5 Operating Instructions

Operation of a Standard Pilot

The Powerfuge Pilot is simple to operate and maintain.

NOTE: If you are running with the optional vacuum system, refer also to
page 5-3, “Operation of a Vacuum-equipped Pilot”. If you are running a
hazardous-duty Pilot, refer to page 5-6, “Operation of a Hazardous-duty
Pilot”.

1. Make all safety checks according to Chapter 4.

2. Plug in the Unit (refer to the serial number plate on the side of Frame for
power requirements).

3. Close the Drain Valve (attached to the Bowl Case Drain Port).

Figure 5-1.
Drain Valve

4. Circulate the cooling solution for 5-10 minutes to stabilize temperature in

the Bowl Case.

CAUTION: The Centrifuge will heat up in the absence of feed

solution flow or coolant flow.
5-2 OPERATING INSTRUCTIONS PILOT OPERATOR’S MANUAL

5. Connect feed line to feed inlet tube.

Separation Cycle—Standard Pilot

1. To start a separation cycle, push the FWD Key on the Control Pad
(Figure 5-2). The digital display will indicate the current RPM value,
which affects G force. To change this value, simply press the white UP
arrow for higher speeds, or the DOWN arrow for lower speeds. (See
Table 5-1, Frequency, RPM and G-force.)

Figure 5-2.
Pilot Drive Control Pad
(Standard Pilot)
D V G P
O
FW RE JO ST

LOC AT SPEED
FWD 12,350 RPM

G T R C
O IF TE
PR SH EN LO EM
R

NOTE: The Reverse and Jog keys have been disabled.

2. The machine will accelerate to its preset RPM. RPM may be changed
during operation by pressing the Up or Down keys.

CAUTION: This unit is designed to run at a maximum frequency

of 87 Hertz (15,325 RPM or 20,000 G’s). Do not attempt to run the
machine at higher speeds.
CAUTION: Ensure that there are no liquids or solids in the Bowl
before starting the Centrifuge.

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PILOT OPERATOR’S MANUAL OPERATING INSTRUCTIONS 5-3

Table 5-1.
Drive Frequency, RPM Drive Freq. (Hz)* Bowl RPM G-Force
& G-Force
64 10,913 10,000
71 12,250 12,777
75 13,000 14,389
77 13,275 15,000
80 13,750 16,097
84 14,500 17,901
87 15,325 20,000

*Hertz values are approximate for Standard Model Pilot.

3. When the machine has reached its preset speed, turn on the pump to
supply feed into the Centrifuge.

WARNING—OPERATOR HAZARD: NEVER push the Bowl Lock

Handles into the Bowl during operation.

Stopping the Pilot

1. Turn off the feed pump.

2. Press the STOP key to brake the Centrifuge. The machine will then go
into deceleration mode according to factory-set defaults.

CAUTION: Failure to turn off the feed pump BEFORE stopping the
Drive will flood the Bowl Case, causing possible spindle damage.

3. When the machine stops, reverse the feed pump to evacuate residual
feed solution from the Bowl.

4. Open the Bowl Case Drain Valve to drain any residual liquid from the
Bowl Case.

5. Disassemble the machine and remove the solids from the Bowl. See
Chapter 6.

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5-4 OPERATING INSTRUCTIONS PILOT OPERATOR’S MANUAL

Operation of a Vacuum-equipped Pilot

The following section describes operation of the Powerfuge Pilot with the
optional Vacuum System. Before beginning, review all notes, cautions
and warnings in Operation of a Standard Pilot beginning on page 5-1.

Setup
1. Make all safety checks according to Chapter 4.

2. Using Tri-Clamps and Gaskets, attach the Vacuum Vessel to the

Centrate Out Port. Attach a .2 micron filter and reducer to the assembly
and make all connections according to technical drawing 61-89-0018
(see Technical Drawings section at the end of this manual). Double
check tightness of all hose connections.

3. Close the Bowl Case Drain Valve.

4. Connect the Vacuum Pump to an air supply of 80-100 psi, 3 SCFM. A

means of turning the air supply on and off without detaching the air line is
a required accessory.

5. Plug in the Unit (refer to the serial number plate on the side of Frame for
power requirements).

6. Set the flow rates of both the Feed and Centrate Pumps.

CAUTION: When operating the Pilot under vacuum, the flow rate
of the Centrate Pump must always be greater than the flow rate of
the Feed Pump to allow complete evacuation of centrate from the
Vacuum Centrate Vessel.

7. Circulate the cooling solution for 5-10 minutes to stabilize temperature in

the Bowl Case.

Separation Cycle—Pilot with Vacuum Option

1. Turn on the Vacuum Pump and watch the Gauge. It should take 1
minute or less for the Pump to pull 25" Hg in the System. If it takes
significantly longer, check for leaks.

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PILOT OPERATOR’S MANUAL OPERATING INSTRUCTIONS 5-5

2. To start a separation cycle, push the FWD Key on the Control Pad. The
digital display will indicate the current RPM value, which affects G force.
To change this value, simply press the white UP arrow for higher speeds,
or the DOWN arrow for lower speeds. (See Table 5-1, Frequency, RPM
and G-force.)

3. The machine will accelerate to its preset RPM. RPM may be changed
during operation by pressing the Up or Down keys until the desired
speed is attained.

4. Turn on the Centrate Pump and then the Feed Pump.

5. Continue the separation cycle until the Bowl is full of solids.

CAUTION: During separation cycles, periodically check the Bowl

Case View Port to ensure there is no liquid buildup inside the Bowl
Case (see Figure 2-1 in Section 2). If liquid is observed building up
inside the Case, immediately TURN OFF the Feed Pump and press
the STOP button on the Drive—the pumps may be set incorrectly, or
there is a problem with the Centrifuge. Determine the source of the
problem before attempting to run again. If necessary, call CARR
Separations.

Stopping the Pilot and Relieving Vacuum

1. Once a separation cycle has been completed and the Bowl is full of
solids, perform the following in the order indicated:
• TURN OFF the FEED PUMP, then the CENTRATE PUMP
• Press the STOP key on the Drive
The machine will then go into deceleration mode according to factory-set
defaults.

CAUTION: Failure to turn off the feed pump BEFORE stopping the
Drive will flood the Bowl Case, causing possible spindle damage.

2. When the machine stops, TURN OFF the vacuum pump and slowly open
the vent valve on the vacuum filter.

3. Reverse the feed pump to evacuate residual feed solution from the Bowl.

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5-6 OPERATING INSTRUCTIONS PILOT OPERATOR’S MANUAL

Operation of a Hazardous-duty Pilot

This section describes operation of the Hazardous-duty Powerfuge Pilot
only. Instructions for operating a standard Pilot or a vacuum-equipped Pilot
are included earlier in this chapter.

Setup
1. Attach the Underflow Assembly to the Centrate Out Port.

2. Connect a nitrogen supply with a low pressure regulator to the Nitrogen

IN “Quick Connect” fitting on the Purge Panel. (See Figure 5-8.)

3. Carefully attach the (2) Purge Panel Nitrogen Lines to their

corresponding connections on the Centrifuge. (Refer to Figures 2-3,
2-4 and 2-5 in Chapter 2, and Figure 5-7 in Chapter 5.)

4. Remove the 8" Tri-Clamp and slide the Case Cap to the side to gain
access to the Centrate Case.

Figure 5-6.
Nitrogen OUT
Powerfuge Pilot– (NPT Connection)
Hazardous-duty Model
Condensate Trap

End Cap Feed

(4" Tri-Clamp)
(1/2" Tri-Clamp)
Case Cap
(8" Tri-Clamp)
Underflow (Top)
Centrate Case (1-1/2" Tri-Clamp)
Reservoir

Centrate Case

Centrate Out
Motor (1-1/2" Tri-Clamp)
1.5 HP Variable
Frequency Underflow (Bottom)
TEFC (1-1/2" Tri-Clamp)

Bowl Case Drain

(1/2" Tri-Clamp)

Nitrogen IN
(Tri-Clamp)
(shown 90° out
of position)

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PILOT OPERATOR’S MANUAL OPERATING INSTRUCTIONS 5-7

5. Carefully add liquid compatible with the intended output stream into the
Centrate Case Reservoir until it begins to flow out from the Centrate Out
Port on the Underflow Assembly. Avoid spilling liquid between the Bowl
Lip and Centrate Case Reservoir.

6. Slide the Case Cap slowly back in place and clamp down.

7. Set the pressure on your nitrogen tank to 10-15 psi.

8. Before starting a run, check the Condensate Drain Tube for moisture,
and drain if necessary.

Purging the Centrifuge Case

Figure 5-7. (right) 1. Start the purge flow by slowly opening
Centrifuge Purge Panel Purge
the PURGE RATE VALVE at the Rate Inches of Water
4 6
Indicator 2 8
bottom of the Purge Rate Indicator. (SCFH) 0 10

The purge pressure should start to rise

Purge Pressure
(as indicated by the large Purge Purge
Rate Valve
Pressure Gauge). If pressure does
not start to rise, check that the
Centrifuge is fully sealed, i.e., that all
Clamps are tight, that all Purge Lines Pressure
Switch
are securely connected, and that the
Underflow Tube is filled to the
Centrate Out Port. Nitrogen IN

2. Adjust the purge flow rate (use the

Purge Rate Indicator) to 9 SCFH (+/-
0.5 SCFH).

NOTE: It is normal for some liquid to spill out from the Centrate Port
on the Underflow Assembly during the purge procedure.

3. As soon as pressure stabilizes and flow requirements are met, the Timer in
the Drive Case begins counting down (indicated by a flashing green light).
After 4 volume exchanges of gas are attained in the Centrifuge Case
(approximately 20 minutes), the Timer light stops flashing, which indicates
that the Drive is enabled and the System is ready to run.

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5-8 OPERATING INSTRUCTIONS PILOT OPERATOR’S MANUAL

CAUTION: Before beginning a separation cycle, ensure that

there is an adequate supply of nitrogen for the entire run, or
series of runs.

Separation Cycle—Hazardous-duty Pilot

1. Use the Potentiometer on the Drive Unit to set the desired speed
(multiply the potentiometer setting [from 0–10] by 1500 to determine the
approximate RPM of the Bowl). The explosion-proof Drive Unit displays
Bowl speed as Hertz. Refer also to Table 5-1 to set the approximate
desired running speed and G-force, or see Appendix A for Hz/G-force
chart with greater resolution.)

2. Push the green ON button to start a run.

3. When the machine reaches speed, you may begin supplying feed
material; the Feed Rate should be set to a maximum of 1 liter per
minute.

As the Bowl begins filling and the Purge Pressure Gauge stabilizes,
pressure will be maintained between 3 and 8 inches of water. If
pressure falls below 1.5–2.0 inches of water (due to any reason), the
system will shut down because of loss of purge pressure and the
Centrifuge will brake to a stop.

CAUTION: Immediately TURN OFF the feed pump if the Drive

begins braking due to a loss of purge pressure or any other fault
condition.

To correct a fault condition due to loss of purge, determine the source

of the problem, i.e., loose connections, low nitrogen, etc. (see
troubleshooting Section below). After the cause of the fault has been
determined and corrected, the Timer will begin counting down again
until another 4 volume exchanges of gas are attained and then the
Centrifuge will be ready to resume running.

4. Reverse the feed pump and drain the Bowl before restarting the
Centrifuge.

CAUTION: Ensure that there are no liquids or solids in the Bowl

before restarting the Centrifuge.

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PILOT OPERATOR’S MANUAL OPERATING INSTRUCTIONS 5-9

Stopping the Pilot

1. Once a separation cycle has been completed and the Bowl is full of
solids, perform the following in the order indicated:
• TURN OFF the FEED PUMP
• Press the STOP button on the Drive Unit

CAUTION: Failure to turn off the feed pump BEFORE stopping the
Drive will flood the Bowl Case, causing possible spindle damage.

2. When the machine stops, reverse the feed pump to evacuate residual
feed solution from the Bowl.

3. Turn off the nitrogen supply.

4. Open the Bowl Case Drain Valve to drain any residual liquid from the
Bowl Case.

5. Check and drain the Condensate Drain Tube on the rear of the Purge
Panel.

6. Disassemble the machine and remove the solids from the Bowl (see
Chapter 6).

Troubleshooting a Loss of Purge

Problem: Erratic pressure swings, Centrifuge shuts down.

Cause: Liquid in Return Line from Centrifuge to Purge Unit Pressure
Switch.
Solution: Install larger diameter return line.

Problem: Erratic pressure swings, Centrifuge shuts down.

Cause: No liquid in Underflow Assembly
Solution: Fill Underflow Assembly with water or liquid compatible with
your process.

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5-10 OPERATING INSTRUCTIONS PILOT OPERATOR’S MANUAL

Problem: Low nitrogen purge pressure.

Cause: Nitrogen supply inadequate.
Solution: Verify nitrogen supply pressure of at least 10 psi

Problem: Low nitrogen purge pressure.

Cause: Large pressure head buildup in nitrogen return line.
Solution: Drain liquid from Condensate Drain Line (refer to Figure 2-5).

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