Part 2: Installation Process and Precautions for Overflow Screw Conveyor -- Post-Installation Commissioning & Key Installation Taboos and Risk Alerts
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Continuing from the previous blog < Part 1: Installation Process and Precautions for Overflow Screw Conveyor -- Pre - Installation Preparation & Core Component Installation >
III. Post-Installation Commissioning
After installation, the equipment must undergo no-load and load commissioning to ensure normal operation.
1. No-Load Commissioning (Core: Check Operational Stability)
Process Steps:
- • Inspect Connections: Tighten all bolts again (especially the bearing housing and drive unit anchor bolts) and confirm that the seals are not loose.
- • Manual Rotation: Rotate the screw shaft 2-3 turns manually to ensure there is no jamming or abnormal noise, and that the bearings rotate smoothly.
- • Power - On Test Run:
• Spot Test the Motor: Run the motor intermittently (for 10-15 seconds each time) to observe whether the rotation direction of the screw shaft is consistent with the designed conveying direction (if reversed, adjust the motor wiring).
• Continuous No-Load Operation: Run continuously for 1-2 hours under no-load conditions. During this period, check the following:
• Bearing Temperature: Should be ≤70°C (measured with an infrared thermometer).
• Motor Current: Should not exceed 60% of the rated current.
• Equipment Noise: Should be ≤85dB (measured with a sound level meter).
• If the bearings overheat (exceeding 70°C), check whether the lubricating grease is sufficient or if the bearings are installed too tightly. If the noise is too high, check the coaxiality of the coupling or the gap between the screw shaft and the casing.
Precautions:
- • During no-load commissioning, personnel are prohibited from approaching the ends of the screw conveyor and the inlet to prevent accidental entanglement.
- • If any abnormalities occur during commissioning (such as motor tripping or abnormal noise), the power must be immediately cut off and the machine stopped. Troubleshoot the problem before re-commissioning. Do not force the machine to run.
2. Load Commissioning (Core: Verify Conveying Efficiency and Sealing)
Process Steps:
- • Gradual Feeding: Start by feeding at 30%of the designed conveying capacity and run for 30 minutes to observe whether the material is conveyed smoothly and whether there is any accumulation at the discharge port. If normal, gradually increase to 50%, 80%, and 100% of the designed capacity, running for 1 hour at each load level.
- • Check Key Indicators:
• Conveying Efficiency: Measure the actual conveying capacity by weighing, with the deviation from the designed value being ≤±5%.
• Sealing: Check for material leakage at the casing flanges, hopper, discharge port, and shaft end seals. If leakage is found, adjust the tightness of the seals or replace the gaskets.
• Motor Load: During full-load operation, the motor current should not exceed the rated current. Otherwise, check for material blockages or screw shaft jams.
Precautions:
- • During load commissioning, a dedicated person must monitor the equipment’s operating condition, especially the inlet and discharge ports, to prevent material blockages (if blocked, stop the machine immediately, clear the material, and then resume operation. Do not run with blockages).
- • If conveying materials that easily generate dust, the dust collection device must be activated to ensure that the dust concentration in the working environment meets national standards (e.g., ≤10mg/m³).
IV. Key Installation Taboos and Risk Alerts
- • Prohibit Forced Installation: When components are deformed (such as bent screw blades or misaligned casing flanges), they must not be forcibly connected. Components should be corrected or replaced first. Otherwise, it will lead to increased component wear during operation and may even cause equipment failure.
- • Avoid Lubrication Omissions: Moving parts such as bearings and reducers must be lubricated with grease/ oil according to the manual requirements, and the type and amount must be accurate (for example, do not overfill the reducer with lubricating oil, as this can cause oil temperature to rise and oil leakage).
- • Emphasize Electrical Safety: The grounding and wiring of the drive unit must comply with electrical standards. Unauthorized personnel are strictly prohibited from wiring. Before commissioning, ensure that the supply voltage matches the motor’s rated voltage (e.g., 380V/220V) to prevent motor burnout.
- • Special Requirements for Inclined Installation: If the conveyor is inclined (the inclination angle is usually ≤20°, depending on the equipment model), an “anti - backflow baffle” must be installed at the bottom of the casing to prevent material backflow due to gravity. At the same time, the power of the drive unit needs to be increased (the power for inclined installation should be 10% - 20%higher than that for horizontal installation).
By strictly following the above installation procedures and precautions, the installation quality of the overflow screw conveyor can be maximized, reducing subsequent operational failures and extending the service life of the equipment. If complex problems are encountered during installation (such as deflection control of large - span conveyors or sealing design for special materials), it is recommended to consult the equipment manufacturer’s technical personnel for targeted guidance.
Overflow Screw Conveyor,Trough Screw Conveyor,screw conveyor,Installation Process
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