS 250 Nm
K Discharge Valve Cone to Pushrod M20 Hexagon Head SS 300 Nm
L Torque Reaction Arm to Rod and Motor M16 Hexagon Head HTS 250 Nm
M Frame to Casing and Casing to Floor M24 Hexagon Head HTS 500 Nm
NOTES SS indicates stainless steel and HTS indicates high tensile steel fasteners
Note A: Basket to Spindle Fasteners have built in load indicators -
Tighten until the cap on the screw head can no longer be turned by finger pressure.
These bolts should always be replaced on each basket removal.
IMPORTANT All Fasteners to be locked using Loctite Nutlock 242 or Permabond Threadlock A130

2.8 CONVERSION FACTORS

All data in this operating manual is given in metric units. Conversion factors to other
common units are given below.
Selected Conversion Factors

Length 1 m (metre) = 1000 mm (millimetre) = 39.4" (inch) = 3.28 ft (foot)
1 mm (millimetre) = 0.001 m (metre) = 0.0394" (inch)
1" (inch) = 0.0833 ft (foot) = 0.0254 m (metre) = 25.4 mm (millimetre)
1 ft (foot) = 12" (inch) = 0.3048 m (metre) = 304.8 mm (millimetre)
Velocity 1 m/s (metre/sec) = 3.6 kmph (kilometre/hour) = 3.28 fps (foot/sec) = 2.24 mph (mile/hour)
1 fps (foot/second) = 0.3048 m/s (metre/second)
Acceleration 1 G (acceleration due to gravity) = 9.81 m/s2 (metre/second2) = 32.2 ft/s2 (foot/sec2)
1 m/s2 (metre/sec2) = 3.28 ft/s2 (foot/sec2) = 0.102 G
1 ft/s2 (foot/sec2) = 0.3048 m/s2 (metre/sec2) = 0.0311 G
Volume 1 m3 (cubic metre) = 1000 litre = 220 Imperial gallon = 264 US gallon = 35.3 ft3 (cubic foot)
1 litre = 1000 cm3 (cubic centimetre) = 0.0353 cuft (cubic foot) = 35.2 floz (fluid ounce)
1 cm3 = 0.061 in3 = 0.0352 floz (fluid ounce)
1 Imperial gallon = 1.20 US gallon = 4.546 litre = 4546 cm3 (cubic centimetre)
1 US gallon = 0.833 Imperial gallon = 3.785 litre = 3785 cm3 (cubic centimetre)
Mass 1 Te (metric tonne) = 1000 kg (kilogram) = 0.984 ton = 2205 lb (pound)
1 kg (kilogram) = 1000 gm (gram) = 2.205 lb (pound)
1 lb (pound) = 0.4536 kg (kilogram) = 453.6 gm (gram)
Force 1 kgf (kilogram-force) = 9.81 N (newton) = 2.205 lbf (pound-force)
1 N (newton) = 0.102 kgf (kilogram-force) = 0.225 lbf (pound-force)
1 lbf (pound-force) = 0.4536 kgf (kilogram-force) = 4.448 N (newton)
Pressure 1 bar = 0.1 MPa (megapascal) = 14.50 psi (pounds/inch 2)
1 psi = 0.06895 bar = 6895 Pa (pascal)
Torque 1 Nm (newton-metre) = 0.737 lbft (pound-foot)
1 lbft (pound-foot) = 1.356 Nm (newton-metre)
Power 1 kW (kilowatt) = 1000 Nm/sec (newton-metre/sec) = 1.341 hp (horsepower)
1 hp (horsepower) = 0.746 kW (kilowatt) = 746 Nm/sec (newton-metre/sec)

3 INSTALLATION

3 INSTALLATION
3.1 SITE PREPARATION
3.1.1 Support Structure
3.1.2 Process Connections
3.1.3 Electrical Services
3.2 INSTALLATION PROCEDURE
3.3 COMMISSIONING PROCEDURE
3.3.1 Initial Checks
3.3.2 Dry Commissioning
3.3.3 Wet Commissioning

3 INSTALLATION
3.1 SITE PREPARATION

This section details the minimum structural, service, and control requirements for
installing Broadbent batch centrifuges. All this equipment can be provided by Broadbent,
but unless specifically included in the scope of supply, it remains the responsibility of the
customer. Specific numerical data is given in section 2.
3.1.1 Support Structure

Each centrifuge is a completely free standing, independent unit. The rotating
assembly and ancillary equipment are all mounted on the outer casing, which must
be bolted down to a support structure, which forms part of the civil works of the
building. Figure 3.1 shows a battery of machines on a typical support structure.
Figure 3.1 Typical Structure for Battery of Centrifuges
Centrifuge
Mixer Tank
rigidly attached
to backs of
Centrifuge Frames
H
H
V
V
V
V
V
V
Main Support
Beams
Lateral Web Stiffeners

Stiffening at attachment
Beams points

Batch centrifuges are inherently a source of vibration, so the support structure

must be designed to meet the strength and stiffness requirements detailed below.
These requirements are considerably more demanding than those for static
equipment such as storage tanks etc.
WARNING: Failure to design the support structure with adequate

strength and stiffness could result in serious damage or poor
performance.
3.1.1.1 Strength Requirements
The foundation drawing for the equipment details the locations and bolting
patterns for the attachments to the main support beams. It also lists the static
dead weights W at each point. These weight values include the weight of the
centrifuge and support structure and a full charge of massecuite in the
basket. If a Broadbent designed mixer is specified, the dead weight of the
tank, agitator, drive and a full load of massecuite is also included in the
foundation drawing. If a mixer from another manufacturer is to be used, the
dead weights must be added to those given on the drawing.
To allow for dynamic effects, the static weights must be multiplied by a

vibration factor f of 2 to give a vertical force of V, where V = fW, at each
attachment point as shown in Figure 3.1. In addition, allowance must be
made for a rotating out-of-balance force H at the suspension buffer of each
centrifuge, and this value is also detailed on the foundation drawing. This
force produces a horizontal overturning force which can be assumed to
apply in any of the four principal directions as shown in Figure 3.1.
An appropriate national or international standard for structural design should

be used to ensure that the support structure can safely carry all loads, V and
H, simultaneously and in the worst possible combinations.
3.1.1.2 Stiffness Requirements
The dynamic loads are all produced by out-of-balance forces and will
therefore alternate at the centrifuge's rotational speed. To avoid resonance,
the complete support structure, and each individual component, must be
sufficiently stiff to ensure that its resonant frequency is at least 50% higher
than the maximum running speed of the centrifuge, as shown in the
following table. The resonant frequency of the structure is related to its
static deflection under self weight plus all the applied loads W. The structure
will be sufficiently rigid if the average of the static deflections at all the load
points W is less than the value given below.
Resonant Frequencies and Static Deflections

Maximum Rotational Speed of Centrifuge - rpm 900 1000 1100 1200
Minimum permitted Resonant Frequency of Structure - Hz 22.5 25 27.5 30
Maximum Permitted Average Static Deflection - mm 0.49 0.4 0.33 0.28

Recommendations for Improving Strength and Stiffness
To improve the vertical strength and stiffness of the main front to back
support beams, use heavy duty ‘I’ beams and minimise the span. If a long
span is necessary, add diagonal braces to the vertical members. Diagonal
bracing can also be used to minimise the sideways swaying effect of the
complete structure caused by the horizontal component of the out of balance
force H.
To improve the horizontal strength and stiffness of the main support frames,
add lateral stiffening beams, as shown in Figure 3.1. Diagonal braces can
also be used if required.
To further minimise vibration it is strongly recommended that the mixer tank

is rigidly attached to the backs of the centrifuge frames at the anchoring pads
provided. This allows the side of the mixer tank to act as a shear panel,
stiffening the centrifuge frames and adding mass to damp vibration forces.
3.1.2 Process Connections

3.1.2.1 Feeding Arrangements
Rapid fluctuations in the level of product in the mixer tank feeding the
centrifuges will result in highly variable flowrates into the centrifuge. The
centrifuge may have difficulty in adjusting to rapidly changing feeding
conditions. It is therefore essential that the mixer tank capacity is large
enough to smooth out these variations. The capacity of the mixer tank
should not be less than,
Minimum Mixer Nominal Basket Number of

Tank Capacity = 2 x Capacity in kg of x Centrifuges in
in litres Massecuite Battery
This would allow the mixer tank to be emptied in only 3 cycles of all the
centrifuges in the battery (approximately 7 to 8 minutes). Ideally, the mixer
tank capacity should be double this. The nominal basket capacity is given in
section 2.
The product feed to each centrifuge normally comprises a butterfly type flow
control valve, a feeding spout, and an anti-drip valve mounted directly on
the centrifuge casing top. To prevent plugs of massecuite setting and
blocking the feed, the flow control valve should be mounted as close as
possible to the supply mixer tank via a short stub pipe cut to suit the tank
wall and seal welded. As a further precaution, a steaming out connection
should be welded into this stub pipe.

3.1.2.2 Discharge Arrangements
Dry product is discharged from a large, flanged circular central opening in

the bottom of the centrifuge casing. A conical discharge chute bolted to this
flange is required to direct the sugar onto a conveyor running side to side
beneath the centrifuge. The sides of the chute should not be shallower than
30o from vertical and, given the width of the conveyor, this determines the
height required between the base of the centrifuge and the top of the
conveyor. It is recommended that the discharge chute incorporates a sealed
hatch to allow access to the underside of the centrifuge for inspection and
maintenance.
Liquor is discharged from a large, rectangular flanged opening under the

back of the centrifuge casing. When liquor classification is specified, a
separator unit with two circular flanged outlets will be attached to this
opening.
If the sugar conveyor system is covered and sealed to the discharge chutes,
hot vapour generated by the water wash and steam injection will be blown
from centrifuges running at high speed along the conveyor system and out
through the covers of centrifuges running at low speed and this will damage
the speed sensors, disc brake, and main bearings. If it is planned to use a
sealed system, vapour must be extracted from takeoff points on the
conveyor covers by means of extraction fans and cyclones. Broadbent can
advise on the required flowrates.
For similar reasons, the liquor collection pipework and vessels must also be
vented to atmosphere.
3.1.2.3 Fluid Services
Water is required for spray washing of the product in the basket and for
rinsing the feeding chute. Steam is required for heating the product in the
basket. Compressed air (see 3.1.2.4 below) is required for operating the
various actuators. The termination points are shown in the reference
drawings specified in section 2. All these services must be supplied at the
temperatures, pressures and quantities specified in section 2. The supply
pipework must be of sufficient size to ensure that the specified pressures are
achieved at the termination points on the centrifuge.
3.1.2.4 Compressed Air Supply
Must be supplied clean (filtered), dry, unlubricated, between 4 bar g to 6 bar

g (60 psi to 90 psi), 5.5 bar g optimum, at ambient temperature. Quality
class 3.4.4 (taken from ISO standard 8573.1) is adequate. This implies 5
micron maximum particle size, 3°C dew point maximum, and 5mg per cubic
metre maximum oil content. Mean consumption of compressed air is 70
litres/minute of free air, peak flowrate 140 litres/minute of free air.

3.1.3 Electrical Services

The electrical supply must be maintained at the voltage and frequency specified in
section 2 at all times when the centrifuge is operating. Failure to provide the
specified supply could result in damage to the Drive Panel.
3.1.3.1 Electrical Cabinets
Each centrifuge is supplied with a Drive Panel containing the inverter and a
Control Panel containing the PLC and ancillaries. Drawings giving sizes and
weights are provided.
The electrical cabinets must be installed in a clean area free from vibration
and risk of splashing, with an ambient temperature below 40oC. The
atmosphere should be dust-free with low humidity. Air conditioning is
recommended.
If more than one machine is to be supplied, it is recommended that the

cabinets are installed side by side with at least 1000 mm clearance to the
front. The back and sides of the cabinets may be placed adjacent to walls or
other cabinets provided that a minimum of 100 mm clearance is allowed for
cooling. Access is only required from the front and top. To simplify
installation, each cabinet is mounted on a plinth. The plinth can be removed
from the cabinet and bolted down to a steel floor or grouted into a concrete
floor before remounting the cabinet. All cables should enter the cabinets
through the bottom.
3.1.3.2 Cable Sizes and Wiring
All electrical wiring must be in accordance with local regulations. Broadbent

can recommend suitable power supply cable sizes. Information on suitable
control cable sizes is given in the electrical hook-up drawings.

3.2 INSTALLATION PROCEDURE

To minimise on site installation work, each centrifuge is despatched almost fully
assembled laying its side on a substantial transportation frame. The drive cabinet, control
cabinet, cooling fan and filter, feed valve, liquor classification unit, plough blade, and
tools are packed separately.
The plough mechanism slightly overhangs the right hand side of the casing when viewed
from the front. To avoid interference during installation, centrifuges should be installed
in order from right to left along the battery when viewed from the front. Installation
will also be simplified by installing the centrifuges after the sugar conveyor but before
the mixer tank.
The installation procedure for each centrifuge is as follows,

(a) Open the packages and check all items against the advice note. Report
any damage or deficiencies to the manufacturer.
(b) Remove the outer packaging and retention clamps and straps from the
centrifuge. Ensure the four special swivel type lifting eyes are fitted and
tightened into their seatings at the corners on top of the upper frame.
WARNING: Standard collared eyebolts are NOT suitable for lifting

the centrifuge as described in this procedure.
Figure 3.2 Lifting Centrifuge off Transport Plinth
T
EN
DB
OA
BR
8 Tonne SWL
Lifting Beam
rigged for 2 leg lift
Swivel 7200 kg Lift

Eyebolts
CG
T
EN
DB
OA
BR
BROADBENT
BROADBENT
CG
Transportation
Plinth

(c) Rig the lifting beam for a 2 leg lift and attach to two M36 swivel eye
bolts screwed hard down into the tapped holes in the top right of the
frame (next to the plough assembly). Hook onto a crane with at least 8
Tonne lifting capacity. Gently lift the centrifuge up out of the transport
plinth. The centrifuge will gradually swing to a near vertical position. Set
the lower corner of the centrifuge down on the floor and move the crane
sideways until the centrifuge sits upright on the bottom of the casing.
See Figure 3.2.
(d) Check that the 4 seating pads on the support structure are clean and
level to better than 0.5 mm.
(e) Remove the lifting beam, rig for a 4 leg lift, and attach to four M36
swivel eye bolts screwed fully down into the four tapped holes in the top
of the frame. Hook onto a crane with at least 8 Tonne lifting capacity.
Lift the centrifuge into position on the support structure. See Figure 3.3.
Figure 3.3 Lifting Centrifuge onto Support Structure
8 Tonne SWL
Lifting Beam
BROADBENT
Swivel
Eyebolts
7200 kg Lift
CG
BROADBENT
(f) Remove the 4 inspection panels in the rectangular side frames. There
should be enough slack in the pipes and cables behind the
electropneumatic panel EP and control terminal box CTB to avoid
having to perform any disconnections. Fit and torque tighten the
anchoring bolts attaching the centrifuge to the support structure. Refit
the inspection panels. Remove the lifting frame.

(g) The following items which secure the centrifuge rotating assembly inside
the casing during transit must be removed.
w Four steel brackets and several wooden blocks holding the basket
bump ring concentric with the casing.
w Wooden blocks between the underside of the upper frame and the
torque reaction rods and brake bracket which prevent the rotating
assembly moving axially.
(h) Attach the discharge chute to the flange under the casing using the
tapped holes provided. See section 3.1.2.2.
WARNING: When electric arc welding, attach the earthing clamp as

close as possible to the working area. On no account attach the
earthing clamp to any part of the rotating assembly or basket since
this could allow currents to pass through and damage the bearings.
(i) Where applicable, attach the liquor classification unit and valves to the
rectangular flange under the casing and fit the discharge pipework. See
section 3.1.2.2.
(j) Fit brackets to rigidly attach the mixer tank to the mounting pads on the
rear of the upper frame back cross member.
(k) Fit the feed chute and feed valve. Trim the stub pipe and seal weld to the
mixer tank. See section 3.1.2.1.
(l) Remove the transit cover on the cowl top air inlet flange and fit the
cooling fan and filter.
(m) Fit the plough blade to the plough arm.
(n) Connect water services to the wash spray pipe and feed chute rinse
valves on the pan top. Connect steam services to the injection pipe valve
on the pan top. Connect compressed air services to the regulator on the
rear right of the casing near the control terminal box CTB.
(o) Install the control and drive cabinets in an air conditioned room. See
section 3.1.3.1.
(p) Install and connect mains and control cabling in accordance with the
Hook up drawing specified in section 2. See section 3.1.3.2.

3.3 COMMISSIONING PROCEDURE

WARNING: The operating controls and procedures detailed in
section 4 and the fault diagnosis procedures in section 6 should be
studied before attempting to commission the centrifuge.
3.3.1 Initial Checks

WARNING: The mixer tank must be empty and the electrical, water
and steam supplies isolated for this stage of commissioning.
(a) Check all wiring for continuity and correct termination.
(b) Adjust the plough settings as detailed in section 5.3.6,

w Check the vertical adjustment of the blade in the basket.
w Check the horizontal clearance of the blade to the basket, flinger,
and spindle.
w Remove the blanking plug in the top of the vertical dashpot. With
the plough in its down position, check the oil level in the sight glass
and top up if necessary. Fit the breather plug in place of the sealed
blanking plug.
w Check the plough horizontal cylinder in and return pressures.
w Move the plough through its operating cycle, using the override
switches on the solenoid valves in the electro-pneumatic EP panel
(refer to Appendix C).
(c) Check that all proximity sensors are adjusted correctly and that the leads
are connected.
(d) Check that the transit brackets and wooden wedges have all been
removed (see section 3.2)
(e) Use the pneumatic overrides to lift the brake. Temporarily remove the
inspection cover in the pan top and rotate the basket by hand. The basket
should turn easily without any abnormal noises.
3.3.2 Dry Commissioning

WARNING: The mixer tank must be empty and the water and steam
supplies isolated for this stage of commissioning.
3.3.2.1 Running In at Medium Speed
(a) Remove the 2 grease nipples located just beneath the bearing housing.
(b) Switch on the power supply and check that the PLC input LED
associated with the 'feed valve closed' proximity switch is on. If the LED
is off, check that the feed valve is closed and check the operation of the
'feed valve closed' proximity switch.

(c) Start the centrifuge in Manual Cycle Mode and Preset Feed Mode with
the feed valve preset opening to 10%. Check that the basket rotates
clockwise when viewed from above. If the rotation is not correct, Stop
the centrifuge immediately and correct the phase rotation of the main
motor leads.
(d) When ‘feeding’ starts, operate the Feed Valve Slider and check that
the feed valve opens and closes. Operate the Trip Lever on the feed
limiter to terminate feeding. The centrifuge will accelerate to holding
speed. Do not press the Start button to continue.
(e) Allow the centrifuge to run for 3 hours at this medium speed to expel
excess grease from the bearings. Stop the centrifuge.
(f) Refit the grease nipples.
3.3.2.2 Cycle Checks
(a) Fit a temporary stop on the pan top to restrict the horizontal movement
of the lever arm at the bottom of the plough mechanism. This should be
adjusted to hold the plough tip about 5 mm off the working screens.
Figure 3.3.2 Temporary Stop - Plough Tip Adjustment
TEMPORARY
STOP
ADJUSTMENT
(b) Carry out several Plough Only Cycles. Check for correct operation and
adjust the vertical hydraulic damper valve so that the travel of the plough
down the basket takes about 12 seconds.
(c) Run the centrifuge through several cycles in Manual Cycle Mode and
Preset Feed Mode, checking for the correct operation of all controls.
(d) Switch to Automatic Cycle Mode and Calculate Feed Mode and run
through several cycles checking for correct operation of all controls.

(e) Check correct operation of the Out of Balance Trip at different parts of
the cycle by pulling the mushroom head of the switch unit outwards.
(f) Remove the temporary stop to allow the plough tip to contact the
working screens.
3.3.3 Wet Commissioning

WARNING: Check the mixer tank is clear of debris and foreign
objects before filling with product.
(a) Check all presets are set to the initial values recommended in section 2.
Set the feed limiter to trip at about half the maximum cake thickness
(about 100 mm off the screens).
(b) Run the centrifuge through several cycles in Manual Cycle Mode and
Preset Feed Mode carrying out the following adjustments to obtain
smooth, reliable operation (Refer to Appendix D).
w Modify process parameters using the QuickPanel.
w Adjust the angle of the secondary valve flap in the open position so
that the product is directed onto the flinger. Use the threaded
adjustment in the actuating cylinder ball joints.
w Gradually increase the cake thickness in the basket up to the full
depth by adjusting the feed limiter.
w Twist the wash pipe to adjust the spraying distance and thus the
spread of the pattern. Attempt to obtain an even distribution of
water over the full height of the product cake, without spraying
excessive amounts over the top of the basket lip, or onto the basket
bottom.
(c) Switch to Automatic Cycle Mode and Calculate Feed Valve Mode and
run through several cycleas.

4 OPERATION

4 OPERATION
4.1 MANDATORY LIMITATIONS
4.2.1 Cycle Modes
4.2.2 Feeding Modes
4.2.3 Stopping Modes
4.3 OPERATOR INTERFACE
4.3.1 Hardwired Controls
4.3.2 QuickPanel
4.4 OTHER CONTROLS
4.4.1 Drive Panel
4.4.2 Control Panel
4.4.3 Feed Limiter
4.4.4 Pneumatic Overrides
4.5 OPERATING PROCEDURES
4.5.1 Starting
4.5.2 Running Routines
4.5.3 Shutdown and Stopping
4.5.4 Off Crop Routines

4 OPERATION
4.1 MANDATORY LIMITATIONS

The centrifuge is designed to operate within the parameter ranges specified in section 2.
To ensure the safety of operating personnel and to avoid premature failure of the
centrifuge, the following restrictions must be observed,
w Operation of this centrifuge should only be undertaken by personnel

specifically trained in its use.
w The centrifuge must not be run with the casing covers or spindle
guards removed.
w The basket must not be run at speeds greater than those specified.
w Non-permeable materials or materials with a density greater than
that specified must not be allowed to enter the basket.
w Free liquor on the surface of the cake in the basket is a serious
hazard. This must be avoided by ensuring that the product slurry
and wash supplies are within the limits specified. Feeding must take
place within the speed range specified.
w The pneumatically operated plough and feed valve mechanisms
fitted to this machine will move through their operating cycles
automatically. Remain well clear of all plough and feed valve parts
during machine operation.
w If unusual noise or vibration are experienced, the centrifuge must be
stopped immediately.


The sequence of events during a normal operating cycle of the centrifuge is as follows,
The centrifuge accelerates to a low speed. The butterfly feed control valve and a flap
valve open, allowing product to flow down a feeding chute onto a flinger disc attached
to the spindle. This throws the product onto the inside of the basket, where it flows
under centrifugal force to form a uniform wall. Liquor starts to flow out through the
filtering screens and basket perforations and is collected in the outer casing, and
discharged down pipework under the machine. The product thickness builds up inside
the basket until the feed detector trips, causing the feed control valve to close. The
inside of the feed chute is sprayed with water, and after a short delay the flap valve
closes to prevent any remaining dark coloured product dripping onto the product inside
the basket. The feeding rate depends on how far the feed valve opens and this can be
manually or automatically controlled.
On completion of feeding, the centrifuge accelerates to a medium speed hold point, to

await operator or sequence permission to proceed. The centrifuge then accelerates to its
maximum spin speed. During this time, purging of liquor from the product cake
continues, and water and steam can be sprayed on to remove the final traces of mother
liquor from the crystals. The purity of the run off liquor rises, and a classification valve
system can be used to direct this liquor down a different discharge pipe. The centrifuge
pauses at spin speed for a preset time to dry the crystal cake to the desired level.
On completion of spinning, the centrifuge decelerates to a very low speed. The

discharge valve plate under the bottom of the basket opens. The plough blade cuts into
the top of the cake and moves slowly down the basket screens, discharging dried
crystals through the basket bottom, and down a chute onto a conveyor running beneath
the casing. The plough blade moves back to its parked position, the discharge valve
shuts, and the machine accelerates to feed speed to begin another cycle. During
acceleration, the filtering screens can be sprayed with a small amount of water to remove
any remaining crystals and thus prevent clogging.
A number of different operating modes can be selected by the operator,
4.2.1 Cycle Modes

AUTOMATIC CYCLE MODE The centrifuge cycles automatically with the
operator able to change feed, spin, wash, and plough parameters without affecting
the centrifuge sequence. The centrifuge continues in this mode unless the Stop or
Emergency Stop buttons are pressed, or a fault occurs. Faults will switch the
centrifuge into Manual Cycle Mode and, depending on the type and severity of the
fault, may also stop the centrifuge, or shift it to another part of the cycle.

MANUAL CYCLE MODE The centrifuge cycles in the same way as in

Automatic Cycle Mode except that the centrifuge pauses awaiting operator
intervention at certain parts of the cycle and also comes to rest at the end of each
cycle. The operator is required to press the Start button at the following points,
(a) To allow feeding to commence
(b) To allow acceleration from holding speed to spin speed
(c) To allow continuation to another cycle
Manual Cycle Mode is useful when commissioning the centrifuge, to find the
optimum operating parameters, and also during fault finding.
PLOUGH ONLY CYCLE The centrifuge performs a discharging cycle. The

discharge valve opens, the plough moves through its cycle, and the discharge valve
closes. The centrifuge can only start a Plough Only Cycle from rest and comes to
rest when complete.
4.2.2 Feeding Modes

To allow for massecuites of different characteristics, the butterfly feed control
valve can open to different apertures thus giving different feeding rates. The feed
valve opening can be controlled in two different modes,
PRESET MODE The operator sets a Feed Valve Preset percentage opening and
the feed control valve always opens to this position. This preset opening value can
be changed at any time.
CALCULATE MODE The operator sets an Ideal Feed Time and the valve
opening changes to try and achieve this. If the actual feed time on a particular
cycle is longer than the Ideal Feed Time, the valve will open by 5% for the next
cycle. If the actual feed time on a particular cycle is shorter than the Ideal Feed
Time, the valve will close by 5% for the next cycle. For the first cycle after the
centrifuge has been stopped, the valve opens to the preset percentage valve
opening for the first new cycle and then modifies the opening as above. Calculate
Mode can compensate for slowly changing massecuite characteristics. It cannot
cope with sudden changes in massecuite consistency or feeding tank head.
The feed valve operating modes are the same regardless of the cycle mode. The
feed valve position can be manually "inched" open or closed by the operator
during feeding whichever mode is selected, without affecting the preset or
calculated value for the next cycle.
The operator sets a Fail Feed Time. If feeding continues longer than the Fail Feed
Time, feeding terminates, and the machine changes into Manual Cycle Mode.

4.2.3 Stopping Modes

CONTROLLED STOP A controlled stop is initiated by pressing the stop button.
The machine is brought to rest in a controlled manner leaving the machine in a
safe, power on state with all systems and mechanisms ready for the next Start
command.
EMERGENCY STOP The emergency stop operation is initiated by pressing the

hardwired emergency stop pushbutton. The machine stops in a controlled manner
leaving the machine in a safe state. The power is then removed from all
components except those that are required for restarting. The power reset
pushbutton must be pressed before the machine can be restarted.
POWER DISCONNECT The Power Disconnect operation is initiated by

pressing the hardwired power disconnect pushbutton. Power is immediately
removed from all components except those that are required for restarting. All
pneumatically operated devices return to a safe position and the machine comes to
rest on the mechanical brake. The power reset pushbutton must be pressed before
the machine can be restarted. Note this method of stopping will result in the
centrifuge taking considerably longer to come to rest.
FAULTS AND AUTOMATIC TRIPS The machine automatically detects fault

conditions which may produce a dangerous situation or cause damage to the
machine. Minor faults simply cause the machine to move to a safe position in the
cycle, and hold. Major faults cause the machine to trip via a controlled stop. In all
cases, the faults must be accepted to allow the fault to be cleared before operation
can continue.

4.3 OPERATOR INTERFACE

The Operator Interface Panel is attached to the front right hand leg of the centrifuge
upper frame. It incorporates all the controls necessary to operate the centrifuge. The
panel comprises a ‘Quickpanel’ touch sensitive screen, which is used for all normal
operation, surrounded by a number of hardwired pushbuttons which are used for critical
functions such as emergency shutdowns.
EMERGENCY STOP
Serial
BROADBENT
Number
QUICKPANEL ///
POWER POWER FEED VALVE

RESET DISCONNECT CLOSE
4.3.1 Hardwired Controls

For safety reasons, certain critical functions are performed via hard wired
pushbuttons mounted on the Operator Interface Panel,
The EMERGENCY STOP PUSHBUTTON (Red) is used to stop the centrifuge

in an emergency situation. The centrifuge decelerates to rest by inverter
regenerative braking, and then cuts the electrical power to all components except
those necessary to restart the machine. This is a self locking mushroom head
pushbutton and must be twisted clockwise to release it.

The POWER DISCONNECT PUSHBUTTON (Black) immediately cuts all

electrical power to the centrifuge in an emergency situation. The centrifuge
decelerates to rest only by means of the emergency mechanical disc brake which
could take several minutes.
The POWER RESET PUSHBUTTON (Blue) is normally lit on initial power up,
or after the Emergency Stop pushbutton has been pressed. Pressing the reset
button extinguishes the lamp and restores electrical power.
The FEED VALVE CLOSE PUSHBUTTON (Yellow) immediately stops

feeding in an emergency situation. The feed control valve and secondary drip valve
close immediately, and the centrifuge returns to the start of feeding, awaiting
operator intervention. This is a latching pushbutton and must be pressed again to
release it.
Fitted beneath the Operator Interface is a flashing FAULT BEACON to give a

visible indication that a fault has occurred, requiring intervention by the operator.
4.3.2 QuickPanel
The main part of the interface is the QuickPanel screen which operates via the
PLC. This is touch sensitive so it can both display and accept information. The
QuickPanel displays the status of the centrifuge, and allows the operator to start
and stop the centrifuge, change process parameters, and switch between the
various cycle and feeding modes. All normal operations are performed via the
QuickPanel.
It is not possible to display all the information and controls on a single screen.
Instead, the various functions are grouped into a number of different screens, with
each screen representing a different aspect of the centrifuge operation. Each
screen is described in detail in the following sections.
A number of conventions are used in all the QuickPanel displays,
Stop Pushbutton. Red with White Text.

Pressing this panel initiates a controlled stop. The centrifuge
decelerates to rest using regenerative braking and all mechanisms
return to their parked positions ready for the next Start command.
This pushbutton is present at the top left corner on all screens.
Parameter Display Panel. Black with Yellow Text.
This displays the current value of the stated machine parameter.
Displays of speed (rpm) and vibration level (0.01 G) are present
on the top row of all screens.
Fault Display Panel. White with Red Text.
This displays details of any faults present causing the centrifuge
to stop.
This panel is present on the top right corner on all screens.

Status Display Panel. Green with Blue Text.

This displays the current status of the centrifuge. If the centrifuge
is being inhibited from starting, the reason will be given. If the
centrifuge is running, the position in the cycle is displayed.
After a fault, this panel must be pressed to silence the alarm and
reset the control system before operation can be resumed.
This panel is present on the top row on all screens.
Option Pushbutton. Green with Black Text and Indicator.
This type of panel behaves as a switch toggling between two
options. The option is available if the indicator is white. The
option is not available if the indicator is red.
This type of pushbutton is used to initiate starts, swap between
cycle or feed modes, initiate manual washing etc.
Preset Value Pushbutton. Blue with Black and Yellow Text.
This type of panel displays the current value in yellow of the
parameter stated in black. Pressing the panel changes the display
to a Calculator Screen, allowing a different value to be entered
within maximum and minimum limits set at the factory.
This type of pushbutton is used to change process parameters
such as speeds and times required to optimise the performance of
the centrifuge.
Goto Pushbutton. Blue and Yellow with Black Text.
Pressing this panel forces the display to change to a different
screen and is present on the bottom right corner of all screens.
There are eight screens programmed into the QuickPanel, these screens are
accessed by means of the Goto pushbuttons
When any area of any QuickPanel screen is touched, that screen is kept on the
display for a preset delay time. When this delay expires, the display will
automatically change to the default screen. The default screen displayed is the
Main Screen unless feeding is about to take place, in which case the Feed Screen
will be displayed.
NOTE: The parameter values shown in the following screen

illustrations are default digit displays and are NOT realistic values
which would be seen on actual operating centrifuges.
4.3.2.1 Main Screen
This screen is the default screen at all times except during feeding and is
used for selecting the mode of operation, the starting and monitoring of the
centrifuge.
In addition to the standard panels which are present on the top row of all
screens, the main components on this screen are,

MAIN SCREEN
The Mimic in the centre of the screen is a simplified representation of the

current status of the centrifuge,
w The numeric display inside the motor gives the current actual
centrifuge speed (rpm).
w During feeding, the square indicator on the feed valve changes from
green to yellow and the numeric display next to it gives the preset
percentage valve opening.
w During ploughing, the ‘L’ shaped plough on the mimic moves to
indicate the plough blade position, and the square indicator at its top
turns from green to red to indicate that the plough is no longer
latched in its parked position. At the same time the discharge valve
changes from green to yellow when it opens.
w During washing and steaming, the colours of the water and steam
spray pipes change. The water spray pipe also indicates which of the
three washes is active.
w The square indicators on the liquor outlet show whether discharging
is to mother liquor or washings.
w The conveyor changes from green to red if the conveyor stops.
w The ‘T’ shaped indicator on the side of the motor changes from
green to red if the Out of Balance Switch trips. The square indicator
on the side of the motor changes from green to red if the Vibration
Monitor trips. In both cases, the numeric value next to it gives the
speed at which the trip occurred.
Pressing the appropriate area of the mimic is an alternative method of
changing the display to a different screen. For example, pressing the motor
will change to the Spin Screen or pressing the feed valve will change to the
Feed Screen.

The Main Screen incorporates various option pushbuttons as follows,
The Start Pushbutton is pressed to start the centrifuge. When in Manual

Cycle Mode, this must also be pressed to commence feeding, to accelerate
from holding speed, and to continue on to another cycle.
The Cycle Mode Pushbutton is pressed to switch between Manual

Cycle Mode and Automatic Cycle Mode.
The Feeding Mode Pushbutton is pressed to switch between Preset

Feed Mode and Calculate Feed Mode.
The Plough Only Cycle Pushbutton is pressed to switch to a Plough

Only Cycle. The Start pushbutton must then be pressed to initiate the
ploughing sequence.
The Manual Wash Pushbutton is pressed to apply wash water onto the
product or screens through the spray pipe. Washing stops when the
pushbutton is released.
If the indicator on a pushbutton is red, that option is not available at that

particular time.
4.3.2.2 Feed Screen
During feeding, the display automatically changes to the Feed Screen. This is
used for viewing and changing all parameters associated with feeding.
FEED SCREEN
In Manual Cycle Mode, the centrifuge pauses at the start of feeding. The
Start Feeding Pushbutton must be pressed to commence feeding.
The Stop Feeding Pushbutton is pressed to terminate feeding

immediately and continue through the operating cycle.

The Feeding Mode Pushbutton is pressed to switch between Preset

Feed Mode and Calculate Feed Mode.
The Feed Valve Position Slider displays the current desired feed valve
percentage opening. This will be either the Preset Value (PV) associated
with Preset Feed Mode or the Calculated Value (CV) associated with
Calculate Feed Mode which are given as numeric displays under the slider.
The slider position can be moved by pressing the ends marked + and -,
w Moving the slider during feeding causes the valve to inch open or
closed accordingly, but by itself this does not affect the preset or
calculated valve opening for the next cycle.
w If the Accept Feed Valve Position as New Feed Valve
Preset Pushbutton is pressed during feeding, the current
position of the slider becomes the new Feed Valve Preset value used
in Preset Feed Mode.
Process parameters associated with feeding can be adjusted as follows.
The Feed Speed Preset is the centrifuge rotational speed (rpm) at which
feeding occurs.
The Feed Valve Preset is the percentage opening that the feed valve will
open to on every cycle when in Preset Feed Mode. This value can also be
changed using the slider as described above.
The Ideal Feed Time is the target feeding time (seconds) the centrifuge
will attempt to achieve by varying the feed valve opening from cycle to cycle
in Calculate Feed Mode.
The Fail Feed Time is the longest time (seconds) allowed for feeding
before a fault is assumed. After this time limit expires feeding terminates, the
control system switches into Manual Cycle Mode and the centrifuge
continues to the end of the cycle and stops.
The Cake Settle Preset inserts a pause (seconds) between the end of
feeding and the start of acceleration to holding speed. This can be useful to
stabilise difficult to purge product cakes.
4.3.2.3 Wash Screen
This screen is used to set all the process parameters associated with washing
the product with water and steam during acceleration and spinning.
Up to three water washes and one steam injection can be programmed.

Water Washes ‘A’ and ‘B’ occur during acceleration and are initiated at
specified centrifuge speeds. Water Wash ‘C’ and Steam Injection occur
during spinning and are therefore initiated at a specified time from the start
of spinning. The liquor classification system changeover from mother liquor
to washings occurs at a specified delay after Wash ‘A’ has started. Wash ‘A’
can be set to occur before or after wash ‘B’.

WASH SCREEN
The Wash A / Wash B Speed Presets are the centrifuge rotational

speeds (rpm) to start the two product water washes during acceleration.
The Wash C Delay Time Preset is the time (seconds) between the start
of spinning and the start of the single high speed product water wash.
The Wash A / Wash B / Wash C Duration Presets are the durations

(seconds) of the product water washes. Setting the duration to zero
effectively turns the wash off.
The Steam Delay Time Preset is the time (seconds) between the start of
spinning and the start of injecting steam into the basket.
The Steam Duration Preset is the duration (seconds) of the steam

injection. Setting the duration to zero effectively turns the steam off.
The Molasses Classification Time is the delay (seconds) from the start
of Wash ‘A’ to changing over the classification system from discharge to
mother liquor to discharge to washings.
The Screen Rinse Time is the duration (seconds) that the screens are
sprayed with water to clean off traces of product during acceleration to feed.
The Chute Wash Duration is the duration (seconds) that the inside of the
feed chute is sprayed with water to remove traces of product before the
secondary drip valve closes.

4.3.2.4 Spin Screen
This screen is used to set all the process parameters associated with spinning
the product and sequencing.
SPIN SCREEN
The Spin Speed Preset is the rotational speed (rpm) at which the
centrifuge spins the product.
The Spin Time Preset is the time (seconds) the centrifuge remains at spin
speed.
In a battery of centrifuges, it is sometimes desired to avoid several

centrifuges carrying out the same part of the cycle simultaneously. The usual
sequencing points are at the start of acceleration to spin (to avoid
overloading the power supply) or at the start of ploughing (to avoid
overloading the sugar conveyor).
The Override Sequence Interlock Pushbutton is pressed to turn

sequencing on and off.
The Sequence Select Pushbutton is pressed to toggle between

sequence on acceleration and sequence on ploughing.
4.3.2.5 Plough Screen
This screen is used to set all the process parameters associated with
discharging the product.
The Plough Speed Preset is the rotational speed (rpm) at which product
is ploughed and discharged from the centrifuge.When the plough blade first
reaches the screen after cutting through the top of the product cake, the

Plough Down Delay Time Preset is the pause (seconds) before the
plough starts to move down the screens. When the plough blade reaches the
bottom of the basket, the Plough Return Delay Time Preset is the
pause (seconds) to remove all traces of product before starting to move back
to the parked position.
PLOUGH SCREEN
It is advisable to interlock the centrifuge with the conveyor so that product

cannot be discharged if the conveyor is stopped. The Override Conveyor
Interlock Pushbutton is pressed to turn this interlocking on and off.
4.3.2.6 Alarm Screen
This screen displays the last ten faults causing shutdowns, the total time
taken for the last cycle, and the number of cycles completed.
ALARM SCREEN

4.4 OTHER CONTROLS

4.4.1 Drive Panel (Inverter)
The following are fitted to the front of the panel,
An Isolator is fitted to isolate the electrical supply input to the inverter.
A Keypad with integral display is fitted for entering parameters and fault
diagnosis. Refer to the Inverter Operating Manual
CAUTION: The Inverter Drive should only be disconnected from the

Mains Supply as specified in the Inverter Operating Manual. Failure
to observe these instructions could result in Inverter fuse failure.
4.4.2 Control Panel (PLC)

The following are fitted to the front of the panel,
An Isolator is fitted to isolate the electrical supply input.
A Power On Lamp lights when the electrical power supply to the Control Panel
is turned on.
A Machine Running Lamp lights when the centrifuge main drive motor is
running.

4.4.3 Feed Limiter

The Feed Limiter is fitted to the pan top. It is used during feeding to detect when
the product cake reaches the desired thickness and signal the feed valve to close.
Cake Thickness Adjustment is by rotating the entire feed limiter box about
its shaft so as to move the slipper closer to or further from the basket shell. The
box is locked in position by a nut and slot.
The Trip Lever mounted on top of the feed limiter box is directly connected to
the slipper. If the feed limiter slipper is deployed in its sensing position, turning the
lever clockwise closes the feed valve and continues with the cycle. This is
equivalent to pressing the Stop Feed Pushbutton on the QuickPanel Feed Screen.
4.4.4 Pneumatic Overrides

The solenoid valves in the Electro-Pneumatic Panel EP are fitted with override
switches which allow all the pneumatic actuators to be operated manually when
carrying out maintenance or fault diagnosis. Refer to Appendix C for details.
WARNING: Do not use the overrides when the centrifuge is

operating normally under PLC control since this could cause serious
damage or injury.

4.5 OPERATING PROCEDURES

WARNING: Operators must be familiar with the Operating Principles
and the Controls detailed in sections 4.1 to 4.3 before attempting to
carry out any of these procedures.
4.5.1 Starting
If the centrifuge has been stopped for more than a few minutes or as the result of a
fault, it is strongly recommended that the centrifuge is started in Manual Cycle
Mode and Preset Feed Mode and run through at least one complete cycle before
switching to other modes. It is possible to start directly in Automatic Cycle Mode
and Calculate Feed Mode, but this should only be considered if the machine has
been paused for a short time and the product feed conditions have not changed.
(a) First turn on the isolator on the Control Panel. Then turn on the isolator
on the Drive Panel.
(b) Press the Power Reset pushbutton on the Operator Interface. Select
Manual Cycle Mode and Preset Feed Mode. Check the various process
parameter presets are set to reasonable values. Check the feed limiter is
set to give the desired cake thickness.
The Main Screen appears. The centrifuge is ready to start.
(c) Visually check there are no obstructions or foreign objects in basket and
that personnel are clear of moving parts. Press the Start pushbutton.
The mechanical brake releases. The centrifuge accelerates to feed
speed and the screens are rinsed. At feed speed, the liquor
classification system sets to discharge to mother liquor, the feed
limiter slipper moves to its sensing position, and the secondary drip
valve opens. The Feed Screen appears and the cycle pauses.
(d) Press the Start Feeding pushbutton.
The feed control valve opens and product flows into the basket and
starts to form a cake on the screens.
(e) Adjust the rate of feeding by inching the feed valve open or closed using
the Feed Valve Position slider. Feeding can be stopped prematurely
by one of the following methods,
w Press the emergency Feed Valve Close hardwired pushbutton.
This closes the valve and returns to the start of feeding. Press the
button again to reset it and continue from (d).
w Press the Stop Feeding pushbutton. This closes the feed valve
and continues the cycle.
w Twist the Trip Lever on the feed limiter clockwise. This closes the
feed valve and continues the cycle.

Feeding continues until the feed limiter trips or feeding is

terminated manually using one of the methods above. The feed
control valve closes. The inside of the feed chute is rinsed with
water and after a short delay the flap valve closes. The centrifuge
accelerates to holding speed and pauses.
(f) Press the Start pushbutton. If sequencing on acceleration is selected, the
centrifuge may still wait. In this case, pressing the Sequence
Override pushbutton will allow the cycle to continue.
The centrifuge accelerates to spin speed. During this time, the
water wash sprays and steam injection come on at the preset times
and the liquor classification switches over to the washings outlet.
After spinning is completed, the centrifuge decelerates to ploughing
speed. The discharge valve opens and the centrifuge pauses.
(g) If sequencing on discharging and/or the conveyor interlock are selected,
the centrifuge may pause at this point. These may be ignored by pressing
the Sequence Override or Conveyor Interlock Override
pushbuttons.
The plough unparks and moves into the top of the basket, pauses,
moves down the basket, pauses, lifts off the screens, moves to the
top of the basket and then towards the spindle and parks. The
centrifuge decelerates to rest and the mechanical brake is applied.
(h) Press the Start pushbutton to initiate another cycle from (c) above.
4.5.2 Running Routines

(a) Optimise the performance of the centrifuge by modifying the various
process parameters using the preset value pushbuttons on the various
screens. These values can be modified at any time. Two of the key
parameters affecting performance are the feeding speed and the feed
valve opening. Guidance on optimising process performance is given in
Appendix D.
(b) Once the centrifuge is cycling reliably, switch from Manual Cycle Mode
to Automatic Cycle Mode by pressing the Cycle Mode pushbutton. In
Automatic Cycle Mode, the centrifuge may still pause if the sequence
and/or conveyor interlock options are selected, but will not require
operator intervention to continue. It is possible to switch between the
two cycle modes as desired. Note that faults generally switch the
centrifuge back into Manual Cycle Mode.
(c) When feeding conditions have stabilised and it is not necessary to make
large adjustments to the feed valve preset opening, switch from Preset
Feed Mode to Calculate Feed Mode using the Feed Mode pushbutton.

4.5.3 Shutdown and Stopping

There are a number of methods of stopping the centrifuge. See also section 4.2.3.
(a) To complete the current cycle and shut down the centrifuge in a
completely controlled manner, change to Manual Cycle Mode by
pressing the Cycle Mode pushbutton after the holding point has been
passed. The centrifuge will finish processing the current charge,
discharge the product, and automatically come to rest awaiting another
start command.
WARNING: Using Stop, Emergency Stop, or Power Disconnect can

result in product being left in the basket which has not been
completely processed and could cause contamination downstream
of the centrifuge.
(b) An immediate controlled stop can be initiated by pressing the Stop

pushbutton. The centrifuge ceases the current operation and decelerates
to rest immediately. The recommended procedure is to initiate the Stop
command at the end of spinning or during deceleration, wait for the
centrifuge to come to rest, then initiate a discharging cycle using the
Plough Only Cycle pushbutton. The centrifuge will then stop awaiting
another start command.
(c) Pressing the Emergency Stop or Power Disconnect pushbuttons

initiates immediate uncontrolled stops and disconnects electrical power.
These may result in mechanisms not being left in their parked positions
and further work may be required to get the centrifuge ready for another
start. These stopping methods should therefore only be used in
emergencies. Note also that power disconnect removes all
power from the components in the PLC panel except for
those needed for restarting. This results in the signals to
the inverter drive been lost and hence the centrifuge can
only stop by way of the mechanical emergency brake. This
will considerably lengthen the stopping time of the
centrifuge.
4.5.4 Off-Crop Routine

When the centrifuge is to be shut down and left idle for 2 or more weeks, the
following procedures are recommended,
(a) At the end of operations, thoroughly wash out the interior of the
centrifuge with water and steam to remove all traces of massecuite and
molasses. Give particular attention to the bottom of the basket and hub.
(b) Every week, run the centrifuge dry at full speed for about 20 minutes.
This will prevent condensation in the drive motor and avoid brinnelling
of the bearings.

5 MAINTENANCE

5 MAINTENANCE
5.1 SAFETY
5.2 ROUTINE MAINTENANCE
5.2.1 Lubrication
5.2.2 Cooling Fan Filter
5.3 OVERHAUL PROCEDURES
5.3.1 Rotating Assembly
5.3.2 Basket
5.3.3 Screens
5.3.4 Main Drive Motor
5.3.5 Discharge Valve
5.3.6 Plough
5.3.7 Anti-Precession Damper
5.3.8 Disc Brake
5.3.9 Wash Pipe
5.3.10 Feed Valve

5 MAINTENANCE
5.1 SAFETY
All maintenance and overhaul activities must be carried out by suitably qualified and
trained personnel. Training courses on operation and maintenance are available - please
contact Broadbent for details. If in doubt experienced service engineers are available via
Broadbent Customer Services.
Replacement parts used on the centrifuge should be obtained from Broadbent.

Replacement parts not obtained from Broadbent or parts fitted incorrectly may
compromise the safety of the centrifuge. Broadbent does not accept responsibility for
the consequences of using such parts.
If work is to be carried out inside or under the centrifuge,

w Stop the machine and isolate and lock off the main electrical power
supply, the pneumatic air supply, the water supply, and the steam
supply. Place suitable warning notices.
w Place protective covers over the conveyor before working under the
machine.
w If possible, position a safety man by the centrifuge

5.2 ROUTINE MAINTENANCE

The following schedule is based on continuous usage throughout the operating season.
It is recommended that full maintenance and service records be kept for each centrifuge.
Recorded details should include machine serial number, date and time, inspections
undertaken, procedures carried out, and comments regarding problems encountered or
other observations. Such records will assist troubleshooting and may be required for
evidence in the event of a claim under warranty.
Figure 5.1 Recommended Schedule for Routine Preventative Maintenance

Frequency Item Action
Daily Centrifuge Exterior Clean, especially casing top
Process Lines Inspect lines and connections for leaks and repair
if necessary
Flexible Cables Inspect for chafing or kinking and repair if
necessary
Weekly Spindle Bearings Lubricate with specified grease
Basket Screens Steam clean and inspect for damage or blockage.
Replace if necessary
Plough Check for smooth operation and lubricate
mechanism bushes and sliding surfaces
Check security of fasteners holding blade to arm
Check position and security of horizontal and
vertical latches
Check Plough Horizontal Cylinder pressures
Proximity Switches Check security and connections
Monthly Structural Fasteners Check security of fasteners between frames,
casing and support structure
Plough Check clearances of plough blade to top and
bottom of basket and adjust as necessary
Spindle Bearings Check for signs of unusual noise, vibration, or
overheating. If necessary, strip down and replace
defective parts
Drive Motor Cooling Fan Check filter pressure drop. Clean and relubricate
filter as necessary
Anti-precession System Check damper plate is in firm contact with motor
top plate.
Check damper plate slides relative to motor top.
Replace centering ring if necessary
Out of balance limit switch Check clearance between plunger and target plate
on motor is correct and that plunger is not seized
Annually Basket and Attachment Remove Basket and carry out detailed safety
to Spindle inspection
As Required or Complete Centrifuge Strip and Inspect
every 5 years Spindle Bearings Replace

5.2.1 Lubrication
WARNING: Use only the specified lubricants for topping up or the
lubricant type already in use. Mineral oils must NOT be mixed with
synthetic oils. Lithium based greases are NOT compatible with
Sodium, Potassium or Calcium based greases.
Figure 5.2 Lubrication Schedule

Lubrication Points Frequency Recommended Lubricant Quantity
Main bearings Weekly Greases based on mineral oil dispersed in 0.25in3 (4 cc)
Lithium hydroxystearate soap with at each of the two
anti-oxidants to consistency NLGI 2 or 3. grease nipples under
Examples are Shell Albida RL2, the lower bearing
Batoyle Proteus 'A'. cap
Plough damper Monthly Heavy hydraulic oil viscosity 68cSt. @ 40° C As required
Examples :
Shell - Tellus HD68
Texaco - Rando HD68
Batoyle - Apollo 68
Plough mechanism Weekly Good quality general purpose grease to 0.12in3 (2 cc) at the
bushes consistency NLGI 1 or 2 grease nipples on
each of the 3 bushes
and at the latch pin
Air cylinder trunnion Weekly Good quality light lubricating oil As required
mountings
All sliding surfaces Weekly Good quality light lubricating oil As required
Cooling Fan Filter As required Water soluble oil As required
e.g. Filter Kote K, Shell Tonna Oil 33
5.2.2 Cleaning and Oil Wetting the Cooling Fan Filter

The filter has a soluble oil wetted filter designed to operate with a pressure drop of
0.45" water gauge when clean. The filter requires cleaning and re-wetting when
the pressure drop increases to 0.9" w.g.
5.2.2.1 Cleaning
Remove the filter from the cooling fan. Clean the filter by either hosing
down with hot water or immersing the filters in a cleaning bath containing a
suitable detergent. A mixture of tri-sodium phosphate and hot water is
recommended. The filters must be dried before oil wetting.
5.2.2.2 Oil Wetting
Completely immerse the filters in the recommended oil, remove from oil and
allow excess oil to drain off before refitting. This should be carried out in a
warm atmosphere to ensure complete drainage of excess oil before installing
on the fan unit.
5.3 OVERHAUL PROCEDURES

GENERAL ADVICE: During stripping, mark the angular positions of
components relative to one another using an indelible pen. These
marks can be used during reassembly to ensure the parts are fitted
together in exactly the same orientation, and thus avoid changes in
dynamic balance.
5.3.1 Rotating Assembly

5.3.1.1 Removal - Preferred Method
This method involves withdrawing the rotating assembly out through the
support buffer, while leaving the plough and upper frame in position. This is
the simplest and quickest method, however if headroom is limited it may be
necessary to use the method given in section 5.3.1.2.
(a) Remove complete feed chute assembly between casing top and mixer
tank (Blank off opening in mixer tank if necessary). Remove the brake
guard, the spindle guard, and the steaming cover from the casing top.
(b) Use the pneumatic valve override to open the discharge valve. Remove
the discharge valve cone from the bottom of the pushrod, by unscrewing
the single M20 x 65 long retaining bolt, after opening the tab washer.
Close the discharge valve cylinder.
(c) Remove the 4-off M12 x 45 long setscrews from the top of the discharge
valve spring hanger/rotor hub. This will allow the assembly to be raised
clear inside the spindle when the bottom plate is attached or removed
completely, protecting the mounting face.
(d) Remove the 8-off M10 x 35 long stainless steel socket capscrews from
the spindle sleeve/basket centre. Remove the pushrod seal assembly from
beneath the basket, taking care not to damage the lip seal. (see section
5.4.5).
(e) Gradually unscrew the basket bolts in an even pattern, so as to gently

lower the basket on to the casing curb ring. When the basket is fully
supported, remove the basket bolts completely. Mark the orientation of
the spindle relative to the basket.
(f) Lower the spindle sleeve assembly (including flinger) on to the basket
centre top. This may be a tight fit on the brake disc split taper hub, but
should become free with a few light knocks on the flinger mounting
flange with a soft faced mallet.
(g) Remove the motor cooling fan unit, the anti-precession damper and the
motor cowl (see section 5.3.7).

(h) Mark the positions of the two torque reaction brackets on the
underside of the bearing housing flange. Unfasten the torque reaction
brackets and swing them down to rest on the upper frame.
(i) Remove the brake caliper, (including any packers that have been used to
centralize the brake pads). The brake disc can be supported by using the
3-off M16 tapped holes in the brake support bracket. Unscrew the
fasteners holding the brake disc to its split taper hub, lift the disc until
the hub halves can be removed. Lower the brake disc to rest on the outer
casing top. Unfasten the brake support bracket from the lower bearing
cap and rest it on the brake disc.
WARNING : Ensure that the spindle sleeve assembly,

brake disc and brake support bracket are secure,
BEFORE lifting the spindle assembly clear of the casing.
Figure 5.3 Removal of Rotating Assembly - Preferred Method
8 Tonne SWL
Lifting Beam
Pair of Lifting
Brackets
bolted to Motor
6600 mm Approximate
2100 kg Lift
BROADBENT

(j) Bolt the two lifting brackets to the sides of the motor stator and attach
the lifting beam rigged for a 2 point lift. Lift the rotating assembly (2100
kg) slightly until the spindle comes clear of the socket in the basket hub
and check that the spindle and hub are marked on the underside, so
that they can be refitted in the same angular position. Continue to lift the
rotating assembly out through the upper frame, avoid knocking the
spindle sleeve assembly. Retrieve the two drive pins from the basket or
from the end of the spindle.
(k) Before lowering to the floor, attach the bottom plate (provided), with
4-off M24 x 40 long setscrews, ensuring that the discharge valve
mechanism is secure within the spindle, or has been removed completely.
Set it down on the floor as shown in Figure 5.3.
(l) After removing rotating assembly, lift the brake support bracket and then
the brake disc over the spindle sleeve, and clear of the casing. Unfasten
screws securing flinger cone and lower on to basket centre top. Lift
spindle sleeve assembly with ‘O’ Ring clear of the casing. Identify all
these parts and retain them for reassembly.
5.3.1.2 Removal - Method requiring Least Headroom
This method involves removal of the rotating assembly, complete with the
upper frame still attached. This method requires considerably more work
than the method described in section 5.3.1.1.
(a) Remove complete feed chute assembly between casing top and mixer
tank (Blank off opening in mixer tank if necessary). Remove the brake
guard, the spindle guard, and the steaming cover from the casing top.
(b) Use the pneumatic valve override to open the discharge valve. Remove
(c) Remove the 4-off M12 x 45 long setscrews from the top of the discharge
valve spring hanger/rotor hub. This will allow the assembly to be raised
clear inside the spindle when the bottom plate is attached or removed
completely, protecting the mounting face.
(d) Remove the 8-off M10 x 35 long stainless steel socket capscrews from
the spindle sleeve/basket centre. Unfasten screws securing flinger cone
and lower on to basket centre top. Remove the pushrod seal assembly
from beneath the basket, taking care not to damage the lip seal. (see
section 5.4.5).

(e) Gradually unscrew the basket bolts in an even pattern, so as to gently

lower the basket on to the casing curb ring. When the basket is fully
supported, remove the basket bolts completely. Mark the orientation of
the spindle relative to the basket.
(f) Remove the motor cooling fan unit, the anti-precession damper and the
(g) Mark the positions of the two torque reaction brackets on the
underside of the bearing housing flange. Unfasten the torque reaction
brackets and swing them down to rest on the upper frame. Remove the
brake caliper, (including any packers that have been used to centralize
the brake pads).
(h) Only if it is necessary, the required lifting capacity can be reduced

from 2700 kg to 2100 kg by removing the motor stator, as described in
section 5.3.4. (DO NOT REMOVE THE MOTOR ROTOR).
(i) Remove the plough assembly (see section 5.3.6).
(j) Disconnect all electrical and pneumatic connections between the upper
frame and the outer casing at the rear right of the centrifuge. Fit
identification tags to aid later reconnection. Disconnect the lead from the
operator interface panel, which passes down the inside of the front right
leg of the upper frame into the casing side box.
(k) Remove the four covers on the casing side boxes, and remove the
fasteners securing the upper frame to the casing. Unfasten the
connections between the rear of the upper frame and the mixer tank.
(l) Fit four M36 swivel eyebolts into the tapped holes on the top of the
upper frame and attach the lifting beam rigged for a 4 leg lift.
(m)Lift the upper frame with the bearing housing, motor and rotating
assembly (2700 kg) slightly until the spindle is clear of the socket in the
basket hub, check that the spindle and hub are marked on the
underside, so that they can be refitted in the same angular position.
(n) Move forward to allow the upper frame legs to clear the mixer tank and
continue to lift until the spindle is clear of the casing as shown in Figure
5.4. Retrieve the two drive pins from the basket or from the end of the
spindle. Before lowering to the floor, attach the bottom plate (provided),
with 4-off M24 x 40 long setscrews, ensuring that the discharge valve
mechanism is secure within the spindle, or has been removed completely.

(o) Lower the upper frame on to suitable supports or above a hole, so that
the spindle is clear of the floor and sufficient room is available to remove
the spindle sleeve assembly (1540mm long).
(p) Retrieve any spacer plates which were fitted between the upper frame
and casing. Identify all these parts and retain them for reassembly. If a
new rubber buffer is being fitted, the packers may not be required when
machine is reassembled, but must be retained for future use.
(q) Working from the lower end of the spindle, remove the bottom plate
(preventing the spindle sleeve from dropping off). Lower the spindle
sleeve assembly (1540mm long). This may be a tight fit on the brake disc
split taper hub, but should become free with a few light knocks on the
flinger mounting flange with a soft faced mallet.
(r) The brake disc can be supported by using the 3-off M16 tapped holes in
the brake support bracket. Unscrew the fasteners holding the brake disc
to its split taper hub, lift the disc until the hub halves can be removed.
Lower the brake disc clear of the spindle. Unfasten the brake support
bracket from the lower bearing cap and remove from spindle.

Figure 5.4 Removal of Rotating Assembly - Least Headroom Method
8 Tonne SWL
Lifting Beam
Swivel
Eyebolts
CG
5000 mm Approximate
2700 kg Lift
BROADBENT

(s) If motor stator has been removed, refit, taking care to avoid the bore of
the stator scraping against the outside diameter of the rotor. (see section
5.3.4).
(t) Bolt the two lifting brackets to the sides of the motor stator and attach
the lifting beam, rigged for a 2 point lift. Attach the bottom plate
(provided), with 4-off M24 x 40 long setscrews, ensuring that the
discharge valve mechanism is secure within the spindle, or has been
removed completely. Lift the rotating assembly (2100 kg) out through
the upper frame and set it down on the floor as shown in Figure 5.3.
5.3.1.3 Stripping
(a) Remove the conical rubber suspension buffer from the bearing housing
or the seating in the upper frame.
(b) Refit the brake disc and its split taper hub and tighten the fasteners.
Support the spindle with its axis vertical, by placing suitable supports
under the brake disc.
(c) Remove the stator, taking care to avoid the bore of the stator scraping
against the outside diameter of the rotor. (see section 5.3.4).
(d) Withdraw discharge valve assembly out of the spindle (if still in
position).
WARNING: The Discharge Valve Mechanism contains a powerful

spring under compression. Do not loosen or remove the 4 screws
securing the air cylinder adaptor plate to the upper mounting flange
of the spring hanger.
(e) Remove the motor rotor (see section 5.3.4.).

WARNING: The spindle assembly must never be moved without

either the rotor or dummy rotor fitted. This is essential to prevent the
bearing components sliding off the spindle.
Figure 5.5 Bearing Assembly Details
Motor Rotor
Top Collar
Top Bearing C
Cap
A
Anti-Rotation B 4 Point Angular
Grubscrew Contact Thrust
Ball Bearing
Outer Spacer
Ring
Inner Spacer
Upper Ring
Grease Cup
Upper Cylindrical
Roller Bearing
Bearing
Housing Inner Distance
Piece
Lower Cylindrical
Lower
Roller Bearing
Grease Cup
Bottom Spacer
Bottom
Bearing Cap
Grease Flinger
Brake Support
Spindle Bracket with
Grease Cup
A Protrusion of Anti-Rotation Grubscrew 5 to 6 mm

B Depth of Outer Spacer Ring below Bearing Housing seating 0.2 to 0.9 mm
C Gap between Top Bearing Cap and Bearing Housing 2.7 to 3.2 mm
D Gap between Bottom Bearing Cap and Bearing Housing 1.7 to 2.3 mm
(f) Remove the top bearing cap.
(g) Remove the bottom bearing cap and lower it onto the brake disc.

(h) Ensure that the spindle is securely supported. Lift the bearing housing,
top bearing, outer spacers and the outer races of the two cylindrical
roller bearings off the spindle. Lift slowly and squarely to avoid
damaging the bearing rollers.
(i) Remove the top bearing, outer spacer ring and outer races of the
cylindrical roller bearings from the bearing housing.
(j) Support the spindle unit horizontally. Remove the brake disc and its split
taper hub. Remove the rubber spindle grease flinger, (check condition
and replace if necessary). Remove the bottom bearing cap.
(k) Remove the inner spacer ring. Attach the top draw plate to the top of the
spindle, fit the bottom draw plate beneath the bottom distance piece.
Attach the three M24 draw studs and nine M24 nuts as shown in Figure
5.6. Tighten the top nuts evenly to pull the bearing inner races and
bottom grease flinger off the spindle. Do NOT attempt to remove the
bottom collar, since this is a heavy shrink fit on the spindle.
Figure 5.6 Removal of Spacers and Bearing Races from Spindle
Top M24 Bottom

M24 Nut Drawplate Drawplate M24 Nut
Drawstud
Upper Roller Inner Lower Roller Bottom Bottom

Spindle Bearing Inner Distance Bearing Inner Spacer Collar
Race Piece Race
5.3.1.4 Bearing Handling - General Guidance
WARNING : Absolute cleanliness must be maintained at all times

when handling bearings since even small particles can damage the
rolling surfaces.
(a) It is recommended that new replacement bearings be fitted when

possible. Use only bearings provided by Broadbent. These have carefully
specified cage materials, internal clearances and dynamic load ratings.
Simply using locally obtained bearings of similar external dimensions
could result in seriously reduced bearing life. The bearing will be
supplied preserved in anti-corrosive oil, which need not be removed.

(b) Bearings should only be re-used where there is no doubt about their
condition. All traces of old grease should be removed by cleaning in
petroleum based solvent. Examine the raceways, cage and rolling
elements for scratches, marks, cracks, discolourations etc. Spin the
bearing and check that it runs evenly, without abnormally large
clearance. Soak the bearing in clean, new lubricating oil ready for
assembly.
(c) The bearing inner races are an interference fit on the spindle and should
be heated to between 80oC and 100oC to ease mounting. The heating
must be uniform and the temperature must be accurately controlled.
Alternative recommended heating methods are,
w Place the bearing in a thermostatically controlled oil bath, with the
bearing supported clear of the bottom, to prevent local overheating
or contamination by settled solids.
w Use a proprietary, thermostatically controlled induction heater.
WARNING : Bearings must not be heated above 120oC.
(d) Bearings must be removed or fitted square to the spindle or housing

using the tools provided, so as to avoid applying abnormal loads to the
rolling surfaces. Hammering or shock must be avoided.
5.3.1.5 Rebuilding
Refer to Figure 5.5 for the various clearances to be measured.
(a) Clean and degrease all components and check for wear or damage. Any
components that are worn or damaged must be replaced or repaired.
(b) Using a grease gun charged with the grease specified in section 5.2.1,
purge the grease galleries in the bearing housing until only new grease is
expelled.
(c) Fit the brake disc and taper hub to the spindle and place supports under
the disc to hold the spindle vertical.
(d) Slide the bottom bearing cap over the spindle and rest it on the disc
brake.
(e) Heat the two cylindrical roller bearing inner races as described in section
5.3.1.4.
(f) Fit the bottom spacer. Ensure it is fitted in the correct orientation (with
the flange towards the bottom end of the spindle), and is hard up against
the bottom collar, which is a shrink fit on the spindle.

(g) Fit the lower cylindrical roller bearing inner race, inner distance piece
and the upper bearing cylindrical roller bearing inner race. Ensure they
are hard up against each other and against the bottom bearing inner
distance piece.
(h) Fit the upper and lower grease cups, and cylindrical roller bearing outer
races to the bearing housing. Charge the rollers and cavities between ¼
and ½ full with the specified grease. Do not overcharge with grease.
(i) Slide the bearing housing assembly over the spindle and fit the bottom
bearing cap, ensuring the grease pipes in the bearing housing protrude
through the bottom bearing cap. Check the gap between the bottom
bearing cap and the bearing housing (Reference ‘D’ in Figure 5.5).
(j) Fit the inner and outer bearing spacer rings. Ensure the outer bearing
spacer is below the bearing housing seat for the thrust ball bearing
(Reference ‘B’ in Figure 5.5). This is to ensure that the thrust bearing
rests on the bearing housing, and not on the upper roller bearing.
(k) Fit a new thrust ball bearing anti-rotation grubscrew into the bearing
housing using thread lock compound. With the screw bottomed in the
hole, the grubscrew must protrude from the corner (Reference ‘A’ in
Figure 5.5).
(l) Heat the thrust ball bearing as described in section 5.3.1.4. and fit the
bearing.
(m) Fit the top bearing cap and check the axial gap between the top bearing
cap and the bearing housing (Reference ‘C’ in Figure 5.5).
(n) Fit the drive pins into the end of the spindle. Fit the top collar and motor
rotor, ensuring that the drive pins in the spindle are located in the correct
holes in the rotor. Check the axial gap in the bore between the rotor and
the spindle. The gap should be 2.8 to 4.4 mm.
(o) Support the rotating assembly beneath the bearing housing and remove
the disc brake and split hub. At this stage the rubber spindle grease
flinger should be refitted, or replaced with a new one.
(p) Attach a dial indicator to the upper face of the bearing housing, and turn
the spindle to check that the runout on the outside of the laminated rotor
core is less than 0.10 mm TIR.

5.3.1.6 Replacement
Replacement of the rotating assembly is an exact reversal of the removal

procedure, used either section 5.3.1.1 or 5.3.1.2 but note the following,
(a) The conical rubber suspension buffer must be fitted onto the bearing
housing before lowering into the upper frame. It must NOT be fitted in
the upper frame, and the bearing housing lowered in.
(b) It is essential that the correct orientations are obtained when assembling
the motor stator, torque reaction brackets, and brake caliper support
bracket to the bearing housing. The parts should have been marked
before disassembly, to aid this.
w The main motor connection leads on the side of the stator should be
to the left.
w The bearing grease points under the bearing housing should be to
the front.
w The torque reaction brackets should be to the left and right.
w The brake caliper should be to the left.
(c) To aid alignment when lowering the spindle into the basket hub,
temporarily screw two lengths of M24 studding into two opposite holes
in the end of the spindle, and guide these into the correct holes in the
hub, to ensure the two drive pins engage properly. Ensure the spindle
fits into the basket hub in the same orientation as it was removed - it
is possible to be 180o out.
(d) The basket bolts have built in load indicators. Tighten the bolts
progressively, using a diagonal sequence until the caps on the bolt heads
can no longer be turned with light finger pressure, indicating that the
correct tension has been achieved.
WARNING: Do not remove the caps on the heads of the basket bolts
Load Indicating bolts should always be replaced on

each basket removal.
(e) Check that the clearance between the underside of the basket bottom,
and the top edge of the casing curb ring is 15 to 25 mm (see Figure 1.4
in section 1). If not, adjust the thicknesses of the packers between the
upper frame and casing.

5.3.2 Basket
5.3.2.1 Removal and Inspection
(a) Remove the rotating assembly and support frame. (See section 5.3.1.)
(b) Disconnect all electrical, pneumatic, water and steam connections to

equipment fitted to the pan top. Identify them for later reconnection.
(c) Remove the wash pipe, steam pipe and feed limiter from the pan top.
(d) Remove the plough assembly as described in section 5.3.6.
(e) Remove the pan top from the outer casing.
(f) Lift the basket out of the outer casing. This can be achieved by placing a
lifting bar under the lip of the basket.
WARNING: Take care to avoid catching the basket hoops on the

casing flange or feed stub pipe flange during removal.
(g) Inspect the basket in accordance with the Basket Safety Inspection
procedure in Appendix B, using the original dimension information given
in section 2.
WARNING: For safety reasons, all baskets must be thoroughly

inspected annually, to ensure freedom from harmful corrosion or
wear. It is possible to inspect the basket in situ without removing it
from the centrifuge.
5.3.2.2 Replacement
This is an exact reversal of the removal procedure.

5.3.3 Screens
If work is to be carried out inside or outside of the basket.
w Stop the machine and isolate, and lock off the main electrical
power supply, the pneumatic air supply, the water supply, and the
steam supply. Place suitable warning notices.
w Place protective covers over the conveyor before working under the
machine.
w If possible, position a safety man by the centrifuge
WARNING : Wear heavy duty protective gloves to prevent injury by
sharp edges.
5.3.3.1 Removal
The screens can be removed with the basket and spindle unit in place. If the
screens have to be renewed, the opportunity should be taken to inspect the
inside surface of the basket shell.
WARNING: Secure the plough and isolate the feed, wash water, and
steam injection valves before entering the basket.
(a) Remove the spindle guard and the steaming cover from the casing top.
(b) The screens can now be removed.
5.3.3.2 Replacement
(a) Fit the No 4 woven mesh backing screen next to the basket shell. This
should just fit without overlap, and without a gap greater than 10 mm
between the edges. Secure the backing screen to the basket shell, by
threading stainless steel wire ties through the perforations in the basket
shell and backing screen. Bend the twisted ends to ‘trail’ the basket
rotation. Fit 3 rows of ties at the top, middle, and bottom of the basket,
with each row containing about 8 ties evenly spaced around the
circumference. Start fitting these ties opposite the edges, and work in
both directions towards the joint. Finally fit 4 more ties equally spaced
along the joint in the mesh, between the existing rows.
Fit the No 7 woven mesh intermediate screen, with its edges positioned
at 180º (opposite) to the backing screen joint. There should be a gap at
the joint of at least 70 mm. Secure the intermediate mesh through the
basket perforations, using 3 rows of about 8 stainless steel wire ties
located between the existing backing mesh ties. Start fitting the ties
opposite the joint, (at the backing mesh joint), and work in both
directions towards the joint.

(b) Fit the perforated sheet working screen into the basket, with the face
marked ‘working side’ towards the spindle. The ‘lock lap’ joint must be
interlaced, such that there are no raised edges on the ‘leading’ side,
which could be caught by the plough tip. The lock lap joint must be
positioned to fit into the 70 mm gap in the intermediate mesh.
(c) Start the machine and allow it to run for several minutes at top speed,
without massecuite. Stop the centrifuge and inspect the screens to ensure
they have bedded in correctly against the basket shell.
WARNING: Do NOT operate the plough at this stage.
Figure 5.7 Fitting of Screens and Meshes

70 mm gap in Intermediate Screen
Basket to accomodate lock-lap joint in Working Screen Basket
Shell Perforations
Perforated Sheet
No4 Backing No 7 Intermediate
Working Screen
Mesh Mesh
Direction of Rotation
Ties holding Backing Mesh to Shell -
Ties holding Intermediate Mesh to Shell - 3 rows near top, middle, and bottom of
See detail above
Basket. Approximately 8 ties per row
Mesh ties. equispaced
Lock-lap joint in Lock-lap joint in Lock-lap joint in

Working Screen Working Screen Working Screen
before engagement after engagement before engagement

5.3.4 Main Drive Motor

5.3.4.1 Removal
(a) Remove the motor cooling fan unit, the anti-precession damper and the
(b) Withdraw discharge valve assembly out of the spindle (if still in
position). (see section 5.3.1).
(c) Bolt the lifting brackets to the side of the motor stator, and attach the
lifting beam, rigged for a 2 leg lift..
(d) Mark the circumferential position of the stator relative to the bearing
housing. Remove the screws attaching the stator to the bearing housing
and lift the stator off the bearing housing and rotor (400 kg), as shown in
Figure 5.8, taking care to avoid the bore of the stator scraping against
the outside diameter of the rotor.
Figure 5.8 Removal of Stator
8 Tonne SWL
Lifting Beam
600 kg Lift
Pair of Lifting
Brackets
bolted to Motor
WARNING: The rotating assembly must be supported from below

before attempting to remove the motor rotor. This is essential to
prevent the bearing components sliding off the spindle.
(e) Support the rotating assembly from below, with its axis vertical, using
one of the following methods,
w Fit the brake disc and rest the disc on some suitable supports.
(Recommended when the rotating assembly is out of the casing and
frame and no basket attached).
w Hold the brake disc up to the brake caliper bracket, using three M16
x 120 long screws with large washers, through the speed sensing
holes in the disc. (Recommended when the rotating assembly is in
the casing and frame, and the basket is not attached).
w Support the basket either using large ‘G’ clamps to hold the basket
lip up to the casing top, or by putting support blocks under the
basket bottom. (Recommended when the rotating assembly is in the
casing and frame, and the basket still attached).
(f) Remove the capscrews securing the rotor hub to the spindle, and remove
the motor rotor and air baffle, using the extractor plate and screws
supplied, as shown in Figures 5.9.1, 5.9.2 & 5.9.3.
Figure 5.9.1 Removal of Rotor
Extractor Plate
31071-010 Rotor Air Baffle
Motor Rotor
Top Collar
Bearing Housing
Screw 4 - M16 x 140 long hexagon head bolts fully into the spindle end.
Place extractor plate on M16 screw heads and screw M12 x 140 long
hexagon head screws (fitted with nuts) fully into the rotor hub. Tighten
down M12 nuts onto the extractor plate, applying pressure a little at a time
to each nut, approximately opposite from the last one tightened. This will
draw the rotor hub up off the spindle locating diameters.
DO NOT USE THE LIFTING EYEBOLT AT THIS STAGE OF THE
REMOVAL PROCEDURE

Extractor Plate
Rotor Air Baffle
31071-010
Motor Rotor
Top Collar
Bearing Housing

Extractor Plate
Rotor Air Baffle
31071-010
Motor Rotor
Top Collar
Bearing Housing
When the rotor hub is clear of the spindle locating diameters, use the lifting
eyebolt and a suitable lifting device to take the weight of the rotor, and start
to remove the M16 bolts from the spindle. Lift the rotor by small amounts
and unscrew the M16 bolts at the same time, until the bolts are clear of the
tapped holes in the end of the spindle. The rotor can then be lifted
completely from the spindle.
(g) Take care to ensure that the laminations, rotor end rings and rotor bars
are not damaged, and that the rotor is never laid to rest on the outside
diameter of the laminations. Retrieve the two drive pins from the rotor
or the end of the spindle, and retain them for reassembly.
If at this stage a complete stripdown is not required, fit the dummy
rotor hub (Fig 5.9.4) to secure the spindle assembly. This is essential to
prevent the bearing components sliding off the spindle.
Figure 5.9.4 Fitting of Dummy Rotor

5.3.4.2 Replacement
(a) Refit the rotor, using the extractor plate and screws supplied, as shown
in Figures 5.10.1 & 5.10.2
Figure 5.10.1 Refitting of Rotor
Check that the top collar is in position on the spindle/bearing housing.

Secure the extractor plate to the rotor hub, using 4 - M12 x 50 long hexagon
head screws. Place 4 - M16 x 140 long hexagon head bolts thro’ the holes in
the extractor plate. Lift the rotor into position on the spindle and use the
M16 bolts to position the rotor relative to the spindle tapped holes, and
drive pin holes. Remove the M16 bolts, M12 screws, extractor plate. Fit the
drive pins (check the drive pins for wear and condition and replace if
necessary). Fit the M16 x 70 long socket capscrews (torque tighten to 250
Nm).
Figure 5.10.2 Refitting of Rotor

4.4mm
2.8
After refitting, the following checks are required,
(b) Check the axial gap in the bore between the rotor and the spindle. The
gap should be between 2.8 to 4.4 mm.
(c) Attach a dial indicator to the upper face of the bearing housing. Turn the
spindle to check that the runout on the outside of the laminated rotor
core is less than 0.10 mm TIR.
(d) Refit the stator, taking care to avoid the bore of the stator scraping
against the outside diameter of the rotor.

5.3.5 Discharge Valve Assembly

5.3.5.1 Removal
Withdrawal of the discharge valve actuating assembly, from the fully

assembled centrifuge, requires a minimum headroom of 5.0 metre above
floor level, ideally 6.0 metre. If this headroom is not available, it will first be
necessary to remove the rotating assembly (see section 5.3.1.2).
(a) Use the pneumatic valve override to open the discharge valve. Remove
(b) Remove the discharge valve pushrod seal assembly from under the
basket, taking care not to damage the lip seal.
(c) Remove the anti-precession damper (see section 5.4.7).
(d) Remove the 4-off M12 x 45 long setscrews from the top of the discharge
valve spring hanger/rotor hub.
WARNING: The Discharge Valve Mechanism contains a powerful

spring under compression. Do not loosen or remove the 4 screws
securing the air cylinder adaptor plate to the upper mounting flange
of the spring hanger, unless suitable equipment is fitted which will
safely control the extension of the spring.
(e) Lift the discharge valve mechanism out of the spindle. If headroom is
limited, it may be necessary to remove the lower pushrod (see section
5.3.5.2) with the assembly partially withdrawn.
5.3.5.2 Stripping
(a) Open the discharge valve by applying air to the top of the cylinder.
Slacken the M6 x 12 long HTS grubscrew that locks the threaded joint
between the lower pushrod and the upper pushrod. Unscrew the lower
pushrod. Screw the M36 x 1.2 metre long threaded bar into the upper
pushrod, until approximately 50mm of thread is engaged. Drill 5mm dia
dimple through the grubscrew hole into the M36 bar, then fit the
grubscrew to prevent the bar unscrewing from the pushrod. Fit the
discharge valve drawplate, M36 washer and M36 nut as shown in Figure
5.9. Ensure the M36 nut and washer are tight against the drawplate and
upper pushrod. Close the discharge valve, ensuring the drawplate and
M36 nut and washer are tight against the spring hanger.
(b) Disconnect the hose assembly from the rotating joint at the end of the
cylinder. Remove the screws securing the cylinder adaptor plate to the
spring hanger, remove the discharge valve air cylinder assembly.

Figure 5.11 Fitting and Removal of Discharge Valve Spring
Upper M36 Threaded

Drawplate
Pushrod Bar
Spring Spring Hanger M36 Nut and

Washer
(c) Remove the capscrew securing the discharge valve upper pushrod key
and remove the key.
(d) Slowly unscrew the M36 nut to release the discharge valve spring.
WARNING: Ensure the M36 stud does not screw out of the upper
pushrod.
(e) When the tension in the spring has been released, remove the M36 nut
and washer, and the drawplate. Withdraw the discharge valve upper
pushrod and discharge valve spring from the spring hanger. Slacken the
grubscrew that locks the M36 bar in place and remove the bar.
5.3.5.3 Rebuilding
(a) Refit the M36 threaded bar to the end of the discharge valve upper
pushrod and lock with the M6 x 12 long HTS grubscrew (see section
5.4.5.2).
(b) Slide the discharge valve spring into the spring hanger and fit the upper
pushrod, so that the M36 threaded bar protrudes through the bottom of
the spring hanger. Fit the drawplate and M36 nut and washer.
(c) Tighten the nut to compress the spring.
(d) Fit the upper pushrod key through the slot in the spring hanger to the
upper pushrod flange and tighten the capscrew.
(e) Check the lower bearing pad for wear, (replace if necessary). Refit
discharge air cylinder assembly to top of spring hanger, checking
rotating joint is in a good working condition, (replace if necessary).
WARNING: The Discharge Air Cylinder assembly must be securely

fastened before removing the M36 nut and draw plate.
(f) Remove the M36 nut and washer and draw plate.

(g) Attach the hose assembly between the rotating joint and bulkhead
through the fan ducting.
(h) Compress the discharge valve spring and upper pushrod, by applying air
to the air cylinder. Slacken the grubscrew locking the M36 threaded bar
to the upper pushrod and remove the threaded bar. Screw the lower
pushrod into the upper pushrod and tighten the grubscrew to lock the
joint.
WARNING: The grubscrew must screw into the drilled hole in the
lower pushrod thread to lock the joint.
(i) Remove the air from the air cylinder.
5.3.5.4 Replacement
Replacement is an exact reversal of the removal procedure (see section

5.3.5.1).
5.3.5.5 Testing
(a) Check for smooth operation of the mechanism over several cycles using
the overrides on the air solenoid valve.
(b) Check the discharge valve cone position when closed. There should be
no appreciable gaps between the discharge valve cone and the
elastomeric seal, (replace if necessary). fitted to the basket bottom.

5.3.6 Plough Assembly

5.3.6.1 Routine Maintenance and Adjustments
Use the override switches on the pneumatic solenoid valves inside Panel EP,
on the front of the centrifuge, to move the mechanism to the various
positions required for adjustment as detailed in Appendix C.
WARNING: Keep clear of the plough mechanism parts when

operating the solenoid valve overrides. Ensure that electrical power
to the Drive Panel is locked off to prevent the centrifuge rotating.
(a) VERTICAL SPEED ADJUSTMENT. The speed of the downwards

ploughing stroke is controlled by the oil filled dashpot. Adjust the valve
on the bottom of the vertical dashpot (see Figure 5.15) to give a total
time for the vertical stroke of about 12 seconds. Screwing the valve in
reduces the speed, and screwing it out increases the speed. If the motion
is jerky or uneven, the dashpot needs refilling as described in (d) below.
Note that the oil must be warmed by running through several cycles
before the speed will settle to a steady value.
(b) HORIZONTAL PLOUGHING PRESSURES. The horizontal forces

applied to the plough vary throughout the ploughing cycle. Refer to
Appendix A and Appendix C.
w The plough first cuts into the top of the product cake at maximum
pneumatic pressure, and no adjustment is required.
w During the downwards ploughing stroke, the plough tip is held
lightly against the working screen by a reduced pneumatic pressure.
Too large a pressure will wear the screen. Too low a pressure will
leave product on the screen. This pressure is controlled by the
(upper) pressure regulating valve attached to solenoid valve H3
inside the electro-pneumatic panel EP. Increasing the pressure
increases the force onto the screen. Adjust this pressure until it is
just possible to push the plough arm back off the screen with firm
hand pressure (about 20 kgf) which will require about 1.0 bar g.
(Note: The minimum allowable pressure setting is 0.7 bar g -
below this pressure, the pneumatic valves may not operate).
w During the return upwards stroke and when parked, the plough is
pulled towards the spindle at a reduced pressure to avoid excessive
force on the latching pin. This pressure is controlled by the (lower)
pressure regulating valve attached to solenoid valve H2 inside the
electro-pneumatic panel EP. This should be set to 3 to 3.5 bar g.
(c) LUBRICATION. Apply the specified light grease to the grease nipples
on the carriage upper and lower bushes, the upper support bracket bush,
and the latching pin housing as illustrated in Figure 5.14 at the frequency
specified in section 5.2.1. At the same time wipe the plough shaft and the
cylinder and dashpot rods clean and smear with light lubricating oil.

(d) VERTICAL DASHPOT FILLING. Put the mechanism in the fully

down position, with the vertical cylinder fully retracted. Remove the
breather cap on the top of the damper and pour in the specified oil, using
a funnel and small tube, until the level reaches the transparent sight glass
on the side of the damper. Refit the breather plug. (Note that when
initially supplied, a sealed blanking plug will be fitted - this must be
replaced by the vented breather plug). Run the plough through a few
cycles and recheck the level. Add more oil if necessary.
(e) COMPENSATION FOR BUFFER DROP. Over time, the conical

rubber suspension buffer settles, causing the rotating assembly to drop
slightly. This drop may be several mm in the first few days, but then
reduces to a very slow rate. To avoid the plough blade catching the
underside of the basket top, the plough mechanism must be adjusted to
compensate. This is achieved by adjusting the position of the plough arm
downwards on the carriage, to maintain the clearance of the top of the
plough blade tip at 3 to 5 mm below the top corner of the basket.
GENERAL ADVICE: During stripping, mark the positions of

components relative to one another using an indelible pen. These
marks can be used during reassembly to ensure the parts are fitted
together in the same positions and thus minimise readjustment.
5.3.6.2 Removal
(a) Disconnect all electrical and pneumatic connections from the plough
assembly. Identify them for later reconnection.
(b) Remove the plough blade from the plough arm. If it is difficult to
disengage the taper, remove the large T shaped washer from beneath the
attachment boss, turn it upside down ⊥, and tighten it onto the boss
using the 2 screws provided to jack the taper apart. See Figure 5.12.
Figure 5.12 Attachment of Plough Blade to Plough Arm
Plough Arm
Plough Blade
Attachment Boss
Special Washer
Lockwasher
Fixing Blade Removing
to Arm Blade from Arm

(c) Mark the position of the flange on the plough arm relative to its seating
on the carriage. Attach a sling to support the weight of the plough arm.
Remove the fasteners and clamping strips holding it to the carriage, and
lift the arm out of the rollers on the end of the lever arm.
(d) Remove the sliding cover and the rollers from the end of the lever arm.
(Note - The sliding cover has a removable cover to allow inspection of
the rollers, when the plough arm is still in position).
(e) Disconnect the plough horizontal cylinder from the lever arm.
(f) Attach a sling to support the weight of the carriage in its up (parked)
position. Disconnect and remove the vertical cylinder and vertical
dashpot from the carriage and lever arm.
Figure 5.13 Plough Adjustment - Plan View
Horizontal
Cylinder
Upper
Support
Sliding Bracket
Cover
Latching
Pin
Spindle
Locking
Plate
Plough Plough
Arm Shaft
A Plough
Carriage
Basket
Plough Blade OUT

B Lip
(Parked Position)
A Clearance from back of Plough Blade to Spindle Minimum 35 mm

B Clearance from Plough Tip to Basket Lip Minimum 50 mm

(g) Mark the position of the upper support bracket relative to the upper
frame bracket and remove the fasteners and clamping plate.
(h) Remove the pin locating the locking plate on the plough shaft and
unfasten the clamping screw.
(i) Slowly lift the carriage up the plough shaft. First the carriage upper
bush, then the support bracket, then the locking plate, and finally the
carriage lower bush come clear of the top end of the shaft.
(j) Lift the plough shaft/lever arm assembly out of the bush in the casing
top.
(k) Inspect the bushes and scraper seals in the carriage, upper support
bracket, and casing (replace if necessary). Note that the bushes in the
carriage and support bracket are secured by grubscrews.
(l) Inspect the plough blade key and the rollers on the end of the lever arm,
(replace if necessary).

Figure 5.14 Plough Adjustment - Side View
Vertical
Lubrication
L Points
Stroke
Adjustment
Plough
Carriage L Plough
Shaft
Dashpot
Breather and
Oil Top Up Upper
Latching Support
Vertical L Pin Bracket
Position
Adjustment
L
Locking
Plate
L
Location
Pin
Vertical
Dashpot
Plough Damper
Arm
Lever Vertical
Dashpot
Arm Cylinder
Speed
Adjustment
Lower Horizontal
Bush Cylinder
Plough
Blade

Figure 5.15 Dashpot Damper

5.3.6.3 Vertical Dashpot Damper
Piston Rod
Figure 5.15 shows the damper with the
Breather and
rod in both full extended and fully
Filler Cap retracted positions.
Rod Bearing When the plough moves down the

basket, the rod retracts. The piston
O Ring
pushes oil down the piston tube and out
Sliding Seal
through a needle type flow control valve
into the outer reservoir annulus. The oil
at the top of the reservoir can flow back
Level Sight
into the piston tube via radial drillings.
Glass Screwing in the flow control valve
restricts the oil flow and thus the speed
of the piston and the ploughing speed.
Reservoir
Tube
On the plough return stroke, the rod
extends. The piston pulls oil into the
piston tube via a ball type non-return
valve, which bypasses the flow control
Piston Tube
valve and thus allows rapid movement.
Oil at the top of the piston tube can flow
back into the reservoir tube via radial
Piston drillings.
Coil Spring Maintenance of this dashpot damper unit
Non Return
is usually only required after very long
Valve Ball periods of operation. Dismantling of the
damper to replace seals, the piston, or
O Ring the valves is accomplished by
unscrewing the top cap from its threaded
attachment to the piston tube. Refer to
Flow Control Figure 5.15.
Valve
5.3.6.4 Replacement
(a) Replacement is an exact reversal of the removal procedure but note,

w Use the markings made during removal to ensure components are
aligned correctly relative to one another.
w Ensure that the pin locating the locking plate on the plough shaft is
correctly fitted.
w Ensure that large washer under the plough arm boss is fitted with
the small diameter down T and not up ⊥. See Figure 5.12.

(b) Carry out the initial setting procedure in section 5.3.6.3.
(c) Top up the dashpot and lubricate the bushes as in section 5.3.6.4.
(d) Test the plough by running it through several cycles, using the pneumatic
overrides. The sequence for operating the valves is detailed in Appendix
C.
5.3.6.5 Initial Setting of Plough
Use the override switches on the pneumatic solenoid valves inside Panel EP
on the front of the centrifuge to move the mechanism to the various
positions required for setting as detailed in Appendix C.
WARNING: Keep clear of the plough mechanism parts when

operating the solenoid valve overrides. Ensure that electrical power
to the Drive Panel is locked off to prevent the centrifuge rotating.
(a) Set the plough arm at its lowest position on the carriage allowed by the
slotted attachment.
(b) HORIZONTAL POSITION SETTING. Put the mechanism in the

parked position, with the blade next to the spindle, and with the lug on
the carriage resting on the lug on the upper support bracket. Adjust the
rod end on the horizontal cylinder, and the upper support bracket on the
frame bracket until all the following conditions are achieved
simultaneously,
w The plough shaft is vertical (check using a spirit level)
w The latching pin is central in the hole in the locking plate.
w The horizontal cylinder is fully retracted.
w The minimum clearance from the back edge of the blade to the
spindle is greater than ‘A’ in Figure 5.13.
w The minimum clearance from the plough tip to the basket lip is
greater than ‘B’ in Figure 5.13.
(c) VERTICAL POSITION SETTING. Put the mechanism in the fully up
position (not the parked position), and in the on screen position, with
the vertical cylinder fully extended. Adjust the vertical position of the
plough arm on the carriage until the top of the plough blade tip is 3 to 5
mm below the top corner of the basket.
(d) VERTICAL STROKE SETTING. Put the mechanism in the fully down
and the on screen position. Adjust the long screw on the top bush of the
carriage, until the bottom edge of the plough blade is 1 to 3 mm above
the bottom of the basket. Tighten the locknut.

5.3.7 Anti-Precession Damper

5.3.7.1 Removal
(a) Remove the inspection panel in the top of the fan ducting, disconnect the
flexible hose from the rotating joint to the bulkhead connector, through
the top of the fan ducting.
(b) Disconnect the electrical connections to the cooling fan motor.
WARNING: Ensure that the damper plate does not drop off the fan
ducting during lifting, by fitting bolts or pins through the holes in the
anti-rotation forks & damper plate.
(c) Remove the fasteners attaching the cowl top to the motor cowl, fitting
lifting eyes into the 3 - M12 tapped holes, on the same PCD as the
fasteners. (These are spaced to give an even lifting, allowing for the
weight of the fan unit assembly). Lift the assembly clear of the top of
the machine.
Figure 5.16 Anti-Precession Damper Assembly
M20 Adjusting
Screw
B
A M20 Locknut
Spring Clamping
Housing Plug
Damper
Spring
Fan Ducting Inspection
Panel
Centering Motor Cowl
Ring Top
Damper Plate
with rivetted Motor Cowl
Friction Lining Striker Plate
Out of Balance
Switch
Drive Motor
Stator Top
A Length of Adjusting Screw 100 mm

B Spring Tension Initial Setting 40 mm
C Out of Balance Switch Gap Setting 6.5 to 7.5 mm

(d) Open the lid on the Auxiliary Terminal Box ATB and remove the screws
holding the box to the cowl. Lift the box away, far enough to disconnect
the motor thermistor leads and the vibration monitor lead. Remove the
vibration monitor and out of balance switch.
(e) Remove the screws holding the cowl to the upper frame and carefully lift
off the cowl, marking the position of the cowl to the upper frame.
5.3.7.2 Refurbishment of Damper
(a) Slowly remove the bolts from the damper spring caps to release the
tension in the damper springs. Remove the springs, plugs and housings.
(b) After removing the bolts or pins between the anti-rotation forks and
damper plate, pull the damper plate off the fan ducting.
(c) Check the condition of the friction linings attached to the underside of
the damper plate. If they are loose, torn, or worn down to the rivet
heads, the linings must be replaced. Drill out the pop rivets (fitted when
new at Broadbent), fitting new linings and new copper rivets (supplied
when replacing original linings), and peen over the rivet heads.
(d) Check the condition of the rubber centering ring. If it is cracked or worn,
the ring must be replaced by a new rubber moulding. The replacement
rubber moulding is supplied 1775 mm long, and will require cutting to
the correct length.
(e) With the rubber ring fitted in the groove in the damper plate. The
damper plate must be a tight fit on the fan ducting, requiring heavy force
to push over the machined seating diameter, even when lightly lubricated
with silicon grease. Do not use mineral based grease, as this will cause
deteriation of the rubber. If necessary, fit shims between the back of the
ring and the groove in the damper plate to achieve a tight fit.
5.3.7.3 Reassembly
(a) Refit the cowl over the motor and fasten to the upper frame, ensuring
that the terminal box is to the left, when viewed from the front.
(b) Reassemble the vibration monitor and out of balance switch, and set the
switch gap ‘C’ shown in Figure 5.16.
(c) Reconnect the thermistor and vibration monitor leads and refit the
Auxiliary Terminal Box ATB.

(d) Lightly smear the bore of the damper plate centering ring with silicon
grease. Do not use mineral based grease, as this will cause
deterioration of the rubber. Push the damper plate onto the fan ducting,
far enough for the ribs on the upper face of the damper plate to engaging
the anti-rotation forks under the cowl top. When the holes in the damper
are in line with the 2 holes in each anti-rotation fork, fit bolts or pins
through each set of holes, to prevent the damper plate dropping off when
lifting.
(e) Lift the cowl into position on top of the motor, using the lifting eyes in
the 3 - M12 tapped holes on the same PCD as the fasteners. (These are
spaced to give an even lifting, allowing for the weight of the fan unit
assembly). Remove the lifting bolts or pins, through the inspection
openings. Tighten the fasteners holding the cowl top to the cowl.
(f) Check the lengths of the M20 adjusting screws ‘A’ in Figure 5.16.
Assemble the three damper springs, plugs, housings, and screws to the
cowl top. Set the spring compressions to dimension ‘B’and tighten the
locknuts.
(g) Check the damper plate friction liner is in firm contact with the motor
top plate
(h) Reconnect the cooling fan motor leads
(i) Reconnect the flexible hose from the discharge cylinder rotating joint to
the bulkhead connector, through the top of the fan ducting.
(j) Refit the inspection covers and gaskets.

5.3.8 Disc Brake

5.3.8.1 Maintenance and Care.
ALL MAINTENANCE OPERATIONS MUST ONLY BE PERFORMED

WHEN THE MACHINE IS STOPPED
(a) To level the brake caliper, adjust the screw between the arms using a
10mm A/F spanner as shown below. Lock the screw after final
adjustment by tightening the nuts against the centre boss. See Figure
5.17
Figure 5.17 Caliper Balance Adjustment
CH 10mm
5.3.8.2 Gap Adjustment
(a) Supply air pressure to the thruster.
(b) Loosen the C61600 nut and the C61728 inner screw by using a 12mm
A/F allen key. See Figure 5.18
Figure 5.18 Gap Adjustment
C61728 C61600
(c) Turn the gap adjustment screw to set a 1mm gap between the brake disc
and each lining pad.

(d) Lock back the C61660 nut and the C61728 inner screw.
(e) Realign the lining pads by using a 3mm allen key. Adjust the C61724
inner screw to align the lining pads parallel to the disc. See Figure 5.19
Figure 5.19 Setting Pads Parallel
C61724
5.3.8.3 Lining Pads Replacement
(a) Apply air pressure to the thruster, replace the C61126 silencer with the
C61225 M10 safety screw.
Figure 5.20 M10 Safety Screw Fitting & Removal
C61126 SILENCER
C61225 SAFETY SCREW
(b) Loosen the C61600 nut and the C61728 setscrew, unscrew the gap
regulator. Loosen the C61594 nuts and screw or unscrew the C61205.
Turn the E80806 arm to enable the pad to be moved away from the
brake disc.

(c) Remove the worn pad, using a lever on its metallic back plate, with
sufficient force to overcome the strength of the magnet that holds the
pad in place. Ensure that the magnet remains correctly located in the
socket before mounting the new pad. Repeat the operation with the
other arm. Readjust the gap between the lining pads and the disc.
(d) Apply air pressure to the thruster, replace the C61225 M10 safety screw
with the C61126 silencer.
5.3.8.4 Friction Surface Cleaning
(a) Remove lining pads. Use a non-polluting cleaning product to remove oil
and grease traces from the disc surface.
(b) In case of shallow contamination of linings by any lubricant agent, the

surfaces may be cleaned using a medium abrasive emery sheet. In case of
deep contamination, the full replacement of linings is recommended.
5.3.8.5 Spring Replacement
(a) Apply air pressure to the thruster. Replace the C61126 silencer with the
C61225 M10 safety screw. Turn off the air supply and disconnect the
tubing. Loosen the C61133 nuts and remove the thruster from the brake
unit.
(b) Take out the C61232 screws from the thruster, VERY CAREFULLY
loosen the C61225 M10 safety screw so that the pre-loaded springs will
gradually be released.
(c) Pull off the C62082 and C62081 plates and the Z50165 cover. Replace
the whole spring set, even if any appear undamaged. Reassemble the
thruster in reverse order.
(d) Reassemble the thruster onto the brake unit and secure using the C61133
nuts. Apply air and replace the C61225 M10 safety screw with the
C61126 silencer.
(e) Operate the brake for several times to ensure that there are no air leaks
and the piston is operating correctly.
5.3.8.6 Lining Pads Alignment Springs Replacement
(a) Apply air pressure to the thruster. Replace the C61126 silencer with the
C61225 M10 safety screw.
(b) Pull out the snap ring C61275 and remove the pin C61110-F then take
out the socket Z50263. Remove the C61968-F spring from its guide. A
new spring must be refitted. Reassemble the lining.
(c) Realign the gap between the lining and the disc.
Replace the C61225 M10 safety screw with the C61126 silencer. Replacement of
Seals.
(d) Pull out the piston rod assembly Z50166-F. Check the seals, (replacing
any that appear worn or damaged).
(e) Lubricate all seals before reassembly, using a lithium based grease,
mineral oil or a solid lubricant. The piston rod should also be lubricated
with grease before replacing in the housing.
(f) Reassemble.
5.3.8.7 Periodic Inspection
AS THE BRAKE IS EMPLOYED AS A FAILSAFE DEVICE, WE

RECOMMEND THE FOLLOWING TESTS EVERY THREE MONTHS.
Ensure that the gap between the lining pads and the disc will not exceed 2mm.
Whenever the gap is greater then the 2mm, adjust the gap. Replace the linings
when the wear is greater than 5mm.
Check that no lubricant traces are found on the brake disc or lining surfaces. In
case of contamination, follow up the procedure 5.3.8.4.
Check that all locking screws are correctly tightened.
Switch on and off the air supply several times to check the seals integrity, springs
functionality and the correct operation of the pushrod.
5.3.8.8 Spare Parts
Linings:(Pairs) Broadbent No. 22191-003

Spares Kit Complete Broadbent No. 22191-005
Spare parts should be stored in a cool dark place and far

away from any agent that could damage them or reduce their
life and efficiency.

5.3.9 Wash Pipe - 45” (1150mm) Deep Basket

It is essential that wash water is applied uniformly to the product cake (see
Appendix D). Poor adjustment will be indicated by varying colour up the cake or
by grooves locally eroded into the cake surface. Adjustment is as follows,
(a) Ensure that the correct nozzles are fitted in the correct locations along
the spray bar. To avoid interference between the ‘fans’ from adjacent
nozzles, they should be twisted slightly off the spray bar axis.
(b) Ensure that the spread of the spray pattern covers the whole cake
surface but not too much water is sprayed over the basket lip or onto the
basket bottom. This is adjusted primarily by twisting the pipe to increase
or decrease the distance to the cake ‘X’. There is also limited adjustment
up and down ‘Y’. To avoid high impact onto the cake, the nozzles must
be directed with the direction of rotation.
Figure 5.21 Wash Pipe Adjustment
Direction of
PLAN Rotation Nozzles
VIEW
Ref Part Number Marking Angle
X
A 22760-095 670.844 60o
B 22760-096 670.886 90o
Spray
Bar Y Basket C 22760-094 670.882 30o
A Lip
10º
Initial Settings
B X Spraying Distance 260 mm
Y Basket Lip to Top Nozzle 90 mm
B
Product Flowrates for complete Wash Pipe

Detail of B Cake Supply Pressure Total flowrate
Nozzle Surface bar g litre/minute
Fixing
B 1 74
A 2 105
C
3 129
5 166
10 235
Basket
Bottom

5.3.10 Feed Valve

Loading of the centrifuge is via a butterfly valve, operated by a vane type double
acting pneumatic actuator, which is controlled by an electro-pneumatic positioner.
The valve automatically opens and closes under control of the main PLC.
5.3.10.1 Principles of Operation
The main centrifuge PLC outputs a 4-20mA signal to the valve, which is
proportional to the required valve opening. The valve actuator is fitted with
a combined I/P converter and positioner unit, as illustrated in Figure 5.22.
The I/P (Current to Pressure) Converter converts the 4-20mA electrical

signal to a 3-15 psi pneumatic signal. Compressed air at normal mains supply
pressure enters the unit via a filter and a needle valve restrictor. Air
downstream of this restriction can bleed back out to atmosphere via a
nozzle. A flapper is pressed against the nozzle by a coil fed with the 4-20mA
signal, which is mounted inside a permanent magnet. The nozzle thus acts as
a variable pressure relief valve, producing a pressure in the unit proportional
to the current in the coil. The needle valve limits the air consumption of the
unit.
Figure 5.22 Positioner Unit
I/P CONVERTER POSITIONER

Coupling to
Actuator
Feedback
Cam
4-20mA Relieved Spool Feedback
Coil Air Valve Linkage
Signal Air Air
3 to 15 psi Exhaust
Mains
Air
Nozzle
Air to
Flapper Actuator
Force Balance
Lever
Zero
Needle Adjuster
Valve
Mains
Filter
Air
Range Feedback
Diaphragm
Adjuster Spring

The resulting 3-15 psi pressure is fed into a diaphragm chamber in the
Positioner. As the pressure increases, the diaphragm pushes the force
balance lever, which in turn moves a spool valve to supply mains pressure air
to one side of the valve actuator. As the valve moves, the positioner
coupling turns. This rotates a cam, and operates a linkage containing a
spring, which pulls the force balance lever back against the diaphragm, and
returns the spool valve to its mid position. Cutting off the mains air supply
to valve actuator, and holding the valve at the desired position. The shape of
the cam determines the relationship between the valve opening and the input
signal. Normally, a cam giving a linear characteristic is fitted.
5.3.10.2 Butterfly Valve Maintenance (Wafer pattern or Lugged)
(a) The valve is supplied with a bonded EPDM liner, therefore replacement
liners are not available.
(b) If the liner becomes damaged or worn, then a valve with liner can be
supplied (See mechanical spares list Table 7.1). This can be attached to
the existing actuator & positioner. However care must be taken to
ensure that the new valve is mounted to open in the same direction as the
original valve, or the positioner will be reading the opening and closing
values in reverse.
THE ACTUATOR SHOULD BE MOUNTED TO OPEN IN A CLOCKWISE

DIRECTION WHEN VIEWED FROM THE TOP OF THE ACTUATOR
WARNING: Valves must be stored in a dry, clean and corrosion-free

environment, with no direct exposure to the sun. Leaving valves open by 10
deg, for prevention of permanent distortion of resilient seats. Refrain from
overloading valves and their actuators, such as storing them in piles, or
placing other objects on them

5.3.10.3 Actuator Maintenance
The vane type actuator does not normally require maintenance. However,
the lip seals on the vane can be renewed by splitting the halves of the casing
at the screwed joint.
5.3.10.4 Positioner Maintenance and Adjustments
The positioner will have been factory set to suit the valve and actuator, but
adjustments may occasionally be necessary. Refer to Figures 5.22 and 5.23.
Figure 5.23 Positioner Unit
Zero and Range Adjustment

(a) Move the positioner/actuator to the zero end of the stroke by connecting
mains air to the positioner. Disconnect the mains air to the I/P converter.
Exhaust the air supply and move the internal angle indicator to indicate
zero. Set the coarse zero by slackening the coupling screw by half a turn,
until the top part of the coupling can be turned by hand, and rotate until
the cam just starts to rise up the cam profile.

(b) Reconnect the mains air supply, and send a 4mA signal (valve closed) to
the I/P converter. Slacken the fine zero adjustment clamp screw, and
turn the zero adjuster until the actuator moves to indicate zero on the
internal indicator. Tighten the clamp screw.
(c) Increase the input signal to 20 mA (valve fully open). Slacken the range
adjuster clamp screw, and turn the adjuster knob until the actuator
moves to the desired position on the angle indicator. Tighten the clamp
screw.
Speed Adjustment
There are two restrictor valves controlling the flowrate of the air exhaust,
one for each direction of travel. They are located on the body of the
positioner unit, just above the main air supply connection. Screw in to
reduce speed, and out to increase speed.
I/P Unit Air Bleed

To function correctly, the I/P unit requires a constant bleed of air of 2.5 to
3.5 litre/minute. The air flow can be blocked by contamination.
(a) Disconnect the mains air supply. Unscrew the needle valve from the
body of the I/P unit and clean. Refit and screw fully in.
(b) Reconnect the air supply and unscrew the needle valve by ¼ to ½ a turn
until the required bleed flow is obtained.

6 FAULT DIAGNOSIS

6 FAULT DIAGNOSIS
6.1 GENERAL FAULTS
6.1.1 Procedure for dealing with Faults
6.1.2 Fault Messages
6.1.3 Finding and Clearing Faults
6.2 OUT OF BALANCE AND VIBRATION FAULTS
6.2.1 Types of Vibration and Instability
6.2.2 Sensors and Trips
6.2.3 Procedure for dealing with OOB and Vibration Trips
6.2.4 Solving Persistent OOB and Vibration Problems

6 FAULT DIAGNOSIS
Broadbent centrifuges are of simple, robust construction and provided that the recommended
maintenance schedules in section 5 are followed, they should give trouble free service.
However, faults may occur from time to time and this section can be used to diagnose and
solve any problems that may occur.
Faults fall into the following categories,

Power Supply Faults arise from failure of the mains, control, or low voltage
electrical supplies to the centrifuge. Such faults are external to the centrifuge and
should be dealt with using normal electrical engineering practice.
The following faults are initiated automatically by the centrifuge control system. These
protection systems are incorporated into the main PLC program to prevent situations
occurring which may damage the centrifuge, or present hazards to operators,
Machine Start Inhibit Faults are faults detected while the centrifuge is at rest
and prevent the centrifuge from being started. Examples are the absence of signals
from critical instruments, mechanisms in the incorrect position etc.
Machine Shutdown Faults are faults detected while the centrifuge is cycling
and cause the centrifuge to stop. Examples are speed outside acceptable limits,
mechanisms in incorrect positions etc.
Out of Balance Faults are a particular class of Machine Shutdown Fault

caused by the out of balance switch being tripped or the vibration monitor giving
unacceptably high readings. Depending on the point in the cycle where the fault
occurs, the centrifuge may stop or decelerate to a lower speed. These can be
caused by faults in the centrifuge or by process problems. See section 6.3.
Cycle Faults are a particular class of Machine Shutdown Fault where the
centrifuge ‘sticks’ at some point in the cycle, due to failure or maladjustment of
actuators, instrumentation, or control system hardware. They are detected by the
failure to complete any step in the cycle (except spinning or awaiting sequence or
interlock permission) in less than 60 seconds. See section 6.4.
As a final protection against failure of the main PLC and/or inverter control electronics,
a completely separate secondary PLC is hardwired via relays to inhibit ploughing,
feeding, and spinning above preset speed limits,
PLC2 Speed Protection Faults may de-energise the plough mechanism or
feed mechanism or turn off the inverter. No fault indications will be given on the
QuickPanel because these trips will only occur if the main control system has
failed completely.

6.1 GENERAL FAULTS

6.1.1 Procedure for dealing with faults
Most of the display screens on the Operator Interface QuickPanel have the
following displays at the top right hand corner,
Status Display Panel Fault Display Panel

and Reset Pushbutton White with Red Text
Green with Blue Text Gives reasons why
Gives reasons why centrifuge has stopped
centrifuge will not start
The Fault Screen on the QuickPanel gives the causes of the last ten faults.
The procedure for dealing with faults is as follows,
(a) When a fault occurs, the beacon under the Operator Interface will flash
and there may also be an audible alarm.
In the case of a Start Inhibit Fault, the Status Display Panel will
display one of the messages listed in Figure 6.1 which gives the
reason why the centrifuge will not start.
In the case of a Shutdown, Out of Balance, or Cycle Fault, the Fault
Display Panel will display one of the messages listed in Figure 6.2
which gives the reason why the centrifuge has stopped or paused.
(b) Visually check the status of the centrifuge and note the displayed fault
messages. If necessary, refer to the control system flowchart in Appendix
A to decide exactly where in the cycle the fault occurred.
(c) Press the Reset Pushbutton (the same as the Status Display Panel). This
will cancel the flashing beacon and audible alarm.
(d) Depending on the fault message, use the appropriate fault finding
procedure given in Figure 6.3 to find and clear the fault. The centrifuge
will not start automatically after clearing the fault.
(e) Restart the centrifuge as follows,

In the case of a Start Inhibit Fault or Shutdown Fault press the Start
Machine Pushbutton.
In the case of a Cycle Fault, press the Reset Pushbutton again to
allow the centrifuge to continue through its cycle.
In the case of an Out of Balance Fault, the best action depends on
the state of the product in the basket. See section 6.2.3 for
guidance.
If the centrifuge fails to restart, either the fault has not been cleared or
the Reset Pushbutton has not been pressed at step (c).

6.1.2 Fault Messages

Figure 6.1 Start Inhibit Fault Messages
Message Comment Action
Safety Relay Safety relay circuit tripped Check Emergency Stop Pushbutton released
Check Safety Relay Circuit
Feed Valve Proximity switches indicate feed Check Feed Valve mechanism
Not Closed valve is open Check Feed Valve proximity switches
Check associated PLC inputs/outputs
PLC2 Fault Secondary PLC internal check Replace faulty secondary PLC
Inverter Fault Inverter internal check Refer to Inverter Manual
Machine Speed measurement system Check centrifuge stopped
Speed>10rpm indicates centrifuge still rotating Check Speed Measuring System
Inverter Not Ready Inverter ready signal off Refer to Inverter Manual
OOB Switch Set Out of Balance switch tripped Check switch not jammed
Check switch not damaged
Vibration Fault Signal from vibration Check Vibration Monitor
monitor <4mA Check associated PLC analogue input
Plough Not Latched Proximity switches indicate plough Check plough mechanism
mechanism is not in its parked Check plough proximity switches
Plough Not Parked
position and latched Check associated PLC inputs/outputs
Plough Out
Switch Not Set
Plough In Switch Set
Plough Down
Switch Set
Plough Up Switch
Set
Discharge Not Closed
Low Air Pneumatic Air Pressure has dropped Check Compressor
Pressure below the preset minimum value for Check for leaks in supply pipework
more than the preset time Increase size of supply pipework
Thermistor/Fan Centrifuge drive motor has Allow motor to cool.
Overload overheated or cooling fan has Check for too many starts
tripped Check for high ambient temperature
Check for blocked air filter
Check for blocked windings
Check fan motor running
Check fan not running in reverse
Check for rubbing brake
Check for faulty bearings
Brake released Emergency/parking disc brake off Check brake mechanism
Check brake proximity switch
Stop Pushbutton Release Stop Pushbutton
Pressed

Figure 6.2 Shutdown Fault Messages

Message Comment Action
M/C Stoppped Safety relay circuit tripped Check Emergency Stop Pushbutton released
Safety Relay Tripped Check Safety Relay Circuit
M/C Stopped Proximity switches indicate feed Check Feed Valve mechanism
Feed Valve Open valve is open at high speed Check Feed Valve proximity switches
above 450 rpm Check associated PLC inputs/outputs
M/C Stopped Spin speed exceeds 25 rpm above Check Speed Measuring System
Overspeed Trip maximum permitted spin speed Check Inverter
M/C Stopped Spin speed less than 90% of Refer to Inverter Manual
Spin Underspeed selected spin speed
M/C Stopped Speed has not increased Check Speed Measuring System
M/C Failed to Check Inverter
Accelerate
M/C Stopped Pulse counting measurement by Check Speed Measuring System
Speed Mismatch Main PLC not consistent with pulse
counting measurement by PLC2
M/C Stopped Ploughing speed exceeds 10 rpm Check Speed Measuring System
Plough Overspeed above maximum permitted speed Check Inverter
M/C Stopped Ploughing speed less than 10 rpm Check for obstructions in basket
Plough Underspeed below minimum permitted speed Check for jamming of plough blade
Check Speed Measuring System
Check Inverter
M/C Stopped Secondary PLC internal check Check Secondary PLC2
Secondary PLC Fault
M/C Stopped Inverter internal check Check Inverter
Inverter Fault
M/C Stopped Feeding time exceeds preset fail Check mixer tank not empty
Fail Feed feed time. Centrifuge stops feeding, Open feed valve preset
changes to manual cycle and pauses
at holding point
M/C Stopped
Hi Hi Vibration
M/C Stopped
Hi Vibration See section 6.2
M/C Stopped
OOB Switch Hit
M/C Stopped Signal from vibration Check Vibration Monitor
Vibration Monitor monitor <4mA Check associated PLC analogue input
Fault
M/C Stopped Proximity switches indicate plough Check plough mechanism
Plough Not Latched mechanism is not in its parked Check plough proximity switches
position and latched Check associated PLC inputs/outputs
M/C Stopped
Plough Not Parked

M/C Stopped Pneumatic Air Pressure has dropped Check Compressor

Low Air Pressure below the preset minimum value for Check for leaks in supply pipework
more than the preset time Increase size of supply pipework
M/C Stopped Centrifuge drive motor has Allow motor to cool.
Thermistor/Fan overheated or cooling fan has Check for too many starts
Overload tripped Check for high ambient temperature
Check for blocked air filter
Check for blocked windings
Check fan motor running
Check fan not running in reverse
Check for rubbing brake
Check for faulty bearings
M/C Stopped Emergency/parking disc brake on Check brake mechanism
Brake On Check brake proximity switch
M/C Stopped Release Stop Pushbutton
Stop Button Pressed
M/C Stopped One of the PLC program steps Check mechanism, instruments, or controls
Cycle Time Exceeded (except spinning or awaiting where cycle has stuck. See section 6.1.3
(This Cycle Insurance sequence or interlock permission)
Fault drops the has failed to complete within 60
machine into Manual seconds indicating cycle has stuck
Cycle Mode which due to a failure or maladjustment of
causes it to Stop at the a mechanism, instrument or control
end of the cycle) system hardware
6.1.3 Finding and Clearing Faults

Visually check the status of the machine and note the messages on the Fault
Display and Status Display panels on the QuickPanel screen. This will indicate the
point in the cycle where the fault has occurred. Diagnose and clear the fault as
follows. There are basically two types of fault.
6.1.3.1 Mechanism or Valve Fails to Operate
(a) Check if the mechanism or valve has actually moved. Possible faults
which could prevent movement are,
w Mechanical jamming
w Seizure caused by corrosion or contamination by product
w Leaking of pneumatic actuators
w Fracture or disconnection of air lines
w Failure of solenoid valve
w Loss of air pressure
(b) Check if the associated proximity switch has sensed the movement by
observing the indicator light on the switch. Reasons for the switch not
operating are,
w Incorrect gap setting
w Faulty switch
w Faulty or disconnected lead
(c) Check if the PLC inputs and/or outputs have operated by observing the
indicator lights on the modules in the Control Panel. Failure could result
from,
w Faulty input/output module
w Loss of low voltage dc power supply
6.1.3.2 Failure to carry out a Speed Change
(a) Check if the speed measuring system is operating correctly. Refer to

section 1.14.5. Possible faults are,
w Incorrect gap setting of proximity switches to brake disc
w Faulty proximity switch
w Faulty or disconnected lead
w Faulty proximity switch isolation amplifier (2 to 3 wire converter)
w Faulty PLC input module
w Faulty Secondary PLC2
w Loss of low voltage dc supply
(b) Check inverter is operating correctly. Refer to Inverter Manual.

6.2 OUT OF BALANCE AND VIBRATION FAULTS

These are the most common type of fault. Although they can arise from faults in the
centrifuge, they are more likely to be caused by process problems such as out of
specification product or inappropriate parameter settings. The protection features built
into the control system are designed to prevent potentially damaging situations occurring
while not unnecessarily causing incompletely processed product to be dumped on the
conveyor.
6.2.1 Types of Vibration and Instability
An understanding of the types of vibration and instability that can occur and the
reasons for them will help in fault finding.
The load in the basket of a centrifuge will Centrifuge Drive

always be slightly out of balance. Sugar Casing Motor
centrifuges usually spin at a speed giving a
separating effect of about 1000 ‘G’ (one
thousand times normal gravity) so each 1 kg
out of balance will give a corresponding
centrifugal force of about 1 Tonne which
acts radially outwards and rotates at the
speed of the centrifuge.
In a centrifuge with a rigidly mounted shaft

and basket as shown right, all of this rotating
Basket
force is transmitted directly to the casing and Unbalanced
Load
would quickly damage the bearings and
shake the supporting structure.
For this reason, Broadbent batch sugar

Anti-Precession
centrifuges are pendulum suspended with the
Damper
Drive
rotating assembly hanging from a conical
Motor rubber Support Buffer as shown left.
Provided that the rotating speed is above the
Support
Buffer swinging resonance, the basket swings
slightly in the opposite direction to the
position of the unbalance to find a better
balanced axis of rotation and thus reduce the
transmission of forces to the support
structure. The swinging resonance is the
frequency that the rotating assembly would
naturally swing if it were pushed slightly to
one side and then released. To ensure that
this self balancing action occurs whenever
Unbalanced
the basket is loaded, the feed speed must
Basket Centrifuge
Casing Load always be substantially above the swinging
resonant frequency.

In a pendulum suspended centrifuge the self balancing action means that only a
fraction of the out of balance force is transmitted to the frame and structure but
this residual transmitted force can be felt as vibration at the same frequency that
the shaft rotates. This is known as Shaft Rate Vibration. Since the whole
rotating assembly tilts slightly in a fixed orientation relative to the unbalance, as
the centrifuge rotates, the basket and motor appear to move side to side at the
same speed as the shaft. A vibration sensor (accelerometer) attached to the top of
the motor can detect this small movement (around 0.1 to 0.2 mm per 1 kg
unbalance in the basket). This acceleration is proportional to the amount of
unbalance in the basket and to the corresponding stresses in the basket and shaft
caused by the unbalance. The vibration sensor can therefore be used to protect the
basket and shaft against excessive stresses.
Feeding is usually carried out at a low rotational speed but higher than the
swinging resonant speed. During Stationary
feeding, the centrifugal force causes Guide
the product to climb up the inside of Centering
Accelerometer Ring
the basket and also flow around the Springs
('Monitran')
basket to produce an even cake Motor
thickness. While the product is Moves Friction
Plate
flowing inside the basket, the basket
tends to swing by quite large amounts
Switch
and this is known as Gyration. At
the same time, the centrifugal force
Drive
causes liquor to start to purge out of Motor
the product. The higher the rotational
speed, the faster the cake purges. The
aim is to feed more product into the
basket just fast enough to replace the
liquor lost by purging and thus keep
the cake mobile long enough to allow Tilting Support
Centre Buffer
it to flow and balance itself.
If the cake purges too quickly during

feeding (e.g. if the feeding speed is
too high or the feeding rate is too low), the cake solidifies before it can balance
itself and this is the cause of unbalance and Shaft Rate Vibration at high speed. On
the other hand, if the feed speed is too low the cake will remain fluid longer and
the rotating assembly will be closer to the swing resonance which will both tend to
increase Gyration. Increasing the feed speed reduces Gyration during feeding
but increases Shaft Rate Vibration at high speed. Reducing the feed speed
decreases Shaft Rate Vibration but increases Gyration. To some extent it is
possible to compensate for a high feed speed by increasing the feeding rate or a
low feed speed by reducing the feeding rate.
If the product contains a lot of very small crystals (e.g. a ‘false grain’ massecuite)
and a high proportion of liquor or if the filtering screen is blinded by product or
contaminants blocking the perforations, the liquor may have difficulty in purging
out of the cake. Instead, a layer of liquor will form on the surface of the cake.

Waves will start to form in this layer of liquid and when the speed of these waves
synchronises with the rotational speed of the basket the basket will suddenly ‘kick’
sideways and hit the casing. This is known as a Liquor Loading Instability and
can cause serious damage. Liquor Loading Instabilities occur so suddenly that the
centrifuge control system is unable to take any corrective action and for this
reason they are potentially dangerous.
WARNING: The centrifuge must not be fed with very poorly purging
or impermeable materials and the filtering screens must be kept
clear at all times.
When spinning at high speed, the centrifuge rotating assembly is susceptible to

Gyroscopic Precession. This is the tendency for the axis of any rotating
object to start slowly orbiting with a gradually increasing amplitude and can be
seen in the ‘wobbling’ of a toy spinning top. If unchecked, the basket eventually
impacts the casing causing serious damage. This is prevented by a plate with a
friction lining being pushed onto the top of the motor by spring pressure (see
Figure 3). This Anti-Precession Damper system also helps to reduce the
Gyration movements during feeding. Any sign that the rotating assembly is slowly
wandering in circles during spinning is an indication that the Anti-Precession
Damper requires maintenance.
It is clear from the above that many vibration and instability problems arise from
poor quality product feed or badly adjusted feed speed and feed rate. Figure 6.3
summarises some typical problems and the means of correcting them.
6.2.2 Sensors and Trips

The Out of Balance (OOB) Switch is a robust mechanical switch which is
designed to detect large amplitude, slow speed movements of the rotating
assembly due to Gyration or Precession. The gap between the switch and a striker
plate on the top of the motor (see Figure 5.8) is set to trip the switch if the
rotating assembly swings enough to take up about 50% of the clearance between
the basket bump ring and the casing curb ring.
The Vibration Monitor is a simple accelerometer with a built in filter and

amplifier to respond only to shaft rate movement at the rotational speed of the
centrifuge. It is designed to detect the small amplitude, high speed movements of
the centrifuge caused by Out of Balance in the basket. The vibration monitor gives
a continuous reading of vibration acceleration in 0.01 G rms on the QuickPanel.
This reading is almost exactly proportional to the stresses in the spindle and basket
and is used to set two levels of trip based on the vibration exceeding a set
amplitude for more than a set time. The Hi Hi Vibration trip amplitude and time
are both greater than the Hi Vibration trip amplitude and time (see section 2 for
values).

Figure 6.3 Feeding Problems

Symptom Appearance Cause Action
Unable to fill Cake tapers Insufficient ‘G’ for Increase feed
basket. High from top to product to climb speed.
Gyration bottom but is basket
during feeding. even around
Low Shaft Rate basket
Vibration at
high speed
Unable to fill Cake thicker Product purging Decrease feed speed

basket. Cake is where product too quickly and and/or increase feed
unbalanced first contacts unable to flow to rate.
giving high basket distribute itself
Shaft Rate evenly around the
Vibration at basket.
high speed.
Excessive Shaft Cake undercut ‘Rat holing’ past Check fit of screens
Rate Vibration at top or edges or through in basket.
at high speed. bottom. holes in filtering Check screens not
Depressions Rat-hole screen. torn or holed. Check
or holes at wash pipe not
random Undercut dribbling on basket
positions. bottom.
Basket Free liquid Product Check screens not

suddenly visible on Free sedimenting blocked.
impacts casing surface of Liquid instead of purging. Check quality of
during cake. Waves set up in product feed for high
acceleration liquid layer cause a free liquor content,
due to Liquor sudden instability. excessively small
Loading crystals.
Instability
6.2.3 Procedure for dealing with OOB and Vibration Trips

The Fault Display Panel will indicate which type of trip has occurred. In addition,
the ‘T’ shaped indicator on the side of motor on the mimic on the QuickPanel
Main Screen will turn red if the OOB switch trips, the square indicator will turn
red if the vibration monitor trips, and the numeric display near these indicators
gives the speed that the trip occurred.
The action taken by the control system depends on the position in the cycle when
the OOB switch or vibration monitor trips,
In the case of a Hi Vibration or OOB Switch trip during feeding,

acceleration to spin, or during spinning, the centrifuge immediately switches
into Manual Cycle Mode, decelerates to feed speed and pauses ready to feed
with an alarm. (If a trip repeats again while at feed speed, the centrifuge
stops).

In the case of a Hi Vibration or OOB Switch trip during acceleration to

feeding, deceleration from spin, or during ploughing, the centrifuge stops.
In the case of a Hi Hi Vibration trip at any time in the cycle, the centrifuge
immediately stops.
Accept the trip as described in section 6.1.1. Note the point in the cycle where the
trip occurred and observe the condition of the product in the basket to determine
the appropriate action as follows,
If the centrifuge has decelerated to feed speed and paused,
(a) If the product cake has been washed and is fairly dry (e.g. If the trip
occurred during spinning), press Stop and then initiate a Plough Only
Cycle to discharge the product.
(b) If the product cake has not been washed but is fairly dry (e.g. If the trip
occurred during acceleration), press Start Feeding to try rebalancing the
load by refeeding over the existing cake, then when the hold point is
reached, press Start Machine to accelerate to spin.
(c) If the product cake is still wet (e.g If the trip occurred during feeding),
press Start Feeding then Stop Feeding immediately to prevent refeeding
over the existing cake, then when the hold point is reached, press Start
Machine to accelerate to spin.
(d) If actions (b) or (c) result in repeat trips so that it is impossible to reach
spin speed, proceed as (c) but allow the centrifuge to spin at the holding
speed for 15 to 20 minutes while washing using the Manual Wash
button. When the cake is clean and reasonably dry, press Stop and then
initiate a Plough Only Cycle to discharge the product.
If the centrifuge has come to rest, there is little alternative except to

discharge the product by initiating a Plough Only Cycle. If the product is
very wet and has slumped into the bottom of the basket, the speed of vertical
motion of the plough down the basket should first be reduced by adjusting
the valve on the plough dashpot.
6.2.4 Solving Persistent OOB and Vibration Problems

The most likely cause of regular OOB and Vibration trips is that the process
parameters being used are incorrect for the product being processed. In particular,
the rotational speed at feeding and the rate of feeding as controlled by the feed
valve opening have a large effect on the ability of the centrifuge to balance itself. If
the consistency of the product being fed varies significantly, these parameters must
be changed. More guidance is given in Appendix D.
A less likely cause of problems is some mechanical defect in the centrifuge. This
will only be the case if the problems persist when the centrifuge is run empty.

Figure 6.4 Diagnosis of Vibration and Out of Balance Problems

Symptom Causes Actions
Trips occur Faulty OOB Switch Check OOB Switch Gap (See drawings or manual)
without apparent Check OOB Switch not damaged
excessive vibration
Faulty Vibration Monitor Check Monitor Wiring and Earthing
or swinging
Check Monitor Calibration
Shaft Rate Debris in Basket Check there are no remnants of product left in basket
Vibration persists Check there are no foreign objects in basket
when centrifuge
Mechanical Fault Check there is no debris trapped between the spindle
run empty without
and basket flange faces and check basket bolts are tight
product in basket
Check spindle is not bent or damaged
Check basket is not damaged
Excessive Gyration Product with high liquor Reduce feed rate by reducing feed valve opening
during feeding content or feed rate too high Check for excessive liquor in fed product
causing heavy impact on basket
Feed speed is too low, close to Increase feed speed
centrifuge swinging resonance
Anti-precession damper Check damper spring settings (see drawings or manual)
defective Check friction linings on damper plate not loose or
worn
Check centering ring is a tight fit on fan ducting
Basket ‘kicks’ at Product cake is too fluid and Increase feed speed
start of mobile due to insufficient Reduce feed rate by reducing feed valve opening
acceleration after purging during feeding Change purge settle delay from zero to a few seconds
feeding Check for large quantities of small crystals or
excessively viscous liquor in fed product
Sudden Liquor Product purges poorly due to Improve quality of fed product
Loading Instability small crystals or high liquor Adjust feed limiter to reduce cake thickness
during acceleration content allowing a visible layer Change purge settle delay from zero to 30-60 seconds
to spin of liquor to form on cake Reduce feed rate by reducing feed valve opening
surface Increase feed speed (with caution)
SAFETY
Filtering screen is blocked, Check if holes in filtering screen are blocked by product
HAZARD
preventing purging and not removed during ploughing or by contaminants
allowing a visible layer of Increase duration of screen rinse time
liquor to form on cake surface
Shaft Rate Product cake has purged too Reduce feed speed
Vibration steadily quickly during feeding Increase feed rate by increasing feed valve opening
increases to an preventing it flowing to Check fed product does not have excessively large
excessive level produce an even cake crystals
during acceleration
Defective filtering screen Check for holes in filtering screen
from feed to spin
allows ‘ratholing’ producing Check for gaps between top and bottom edges of screen
holes, gaps or depressions in and basket
cake surface Check for gaps at lock-lap joint in filtering screen
Shaft Rate Support structure is too flexible Increase stiffness of support structure (see Broadbent
Vibration rises to a giving rise to a lateral Information Sheet SI/96/1 or SI/97/1)
peak and then falls resonance below spin speed Improve rigidity of connection between back of
during acceleration centrifuge upper frame and mixer tank (see Broadbent
from feed to spin Information Sheet SI/96/1 or SI/97/1)

Precession during Anti-precession damper Check damper spring settings (see drawings or manual)
spinning defective allowing rotating Check friction linings on damper plate not loose or
assembly to slowly orbit worn
Check centering ring is a tight fit on fan ducting
Figure 6.4 lists symptoms, causes and recommended actions for correcting all
types of vibration and instability problems. Work through Figure 5 methodically as
follows,
(a) Is the Out of Balance Switch or Vibration Monitor faulty?
(b) Does the problem persist when the centrifuge is run empty?
(c) Is the problem Shaft Rate Vibration, Gyration, Liquor Loading

Instability or Precession and when does it occur?
Note that any changes to feed speed should be made slowly, no more than 5 rpm
at a time and the feed speed should never be less than 25 rpm above the swinging
resonance.

7 PART LISTS

7 PART LISTS
7.1 SPARES
7.2 TOOLS

7 PART LISTS
7.1 SPARES
WARNING : MANY OF THE COMPONENTS IN CENTRIFUGES ARE
HIGHLY STRESSED SO ONLY GENUINE BROADBENT PARTS
SHOULD BE USED. THE USE OF SUBSTANDARD COMPONENTS
COULD RESULT IN INJURY TO PERSONNEL, DAMAGE TO THE
CENTRIFUGE OR INVALIDATE ANY WARRANTY AGREEMENT.
Tables 7.1 and 7.2 list only those items which may need to be replaced during the life of
the centrifuge. Part numbers for other components such as the monitor casing,
discharge chutes etc. can be obtained from the appended reference drawings.
The 'spares factors' given in Tables 7.1 and 7.2 indicates the probability that a particular
part will be needed over a 5 year period of operation. Items with a spares factor of 1 or
greater are parts which will be needed for the planned, preventative maintenance
schedules given in Section 5. Items with a spares factor less than 1 are contingency
spares for items which may need to be replaced due to wear, damage, or loss.
The recommended spares holding of an item for any number of centrifuges over any
desired period is calculated from the spares factor as follows,
S=NxMxFxY/5
Where, S = Recommended spares holding

N = Number of centrifuges
M = Number of items per centrifuge
F = Spares factor
Y = Number of years spares are to cover
S should be rounded to the nearest whole number. If S is less than 0.5 the probability of
the item being required is low and the user must decide whether the possible loss of
availability while a replacement is ordered justifies the cost of holding a spare item in
stock.
The form appended to this section can be used to order spares.

Table 7.1 Recommended Mechanical Spares C46MT (5545)

Number per Spares
Item Part Number Centrifuge Factor
M F
Spindle
Top Angular Contact Ball Bearing 24130-025 1 1
Lower Cylindrical Roller Bearing 24150-066 1 0.5
Upper Cylindrical Roller Bearing 24150-067 1 0.5
Suspension Buffer 31890-118 1 0.5
Drive Pin 31020-173 4 1
Motor Cooling Fan
Fan Filter 22900-003 1 0.5
Disc Brake (Coremo)
Disc Brake Pad Assembly (pair) 22191-003 1 2.5
Spares Kit Complete 22191-005 1 0.5
Anti-Precession System
Centering Rubber Ring (Cut to size) 18210-011 1 1
Damper Plate Friction Lining (six segments) 38621-001 1 1
Friction Lining Rivets 27080-007 36 1
Damper Plate Spring 38510-075 3 0.5
Basket 5545 Mk2 and Linings
Basket Bolt 38830-010 8 0.5
No 4 Backing Gauze Stainless Steel 39030-209 1 1
No 7 Intermediate Gauze Stainless Steel 39030-210 1 1
Perforated Stainless Steel Working Screen 39030-211 1 5
Plough Discharger
Plough Blade Retaining Bolt 27510-003 1 1
Plough Blade Special Tab Washer 36210-043 1 1
Plough Tip 39080-044 1 5
Tip Retaining Screws 27610-014 7 5
Plough Latching Pin 32620-044 1 1
Plough Latching Pin Spring 22250-013 1 1
Plough Arm Roller 32950-089 2 1
Plough Horizontal Cylinder 20020-167 1 0.2
Plough Horizontal Cylinder Repair Kit 20070-476 1 0.5
Plough Vertical Cylinder 20020-166 1 0.2
Plough Vertical Cylinder Repair Kit 20070-475 1 0.5
Plough Vertical Damper C46MT/C60MT 54230-006 1 0.2
Plough Vertical Damper Flow Control Valve 22371-003 1 0.5
Plough Vertical Damper Nose Seal 25840-034 1 0.5
Plough Carriage Bush 32390-098 3 0.2
Plough Shaft Bush 32200-108 1 0.2
Plough Bush Wiper Seal 25840-008 6 0.2
Discharge Valve
Discharge Valve Cylinder 20021-019 1 0.2
Discharge Valve Cylinder (100 Bore) Repair Kit 20070-475 1 0.5
Discharge Valve Rotating Joint 25771-004 1 1
Exhaust Port Filter 20071-015 1 0.2
Discharge Valve Bottom Bush 31540-056 1 0.2
Discharge Valve Bottom Seal 31640-156 1 0.2
Discharge Valve Lower Bearing Pad 31800-292 1 0.2

Number per Spares

M F
Enclosed Feed Valve and Chute Wash
12” (300mm) B/V lugged with actuator & positioner 22361-029 1 0.2
12” (300mm) B/V (Spare valve with liner only) 22361-030 1 0.3
Actuator Complete (120-100) 20120-007 1 0.2
A-P Positioner Complete 22880-028 1 0.2
1/2" BSP Actuated Ball Valve (Chute Wash) 22420-069 1 0.2
Secondary Flap Valve (5545)
Flap Valve Cylinder 20020-169 2 0.2
Flap Valve Cylinder Repair Kit 20070-476 2 0.5
Sealing Plate 39240-092 1 0.5
Pivot Bush 39730-015 2 0.5
Feed Limiter
Feed Limiter Cylinder (No repair kit) 20020-121 1 1
Feed Limiter Spring 38520-032 2 2
Wash System (5545)
Flatjet Nozzle 30º 22760-094 1 0.5
1" BSP Actuated Ball Valve 22420-068 1 0.2
1" BSP Valve Repair Kit 22880-030 1 1
Steam System
1" BSP Actuated Ball Valve 22420-068 1 0.2
1" BSP Valve Repair Kit 22880-030 1 1
Molasses Classification System (One Valve)
8” (200mm) B/V wafer pattern with actuator 22361-035 1 0.2
8” (200mm) B/V wafer (Spare valve with liner only) 22361-036 1 0.3
Actuator Repair Kit (size 090) 20120-008 1 0.5
Pneumatics General
Solenoid Valve 22580-033 14 0.2
Lubrication System
Shell RL2 Grease (12.5kg) 10550-214 1 0.5

Table 7.2 Recommended Electrical Spares

Number per Spares
M F
Control Panel with a Allen bradley Micrologix 1500
Panel anti-condensation heater 21640-004 1 0.6
Panel Fan and Filter 20861-011 1 0.6
Panel Fan Filter 20861-012 1 0.6
Indicator Lamp Clear 21470-088 1 2.5
Indicator Lamp Green 21470-091 1 2.5
Indicator Lamp Bulb 24 V dc 21420-016 2 5
Thermistor Relay 23851-001 1 1
2 - 3 Wire Converter 23470-040 1 1
Single Pole MCB 3 A 26740-065 1 1
Mini Plug-in 110 V ac Relay 23100-136 1 1
Mini Plug-in 24 V dc Relay 23100-138 6 0.6
Base for Mini Plug-in Relays 23100-137 7 0.6
Control Transformer 250 VA 23820-080 1 0.6
Supressor 130 V ac 26730-010 1 1.2
Fused Isolator 23200-046 1 0.6
Fuse Link 20 A 26710-018 3 2.5
2 Pole MCB 8 A 26740-071 1 1
PLC CPU - SLC500 23700-102 1 0.5
PLC 64k Flash EPROM 23700-101 1 0.5
PLC Analog Input / Output Module 23710-098 1 0.5
PLC Digital Fast Input Module 23710-151 1 0.5
PLC Digital Input Module 23710-097 1 0.5
PLC Digital Output Module 23710-096 1 0.5
PLC 7 Card Rack 23740-038 1 0.5
PLC Power Supply Unit 23780-036 1 0.5
DH485 Link Coupler Module 23700-087 1 0.5
5 A 24 V dc Power Supply 23781-002 1 1.2
Saftey Relay 23100-141 1 0.6
2 - 3 wire Converter for Speed Sensor 23470-017 2 1
Optical Coupler Terminal 23360-012 4 1
14 Input/Output Micro PLC 23700-079 1 1
Cooling Fan Overload
2.2 kW Fan Overload 280-480 V 26750-039 1 1
Operator Interface
6” Colour Quick Panel, Touch Screen 28501-028 1 0.5
Illuminated Pushbutton Blue 23221-010 1 2.5
Indicator LED (white) 85 -230 V a.c. 21421-004 1 20
Pushbutton Black 23221-011 1 2.5
Pushbutton Red Mushroom Head 23221-013 1 2.5
Contact Block N/O - N/O 23271-005 1 2.5
Contact Block N/C - N/C Butt Action 23271-006 3 1.2
Push Button Yellow Mushroom Head 23221-012 1 2.5
Beacon Base 21470-072 1 1.2
Flashing Beacon 21470-073 1 1.5
DH485 Interface Lead 28500-901 1 0.5
DH485 Link Coupler 23700-087 1 1

Number per Spares

M F
Items Fitted to Centrifuge
Proximity Sensor M12 (Flying Lead) 28391-063 2 2.5
Proximity Switch M18 (Plug In) 28390-037 13 3
Proximity Switch M12 (Feed Limiter) 28391-071 1 3
Out of Balance Switch 54520-025 1 1
Vibration Monitor 0-1 'G' 4-20 mA 28390-042 1 1
Proximity Switch Lead 8 Way Splitter Box 28391-067 1 0.7
Proximity Switch Lead Dual Port Splitter 28391-066 5 0.7
Proximity Switch Lead 5.0 m (3 pole) Straight - Straight 28390-068 1 0.6
Proximity Switch Lead 3.0 m 90º - Straight 28391-065 13 0.6
Sequence Panel (if fitted)
Relay 24 Volts dc 23100-078 2 0.6
Auxiliary contact for dc Relay 23140-064 2 0.6
Diode for dc Relay 23140-052 2 0.6
MCB 2 Pole 0.5A 26740-064 1 1
Isolator 23200-044 1 1
100VA Transformer 23820-053 1 0.6
24 Volt dc Power Supply 1.3A 23780-067 1 1.2
MCB 1 Pole 1A 26740-055 1 1
PLC 20 I/O AB Micrologix 23701-012 1 1
LED Green 24V with Bezel 21400-024 12 0.6
Mitsubishi E100 HMI 28501-003 1 0.5
5VDC PSU 85-264 V ac 23781-001 1 1.2
Memory Module M/L 1200 23701-012 1 0.5
Relay DPCO 24 V dc 5A 23100-101 10 0.6
Relay Base DPCO 23100-102 10 0.6
Comms Cable Cab2 28501-004 1 0.5
Jack Plug with lead 28391-011 1 0.5

7.2 TOOLS
Maintenance work requires a set of standard hand tools as listed in Table 7.3.
Table 7.3 Standard Tools

Item Sizes
Square Drive Ratchet Wrench
Square Drive Torque Wrench 0-500 Nm
Metric Open Ended Spanner 10 13 17 19 24 30 36 mm A/F
Metric Hexagon Square Drive Sockets 10 13 17 19 24 30 36 mm A/F
Metric Allen Key Square Drive Sockets 3 5 6 8 10 14 mm A/F
Screwdrivers Various Blade Widths
Soft Faced Mallet Hide or Copper Anvils
A set of special tools and fixtures, listed in Table 7.4, can be provided to assist with
work on the basket and spindle assemblies.
Table 7.4 Special Tools

Item Part Number No off Used for
Lifting Gear Assembly 56850-040 1 Machine Lifts
Top Draw Plate 31070-007 1
Bottom Draw Plate 32250-092 1 Lower Cylindrical Roller
Bearing Removal & Basket
M24 x 1000mm lg Threaded Bar 12510-213 3 Fitting
M24 Plain Hex Full Nut 27800-019 9
M24 Extra Large Washer 27140-064 6
M36 x 1200mm lg Threaded Bar 31150-050 1
Dismantling & Refitting
M36 Plain Washer 27140-003 1 Discharge Valve
Assembly
Discharge Valve Drawplate 31420-073 1
Spindle Bottom Plate 31071-011 1
M24 z 40 Lg Hex Hd Screw 8.8 27500-110 4
Dummy Rotor Hub C46MT 40050-078 1
Rotor Extractor Plate C46MT 31071-010 1
M16 z 140 Lg Hex Hd Bolt 8.8 27500-086 4 Rotor Removal
M12 z 140 Lg Hex Hd Screw 8.8 27501-009 4
M12 z 50 Lg Hex Hd Screw 8.8 27500-033 4
M12 Plain Washer 27140-036 1
M20 Collar Eyebolt with Link 24880-002 1

APPENDIX A - CONTROL SYSTEM

This Appendix details the control system for the centrifuge in the form of a flowchart, and can
be used to assist in diagnosing faults. This Appendix should be read in conjunction with
sections 2, 4 and 6.
The whole production cycle of the machine, including operation of the inverter, feed
valves, plough, discharge valve and process fitments is controlled by an electronic Main
Programmable Logic Controller (PLC). The central processing unit (CPU) of the Main
PLC holds the operating program for the centrifuge within its EPROM memory. The
CPU scans the inputs to the PLC from the operator interface and the various sensors on
the centrifuge, acts upon these inputs as determined by the program, and then turns on
the appropriate outputs to the inverter and centrifuge actuators in a cyclic manner. The
program sequence and logic is detailed in the following flowcharts. The program
comprises,
A Main Cycle Sequence Program. This has sequential logic, reflecting the cyclic
nature of the centrifuge operation.
A Stop Sequence Program which can be initiated by the operator at any time.
Several Continuous Loop Programs running in parallel. These are associated with
speed measurement and automatic protection functions.
It is possible that faults in the Main PLC, Inverter, or other electronic device could
cause random, uncontrolled actions. To ensure that such faults cannot cause a
dangerous situation, an entirely independent Secondary Programmable Logic
Controller (PLC2) from a different manufacturer is fitted. This is a simple pulse
counting unit, connected directly to a proximity switch measuring the centrifuge speed.
It is configured to operate 6 sets of contacts corresponding to different speeds. One set
of contacts isolates the plough actuators to prevent the plough deploying above low
speed. Another set of contacts isolates the feed valve actuators to prevent feeding above
medium speed. Two other sets of contacts first disable and then isolate the inverter to
prevent overspeeding. The operation of these contacts is illustrated on the flowchart for
the Main Cycle Sequence Program. In addition, one of the Continuous Loop Programs
continuously checks that the status of the PLC2 contacts is consistent with the speed
measurement used in the Main PLC, and stops the centrifuge if a mismatch is detected.

Main Cycle Sequence (1)
PRE-START CHECKS
Plough Parked and Latched
Feed and Drip Valves Closed
No Other Faults
Set TF=TFT
Press
START
SECONDARY
CONTROLLER
PLC2
LIft Brake
& Check Switch
Set Inverter Speed

Reference to NP
N Inverter
Running?
N Speed
>10rpm?
Y
LOW SPEED
Speed NP
Plough
Only Open Discharge
Cycle Valve
Mode? (& Check Switch)
Speed<N1Contact
Manual
Opens
or Auto
Go To START
PLOUGHING
Set Inverter Speed Screen Rinse

Reference to NF for TWS
Speed>N2 Contact
Closes
N Isolates Plough Latch
Speed
& Horizontal Actuator
NF ±10rpm?
Solenoid Valves
Y
FEED SPEED
Speed NF

Open Drip Deploy Feed Open Mother Close Wash

Valve Detector Liquor Valve Liquor Valve
AND
SECONDARY
CONTROLLER
Check Drip Valve Switch PLC2
Check Feed Detector Position Switch
Check Mother Liquor Valve Switch
Check Wash Liquor Valve Switch
Feeding Calculate Last TF> Y Reset CVP

Mode? TFT+2sec ? =CVP+5%
Preset N
Last TF< Y Reset CVP
TFT-2sec ? =CVP-5%
N
OR
Set
OR
VP=CVP
START FEED
Speed NF
Pause Cycle
Timer TC
Manual Cycle
Mode?
Auto
Press OR
START FEED
Resume Cycle
Timer TC

Open Feed Start Feed Press Press FEED

Valve to VO=VP Timer TF STOP FEED VALVE CLOSE
Inch Valve Fail Feed

Opening VO TF>TFF? Close Feed
Y Valve
Feed Detector Switch to

Trips MANUAL CYCLE Stop Feed
Timer TF
OR
Switch to
MANUAL
CYCLE
Close Feed Valve Stop Feed Park Feed
& Check Switch Timer TF Detector
Go To
AND START FEED
END FEED
Speed NF
SECONDARY
CONTROLLER
PLC2
Feed Chute Rinse Cake Settling Delay
for TCR Run Timer TCS
Chute Rinse Delay Set Inverter Speed

Run Timer TCD Reference to NH
Close Drip Valve

& Check Switch
AND
HOLD POINT
Speed NH
Pause Cycle
Timer TC

Manual Cycle
Mode? SECONDARY
Auto CONTROLLER
SEQUENCE PANEL PLC2
Press OR (OPTIONAL)
START
Sequence
AND Permission to
Accelerate
Resume Cycle
Timer TC
Set Inverter Speed

Reference to NS
PRIMARY SECONDARY Speed>N3 Contact

WASH 'A' WASH 'B' Closes
At Speed NWA At Speed NWB Isolates Feed Valve
Wash for TWA Wash for TWB and Drip Valve
Actuator Solenoids
Washing Flow Delay

Run Timer TWF
Open Wash Liquor Speed>N4 Contact

Valve & Check Switch Closes
Speed> N
0.9xNS?
Close Mother Liquor Y

Valve & Check Switch START SPIN
Speed 90% of NS
Speed>N5 Contact
Closes
Spinning OVERSPEED1
Y Speed Y
Run Timer TS Speed Remove Inverter
<NSMAX Enable Signal
>90% NS? +25rpm? & Apply Brake
N N
OR
SPIN
STEAMING
WASH 'C' Speed>N6 Contact
At Time TSS
At Time TSW Closes
Steam for TSD STOP
Wash for TWC OVERSPEED 2
Trip Inverter Input
Contactor & Power
END SPIN Disconnect
Speed NS

Set Inverter Speed

Reference to NP Speed>N4 Contact
Opens
Speed>N3 Contact
Opens
Energises Feed
Valve and Drip Valve
Actuator Solenoids
N Speed>N2 Contact
Speed
Opens
<ND
Energise Plough Latch
Y & Horizontal Actuator
Solenoid Valves
Open Discharge Valve Speed N
(& Check Switch) NP ±10rpm?
Speed<N1Contact
Y Closes
AND
READY TO
PLOUGH
Speed NP SECONDARY
CONTROLLER
INTERLOCKS Pause Cycle SEQUENCE PANEL PLC2
(OPTIONAL) Timer TC (OPTIONAL)
Conveyor Running & Sequence

Wash Water Flow AND Permission to
Switch Operated Plough
Resume Cycle
Timer TC
Open Steaming
Y Speed Speed Y
Covers
>NPMIN <NPMAX
-10rpm? +10rpm?
Disengage Plough N N
Parked Latch OR
& Check Switch
Move Plough In STOP

to Screen
& Check Switch
Engage Plough
Return Latch
& Check Switch

Plough Force Delay

Run Timer TPF
SECONDARY
CONTROLLER
PLC2
Reduce Plough
Force onto Screen
Plough Basket
Top Delay
Run Timer TPT
Move Plough
Down Basket until
Switch Makes
Plough Basket
Bottom Delay
Run Timer TPB
Move Plough
Up Basket &
Check Leaves Switch
Move Plough
Off Screen &
Check Leaves Switch
Continue to Move
Plough Up Basket
until Switch Makes
Disengage Plough
Close Discharge
Return Latch
Valve
& Check Switch
Move Plough to
Spindle & Check
Switch
Engage Plough
Parked Latch
& Check Switch
Close Steaming
Covers
AND
END OF
PLOUGHING
Speed NP

Auto SECONDARY
Cycle Go To
CONTROLLER
Mode? LOW SPEED
PLC2
Manual or Plough Only
Set Inverter Speed

Reference to Zero
Inverter Y
Running?
N
Let Brake On
& Check Switch
Speed
<10rpm?
Y
Speed Check
AND Speed<N1Contact
Closes
STOPPED
Speed Zero

Stopping Procedures
Press
STOP
STOP
OR
Plough Parked Feed or Drip Set Inverter Speed

& Latched? Valve Open? Reference to Zero
N N
Move Plough
Up Basket &
Check Leaves Switch Close Feed Valve Inverter Y
& Check Switch Running?
Move Plough N
Off Screen &
Check Leaves Switch Close Drip Valve Let Brake On
& Check Switch & Check Switch
Continue to Move
Plough Up Basket
until Switch Makes Move Feed Detector Speed
to Parked Position <10rpm?
Disengage Plough Y
Return Latch
AND Speed<N1Contact
& Check Switch
Closes
Move Plough to
Spindle & Check
Switch
Engage Plough
Parked Latch
& Check Switch
Close Steaming SECONDARY

Covers CONTROLLER
PLC2
Close Discharge AND

Valve
STOPPED
Speed Zero
Press
ESTOP
ESTOP
OR
Disconnect Power to
STOP
Inverter and PLC

Speed Checking Continuous Routine
PLC2 Speed<N1 Closed

PLC1 Speed Y Contact Speed>N2 Open N
<N1-10rpm Speed>N3 Open STOP
Status
Correct? Speed>N4 Open
N Y
PLC2 Speed>N2 Open

<N1+10rpm STOP
Status Speed>N4 Open
Correct?
N Y
PLC2 Speed<N1 Open

Status
N Y
PLC2 Speed<N1 Open

<N2+10rpm STOP
Correct?
N Y
PLC2 Speed<N1 Open

PLC1 Speed Y Contact Speed>N2 Closed N
Status
N Y
PLC2 Speed>N1 Open

<N3+25rpm STOP
Correct?
N Y
PLC2 Speed<N1 Open

<N4-25rpm Speed>N3 Closed STOP
Status
N Y
PLC2 Speed<N1 Open

<N4+25rpm STOP
Status Speed>N3 Closed
Correct?
N Y
PLC2 Speed<N1 Open

N PLC1 Speed Y Contact Speed>N2 Closed N
STOP <NSMAX+25rpm Speed>N3 Closed STOP
Status
Correct? Speed>N4 Closed
Y

Automatic Protection Continuous Routines (Miscellaneous)
N PLOUGH NOT N FEED VALVE OPEN N BRAKE ON AND

PARKED OR LATCHED INVERTER RUNNING?
above NFMAX?
above NPMAX?
Y Y Y
STOP STOP STOP
N LO AIR PRESSURE N SPEED SYSTEM N SECONDARY PLC2

Pressure<PMIN for FAILURE FAILURE
Time>TPMIN? No Signal to PLC1? PLC2 Not Running?
Y Y Y
STOP STOP STOP
N DRIVE MOTOR N COOLING FAN INVERTER FAULT N

THERMISTOR TRIP? MOTOR OVERLOAD? Inverter Running?
Y Y Y
STOP STOP Run Timer TIR
Y Speed
>NIR?
N
STOP

Automatic Protection Continuous Routines (Vibration and Out of Balance)
N VIBRATION
MONITOR FAILURE
No Output Signal
Y
STOP
N HI HI VIBRATION N HI VIBRATION N
Vibration>V2 for Vibration>V1 for OUT OF BALANCE
Time>TV2? Time>TV1? OOB Switch Trips
Y Y Y
OR
STOP
N After START
STOP FEED and before
END SPIN?
Y
Set Inverter Speed Close Feed Valve Switch to

Reference to NF & Check Switch MANUAL CYCLE
AND
N Speed
NF ±25rpm?
Y
Run Delay Timer
for 5sec
Go To
FEED SPEED

APPENDIX B - BASKET INSPECTION

It is essential that the basket is subjected to a safety inspection every 12 months. The
procedure is detailed below. It is recommended that records of these inspections are
made using photocopies of the attached form.
DANGER
IMPORTANT SAFETY INFORMATION
Sugar Centrifuge baskets are highly stressed components. At full speed, the
rotational kinetic energy of even a small 1 Tonne capacity basket is
equivalent to the kinetic energy of a family car travelling at about 200 mph
(300 km/hour). If the basket were to fracture, debris would not be contained
within the monitor casing. For this reason, great care is given to the design,
selection of materials, manufacture, and testing of baskets.
Baskets should only be used for purposes agreed at the time of sale and
notified at such time to Thomas Broadbent and Sons Ltd. Baskets must NOT
be used with DIFFERENT MATERIALS and must NOT be run at HIGHER
SPEEDS without the written approval of Thomas Broadbent and Sons Ltd.
Corrosion and wear in service inevitably reduce the strength of the basket.
For safe and reliable operation, baskets MUST BE INSPECTED EVERY 12
MONTHS to ensure that this degradation remains within the design limits as
defined in this procedure. Any basket failing to meet any one of the
acceptance criteria must be removed from service. Repairs must not be
attempted without first obtaining the guidance and approval of Thomas
Broadbent and Sons Ltd. IN CASE OF DOUBT REMOVE THE BASKET
FROM SERVICE IMMEDIATELY and contact,
BROADBENT CUSTOMER SERVICES LTD

Huddersfield, HD1 3EA, England
Telephone: 01484 477200 Telex: 51515 TBS G Fax: 01484 516142
Outside Normal Office Hours: Telephone 01484 424660 (Emergencies Only)
FAILURE TO COMPLY WITH THIS PROCEDURE

COULD RESULT IN SEVERE OR FATAL INJURIES

B1 General
For safe and reliable operation, baskets must be inspected at intervals not exceeding 12
months of operation. The inspection must be carried out by a responsible person with
sufficient practical and theoretical knowledge to understand and apply the procedures detailed
below. The inspection procedure involves Visual Examination, Crack Detection (by Liquid
Penetrant or Magnetic Particle Testing as appropriate) and Dimensional Checks. The
inspector must examine the basket in all of the ways stipulated in order to detect faults and
weaknesses and assess their importance in relation to safe operation. The results of the
examination must be recorded by the inspector and then countersigned and filed by the user.
These results should be used for reference at the next inspection when defects noted
previously can be located and checked.
Figure 1 Typical Sugar Centrifuge Basket
B2 Description of Basket
Figure 1 shows a typical Broadbent basket. The Bottom is a casting or fabrication with a
central hub for attachment to the spindle, a spoked opening to allow discharge of the sugar,
and a flat outer plate. The bottom usually incorporates a Bump Ring which is designed to be
the first point of contact between the basket and casing in the event of a large out of balance.
The cylindrical Shell is rolled from plate with a single radiographed seam weld and is
perforated to allow escape of the molasses. The Top is a dished plate whose inside diameter or
Lip defines the maximum possible thickness of massecuite cake. Depending on the basket
speed and shell materials, the shell may be reinforced by Hoops. These are made from
seamless rolled ring forgings in high tensile materials which are shrink fitted onto the shell and
retained by small spacers tack welded to the shell.

When the basket rotates, centrifugal forces are generated on the product load and also on the
basket itself. All these must be carried by circumferential stresses in the shell and the hoops.
The basket is designed so that these stresses are within the strength of the materials with
allowances for occasional incorrect operation, stress concentration effects, and a degree of
thickness reduction due to corrosion. These allowances are taken into account by this
inspection procedure and once these allowances are used up there is no further margin of
safety. It should also be noted that if the thickness of the shell or hoops is reduced in just one
place, the weights and the centrifugal loads will be virtually unchanged but the area carrying
these loads is reduced locally and so the stresses are much higher and may exceed the safe
limits so,
WARNING: Measuring the weight loss of the whole basket is NOT

an acceptable method of assessing the safety of the basket
B3 Types of Defect
To be able to examine the basket competently, it is important to be able to recognise the types
of defect which may be present. Illustrations are shown in Figure 2. Examples are given in
Figure 3.
Figure 2 Detail of Shell and Hoops illustrating Typical Defects

MECHANICAL DAMAGE
General Distortion can occur if the basket hits the casing due to a heavy out of balance and
may cause the spindle attachment on the basket bottom to twist relative to the bottom plate so
that basket runs out of true and the centrifuge vibrates even when empty. In this case, it is
usually necessary to replace the basket.
Localised Indentation of the shell or hoops causing them to be out of round or Slippage of
the hoops on the shell may occur due to accidents in handling. These can affect the strength of
the basket and should be referred to Broadbent for advice.
Some degree of Scoring is to be expected on the bump ring and unless it is very deep this is
acceptable. Scoring on the shell or hoops is potentially more serious and should be assessed as
surface corrosion.
GENERAL CORROSION AND WEAR

Widespread Surface Corrosion in the form of Rusting is to be expected anywhere on carbon
steel components. This type of corrosion produces scale which flakes off leaving a rough but
not jagged or deeply pitted surface.
Where dissimilar materials touch, electrochemical effects can produce Galvanic Corrosion.
For example, stainless steel backing meshes can corrode an impression of themselves into
carbon steel shells.
On any materials, the abrasive action of the product moving over surfaces can cause Erosion.
Expulsion of molasses through the perforations can wear the shell around the perforations and
produce jetting grooves in adjacent hoops. Substantial wear of the basket bottom at the
discharge lip is also very common.
The common factor with all these mechanisms is that they progressively reduce the load
bearing thickness as time goes on. The effect on mechanical strength of the basket is
straightforward to estimate and so the acceptable limits, based on dimensional checks, are well
established. In general, the design stresses allow a reduction in load bearing cross sectional
area down to a minimum of 80% of the original area. Reductions to between 90% and 80% of
the original area are acceptable but must be recorded for checking at the next inspection.
DEEP PITTING CORROSION

In contrast to the general corrosion described above, some materials such as stainless steels
are more susceptible to extremely localised Pitting which is small in extent on the surface but
very deep. Some types such as Crevice Corrosion and Chloride Corrosion can produce large
holes within the body of the material with only a tiny corrosion spot on the surface.
This type of defect is difficult to detect but can have a very serious effect on basket integrity.
Ordinary pitting can be an initiation site for fatigue cracks and must be recorded for checking
at the next inspection. Baskets showing signs of chloride corrosion must be removed from
service immediately.
CRACKS
Cracks can be linked with corrosion in the form of Stress Corrosion Cracking in stainless
steels. More often, Fatigue Cracking is initiated from tiny microscopic defects in the original
material or from corrosion pits which then grow as the stresses in the basket increase and
decrease with each operating cycle of the centrifuge.
Fatigue cracks are most likely to be perpendicular to the circumferential stresses and in areas
of stress concentration such as at perforations or welds. In stainless steel hoops, cracks can
propagate from crevice corrosion pitting at the interface with the shell and this is often not

visible on the accessible surfaces. By the time cracks are a few millimetres long, most of the
fatigue life will have been used up and the component will be in imminent danger of rupturing.
Any basket containing cracks must be taken out of service immediately.
Figure 3 Examples of Serious Defects
Galvanic Corrosion on inside of Shell

caused by contact with Backing
Meshes
Erosion of Hoops and Shell

caused by liquor jetting from Perforations
Axial Fatigue Cracks in Shell due to

stress concentrations at Perforations
Radial Fatigue Cracks in Hoop

propagating from crevice corrosion
pitting and stress corrosion cracking
at face in contact with Shell
In general, Carbon Steel components are most liable to general wear and corrosion which will
be easily apparent but progresses steadily as time goes on so there is unlikely to be any sudden
deterioration in basket integrity. In contrast, Stainless Steel components may superficially
appear to be completely unaffected by corrosion even after long periods of time but in fact
they are more sensitive to pitting and cracking which are much more difficult to detect but can
lead to catastrophic failure. In practice, most basket failures tend to be in stainless steel
components.
WARNING: For STAINLESS STEEL components, special care must be

given to detailed visual inspection for cracking, pitting and crevice
corrosion. It is strongly recommended that stainless steel components
are subjected to additional Dye Penetrant and/or Ultrasonic examination
B4 Inspection Techniques
The most appropriate inspection technique depends on the material of construction of the
component being examined. The following are the most appropriate for centrifuge baskets.
VISUAL EXAMINATION
All components must be thoroughly visually inspected. An overall methodical examination by
eye should be followed by detailed examination of suspect areas using a magnifying glass. This
is the simplest technique but cannot be relied on to detect cracks and pitting. Visual
examination should be regarded as the barest minimum requirement and only for carbon steel
components. For stainless steel components, this must be supplemented by one or more of the
following techniques.
MAGNETIC PARTICLE EXAMINATION

In this technique, the component surface is sprayed or painted with a light coloured
background covering, an electromagnet is applied to induce magnetic flux parallel to the
surface and a suspension of fine dark magnetic particles in a suitable liquid is sprayed or
brushed onto the surface. If there are any surface breaking defects, the lines of flux are
diverted out of the surface where they attract the magnetic particles giving a clear indication of
the defect. This is a well established technique but can only be used to examine magnetic
materials and will only detect flaws on the surface.
Magnetic Particle Inspection (MPI) is the recommended technique for examining all carbon
steel tops, shells, bottoms and hoops. It is also suitable for martensitic stainless steel hoops but
not for duplex or austenitic stainless steels.
DYE PENETRANT EXAMINATION

In this technique, the component is painted with a brightly coloured, highly penetrating dye.
After a predetermined period, this is wiped off and the surface sprayed with a light coloured,
highly absorbent powder developer. The developer draws dye out of any surface breaking
defects giving a clear indication. This is a well established technique but it is important that the
surfaces are thoroughly cleaned beforehand and can therefore be unreliable on centrifuge
baskets due to the difficulty of removing all traces of liquor.
Dye Penetrant Inspection (DPI) is the recommended technique for non-magnetic stainless steel
tops, shells, bottoms, and hoops.
ULTRASONIC EXAMINATION
In this technique, a piezoelectric probe applied to the surface of the component radiates pulsed
high frequency sound waves into the body of the component. These pulses are reflected back
from the back faces of the component but also from any internal defects and are detected by
the probe. This is the most practical technique for finding defects which do not appear at the
surface but interpretation of the signals is not straightforward and this method should only be
used by qualified specialists.

Ultrasonic Testing (UST) is recommended for finding non-surface breaking cracks which can
occur in high strength stainless steel hoops (Figure 4) but it can also be used to inspect shells.
Since cracks are usually perpendicular to the surface, an angled probe must be used.
Figure 4 Detection of Internal Defects in Hoops by Ultrasonic Technique
The most appropriate non destructive examination techniques for various types of component
are given in Figure 5. The alternatives given are technically possible but are generally less
reliable for this application. Note that ultrasonic testing is mandatory for all types of stainless
steel hoops since this is the only method capable of detecting radial cracking propagating from
the contact with the shell as shown in Figure 4.
Figure 5 Recommended Non Destructive Inspection Techniques

Top, Bottom, Shell Hoop
Recommended Alternatives Recommended Alternatives
Carbon Steel Magnetic Particle Dye Penetrant Magnetic Particle Ultrasonic
Ultrasonic Dye Penetrant
Austenitic Dye Penetrant Ultrasonic Ultrasonic PLUS None
Stainless Steel Dye Penetrant
Duplex Dye Penetrant Ultrasonic Ultrasonic PLUS None
Stainless Steel Dye Penetrant
Martensitic Dye Penetrant Magnetic Particle Ultrasonic PLUS Ultrasonic PLUS
Stainless Steel Ultrasonic Dye Penetrant Magnetic Particle
B5 Inspection Procedure
Reference should be made to the information sheet provided with the basket which gives the
materials of construction and the original dimensions.
ACCESS
It is essential to have access to all surfaces both inside and outside the basket. The preferred
method is to remove the basket from the centrifuge but it is possible to carry out the
inspection in situ. All the interior surfaces can be inspected by climbing inside the basket. The
outside of the top and top weld can be inspected through the small removable rectangular
panel in the monitor casing cover. The outside of the shell, seam weld, bottom weld and hoops
can be inspected through the removable panel on the side of the monitor casing. The underside
of the bottom and spokes can be inspected from inside the discharge chute. In all cases, the
working screens and backing meshes must be removed.

PREPARATION
Remove all loose corrosion scale using a wire brush. Remove stubborn deposits using emery
paper. Water wash and then steam clean all surfaces to remove all traces of liquor from
crevices. This is essential if liquid penetrant examination is to be carried out.
VISUAL INSPECTION
Methodically examine the surfaces of all components. Check for any signs of mechanical
damage such as displaced hoops and bulges or dents in the shell and hoops. Note the areas of
worst general corrosion and erosion for carrying out dimensional checks later. Look for signs
of pitting and cracking and check any suspect areas with a magnifying glass paying particular
attention to the welds, shell perforations and the basket bottom spokes. Assess any findings as
detailed in Figure 6.
MAGNETIC PARTICLE, DYE PENETRANT AND ULTRASONIC TESTING

These are strongly recommended as aids to detect pitting and cracking which may easily be
missed by just visual inspection. Methodically examine 100% of all surfaces using the
recommended non destructive technique as given in Figure 5. In all cases use an accepted
procedure (e.g. as used on pressure vessels) to examine all surfaces. Assess any findings as
detailed in Figure 6.
Figure 6 Visual, Magnetic Particle and LiquiPenetrant Examination

Observation Action
Hoop slipped on Shell Submit details to Broadbent for advice
Bulge or Dent in Shell or Hoop
Scoring Record and carry out dimensional checks
Wear due to Corrosion or Erosion
Pitting and Crevice Corrosion Record
Chloride Corrosion Remove basket from service immediately
Cracking
DIMENSIONAL CHECKS
Having noted the areas of worst general wear due to corrosion and/or erosion, check the
dimensions in these areas and assess the findings as detailed in Figure 7. For the shell thickness
and perforation measurements, it may be worthwhile making some simple gauges.
CHECKS ON SPINDLE ATTACHMENTS

While the basket is removed, both the spindle flange and the fasteners used for attaching the
basket to the centrifuge must be carefully inspected. The spindle is carbon steel and if any
signs of cracks are found it must be removed from service immediately. Any corrosion on the
attachment face may affect basket concentricity and advice must be sought from Broadbent.
The fasteners may be carbon steel or stainless steel and must be scrapped if any signs of
cracking, pitting or thread damage are found. It is strongly recommended that fasteners be
replaced every 10 years as a matter of course.

RECORDS
Use copies of the attached form to record the results of the inspection. These records will be
found useful for future inspections.
Figure 7 Dimensional Inspection
Item Method Result Action
Shell Measure shell Thickness at any one position less Remove basket from
thickness using a pin than 80% of original thickness service immediately
through the Thickness at any position between Record measurements and
perforations 90% and 80% of original thickness check at next inspection
Measure elongation Enlargement of any one hole Remove basket from
or enlargement of exceeds 120% of original diameter service immediately
perforation diameter Enlargement of any holes to 110% Record measurements and
using a plug to 120% of original diameter check at next inspection
Hoops Measure hoop cross Cross section at any one position Remove basket from
sectional area (depth less than 80% of original thickness service immediately
x width) using scale Cross section at any position Record measurements and
ruler between 90% and 80% of original check at next inspection
thickness
Top Measure thickness Thickness at any one position less Remove basket from
of basket top using than 80% of original thickness service immediately
long reach calipers Thickness at any position between Record measurements and
90% and 80% of original thickness check at next inspection
Bottom Measure depth of Depth of wear at any one position Remove basket from
wear using straight exceeds 5mm service immediately
edge across upper
and lower faces of Depth of wear at any position Record measurements and
bottom plate and between 3 mm and 5 mm check at next inspection
spokes

BASKET INSPECTION RECORD

Broadbent Basket Type Basket Serial No
Sugar Centrifuges Inspected by Date
Sentence ACCEPT / REJECT Delete as
Appropriate
To specify positions of any defects,

Angles are measured clockwise from serial number engraved on basket top when viewed from above
For Shells, depths are measured down from basket top
For Hoops, numbers are counted down shell from number 1 nearest basket top
For Bottoms, locations are bottom plate upper face, bottom plate lower face, spokes, or attachment hub
TOP
Material Original thickness 90% thickness 80% thickness
Inspection Method Visual • Magnetic Particle • Dye Penetrant •

Ultrasonic • Dimensional •
Tick as Appropriate
Pitting Angle Check at next

Radius inspection
Cracks and Angle Remove from

Chloride Corrosion Radius service
Thickness Angle
between 80% and Radius Check at next
90% of original inspection
Thickness
Thickness less Angle
than 80% of Radius Remove from
original service
Thickness
BOTTOM
Material Type of Bottom

Tick as Appropriate

Location inspection

Chloride Corrosion Location service
Depth of wear on Angle

any surface Location Check at next
between 3 mm inspection
and 5 mm Wear
Depth of wear on Angle
any surface Location Remove from
exceeds 5 mm service
Wear

SHELL
Material Original thickness 90% thickness 80% thickness
Original diameter 110% diam 120% diam

Tick as Appropriate
Bulges and Angle Seek advice

Scoring Depth from Broadbent

Depth inspection

Chloride Corrosion Depth service
Thickness Angle
between 80% and Depth Check at next
90% of original inspection
Thickness
Thickness less Angle
than 80% of Depth Remove from
original service
Thickness
Perforation Angle
diameter between Depth Check at next
110% and 120% inspection
of original Diameter
Perforation Angle
diameter over Depth Remove from
120% of original service
Diameter
HOOPS
Material Original CS area 90% area 80% area Depth x Width
area of hoop
Tick as Appropriate

Radius inspection

Chloride Corrosion Radius service
Cross sectional Angle

area between 80% Radius Check at next
and 90% of inspection
original Thickness
Cross sectional Angle
area less than Radius Remove from
80% of original service
Thickness

APPENDIX C - PNEUMATIC CIRCUIT

The brake, feeding, washing and discharging mechanisms are all actuated by pneumatic
cylinders controlled from solenoid operated valves inside the Electro-pneumatic Panel EP.
This Appendix details the operation of the pneumatic circuits.
C1 PNEUMATIC CIRCUIT SYMBOLS
Pilot Off Pilot On De-energised Energised

5/2 Pilot-Spring Valve 5/2 Solenoid-Spring Valve
L/H Pilot On - R/H Pilot Off Both Pilots Off L/H Pilot Off - R/H Pilot On
5/3 Double Pilot Spring Centred Valve
Operated Released Operated Released

3/2 Hand Pad Valve 3/2 Key Operated Valve
Non-Return Valve Flow Regulator Pressure Regulator
Flow Control Valves

Single Acting Cylinder Double Acting Cylinder
Double Acting Cylinder With Process valve

Fail Safe Spring Return Actuator
Air Supply Plugged Port
Secondary
Drip Valve Pressure Line Exhaust Line
Electro-Pneumatic
Positioner
Butterfly Feed Valve with Lines Joining Lines Crossed

Electro-Pneumatic Positioner
Air Reservoir Disc Brake Caliper

C2 BRAKE SYSTEM
In normal cyclic operation, all braking is provided by regenerative braking in the inverter
drive. The mechanical brake is used only for parking, and for emergency braking if the inverter
stops running. The brake has a spring on-air off actuator, so that the brake fails safe in the on
position. The brake is interlocked with the electrical control system, to ensure that power
cannot be supplied to the motor when the brake is applied, thus preventing the centrifuge from
attempting to rotate until the brake has been released.
C2.1 Centrifuge at rest and during braking
Air Supply
Disc Brake Caliper
With the machine at rest or during braking, solenoid valve B is de-energised. Air is
exhausted from the chamber of the disc brake caliper and the brake is applied by the
pressure of the internal spring.
C2.1 Centrifuge running normally

Air Supply
Disc Brake Caliper
With solenoid B energised, air is applied to the chamber of the disc brake caliper, lifting
the brake against the pressure of the internal spring, and the machine is free to rotate.

C3 FEED SYSTEM
Product is fed into the basket, with the centrifuge rotating at a controlled low speed via a flow
control valve, streamlined feed spout, and a secondary anti-drip valve. The flow control valve
is a butterfly valve, with a double acting actuator, with an integral electro-pneumatic
positioner, which responds to a 4-20 mA signal from the control system. The secondary valve
is a flap, pulled up onto a soft seating under the feed spout by a pair of double acting
cylinders. The thickness of the product cake formed in the basket is detected by a feed limiter
slipper which is moved into its sensing position by a single acting spring return cylinder.
C3.1 Centrifuge not in Feeding Sequence
Air Supply
Reservoir
Electro-Pneumatic
Positioner
Feed Valve Closed
Feed Drip Valve Closed

Limiter
Cylinder
At all stages of the cycle, except during feeding, the feed valve and drip valve are held
closed pneumatically, and the feed limiter slipper is withdrawn from the basket in its fail
safe position under spring pressure.
C3.2 Feed Valve Ready, Limiter Set, Drip Valve Open
Air Supply
Reservoir
Electro-Pneumatic
Positioner
Feed Valve Closed
Feed
Limiter
Cylinder
Drip Valve Open
Solenoid D is energised, reversing the air supply to the cylinders, thus opening the drip
valve. Solenoid L is energised, to supply air to the feed limiter cylinder, and the slipper
moves into the massecuite zone of the basket. The electro-pneumatic positioner remains
de-energised, and the feed valve remains closed.

C3.3 Feed Valve Opening
Air Supply
Reservoir
Electro-Pneumatic
Positioner
Feed Valve Open
Feed
Limiter
Cylinder
Drip Valve Open
With the feed limiter in its set position, a 4-20mA signal is sent to the feed valve
actuator, which begins to open the valve, allowing product to flow into the basket. The
feed valve continues to open until the preset value is reached.

C3.4 Feed Valve Closing
Air Supply
Reservoir
Electro-Pneumatic
Positioner
Feed Valve Closed
Feed
Limiter
Cylinder Drip Valve Open
With the basket full of massecuite, the feed limiter mechanism is tripped, causing
solenoid L to be de-energised. Air is vented from the feed limiter cylinder which retracts
under spring pressure. The valve positioner is de-energised, and the feed valve moves to
the fully closed position. When the feed valve is fully closed, and after a timed delay,
solenoid D is de-energised, reversing the air supply to the cylinders, closing the drip
valve, and returning the air circuit to stage C3.1.

C4 DISCHARGE SYSTEM
Sugar is discharged from the basket with the centrifuge rotating at very low speed. The
horizontal and vertical motions of the plough discharger mechanism are each actuated by
double acting cylinders. The discharge valve under the basket bottom is normally held closed
by spring pressure and is opened by a single acting cylinder.
C4.1 Centrifuge not in Discharge Sequence
Air
Supply
Discharge
Cylinder
P
V
R2
R1
H3
Vertical
H2 Cylinder
H1
Latch
Pin
Horizontal
Cylinder
At all stages of the centrifuge cycle, except during ploughing, the plough is held down
onto a parking block, and pulled in towards the spindle and mechanically latched. The
discharge valve is held closed by spring pressure.

C4.2 Discharge Valve Opens. Plough unlatches
Air
Supply
P Discharge
V
Cylinder
R2
R1
H3
Vertical
H2
Cylinder
H1
Latch
Pin
Horizontal
Cylinder
As the centrifuge decelerates close to plough speed, solenoid P is energised to allow air
supply to the discharge cylinder and open the discharge valve. When plough speed is
attained, solenoid V is de-energised to allow air supply to the plough vertical cylinder,
lifting the plough mechanism, which in turn lifts the latch pin to allow the plough to
move horizontally.
C4.3 Plough moves horizontally IN to basket
Air
Supply
P Discharge
V Cylinder
R2
R1
H3
Vertical
H2
Cylinder
H1
Latch
Pin
Horizontal
Cylinder
With the centrifuge running at ploughing speed and the plough latch pin lifted, solenoid
H1 is energised to supply air at system pressure to the tail end of the horizontal cylinder.
This causes the plough blade to cut into the product cake at maximum force and move in
until it reaches the filtering screen.

C4.4 Plough IN delay and Plough IN force reduced
Air
Supply
P Discharge
V Cylinder
R2
R1
H3
H2 Vertical
Cylinder
H1
Latch
Pin
Horizontal
Cylinder
A proximity switch detects the plough blade coming into contact with the filtering
screen, and starts a short delay, to ensure that the top of the cake is ploughed out at full
force. After the pause, solenoid H3 energises, which supplies air at reduced pressure
(which can be adjusted via a regulator inside the pneumatics panel), to the tail end of
the horizontal cylinder. This reduces the force of the blade on the screen, thus
minimising wear.

C4.5 Plough moves vertically DOWN basket
Air
Supply
P Discharge
V Cylinder
R2
R1
H3
Vertical
H2
Cylinder
H1
Latch
Pin
Horizontal
Cylinder
Solenoid V is energised, reversing the air supply to the vertical cylinder. The plough
then moves down the basket wall, with its speed controlled by an hydraulic oil filled
dashpot. As the plough moves down the basket, the spring loaded latch pin locks the
horizontal cylinder in towards the basket, so that the plough blade cannot inadvertently
return towards the spindle and contact the flinger disc.

C4.6 Plough return delay
Air
Supply
P Discharge
V Cylinder
R2
R1
H3
Vertical
H2 Cylinder
H1
Latch
Pin
Horizontal
Cylinder
A proximity switch detects the plough blade reaching the bottom of the basket, and
starts a short delay, to allow all the sugar to be ploughed from the bottom of the basket.
After the pause, solenoid V is de-energised, reversing the air supply to the vertical
cylinder, and the plough then starts to move up the basket.

C4.7 Plough moves vertically UP. Discharge Valve closes
Air
Supply
Discharge
V Cylinder
R2
R1
H3
Vertical
H2 Cylinder
H1
Latch
Pin
Horizontal
Cylinder
As a proximity switch detects the blade moving up off the basket bottom, solenoids H3
and H1 are de-energised and solenoid H2 is energised. This causes the blade to move
horizontally out of the basket at reduced force, until it comes up against the latching pin.
This prevents it moving further, where it could contact the flinger disc on the spindle.
The air pressure from solenoid H2 is adjustable within the pneumatic panel, to minimise
wear on the side of the latch pin. Also as the blade leaves the basket bottom, solenoid P
is de-energised, allowing the discharge valve to close under spring pressure.

C4.8 Plough moves OUT towards parked position
Air
Supply
Discharge
V Cylinder
R2
R1
H3
Vertical
H2
Cylinder
H1
Latch
Pin
Horizontal
Cylinder
As the plough reaches the top of the basket, the mechanism lifts the latch pin, solenoid
H2 is de-energised, returning the air to full pressure, and this allows the horizontal
motion in towards the spindle to be completed.

C4.9 Plough Latches
Air
Supply
Discharge
Cylinder
P
V
R2
R1
H3
Vertical
H2
Cylinder
H1
Latch
Pin
Horizontal
Cylinder
Once the plough reaches the parked position, the plough latch pin drops, and the plough
parked switch signals the control system to energise solenoid V, lowering the plough on
to the latch block. The pneumatic circuit reverts to figure C4.1.

APPENDIX D - PROCESS
This Appendix gives an introduction to the principles underlying the process performance of
batch sugar centrifuges. By understanding these principles, the quality of the sugar produced
can be optimised by systematically carrying out trial runs at various parameter settings.
D1 PRINCIPLES OF CENTRIFUGAL SEPARATION

Batch sugar centrifuges are basically filters using the centrifugal force due to rotation as an
artificial means of increasing the separating effect. The processes occurring during the
separation of massecuite into its constituent solid crystals and mother liquor in a filtering type
centrifuge are shown below,
STAGE 1 Sedimentation STAGE 2 Draining STAGE 3 Drying
In Stage 1, the heavier crystals initially tend to sink towards the filtering screens and the
lighter liquor migrates away from the filtering screens. Some types of centrifuge have no
filtering screens to allow the liquor to escape and this Sedimentation process is the only
separating effect with the liquor being decanted off the surface.
In Stage 2, the liquor starts to drain through the crystals and escapes through the filtering
screens. The flow through the crystals is laminar and it can be shown that the factors affecting
this Draining process are,
(Crystal Size ) 2 % (Centrifuge G ) % (Time )
Proportion of Liquor Purged i
(Liquor Viscosity) % (Cake Thickness )
In Stage 3, the bulk of the liquor has been purged but some liquor remains attached to the
surface of the crystals. The adherence of thin layers of liquid is governed by surface tension
effects and it can be shown that the factors affecting this Drying process are,
(Crystal Size ) 2 % (Centrifuge G )
Final Cake Dryness i
(Liquor Surface Tension )
In both these relationships, 'Centrifuge G' is the centrifugal acceleration due to rotation
expressed as the number of times natural gravity and is a measure of the separating effect of
the centrifuge design,

(Diameter in metres ) % (Rotational Speed in rpm) 2

Centrifuge G i
1790
The process performance objectives for a centrifuge are,
Optimise the massecuite throughput to suit the overall process. Usually this involves
maximising the rate that massecuite can be separated so as to require the minimum
number of centrifuges. Throughput is increased by reducing the times required for both
the draining and drying processes.
Minimise the amount of impurities in or adhering to the sugar. This can be expressed as
purging efficiency which is defined as the percentage of impurities in the massecuite
that end up in the molasses outlet stream and should be as high as possible or as crystal
colour which should be as low as possible. Purging efficiency is directly related to the
effectiveness of the drying process.
Minimise the amount of moisture in the sugar to reduce lump formation and to allow
smaller thermal dryers to be used downstream. This is expressed as dryness which is
defined as the percentage of moisture in the product and should be as low as possible.
Dryness is related to the effectiveness of the drying process.
Minimise the loss of sugar through the filtering screens into the molasses. Sugar can
pass through the filtering screen either as crystal fragments or as a solution in water.
This can be expressed as molasses purity rise and should be as low as possible.
Purity rise is related to the design of the filtering screens but is also affected by measures
such as washing which are used to improve purging efficiency.
The simple equations above give guidance on the effects of various process parameters,
D1.1 Massecuite Quality

Larger crystals have larger gaps between them so the liquor drains out more easily.
Also, larger crystals have a smaller surface area to volume ratio so less liquor will
remain adhering to their surfaces. Similarly, a 'thin' mother liquor will have a low
viscosity so it will flow easily through the gaps between crystals and will have a low
surface tension so it will not adhere firmly to the crystals. Thus ‘Slack’ massecuites
having large crystals and thin liquors drain and dry easily. Conversely, ‘Tight’
massecuites with small crystals and very viscous liquors are difficult to separate.
D1.2 Centrifuge Design

Increasing the centrifuge speed and diameter both increase the separating effect 'G'
which then aids the draining and drying processes resulting in improved throughput,
purging efficiency, and final dryness. Increasing the speed has a greater effect than
increasing diameter.

Increasing the cake thickness by increasing the basket ‘lip’ increases the theoretical
capacity of the basket. However, it also increases the distance liquor must flow through
the cake and therefore means that the times for the draining and drying must be
increased resulting in increased cycle times. Throughput is the basket capacity times
divided by the overall cycle time. In practice it is found that for each quality of
massecuite, there is an optimum cake thickness to give the largest throughput. Tight
massecuites require smaller cake thicknesses than slack massecuites.
Batch centrifuges are generally used for separating high grade Refined and ‘A’
massecuites which have large crystals and low viscosity liquors and are therefore easily
purged. Low grade ‘B’ and ‘C’ massecuites with small crystals and thick liquors are
difficult to separate in batch centrifuges and require very long spin times. These low
grade massecuites are generally processed in conical basket continuous centrifuges
where the much higher separating effect ‘G’ and the very small cake thickness (only a
few crystals thick) mean that the separation can be completed in the very short time that
the product is sliding up the basket. The disadvantage of continuous centrifuges is that
the action of sliding along the filtering screen and impact with the casing on leaving the
basket both damage the crystals. Batch centrifuges do not damage the crystals.
D1.3 Filtering System

The filtering system comprises three elements.
The actual filtering screen is a brass or stainless
steel sheet about 0.5 mm thick perforated with
Basket Shell many holes or slots about 0.5 mm across to give an
open area of around 20%. Even if the crystals are
Basket Perforations smaller than the perforations, they ‘arch’ to span
the opening so the loss of crystals past the screen is
Backing Meshes not significant. Since the perforations are put in the
screen by punching, the holes are sometimes
Filtering Screen
tapered so it is important that the smallest size
‘working surface’ is facing the sugar to avoid
plugging.
Woven wire meshes support the filtering screen off

the basket shell. These allow liquor that has passed
through the screen to move sideways to find
perforations in the basket shell. Often, two meshes
Sugar Crystals are fitted. A coarse mesh next to the basket shell
provides the flow area and a fine mesh over this
provides more even support for the filtering screen.
The basket shell carries the centrifugal forces
on the cake, screens, and meshes and may be reinforced by external hoops. The shell is
perforated with many holes, typically 3 to 8 mm diameter, giving around 1 to 3% open
area.

D2 BATCH CENTRIFUGE CYCLE

The principles discussed above can be used to determine the optimum process parameter
settings at each part of the centrifuge cycle.
D2.1 Feeding
Feeding massecuite into the basket has the most significant effect on the process
performance of the whole cycle. It is also the key to avoiding vibration and instability
problems.
Feed During feeding, sedimentation and

Control Massecuite
draining are occurring and at the same
Valve Feed time the product is flowing up, down,
and around the basket to form an even
cake. The basket must be rotating fast
Drip enough to give sufficient ‘G’ to allow the
Valve product to climb the basket. Since this
causes liquor to purge out of the cake,
product must be fed in fast enough to
keep the cake just mobile enough to flow
and distribute itself evenly. Feeding is
therefore a balance between feeding rate
which is controlled by the feed valve
opening and purging rate which is
controlled by rotational speed.
On smaller centrifuges, the product is fed

into the bottom of the basket. On very
deep baskets, flinger discs may be fitted
Classification to the spindle to throw the product onto
Valve (Option) Mother
the screens about half way up the basket
Liquor
and thus aid product distribution.
The feed speed is mainly determined by the quality of the massecuite. For refined and
‘A’ sugar massecuites, the feed speed should be sufficient to give a separating effect of
about 40 to 60 ‘G’. For special products with fine crystals such as dextrose, feed speeds
corresponding to as much as 150 ‘G’ may be more appropriate. Typical feeding times to
fill the basket are about 10 to 20 seconds. Despite the relatively low ‘G’, a significant
proportion of the liquor is purged during feeding and this ‘spin off’ effect means that a
basket can usually be fed with 5 to 10% more massecuite than its true volumetric
capacity.
If the feed speed and feed rate are not correctly balanced, the product cake will not be of
even thickness. This will make it impossible to fully fill the basket, will cause uneven
washing and drying, and will cause vibration due to unbalance. Some typical feeding
errors are shown below. The diagrams show the cake appearances with and without a
flinger.

Symptom Appearance Cause Action

Unable to fill Cake tapers Insufficient ‘G’ for Increase feed
basket. High from top to product to climb speed.
Gyration during bottom but is basket
feeding. Low even around
Shaft Rate basket
Vibration at
high speed
Unable to fill Cake thicker Product purging Decrease feed speed

basket. Cake is where product too quickly and and/or increase feed
unbalanced first contacts unable to flow to rate.
giving high basket distribute itself
Shaft Rate evenly around the
Vibration at basket.
high speed.
Excessive Shaft Cake undercut ‘Rat holing’ past Check fit of screens
Rate Vibration at top or edges or through in basket.
at high speed. bottom. holes in filtering Check screens not
Depressions Rat-hole screen. torn or holed. Check
or holes at wash pipe not
random Undercut dribbling on basket
positions. bottom.
Basket suddenly Free liquid Product Check screens not

impacts casing visible on Free sedimenting blocked.
during surface of Liquid instead of purging. Check quality of
acceleration due cake. Waves set up in product feed for
to Liquor liquid layer cause a high free liquor
Loading sudden instability. content, excessively
Instability small crystals.
D2.2 Acceleration and Washing

Wash After the feed detector trips, the feed control
Water valve closes and after a short delay the
secondary drip valve closes to prevent any
coloured product remaining in the feed chute
dropping onto the crystals in the basket. As
the basket accelerates to spin speed, the
draining process is completed and the cake
goes light in colour as the dark liquor is
purged. During acceleration, wash water is
sprayed onto the cake by a spray bar fitted
with nozzles whose flowrates and spray
Spray Washings patterns are designed to give uniform
Bar coverage over the full height.

Washing is carried out after most of the liquor has been drained. The water dilutes the
liquor still adhering to the surface of the crystals thus reducing its viscosity and surface
tension to allow it to flow more easily. Washing therefore aids the draining and drying
processes and consequently increases the final purity of the crystals and, paradoxically,
increases the final cake dryness. Increasing the quantity and temperature of wash water
reduces the mother liquor viscosity still further and improves the final purity and
dryness.
The disadvantage of washing is that water can dissolve many times its own weight of
sugar (up to 2.6 times at 50oC and up to 3.5 times at 70oC). The greater the quantity and
temperature of wash water, the greater the loss of sugar as a solution passing through
the filtering screens.
Typical variation of ash & sugar loss with wash water usage.
0.014% 25.0%
0.012%
20.0%
Sugar dissolved as % of unwashed sugar.

% Ash content of discharged sugar.
0.010%
15.0%
0.008% S ugar
Loss
0.006%
10.0%
0.004%
Ash
Content 5.0%
0.002%
0.000% 0.0%
0.0% 1.0% 2.0% 3.0% 4.0% 5.0%
Wash water usage as % of massecuite.
Source : Based on Drean, Laurie & Orchard (See Ref 2). MA:500 microns. Spin G:980. Temp 50C. Refinery Sugar.
Typical data only : Ash content and sugar loss depend on massecuite characteristics and other process parameters.
The amount of wash water applied should be the minimum to produce the required
purity of sugar. The data above shows that the optimum wash water applied should be
between 1% and 2% by weight of the massecuite charge. Applying more water does not
significantly improve purity but would greatly increase the sugar loss by dissolving.
It is important that the water is sprayed evenly over the cake. A poor spray pattern or a
non uniform cake thickness will result in varying purity at different parts of the sugar
charge. The spray bar must be correctly adjusted to spray over the full depth of the cake
but not onto the basket bottom or top. The water must also be supplied at the specified
pressure since the spread of the fans from the nozzles fitted to the spray bar varies with
pressure.

Even if the minimum of wash water is used, some sugar is inevitably dissolved and lost
through the screens. A common option is to fit a liquor classification system to the
outlet under the casing so that the high purity liquor resulting from washing is diverted
to a different receiver than the low purity mother liquor spun off during feeding and the
start of acceleration. The classification system is usually arranged to switch over at a
preset time after the start of washing to allow for the delay in the washings moving
through the cake and casing.
D2.3 Spinning
During spinning, the final drying process occurs. The final achievable dryness is fixed by
the crystal size, liquor surface tension and the separation effect ‘G’ during spinning. The
duration of spinning determines how close the final dryness comes to this theoretically
achievable dryness.
Approximate variation of sugar moisture

with spin time and temperature
1.4%
1.2%
Discharged sugar moisture W/W%.
1.0%
55ºC
0.8%
0.6%
70ºC
0.4%
0.2%
20 30 40 50 60
Spin time. Seconds.
Basket G 1000. MA of sugar 600 microns. Sugar washed. Accel/Decel time ignored.
Data is typical and depends on massecuite & wash quality. (C) Broadbent Ltd. 1993.
For refined and ‘A’ sugar massecuites, a separation effect at spinning of about 1000 ‘G’
is usually sufficient. The data above shows that the benefits of longer spin times diminish
as time increases and spin times are usually in the range 20 to 50 seconds. Increasing the
temperature of the cake by increasing the massecuite feed temperature, using
superheated wash water, or injecting steam all help the drying process but can be at the
penalty of increasing the losses by dissolving during washing. For more difficult
products such as dextrose, separation effects of up to 1500 ‘G’ and spin times of up to
300 seconds may be necessary.

D2.4 Discharging (Ploughing)

After spinning, the centrifuge
Plough decelerates to about 50 to 60 rpm, the
discharge valve in the base of the basket
opens, and a pneumatically actuated
scraper ploughs the sugar out of the
basket.
In some designs of centrifuge, a
mechanical stop prevents the tip of the
plough blade touching the filtering
screens. This inevitably leaves a thin
layer of sugar on the screens. Leaving
just 3 mm thickness of sugar represents
Sugar a loss of capacity of 2% on every cycle.
Discharge In addition, to prevent this sugar
Valve Open hardening and blocking the filtering
screens, it must be washed off before
feeding. This represents an unnecessary
Sugar
increase in water and power usage.
To avoid these disadvantages, all Broadbent centrifuges use a floating plough which
allows the plough blade to gently ride on the screen completely removing all traces of
sugar.
In plan view, the plough mechanism
has a castoring geometry. On Plough
entering the cake, the line of action Spindle Arm
of the cutting force relative to the
pivot draws the blade into the cake. Plough
When touching the screen, the line of Blade
Pivot
action of the cutting force pushes the
blade back out towards the spindle.
The equilibrium position of the blade
is about the centre of the cake depth.
The blade is therefore gently pushed
in onto the screens by carefully Basket Pivot
controlled pressure on a pneumatic
actuator. In this way, the blade
gently rides on the screens and rce
moves with any slight swinging of Fo
g
the basket. uttin
C
The materials of the plough blade tip
and filtering screens are carefully
selected to give minimal wear and PLAN VIEW
virtually no contamination of the
sugar.

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Operating Manual for C46MT Batch Centrifuges MH97177-8 Page 1

Thomas Broadbent and Sons Limited

C46MT (5545) BATCH

Thomas Broadbent & Sons Ltd

© May 2009 Thomas Broadbent & Sons Ltd

© May 2009 Thomas Broadbent & Sons Ltd

If in doubt regarding any aspect of these instructions or if requiring additional information

© May 2009 Thomas Broadbent & Sons Ltd

© May 2009 Thomas Broadbent & Sons Ltd

© May 2009 Thomas Broadbent & Sons Ltd

APPENDIX A CONTROL PROGRAM

APPENDIX B BASKET INSPECTION

APPENDIX C PNEUMATIC CIRCUIT

APPENDIX D PROCESS PERFORMANCE

© May 2009 Thomas Broadbent & Sons Ltd

© May 2009 Thomas Broadbent & Sons Ltd

© May 2009 Thomas Broadbent & Sons Ltd

NOTE: ILLUSTRATIONS IN THIS MANUAL MAY DIFFER IN DETAIL

© May 2009 Thomas Broadbent & Sons Ltd

© May 2009 Thomas Broadbent & Sons Ltd

© May 2009 Thomas Broadbent & Sons Ltd

FAILURE TO COMPLY WITH THIS PROCEDURE COULD RESULT IN SEVERE OR

In case of doubt or continuing difficulty concerning the installation or operation of this

BROADBENT CUSTOMER SERVICES LTD

© May 2009 Thomas Broadbent & Sons Ltd

© May 2009 Thomas Broadbent & Sons Ltd

1.1 PRINCIPLES OF OPERATION

1.3 MAIN DRIVE MOTOR

1.4 SPINDLE AND BEARING HOUSING

1.5 CASING AND SUPPORT FRAME

1.6 COOLING AND ANTI-PRECESSION SYSTEMS

1.7 BRAKING SYSTEM

1.8 FEED SYSTEM

1.9 FEED LIMITER

1.10 PLOUGH DISCHARGER

1.11 DISCHARGE VALVE

1.12 PROCESS FITMENTS

1.13 DRIVE PANEL (INVERTER)

1.14 CONTROL PANEL (PLC)

1.15 MACHINE ELECTRICAL EQUIPMENT

1.16 CONTROL FUNCTIONS

© May 2009 Thomas Broadbent & Sons Ltd

1.1 PRINCIPLES OF OPERATION

On completion of feeding, the centrifuge accelerates to a medium speed hold point to

On completion of spinning, the centrifuge decelerates to a very low speed. A discharge

© May 2009 Thomas Broadbent & Sons Ltd

Figure 1.1 General Arrangement of Centrifuge

Coolong Fan Anti-Precession

© May 2009 Thomas Broadbent & Sons Ltd

Figure 1.2 Sectional Arrangement of Centrifuge

Pan Top Discharge Valve

Hooped and Pushrod Seal

© May 2009 Thomas Broadbent & Sons Ltd

Figure 1.3 Upper Sectional Arrangement of Centrifuge

Upper Roller Bearing

Lower Roller Bearing

Split Taper Hub

Top Bearing Cap

Contact Thrust Ball

Outer Spacer Ring