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CONTENIDO

SECCIÓN 1 – INTRODUCCIÓN ................................................................................... 5 Acerca de este Manual .................................................................................................... 5 Guías de Seguridad ......................................................................................................... 5 Garantía........................................................................................................................... 6 Introducción a la Mezcladora.......................................................................................... 6 Descripción de la Operación y mecanismos de la Mezcladora....................................... 7

SECCION 2 – USO DE LA MEZCLADORA/BATIDORA.......... 8 Instrucciones de Operación e Instalación ....................................................................... 8 Instalación ....................................................................................................................... 8

Inspección antes de puesta en marcha ........................................................................ 8 Configuración del Equipo ......................................................................................... 10 Prueba de puesta en marcha...................................................................................... 13

Llenado de la Mezcladora/Batidora .............................................................................. 15 Directrices de Operación............................................................................................... 15 Descarga de la mezcladora............................................................................................ 16

SECCION 3 – MANTENIMIENTO ............................................................................. 17 Procedimientos de Mantenimiento ............................................................................... 17 Ensamble y Desensamble de sellos de ejes................................................................... 17

Reemplazo del empaque del sello............................................................................. 20 Agitadores ..................................................................................................................... 21

Lubricación de rodamientos de agitadores ............................................................... 21 Alineamiento del Agitador........................................................................................ 22

Componentes de Unidad Motriz ................................................................................... 22 Mantenimiento del Reductor de Engranes................................................................ 22 Mantenimiento de Motor Eléctrico........................................................................... 23 Alineación de las poleas............................................................................................ 24 Tensión de las correas............................................................................................... 25 Reemplazo de correas ............................................................................................... 27 Reemplazo de Rodamientos de Agitador.................................................................. 27 Reemplazamiento de Eje Piloto ................................................................................ 31

Mantenimiento Sistema Neumático.............................................................................. 32 Mantenimiento de Filtro-Regulador-Lubricador (F-R-L)......................................... 32 Cilindros Neumáticos................................................................................................ 34 Ajuste del flujo de aire del cilindro........................................................................... 34 Ensamble y desensamble de los cilindros................................................................. 35

Mantenimiento de Compuerta de Descarga.................................................................. 36 Seguro mecánico....................................................................................................... 37 Ajuste del seguro mecánico ...................................................................................... 38 Reemplazo del empaque de las compuertas de descarga.......................................... 38

Instrucciones de lubricación ......................................................................................... 40

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Operación en presencia de polvo, agua o vapores corrosivos .................................. 40 Tipo de grasa............................................................................................................. 40 Programa de lubricación ........................................................................................... 41

Mantenimiento del sistema hidráulico .......................................................................... 41

SECCION 4 - LIMPIEZA E HIGIENIZACION......................................................... 43

SECDi

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Mantenimiento preventivo ............................................................................................ 42 Mantenimiento diario recomendado ......................................................................... 42 Mantenimiento semanal recomendado ..................................................................... 42 Mantenimiento trimestral recomendado ................................................................... 42 Mantenimiento semestral requerido.......................................................................... 42

Limpieza del sello del eje ............................................................................................. 43 Limpieza de los agitadores y paletas ............................................................................ 44 Limpieza de las compuertas.......................................................................................... 44

CIÓN 5 - LOCALIZACIÓN DE FALLAS........................................................... 45 agnóstico de la localización de fallas........................................................................ 45

Solo para unidades equipadas con rocío de agua.......................................................... 46 Solo para equipos equipadas con unidad Hidráulica .................................................... 46

CCION 6 – PARTES DE REPUESTO .................................................................... 48

INDICE ............................................................................................................................ 49

TABLA OF FIGURAS gura 1: Ensamble de Mezcladora (Lado Motriz)............................................................. 6

ura 2: Ensamble de Mezcladora (Descargando a un Cargador de Tornillo Cozzini) .... 7ra 3: Lineas de Aire ..................................................................................................... 8

gura 4: Ensamble de Reductor......................................................................................... 9 ra 5: Cilindros de Compuertas de Descarga ................................................................ 9 ra 6: Estructura con patas Ajustables......................................................................... 10 ra 7: Estructura con bases para montaje .................................................................... 10 ra 8: Conectando alimentación de aire a mezcladora ................................................ 11 ra 9: Lubricación de Rodamientos de Agitadores ..................................................... 11 ra 10: Sensores de Proximidad sobre Rejilla equipada de rocio de agua .................. 12 ra 11: Conexión de suministro de agua y medidor .................................................... 12

gura 12: Correcta rotación de agitadores en la mezcladora........................................... 14 ra 13: Agitador rozando la pared del tanque durante la puesta en marcha................ 14 ra 14: Palanca de Sellos (posición cerrada)................................................................18 ra 15: Palanca de Sellos (posición abierta).................................................................18 ra 16: Ensamble de bloque de Sellos..........................................................................18

gura 17: Ensamble de bloque de sellos (lado de descarga)............................................19 ra 18: Ensamble de Sellos………………………………………………………...…19 ra 19: Desensamble de Sellos.... ................................................................................20 ra 20: Lubricación de Rodamientos de Agitadores ……………………………...…21

gura 21: Rodamiento de Agitadores en lado de descarga............................................ 222 etalle de Reductor ……………………………………………………….…23

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FiguFiguFiguFiFi#8)..FiguFiguFiguFigura 31: Ensamble de lado de descarga tipico............................................................... 31

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DIBUJOS Y LISTA DE PA

ra 23: Detalles de Motores..........................................................................................24 ra 24: Ensamble de Poleas .........................................................................................25 ra 25: Motor con polea y placas de tensión................................................................26

gura 26: Tensores de Poleas ..........................................................................................26 gura 27: Ensamble de Partes de Reductor ( Rodamiento, pieza

..............................27 ra 28: Chumacera de Agitador, lado de reductor……………………………………29 ra 29: Reemplazo de rodamientos de agitador del lado de descarga..........................30 ra 30: Rodamientos de Agitador lado de descarga y Eje Piloto.................................30

Figura 32: Ensamble de Filtro/regulador/lubricador ........................................................ 32 gura 33: Detalle de tapón de drenado del F-R-L y tazón de engrasado........................ 33 gura 34: Desemblado de Filtro/Regulador/Lubricador.................................................. 33 gura 35: Cilindros de Compuerta de Descarga.............................................................. 34

Figura 36: Control de flujo de cilindros de aire/ valvula de control y tornillo de ajuste .. 35Figura 37: Sección transversal tipica de cilindro de aire .................................................. 35

gura 38: Lado de Descarga de Mezcladora ................................................................... 36 gura 39: Compuerta de Descarga de Mezcladora.......................................................... 37 gura 40: Seguro Mecánico en compuerta de descarga (cerrado)................................... 37

Figura 41: Seguro Mecánico en compuerta de descarga (abierto).................................... 38 Figura 42: Empaque de compuerta de descarga ............................................................... 39 Figura 43: Palanca de sellos en posición cerrada.............................................................. 44

igura 44: palanca de sellos en posición abierta............................................................... 44 F

RTES INCLUIDAS Ensamble General Lado de Descarga Lado de Reductores Diagrama de Control Neumático de Mezcladora Ensamble de sello hermético

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SECCIÓN 1 – INTRODUCCIÓN Acerca de este Manual Este manual está dirigido a los técnicos y al personal de mantenimreparación y el mantenimie

iento responsable de la nto rutinario del equipo. Se recomienda familiarizarse con los

componentes de la unidad motriz y leer los dibujos o esquemas técnicos. El manual trata sobre la operación mecánica y el mantenimiento del equipo así como de las ilustraciones de los subsistemas que componen la mezcladora. Guías de Seguridad Como parte de su obligación y compromiso con cada uno de sus clientes, Cozzini ha dado todos los pasos posibles para hacer de la mezcladora/batidora Cozzini un equipo libre de cualquier riesgo conocido, que pueda causar lesiones o lastimar a cualquier persona que pueda operarlo. Se han hecho todos los esfuerzos para cumplir con todas las secciones pertinentes de los Estándares de seguridad y salud ocupacional publicados por el Departamento de trabajo de los Estados Unidos (United States Department of Labor).

Dondequiera que usted vea este símbolo en el manual, por favor siga las guías de seguridad cuando opere la maquina.

• Mantenga las manos lejos de las compuertas de descarga y de los agitadores en todo momento. Hay una pequeña demora entre el momento en que se oprime el botón de PARO y el momento en que el agitador llega a detenerse por completo.

• mezcladora/batidora por ningún motivo mientras la máquina Nunca ingrese a laesté en operación. Si la maquina no está en operación y es necesario ingresar a la máquina, asegúrese de que la energía haya sido desconectada y que se hayan seguido todos los procedimientos de bloqueo y paro.

• e PARE (STOP) de la caja de control está equipado Para su seguridad, el botón dcon un dispositivo adicional de seguridad. Este dispositivo evitará que la máquina arranque accidentalmente. Este dispositivo fue diseñado para su seguridad y se debe usar durante todas las operaciones de limpieza y cualquier operación fuera de servicio.

• El botón de control a dos-manos esta diseñado para operar los agitadores cuando una o ambas compuertas de descarga están abiertas y la rejilla esta cerrada. Esto asegura que ambas manos del operador están en el panel de control y no en la máquina. No desconecte o modifique este dispositivo de seguridad importante.

• No obstruya ni retire ningún aviso de advertencia que esté adherido a la máquina. Si algún aviso de advertencia se daña, se pierde o se vuelve ilegible, por favor ordene reemplazarlo inmediatamente

• No opere la máquina sin todas las protecciones y cubiertas en su posición correcta.

• No use esta máquina para ningún propósito diferente al de su aplicación como procesador de alimentos.

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• No se introduzca en esta máquina bajo ninguna circunstancia. • No sobrecargue la máquina. Trabaje la máquina a su capacidad recomendada. • No opere la máquina hasta que usted haya cumplido con todas las reglas y

regulaciones locales de seguridad. • No desconecte ni anule ningún interruptor de seguridad por ninguna razón

• Preste atención en todo momento. No opere esta máquina de manera negligente.

Garantía Es política de Cozzini garantizar todo equipo fabricado por Cozzini por un período de 1 año a partir de la fecha de facturación. Todos los componentes no fabricados pero vendidos por Cozzini están cubiertos por la garantía de fabricación del proveedor. Todas las garantías se aplican siempre y cuando el producto haya sido operado bajo las condiciones normales especificadas por los procedimientos y guías de mantenimiento ilustradas en este manual. El no seguir los procedimientos y guías de mantenimiento como se

El uso en este equipo de partes que no

especifica en este manual anulará todas las garantías del producto.

estén aprobadas como repuestos autorizados por el vendedor anulará todas las garantías.

Introducción a la Mezcladora

Figu 1

ra : Ensamble de Mezcladora (lado de Motores)

Medidor de Agua (solequipos con rocío de a

o gua)

Palanca de apoyo de Rejilla

Motor

Rejilla

Guarda Ladode Descarga

Lineas de Aire

Solamente lla mezclado

evante ra en la

estructura.

Palanca de de Agitador

Sello es

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Figura 2: Ensamble de Mezcladora (descargando dentro de un Cargador de Tornillo Cozzini)

mecanismos de la Mezcladora La Mezcladora/Batidora Cozzini se llena con carne, especias y otros aditivos yen una mezcla homogénea en el tanque de proceso durante una cantidad predde tiempo. Un par de agitadores revuelven el producto dentro del tanque. Un motor y un reductor de engranajes conducen cada agitador por medio de un sistema m de poleas y correas. Los sellos en ambos extremos de los ejes de los agitadores impiden al producto gotear fuera de la unidad. Del lado de la descarga del mezclador, dos compuertas de descarga se abrendescargar el producto de carne mezclada en una carrito u otro receptáculo. Un cilindro neumático abre y cierra cada compuerta. Después que el proceso de mezcla se el producto puede transferirse entonces a otra máquina para embutido o emulsificación. Unidades equipadas con rocío de agua en la rejilla tienen una capacidad adicpermite agregar una cantidad predeterminada de agua a la receta de la mezcla everterlo mediante un volteador u otros medios.

Descripción de la Operación y los mezcla eterminada

ecánico

para

completa,

ional que n lugar de

Cilindroscompuert

de as de

descarga

Eje de Rejilla

Guarda Pospara compude descarga

terior ertas .

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SECCION 2 – USO DE LA MEZCLADORA/BATIDORA

ones de Operación e Instalación Instrucci IMPORTANTE: Revise cualquier daño que pueda tener su mezcladora/batidora al

momento de recibirla. Es importante que usted informe cualquier daño inmediatamente de tal manera que se pueda hacer el reclamo correspondiente al transportista.

Instalación Inspección antes de puesta en marcha

IMPORTANTE: Al descargar su mezcladora, manéjela con cuidado, dejarla caer o golpearla puede dañarla seriamente y desalinear los reductores, motores y agitadores. No arrastre la máquina en el piso. Vea la Fig. 1 para la manera apropiada de levantar la mezcladora.

Inspeccione estos elementos cuando reciba la máquina (Figura 3 a la Figura 5):

1. Revise abolladuras en el cuerpo.

2. Revise si hay daño en el sistema neumático.

Figura 3: Lineas de Aire

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Figura 4: Ensamble unidad motriz

Figura 5: Cilindros de Compuertas de Descarga

4. Revise si hay daño en los Reductores

5. Revise si hay daño elos motores

n

5. Inspeccione los pistones neumáticos

3. Revise el nivel de aceite del reductor

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Configuración del Equipo Paso 1. Si la máquina esta provista de estructura con patas ajustables (Figura 6), usted debe nivelar la maquina al piso. Si la mezcladora tiene bases de montaje (Figura 7), nivele el mezclador con calzas y aplique una lechada alre hay un bastidor separado, la Mezcladora deberá soldarse o atornillarse a este después de que ha sido fijado en el sitio. Si es posible, instalar la mezcladora con una ligera pendiente, 1/4" a 1/2", para que el agua fluya a un desagüe durante el proceso de limpieza e higienización..

dedor de las bases. Si

Figura 6: Estructura de patas ajustables

Figura 7: Estructura con bases de montaje

IMPORTANTE: Si se han provisto celdas de carga electrónicas, no realice ninguna

soldadura en la máquina una vez que las celdas de carga se han instalado, las corrientes parásitas por la soldadura podrían causar daño a las partes electrónicas.

Paso 2. Los reductores de velocidad han sido llenados de aceite antes del embarque para su conveniencia. Asegure que el aceite en los reductores está al nivel del tapón (vea Figura 4). Para instrucciones de lubricación adicionales de los reductores, refiérase a pag. 21. Paso 3. Conecte la energía eléctrica a la mezcladora/batidora refiriéndose a los diagramas eléctricos suministrados con el equipo. Los diagramas esquemáticos ilustran la rotación de los agitadores con relación a los controles de botón que están identificados en la caja de control. Paso 4. Proporcione el suministro -125 PSI, pero a no menos de

las compuertas de descarga y la rejilla de la ezcladora (Figura 8).

de aire idealmente a 10080 psi, a la caja de control neumático para m

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Figura 8: Conectando el suministro de aire a la mezcladora

Paso 5. Engrase los rodamientos de los agitadores antes de operar la máquina. Durante el transporte y la instalación se puede haber acumulado polvo, agua y suciedad.

1. Aplique grasa grado alimento por las graseras de cada rodamiento de los agitadores para purgar la grasa vieja (Figura 9).

2. Continúe engrasando hasta que observe salir grasa nueva por el rodamiento.

Figura 9: Lubricación de rodamientos de agitadores.

Conexión de Aire principal

Grasera en la chumacera del agitador

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Paso 6. Solo para unidades equipadas con rocío de agua: Inspeccione la articulación de la rejilla de la mezcladora para asegurarse que el sensor de proximidad detecte la oreja del enrejando cuando esta se baja sobre el tanque (Figura 10). El sensor puede dañarse si el enrejando choca con él mientras se esta cerrando.

Sensor de Proximidad debe estar despejado para detectar la oreja de la rejilla

0: Sensor de proximidad en equipos con rejilla con rocíoFigura 1 de agua

Conecte la mezcladora a una línea de alimentación de agua limpia (Figura 11).

Conecte al suministro de agua

Oreja de la rejilla para sensor de proximidad

Figura 11: Conexión a suministro de agua y medidor

Paso 7. Para mezcladoras accionadas hidráulicamente solamente: La máquina viene con su propia unidad de poder hidráulica; las instrucciones siguientes aplican::

eramente por encima de la marca l aceite

adicional se requiere para llenar las líneas que van a los motores hidráulicos. Use

• El depósito de aceite se debe llenar a un nivel ligsuperior del visor de nivel de aceite localizado a un lado del depósito. E

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el aceite como se recomienda en las instrucciones de la unidad hidráulica incluidas con la unidad.

A. Gire manualmente el motor eléctrico/bomba hidráulica. En unidades con

acoplamiento motor/bomba inaccesibles, retire la cubierta del ventilador del motor y gire el ventilador. Si no gira libremente, revise la alineay el motor con su indicador de alineación. Haga la alineación dentro de .003 pulg. (0.08 mm) de la lectura del indicador.

• Asegúrese de que la rotación del motor corresponda a la dirección de la flecha

marcada en la carcasa del motor o de la bomba pulsando el control del motor eléctrico.

• Donde se usen válvulas solenoides direccionales, las solenoides deben estar

conectadas a una fuente de control adecuada.

• Si se provee un intercambiador de calor, conéctelo a una fuente fría.

Refiérase al manual de mantenimiento de unidad hidráulica incluido con el manual del

a y localización de llas.

Prueba de puesta en marcha. Una vez la máquina esta instalada y conectada a la energía eléctrica, realice una prueba de puesta en marcha para ver si la unidad está trabajando correctamente..

1. Baje la rejilla sobre el tanque. 2. Encienda la mezcladora y accione los agitadores durante 1-2 minutos. En el modo

de mezcla los agitadores deben estar girando uno hacia el otro, como se muestra en la Figura 12 en el lado izquierda.

3. Escuche si hay cualquier sonido raro o ruidos como molie IMPORTANTE: Después de soltar el botón de PARO (STOP), pero antes de

ción de la bomba

de agua limpia,

equipo. El cual tiene sus propias instrucciones de puesta en marchfa

ndo o raspando.

cambiar la rotación de los agitadores, hay un período de demora. Éste es el tiempo que las paletas del agitador necesitan para detenerse completamente. Asegúrese de permitir a los agitadores detenerse antes de invertir la rotación. 4. Accione los agitadores brevemente en modo inverso. Los agitadores deben estar

girando hacia afuera entre ellos como en el lado derecho de la Figura 12.

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Figu

5.

ra

Figura

Rotación en modo de Mezcla

1

Después de accionar los agitadores, revise las

13). Refiérase a Sección 5 - Localización de F

2: Rotación correcta de agitadores en mezcladora

ver si cualquier rozamiento tuvo lugar entre loAparecerá como una marca de la raspadura lu

diagnósticos detallados si esto ocurre..

13: Rozamiento de agitadores en paredes del tanque

Rs

Re

14

Rotación en sentido inverso

paredes laterales del tanque para

allas en este manual para

s agitadores y la pared del tanque.minosa dentro del tanque (Figura

durante la puesta en marcha

ozamiento de agitador obre la pared lateral

evise raspaduras en l fondo del tanque

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IMPORTANTE: Los agitadores deben girar suavemente y en las direcciones apropiadas en los modos de operación (refiérase al manual eléctrico). Revise que los motores eléctricos no consumen excesiva corriente de mas a su valuación de rango de carga y que los rodamientos del agitador y los sellos del eje no se sobrecalienten. 6. Solo modelos provistos de rocío de agua: Calibre el medidor de agua. Para

hacer esto, siga las instrucciones específicas provistas en el manual para su modelo en particular de medidor.

7. Si la prueba de puesta en marcha se realiza exitosamente, el mezclador debe estar en buenas condiciones de operación. Si hubiera cualquier problema, refiérase a Sección 3 - Mantenimiento y Sección 5 - Localización de Fallas este manual para un diagnóstico detallado..

lena a/Batidora a mezcladora/batidora puede ser cargada mediante un volteador o mediante un

iento. La mezcladora debe llenarse a n nivel ligeramente por encima del agitador. La capacidad de trabajo de la mezcladora sta

agit

L do de la MezcladorLtransportador directamente en el tanque de procesamue basada en el volumen del tanque, llenando ligeramente sobre la parte superior del

ador, y la densidad del producto de 55 lbs. por pie cúbico (881.1 kg/m3).

PRECAUCION: La Mezcladora Cozzini no debe llenarse ni operarse a una capacidad mayor a la capacidad nominal del equipo.

Directrices de Operación

• Para mezclar lotes de 2/3 o menos de la capa dor, opere los agitadores en el modo INVERSO.

• Asegúrese que la rejilla este en su lugar antes de intentar operar la mezcladora.

Para una mezcladora accionada hidráulicamente, se aplican las siguientes instrucciones: • No encienda los motores eléctricos si el depósito no está lleno con el fluido

hidráulico • Al poner en marcha inicialmente, la bomba hidráulica debe ser cebada pulsando el

motor eléctrico El nivel de ruido de la unidad de energía debe disminuir después de unos pocos impulsos a medida que se log ecuadamente. Si la bomba no ceba después de algunos impulsos, refiérase a su manual de la unidad hidráulica en busca de posibles fallas.

Note: Es necesario operar la mezcladora/batidora descargada por lo menos una

cidad nominal del mezcla

ra cebar la bomba ad

hora para lubricar los motores hidráulicos suficientemente.

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Descarga de la mezcladora a descargar la mezcladora, ponga una tina bajo el lado de descarga, debajo de las puertas. Abra las compuertas de descarga para permitir que el producto fluya hacia

era. Operando los agitadores mientras sé esta descargando acelera el proceso dcarga. El producto

Parcom afu e la des en la mezcladora puede descargarse de varias formas, como se describe en el manual del control eléctrico.

Mantenga las manos lejos de las compuertas de descarga y de los agitadores en todo momento. Hay una pequeña demora entre el momento en que se oprime el botón y el momento en que el agitador se detiene por completo.

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SECCION 3 – MANTENIMIENTO

as ia a esta sección para las explicaciones

detalladas del ensamblado de componentes y los procedimientos de mantenimiento.

ves americanas estándar y llaves Allen.

Procedimientos de Mantenimiento La siguiente sección cubre los procedimientos de mantenimiento rutinario y de reparación que se puedan necesitar al montar, ajustar o analizar fallas de la máquina. Lotras secciones de este manual hacen referenc

La mezcladora/batidora no requiere ninguna herramienta especial para su reparación. Se recomienda al personal de mantenimiento que tenga lla

Antes de hacer cualquier trabajo de mantenimiento en cualquier componente, siempre siga los procedimientos de bloqueo/paro en planta

Ensamble y Desensamble de sellos de ejes

ara limpieza de rutina, los sellos de los ejes deben sacarse fuera del tanque para lavarse. uando sea necesario desmontar el bloque de sellos y revisar o reemplazar los empaques, ga las instrucciones e ilustraciones siguientes.

PCsi

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Figura 15: Palanca de sellos de Ejes

(posición abierta)

Figura 14: Palanca de sellos de Ejes

(posición cerrada)

Figura 16: Ensamble de bloque de sellos de Hermeticidad

Pza. DESCRIPCION

1 CAJA DEL SELLO (LA FRONTAL Y LA POSTERIOR PUEDEN DIFERIR.)

2 PERNO DE SELLOS

3 EMPAQUE (CORTADO A LA MEDIDA)

4 SELLO DE BORDE (CORTADO A LA MEDIDA)

5 ABRAZADERA DE CAJA DE SELLOS

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Figura 17: Ensamble de bloque de sellos (lado de descarga)

Herramientas necesarias: desarmador plano/estríado, llaves de 9/16”

1. Desconecte la energía de la mezcladora/batidora. 2. Jale el asa de palanca de sellos y mueva el ensamble de sellos hacia afuera del

tanque (Figura 14 a la Figura 17). 3. Abra el bloque de sellos usando un destornillador plano/estriado para soltar la

abrazadera (Figura 18 y Figura 19). 4. Con una llave de 9/16", afloje el perno retenedor del sello en cada lado para

separar las mitades de la caja de sellos.

Figura 18: Ensamble de bloque de sellos

Bloque de sellos (separado en dos mitades)

Abrazadera

Perno de retención de bloque de sellos

Abrazadera

Ranura para perno de retención

Empaque

Bloque de sellos (dos mitades)

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19

Sellos de labio

Empaque

Abrazadera

Figura 19: Desensamble de bloque de sellos

5. Retire el empaque y el sello de labio interior. tos han sufrido desgaste o

8. o debe mirar hacia el tanque. Coloque la otra oque

Reemplazo del empaque del sello El empaque del sello hace presión contra la pared del tanque cuando el sello está asegurado en su sitio. El material del empaque está disponib sea necesario cambiar el empaque, siga estas instrucciones:

Herramientas necesarias: cinta métrica, cuchillo, adhesivo transparente de Loctite o “Goma loca” (Crazy Glue) Retire el empaque usado del conjunto del sello. Corte el empaque si no está roto y estírelo en línea recta.

1. Tome el empaque nuevo y estírelo en línea con el em compararlos. 2. Corte los extremos de la tira de empaque a aproxima bos empaques

(viejo y nuevo) deben tener la misma longitud. nuevo en el bloque del sello antes de engomar los

extremos.. 4. Si el ajuste es bueno, tome los dos extremos y péguelos con un adhesivo claro y

permanente..

6. Reemplace el empaque y el sello de labio interior si es

deterioro (al menos cada 3 meses). Ensamble de nuevo los sellos del bo7. rde divididos y el empaque. Los sellos de borde deben quedar mirando hacia el tanque para sellar herméticamente. El empaque frontal en la caja del sell mitad de la caja del sello y ajuste la brida alrededor de todo el conjunto del bldel sello.

le por pies. Cuando

paque usado paradamente 45º. Am

3. Pruebe el ajuste del empaque

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20

Agitadores Los agitadores revuelven el producto dentro del tanque. Los ejes están accionados mediante un motor y un reductor de engranajes por medio de un sistema de bandas y poleas. Las chumaceras a cada lado del tanque soportan a los agitadores. La sección siguiente se refiere a los procedimientos de mantenimiento comunes para los agitadores. Lubricación de rodamientos de agitadores Los rodamientos de rodillos esféricos se han lubricado antes de su embarque. Re-engráselos cada semana con Grasa Texaco Cygnus #2 o una equivalente.

Herramientas necesarias: pistola de grasa 1. Aplique grasa grado alimenticio dentro de la grasera en cada uno de las

chumaceras de los agitadores para purgar la grasa vieja (Figura 20). 2. Continúe engrasando hasta que observe salir grasa nueva por el rodamiento.

Grasera en la chumacera del agitador

Figu

ra 20: Lubricación de rodamiento de Agitador

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Alineamiento del Agitador

Figura 21: Rodamiento de Agitador en el lado de descarga

Cada rodamiento del agitador está montado en una ménsula con calzas para lograr la alineación vertical correcta. Hay también un perno de ajuste lateral con una tuerca para permitir la alineación horizontal (Figura 21). Para a , se necesita ajustar la posición de los rodamientos.

Herramientas necesarias: llaves inglesas estándar 1. Afloje (no los quite)los pernos de montaje que sostienen el ensamble de la chumacera. 2. Gire la cabeza del tornillo de ajuste lateral localizada al lado de la chumacera. Cuando

se gira, el tornillo va empujando la chumacera. 3. Una vez que se ha logrado la posición deseada de la chumacera, apriete tuerca en el

tornillo de ajuste para asegurar esa posición.. 4. Re-apriete los pernos que sostienen el ensamble de la chumacera. 5. Repita este procedimiento en el lado opuesto.

Componentes de Unidad Motriz

linear los ejes del agitador

Antes de hacer cualquier trabajo de mantenimiento en los componentes de la unidad motriz, siempre siga los procedimientos de bloqueo/paro en-planta.

M(A

antenimiento del Reductor de Engranes plica a todas las mezcladoras, excepto aquéllas con sistema motriz de motor

hidráulico) Los reductores de velocidad han sido lubricados antes de su embarque. El nivel de aceite debe verificarse regularmente y debe cambiarse cada seis meses o más frecuentemente dependiendo del ciclo de servicio de su máquina.

Placa calzadora

Tornillo de ajuste lateral

Pernos de Montaje

Tuerca

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22

Revise el aceite destornillando el tapón de nivel con una llave Allen. Debe haber aceite en el tornillo (Figura 22) cuando este se saca. El aceite debe llenar casi la mitad del interior de la caja de engranajes. Agregue el aceite llenándolo a trlocalizado encima de la caja de engranajes. Para las especificaciones del lubricante refiérase al manual del fabricante del reductor incluido con este m

avés del respirador

anual.

Figura 22: Detalle de Reductor de engranes

o llenadas con grasa por el fabricante. No se requiere engrasado periódico. Si un motor se desmonta, la cámara de rodamiento, así como l grasa Tfabrica nto de

bricación especial.

Mantenimiento de Motor Eléctrico El motor tiene balineras blindadas que han sid

a cámara de la campana exterior detrás del rodamiento, debe reensamblarse conexaco Cygnus #2 o una equivalente (Figura 23). Refiérase al manual del nte de motor para los detalles del ensamble de motor y cualquier requerimie

lu

IMPORTANTE: En algunos motores los rodamientos son lubricados con grasa a base de poliurea que no es compatible con las grasas a base de litio. Mezclar grasas de poliurea y de litio puede causar pérdida del lubricante y llevar a una falla del rodamiento o del motor. Refiérase al manual del fabricante del motor en lo que respecta a lubricantes compatibles.

Respirador/Llenador de aceite

Tapón de nivel de aceite

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23

Grasera

Figura 23: Detalles de Motor

Alineación de las poleas Las poleas superiores e inferiores deben estar localizadas en el mismo punto sobre sus respectivos ejes (Figura 24). Esto permite que las correas tensionen uniformemente sobre el mismo plano. Cuando las poleas no están alineadas adecuadamente, usted puede notar un olor a caucho quemado cerca de los componentes de la unidad de conducción. Para revisar la alineación de las poleas, siga estas instrucciones: .

Herramientas necesarias: llaves de boca fija, nivel o regla, mazo de goma 1. Siga el procedimiento de bloqueo/paro de seguridad antes de llevar a cabo

cualquier trabajo en la máquina. f inar si

mo plano. el buje de una polea para permitir moverla

2. Coloque el nivel o la regla en la cara ambas están a nivel sobre el mis

rontal de cada polea para determ

3. Si existe alguna desalineación, aflojesobre el eje.

4. Deslice la polea hacia adelante o hacia atrás hasta que se logre la nivelación. 5. Ajuste el buje de la polea.

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Polea superior (conducida)

Polea in erior f(conductora)

Figura 24: Ensamble de poleas

TensióLa mm) cu leas. Una correa tensionada inadestán localizadas un par de platinas equipadas de tensores. .

Herramientas: regla, llaves de boca fija (2) 1. Desconecte la energía, siga el procedimiento de bloqueo/paro de seguridad para la

mezcladora. 2. Afloje las 4 contratuercas de un lado de la platina para aumentar o disminuir el

espacio entre las platinas (Fig. 28 y 29). 3. Una vez que se logre la tensión deseada de la correa, ajuste las tuercas para evitar

que la platina se mueva.

n de las correas correa está tensionada correctamente cuando cede sólo aproximadamente ½” (12.7

ando se hace presión en ella entre las dos poecuadamente puede causar deslizamiento y desgaste prematuro. Encima del motor

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Figura 25: Motor con polea y placas de tensión

Figura 26: Detalle de los tensionadores de polea

Placas de tensión de las correas

Correas

Tensionadores de las correas

Igual espacio en todos los tensionadores cuando ltensión es correcta.

a

Contratuercas

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26

Reemplazo de correas Cuando la parte superior de una correa está por debajo de la superficie del dexterior de la polea, la correa se ha desgastado y debe ser reemplazada. Las mezcladora siempre

iámetro correas de la

se deben reemplazar en juegos completos..

Herramientas necesarias: llaves de boca fija, regla 1. Desconecte la energía, siga el procedimiento de bloqueo/paro de seguridad para la

mezcladora. 2. Retire la cubierta para tener acceso a las correas conductoras. 3. Afloje la tensión de las correas levantando los cuatro tornillos del motor

conductor (Fig. 26). 4. Cuando las correas estén suficientemente flojas, retírelas de la polea. 5. Coloque las correas nuevas. 6. Tensione las correas nuevas bajando los pernos del motor y ajustando las

contratuercas. 7. Revise que el eje del motor esté paralelo al eje del reductor arriba de él. Los 4

pernos de la placa de tensión del motor deben tener la misma longitud expuesta para que el eje esté correctamente orientado (Fig. 26).

eemplazo de Rodamientos de Agitador Para reemplazar los rodamientos del agitador en el lado motriz se requiere un desmontaje extenso (Figura 27). En el lado de descarga los rodamientos son más rápidamente accesibles. Cuando se cambian los rodamientos del agitador, siempre cambie ambos lados de la unidad..

R

117

5

1

2

4

6

3

9

8

10

Figura 27: Ensamble de Unidad Motriz típica (Rodamiento de Agitador es la pieza 8)

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27

PZA. DESCRIPCION

1 MOTOR ELECTRICO

2 BASE DE MOTOR

3 ADAPTADOR DE BASE DE MOTOR

4 REDUCTOR DE ENGRANES

5 POLEA DEL MOTOR

6 POLEA DEL REDUCTOR

7 CORREAS EN V

8 CHUMACERA DE AGITADOR

9 SELLO POSTERIOR DE EJES

10 CERROJO, ¼-TURN LOCK

11 ENSAMBLE DE EJE DE AGITADOR

Para reemplazar el rodamiento del agitador del lado motriz, siga estas instrucciones:

a energía, siga el procedimiento de bloqueo de seguridad para la mezcladora.

2. En el lado de motores, retire las siguientes partes en este orden: Correas Poleas Reductor de Engranes Guardamotores Chumaceras de Agitador

3. Una vez que se accede a los rodamientos del agitador, afloje los opresores que sostienen los collarines en ambos lados de la chumacera (Figura 28).

Herramientas necesarias: Llaves Allen, Llaves inglesa de boca fija, martillo de

goma, pasta anti-fricción 1. Desconecte l

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Opresores de collarines en ambos lados de chumacera

Pernos de montaje de chumacera

Fi a o de motor

4. Desatornille los pernos de la chumacera. ría

erá

8. Reinstale l s dentro de las chumaceras. Reinstale las placas calzas, apriete los ntaje de la chumacera y opresores de collarines.

9. Realineé la h i es necesario. (Ver pag.22). 10. Reensambl o idad motriz:

Para reemplazar los rodamientos de agitadores del lado de descarga, siga estas instrucciones refiriéndose a la Figura 29 y Figura 30.

Herramientas necesarias: Llaves Allen, Llaves inglesa de boca fija, martillo de goma, pasta anti-fricción

1. Desconecte la energía, siga el procedimiento de bloqueo de seguridad para la mezcladora.

2. Retire los cilindros neumáticos de las compuertas de descarga de enfrente de la chumacera.

3. Una vez que se accede a los rodamientos del agitador, afloje los opresores que sostienen los collarines en ambos lados de la chumacera (Figura 29).

gur 28: Chumacera de Agitador del lad

5. Retire el rodamiento de rodillos esféricos dentro de la chumacera. En la mayode los casos, la carcasa se puede reutilizar a menos que esté dañada. Si se coloca toda la carcasa, asegúrese de conservar las calzas de cada rodamiento ya que snecesario realinearlos.

6. Aplique pasta anti-fricción al eje del agitador. 7. Reemplace el rodamiento interior o todo el conjunto de la chumacera si es

necesario. os rodamiento

opernos de ms c umaceras del agitador s

e la une l s componentes d Guardamotores Reductor Poleas Correas conductoras

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Figura 29: Reemplazando los rodamientos del agitador del lado de descarga

dentro de la chumacera. En la mayoría a menos que esté dañada.

6. 7. to interior o todo el conjunto de la chumacera si es

lzas, ernos de montaje de la chumacera y opresores de collarines.

10.

4. Retire el rodamiento de rodillos esféricos de los casos, la carcasa se puede reutilizar

5. Asegúrese de conservar las calzas de cada rodamiento ya que será necesario realinearlos. Aplique pasta anti-fricción al eje corto del agitador . Reemplace el rodamiennecesario..

8. Reinstale los rodamientos dentro de las chumaceras. Reinstale las placas caapriete los p

9. Realineé las chumaceras del agitador si es necesario. (Ver pag.22). Reinstalé los cilindros neumáticos y conecte las líneas de aire.

0: Chumacera de Agitador del lado de descarga y Eje piloto Figura 3

Retire el cilindro cuando cambia los rodamientos

Opresor de collarin

Pernos de Montaje

Eje “corto” (piloto)

Ensamble de e sellos bloque d

Pernos de Montaje

Eje corto

Placas de Calza

Rodamiento interno

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Reemplazamiento de Eje Piloto El Eje Corto, también conocido como “Eje Piloto”, esta localizadde la mezcladora (pieza 4 en la Figura 31). Se sostiene por la chudesliza dentro del eje del agitador (pieza 6) en el otro.

o en el lado de descarga macera de un lado y se

Figura 31: Ensamble del lado de descarga típico

PIEZA DESCRIPCION

1 CHUMACERA

2 CILINDRO NEUMATICO DE COMPUERTA DE DESCARGA

3 FLASHING LIGHT

4 EJE PILOTO DE AGITADOR

5 SELLO FORNTAL DE EJE

6 ENSAMBLE DE AGITADOR

7 EMPAQUE DE COMPUERTA

Para reemplazar el eje piloto del agitador::

Herramientas necesarias: Llave Allen, Llaves inglesas, martillo de g nti-fricción, grúa o soporte para el eje del agitador del lado del eje piloto

1. Desconecte la energía, siga el procedimiento de bloqueo de seguridad para la mezcladora.

2. Retire los cilindros neumáticos de las compuertas de descarga dchumacera..

3. Utilice una grúa o algún otro medio de izaje o un apoyo pa im

oma, pasta a

e enfrente de la

ra pedir que el eje del agitador caiga o se incline cuando se retire el eje piloto. Esto podría doblar o dañar el eje del agitador.

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31

4. Una vez que se accede a los rodamientos del agitador, afloje los opresores que lados de la chumacera (Figura 30).

7. Retire el eje piloto. 8. Aplique pasta anti-fricción al nuevo eje piloto que entra en el eje del agitador y

aplicar algo alrededor del área de la chumacera. 9. Reinstale el bloque de sellos. 10. Coloque la chumacera, junto con las placas de calza y opresores de collarines. 11. Restaure el cilindro de la compuerta de descarga 12. Ejecute una prueba corta con el agitador girando. Alineé la chumacera si es

necesario (vea pag.21) Mantenimiento Sistema Neumático Mantenimiento de Filtro-Regulador-Lubricador (F-R-L) Para mantener la confiabilidad de los cilindros y válvulas, es importante mantener el sistema neumático limpio. Hay un tapón de drenado al fondo del filtro de aire y un tazón lubricador (Figura 32 & Figura 33). Abra estos cada semana para permitir el drenado de sedimentos.

sostienen los collarines en ambos5. Retire los pernos de montaje de la chumacera y saque la chumacera del eje. 6. Retire el bloque de sellos (ver pag.17 para las instrucciones de ensamble y

desensamble).

Empuje hacia abajo para bloquear (posición cerrada)

Regulador de aceite ajustado a 1-2 gotas/minuto

Conexión principal de aire

Figura 32: Ensamble de Filtro/Regulador/Lubricador

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Figura 33: Detalle de tapón de drenado y depósito de aceite del F-R-L

Figura 34: Desensamble del Filtro/Regulador/Lubricador

El filtro/lubricador puede desensamblarse y limpiarse si es necesario (Figura 34).

1. Antes de desensamblar, cierre el suministro de aire de la planta, aplastando el botón amarillo (Figura 34).

2. Desensamble el filtro/lubricador desenroscando la trampa de agua y el depósito de aceite.

3. Limpie todas las partes con metanol y sóplelas con aire comprimido. Limpie los tazones plásticos y los visores solamente con jabón común.

4. Reemplace el filtro del lubricador por uno limpio.

Herramientas necesarias: ninguna

T rampa de agua

Salida de aire cerrada

Tubo de lubricante

Regulador de aceite

Llene el depósito de aceite cada semana

Tapón de Drenado

Depósito de aceite

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5. Ensamble nuevamente y llene el lubricador con aceite lubricante liviano Mobil DTE.

El lubricante usado en el lubricador debe cumplir los siguientes requisitos: • Viscosidad de 100-150 SUS (Segundo Universal de Saybolt) a 100º F • Índice alto de viscosidad: más de 90. • Compatible con el empaque Buna-N • Antiespumante • Estabilidad a la oxidación (más de 2000 en prueba ASTM [So

para el Ensayo de Materiales] D943 • Rango de anilina 180-210

Cilindros Neumáticos Los cilindros neumáticos no requieren mantenimiento regular. Si los sellos se desgastan y requieren ser cambiados, existen juegos de sellos de reemplazo. Refiépartes neumáticas incluidas con este manual para los juegos de sellos aplicables al

Si una compuerta de descarga abre o cierra más rápidamente que la otraajustar el flujo de aire para igualar los cilindros neumáticos (Figura 35).

ciedad Americana

rase a la lista de las

tamaño del cilindro en particular. Ajuste del flujo de aire del cilindro

, es necesario

Válvula de flujo/control

Ajuste de h

Válvula de flujo/control

orquilla

Figura 35: Cilindros de compuertas de descarga

Herramientas necesarias: Destornillador (paleta), llave inglesa de boca fija 1. Cierre el suministro de aire a la unidad. 2. Revise las válvulas de flujo/control de cada uno de los cilindros para ver si están

ajustados aproximadamente a la misma velocidad. Gire los tornillos de ajuste ranurados de cada uno si es necesario (Fig. 36). Esto garantiza que la cantidad de aire que va a cada cilindro sea la misma.

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Tornillo ranurado de el control

del flujo de aire ajuste para

Figura 36: Válvula de flujo/control y tornillo de ajuste del cilindro de aire

ste con una llave de boca fija en el punto plano para controlar la cantidad expuesta de rosca del eje del pistón. Ambos cilindros deben tener el mismo número de hilos de rosca en el eje del pistón expuestos por la horquilla.

4. Cuando está ajustada adecuadamente, la cubierta debe subir y la misma velocidad a ambos lados de la máquina..

Ensamble y desensamble de los cilindros

Figura 37

El cilindro de aire necesita ser desensamblado para cambiar los sellos internos. Refiérase a la Fig. 37 para ver el ensamble típico de un cilindro de aire.

3. Otro ajuste que se hace es en el eje del pistón de la horquilla. Aju

bajar suavemente a

: Sección transversal típica del cilindro de aire

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35

Herramientas necesarias: llaves de boca fija 1. Cierre el suministro de aire a la unidad. 2. Retire el cilindro de las horquillas de la cubierta y del fondo. 3. Desenrosque la tapa del extremo del eje del cilindro girando ales

de él. Esto le permitirá jalar hacia afuera el pistón y tener acceso a los sellos tipo anillo “O” internos.

4. Desenrosque el extremo inferior del cilindro con una llave. Esto proporcionará acceso al anillo “O” del fondo.

Mantenimiento de Compuerta de Descarga Las compuertas de descarga están localizadas en el lado de la máquina opuesto a los componentes de la unidad conductora. Las compuertas proporcionan una salida para el producto mezclado y permiten el desagüe del tanque durante la limpieza. Cada compuerta es accionada por un cilindro neumático. Alrededor de las partes móviles hay una protección para evitar lesiones pero al mismo tiempo permite una limpieza completa

las caras hexagon

(Figura 38).

Figura 38: Lado de descarga de la mezcladora

Palanca de sellos

Guarda de Compuertas de descarga

(2) Cilindros de accionamiento de compuerta de descarga

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Figura 39: Compuerta de descarga de la mezcladora

Seguro mecánico Las compuertas de descarga tienen un seguro mecánico a cada lado para evitar que la compuerta se abra en caso de pérdida de la presión de aire hacia los cilindros. El seguro mecánico consiste en un tensor y un pivote que actúan contra la compuerta de descarga (Figura 39 y Figura 40)

Figura 40: Seguro mecánico en la compuerta de descarga (cerrada)

Cuando la compuerta está cerrada, el tensor ebe estar perpendicular a la compuerta. d debe escuchar un fuerte "chasquido" cuando

los cilindros cierran la compuerta y ponen el seguro mecánico en posición. En caso de que el cilindro neumático falle, la fuerza del producto empujando contra la compuerta de descarga se encontrará con una fuerza igual y opuesta del tensor. Esto sostendrá el producto dentro del tanque y la placa pivote no se moverá.

Eje del Cilindro de aire

Tensor perpendicular a la compuerta

Contratuercas

Placa pivote

Ajuste del extremo del eje

Horquilla

dCuando está ajustada adecuadamente, uste

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La compuerta de descarga se abre cuando el cilindro de aire se retracta hacia arriba y levanta el pivote (Fig. 41). El seguro no sostendrá la compuerta en esta posición. .

Pivote posición arriba

Figura 41: Seguro mecánico en la compuerta de descarga (abierta)

Ajuste del seguro mecánico Si el seguro no está manteniendo la compuerta cerrada o si no está pela compuerta se cierra, usted necesita ajustar las contratuercas del tenFig. 40 de la página anterior.

Herramientas necesarias: llaves de boca fija (2) 1. Asegúrese que la compuerta esté en posición cerrada. 2. Cierre el suministro eléctrico y de aire a la mezcladora. 3. Retire los pernos que sostienen la horquilla del cilindro de aire a la placa pivote. 4. Usando las llaves, ajuste igualmente ambos lados del tensor p tar o

disminuir la distancia entre el pivote y el punto de enlace en el otro extremo del tensor.

5. Reinstale la horquilla del cilindro a la placa pivote. 6. En este punto, puede ser necesario ajustar la tuerca en el extr l

cilindro neumático. 7. Restablezca la energía a la unidad y pruebe la operación de lo

las compuertas de descarga. Si usted escucha el "chasqu o" sor á ajustado correctamente.

salga del tanque. El mpaque alrededor de las compuertas (Figura 42) necesita ser reemplazado cuando

rpendicular cuando sor. Refiérase a la

ara aumen

emo del eje de

s cilindros de aire de y observa el tenid

perpendicular a la compuerta, el seguro mecánico estSi es necesario, ajuste la velocidad del flujo de aire en los cilindros neumáticos, vea pag.34. Reemplazo del empaque de las compuertas de descarga El empaque alrededor de las compuertas de descarga (Cozzini #12-004-0002) proporciona un sello hermético para evitar que el producto see

REV. B: 4/28/03

38

empiece a salirse o cuando el daño sea evidente. Cuando sea necesario cambiar el empaque de la compuerta, siga estas instrucciones.

No intente cambiar el empaque con la compuerta adherida a la mezcladora.

Empaque de compuerta #12-004-0002

Retire el perno

Retire el perno

Figura 42: Empaque de la compuerta de descarga

Herramientas necesarias: llaves de boca fija, cinta para medir, cuchillo, adhesivo oma loca” (Crazy Glue) y sellador de silicón

o se muestra en la e trabajo aparte.

7.

10.

el uevo empaque.

Prisma transparente de Loctite o “Gtransparente

1. Coloque las compuertas de descarga en posición abierta. 2. Cierre el suministro de energía y de aire hacia la mezcladora. 3. Desprenda la compuerta de descarga retirando los 2 pernos com

Figura 42. Lleve la compuerta de descarga a un lugar d4. Retire el silicón que sostiene el empaque y retire el empaque viejo de la

compuerta. 5. Raspe cualquier residuo de silicón que haya en la compuerta. 6. Corte el empaque si no está roto y estírelo en línea recta.

Tome el empaque nuevo y tiéndalo en línea con el empaque viejo para compararlos.

8. Corte los extremos de la tira de empaque aproximadamente a 45º. Mídalos para confirmar que ambos empaques (viejo y nuevo) tienen la misma longitud. Pruebe el ajuste del e9. mpaque nuevo en la ranura de la compuerta antes de engomar los extremos. No estire demasiado la tira de empaque. Si el ajuste es bueno, tome los dos extremos y péguelos al mismo nivel con un adhesivo claro y permanente.

11. Aplique un poco de silicón en la ranura del empaque de la compuerta e instalen

12. Cuando el silicón esté seco, reinstale la compuerta en la mezcladora. 13. Revise que el seguro esté ajustado correctamente (ver pag.37).

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Instrucciones de lubricación

Operación en presencia de polvo, agua o vapores corrosivos Bajo estas condiciones, los rodamientos deben contener tanta grasa como la velocidad lo permita. Un rodamiento lleno de grasa con un ligero escape consecuente protege mejor contra la entrada de materiales extraños. Si el exceso de grasa en el rodamiento produce sobrecalentamiento, retire las graseras para permitir el escape del exceso de grasa. Los rodamientos vienen engrasados de fábrica y están listos para funcionar. Temperatura de operación Las temperaturas anormales de los rodamientos pueden ser indicac lubricación. La temperatura normal puede oscilar desde “fría o tibia al tacto” hasta el punto de “muy caliente al tacto durante más de unos pocos segundos”, dependiendo del tamaño del rodamiento, la velocidad y las condiciones circundantes. • La temperatura normal y una ligera indicación de grasa en la superficie del sello

indican una lubricación adecuada. añada de una fuga excesiva de grasa indica

mente si el rodamiento parece tener un ruido, indica muy poca lubricación. TipLa Lubriqu le con el lub

ión de una mala

• Una temperatura inusualmente alta acompdemasiada lubricación.

• Una alta temperatura sin indicación de grasa en la superficie del sello, particular

o de grasa grasa Texaco Cygnus #2 es ideal para las condiciones normales de operación.

e nuevamente con la grasa Texaco #2 o con una grasa que sea compatibricante original y que sea adecuada para el servicio de rodamientos.

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Programa de lubricación

Punto de lubricación Lubricante Intervalo Rodamiento del motor eléctrico

Grasa Cygnus #2* (USDA H1)

Reparar

Reductor Ver manual del fabricante Rodamientos del agitador Grasa Cygnus #2*

(USDA H1) 1 Semana

Lubricador neumático Aceite lubricante liviano Mobil

1 Semana DTE

*IMPORTANTE: En algunos motores los rodamientos son lubricados con grasa a

base de poliurea que no es compatible con las grasas a base de litio. Mezclar grasas de poliurea y de litio puede causar pérdida del lubricante y llevar a una falla del rodamiento o del motor. Refiérase al manual del fabricante del motor en lo que respecta a lubricantes compatibles.

Sistemas Hidráulicos solamente: Al cambiar el aceite en el sistema de la bomba hidráulica Use aceite Texaco Cygnus #46 para las máquinas que trabajan a temperatura ambiente por debajo de los 50º F (10º C). Use aceite Texaco Cygnus #68 para las máquinas que trabajan a temperatura ambiente por encima de los 50º F (10º C).

ntenimiento del sistema hidráulico Maladoras con unidad motriz hidráulica)

to es,

temperatura del sistema se debe mantener por debajo de 140° F (60° C.), ya que el sobrecalentamiento descompondría el aceite hidráulico y formaría lodo. Es obligatorio establecer y seguir un programa regular de cambio de los elementos del filtro y de limpieza de los filtros de succión. Los procedimientos específicos de mantenimiento dependen del tipo particular de sistema hidráulico suministrado con su mezcladora.

(Aplicable a MezcEs importante que el fluido hidráulico sea mantenido en condiciones adecuadas, eslibre de contaminación por químicos o partículas. Abra periódicamente el tapón de drenaje localizado en la parte inferior del depósito para drenar cualquier condensación dehumedad, lodo o producto que se hayan acumulado ahí. Durante la operación, la

IMPORTANTE: Si la mezcladora/batidora trabaja más de 8 horas al día, o está bajo condiciones más severas de lo normal, los intervalos de mantenimiento se deben ajustar convenientemente. Use aceite Texaco Cygnus #46 para las máquinas que trabajan a temperatura ambiente por debajo de los 50º F (10º C). Use aceite Texaco Cygnus #68 para las máquinas que trabajan a temperatura ambiente por encima de los 50º F (10º C). Refiérase al manual del sistema hidráulico que se incluye con su mezcladora equipada con unidad hidráulica. El manual contiene información específica sobre los componentes y los requisitos de mantenimiento.

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Mantenimiento preventivo La nto preventi a referencias a los

ección ara instruc talladas sobre cada . i recomienda ampli mie tos. Mantenga una tabla

sección de Mantenimie vo proporcion tópicos correspondientes de la Soperación

3- Mantenimiento p ciones de

Cozzin amente seguir estos procedi npara los operarios y el per nto. Esta t numerar todos sonal de mantenimie abla debe elos pasos de mantenimiento y sus intervalos y debe requerir de una firma al lado de cada tarea cuando se lleve e tod edimientos de a cabo. Esto garantiza qu os los procmantenimiento preventivo se hayan llevado a cabo a sus intervalos requeridos.

Mantenimiento diario recomendado

1. Revise que todas las guardas de seguridad estén puestas y funcionando: Rejillas del tanque, Guarda de Compuertas de descarga.

2. Revise que no haya condensación en los controles e interruptores de segurida3. Revise que los sellos de los ejes d

d. e los agitadores no tengan señas de desgaste o

estén dañados (pag.17)

2. Revise las chumaceras de los agitadores y lubríquelas con grasa Texaco Cygnus

o de las poleas. (pag.24)

lico,

compuertas; ajuste si es necesario. (pag.37) e

Inspeccione todas las mangueras y

1. El nivel de aceite de los reductores se debe revisar regularmente y el aceite se

Mantenimiento semanal recomendado

1. Revise que el filtro/regulador/lubricador tenga el nivel de aceite adecuado (pag.32)

#2 si es necesario. (pag.21) 3. Revise se están dañadas las correas y el alineamient4. Inspeccione la condición de los empaques de las compuertas de descarga (pag.38)5. Para las unidades Hidráulicas solamente: Revise el filtro de retorno hidráu

reemplácelo de ser necesario. 6. Para las unidades hidráulicas solamente: Revise si el aceite del depósito

hidráulico tiene alguna contaminación. Cambie el aceite y los filtros si es necesario.

Mantenimiento trimestral recomendado

1. Revise la alineación correcta de los cilindros neumáticos y los seguros de las

2. Revise la hermeticidad del cierre de las compuertas de descarga y la condición dlos empaques de las compuertas . (pag.38)

4. Reemplace sellos y empaques. (pag.17) 5. Para las unidades hidráulicas solamente:

acoples hidráulicos. Mantenimiento semestral requerido

debe cambiar cada seis meses o más frecuentemente, dependiendo del ciclo de trabajo de la máquina. Esto no se aplica a los sistemas motrices hidráulicos.

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SECCION 4 - LIMPIEZA E HIGIENIZACION

ntiene compuestos de curado o de adobo, estos pueden corroer el equipo si no

Limpie la mezcladora/batidora tan pronto como sea posible después de cada uso. Si el producto cose limpia total y adecuadamente.

Antes de empezar cualquier procedimiento de limpieza o higiene, el motor debe ser colocado en posición de apagado (“off”). Siempre siga los procedimientos de bloqueo/paro de seguridad de la planta.

En la m

escarga • Rejilla

evantarse a la posición totalmente abie versal posterio

IM ua directamente sobre el panel de control. Solo

ezcladora, limpie las siguientes partes diariamente: • Tanque de mezcla • Paletas de los agitadores • Conjuntos de sello • Compuertas de d

La rejilla sobre el tanque de la mezcladora debe lrta con la espiga de seguridad que contacta directamente con el elemento trans

r.

PORTANTE: Nunca rocíe aglimpie manualmente.

LimPar . Para lim

1. idad agitadores girando en cualquier modo.

e de la mezcladora (Figura 43 y

pieza del sello del eje a la limpieza de rutina diaria, los sellos de los ejes no necesitan ser desmontadospiar los sellos del eje del agitador:

Cierre las compuertas de descarga y la rejilla de seguridad. Arranque la uncon ambos

2. Baje la palanca para retirar el sello del tanquFigura 44). Esto le permitirá tener acceso completo para limpiar el área de los sellos de los ejes con una manguera de agua a alta presión. Para cerrar los sellos de los ejes después de u3. na limpieza completa, mueva la palanca de los sellos de regreso a su posición original.

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ra 43: Palanca de los sellos (cerrada) Figu Figura 44: Palanca de los sellos (abierta)

Si los s o reemplácelos. Ver la Sección 3 - Mantenimiento, pag.17 para una explicación detallada del ensamble y desensamble de los sellos.

ell s aparecen dañados,

NOTA: e ble o desensamble cualquier superficie de sello. T nga cuidado cuando ensamUna fuga causado por los sellos o superficies de sello dañados puede causar pérdida del producto.

impiezL a de los agitadores y paletas

git agitadores y paletas se han limpiado completamente, abra la r que salga todo el exceso de agua y producto de la

Para limpiar los agitadores, cierre la rejilla de seguridad y encienda los agitadores en cualquier modo. Use una manguera de alta presión para rociar las paletas de los

adores. Una vez que los acompuerta de descarga para permitimezcladora/batidora.

A través de la rejilla de DVERTENCIA: No introduzca su brazo o manos aseg s en uridad intentando quitar cualquier exceso de producto del agitador o sus paletaningún el momento durante este procedimiento de limpieza. No inserte ninguna parte dcuerpo y puede producir en la compuerta de descarga. Esto es sumamente peligrosouna lesión seria.

Limpieza de las compuertas Para limpiar las compuertas de descarga, póngalas en posición “abierta”. Usando una manguera de alta presión, limpie completamente las compuertas, por dentro y por fuera. Usted puede rociar con la manguera hacia arriba desde la guarda de seguridad o rociar con la manguera desde arriba hacia las compuertas de descarga.

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ADVERTENCIA: No gire los agitadores en ningún momento durante este procedimiento de limpieza. Nunca introduzca ninguna parte de su cuerpo en las compuertas de descarga. Esto es extremadamente peligroso y puede resultar en lesiones graves.

SECCIÓN 5 - LOCALIZACIÓN DE FALLAS Diagnóstico de la localización de fallas Estos son los problemas comunes encontrados durante la operación de la mezcladora y las ibles causprobabilidad de ocurrencia. Para llevar a cabo las operaciones de mnecesarias, refiérase al tó to.

R A

sugerencias para solucionarlos. Las pos as se enumeran por orden de antenimiento

pico correspondiente descrito en la Sección 3 - Mantenimien

OBLEMA: EL AGITADOR ROZA EN EL CUERPO DE LA MEZCLADORPPOSIBLES CAUSAS: A Agitadores desalineados – alineé las chumaceras (pag.22) B Desgaste excesivo de los rodamientos. Cambie los rodamientos (pag.27) C s tornillos de las chumaceras . están flojos. Ajuste lo necesario. LoD El eje del agitador está torcido. E Eje gastado en el lado de la descarga – Reemplácelo (pag.31) PROBLEMA: EL PRODUCTO SE SALE POR LOS SELLOS POSIBLES CAUSAS: A Los sellos están instalados incorrectamente (ver la pág. 16 para todos l

detallesos

del ensamblaje de los sellos) B Dentro de la caja del sello hay un sello de borde y un empaque. Es necesario

que ambos estén instalados. C La abrazadera del sello no está ajustada adecuadamente D Los sellos están gastados y necesitan ser reemplazados PROBLEMA: OLOR A CAUCHO QUEMADO CERCA DE LA UNIDAD MOTRIZ POSIBLES CAUSAS: A Correas flojas y no tensionadas correctamente (pag.25) B Correas desgastadas o dañadas: reemplácelas inmediatamente (pag. 27) C Poleas desalineadas que causan que las correas se rocen unas a ot

Verifique la alineación de la polea. (pag.24) ras.

PROBLEMA: FUGA DE PRODUCTO POR LAS COMPUERTAS DE DESCARGA

POSIBLES CAUSAS: A El empaque alrededor de la compuerta esta dañada o incorrectamente

instalado. (pag.38)

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B El seguro mecánico necesita ajustarse (pag.37) PROBLEMA: PARTES DEL PRODUCTO SIN MEZCLAR POSIBLES CAUSAS: A La mezcladora esta sobrecargada o por debajo de su capacidad. Cuando el

nivel del producto es demasiado alto, es inseguro operar el equipo. El volumen de la mezcladora debe llenarse a un nivel ligeramente sobre la cima de los agitadores.

Solo para unidades equipadas con rocío de agua PROBLEMA: SALIDA DE AGUA REDUCIDA POSIBLES CAUSAS: A Bobina de válvula pegada en la posición cerrada impide entrada de agua B Obstrucción u obstáculo en el conducto de agua

E AGUA DE LOS ROCIADORES EN LA REJILLA PROBLEMA: NO SALPOSIBLES CAUSAS: A La válvula de agua de la línea esta cerrada B La bobina de la válvula esta pegada en la posición cerrada. Reemplace la

bobina si es necesario.

oS lo para eqido en mezcladoras

OBLEMA:

uipos equipadas con unidad Hidráulica Refiérase al manual del sistema hidráulico adicional que viene inclu

ulica. Este contiene la información sobre los componentes y los provistas de unidad hidráuisitos de mreq

antenimiento específicos

PR TEMPERATURA DE ACEITE ALTA POSIBLES CAUSAS: A El ajuste de la válvula de alivio está muy bajo. B Mal funcionamiento de la bomba C Suministro de agua inadecuado a través del intercambiador de calor D La bomba tiene excesivo desgaste. PROBLEMA: EL SISTEMA HIDRÁULICO ESTÁ PRODUCIENDO RUIDO

CESIVO. EXPOSIBLES CAUSAS: A La bomba puede estar cavitando. B El fluido puede estar muy frío para fluir. C El filtro de succión puede estar obstruido. D Revise la manguera de succión. Puede haber colapsado. E El respirador del tanque puede estar obstruido. F Se puede estar formando vapor G El nivel del depósito de aceite puede estar muy bajo. H ando el tipo o la cantidad equivocada de fluido Se puede estar us

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hidráulico. I Los acoples pueden estar desalineados. J Los acoples pueden estar flojos. K La bomba puede estar dañada o gastada. PROBLEMA: PRESIÓN HIDRÁULICA INADECUADA POSIBLES CAUSAS: A a. La bomba no está cebadB La bomba está dañada o gastada. C Mal funcionamiento de la válvula de alivio. D Mal funcionamiento de la válvula de control direccional. PROBLEMA: Y FLUJO. FLUJO DEL PRODUCTO BAJO O NO HAPOSIBLES CAUSAS: A La bomba está cavitando. B Aireación del fluido. C La bomba está desgastada o dañada. D Mal funcionamiento del compensador de presión E a no es la adecuada. La rotación de la bomb

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SECCION 6 – PARTES DE REPUESTO siguiente es e mantener disponibles así como cantidades r los componentes pueden variar un modelo a rtes incluidas en el manual para

s números de parte específicos para su unidad.

Lalas

una lista de partes de repuesto que se debecomendadas. Los números de parte para otro. Refiérase a los dibujos y listas de pade

lo

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INDICE Agitadores, 14 Barra del pistón, 35 Base de montaje, 10 Bloqueo/Paro, 22, 24, 25, 27

Reductor de engranes, 22 Rocío de agua, 7, 12 Rodamientos, 21, 27

Capacidad de Mezcladora, 15 Caja del reductor, 9,10, 23 Celdas de carga, 10 Cilindros neumáticos, 7, 30, 35 Compuerta de Descarga, 7,16, 36, 37, 38 Correas, 25, 26, 27 Chumacera, 11, 29, 30 Eje piloto, 30,31 Engrasado, 11, 21, 40 Empaque de compuerta de descarga, 38, 39 Empaque de sellos, 18, 19, 20 Filtro/lubricador, 32,33 Garantía, 6 Guías de Seguridad, 5 Inspección, 8 Juego de sellos, 36 Lubricador, 32, 33 Mantenimiento hidráulico, 41 Mantenimiento Preventativo, 42 Mantenimiento semanal, 42 Medidor de agua, 12 Motor, 23 Nivel de aceite, 23, 34 Palanca de sellos, 18, 36 Patas ajustables, 10 Poleas, 24, 25, 26 Prueba de puesta en marcha, 13

Rotación de Agitador, 14 Rozamiento de Agitadores, 14 Seguro, 38 Sellos, 17, 19, 20 Sensor de proximidad, 12 Sistema hidraulico, 41 Suministro de aire, 11, Tapón de drenado, 33 Temperaturas del rodamiento, 40 Tensión de correas, 25 Unidad de potencia hidraulica, 12 Válvulas flujo/control, 34, 35

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CONTENTS

SECTION 1 – INTRODUCTION.................................................................................... 5 About This Manual ......................................................................................................... 5 Safety Guidelines ............................................................................................................ 5 Warranty ......................................................................................................................... 6 Getting to Know the Mixer ............................................................................................. 6 Mixer Operation and Mechanical Overview................................................................... 7

SECTION 2 – USING THE MIXER/BLENDER .......................................................... 8 Installation and Operating Instructions........................................................................... 8 Installation....................................................................................................................... 8

Inspection Before Startup ........................................................................................... 8 Equipment Setup......................................................................................................... 9 Start-Up Test............................................................................................................. 13

Filling the Mixer/Blender ............................................................................................. 14 Operating Guidelines .................................................................................................... 15 Unloading the Mixer ..................................................................................................... 15

SECTION 3 – MAINTENANCE................................................................................... 15 Maintenance Procedures ............................................................................................... 15 Shaft Seal Assembly and Disassembly ......................................................................... 16

Replacing the Seal Gasket ........................................................................................ 18 Agitators........................................................................................................................ 18

Agitator Bearing Lubrication.................................................................................... 19 Agitator Alignment ................................................................................................... 20

Drive Components ........................................................................................................ 20 Gear Reducer Maintenance....................................................................................... 20 Electric Motor Maintenance ..................................................................................... 21 Pulley Alignment ...................................................................................................... 22 Belt Tensioning......................................................................................................... 23 Belt Replacement ...................................................................................................... 25 Agitator Bearing Replacement.................................................................................. 25 Stub Shaft Replacement............................................................................................ 28

Pneumatic System Maintenance ................................................................................... 29 Filter-Regulator-Lubricator (F-R-L) Maintenance ................................................... 29 Pneumatic Cylinders ................................................................................................. 31 Adjusting Air Cylinder Flow Rate............................................................................ 31 Cylinder Assembly and Disassembly ....................................................................... 33

Discharge Door Maintenance ....................................................................................... 33 Mechanical Interlock ................................................................................................ 34 Adjusting the Mechanical Interlock.......................................................................... 36 Discharge Door Gasket Replacement ....................................................................... 36

Lubrication Instructions ................................................................................................ 37 Operation In The Presence Of Dust, Water Or Corrosive Vapors............................ 37

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Operating Temperature ............................................................................................. 37 Type of Grease.......................................................................................................... 37 Lubrication Schedule ................................................................................................ 38

Hydraulic System Maintenance .................................................................................... 38 Preventative Maintenance............................................................................................. 39

Required Daily Maintenance .................................................................................... 39 Required Weekly Maintenance................................................................................. 39 Required 3-Month (90-Day) Maintenance................................................................ 39 Required 6-Month Maintenance ............................................................................... 39

SECTION 4 - SANITATION AND CLEANING......................................................... 40 Cleaning the Shaft Seals ............................................................................................... 40 Cleaning of the Agitator and Paddles ........................................................................... 41 Cleaning The Doors ...................................................................................................... 41

SECTION 5 – TROUBLESHOOTING ........................................................................ 42 Troubleshooting Diagnostics ........................................................................................ 42 Water Spray-Equipped Units Only ............................................................................... 42 Hydraulic-Equipped Units Only ................................................................................... 43

SECTION 6 – SPARE PARTS ...................................................................................... 44

INDEX.............................................................................................................................. 45

TABLE OF FIGURES Figure 1: Mixer assembly (drive end)................................................................................. 6 Figure 2: Mixer assembly (shown discharging into Cozzini screw loader)........................ 7 Figure 3: Pneumatic lines.................................................................................................... 8 Figure 4: Drive assembly .................................................................................................... 9 Figure 5: Discharge door cylinders..................................................................................... 9 Figure 6: Frame with adjustable feet ................................................................................ 10 Figure 7: Frame with mounting pads ................................................................................ 10 Figure 8: Connecting the air supply to mixer ................................................................... 11 Figure 9: Agitator bearing lubrication .............................................................................. 11 Figure 10: Proximity switches on water spray equipped grating...................................... 12 Figure 11: Water supply connection and meter ................................................................ 12 Figure 12: Correct agitator rotation in mixer.................................................................... 13 Figure 13: Agitator rubbing tank wall during startup ....................................................... 14 Figure 14: Shaft seal lever (locked) .................................................................................. 16 Figure 15: Shaft seal lever (open)..................................................................................... 16 Figure 16: Watertight seal block assembly....................................................................... 16 Figure 17: Seal block assembly (discharge end)............................................................... 17 Figure 18: Assembled seal block ...................................................................................... 17 Figure 19: Disassembled seal block.................................................................................. 18 Figure 20: Agitator bearing lubrication ............................................................................ 19 Figure 21: Agitator bearing on discharge end................................................................... 20 Figure 22: Gear reducer detail .......................................................................................... 21

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Figure 23: Motor detail ..................................................................................................... 22 Figure 24: Pulley assembly............................................................................................... 23 Figure 25: Motor with pulley and tensioning plates ......................................................... 24 Figure 26: Pulley tensioning standoff detail .................................................................... 24 Figure 27: Typical drive end assembly (Agitator bearing is item 8) ................................ 25 Figure 28: Drive end agitator bearing............................................................................... 26 Figure 29: Replacing the discharge side agitator bearing................................................. 27 Figure 30: Discharge end agitator bearing and stub shaft................................................. 28 Figure 31: Typical discharge end assembly...................................................................... 28 Figure 32: Filter/regulator/lubricator assembly ................................................................ 30 Figure 33: Close-up of F-R-L drain cock and oiler bowl ................................................. 30 Figure 34: Disassembled filter/regulator/lubricator.......................................................... 31 Figure 35: Discharge door cylinders................................................................................. 32 Figure 36: Air cylinder flow control/check valve and adjustment screw ......................... 32 Figure 37: Typical air cylinder cross-section.................................................................... 33 Figure 38: Discharge end of mixer ................................................................................... 34 Figure 39: Discharge door on mixer ................................................................................. 34 Figure 40: Mechanical interlock on discharge door (closed)............................................ 35 Figure 41: Mechanical interlock on discharge door (open) .............................................. 35 Figure 42: Discharge door gasket ..................................................................................... 36 Figure 43: Seal lever closed.............................................................................................. 41 Figure 44: Seal lever open ................................................................................................ 41 DRAWINGS & PART LISTS INCLUDED

General Assembly Discharge End Drive End Mixer Pneumatic Control Diagram Watertight Seal Assembly

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SECTION 1 – INTRODUCTION About This Manual This manual is intended for service technicians and personnel responsible for repair and routine maintenance of the equipment. Familiarity with drive components and reading technical drawings or schematics is recommended. The manual addresses mechanical operation and maintenance as well as illustrations of subsystems that comprise the mixer. Safety Guidelines As part of its obligation and commitment to each of its customers, Cozzini has taken every step possible to make the Cozzini Mixer/Blender free from any recognized hazards, which may cause harm or injury to anyone who may operate this equipment.

Wherever you see this sign in the manual, please follow the prescribed safety guidelines when operating the machine.

• Keep hands away from the discharge openings and the agitators at all times. There is a short delay from the time the STOP button is pushed and the agitators actually come to a complete stop.

• Never reach into the mixer/blender for any reason during operation. If the mixer/blender is not in operation and there is a reason you need to reach in the machine, ensure the power has been disconnected and all locked out/tagout procedures have been followed.

• For your safety, on the control box the STOP button is equipped with an added safety-locking device. This will prevent the machine from any accidental startup. This was designed for your safety and should be used during all cleaning operation and for any downtime.

• The two-handed push button control feature is designed to operate the agitators when one or both discharge doors are opened and the grating is closed. This ensures both hands of the operator are on the control panel and not in the machine. Do not disconnect or modify this important safety feature.

• Do not obstruct or remove any warning signs that are attached to the machine. If warning signs become damaged, lost or illegible, please order replacement signs immediately.

• Do not operate the mixer without guards and covers fully in place. • Do not use for any application other than its intended use. • Do not enter mixer tank for any reason. • Do not overload the machine. Run equipment at its recommended capacity. • Do not operate the machine until you have complied with all local safety rules

and regulations. • Do not disconnect or override any safety interlocking switches for any reason.

• Pay attention at all times. Do not operate this machine in a careless manner.

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Warranty Cozzini, Inc. and its subsidiaries (Cozzini Group) warrant all equipment it manufactures for a period of one (1) year from date of final invoice. All components not manufactured but sold by Cozzini Group are covered under the original manufacturer’s warranty. All warranties apply provided the equipment is operated under normal conditions specified by the procedures and maintenance guidelines illustrated in the equipment manual. Cozzini Group shall not be liable for any other damages, direct, indirect or consequential. Cozzini Group will only be liable to the extent of repairing or replacement of the original equipment and will, under no circumstances, is liable for product loss. Failure to follow procedures and maintenance guidelines as specified will void all product warranties. Use of any replacement parts on this equipment that are not approved by Cozzini Group as authorized replacement parts shall void all warranties. Use of any parts on this equipment that are not approved by Seller as authorized

replacement parts shall void all warranties and guarantees. Getting to Know the Mixer

Figure 1: Mixer assembly (drive end) Water meter (water spray

equipped models only)

Grating

Discharge end guarding

Pneumatic lines

Agitator seal lever

Lift mixer under frame only

Motor

Grating support lever

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Grating pivot

Discharge door cylinder

Discharge doors behind guarding

Figure 2: Mixer assembly (shown discharging into Cozzini screw loader)

Mixer Operation and Mechanical Overview The Cozzini mixer/blender is filled with meat, spices and other additives and blends them into a homogenized mixture in the processing tank for a predetermined amount of time. A pair of agitators stir the product inside the tank. A motor and gearbox drives each agitator by means of a belt and pulley mechanical system. Seals on both ends of the agitator shafts prevent product from leaking out of the unit. At the discharge end of the mixer, two discharge doors open to release the blended meat product into a cart or another receptacle. A pneumatic cylinder opens and closes each door. After mixing is completed, the product can then be transferred to another machine for stuffing or emulsification. Units equipped with water spray on the grating have an added feature that allows a predetermined amount of water to be added to the mixture recipe instead of pouring it in from a dumper or other means.

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SECTION 2 – USING THE MIXER/BLENDER Installation and Operating Instructions IMPORTANT: Check for damage immediately upon receipt of the Mixer/blender. It

is important to report any damage immediately so that an appropriate claim can be filed with the freight carrier.

Installation Inspection Before Startup IMPORTANT: When unloading your Mixer/Blender, handle with care as dropping

or jarring can seriously damage the bearings and misalign drive motors and agitators. Do not draglift the machine into place. See Fig. 1 for the proper way of lifting a mixer.

Inspect these items on the mixer when it arrives (Figure 3 thru Figure 5):

Figure 3: Pneumatic lines

1. Check body for dents

2. Check all pneumatic lines for damage

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Figure 4: Drive assembly

Figure 5: Discharge door cylinders

3. Check gearbox oil level

5. Check motors for damage

4. Check gearboxes for damage

5. Inspect air cylinders

Equipment Setup Step 1. If the mixer frame has adjustable feet (Figure 6), you must level the unit on the floor. If the mixer has mounting pads (Figure 7), level the mixer with shims and apply

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grout around the plates. If there is a separate underframe, the Mixer Blender must be welded or bolted to it after it has been set in place. If possible, place the mixer on a slight slope, 1/4” to 1/2”, so that water will flow to a drain during the cleaning and sanitation process.

Figure 6: Frame with adjustable feet

Figure 7: Frame with mounting pads

IMPORTANT: If electronic load cells have been provided, do not perform any

welding on the machine once the load cells have been installed. Any stray welding currents could cause damage.

Step 2. The gear reducers have been filled with oil prior to shipment for your convenience. Ensure that the oil in the gear reducers is at the level plug (see Figure 4). For further lubrication instructions on the gearboxes, refer to p.20. Step 3. Connect the electrical power to the mixer/blender by referring to the electrical diagram provided in the electrical manual for this machine. The drawing illustrates the agitator rotation in relationship to the push button controls that are labeled accordingly on your control box. Step 4. Provide house air supply ideally at 100-125 PSI, but not less than 80 psi, to the pneumatic control box for discharge doors and grating (Figure 8).

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Main air connection

Figure 8: Connecting the air supply to mixer

Step 5. Grease agitator bearings before running machine. Dirt, water and grime may have accumulated during shipping and installation.

1. Pump food-grade grease into fitting on each of the agitator bearings to purge out the old grease (Figure 9).

2. Keep greasing until you see new, clean grease coming out of the bearing.

Grease fitting on agitator bearing

Figure 9: Agitator bearing lubrication

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Step 6. For units equipped with water spray only: Check the swivel on the tank grating to make sure that the proximity switch clears the tab when the grating is lowered over the tank (Figure 10). The sensor can be damaged if the grating collides with it while coming down.

Grating prox switch tab

Prox switches must clear tab on grating

Figure 10: Proximity switches on water spray equipped grating

Connect the mixer to a supply of clean water (Figure 11).

Connect to water supply

Figure 11: Water supply connection and meter

Step 7. For a hydraulically driven mixer/blender only: The machine comes with its own hydraulic power unit; the following instructions apply:

• The hydraulic reservoir should be filled to a level slightly above the high mark on the oil level sight gauge, located on the side of the reservoir). The extra oil

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provides the volume of fluid required to fill the lines to the hydraulic motors. Use the oil as recommended on the enclosed hydraulic power unit instructions.

• Rotate the electric motor/hydraulic pump by hand. On units with inaccessible

motor/pump couplings, remove the motor fan grating and the rotate the fan. If it does not turn freely, check the alignment of the pump and motor. Align to within .003 inches (.08mm) total indicator reading.

• Make sure the motor rotation corresponds to the arrow-mark on the motor or pump housing by jogging the electric motor control.

• Where solenoid directional valves are used, the solenoids should be connected to

an appropriate control source.

• If a heat exchanger is provided, connect it to a source of cool, clean water. Refer to the separate hydraulics maintenance manual included with the equipment manual. It has its own startup and troubleshooting instructions. Start-Up Test Once the machine is set up and connected to power, run a start-up test to see if the unit is running correctly.

1. Lower the grating over the tank. 2. Turn on the mixer and run the agitators for 1-2 minutes. In mix mode the agitators

should be turning toward each other, as shown in Figure 12 on the left. 3. Listen for any unusual sounds or noises such as grinding or scraping. IMPORTANT: After depressing the STOP button, but prior to changing the rotation

of the agitators, there is a dwell period. This is the time the agitator paddles need to come to a complete stop. Be sure to allow the agitators to stop before reversing rotation. 4. Run the agitators briefly in reverse mode. The agitators should be turning away

from each other as on the right side in Figure 12.

Figure 12: Correct agitator rotation in mixer

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5. After running the agitators, check the side walls of the tank to see if any rubbing took place between the agitators and the tank wall. It will appear as a bright scrape mark inside of the tank (Figure 13). Refer to Section 5- Troubleshooting in this manual for further diagnostics if this occurs.

Agitator rubbing on side wall

Check bottom of tank for scrapes

Figure 13: Agitator rubbing tank wall during startup

IMPORTANT: The agitators should run smoothly and in the proper directions in all operating modes (refer to electrical manual). Check that the electric motors do not draw current in excess of their no-load rating and that the agitator bearings and shaft seals do not overheat. 6. Water spray-equipped models only: Calibrate the water meter. To do this,

follow the specific instructions provided in the manual for your particular model of meter.

7. If the start-up test ran successfully, the mixer should be in good working order. If there were any problems, refer to Section 3 - Maintenance and Section 5 - Troubleshooting in this manual for further diagnostics.

Filling the Mixer/Blender The mixer/blender unit can be loaded from a dumper or conveyor, directly into the processing tank. The mixer should be filled to a level slightly above the agitator. The working capacity of the mixer is based on the tub volume, filled slightly above the top of the agitator, and the product density of 55 lbs. per cubic foot (881.1 kg/m3).

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CAUTION: The Cozzini mixer/blender should not be filled or operated at a capacity higher than its rated load.

Operating Guidelines

• For blending batches of 2/3 or less than the rated capacity of the mixer, operate the agitators in “REVERSE” mode.

• Make sure that the grating is in place before attempting to operate the mixer/blender.

For a hydraulically driven Mixer Blender, the following instructions apply: • Do not start the electric motors unless the reservoir is filled with hydraulic fluid. • On initial start-up, the hydraulic pump must be primed by jogging the electric

motor. The noise level of the power unit should decrease after a few jogs as the proper priming is achieved. If the pump fails to prime after a few jogs, refer to your hydraulics manual for troubleshooting.

Note: It is necessary to operate the mixer/blender unloaded at least one hour to sufficiently lubricate the hydraulic motors.

Unloading the Mixer To unload the mixer, place a vat under the discharge end, below the doors. Open the discharge doors to allow the product to flow out. Running agitators while discharging will accelerate the unloading process. The product in the mixer/blender may be unloaded in various modes, as described in the electrical controls manual.

Keep hands away from the discharge openings and the agitators at all times. There is a short delay between the time that the STOP button is pushed and the time that the agitators actually come to a complete stop.

SECTION 3 – MAINTENANCE

Maintenance Procedures The following section covers routine maintenance and repair procedures that may be required to perform when setting up, adjusting or troubleshooting the machine. The other sections of this manual refer to this section for thorough explanations of each component assembly. The mixer/blender does not require any special tools for servicing. Standard American open-end wrenches and Allen keys are recommended for maintenance personnel.

Before doing any maintenance work on any components, always follow in-plant lockout/tagout procedures.

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Shaft Seal Assembly and Disassembly For routine cleaning, the shaft seals should be pulled away from the tank to wash down. When it is necessary to take apart a seal block and check or replace the gaskets, follow the directions and illustrations below.

Figure 14: Shaft seal lever (locked) Figure 15: Shaft seal lever (open)

Figure 16: Watertight seal block assembly

ITEM DESCRIPTION

1 SEAL HOUSING (FRONT AND REAR MAY DIFFER)

2 SEAL BOLT

3 GASKET (CUT TO SIZE)

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4 LIP SEAL (CUT TO SIZE)

5 SEAL HOUSING CLAMP

Clamp

Seal block (split in two halves)

Seal block retaining bolt

Figure 17: Seal block assembly (discharge end)

Tools required: flat-blade screwdriver, 9/16 wrenches

1. Lock out power to the mixer/blender. 2. Pull the seal lever handle and move the seal assembly away from the tank (Figure

14 thru Figure 17). 3. Open the seal block by using the flat-bladed screwdriver to release the clamp

(Figure 18 & Figure 19). 4. With a 9/16 wrench, loosen the seal-retaining bolt on each side to separate seal

housing halves.

Slot for retaining bolt

Clamp

Seal block (two halves)

Gasket

Figure 18: Assembled seal block

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Split lip seal

Gasket

Clamp

Figure 19: Disassembled seal block

5. Remove the gasket and internal lip seal. 6. Replace gasket and internal split lip seal as the seals become worn or damaged (at

least every 3 months). 7. Re-assemble the split lip seal and gasket. The open side of the split lip should face

toward the tank for a watertight seal. 8. The front gasket pressed in the seal housing should face the tank. Assemble the

other half of the seal housing and tighten clamp around entire seal block assembly.

Replacing the Seal Gasket The seal gasket presses against the wall of the tank when the seal is locked in place. The gasket material is available by the foot. When the gasket needs to be replaced, follow these directions:

Tools required: tape measure, utility knife, Loctite clear Prism adhesive or “Crazy Glue”

1. Remove the old gasket from the seal assembly. Cut the gasket if it is not broken and lay it out in a straight line.

2. Take the new gasket material and line it up beside the old gasket for comparison. 3. Cut the ends of the gasket strip at approximately 45°. The old and new gaskets

should be the same length. 4. Test-fit the new gasket in the seal block before gluing the ends. 5. If the fit is good, take the two ends and join them with a clear, permanent

adhesive. Agitators The agitators stir the product inside the tank. The shafts are driven by a motor and gearbox by means of a belt and pulley system. Bearings at each end of the tank support

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the agitators. The following section addresses common maintenance procedures for the agitators. Agitator Bearing Lubrication The spherical roller bearings have been lubricated prior to shipment. Regrease every week with Texaco Cygnus Grease #2 or an equivalent.

Tools required: grease gun 1. Pump food-grade grease into fitting on each of the agitator bearings to purge out

the old grease (Figure 20). 2. Keep greasing until you see new, clean grease coming out of the bearing.

Grease fitting on agitator bearing

Figure 20: Agitator bearing lubrication

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Agitator Alignment

Jam nut

Lateral adjustment screw

Mounting bolt

Shim plate

Figure 21: Agitator bearing on discharge end

Each agitator bearing is mounted on a bracket with shims underneath to attain correct vertical alignment. There is also a lateral adjustment bolt with a jam nut to allow horizontal alignment (Figure 21). To align the agitator shafts, the bearing position needs to be adjusted.

Tools required: open-end wrenches 1. Loosen (but not remove) mounting bolts holding the pillow block assembly. 2. Turn the head of the lateral adjustment screw located beside the bearing. As it

turns, the screw pushes the pillow block bearing assembly. 3. Once the desired position of the bearing is attained, tighten the jam nut on the

adjustment screw to lock in the position. 4. Re-tighten the bolts holding the pillow block bearing. 5. Repeat this procedure on the opposite end.

Drive Components

Before doing any maintenance work on drive components, always follow in-plant lockout/tagout procedures.

Gear Reducer Maintenance (Applies to all mixer blenders, except those with direct drive hydraulic motors) Gear reducers have been filled with oil prior to shipment. The oil level should be checked regularly and changed every six months or more frequently depending on the duty cycle of your machine. Check oil by unscrewing the level plug with an Allen key. There should be oil on the screw (Figure 22) when it is pulled out. The oil should fill about one-half of the gearbox

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inside. Add oil by filling it through the breather located on top of the gearbox. For lubrication specifications refer to the gearbox manufacturer’s manual included with this manual.

Breather/filler

Oil level plug

Figure 22: Gear reducer detail

Electric Motor Maintenance The motor has shielded ball bearings packed by the manufacturer. No periodic greasing is needed. If a motor is taken apart, the bearing housing, as well as the chamber in the end bell behind the bearing, should be repacked with Texaco Cygnus Grease #2 or an equivalent (Figure 23). Refer to the motor manufacturer’s manual on motor assembly details and any special lubrication requirements. IMPORTANT: On some motors the bearings are lubricated with polyurea based

grease that is not compatible with lithium-based greases. Mixing polyurea and lithium greases may cause a loss of lubricant and lead to bearing or motor failure. Refer to the motor manufacturer manual provided regarding compatible lubricants.

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Grease fitting

Figure 23: Motor detail

Pulley Alignment The upper and lower pulleys should be located at the same point on their respective shafts (Figure 24). This allows the belts to track evenly on the same plane. When pulleys are not aligned properly, you may notice an odor of burning rubber around the drive components. To check pulley alignment, follow these directions.

Tools required: open-end wrenches, level or straightedge, rubber mallet 1. Lock out / tag out before starting any work on the machine. 2. Apply level or straightedge to front face of each pulley to determine if both are

level on the same plane. 3. If there is misalignment, loosen the bushing on a pulley to allow it to move on the

shaft. 4. Slide pulley forward or backward until a level state is achieved. 5. Tighten pulley bushing.

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Upper (driven) pulley

Lower (drive) pulley

Figure 24: Pulley assembly

Belt Tensioning The belt is correctly tensioned when it gives only about ½” when pushed between the two pulleys. An improperly tensioned belt can cause slippage and wear prematurely. Pair of plates, separated by standoffs, are located above the motor.

Tools: straightedge, (2) open-end wrenches 1. Disconnect power, lock out / tag out mixer 2. Loosen 4 jam nuts on one side of the plate in order to increase or decrease the

spacing between the plates (Figure 25 & Figure 26). 3. Once the desired belt tension adjustment is achieved, tighten the nuts to prevent

the plate from moving.

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Belt tensioning plates

Drive belts

Figure 25: Motor with pulley and tensioning plates

Belt tensioning standoffs

Spacing equal on all standoff bolts when properly tensioned

Jam nuts

Figure 26: Pulley tensioning standoff detail

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Belt Replacement When the top of a belt is below the surface of the outer diameter of the pulley, it is worn and need to be replaced. The belts on the mixer should always be replaced as a full set.

Tools required: open-end wrenches, straightedge 1. Disconnect power, lock out / tag out mixer. 2. Remove cover to gain access to drive belts. 3. Loosen tension on belts by raising four bolts on drive motor (Figure 26). 4. Once the belts have enough slack, remove them from the pulley. 5. Replace with new belts. 6. Re-tension the belts by lowering the motor bolts and tightening jam nuts. 7. Check that the motor shaft is parallel to the gearbox shaft above. All 4 bolts on

the motor tensioning plate should have the same amount of length exposed for the shaft to be correctly oriented (Figure 26).

Agitator Bearing Replacement To replace the agitator bearings on the drive end requires extensive disassembly (Figure 27). On the discharge end the bearings are more readily accessible. When changing agitator bearings, always change both sides of the unit.

117

5

1

2

4

6

3

9

8

10

Figure 27: Typical drive end assembly (Agitator bearing is item 8)

ITEM DESCRIPTION

1 ELECTRIC MOTOR

2 MOTOR BASE

3 MOTOR BASE ADAPTER

4 GEAR REDUCER

5 SHEAVE -- MOTOR

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6 SHEAVE – GEAR REDUCER

7 V-BELTS

8 PILLOW BLOCK AGITATOR BEARING

9 REAR SHAFT SEAL

10 LATCH, ¼-TURN LOCK

11 AGITATOR SHAFT ASSEMBLY

To replace the agitator bearing on the drive end, follow these directions:

Tools required: Allen keys, open-end wrenches, rubber mallet, anti-seize paste 1. Disconnect power and lock out/tag out mixer. 2. On the drive end, remove the following parts in order:

Drive belts Pulley Gear reducer Drive guard enclosure Agitator pillow block bearing

3. Once the agitator bearings are accessible, loosen setscrews holding the collars on both sides of the bearing (Figure 28).

Pillow block bearing bolts

Setscrew collar on both sides of bearing

Figure 28: Drive end agitator bearing

4. Unscrew the pillow block bolts. 5. Remove spherical bearing inside of pillow block. In most cases, the housing can

be re-used unless it is damaged. If the entire housing gets replaced, be sure to keep the shims for each bearing since they will need to be realigned.

6. Apply anti-seize paste to agitator shaft. 7. Replace the bearing insert or entire pillow block if needed.

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8. Reassemble bearings inside pillow blocks. Restore the shim plates, tighten the bearing bolts and setscrew collars.

9. Realign agitator bearings if necessary. (See p.20). 10. Reassemble drive components:

Drive guard enclosure Gear reducer Pulley Drive belts

To replace the discharge side agitator bearings, follow these directions and refer to Figure 29 & Figure 30.

Tools required: Allen keys, open-end wrenches, rubber mallet, anti-seize paste 1. Disconnect power and lock out/tag out mixer. 2. Remove discharge door pneumatic cylinder in front of bearing. 3. Once the agitator bearings are accessible, loosen setscrews holding the collars on

both sides of the bearing (Figure 29).

Shim plate

Remove cylinder when changing bearing

Stub shaft

Mounting bolts

Figure 29: Replacing the discharge side agitator bearing

4. Remove spherical bearing inside of pillow block. In most cases, the housing can be re-used unless it is damaged.

5. Save any shim plates under the pillow block since those will need to be restored later.

6. Apply anti-seize paste to the stub shaft. 7. Replace the bearing insert or entire pillow block if needed. 8. Reassemble bearings inside pillow blocks. Restore the shim plates, tighten the

bearing bolts and setscrew collars. 9. Realign agitator bearings if necessary. (See p.20). 10. Restore the pneumatic cylinder and reconnect air lines.

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Mounting bolt

Seal block assembly

Figure 30: Discharge end agitator bearing and stub shaft

Stub Shaft Replacement The stub shaft, also known as the “pilot shaft,” is located on the discharge end of the mixer (item 4 in Figure 31). It is held by the pillow block bearing on one side and slips into the keyed end of the agitator shaft (Item 6) on the other.

Figure 31: Typical discharge end assembly

ITEM DESCRIPTION

1 PILLOW BLOCK BEARING

2 DISCHARGE DOOR AIR CYLINDER

3 FLASHING LIGHT

Stub or “pilot” shaft

Bearing insert

Setscrew collar

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4 AGITATOR PILOT SHAFT

5 FRONT SHAFT SEAL

6 AGITATOR ASSEMBLY

7 DOOR GASKET

To replace the agitator stub shaft:

Tools required: Allen keys, open-end wrenches, rubber mallet, anti-seize paste, hoist or support for agitator shaft end

1. Disconnect power and lock out/tag out mixer. 2. Remove discharge door cylinder in front of the pillow block bearing. 3. Use an overhead hoist or some other means of support to keep the agitator shaft

from falling or tilting when the stub shaft will be removed. This can bend or damage the agitator shaft.

4. Once the agitator bearing is accessible, loosen setscrews holding the collars on both sides of the bearing (Figure 30).

5. Remove bearing mounting bolts and slide bearing off of shaft. 6. Remove seal block assembly (see p.16 for disassembly and assembly

instructions). 7. Pull off the stub shaft. 8. Apply anti-seize paste to the new stub shaft end going into the agitator shaft and

apply some around the area of the bearing. 9. Replace seal block. 10. Replace pillow block bearing, along with shim plate(s) and setscrew collars. 11. Restore discharge door cylinder. 12. Run a short test with the agitator turning. Align the bearing if necessary (see

p.20). Pneumatic System Maintenance Filter-Regulator-Lubricator (F-R-L) Maintenance To maintain the reliability of the cylinders and valves, it is important to keep the air system clean. There are drain cock at the bottom of the air filter and lubricator bowls (Figure 32 & Figure 33). Open these every week to allow sediment to drain.

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Oil regulator set to 1-2 drops/minute

Push down to lock out (shown locked)

Main air connection

Figure 32: Filter/regulator/lubricator assembly

Oil bowl

Drain cock

Figure 33: Close-up of F-R-L drain cock and oiler bowl

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Oil regulator

Air locked out

Fill bowl with oil weekly

Oiler tube

Water trap

Figure 34: Disassembled filter/regulator/lubricator

The filter/lubricator should be disassembled and cleaned as needed (Figure 34).

Tools required: none 1. Before disassembly, lock out the plant air supply by pushing down on yellow tab

(Figure 34). 2. Disassemble the filter/lubricator by unscrewing water trap and oil bowl. 3. Clean all the parts with methanol and blow them out with compressed air. Clean

the plastic bowls and sight glass with a household soap only. 4. Replace the lubricator filter with a clean one. 5. Reassemble and fill the lubricator with Mobil DTE Light Lubricating Oil.

The lubricant used in the lubricator should meet these requirements: • Viscosity of 100-150 SUS at 100° F • High viscosity index: over 90. • Compatible with Buna-N rubber • Anti-foaming • Oxidation stability (over 2000 on ASTM D943 test) • Aniline range 180-210

Pneumatic Cylinders The pneumatic cylinders operating the discharge doors require no regular maintenance. Rebuild seal kits are available if seals are worn and need to be replaced. Refer to the pneumatic parts lists included with this manual for seal kits applicable to your particular cylinder size. Adjusting Air Cylinder Flow Rate If one discharge door opens or closes faster than the other, it is necessary to adjust the airflow to equalize the pneumatic cylinders (Figure 35).

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Flow/check valve

Clevis adjustment

Flow/check valve

Figure 35: Discharge door cylinders

Tools required: screwdriver (flat blade), open-end wrench 1. Lock out air supply to unit. 2. Check the flow control/check valves on each of the cylinders to see if they are set

to the same approximate rate. Turn the slotted screw adjustments on each if necessary (Figure 36). This ensures the amount of air going to each cylinder is the same.

Slotted adjustment screw controls air flow

Figure 36: Air cylinder flow control/check valve and adjustment screw

3. Another adjustment is on the piston rod at the clevis (Figure 35). Adjust the flat

on the rod with an open-end wrench to control the amount of exposed piston rod

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threads. Both cylinders should have the same number of exposed threads on the piston rod by the clevis.

4. When properly adjusted, the discharge doors should open and close smoothly at the same rate on both sides of the machine.

Cylinder Assembly and Disassembly

STD. O-RING(MOVING &STATIC SEALS)

WRENCH FLATS

STAINLESS STEELPISTON ROD

MOUNTING PILOTCONCENTRIC w.

PISTON ROD

HARD DRAWN SEAMLESSBRASS TUBINGHIGHLY FINISHED I.D.

POSITIVE LOCKINGSPECIAL LOCK NUT

HIGH TENSILE ALUM. ALLOYMACHINED BAR STOCK

SELF LUBRICATINGBRONZE BEARING

Figure 37: Typical air cylinder cross-section

An air cylinder needs to be disassembled in order to change the seals inside. Refer to Figure 37 for a typical air cylinder assembly.

Tools required: Open-end wrenches 1. Lock out air supply to unit. 2. Remove cylinder from clevis on the cover and bottom. 3. Unscrew the cap on the rod end of the cylinder by turning the flats on it. This will

allow you to pull out the piston and access the internal o-ring seals. 4. Unscrew the bottom end of the cylinder with a wrench. This will provide access

to the o-ring on the bottom. Discharge Door Maintenance The discharge doors are located on the side of the machine opposite the drive components. The doors provide an exit for mixed product and allow the tub to drain during cleaning. An air cylinder operates each door. Guarding around the moving parts is there to prevent injury but allow clean-through at the same time (Figure 38).

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Seal lever

Discharge door actuating cylinders (2)

Discharge door guarding

Figure 38: Discharge end of mixer

Figure 39: Discharge door on mixer

Mechanical Interlock The discharge doors have a mechanical interlock on each side to prevent the door from opening in case of a loss of air pressure to the cylinders. The mechanical interlock

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consists of a turnbuckle and pivot acting against the discharge door (Figure 39 & Figure 40)

Air cylinder rod

Figure 40: Mechanical interlock on discharge door (closed)

Clevis

Rod end adjustment

Pivot plate

Jam nuts (2)

Turnbuckle perpendicular to door

When the door is closed, the turnbuckle should be perpendicular to the door. When properly set, you should hear a loud “pop” when the cylinder locks the door and puts the mechanical interlock in position. If the pneumatic cylinder should fail, the force of the product pushing out against the discharge door will be met with equal force from the turnbuckle. This will hold back the product inside the tank and the pivot plate will not move. The discharge door opens when the air cylinder retracts upward and causes the pivot to rise (Figure 41). The interlock will not hold back the door in this position.

Pivot higher

Figure 41: Mechanical interlock on discharge door (open)

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Adjusting the Mechanical Interlock If the interlock is not keeping the door shut or if it is not perpendicular when the door is shut, you need to adjust the jam nuts on the turnbuckle. Refer to Figure 40 on the preceding page.

Tools required: open-end wrenches (2) 1. Make sure the door is in the closed position. 2. Lock out electrical and air supply to the mixer. 3. Remove the bolt holding the air cylinder clevis to the pivoting plate. 4. Using the wrenches, adjust both sides of the turnbuckle equally to increase or

decrease the distance between the pivot and the linkage point on the other end of the turnbuckle.

5. Re-attach the cylinder clevis to the pivot plate. 6. At this point, it may also be necessary to adjust the nut on the rod end of the

pneumatic cylinder. 7. Restore power to the unit and test the air cylinder operation on the discharge

doors. If you hear the “pop” and see the turnbuckle is perpendicular to the door, then the mechanical interlock is set correctly.

If it is necessary to adjust the airflow rate on the pneumatic cylinders, see p.31. Discharge Door Gasket Replacement The gasket around the discharge doors (Cozzini #12-004-0002) provides a tight seal to keep product from leaking out of the tank. The gasket around the doors (Figure 42) needs to be replaced when it begins to leak or when damage is visible. Check the condition of the gasket on a weekly basis. If the door gasket needs to be replaced, follow these directions. Do not try to change the gasket with the door attached to the mixer.

Remove bolt

Remove bolt

Door gasket #12-004-0002

Figure 42: Discharge door gasket

Tools required: open-end wrenches, measuring tape, utility knife, Loctite clear Prism adhesive or “Crazy Glue,” clear silicone sealant

1. Put the discharge doors in the open position.

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2. Lock out power and air to the mixer. 3. Detach the discharge door by removing the 2 bolts as shown in Figure 42. Take

the discharge door to a separate workstation. 4. Cut away the silicone holding the gasket and remove the old gasket from the door. 5. Scrape out any remaining silicone on the door. 6. Cut the gasket if it is not broken and lay it out in a straight line. 7. Take the new gasket material and line it up beside the old gasket for comparison. 8. Cut the ends of the gasket strip at approximately 45°. Measure to confirm the old

and new gaskets are the same length. 9. Test-fit the new gasket in the door groove before gluing the ends. Do not

overstretch gasket strip. 10. If the fit is good, take the two ends and join them flush with a clear, permanent

adhesive. 11. Apply a bead of silicone in the door gasket groove and install the new gasket. 12. When the silicone is dry, re-install the door to the mixer. 13. Check that the interlock is set correctly (see p.34).

Lubrication Instructions

Operation In The Presence Of Dust, Water Or Corrosive Vapors Under these conditions, the bearings should contain as much grease as speed will permit. A bearing full of grease with consequent slight leakage best protects against entry of foreign material. If excess grease in the bearing causes overheating, remove grease fittings to permit excess grease to escape. The bearings have been greased at the factory and are ready to run. Operating Temperature Abnormal bearing temperatures may indicate faulty lubrication. Normal temperature may range from “cool to warm to touch” up to a point “too hot to touch for more than a few seconds,” depending on bearing size, speed and surrounding conditions. • Normal temperature and a slight showing of grease at the seal surface indicate proper

lubrication. • Unusually high temperature accompanied by excessive grease leakage indicates too

much grease. • High temperature with no grease showing at the seal surface, particularly if the

bearing seems noisy, indicates too little grease. Type of Grease Texaco Cygnus #2 grease is suitable for normal operating conditions. Relubricate with Texaco #2 grease or grease which is compatible with original lubricant and suitable for roller bearing service.

REV. E: 8/2/04

37

Lubrication Schedule

Point of Lubrication Lubricant Interval Electric Motor Bearing Texaco Cygnus Grease #2*

(USDA H1) Overhaul

Gear Reducer See manufacturer’s manual Agitator Bearings Texaco Cygnus Grease #2

(USDA H1) 1 Week

Pneumatic Lubricator Mobil DTE Light Lubricating Oil

1 Week

*IMPORTANT: On some motors the bearings are lubricated with polyurea based

grease, which is not compatible with lithium-based greases. Mixing polyurea and lithium greases may cause a loss of lubricant and lead to bearing or motor failure. Refer to the motor manufacturer manual provided regarding compatible lubricants.

Hydraulic systems only: When changing oil in the hydraulic pump system, use oil based on the room temperature. Mixers operating in an ambient temperature of under 50° F (10° C) should use Texaco Cygnus Oil #46. Mixers operating in environments over 50° F should use Texaco Cygnus Oil #68. Hydraulic System Maintenance (Applicable to hydraulic driven Mixer Blenders) It is very important that the hydraulic fluid be maintained in proper condition, that is, free of chemical and particle contamination. The drain plug in the bottom of the reservoir should be opened periodically to drain off any moisture condensation, sludge or emulsion that might collect there. During operation, the system temperature should be kept below 140° F (60° C.), since any overheating will break down the hydraulic oil and form sludge. Setting up and adhering to a regular schedule for changing the filter elements and cleaning the suction strainer is mandatory. Specific maintenance procedures depend on the particular type of hydraulic system supplied with your mixer/blender. IMPORTANT: If operating conditions are more than an 8-hour day, or more severe than normal, then maintenance intervals should be adjusted accordingly. Mixers operating in an ambient temperature of under 50° F (10° C) should use Texaco Cygnus Oil #46. Mixers operating in environments over 50° F should use Texaco Cygnus Oil #68. Refer to the hydraulic system manual that is included with your hydraulically equipped mixer unit. It contains information on specific components and maintenance requirements.

REV. E: 8/2/04

38

Preventative Maintenance The Preventative Maintenance section provides references to corresponding topics in Section 3- Maintenance for detailed instructions on each operation. Cozzini strongly recommends following these procedures. Keep a chart for operators

and maintenance personnel. This chart should list all maintenance steps and their intervals and should require a signature next to each task upon completion. This ensures that all Preventative Maintenance procedures have been completed at their required intervals.

Required Daily Maintenance Check to see that all safety guards are in place and operational: tank grating,

discharge door guarding, and flashing lights. Check interior of electric control boxes and safety limit switches for condensation. Check the agitator shaft seals for any sign of wear, damage or missing gaskets (p.16). Required Weekly Maintenance Clean filter/regulator/lubricator and refill oil bowl (p.29) Check the agitator pillow block bearings and lubricate with Texaco Cygnus Grease

#2 as needed. (p.19) Check drive belts for wear and check pulley alignment. (p.22) Inspect the condition of the discharge door gasketing. (p.36) Check the oil level in gearbox. Add oil, drain/refill if necessary. Refer to the gearbox

manual included for oil specifications. Hydraulic units only: Check hydraulic return filter, replace as needed. Hydraulic units only: Check hydraulic reservoir for oil contamination. Replace oil

and filter as needed. Required 3-Month (90-Day) Maintenance Check pneumatic door cylinders and mechanical interlocks for proper alignment;

adjust if necessary. (p.34) Check discharge doors for closing tightness and the condition of door gasket. (p.36) Replace seals and gaskets. (p.16) Hydraulic units only: Inspect all hydraulic hoses and fittings. Required 6-Month Maintenance Change the oil in the gearbox every six months or more frequently depending on the

duty cycle of your machine. This does not apply to direct-drive hydraulic motors.

REV. E: 8/2/04

39

SECTION 4 - SANITATION AND CLEANING Clean the mixer/blender as soon as possible after every use. If the product contains curing or pickling compounds, it can corrode the equipment if it is not properly and thoroughly cleaned.

Before beginning any cleaning or sanitation procedures, the motor should be in the “off” position. Always follow in-plant lockout/tagout procedures.

On the mixer, clean the following parts daily: • Mixing tank • Agitator paddles • Seal assemblies • Discharge doors • Grating

The grating over the mixer tank should be raised to the fully open position with the safety tangs making direct contact with the back cross-member. IMPORTANT: Never spray any water directly on control panels. Hand wash only.

Cleaning the Shaft Seals For daily routine cleaning, the shaft seals do not need to be disassembled. To clean the agitator shaft seals:

1. Close the discharge doors and the safety grating. Start the unit with both agitators turning in any mode.

2. Pull down on the seal lever to pull the seal away from the mixer tank (Figure 43 & Figure 44). This will allow you to have full access to clean the shaft seal area with a high-pressure water hose.

3. To close the shaft seal after thoroughly cleaning it, move the seal lever back to the original position to close.

REV. E: 8/2/04

40

Figure 43: Seal lever closed Figure 44: Seal lever open

If the seals appear damaged, replace as needed. See Section 3 - Maintenance, p.16 for a detailed explanation of seal assembly and disassembly.

NOTE: Use caution whenever assembling or disassembling any seal surfaces. A

leak due to damaged seals or seal surfaces may cause loss of product. Cleaning of the Agitator and Paddles To clean the agitators, close the safety grating and the run the agitators in any mode. Use a high-pressure hose to spray off the agitator paddles. Once the agitator shafts and paddles have been thoroughly cleaned, open the discharge doors to drain water and product out of the mixer tank.

WARNING: Do not extend your arm or hand through the safety grating in an attempt to remove any excess product from the agitator or its paddles at any time during this cleaning procedure. Do not insert any part of the body in the discharge door. This is extremely dangerous and can result in serious injury.

Cleaning The Doors To clean the discharge doors, put the doors in the “open” position. Using a high-pressure hose, thoroughly clean the doors, inside and out. You can spray the hose upward from under the safety guarding, or spray the hose from above, down at the discharge doors.

WARNING: Do not run the agitators at any time during this cleaning procedure. Never insert any part of your body in the discharge door. This is extremely dangerous and can result in serious injury.

REV. E: 8/2/04

41

SECTION 5 – TROUBLESHOOTING Troubleshooting Diagnostics These are common problems encountered while operating the mixer/blender and suggestions for resolving them. The possible causes are listed in the order of probability of occurrence. To perform the maintenance operations required, refer to the corresponding topic addressed in Section 3 - Maintenance. PROBLEM: THE AGITATOR RUBS ON THE MIXER/BLENDER BODY POSSIBLE CAUSES: A Misaligned agitators – align bearings (p.20) B Excessively worn bearings – replace bearings (p.25) C Loose screws on pillow block bearings. Tighten as needed. D Bent agitator shaft E Worn stub shaft on the discharge end – replace (p.28) PROBLEM: PRODUCT IS COMING OUT OF THE SEAL(S) POSSIBLE CAUSES: A Seals are installed incorrectly (see p.16 for all seal assembly details) B Within the seal housing is a lip seal and a gasket. Both need to be installed C The seal clamp is not properly tightened D Seals are worn and need to be replaced PROBLEM: ODOR OF BURNING RUBBER NEAR DRIVE UNIT POSSIBLE CAUSES: A Loose belts not tensioned correctly (p.23) B Worn or damaged belts: replace promptly (p.25) C Misaligned pulleys causing belts to rub together. Check pulley alignment.

(p.22) PROBLEM: PRODUCT LEAKING AT DISCHARGE DOORS POSSIBLE CAUSES: A Gasket around door is damaged or incorrectly installed. (p.36) B Mechanical interlock needs to be adjusted (p.34) PROBLEM: DEAD SPOTS OR UNMIXED REGIONS IN PRODUCT POSSIBLE CAUSE: A Mixer capacity underfilled/overfilled. When the product level is too high,

the equipment is unsafe to operate. Tub volume should be filled to a level slightly above the top of the agitators.

Water Spray-Equipped Units Only PROBLEM: REDUCED WATER OUTPUT POSSIBLE CAUSES: A Valve coil stuck in closed position prevents metering of water

REV. E: 8/2/04

42

B Obstruction or blockage in water piping PROBLEM: NO WATER COMING OUT OF SPRAYERS ON GRATING POSSIBLE CAUSES: A Water valve shut off down the line B Valve coil stuck in the closed position. Replace coil if necessary. Hydraulic-Equipped Units Only Refer to the separate hydraulic system manual that is included with a hydraulically equipped mixer unit. It contains information on the components and specific maintenance requirements. PROBLEM: HIGH OIL TEMPERATURE POSSIBLE CAUSES: A Relief valve setting is too low B Malfunction of the pump C Inadequate water supply through the heat exchanger D Excessively worn pump PROBLEM: THE HYDRAULIC SYSTEM IS MAKING EXCESSIVE NOISE POSSIBLE CAUSES: A The pump may be cavitating B The fluid may be too cold to flow C The suction strainer may be clogged D Check the suction hose. It may have collapsed E The tank breather may be clogged F Vapor may be forming G The reservoir level may be too low H The wrong type or amount of hydraulic fluid may have been used. I The couplings may be misaligned J The couplings may be loose K The pump may be worn or damaged PROBLEM: INADEQUATE HYDRAULIC PRESSURE POSSIBLE CAUSES: A Pump not primed B Damaged or worn pump C Malfunctioning relief valve D Malfunctioning directional control valve

REV. E: 8/2/04

43

PROBLEM: LOW OR NO PRODUCT FLOW POSSIBLE CAUSES: A Pump cavitation B Fluid aeration C Worn or damaged pump D Malfunctioning pressure compensator E Improper pump rotation SECTION 6 – SPARE PARTS The following is a list of spare parts to keep on hand as well as recommended quantities. The part numbers for the components may vary from model to model. Refer to the drawings and part lists included in the manual for specific part numbers for your unit.

REV. E: 8/2/04

44

8000 LB MIXER/BLENDER RECOMMENDED SPARE PARTS

CUSTOMER: CECINAS SAN JORGEMODEL: CMB-8000SERIAL #: P5126-09-I-1036A

PART # DESCRIPTION QTY ON HAND03-007-0037 Master link, drive chain 203-011-0004 Guard latch 403-011-0005 Guard latch key 203-001-0084B Pillow block bearing (discharge end) 203-001-0091B Pillow block bearing (drive end) 205-001-0015 Air cylinder, 2 x 7 105-001-0126 Air cylinder seal kit, 2” 205-002-0206 Solenoid valve, 2-station 24 V 205-002-0022 Solenoid valve 24 V 205-002-0009 Electrical coil, 24 V 112-002-0005 Lip seal (rear drive end) 812-002-0001 Lip seal (front discharge end) 812-004-0002 Gasket (cut to fit) 20 ft

INDEX adjustable feet, 9 agitator bearing, 20, 26, 27, 28, 29 agitator bearings, 11, 14, 19, 25, 26, 27 agitator rotation, 10, 13 Agitator rubbing, 14 agitators, 15 air cylinder, 33 air filter, 29 air supply, 10, 11, 31, 32, 33, 36 bearing temperatures, 37 bearings, 42 belt tension, 23 belts, 42 capacity, 14, 15 cylinders, 32, 33 DEAD SPOTS, 42 discharge door, 15, 27, 29, 31, 33, 35,

37, 39, 41 Discharge door gasket, 36 discharge doors, 5, 7, 10, 31, 33, 34, 36,

39, 40, 41 door gasket, 36, 37, 39 drain cock, 29 dwell period, 13 filter, 31 filter/lubricator, 31 flow control/check valves, 32 gasket, 18, 42 gear reducer, 10 gearbox, 7, 10, 18, 20, 25, 39 grease, 11, 19, 21, 37, 38 hydraulic power unit, 12 hydraulic system, 38, 43 hydraulics maintenance, 13 Inspection, 8 interlock, 36

load cells, 10 lockout/tagout, 15, 20, 40 lubricator, 29, 31 Mixer capacity, 42 motor, 40 mounting pads, 9 oil level, 12, 20, 39 pillow block bearing, 20, 26, 28, 29 pillow block bearings, 42 pilot shaft, 28 piston rod, 32 Pneumatic Cylinders, 31 Preventative Maintenance, 39 proximity switch, 12 pulleys, 22, 23, 42 safety guidelines, 5 seal gasket, 18 seal kits, 31 seal lever, 16, 17, 40 seals, 39, 41 Seals, 42 shaft seals, 14, 16, 40 split lip seal, 18 start-up test, 13, 14 stub shaft, 27, 28, 29, 42 tools, 15 tub volume, 42 turnbuckle, 35 underframe, 10 UNMIXED REGIONS, 42 valves, 29 water meter, 14 water spray, 7, 12 Weekly Maintenance, 39 wrenches, 15

REV. E: 8/2/04

45

SCALE

DATE

TOLERANCE ON DIAMETER

DIMENSIONING SYSTEM:

ANSI/ASME Y14.5M

CONCENTRICITY: T.I.R EQUALS

SQUARENESS AND PARALLELISM

±.015 INCHES PER FOOT

FRACTIONS: ±1/32

UNSPECIFIED TOLERANCES:

ANGLES ±1°

NOTES:

CHECKED BY

PART NAME

ORIGINAL JOB #

DRAWN BY DRAWING NUMBER

MODEL

CHICAGO, ILLINOIS 60646 USA

D

DECIMALS: .0000 .0005

.000 .005

.00 .01

DESCRIPTIONQTYITEM PART NO.

BILL OF MATERIAL

NAMEREV DATE REVISION DESCRIPTIONECN #THE INFORMATION PROVIDED IS THE

CONFIDENTIAL PROPERTY OF COZZINI, INC. COPYING OR USE TO BENEFIT OTHERS IS

A VIOLATION OF PROPRIETARY RIGHTS

EXCEPT WHEN AUTHORIZED BY COZZINI, INC. IN WRITING. RETURN THIS PRINT TO

COZZINI, INC. AFTER IT HAS SERVED ITS INTENDED PURPOSE.

DO NOT SCALE DRAWING

INCH (MILLIMETER)DEBURR ALL SHARP EDGES

ALL FINISHED SURFACES 125 RMS

UNLESS OTHERWISE NOTED

COZZINI, INC.

SIZE MATERIALPROC.

CNC NO.

8000# MIXER/BLENDER GENERAL ASSEMBLY

MBXPN006D

P5126 CMB8000

JFG 4-25-05

1/16"=1"

1 MBXPX100D 1 DISCHARGE ASSEMBLY

2 MBXPN302D 1 DRIVE ASSEMBLY

QUALITY CONTROL

PRELIMINARY DRAWING

* COPIES NOT DATED AND SIGNED ARE INVALID *

MANUFACTURING

QUOTATION

ENGINEER

DATE

MAKE

JOB #

CUSTOMER

3 MBXPX204D 1 TUB ASSEMBLY

5 MBXPX401C 1 REAR SEAL ASSEMBLY

4 MBXPX400C 1 FRONT SEAL ASSEMBLY

8 MBXPX505D 1 SAFETY GRATE ASSEMBLY

9 MBXPN801D 1 DRIVE GUARD ASSEMBLY

7 MBXPX602D 1 FRAME/LEG ASSEMBLY

6 MBXPX700D 1 AGITATOR ASSEMBLY

11 MBXPX900C 1 AIR CONTROL SCHEMATIC

10 MBXPX820D 1 DISCHARGE GUARD

1

2

3

4 5

8

9

10

7

451

421 [0.53]

351

4 [0.90]

855

8

41 5

16

STARTER BOX

LOADCELLS

WATER INLET FAR SIDE

80

LOADCELL

TOTALIZER BOX

(FAR SIDE)

81 1

16 [2.06]

1283

8 [3.26]

14527

32 [3.70]

643

8

120 INSIDE TUB

1251

4

SAFETY GRATE

PRE-DRILLED FOR

CUSTOMER'S WATER SPRAY

(2) DRIVE MOTORS30 HP

380 V-3 PH-50 HZ

1677

8

231

4

68 INSIDE TUB

105 9

1620

130773

8

101 9

16

SCALE

DATE

TOLERANCE ON DIAMETER

DIMENSIONING SYSTEM:

ANSI/ASME Y14.5M

CONCENTRICITY: T.I.R EQUALS

SQUARENESS AND PARALLELISM

±.015 INCHES PER FOOT

FRACTIONS: ±1/32

UNSPECIFIED TOLERANCES:

ANGLES ±1°

NOTES:

CHECKED BY

PART NAME

ORIGINAL JOB #

DRAWN BY DRAWING NUMBER

MODEL

A

DECIMALS: .0000 .0005

.000 .005

.00 .01

DESCRIPTIONQTYITEM PART NO.

BILL OF MATERIAL

NAMEREV DATE REVISION DESCRIPTIONECN #THE INFORMATION PROVIDED IS THE

CONFIDENTIAL PROPERTY OF COZZINI, INC. COPYING OR USE TO BENEFIT OTHERS IS

A VIOLATION OF PROPRIETARY RIGHTS

EXCEPT WHEN AUTHORIZED BY COZZINI, INC. IN WRITING. RETURN THIS PRINT TO

COZZINI, INC. AFTER IT HAS SERVED ITS INTENDED PURPOSE.

DO NOT SCALE DRAWING

INCH (MILLIMETER)DEBURR ALL SHARP EDGES

ALL FINISHED SURFACES 125 RMS

UNLESS OTHERWISE NOTED

SIZE MATERIALPROC.

CNC NO.

COMPLETE FOOD EQUIPMENT SOLUTIONS

CHICAGO, ILLINOIS 60646 USA

MIXER/BLENDER DRIVE ASSEMBLY

MBXPN304A

CMB-8000

JFG 6/4/05

∅4.00

5

6

1

2

6A

4

3

7

5A

7A

8

PARTS LIST FORMODEL CMB-8000

P5126

ITEM PART # DESCRIPTION

1 03-002-0819 GEARMOTOR 30HP, 380V/3 PH/50 HZ

2 MBXPN312C GEARBOX MOUNTING PLATE

3 03-004-0648 DRIVE SPROCKET

4 03-004-0596 DRIVEN SPROCKET

5 03-007-0017 CHAIN

5A 03-007-0037 CHAIN CONNECTING MASTER LINK

6 03-001-0091B PILLOW BLOCK BEARING

6A MBXPX401C REAR SHAFT SEAL (SEE SEAL ASSEMBLY DWG.)

7 03-011-0004 GUARD LATCH

7A 03-011-0005 GUARD LATCH KEY

8 VMXPX700D AGITATOR ASSEMBLY (COMPLETE)

Refer to Dwg. No. MBXPN304A

SCALE

DATE

DISCHARGE END

COZZINI, INC.

BY COZZINI, INC. IN WRITING.

INC. AFTER IT HAS SERVED RETURN THIS PRINT TO COZZINI,

RIGHTS EXCEPT WHEN AUTHORIZED

OF COZZINI, INC. COPYINGOR USE TO BENEFIT OTHERS IS

IS THE CONFIDENTIAL PROPERTY

A VIOLATION OF PROPRIETARY

THE INFORMATION PROVIDED

ITS INTENDED PURPOSE.

PART NAME

DRAWN BY

CHECKED BY

.

AY.

DRAWING NUMBER

MODEL NO.

SAN LEANDRO, CALIFORNIA 94577

NONE

1-31-97

MBXXM100A

CMB

ORIGINAL JOB NO.

.

.

3

2

1

5

4 67

PARTS LIST FORMODEL CMB8000

P5126

ITEM PART # DESCRIPTION

1 03-001-0084B PILLOW BLOCK BEARING

2 05-001-0015 AIR CYLINDER 2 X 7

2A 05-001-0126 AIR CYLINDER SEAL KIT

3 FLASHING LIGHT (REFER TO ELECTRICAL MANUAL)

4 VMRIX711B AGITATOR PILOT SHAFT

5 FRONT SHAFT SEAL (SEE SEAL ASSEMBLY DWG.)

6 VMXPX700D AGITATOR ASSEMBLY (COMPLETE)

7 12-004-0002 GASKET (CUT TO SIZE)

Refer to Dwg. No. MBXXM100A

RIGHT DOORLEFT DOOR

1

2

4

3

ITS INTENDED PURPOSE.

THE INFORMATION PROVIDED

A VIOLATION OF PROPRIETARY

IS THE CONFIDENTIAL PROPERTY

OR USE TO BENEFIT OTHERS ISOF COZZINI, INC. COPYING

RIGHTS EXCEPT WHEN AUTHORIZED

RETURN THIS PRINT TO COZZINI,INC. AFTER IT HAS SERVED

BY COZZINI, INC. IN WRITING.

ORIGINAL JOB NO.

COZZINI,INC.

CHECKED BY

DRAWN BY

PART NAME

CHICAGO, ILLINOIS 60646 USA

MIXER PNEU. CONTROL DIAG.

MODEL NO.

CMB

.

CD

.

DATE

SCALE

12-7-98

NONEMBXXZ302A

DRAWING NUMBER

301

SOLSOL

100 - 120 PSI

AIR PRESSURE

REQUIRED

CLOSE OPEN CLOSE

SOL

OPEN

SOL

PARTS LIST FORMODEL CMB8000

P5126

ITEM PART # DESCRIPTION

1 05-001-0015 AIR CYLINDER 2 X 7

1A 05-001-0126 AIR CYLINDER SEAL KIT 2"

2 05-003-0003 FLOW CONTROL VALVE

3 05-002-0206 VALVE ASSEMBLY 2-STATION / 2-SOLENOID / 2-POSITION 24 V

3A 05-002-0022 SOLENOID VALVE - 24 VOLT

3B 05-002-0009 ELECTRICAL COIL - 24 VOLT

4 05-006-0008 FILTER / REGULATOR / LUBRICATOR WITH SHUT-OFF VALVE

4A 05-006-0013 FILTER

4B 05-006-0014 REGULATOR

4C 05-006-0015 LUBRICATOR

4D 05-006-0016 SHUT-OFF VALVE

Refer to Dwg. No. MBXXZ302A

SCALE

DATE

WATER TIGHT SEAL ASSEMBLY

COZZINI, INC.

BY COZZINI, INC. IN WRITING.

INC. AFTER IT HAS SERVED RETURN THIS PRINT TO COZZINI,

RIGHTS EXCEPT WHEN AUTHORIZED

OF COZZINI, INC. COPYINGOR USE TO BENEFIT OTHERS IS

IS THE CONFIDENTIAL PROPERTY

A VIOLATION OF PROPRIETARY

THE INFORMATION PROVIDED

ITS INTENDED PURPOSE.

PART NAME

DRAWN BY

CHECKED BY

.

CD.

DRAWING NUMBER

MODEL NO.

SAN LEANDRO, CALIFORNIA 94577

NONE

7-28-98

SSXXMW01A

.

REVISION

.

1

12

3

4

5

6

PARTS LIST FORMODEL CMB8000

WATER TIGHT SHAFT SEALS

DISCHARGE ENDITEM PART # DESCRIPTION

1 98-SS404W01B SEAL HOUSING - FRONT

2 98-SPXXX422A SEAL BOLT

4 12-002-0001 LIP SEAL - FRONT

5 06-006-0008 SEAL HOUSING CLAMP - FRONT

6 98-SPXXX432A SEAL LOCK

DRIVE ENDITEM PART # DESCRIPTION

1 98-SS300W01B SEAL HOUSING - REAR

2 98-SPXXX422A SEAL BOLT

3 12-004-0002 GASKET - REAR

4 12-002-0005 LIP SEAL - REAR

5 06-006-0011 SEAL HOUSING CLAMP - REAR

6 98-SPXXX432A SEAL LOCK

Refer to Dwg. No. SSXXMW01A

Ensamblado y desensamblado de los cilindros

BIM-1010/2002/01 1 www.nord.com

BIM-1010/2002UNICASE® Helical Inline GearboxesInstallation and Maintenance Instructions

Retain These Safety Instructions For Future Use

INSPECTION OF UNIT

Thoroughly inspect the equipment for any shipping and handling damage before accepting shipment from the freight company. If any of thegoods called for in the bill of lading or express receipt are damaged or the quantity is short, do not accept until the freight or express agentmakes an appropriate notation on your freight bill or express receipt. If any concealed loss or damage is discovered later, notify your freightcarrier or express agent at once and request him to make an inspection. We will be very happy to assist you in collecting claims for loss ordamage during shipment; however, this willingness on our part does not remove the transportation company’s responsibility in reimbursingyou for collection of claims or replacement of material. Claims for loss or damage in shipment must not be deducted from the NORD Gearinvoice, nor should payment of the NORD Gear invoice be withheld awaiting adjustment of such claims, as the carrier guarantees safedelivery.

If considerable damage has been incurred and the situation is urgent, contact the nearest NORD Gear Sales Office for assistance. Pleasekeep a written record of all communications.

RECORD NAMEPLATE DATA

Locate the gear reducer nameplate and record all nameplate data for future reference.

SK ________________________________________________________ S/N _________________________________

RATIO ______________ MAX TORQUE ____________________ RPM ______________ MTG. POS ______________

STORAGE

PROPER STORAGE UNTIL INSTALLEDKeep unit in a dry, temperature controlled area. If stored otherthan said, long term storage methods must be applied to the unitincluding complete fill with lubricant. Protect machined surfacesand rotate shafts periodically. Prior to putting unit into service,drain lubricant and refill to proper level as determined by themounting position.

PROPER HANDLING OF THE UNITExercise care to prevent damage to the unit when moving. LiftonIy at designed Iifting points. Do not attach other machinery andlift by the unit lifting points. The lifting points are to be used to liftthe unit only. Insure that adequate safety measures are taken toprotect personneI during transportation. Protect the mountingsurface from damage.

CDN

USA

BIM-1010/2002/01 2 www.nord.com

INSTALLATION OF UNIT

To ensure Iong service and dependabIe performance, an encIosed gear drive must be rigidIy supported and the shafts accurateIy aIigned.The foIIowing describes the minimum precautions required to accompIish this end.

FOUNDATIONThe responsibiIity for the design and construction of thefoundation Iies with the user. The foundation must be adequateto withstand normaI operating Ioads and possibIe overIoads whiIemaintaining aIignment to attached system components undersuch Ioads.

MOUNTING POSITIONUnIess a unit is specificaIIy ordered for incIined mounting, thefoundation must be IeveI and fIat. The Iubrication system maynot operate properIy if the unit is not mounted in the position forwhich it is designed. It may be desirabIe to eIevate thefoundation to faciIitate oiI drainage.

CONCRETE FOUNDATIONIf a concrete foundation is used, steeI mounting pads and boIts ofsufficient size to distribute the stress into the concrete shouId begrouted into the foundation.

STEEL FOUNDATIONIf a structuraI steeI foundation is used (i.e. wide fIange beams orchanneIs), a base pIate or soIe pIate of suitabIe thickness shouIdbe used and shouId extend under the entire unit.

FLANGE MOUNTED UNITSIf a structuraI steeI foundation is used (i.e. wide fIange beams orchanneIs), a base pIate or soIe pIate of suitabIe thickness shouIdbe used and shouId extend under the entire unit. If a buIk headpIate is used it shouId be of proper strength to minimize buckIingdistortions.

FIange PiIot ‘AK’ or ‘AK1’ toIeranceMetric (mm)

> ∅ 50 ≤ ∅ 80 = +0.012/-0.007> ∅ 80 ≤ ∅ 120 = +0.013/-0.009> ∅ 120 ≤ ∅ 180 = +0.014/-0.011> ∅ 180 ≤ ∅ 230 = +0.016/-0.013> ∅ 230 ≤ ∅ 315 = +0.000-0.032> ∅ 315 ≤ ∅ 400 = +0.000/-0.036> ∅ 400 ≤ ∅ 500 = +0.000/-0.040

Inch> ∅ 1.969 ≤ ∅ 3.150 = +0.005/-0.0003> ∅ 3.150 ≤ ∅ 4.724 = +0.005/-0.0004> ∅ 4.724 ≤ ∅ 7.087 = +0.006/-0.0004> ∅ 7.087 ≤ ∅ 9.055 = +0.006/-0.0005> ∅ 9.055 ≤ ∅ 12.402 = +0.000/-0.0013> ∅ 12.402 ≤ ∅ 15.748 = +0.000/-0.0014> ∅ 15.748 ≤ ∅ 19.685 = +0.000/-0.0016

BOLT STRENGTHBoIt size, strength and quantity shouId be verified to insure propertorque reaction capacity whatever the mounting arrangement.

PRIME MOVER MOUNTINGAIign the prime mover to the reducer-input shaft using shimsunder the feet. Make sure that the feet are supported. DoweI theprime mover to its foundation.

SHAFT CONNECTIONSWhen connecting shafts to either the input or output of thereducer, consider the foIIowing instructions.

FITSCIearance or interference fits for coupIing hubs shouId be inaccordance with ANSI/AGMA 9002-A86 or as follows.

Output and Input shaft Diameter toIeranceMetric (mm)

≤ ∅ 18 = +0.012/+0.001> ∅ 18 ≤ ∅ 30 = +0.015/+0.002> ∅ 30 ≤ ∅ 50 = +0.018/+0.002> ∅ 50 ≤ ∅ 80 = +0.030/+0.011> ∅ 80 ≤ ∅ 120 = +0.035/+0.013> ∅ 120 ≤ ∅ 180 = +0.040/+0.015

Inch≤ ∅ 1.750 = +0.0000/-0.0005> ∅ 1.750 = +0.0000/-0.0010

Output and Input shaft DriII and tap shaft endMetric (mm)

≤ ∅ 16 = M5 > ∅ 16 ≤ ∅ 21 = M6> ∅ 21 ≤ ∅ 24 = M8> ∅ 24 ≤ ∅ 30 = M10> ∅ 30 ≤ ∅ 38 = M12> ∅ 38 ≤ ∅ 50 = M16> ∅ 50 ≤ ∅ 85 = M20> ∅ 85 ≤ ∅ 130 = M24

Inch ≤ ∅ 0.438 = #10-24 x 0.4 deep> ∅ 0.438 ≤ ∅ 0.813 = ¼-20 x 0.6 deep> ∅ 0.813 ≤ ∅ 0.938 = 5/16-18 x 0.7 deep> ∅ 0.938 ≤ ∅ 1.125 = 3/8-16 x 0.9 deep> ∅ 1.125 ≤ ∅ 1.375 = 1/2-13 x 1.1 deep> ∅ 1.375 ≤ ∅ 1.875 = 5/8-11 x 1.4 deep> ∅ 1.875 ≤ ∅ 3.250 = 3/4-10 x 1.7 deep> ∅ 3.250 = 1-8 x 2.2 deep

Outboard pinion and sprocket fits shouId be as recommended bythe pin sprockets with interference fits shouId be heatedaccording to the manufacturer’s recommendations, generaIIy250°F to 300°F, (120°C to 150° C) before assembIing to the shaft.

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WARNING:LOCK OUT POWER before any maintenance is performed.Make absolutely sure that no voltage is applied while work isbeing done on the gearbox.

The Autovent releases built-up air pressure frominside the gearbox (Max. pressure 2 psi).

LOCATIONCoupIing hubs shouId be mounted fIush with the shaft ends,unIess specificaIIy ordered for overhung mounting. Pinions,sprockets and sheaves shouId be mounted as cIose as possibIeto the unit housing to minimize bearing Ioads and shaftdefIections.

COUPLING ALIGNMENTShaft coupIings shouId be instaIIed according to the coupIingmanufacturer’s recommendations for gap, anguIar and paraIIeIaIignment. In many instaIIations, it is necessary to aIIow forthermaI and mechanicaI shaft movement when determining shaftaIignment. The coupIing manufacturer’s recommendationsshouId be foIIowed.

AXIAL DISPLACEMENTThe gap between shaft ends shouId be the same as the specifiedcoupIing gap unIess overhung mounting of the coupIing hub isspecified. The coupIing gap and shaft gap must be sufficient toaccommodate any anticipated thermaI or mechanicaI axiaImovement.

ANGULAR ALIGNMENTInsert a spacer or shim stock equaI to the required coupIing gapbetween the coupIing hub faces and measure the cIearance usingfeeIer gauges. Repeat this at the same depth at 90-degreeintervaIs to determine the amount of anguIar misaIignment.

PARALLEL ALIGNMENTMount a diaI indicator to one coupIing hub, and rotate this hub,sweeping the outside diameter of the other hub. The paraIIeImisaIignment is equaI to one-haIf of the totaI indicator reading.Another method is to rest a straight edge squareIy on the outsidediameter of the hubs at 90-degree intervaIs and measure anygaps with feeIer gauges. The maximum gap measurement is theparaIIeI misaIignment.

CHECKING ALIGNMENTAfter both anguIar and paraIIeI aIignments are within specifiedIimits, tighten aII foundation boIts secureIy and repeat the aboveprocedure to check aIignment. If any of the specified Iimits foraIignment are exceeded, reaIign the coupIing.

SPROCKET OR SHEAVE ALIGNMENTAIign the sheaves or sprockets square and paraIIeI by pIacing astraight edge across their faces. AIignment of bushed sheavesand sprockets shouId be checked after bushings have beentightened. Check horizontaI shaft aIignment by pIacing a IeveIverticaIIy against the face of the sheave or sprocket. Adjust beItor chain tension per the manufacturer’s specified procedure.

OUTBOARD PINION ALIGNMENTAIign the pinion by adjusting the gear tooth cIearance accordingto the manufacturer’s recommendations and checking foracceptabIe outboard pinion tooth contact. The foundation boItsmay have to be Ioosened and the unit moved sIightIy to obtainthis contact. When the unit is moved to correct tooth contact, theprime mover shouId be reaIigned.

RECHECK ALIGNMENTAfter a period of operation, recheck aIignment and adjust asrequired.

1. Properly install unit on a rigid foundation• adequateIy supported• secureIy boIted into pIace• IeveIed so as not to distort the gear case

2. Properly install couplings suitabIe for the application andconnected equipment.

3. Ensure accurate aIignment with other equipment.4. Furnish and install adequate machinery guards as needed to

protect operating personneI and as required by theappIicabIe standards of the OccupationaI Safety and HeaIthAdministration (OSHA), and by other appIicabIe safetyreguIations;

5. Ensure that driving equipment is running in the correctdirection before coupling to reducers with backstops(designed to operate onIy in a specific direction) ormachinery designed to operate only in one direction.

CHANGES IN PERFORMANCE SPECIFICATIONSOwner has the responsibiIity to consult with NORD GEAR if suchitems such as applied Ioads, operating speeds or other operatingconditions have changed.

START-UP1. Ensure that switches, aIarms, heaters, coolers and other

safety and protection devices are instaIIed and operationalfor their intended purpose.

2. Verify that the installed mounting position is the same as thenametag mounting position. If not, adjust the oil levelaccordingly and relocate the vent plug, fill plug and drainplug according to the mounting position. See following.

AUTOVENT PLUGThe Autovent plug is brass in color and will be located at thehighest point on the gearbox. It operates like a check-valve toallow the reducer to relieve internal pressure while preventinglubricant contamination during cooling. A spring presses a ball orplunger against a machined orifice until pressure exceeds 2 psi.Above 2 psi the air is allowed to escape depressurizing thegearcase. When internal pressure drops below 2 psi, theautovent re-seals closing the unit to the outside environment.After shutdown, the reducer cools along with the air inside thereducer. The unit will temporarily maintain a slight vacuum untilnormalization occurs. NORD Gear supplies an Autovent as astandard feature.

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Two types of plugs for maintenance

FILL LEVEL & DRAIN PLUGSThe drain plugs are metric socket head cap screws. They will belocated at the lowest part of the gearbox for ease of draining. Thefill level plug is a hex head cap screw. It will be located betweenthe Autovent and drain plug. Both types of plugs will have gasketsincluded to prevent oil from leaking.

LUBRICANTAII NORD reducers are shipped from the factory properIy fiIIedwith Iubricant and all plugs are installed according to the mountingposition given on the reducer nametag. Acceptable oil fill level iswithin ½ inch of the bottom of the fill plug threads.

OPERATION AND MAINTENANCE CHECKLIST1. Operate the equipment as it was intended to be operated2. Do not overIoad.3. Run at correct speed.4. Maintain Iubricant in good condition and at proper IeveI.5. Dispose of used Iubricant in accordance with appIicabIe

Iaws and reguIations.6. AppIy proper maintenance to attached equipment at

prescribed intervaIs recommended by the manufacturer.7. Perform periodic maintenance of the gear drive as

recommended by NORD.

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MOUNTING POSITIONSThese charts detail the mounting positions for horizontal and vertical mounting. The Autovent, oil fill plug and drain plug are indicated on eachmounting position picture. The factory set mounting position and plug locations match that shown on the gearbox nametag. For mountingorientations other than shown consult NORD Gear.

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MAINTENANCE

Mineral lubricant should be changed every 10,000 service hours or after two years. For synthetic oils, the lube should be changed every20,000 service hours or after four years. In case of extreme operating (e.g. high humidity, aggressive environment or large temperaturevariations), shorter intervals between changes are recommended.

OIL SPECIFICATIONSNORD supplies aII reducers fiIIed with oiI from the factory. Consult the sticker adjacent to the fill plug to determine the type of lubricantinstalled at the factory. Standard lubricant is ISO VG220 mineral-based oil. However, some units have special lubricants designed to operatein certain environments or to extend the service life of the lubricant. If in doubt about which lubricant is needed, contact NORD Gear.

STANDARD OIL – ISO VG220

Ambient Temperature FormuIationOil

Manufacturer Oil Brand NameOrigin of

Gearbox Assembly20 to 104°F (-5 to 40°C) MineraI Texaco Meropa 220 NORD USA20 to 104°F (-5 to 40°C) MineraI SheII OmaIa EP 220 NORD Canada

OPTIONAL LUBRICANTS

Ambient Temperature FormuIationOil

Manufacturer Oil Brand NameOrigin of

Gearbox Assembly14 to 176°F (-10 to 80°C) Synthetic Texaco PinnacIe EP680 NORD USA14 to 176°F (-10 to 80°C) Synthetic SheII OmaIa HD 680 NORD Canada-13 to 140°F (-25 to 60°C) Synthetic Texaco PinnacIe EP220 NORD USA-13 to 140°F (-25 to 60°C) Synthetic SheII OmaIa HD 220 NORD Canada-40 to 50°F (-40 to 10°C) Synthetic Texaco PinnacIe EP32 NORD USA-40 to 50°F (-40 to 10°C) Synthetic SheII OmaIa HD 32 NORD Canada20 to 104°F (-5 to 40°C) Food Grade Chevron FM ISO 220 NORD USA20 to 104°F (-5 to 40°C) Synthetic Food Grade OilJAX MagnapIate 85W140-FG NORD Canada5 to 125°F (-20 to 50°C) FIuid Grease MobiI MobiIux EP023 NORD USA

-30 to 140°F (-35 to 60°C) Synthetic FIuid Grease MobiI MobiIith SHC 007 NORD USA-30 to 140°F (-35 to 60°C) Synthetic FIuid Grease SheII TiveIa compound A NORD Canada

STANDARD BEARING GREASE – NLGI 2EP Iithium

Ambient Temperature FormuIationGrease

Manufacturer Grease Brand NameOrigin of

Gearbox Assembly-20 to 140°F (-30 to 60°C) MineraI Texaco MuItifak EP2 NORD USA-20 to 140°F (-30 to 60°C) MineraI SheII Cypernia RA/C3 NORD Canada

OPTIONAL BEARING GREASE

Ambient Temperature FormuIationGrease

Manufacturer Grease Brand NameOrigin of

Gearbox Assembly-58 to 230°F (-50 to 110°C) Synthetic Texaco Starfak 2202 NORD USA-58 to 230°F (-50 to 110°C) Synthetic SheII Aero SheII NORD Canada5 to 230°F (-20 to 110°C) Food Grade LubripIate SIF 1 NORD USA

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LUBRICANT CAPACITYEach reducer has the oil level and oil quantity adjusted according to the mounting position shown in the tables. When replacing the oil, consultthe tables below to determine the proper amount of oil to be installed according to the reducer size and mounting position. Note that this isapproximate and the final level will be adjusted when the reducer is installed. Acceptable oil fill level is within ½ inch of the bottom of the fillplug threads.

LUBRICATION CAPACITY – HELICAL INLINE GEARBOXESHorizontal position Vertical position

single reductionMounting positionB 3 B 6 B 7 B 8 B 5 B 5I B 5II B 5III V 1 V 3 V 5 V 6

quarts 0.26 0.37 0.37 0.58 0.32 0.53 0.42 0.42 0.32 0.37 0.42 0.53SK 11Eliters 0.25 0.35 0.35 0.55 0.30 0.50 0.40 0.40 0.30 0.35 0.40 0.50

quarts 0.63 1.06 1.06 1.27 0.53 1.16 0.95 0.95 0.74 1.48 1.06 1.27SK 21Eliters 0.60 1.00 1.00 1.20 0.50 1.10 0.90 0.90 0.70 1.40 1.00 1.20

quarts 1.16 1.80 1.80 2.32 0.85 1.74 2.11 2.11 1.16 1.37 2.43 2.85SK 31Eliters 1.10 1.70 1.70 2.20 0.80 1.65 2.00 2.00 1.10 1.30 2.30 2.70

quarts 1.80 2.75 2.75 3.49 1.06 2.96 3.49 3.49 1.69 2.75 2.64 2.75SK 41Eliters 1.70 2.60 2.60 3.30 1.00 2.80 3.30 3.30 1.60 2.60 2.50 2.60

quarts 2.32 3.59 3.59 4.97 1.90 4.33 4.02 4.02 3.17 3.70 4.23 4.65SK 51Eliters 2.20 3.40 3.40 4.70 1.80 4.10 3.80 3.80 3.00 3.50 4.00 4.40

double reductionMounting position

B 3 B 6 B 7 B 8 B 5 B 5I B 5II B 5III V 1 V 3 V 5 V 6quarts 0.16 0.42 0.42 0.74 0.26 0.63 0.53 0.53 0.63 0.63 0.63 0.63SK 02liters 0.15 0.40 0.40 0.70 0.25 0.60 0.50 0.50 0.60 0.60 0.60 0.60

quarts 0.26 0.53 0.53 0.90 0.37 0.95 0.63 0.63 0.95 0.90 0.79 0.79SK 12liters 0.25 0.50 0.50 0.85 0.35 0.90 0.60 0.60 0.90 0.85 0.75 0.75

quarts 0.53 1.43 1.43 2.11 0.74 2.11 1.64 1.64 1.90 2.11 1.90 1.90SK 22liters 0.50 1.35 1.35 2.00 0.70 2.00 1.55 1.55 1.80 2.00 1.80 1.80

quarts 0.95 2.11 2.11 3.17 1.37 3.49 2.54 2.54 3.28 3.06 3.06 2.64SK 32liters 0.90 2.00 2.00 3.00 1.30 3.30 2.40 2.40 3.10 2.90 2.90 2.50

quarts 1.37 3.38 3.38 4.76 1.90 4.76 3.91 3.91 4.23 4.65 4.54 6.13SK 42liters 1.30 3.20 3.20 4.50 1.80 4.50 3.70 3.70 4.00 4.40 4.30 5.80

quarts 2.64 5.39 5.39 7.19 3.17 6.55 5.92 5.92 7.82 7.19 7.19 7.40SK 52liters 2.50 5.10 5.10 6.80 3.00 6.20 5.60 5.60 7.40 6.80 6.80 7.00

quarts 6.87 15.85 15.85 13.74 7.40 14.79 16.91 16.91 19.55 15.85 16.91 15.85SK 62liters 6.50 15.00 15.00 13.00 7.00 14.00 16.00 16.00 18.50 15.00 16.00 15.00

quarts 9.51 24.30 24.30 19.02 10.57 19.55 24.30 24.30 29.59 24.30 27.47 24.30SK 72liters 9.00 23.00 23.00 18.00 10.00 18.50 23.00 23.00 28.00 23.00 26.00 23.00

quarts 14.79 33.81 33.81 28.53 15.85 30.64 36.46 36.46 47.55 39.10 46.49 36.98SK 82liters 14.00 32.00 32.00 27.00 15.00 29.00 34.50 34.50 45.00 37.00 44.00 35.00

quarts 26.42 54.95 54.95 49.66 27.47 49.66 54.95 54.95 82.42 77.14 80.31 77.14SK 92liters 25.00 52.00 52.00 47.00 26.00 47.00 52.00 52.00 78.00 73.00 76.00 73.00

quarts 38.04 75.02 75.02 69.74 42.27 69.74 76.08 76.08 109.90 85.59 107.78 83.48SK 102liters 36.00 71.00 71.00 66.00 40.00 66.00 72.00 72.00 104.00 81.00 102.00 79.00

triple reductionMounting position

B 3 B 6 B 7 B 8 B 5 B 5I B 5II B 5III V 1 V 3 V 5 V 6quarts 0.32 0.63 0.63 0.85 0.53 0.95 0.85 0.85 1.16 0.86 0.95 1.32SK 03liters 0.30 0.60 0.60 0.80 0.50 0.90 0.80 0.80 1.10 0.81 0.90 1.25

quarts 0.63 0.74 0.74 1.16 0.85 1.27 1.00 1.00 1.27 1.27 1.27 1.32SK 13liters 0.60 0.70 0.70 1.10 0.80 1.20 0.95 0.95 1.20 1.20 1.20 1.25

quarts 1.37 1.69 1.69 2.43 2.64 1.59 2.96 2.96 2.96 2.75 2.48 2.54SK 23liters 1.30 1.60 1.60 2.30 2.50 1.50 2.80 2.80 2.80 2.60 2.35 2.40

quarts 1.69 2.43 2.43 3.38 2.01 3.70 2.75 2.75 4.65 3.59 4.44 3.06SK 33liters 1.60 2.30 2.30 3.20 1.90 3.50 2.60 2.60 4.40 3.40 4.20 2.90

quarts 3.17 3.80 3.80 5.49 3.70 5.28 4.33 4.33 6.45 6.02 6.97 5.92SK 43liters 3.00 3.60 3.60 5.20 3.50 5.00 4.10 4.10 6.10 5.70 6.60 5.60

quarts 4.76 6.34 6.34 8.14 5.49 7.40 7.08 7.08 9.40 8.88 9.19 9.19SK 53liters 4.50 6.00 6.00 7.70 5.20 7.00 6.70 6.70 8.90 8.40 8.70 8.70

quarts 10.57 13.74 13.74 11.62 11.62 12.68 14.79 14.79 19.02 14.79 16.91 15.32SK 63liters 10.00 13.00 13.00 11.00 11.00 12.00 14.00 14.00 18.00 14.00 16.00 14.50

quarts 14.79 21.13 21.13 18.49 14.79 19.02 21.13 21.13 29.06 23.78 28.53 21.13SK 73liters 14.00 20.00 20.00 17.50 14.00 18.00 20.00 20.00 27.50 22.50 27.00 20.00

quarts 23.25 34.87 34.87 27.47 24.30 28.53 35.93 35.93 42.27 35.93 39.10 32.76SK 83liters 22.00 33.00 33.00 26.00 23.00 27.00 34.00 34.00 40.00 34.00 37.00 31.00

quarts 42.27 51.78 51.78 46.49 42.27 46.49 51.78 51.78 78.19 73.97 76.08 73.97SK 93liters 40.00 49.00 49.00 44.00 40.00 44.00 49.00 49.00 74.00 70.00 72.00 70.00

quarts 58.12 70.80 70.80 58.12 58.12 62.34 70.80 70.80 104.61 82.42 102.50 75.02SK 103liters 55.00 67.00 67.00 55.00 55.00 59.00 67.00 67.00 99.00 78.00 97.00 71.00

Note: Filling quantities are approximate figures. Oil level must be checked according to oil level plug after final installation.Acceptable oil fill level is within ½ inch of the bottom of the fill plug threads For mounting angles not shown, consult factory.

BIM-1010/2002/01 9 www.nord.com

SPARE PARTS LISTS

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SPARE PARTS LISTS

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NOTES

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TROUBLE SHOOTING

PROBLEM WITH THE REDUCER POSSIBLE CAUSES SUGGESTED REMEDY

Overloading Load exceeds the capacity of thereducer

Check rated capacity of reducer, replacewith unit of sufficient capacity or reduceload

Insufficient lubrication Check lubricant level and adjust up torecommended levels

Excessive lubrication Check lubricant level and adjust down torecommended levels

Runs Hot

Improper lubrication

Wrong lubrication Flush out and refill with correct lubricant asrecommended

Weak mounting structureInspect mounting of reducer. Tighten loosebolts and/ or reinforce mounting andstructureLoose foundation bolts

Loose hold down bolts Tighten bolts

Worn RV Disc Overloading unit may result indamage to disc

Disassemble and replace disc. Recheckrated capacity of reducer.

May be due to lack of lubricant Replace bearing. Clean and flush reducerand fill with recommended lubricant.Failure of Bearings

Overload Check rated capacity of reducer.

Runs Noisy

Insufficient Lubricant Level of lubricant in the reducer notproperly maintained.

Check lubricant level and adjust to factoryrecommended level.

Overloading of reducer can causedamage.

Replace broken parts. Check rated capacityof reducer.

Internal parts are brokenKey missing or sheared off on inputshaft.

Replace key.Output ShaftDoes Not Turn

Coupling loose or disconnected. Properly align reducer and coupling.Tighten coupling.

Worn Seals Caused by dirt or grit entering seal. Replace seals. Autovent may be clogged.Replace or clean.

Overfilled reducer. Check lubricant level and adjust torecommended level.

Autovent clogged. Clean or replace, being sure to prevent anydirt from falling into the reducer.

Oil Leakage

Improper mounting position, such aswall or ceiling mount of horizontalreducer.

Check mounting position. Name tag & verifywith mounting chart in manual.

Instrucciones de funcionamientoy mantenimiento

Istruzioni d’uso e manutenzioneManual de Operação e Manutenção

B 1010 09/2001

E I P

Guarde estas indicaciones de seguridadQueste istruzioni di sicurezza devono essere osservateEstas instruções de segurança devem ser observadas

Reductores de ruedas helicoidales monobloque

Riduttori a ingranaggi cilindrici

Redutores de Engrenagens Helicoidais

Instalación, preparación− Los cáncamos de transporte en el reductor

están previstos para soportar el peso delaccionamiento

− Dimensionar los fundamentos de formasuficiente y ejecutarlos exentos devibraciones

− Montar el reductor o el motor reductorfirmemente y sin apretar excesivamente

− Prever suficiente ventilación− Utilizar rosca interior de serie según DIN

332 para el montaje de elementos de uniónsobre el eje

− Evitar golpes en los ejes (¡desperfecto decojinetes!)

− Unir máquina y engranaje en lo posible conacoplamientos elásticos

− Antes de la conexión montar los elementosaccionados y asegurar la chaveta

− Para reductores de eje hueco con brazo dereacción, utilizar amortiguadores o mazasde caucho

Conexión eléctrica− Conectar el motor según el esquema de

conexión− Asegurar que la tensión y la frecuencia de

red coincidan con los datos que aparecenen la placa de características

− Conectar de forma segura el conductorprotector

− Corregir un eventual sentido de giroincorrecto cambiando las 2 fases

− Cerrar a prueba de polvo y agua losboquetes de entrada de cables y la caja determinales en sí

− Prevenir sobrecargas y fallos de una fasemediante interruptor de protección

− Ajustar el interruptor protector del motor alvalor de corriente nominal

− Esquemas de conexión en la última página Puesta en marcha− Durante tiempos de almacenaje

prolongados tomar medidas de precauciónespeciales (véase “Almacenaje prolongado”en la hoja de normas de fábrica)

− Verificar la posición del tornillo indicador denivel de aceite según las tablas de posiciónde montaje del respectivo catálogo

− Controlar el nivel de aceite− Quitar el tapón de cierre antes de la puesta

en marcha (¡sobrepresión!); si se diera elcaso, montar tornillo de descarga de aire apresión

− Primer relleno normal: véase tabla delubricantes

− Los motores refrigerados por aire estándiseñados para soportar temperaturasambiente de - 20°C hasta +40°C, así comoalturas de emplazamiento â 1.000 m sobreel nivel del mar

− No se admite el empleo en ámbitos Ex(riesgo de explosión), en tanto no haya sidoexpresamente previsto para este fin

∆∆∆∆ Advertencia Es requisito indispensable que los trabajosfundamentales de planificación de lainstalación, así como el transporte, elmontaje, la instalación, la puesta en marcha,el mantenimiento y las reparaciones seanejecutados por personal cualificado o bien,controlados por técnicos especializados en lamateria. Al realizar trabajos en el motorreductor se ha de estar absolutamente segurode que no hay ninguna tensión conectada, yque el motor está asegurado contra conexiónulterior. ∆∆∆∆ Advertencia Anomalías no conformes con elfuncionamiento normal (mayor consumo deenergía, temperaturas, vibraciones, ruidos,etc., o disparo de los dispositivos devigilancia) son indicios para suponer que lafunción es defectuosa. En todo caso, elpersonal de mantenimiento encargado deberáser informado inmediatamente al respecto, afin de evitar desperfectos que por su partepueden causar directa o indirectamentegraves daños personales o materiales. ∆∆∆∆ En caso de duda, ¡Desconectarinmediatamente la máquina correspondiente!

Installazione e Preparazione− golfari sul motoriduttore

adeguati al peso del gruppo motore− dimensionare adeguatamente le fondazioni

ed eseguirle esenti da vibrazioni.− montare i riduttori o i motoriduttori

saldamente e senza serrareeccessivamente.

− prevedere una ventilazione adeguata− utilizzare filettature interne di serie conformi

alla DIN 332 per sollevare gli elementi dicollegamento sugli alberi.

− evitare di urtare gli alberi (i cuscinettipotrebbero subire danni).

− utilizzare il più possibile giunti elastici perconnettere macchina e riduttore.

− prima di prowedere all’avviamento, serraregli elementi condotti o assicurare lachiavetta.

− in caso di riduttori pendolari con braccio direazione, utilizzare un tampone in gomma.

Allacciamento elettrico− eseguire l’allacciamento del motore secondo

lo schema elettrico.− verificare che la tensione di rete e la

frequenza corrispondano ai dati sullatarghetta.

− realizzare un collegamento sicuro delconduttore di protezione.

− correggere il senso di rotazioneeventualmente errato scambiando 2 fasi.

− sigillare a tenuta di polvere e di acqua leaperture per i cavi non necessarie e lascatola morsettiera stessa.

− prevenire il sovraccarico e la mancanza difase con interruttori di protezione.

− impostare l’interruttore di protezione delmotore sulla corrente nominale.

− schema elettrico nell’ultima pagina. Messa in funzione− in caso si prevedano tempi di stoccaggio

prolungati, è necessario prendere misureparticolari (vedere opuscolo norme interne“Stoccaggio per periodi prolungati”)

− stabilire la posizione del tappo di livellodell’olio secondo le tabelle delle formecostruttive del catalogo corrispondente.

− verificare il livello dell’olio.− prima della messa in funzione, liberare dallo

spinotto di plastica il tappo di sfiato(sovrappressione), eventualmente montaretappi di sfiato a pressione.

− prima carica normale: vedere la tabella deilubrificanti.

− i motori raffreddati ad aria sono progettatiper temperature ambiente comprese fra-20°C e + 40°C e per altezze di montaggiodi ⇐ 1.000 m sul livello del mare.

− non è ammesso il loro impiego in ambienticon pericolo di esplosione se non sonoespressamente previsti a tale scopo.

∆∆∆∆ Attenzione Si dà per scontato che i lavori fondamentali diprogettazione dell’impianto e gli interventi ditrasporto, montaggio, installazione, messa infunzione, manutenzione e riparazione sianoeseguiti da personale qualificato o sianocontrollati da personale responsabile. Quandosi eseguono interventi sul motoriduttore,accertarsi che sia completamente esente datensione e renderlo sicuro contro ilriavviamento. ∆∆∆∆ Attenzione Eventuali variazioni rispetto al normalefunzionamento (aumento della potenzaassorbita, delle temperature, insorgere dioscillazioni, rumorosità, ecc.) fannopresuporre che il funzionamento siaimperfetto. In tali casi per evitare l’insorgere diguasti che, direttamente o indirettamente,potrebbero causare gravi danni alle persone oalle cose, si deve avvisare tempestivamente ilpersonale addetto alla manutenzione. ∆ ∆ ∆ ∆ In caso di dubbio, interrompereimmediatamente l’alimentazione!

Preparo da instalação− Utilizar os olhais de içamento para elevação

e transporte das unidades.− Dimensionar as bases de fundação com

rigidez adequada e livres de vibrações.− Montar a unidade rigidamente e ajustada.− Prever a ventilação suficiente.− Utilizar os furos roscados (DIN 332) para

instalação de elementos de transmissão aoseixos.

− Evitar choques nos eixos (danos aosrolamentos)

− A união entre os eixos de acionamento e damáquina acionada devem,preferencialmente, ser feitos poracoplamentos elásticos.

− Dispositivos que operem solidários ao eixode saída devem ser acoplados antes dainstalação do motor.

− Utilizar braço de torque com amortecedoresde borracha nas unidades de eixo oco.

Ligação elétrica− Efetuar a ligação do motor conforme

diagrama.− Assegurar-se que tensão e frequência

coincidem com dados de plaqueta do motor.− Execute um correto aterramento da

instalação.− Caso se queira inverter o sentido de rotação

deve-se inverter duas das tres fases.− Furos e tampa da caixa de ligação devem

ser mantidos fechados e apertados.− Instalar chaves de proteção contra

sobrecarga e falta de fase.− Ajustar o dispositivo de proteção do motor

para a corrente nominal.− Veja diagramas de ligação na última página. Posta em marcha− Em caso de armazenagem por longos

períodos seguir procedimento especial(conforme procedimento „Armazenagem porlongos períodos“.

− Cheque a posição do bujão de nível de óleoconforme tabelas constantes do catálogo.

− Cheque o nível do óleo.− Antes da posta em marcha retire o pino

plástico que protege o respiro (se houver).− Se não especificado em contrário, a

primeira carga de óleo conforme tabela delubrificantes.

− Motores ventilados a ar são apropriadospara operar em temperatura ambiente entre–20ºC e +40ºC e altitudes inferiores a1.000m.

− A utilização de motores em ambientesexplosivos é proibida, a menos queexpressamente indicados para tal operação(obedecer normalização específica).

∆ ∆ ∆ ∆ AtençãoÉ requisito indispensável que todos ostrabalhos relativos à máquina, desde oprojeto, transporte, montagem, instalação,posta em marcha, manutenção e reparosdevam ser executados por pessoal qualificadoe/ou supervisionados por pessoalespecializado. Deve-se garantir que, duranteos trabalhos de manutenção e reparos oequipamento esteja eletricamente desligado,e que não haja possibilidade de ligaçãoacidental durante o serviço.

∆∆∆∆ AtençãoQualquer anomalia no funcionamento normal(maior consumo de potência, elevação detemperatura, vibrações, ruídos, etc.) oudisparos de alarmes pelos dispositivos deproteção, são sinais de irregularidades defuncionamento. Nestes casos, informarimediatamente o pessoal responsável pelamanutenção para prevenir que a evolução doproblema gere consequências piores e venhaa causar danos físicos ou materiais.

∆∆∆∆ Em caso de dúvida, desligueimediatamente a máquina.

MantenimientoMOTOR− Eliminar las acumulaciones de polvo

(¡sobrecalentamiento!)− Desmontar, limpiar y engrasar los

rodamientos− Se ha de observar que aprox. 1/3 de todo el

espacio libre en torno al cojinete esté rellenocon grasa

− Para el tipo de lubricante, véase la tabla deabajo

ENGRANAJE− Verificar el nivel de aceite con regularidad− Cambiar el lubricante cada 10.000 horas de

servicio o a más tardar después de 2 años− Plazos dos veces mayores para lubricantes

sintéticos− Acortamiento de intervalos de lubricación bajo

condiciones de servicio extremas (humedadde aire elevada, entorno agresivo y grandesfluctuaciones de temperatura)

− Complementar el cambio de lubricante con lalimpieza a fondo del engranaje

∆ ¡No mezclar lubricantes sintéticos conlubricantes minerales! ¡Esto también se aplicapara la evacuación de los lubricantes!

Manutenzione MOTORE− eliminare gli accumuli di polvere

(surriscaldamento)− smontare, pulire e ingrassare i cuscinetti a

rotolamento− accertarsi che tutto lo spazio vuoto attorno al

cuscinetto sia riempito con grasso per circa1/3

− per i tipi di lubrificanti vedere sotto RIDUTTORE− controllare regolarmente il livello dell’olio− sostituire il lubrificante ogni 10.000 ore di

funzionamento o, al più tardi, dopo 2 anni,contemporaneamente pulire e ingrassare icuscinetti riempiti con grasso.

− associare il cambio del lubrificante ad unapulizia approfondita del riduttore.

− con i tempi sintetici i tempi raddoppiano,− con gli oli sintetici i tempi raddoppiano, gli

intervalli fra le sostituzioni di lubrificante siaccorciano in caso di condizioni di esercizioestreme (elevata umidità dell’aria, ambienteaggressivo ed elevate oscillazioni ditemperatura)

∆ Non mescolare i lubrificanti sintetici con quelli

minerali, nemmeno in fase di smaltimento!

Manutenção MOTOR− Remover o acúmulo de poeira

(superaquecimento).− Retire os rolamentos para limpeza e nova

lubrificação.− Cerca de 1/3 do rolamento deve estar

uniformemente preenchido por graxa.− Tipo recomendado de graxa conforme tabela

de lubrificantes. REDUTOR− Checar regularmente o nivel do óleo.− Substituir o lubrificante após cada 10.000

horas de operação ou no máximo a cada2anos.

− Coordenar a troca do lubrificante com a totallimpeza interna do redutor.

− O intervalo de troca será duplicado se foremutilizados lubrificantes sintéticos.

− Se em condições extremas de operação (altaumidade, ambiente agressivo, grandesvariações de temperatura) reduzir o intervalode troca de lubrificante.

∆ Nunca misturar lubrificantes sintéticos eminerais, seja para completar o nível ou após adrenagem.

CANTIDAD DE LUBRICANTE [cm3] QUANTITA� D�OLIO [cm3] QUANTIDADE DE LUBRIFICANTE [cm3]Posición horizontal

Disposizione orizzontalePosição horizontal

Posición verticalDisposizione verticale

Posição verticalReductores de ruedas helicoidales Riduttori a ingranaggi Redutores de engrenagens helicoidaisreducción simple cilindrici ad una riduzione Redução única

B 3 B 6 B 7 B 8 B 5 B 5I B 5II B 5III V 1 V 3 V 5 V 6SK 11 ESK 21 ESK 31 ESK 41 ESK 51 E

250600

1.1001.7002.200

3501.0001.7002.6003.400

3501.0001.7002.6003.400

5501.2002.2003.3004.700

300500800

1.0001.800

5001.1001.6502.8004.100

400900

2.0003.3003.800

400900

2.0003.3003.800

300700

1.1001.6003.000

3501.4001.3002.6003.500

4001.0002.3002.5004.000

5001.2002.7002.6004.400

Reductores de ruedas helicoidales Riduttori a ingranaggi Redutores de engrenagens helicoidaisreducción doble cilindrici a due riduzioni Redução dupla

B 3 B 6 B 7 B 8 B 5 B 5I B 5II B 5III V 1 V 3 V 5 V 6SK 02SK 12SK 22SK 32SK 42SK 52SK 62SK 72SK 82SK 92

SK 102

150250500900

1.3002.5006.5009.000

14.00025.00036.000

400500

1.3502.0003.2005.100

15.00023.00032.00052.00071.000

400500

1.3502.0003.2005.100

15.00023.00032.00052.00071.000

700850

2.0003.0004.5006.800

13.00018.00027.00047.00066.000

250350700

1.3001.8003.0007.000

10.00015.00026.00040.000

600900

2.0003.3004.5006.200

14.00018.50029.00047.00066.000

500600

1.5502.4003.7005.600

16.00023.00034.50052.00072.000

500600

1.5502.4003.7005.600

16.00023.00034.50052.00072.000

600900

1.8003.1004.0007.400

18.50028.00045.00078.000

104.000

600850

2.0002.9004.4006.800

15.00023.00037.00073.00081.000

600750

1.8002.9004.3006.800

16.00026.00044.00076.000102.00

600750

1.8002.5005.8007.000

15.00023.00035.00073.00079.000

Reductores de ruedas helicoidales Riduttori a ingranaggi Redutores de engrenagens helicoidaisreducción triple cilindrici a tre riduzioni Reduçăo tripla

B 3 B 6 B 7 B 8 B 5 B 5I B 5II B 5III V 1 V 3 V 5 V 6SK 03SK 13SK 23

SK 33 NSK 43SK 53SK 63SK 73SK 83SK 93

SK 103

300600

1.3001.6003.0004.500

10.00014.00022.00040.00055.000

600700

1.6002.3003.6006.000

13.00020.00033.00049.00067.000

600700

1.6002.3003.6006.000

13.00020.00033.00049.00067.000

8001.1002.3003.2005.2007.700

11.00017.50026.00044.00055.000

500850

2.5001.9003.5005.200

11.00014.00023.00040.00055.000

9001.2001.5003.5005.0007.000

12.00018.00027.00044.00059.000

800950

2.8002.6004.1006.700

14.00020.00034.00049.00067.000

800950

2.8002.6004.1006.700

14.00020.00034.00049.00067.000

1.1001.2002.8004.4006.1008.900

18.00027.50040.00074.00099.000

8001.2002.6003.4005.7008.400

14.00022.50034.00070.00078.000

9001.2002.3504.2006.6008.700

16.00027.00037.00072.00097.000

1.0001.2502.4002.9005.6008.700

14.50020.00031.00070.00071.000

La carga normal del reductor es de aceite mineral. Aceite sintético se suministra con recargo.La carica normale del riduttore è effettuata con olio minerale. E’ disponibile anche olio sintetico con un supplemento di prezzo.Normalmente os redutores são fornecidos com óleo mineral, podendo tambem ser fornecidos com óleo sintético com custo adicional

NOTA / NOTA / OBSERVAÇÃO:Las cantidades de aceite especificadas son valores aproximados. Verificar el nivel de aceite con ayuda del tornillo indicador.Le quantità di olio sono indicative. Verificare il livello dell�olio utilizzando l� apposito tappo di livello.As quantidades de óleo recomendadas são aproximadas, devendo-se controlar sempre o nível do óleo através do bujão indicador.

Nota:Esta tabla indica lubricantes comparables de distintosfabricantes. Dentro de una viscosidad y tipo de lubricante sepuede cambiar el fabricante de aceite. Al cambiar laviscosidad o el tipo de lubricante, se tendrá que consultar connosotros, de lo contrario no podremos asumir ningunagarantía por la capacidad de funcionamiento de nuestrosengranajes reductores.

Nota:Questa tabella elenca i lubrificanti compatibili di diversifornitori. Avendo la stessa classe di viscosità e tipo dilubrificante il fornitore può essere scelto liberamente. Nelcaso in cui si desideri cambiare viscosità contattare la NORDaltrimenti non potremo assicurare il buon funzionamento delriduttore e di conseguenza la garanzia non sarà valida.

Observações:Esta tabela mostra os lubrificantes similares de diferentesfornecedores. Respeitando-se a classe de viscosidade e tipode lubrificante, o fornecedor pode ser escolhido livremente.A eventual troca por lubrificante de características técnicasdiferentes deve ocorrer através de nossa autorizaçãoexpressa, caso contrário implicará na perda da garantia.

Tipos de lubricante / Tipo di lubrificante / Tipo de lubrificanteTemp. ambientalTemp. ambienteTemp. ambiente

0 ... 40°CISO VG 680

Degol BG 680Degol BG 680plus

-- Alpha SP 680 FalconCLP 680

-- RenolinCLP 680CLP 680 Plus

KlüberoilGEM 1-680

Mobilgear:- 636- XMP 680

OptigearBM 680

ShellOmala 680

Tribol1100/680

ISO VG 220- 5 ... 40°C (normal)

DegolBG 220BG 220 plus

EnergolGR-XP220

Alpha SP 220Alpha MW220Alpha MAX 220

FalconCLP 220

SpartanEP 220

Renolin CLP 220Renolin CLP 220Plus

KlüberoilGEM 1-220

Mobilgear630MobilgearXMP 220

OptigearBM 220

ShellOmala 220

Tribol1100 / 220

ISO VG 100- 15 ... 25°C

DegolBG 100BG 100 plus

EnergolGR-XP100

Alpha SP 100Alpha MW 100Alpha MAX 100

Falcon CLP100

SpartanEP 100

Renolin CLP 100Renolin CLP 100Plus

KlüberoilGEM 1-100

Mobilgear:- 627- XMP 110

OptigearBM 100

ShellOmala 100

Tribol1100 / 100

Tipo delubricanteTipo di lubrif.Tipo de lubrif.

Aceite mineralOlio mineraleÓleo mineral

ISO VG 15- 45 ... - 15°C *

Vitamol1010

BartranHV 15

Hyspin AWS 15Hyspin SP 15Hyspin ZZ 15

AstronHVLP 15

Univis J13 Renolin B 15 HVI Isoflex MT30 rot

Mobil DTE11 M

Ultra 10 Shell TellusT 15

Tribol943 AW 22

-5 ... 60°CISO VG 680

DegolGS 680

EnergolSG-XP 680

-- -- -- Renolin PG 680 KlübersynthGH-6-680

GlygoyleHE 680

OptiflexA 680

Shell TivelaS 680

Tribol800 / 680

Aceite sintéticoOlio sinteticoÓleo sintético

ISO VG 220-25 ... 80°C *

DegolGS 220

EnersynSG-XP 220

AlphasynPG 220

PolydeaPGLP 220

Glycolube220

Renolin PG 220 KlübersynthGH-6-220

GlygoyleHE 220

OptiflexA 220

ShellTivela WBTivela S 220

Tribol800/ 220

ISO VG 680-5 ... 40°C

-- -- -- -- -- Plantogear CLP680

-- -- -- -- --AceitebiodegradableOliobiodegradabileÓleobiodegradável

ISO VG 220-5 ... 40°C

DegolBAB 220

BiogearSE 220

CarelubGES 220

Ergon ELP220

-- Plantogear CLP220

KlüberbioGM2-220

-- OptisyntBS 220

-- Tribol BioTop1418 / 220

-5 ... 40°CISO VG 680

-- -- -- -- -- Bel-Ray No-ToxSynt.Worm GearOil 680

Klüberoil4 UH1-680KlübersynthUH1 6-680

-- OptilebGT 680

ShellCassidaFluid GL680

TribolFoodProof1800 / 680

EuralGear 220

-- VitalubeGS 220

-- Gear OilFM 220

Bel-Ray No-ToxGear Oil 90

Klüberoil4 UH1-220

Mobil DTEFM 220

OptilebGT 220

Shell CassidaFluid GL220

TribolFoodProof1810 / 220

Aceite compat. c.prod. alim.1)

Olio per ambientialimentari 1)

Óleo p/ ind.Alimentícia ISO VG 220

-25 ... 40°CSynt.Gear Oil 220 Klübersynth

UH1 6-220oder1800 / 220

Grasa sintéticafluidaGrasso sinteticoGraxa sintéticafluida

- 25 ... 60°CAralubBAB EP0

EnersynGSF

Alpha Gel 00 -- FließfettS 420

Renolit LX-PG 00 KlübersynthGE 46-1200KlübersynthUH1 14-1600 1)

GlygoyleGrease 00

ObeenUF 00

TivelaComp. ATivela GL 00

Tribol800 / 1000

Tipos de lubricante para rodamientos antifricción / Tipo di lubrificante per cuscinetti / Tipos de lubrificantes para rolamentosTipo delubricanteType oflubricantTipo delubrificante

Temp. ambientalTemp. ambienteTemp. ambiente

- 30 ... 60°C(normal)

AralubHL 2

EnergreaseLS 2

Spheerol AP2 LZV-EP

Glissando 20 GrasauniversalBeacon2

Renolit FWA 160 KlüberplexBEM 41-132

Mobilux 2 LongtimePD 2

ShellAlvania R2

Tribol4020/220-2

Grasa (a base deaceite mineral)Grasso (oliominerale di baseGraxa (base óleomineral)

* - 50 ... 40°CAralubSEL 2

-- SpheerolEPL2

-- -- Renolit JP 1619 -- -- LongtimePD 1

Shell AlvaniaRL 2

Tribol3785

Grasa sintéticaGrasso sinteticoGraxa sintética

* - 25 ... 80°CAralubSKL 2

-- Product783/46

Discor B EP2 LF

Beacon325

Renolit S 2Renolit HLT 2

Isoflex TopasNCA 52

Isoflex TopasNB 52

MobiltempSHC 32

OptitempLG 2

Aero ShellGrease16 oder 7

Tribol3499

GrasabiodegradableBiodegradableGreaseGraxabiodegradável

- 25 ... 40°CAralubBAB EP 2

BP Bio-grease EP 2

Biotec Dolon E EP 2 -- Plantogel 2 S KlüberbioM 32-82

SchmierfettUE 100 B

EF 584 ShellAlvaniaRLB 2

Molub-AlloyBioTop 9488

Grasa compat. c.prod. alim 1)

Grassobiodegradabile 1)

Graxa p/ ind.Alimentícia 1)

- 25 ... 40°CEuralGrease EP 2

BPEnergreaseFM 2

Vitalube HTGrease 2

Tamix FRA 1 Carum330

RenolitG 7 FG 1

KlübersynthUH1 14-151

Mobil-greaseFM 102

ObeenUF 2

Shell CassidaRLS 2

Molub-AlloyFood-Proof823-2 FM

* En caso de temperaturas ambiente inferiores a -30 °C y superiores a 60 °C se tendrán que utilizar retenes de un material de calidad especial* Con temperature ambiente sotto –30°C e sopra approssimativamente i 60°C è consigliabile usare anelli di tenuta speciali* Para temperaturas ambientes inferiores a –30ºC e superiores a 60ºC devem ser utilizados retentores especiais.

1) Aceites + grasas aprobados para la industria alimenticia según la norma H1 / FDA 178.35701) Lubrificanti per ambienti alimentari con USDA-H1 approvato da FDA 178.35701) Lubrificantes aprovados para a indústria alimentícia pelo FDA 178.3570

B 3

B 6

B 7

B 8

B 5

B 5 I

B 5 II

B 5 III

SK 11 E - SK 51 E SK 02 - SK 52SK 03 - SK 53

SK 62 - SK 103

SK 63 - SK 103

SK 62 - SK 102

SK 62 - SK 102

SK 63 - SK 103

SK 62 - SK 102

SK 63 - SK 103

POSICIONES DE MONTAJEPOSIZIONI DI MONTAGGIOFORMAS CONSTRUTIVAS

Posición horizontalDisposizione orizzontale

Posição horizontal

SK 63 - SK 103

SK 62 - SK 102

Motor trifásico con rotor en cortocircuitoMotore trifase con rotore in corto circuitoMotor trifásico de rotor em gaiola

I) Placa de terminales Morsettiera Placa de bornesII) Interruptor

InterruttoreContator

Posición verticalDisposizione verticale

Posição vertical

SK 11 E - SK 51 ESK 02 - SK 03 -SK 52 SK 53 SK 62 - SK 103

V1 *

V3

V5 *

* Posiciones de montaje V1 o V5 con depósito de compensación del aceite (véase catálogo G1000)* Posizione di montaggio V1 o V5 con unità di espansione lubrificante (vedi catalog G 1000)* Formas construtivas V1 ou V5 com câmara de expansão (veja catálogo G1000)

Esquemas de conexión / Schemi di collegamento / Diagramas elétricos

V6

Símbolos:Simboli:Símbolos:

VentilaciónSfiatoBujão de respiro

Nivel de aceiteLivello dell’olioNível de óleo

Salida de aceiteTappo di scaricodell’olioBujão de dreno

FijaciónSuperficie di montaggioSuperfície de montagem

SK 63

SK 63

Motor trifásico con rotor en cortocircuito, conexión DahlanderMotore trifase con motore in corto circuito, collegamento DahlanderMotor trifásico de dupla rotação, ligação Dahlander

Motor trifásico de polos conmutables, dos bobinas separadasMotore trifase a poli commutabili, due avvolgimenti separati, due velocita‘Motor trifásico de dupla rotação, bobinagens independentes

inferior - velocidad - superiorinferiore - numero dio giri - superiorebaixa - rotação - alta

inferior - velocidad - superior inferiore - numero dio giri - superiorebaixa - rotação - alta

Operating and Maintenance Instructions

These safety instructions must be kept in a safe place

B 1091 Status: 06.03

Three-phase Asynchronous Motors – Standard Design SK 63./. – SK 132./.

Explosion-proof Motors with Type of Protection "e"

SK 63./. ED – SK 132./. ED

Dust Explosion-proof Motors (Zone 21)

SK 63./. 2D – SK 132./. 2D

Dust Explosion-proof Motors (Zone 22)

SK 63./. 3D – SK 132./. 3D

GB

Page -2- B1091-D

1. General information These Operating Instructions must be read before you transport, assemble, commission, maintain or repair NORD motors. All persons who are involved with such tasks must observe these Operating Instructions. All safety instructions provided in these Operating Instructions must be strictly observed for reasons of personal protection and protection of property. Information and instructions provided in the manual supplied, safety and commissioning information and all other manuals must be observed. This is absolutely essential in order to avoid hazards and damage! Any applicable national, local and system-specific regulations and requirements must also be observed! Custom designs and design variants may differ on technical details. If any points are not clear, it is urgently recommended that you consult the manufacturer stating the type designation and motor number or have the maintenance work performed by NORD.

Qualified staff are persons who, owing to their training, experience, instruction received, and their knowledge of relevant standards, accident prevention regulations and the appropriate operating conditions, are entitled to perform the activities necessary in order to put the motor into operation. That also calls for knowledge of First Aid and local rescue facilities.

CONTENTS Page 1. General information ...........................................................................................2 2. Description..........................................................................................................3

2.1 Range of application.............................................................................................3 2.2 Design and method of operation ..........................................................................3

3. Operation.............................................................................................................4 3.1 Transport, storage ................................................................................................4 3.2 Installation ............................................................................................................4 3.3 Balancing, output components.............................................................................4 3.4 Alignment..............................................................................................................4 3.5 Electrical connection ............................................................................................5 3.6 Checking insulation resistance.............................................................................5 3.7 Commissioning.....................................................................................................5

4. Maintenance/servicing .......................................................................................6 5. Motors with type of protection Increased Safety EExe ..................................7 6. Motors for protection against dust explosion.................................................9 6.1 General.................................................................................................................9 6.2 Safety instructions ................................................................................................9 6.3 Commissioning instructions/range of application.................................................9 6.4 Design and method of operation ........................................................................10 6.5 Minimum cross-sections of protective earth wires .............................................10 6.6 Inverter operation ...............................................................................................10 6.7 Maintenance.......................................................................................................10 7. Spare parts drawing and spare parts list ......................................................11

B1091-D Page -3-

It is assumed that the work for transport, assembly, installation, commissioning, maintenance and repair will be performed by qualified staff. The following points in particular must be observed: • Specifications and information about permissible use, assembly, connection, ambient and operating

conditions, which are included in the catalogue, the order documentation and any other product documentation

• The local, system-specific regulations and requirements • Expert use of tools, hoisting equipment and transport equipment • Use of personal safety equipment For reasons of simplicity the Operating Instructions cannot contain all detailed information about possible design variants so they cannot take into consideration every imaginable case of installation, operation or maintenance. For this reason these Operating Instructions essentially only contain such instructions as are required for normal use by qualified staff.

To prevent malfunctions it is necessary that the specified maintenance and inspection work be performed by appropriately trained staff.

If the Operating Instructions are lost for any reason, a copy can be obtained from NORD. 2. Description 2.1 Range of application Use of the motors: The motors may only be used for their intended purpose. The motors are designed with at least IP 55 protection (for degree of protection see rating plate). They can be installed in a dusty or moist environment. The necessary degree of protection and any additional precautions required always depend on the operating and environmental conditions. For outdoor installation and vertical designs, e.g. V1 or V5 with shaft pointing down, NORD recommends using the option of the double fan hood. The motors must be protected against intense sunlight, e.g. by means of a protective roof. The insulation is tropic-proof. Ambient temperature: -20°...+40° C Installation altitude: ≤ 1,000 m 2.2 Design and method of operation Motor designs: • Standard NORD 3-phase AC motors are self-cooled (with fan), cooling method IC 411. • In the case of foot-mounted motors in frame sizes 63S/.. to 90L/.. the feet are cast onto the motor housing. • In the case of foot-mounted motors in frame sizes 100L/.. to 132M/.. the feet are bolted onto the motor

housing. • In the case of brake motors the brake operating instructions also have to be observed!

Page -4- B1091-D

3. Operation

Work may only be performed if the system is disconnected from the mains supply. 3.1 Transport, storage

• For transport use all the hoisting lugs fitted to the motor! • The hoisting lugs are designed for the weight of the motor; do not attach any additional loads! • To transport machine sets (e.g. gear unit attachments) only use the hoisting lugs and pins provided! • Machine sets must not be hoisted by attaching to individual machines!

To prevent damage to the motor, the motor must always be lifted with suitable hoisting equipment. The antifriction bearings should be replaced if the time between delivery and motor commissioning under favourable conditions (storage in dry, dust-free and vibration-free rooms) is more than 4 years. Under unfavourable conditions that time is reduced considerably. It may be necessary to treat unprotected, machine surfaces (flanging surface, shaft end; ...) with corrosion inhibitor. If necessary, check the insulation resistance of the winding, see section 3.6. Changes in normal operation (higher power consumption, higher temperatures or higher vibrations, unusual noises or smells, response from the monitoring system, etc.) indicate that operation is impaired. To avoid personal injury and damage to property, the maintenance staff responsible must be informed about the change immediately.

In case of doubt switch off the motor without delay, as soon as the status of the system permits. 3.2 Installation • After installation, tighten up or remove any hoisting lugs that have been screwed in! • Smooth running: accurate alignment of the coupling as well as a well-balanced drive assembly

(coupling, pulleys, fan, ...) are essential for smooth, vibration-free running. • If may be necessary to completely balance the motor with the output assembly. • The top section of the terminal box and the orientation of the terminal box can be rotated 4 x 90 degrees. 3.3 Balancing, output components Fitting and removing output assemblies (coupling, pulleys, gear, ...) must be performed with a suitable device. The rotors are balanced with half key balancing as standard. When fitting output assemblies to the motor shaft observe the appropriate type of balancing! The output assemblies have to be balanced in accordance with DIN ISO 1940! Take the general precautions necessary for providing the output assemblies with shock protection. If a motor is put into operation without an output assembly, prevent the key from being flung out. This also applies if a second shaft end is fitted. Alternatively, remove the key. 3.4 Alignment Especially if there is a direct coupling, align the shafts of the motor and the driven machine with one another axially and radially. Any inaccurate alignment can lead to bearing damage, excessive vibrations and shaft breakage.

B1091-D Page -5-

3.5 Electrical connection Feed the connecting leads into the terminal box with cable glands. The terminal box must be sealed so that it is dust-tight and water-tight. The mains voltage and mains frequency must agree with the figures on the rating plate. ± 5% voltage deviations or ± 2% frequency deviations are permissible without any reduction in performance. The connections and arrangement of the terminal board jumpers must conform to the circuit diagram provided in the terminal box. Connect the protective earth lead to that protective earth terminal.

Provide the ends of the connecting leads with cable lugs or curved ring eyes and connect them to the terminal board. That also applies to the protective earth connection and the external bonding lead. For tightening torques at the screw connections of electric terminals and the terminal board connections (apart from terminal strips) refer to the table below:

Tightening torques for terminal board connections

Thread diameter M4 M5 M6

Tightening torque (Nm) 0.6 – 1.2 1.8 – 2.5 2.7 – 4.0 If the machine has an auxiliary heater, it must not be switched on during operation. 3.6 Checking insulation resistance Before putting the motor into operation for the first time, after a lengthy period of storage or standstill (approx. 6 months), the insulation resistance of the winding has to be determined. During and directly after measurement the terminals carry hazardous voltages in some cases and must not be touched. Insulation resistance The insulation resistance of new, cleaned, repaired windings against the housing and against one another is >200 M Ohm. Measurement In the case of windings up to an operating voltage of 400 V the insulation resistance against the housing must be measured with a DC voltage of 500 V. At operating voltages up to 725 V measure with a DC voltage of 1000 V. When doing this the temperature of the windings should be 25°C ± 15°C. Checking If, in the case of a new, cleaned winding or a repaired motor which has been stored or shut down for any lengthy period, the insulation resistance of the winding against the housing is less than 50 MOhm, the cause may be moisture. The windings will then have to be dried. After any lengthy period of operation the insulation resistance may drop. As long as the measured value does not fall below the critical insulation resistance of < 50 MOhm, the motor may continue to be operated. If the value falls below the critical level, the cause must be established and if necessary, the windings or winding sections must be repaired, cleaned or dried.

3.7 Commissioning Note: Electromagnetic compatibility Emitted interference: If torques are not equal (e.g. drive of a piston compressor) a non-sinusoidal motor current is bound to develop, the harmonics of which may cause impermissible mains influence and hence impermissible emitted interference. If power is fed via an inverter, different levels of emitted interference will occur, depending on the design of inverter (type, suppression, manufacturer). It is absolutely essential that the EMC information provided by the inverter manufacturer be observed. If the manufacturer recommends a screened motor supply lead, screening will be most effective if it is electrically connected to a large area of the metal terminal box of the motor (with EMC cable gland made of metal). In the case of motors with built-in sensors (e.g. PTC thermistors) interference voltages can occur on the sensor line, caused by the inverter. Interference immunity: In the case of motors with built-in sensors (e.g. PTC thermistors) the user himself must ensure adequate interference immunity by making a suitable selection of sensor signal line (possibly with screening, interfacing as with motor supply lead) and the analysing instrument. Prior to commissioning always observe the information and instructions in the operating manuals for inverters as well as all other sets of instructions. After attaching the motors, check them to make sure they are operating properly! In the case of brake motors also check that the brake operates properly.

Page -6- B1091-D

4.0 Maintenance/servicing Safety precautions

Before commencing any work on the motor or device, but especially before opening covers in front of live components, always isolate the motor electrically according to the regulations. Apart from the main circuits also isolate any additional or auxiliary circuits. The standard "5 safety rules", e.g. according to DIN VDE 0105, are: • Isolate electrically • Prevent equipment from being switched on again • Check that there is no voltage • Earth and short-circuit • Cover any adjacent live components or prevent access with barriers The above precautions may only be withdrawn when the maintenance work has been completed and the motor is fully assembled.

Inspect the motors properly at regular intervals. In particular look out for any physical damage, ensure that cooling passages are free, listen for any unusual noises, and ensure that electrical connections are performed in a proper manner.

With the exception of standardised, commercial or equivalent parts the only spare parts which may be used are genuine spare parts! NOTE: Inasmuch as motors are provided with enclosed condensation ports, they must be opened from time to time so that any accumulated condensation can drain off. Condensation ports are always positioned at the lowest point of the motor. When installing the motor ensure that the condensation holes are at the bottom. Bearing changes, grease filling The period for changing bearings in operating hours [h] on IEC motors with coupling drive is as follows, under normal operating conditions and with the motor installed horizontally, depending on coolant temperature and motor speed: 25°C 40°C Up to 1,800 rpm approx. 40,000 h approx. 20,000 h Up to 3,600 rpm approx. 20,000 h approx. 10,000 h

In the case of direct gearbox attachment or under special operating conditions, e.g. vertical motor, substantial vibrations or shock loads, frequent reversing, etc. the above-mentioned operating hours will be reduced considerably. The motor must be subjected to a general overhaul every 5 years! The motors have deeper groove ball bearings with cover disks (2Z design) or shields (2RS design). In the case of frame sizes 63-100 the ball bearings are fitted with normal bearing clearance and in the case of frame sizes 112 and 132 with increased bearing clearance (C3). The filling of grease in the ball bearings is sufficient for the entire service life. Antifriction bearings have to be pulled off with a suitable device. Any soiling of the bearings must be removed!

The shaft seal seats on the shaft must not be damaged in any way whatsoever. Minute scores will cause a leakage. • Before fitting, heat antifriction bearings uniformly to approx. 80 -100°C. • Avoid any hard knocks (e.g. with a hammer, ...). • Also replace any worn sealing elements (e.g. shaft seal, ...). • If shaft seals are fitted without a spring, the spare part must also be inserted without a spring. • When fitting shaft seals apply plenty of antifriction bearing grease; particularly at the sealing lip.

B1091-D Page -7-

General overhaul For this purpose the motor must be dismantled. Perform the following work: • Clean all parts of the motor • Inspect all parts of the motor for damage • Replace all damaged parts • Replace all antifriction bearings • Replace all gaskets and shaft seals The general overhaul must be performed in a specialised workshop with appropriate equipment and by qualified staff. We urgently recommend having the general overhaul performed by NORD Service. 5. Motors with type of protection Increased Safety EExe These motors are subject to the following supplementary or specific information. Explosive gas mixtures or concentrations of dust in conjunction with hot, live and moving parts on electrical machinery can cause serious or lethal injuries. The motors are suitable for use in Zone 1 and conform to equipment group II, category 2G.

The marking is 0102 II 2G EEx e II along with the temperature class. If the motor is connected to a gearbox, the Ex marking of the gearbox must also be observed. The increased hazard in explosive areas calls for particularly careful compliance with the general safety and commissioning instructions. The staff responsible must be trained regarding correct use of motors in explosive areas. Explosion-proof electrical machines comply with the standards in series EN 60034 (VDE 0530) as well as EN 50014 and 50019. It is the degree of explosion risk which determines zone classification. DIN EN 60079, Part 10, provides information on this. It is the user who is responsible for zone classification. If motors are not certified for explosive areas, it is prohibited to use them in explosive areas. Cable entries must be approved for explosive atmospheres. Ports which are not used must be closed off with approved blind plugs. When connecting up the installation lines to the motor terminals and the protective earth lead must be laid with U-shaped lines under the respective terminals so that the wire clamps and the terminal studs are subjected to uniform loading and are not deformed under any circumstances. Alternatively, the connections can be made with a cable lug. When connecting up always ensure that the permissible clearance distances of 10 mm and the permissible creepage distances of 12 mm between live components and housing potential and between individual live components are observed. Before the terminal box is closed, make sure that all the nuts on the terminals and the screw on the protective earth terminal are tight. The terminal box gaskets and the seals on the cable gland must be fitted properly and must not be damaged in any way. If the shaft end is at the top, e.g. designs IMV3 or IMV6, and the motor has EExe protection, the user/installer must fit a cover which prevents foreign bodies from falling into the motor fan hood (see DIN EN 50014). It must not impair cooling of the motor by its fan. A handwheel at the second shaft end is not permitted. If the shaft end is at the bottom, e.g. designs IMV1 or IMV5, the motors are generally provided with a protective roof on the fan hood. The motors are designed for continuous duty and normal, non-recurring start-ups in which no substantial start-up heat develops.

Page -8- B1091-D

Area A in EN 60034-1 (VDE 0530 Part 1) - voltage ± 5%, frequency ± 2%, characteristic, mains symmetry - must be observed so that the development of heat remains within the limits permitted. Any major deviations from the ratings can caused an impermissible increase in the development of heat in the electric machine. The motor temperature class stated on the rating plate must at least conform to the temperature class of any combustible gas that may be emitted. Each machine must be protected against impermissible development of heat by a current-dependent delayed protective switch tested for operation by an appointed body, with phase-failure protection in compliance with VDE 0660 or an equivalent system in all phases. The protective system must be set to the rated current. If windings are connected in a delta circuit the trips must be connected in series with the winding phases and set to 0.58 times the rated current. If such a configuration is not possible, additional precautions will be necessary (e.g. thermal machine protection). If the rotor jams, the protective system must shut down within the tE-time specified for the respective temperature class. Electric machines for heavy starting (ramp time > 1.7 x tE-time) must be protected by a start-up monitoring system in accordance with the provisions of the EC type test certificate. Thermal machine protection by means of direct thermal monitoring of the winding with PTC thermistor temperature sensor is permissible if it is certified and stated on the rating plate.

Do not connect any voltage higher than 2.5V to the PTC thermistor temperature sensor! If the only protection is a PTC thermistor temperature sensor, a performance-tested, certified PTC tripping unit from an appointed body must be used. The PTC tripping unit must be provided with the following marks concerning the degree of protection: II (2) G In Germany reference is made to DIN 57165/VDE 0165 and ElexV for setting up electrical installations in explosive areas! In other countries the appropriate national regulations must be observed! Operation in conjunction with an inverter must be explicitly certified. It is absolutely essential that the separate manufacturer's instructions be observed. For EExe protection the motor, inverter and protective systems must be identified as belonging together and the permissible operating data must be defined on the joint EC type test certificate. The levels of voltage peaks generated by the inverter may be subjected to unfavourable influences by the connecting cable installed between the inverter and the electric machine. In the system comprising inverter-cable-electric machine the maximum figure for voltage peaks at the connecting terminals on the machine must not be less than the figure specified in the separate manufacturer's instructions. In addition, the EMC Directive must also be observed. Any repairs must be performed by NORD or accepted by an officially recognised independent expert. The work must be identified by means of an additional repair plate. With the exception of standardised, commercial and equivalent parts, the only spare parts which may be used are genuine spare parts (see spare parts list): this particularly applies to seals and connecting parts. In the case of motors with closed condensation holes the threads of the plugs must be recoated with Loctite 242 or Loxeal 82-21 after condensation has been drained off. As soon as that has been done the plugs must be reinserted. Checking of electrical connections must be performed at regular intervals. The connection terminals, protective earth terminal and equipotential bonding terminal must be inspected to make sure they are firm. When doing so, check to make sure that the cable entry, cable gland and terminal box gaskets are in good condition.

All work on electric machines must be performed with the machine vertical and with all terminals disconnected from the mains.

If installation resistance is being measured the motor must be removed. Measurement must not be performed in the explosive area. As soon as measurement has been completed discharge the connecting terminals again by shorting them in order to prevent any spark discharges occurring in the explosive area.

6. Three-phase asynchronous motors for use in Zone 21 and Zone 22 6.1 General Motors in categories 2D and 3D are subject to the supplementary or specific information below! 6.2 Safety instructions The increased risk in areas with combustible dust calls for strict observation of the general safety and commissioning instructions. Explosive concentrations of dust can, if ignited by hot or sparking objects, cause explosions which result in serious to lethal injuries to persons as well as considerable damage to property. It is absolutely imperative that the persons responsible be trained for the correct use of motors in explosive areas. 6.3 Commissioning instructions / range of application In accordance with their markings the motors are suitable for use in Zone 21 (category 2D) or Zone 22 – non-conductive dust (category 3D). If the motors are to be suitable for inverter operation, this must be stated when placing the order. The motors must be protected against overheating by means of suitable monitoring devices! The amount of dust settling must not exceed 5 mm! The motors are designed for voltage and frequency range A of EN 60034 Part 1. Motors for use in Zone 21 and Zone 22 with the mark TF may be monitored thermally by a built-in PTC in conjunction with a suitable tripping unit, as sole protection. If the motor is marked TFX, the PTC thermistor may only be used as extra protection in addition to the motor protection switch.

The marks are: 0102 II 2 D T 125°C for Zone 21 Certificate number:

II 3 D T 125°C for Zone 22 (non-conductive dust) If the motor is connected to a gearbox, the Ex marking on the gearbox must be observed in addition! Electrical equipment for use in areas with combustible dust conform to the standards EN 50281-1-1, EN 60034 as well as EN 50014. The degree of explosion risk determines zone classification. The user/employer is responsible for zone classification (Directive 1999/92/EC). If the certificate is supplemented with an X, special rules in the EC type test certificate have to be observed. If standards motors are not certified for explosive areas, it is prohibited to use them in explosive areas. For Zone 21 the cable entries must be approved for explosive applications (degree of protection at least IP 66) and prevented from becoming loose on their own. Any ports not used must be closed off with approved plugs (degree of protection at least IP 66). For Zone 22 the cable entries must at least satisfy the requirements of IP 55 protection. Any ports not used must be closed off with blind plugs (minimum degree of protection IP 55). Any opening of the motor in order to connect electric cables or perform other work must not take place in an explosive atmosphere. The voltage must always be switched off before opening and precautions must be taken to prevent equipment from being switched on again! If the shaft end is at the top, e.g. designs IMV3 or IMV6, the user/installer must fit the cover to the motors which prevents foreign bodies from falling into the motor fan hood (see DIN EN 50 281-1-1). It must not impair cooling of the motor by its fan. A handwheel at the second shaft end is not permitted. If the shaft end is at the bottom, e.g. designs IMV1 or IMV5, the motors are generally provided with a protective roof on the fan hood for Zone 21. Unless the test certificate or the rating plate provides different information as regards mode of operation and tolerances, electric machines are designed for continuous duty and normal, non-recurrent start-ups in which no substantial start-up heat develops. The motors may only be used for the mode of operation stated on the rating plate It is absolutely imperative that the installation specifications be observed!

B1091-D Page -9-

Page -10- B1091-D

6.4 Design and method of operation The motors are self-cooled. Shaft seals are fitted both at the drive end and at the ventilation end. Motors for Zone 21 and for the Zone 22 have a metal fan. The motors have IP 55 protection (Zone 22 - non-conductive dust) or IP 66 (Zone 21). The surface temperature does not exceed 125°C under normal operating conditions. 6.5 Minimum cross-sections of protective earth wires

Cross-section of the live wire for installation S in mm2

Minimum cross-section of the associated protective earth wire SP in mm2

S ≤ 16 16 < S ≤ 35

S > 35

S 16

0.5 S When connecting a wire to the external earthing system the cross-section must be a minimum of 4 mm2. 6.6 Converter operation Each rating plate on converter-compatible motors states the maximum frequency which must not be exceeded. Motors for inverter operation are generally equipped with 3 PTC thermistors. The PTC thermistor tripping unit must be selected according to the valid standard. The temperatures at the points of cable entry are 120°C max. Suitable cables must be used for that temperature. The levels of the voltage peaks generated by the inverter may be subjected to unfavourable influences by the connecting cable installed between the inverter and the electric machine! This must be taken into consideration in configuration! The EMC regulations must be observed! 6.7 Maintenance Always switch off the voltage before opening and take precautions to prevent the equipment from being switched on again! Important! Inside the motor temperatures may occur which are higher than the maximum permissible surface temperature of the housing. Consequently, the motor must not be opened in an explosive dusty atmosphere! Perform a regular check on the motors to ensure that they are reliable! Impermissibly high levels of dust must not be allowed to accumulate! If the motor is not reliable, it must not be used any longer! When the ball bearings are being changed the shaft seals must also be replaced. Use shaft seals made of NBR specified by NORD. Only genuine parts may be used as spare parts, with the exception of standardised, commercial and equivalent parts. This particularly applies to seals and connecting parts. In the case of terminal box parts and spare parts for external earthing the parts must be ordered according to the spare parts list in the Operating Instructions. Gaskets, shaft seals and cable glands must be checked regularly to make sure they are in good working order! Maintenance of dust protection for the motor is of prime importance with regard to protection against explosion.

7. Spare parts drawing and spare parts list

Item No. Description Item No. Description 900 Rotor with shaft 902 End shield at drive end 902.1 Cheese-head screw 902.2 Hexagon nut 904 Shaft seal 905 Bearing at drive end 906 Ball bearing shim 907 Terminal box frame 907.1 Chassis connection terminal wire clamp 907.2 Oval-head screw 908 Terminal box lid 908.1 Cheese-head screw 909 Terminal box frame gasket 910 Terminal box lid gasket 911 Terminal board 911.1 Cheese-head screw 911.5 Spring lock washer 912 Mini-terminal 912.1 Oval-head screw 913 Spacer 913.1 Cheese-head screw 913.2 Spring lock washer 916 Stator with winding 916.1 Equipotential bonding terminal 916.2 Spring pin

918 Key 924 Screw-on foot (BG 100-132) 924.1 Hexagon bolt 924.2 Spring lock washer 924.3 Hexagon nut 929 Bearing at ventilation end 932 End shield at ventilation end 932.1 Cheese-head screw 932.2 Hexagon nut 933 Shaft seal 939 Fan 940 Fan hood 940.1 Oval-head screw 940.2 Countersink screw B3 941 Key 942 947 Circlip 948 Circlip 952 Clamping bush 953 Cable gland 955 Blind plug 956 Blind plug 980 Protective roof 988 Ring seal 989 Rating plate 989.1 Oval-head screw

B1091-D Page -11-

BadgerMeter,Inc.

Installation &Operation Manual

Bulletin No. IOM-067-03Part No. 53400-067

March 2000

®

Model Industrial RCDL

Nutating Disc Meters

GENERAL DESCRIPTION

2

Table 1 - Configuration and Specification Data for Model RCDL Disc Meters

DIMENSIONS (INCHES)

Meter Flow Laying Center Line Register Transmitter ApproximateMeter Size Range Housing End Length to Base Height Height WeightModel Inches GPM Material Connections A B C D Pounds

M 25 5/8 1/2 - 25 BZ or PL NPT - Male 7.5 1.7 3.3 4.4 51 - 25

M 25 3/4 1/2 - 30 BZ or PL NPT - Male 7.5 1.7 3.3 4.4 51 - 30

M 35 3/4 3/4 - 35 BZ NPT - Male 9.0 1.7 3.6 5.0 6M 40 1 3/4 - 50 PL NPT - Male 10.75 1.9 3.8 5.5 5M 70 1 1 - 70 BZ NPT - Male 10.75 2.3 4.2 5.6 12

5 - 70M 120 1 1/2 2 - 120 BZ NPT - Female 12.62 2.4 4.6 6.0 20

10 - 120M 170 2 2 - 170 BZ NPT - Female 15.25 2.9 5.1 6.5 30

BZ = Bronze; PL = PlasticModel 25, Model 70 and Model 120 are available with optional corrosion resistant internals; temperature limit with this optionis increased on the bronze housing model to 250° F.

METER OPTIONS/SPECIFICATIONS

AA

B

C

B

D

C

B

A

E

D

Badger's RCDL positive displacement meters are one of themost cost effective methods in metering industrial fluids.The RCDL meter's simple but efficient design assures highaccuracy and repeatability over the entire meter flow range.

Available in five sizes, 1/2" through 2" for flows up to 170GPM, these meters are extremely rugged and reliable.Maintenance is seldom required, but if necessary, takesonly a few minutes. All parts are designed and built ofmaterials to meet your application, providing you with longlife and a trouble-free, precision flow meter.

To complement the RCDL meter line, Badger offers a com-plete line of accessories that includes totalizers, electrome-chanical and electronic transmitters, rate of flow indicatorsand batch/process controllers.

The metering principle, known as positive displacement, isbased on the continuous fi l l ing and discharging of themeasuring chamber. Controlled clearances between thedisc and the chamber insure precise measurement of eachvolume cycle. As the disc nutates, the center spindle rotatesa magnet, whose movement is sensed through the meterwall by a follower magnet or by various sensors. Eachrevolution of the magnet is equivalent to a fixed volume offluid, which is converted to any engineering unit of measurefor totalization, indication or process control.

Figure 1.

Liquid flowing through the meter chamber (A) causes a disc(B) to nutate or wobble. This motion, in turn, results in therotation of a spindle (C) and drive magnet (D). Rotation istransmitted through the wall of the meter to a secondmagnet (E) or varied style of sensor pickup.

MODEL 25, 35 & 70 MODEL 120 & 170

Meter with Transmitter Meter with Register

CorrosionResistant Internal

CorrosionResistant Internal

CorrosionResistant Internal

CorrosionResistant Internal

3

Any special instructions required for the installation and/or electrical connection of any meter-mounted or free-standing accessory devices such as registers, pulse trans-mitters, and remote batch controllers, will be provided asa supplement to this manual.

A. Please read the following instructions to become fa-miliar with the requirements and the recommended proce-dures involved.

CAUTION: The meter must be operated in an applicationwithin the specified temperature range to obtain opti-mum accuracy and prevent damage to any internalcomponents.

1. Verify the fluid operating temperature range is com-patible with the materials of construction of themeter received.

CAUTION: The life of the meter will be impaired if it isoperated at flow rates in excess of those indicated in theproduct specifications.

2. If any solid material is present in the liquid, instal-lation of a strainer is recommended upstream of themeter.

3. Locate the meter installation with consideration forsufficient space for cleaning and maintenance ofthe meter.

B. Review the overall dimensions (including laying lengthrequirements) of the meter as listed in Table 1 of thismanual on page 2. If necessary, consideration may alsoneed to be given for height dimensions including the metermounted accessory. Then proceed as follows:

1. Measure the overall length of the meter with theconnection pieces attached to the inlet and outletspuds of the meter.

INSTALLATION

2. Be sure to provide this proper gap length in thefacility piping.

CAUTION: Excess gap length may cause excessivestrain on connection assemblies.

3. Remove the connections and install one connectionpiece in each end of the facility pipe gap provided instep #2. Allow for the gaskets at the inlet and theoutlet spuds of the meter.

4. Install the meter making sure that the flow arrowmarking on the meter housing is in the correctrelationship to the direction of the fluid flow in thesystem.

5. Tighten the meter connections.

Note instructions on packaging from connection assem-bly when tightening.

6. To relieve any possible strain on the facility pipingthat might be caused by the weight of any of thelarge size meters, it is recommended that consider-ation be given to incorporating a meter support tobe placed under the housing of the meter.

To ensure that the meter has been properly installed andoperational:

A. Slowly open the upstream valve to apply fluid pressureto the meter. Check the connections for any possibleleakage. Retighten the connections as required.

B. Perform a functional test of the meter utilizing theadjustment and calibration procedures that are includedlater in this manual.

Upon receipt of meter, perform the following:

NOTE: If damage to the shipping container is evident,request the carrier to be present when meter is un-packed.

A. Carefully open the shipping container. Remove all thecushioning material surrounding the meter and carefullylift the meter from the container.

Retain all of the packing material for possible use inreshipment or storage of the meter.

B. Visually inspect the meter and the accessory devicefor any physical damage such as scratches, loose orbroken parts, or any other damage that may have occurredduring shipment of the product.

NOTE: If damage is found upon receipt of the equipment,request inspection by the carrier's agent within 48 hoursof the delivery. Then file a claim with the carrier. A claimfor the equipment damaged in transit is the responsibil-ity of the customer.

UNPACKING AND INSPECTION

In general, the operation of a Model RCDL disc meter iseither manually controlled or accessory controlled. Manualoperation applies to the applications employing hand-operated valves or other manually activated, flow-regulat-ing devices that are not functionally controlled by a meteraccessory. Accessory controlled operation applies to ap-plications when a meter accessory provides a signal out-put to activate and/or deactivate a valve or other flowcontrol device.

CAUTION: Valves controlling the fluid flow through themeter should be opened and closed slowly to preventshock loads that may damage the meter measuringelement.

A. MANUAL OPERATION. The following procedures arefor use in simple metering applications where the flow offluid is controlled by hand-operated valves located up-stream and downstream of the meter.

1. Slowly open the upstream valve to apply fluid to themeter.

2. Slowly open the downstream valve to initiate themetering operation.

3. Adjust downstream valve so the flow rate of thefluid does not exceed the maximum continuousflow rate specification of the meter. (Refer to Table1 of this manual.)

NOTE: On meters with an accessory device providing atotalizing indicator, the flow rate of the fluid can bechecked by timing the number of gallons registered inone minute.

4. To stop metering, slowly close downstream valve;then close upstream valve.

B. ACCESSORY CONTROLLED OPERATION. Operatingprocedures for accessory controlled applications are de-pendent on the specific function of that accessory em-ployed and its electrical interconnection with a flow controldevice or devices. Refer to the bulletin or bulletins cover-ing the applicable accessories for specific operating in-structions (included as a supplement to this manual whenrequired.)

SHUTDOWN INSTRUCTIONS

If the meter is to be shut down for an extended period oftime, it is recommended that the measuring chamber ofthe meter be thoroughly flushed out to prevent the settlingout of undissolved solids or the accumulation of corrosivedeposits.

4

GENERAL OPERATING INSTRUCTIONS MAINTENANCE

PREVENTIVE MAINTENANCE

Preventive maintenance consists of periodic inspection andcleaning procedures. The procedures should be performedat regular intervals and any defects discovered should becorrected before further operation of the meter.

PERIODIC INSPECTION

A. Visually inspect meter and accessory for missing hard-ware, loose connections, broken register glass, damagedwiring, or other signs of wear or deterioration. Repair orreplace components as required.

B. Verify proper flow rate and pressure for meter. A loss inpressure, with the resulting flow rate decrease, may indicatethe meter screen is clogged and requires cleaning.

CLEANING

Clean al l dust, dirt, grease, moisture, or other foreignmaterial from exterior of meter and applicable accessory.

CALIBRATION CHECK AND ADJUSTMENT

The following instructions are provided to assist in perform-ing on-site calibration check and/or adjustment.

ACCURACY TEST

A. Place a test tank of known volume at output of meter.

B. Fill test tank to calibrated level. Make test run at sameflow rate to be used in actual operation.

C. Record quantity indicated on applicable accessory.

D. Repeat test three times and average recorded results.

E. Perform the following calculations to determine percentof accuracy of meter-accessory combination.

Qty. Indicated on Accessoryx 100 = Meter Accuracy

Actual Quantity in Test Tank

Example 1.

95 Gallonsx 100 = 95% Accuracy

100 Gallons

The meter-mounted accessory is slow and reading low so itmust be speeded up by a calibration adjustment.

Example 2.

104 Gallonsx 100 = 104% Accuracy

100 Gallons

In this example, the meter accessory is fast and runninghigh so it must be slowed down by calibration adjustment.

5

CHANGE GEAR CALIBRATION

If the accuracy test of a meter-accessory combination indi-cates that adjustment is required and change gears are themedium; proceed as follows:

A. Remove applicable Driver (Accessory) change gear andDriven (Meter) change gear.

NOTE: The number of teeth and outside diameter isstamped on each gear.

Figure 3 - Change Gear Locations onModel RCDL Meters

B. Calculate ratio of existing change gears as follows:

No. of Teeth on Accessory Change GearRatio =

No. of Teeth on Meter Change Gear

C. Calculate new change gear ratio required by multiplyingthe ratio of existing change gears by the percent-of-meteraccuracy determined in the accuracy test.

Example42 Teeth

Existing Change Gear Ratio = = .97643 Teeth

Meter Accuracy = 95%95

Corrected Change Gear Ratio = .976 x = .927100

D. If change gear charts are available, select a new changegear combination that matches corrected change gear ratio.If new gears are not available, submit order for correctivechange gears to nearest Badger Meter Representative orcontact the Industrial Division of Badger Meter, Inc.

NOTE: When ordering, specify serial number of meter,meter model and size, accessory device employed, num-ber of teeth and diameter of existing change gears, andcorrected change gear ratio required.

E. Observe the position of old change gears on spindlesbefore removing. Install new change gears on meter andaccessory spindles and assemble accessory to meter. Careshould be taken to obtain full mesh when assembling acces-sory to meter gear train adapter. Note position informationfrom old gears.

ELECTRONIC CALIBRATION

If electronic scaling is the accessory medium for calibration,see accessory technical brief for instructions.

Meter (Driver)Change Gear

Accessory (Driven)Change Gear

AccessoryDevice

Magnetic DriveGear Train

Adapter

SERVICING

The following instructions are for removal, inspection andinstallation of meter parts/assemblies. Refer to applicableillustrated parts list for part numbers of components andordering information. Accessory service and repair proce-dures are provided in literature specific to that device.

METER ASSEMBLYThese procedures are for disassembly of the meter:

A. Shut off fluid flow to meter. Place container under meterand relieve fluid pressure in the meter by uniformly loosen-ing bolts (bronze meter) or retaining ring (plastic meter).Fluid will run out into container.

B. Remove bolts or retaining ring while holding housingbottom in place. Remove housing bottom. Chamber assem-bly may drop from housing as bottom is removed.

C. I f chamber assembly is out, set aside. I f not, f i rstremove chamber strap and then chamber assembly.

D. Remove meter screen. Inspect screen for dirt and cor-rosion. Clean or replace as necessary.

E. Inspect the chamber assembly:

1. Check the disc in the chamber assembly for warpage,cracks or wear. A severely worn disc can cause overdelivery of the fluid being metered.

2. Check the thrust roller and thrust roller insert forexcessive wear.

After inspection, clean or replace the chamber assemblyas necessary. If chamber is worn or corroded, it is alwaysrecommended that the entire chamber and disc assembly bereplaced.

F. Re-install housing chamber assembly, screen, chamberstrap and bottom as follows:

1. Assemble screen in proper location.

2. Locate chamber assembly in proper orientation. Addchamber strap.

3. Position housing bottom with the correct seal. (Re-placement of seal is always recommended.)

4. Assemble bolts or retaining ring and tighten.

ALTERNATIVE DISASSEMBLY METHOD FOR SERVICELoosen connection pieces slightly. Turn meter upside down,putting gravity on your side. This will help eliminate thepossibility of the chamber assembly and/or screen compo-nent dropping during disassembly and causing damage.

RECALIBRATIONAfter repair or replacement of a meter component or assem-bly, perform the calibration check and adjustment proce-dure to ensure that the meter is properly calibrated and willoperate in accordance with published specifications.

1 Shroud Assembly, Plastic(Cover, top and roll pin, no btm.)

2 Register Assembly, U.S. GallonsRegister Assembly, Liters/M3

3 Shroud Assembly, Plastic(Cover, top, btm., roll pin)

4 Pulse Transmitter Register RTR7 Coupling (Series 76 Register)8 Change Gear, Driver9 Change Gear, Driven

10 Retaining Ring11 Gear Train (234:1)11 Gear Train (30:1)12 Housing, Mach.13 Gear Train Assy. (234:1)13 Gear Train Assy. (30:1)

Item No. Part Description

6

Models 25 and 40Industrial Disc Meters — Thermoplastic

Item No. Part Description

14 Housing Bottom "O" Ring Seal15 Housing Bottom16 Retaining Ring17 Connection Assembly, 1/2" Plastic

Connection Assembly, 3/4" PlasticConnection Assembly, 1" PlasticConnection Assembly, 1/2" BronzeConnection Assembly, 3/4" BronzeConnection Assembly, 1" Bronze

18 Housing 5/8" x 1/2", 7 1/2" LLHousing 5/8" x 3/4", 7 1/2" LLHousing 1" x 1", 10 3/4" LL

19 Chamber and Disc Assembly, PlasticChamber and Disc Assembly, LCP

20 Chamber Retainer Strap21 Screen

Item No. Part Description

7

Models 25, 35, 40, 70, 120 and 1705/8" - 2" Industrial Disc Meters — Bronze

Item No. Part Description

15 Chamber Retainer Strap16 Spring Clip (High Temp. Only)

(Model 25, 70 and 120 Only)17 Screen18 Housing Gasket , Buna N

Housing Gasket, Viton19 Housing Bottom

19A Washers (6 needed)20 Housing Bolt21 Conn. Assembly (2) 1/2"

Conn. Assembly (2) 3/4"Conn. Assembly (2) 1"Conn. Assembly (2) 1 1/2"Conn. Assembly (2) 2"

22 Conn. Washer (1) 1/2"Conn. Washer (1) 3/4"Conn. Washer (1)

23 Housing Top24 Bottom Seal "O" Ring

1 Shroud Assembly, Plastic .(Cover, top & roll pin) (No btm.)

2 Register Assembly, GallonsRegister Assembly, Liters/M3

3 Shroud Assembly, Plastic(Cover, top, btm. & roll pin)

4 Pulse Transmitter Register RTR7 Coupling (Series 76 Reg.)8 Change Gear, Driver9 Change Gear Driven

10 Retaining Ring11 Gear Train (234:1)11 Gear Train (30:1)12 Housing, Mach.13 Gear Train Assy. (234:1)13 Gear Train Assy. (30:1)14 Chamber & Disc Assy., Std.

Chamber & Disc Assy., LCP

®

BadgerMeter,Inc.P. O. Box 245036 Milwaukee, WI 53224-9536Telephone: (414) 355-0400Fax: (414) 355-7499

Due to continuous research, product improvementsand enhancements, Badger Meter reserves the right to

change product or system specifications without notice.All rights reserved.

BadgerMeter,Inc .

TechnicalBrief

Bulletin No. ITB-072-08December 1999

®

FEATURES

• Accuracy: ±1.5% over full range

• Repeatability: ±0.5%

• Wide flow range

• Rugged bronze or thermoplastic housing

• Maximum Operating Temperature

Plastic Housing: 100° FBronze Housing: 120° FModels 25, 70 and 120; Bronze: 250° F Option

• Maximum Operating Pressure: 150 PSI

• Easily maintained without removing from line

• Durable components for minimal maintenance

• Wide range of compatible accessories

• Direct replacement for SC-ER

Model Industrial RCDL

Nutating Disc Meter (Bronze and Thermoplastic)

GENERAL

Badger's RCDL positive displacement meters are one ofthe most cost effective methods in metering industrial fluids.The RCDL meter's simple but efficient design assures highaccuracy and repeatability over the entire meter flow range.

Available in sizes, 1/2" through 2" for flows up to 170 GPM,these meters are extremely rugged and reliable. Mainte-nance is seldom required, but if necessary, takes but a fewminutes. All parts are designed and built of materials tomeet your application, providing you with long life and atrouble-free, precision flow meter.

To complement the RCDL meter line, Badger offers acomplete line of accessories that includes totalizers, elec-tromechanical and electronic transmitters, rate of flow indi-cators and batch/process controllers.

OPERATION

The metering principle, known as positive displacement, isbased on the continuous filling and discharging of themeasuring chamber. Controlled clearances between thedisc and the chamber insure minimum leakage for precisemeasurement of each volume cycle. As the disc nutates, thecenter spindle rotates a magnet, whose movement is sensedthrough the meter wall by a follower magnet or by electronicsensors. Each revolution of the magnet is equivalent to a fixedvolume of fluid, which is converted to any engineering unit ofmeasure for totalization, indication or process control.

Liquid flowing through the meter chamber (A) causes a disc(B) to nutate or wobble. This motion, in turn, results in therotation of a spindle (C) and drive magnet (D). Rotation istransmitted through the wall of the meter to a secondmagnet (E) which operates the transmitter.

BadgerMeter,Inc .P. O. Box 245036 Milwaukee, WI 53224-9536Telephone: (414) 355-0400Fax: (414) 355-7499®

Due to continuous research, product improvementsand enhancements, Badger Meter reserves the right to

change product or system specifications without notice.All rights reserved.

B C Flow Rates - GallonsMeter A Meter Center Hot Water Approx.Size Housing Meter Length Line Cold Liquids Chemicals & Oils Weight

Inches Material Length w/ Conn. To Base 32° F to 120° F 32° F to 250° F (BZ) Pounds32° F to 100° F (PL)

5/8 BZ or PL 7-1/2 12-7/16 1-3/8 1/2 - 25 1 - 25 53/4 BZ or PL 7-1/2 12-5/8 1-3/8 1/2 - 30 1 - 30 53/4 BZ 9 14-1/8 1-3/4 3/4 - 35 N/A 61 PL 10-3/4 16-3/16 2-1/4 3/4 - 50 N/A 51 BZ 10-3/4 16-5/8 2-1/4 1 - 70 5 - 70 12

1-1/2 BZ 12-5/8 19-3/4 2-5/8 2 - 120 10 - 120 202 BZ 15-1/4 22-7/8 3-3/8 2 - 170 N/A 30

BZ = Bronze; PL = Plastic N/A = Not available in High Temperature / Chemical option.Connection set assemblies available, all having NPT threads.

HEIGHT DIMENSIONS (INCHES) (D) WITH REGISTER AND ACCESSORIES

With With WithWith Non Resetable With MS-ER1 With ECA 258 Series 76

Meter Size Register Transmitter Transmitter Transmitter Register Registers

5/8 & 5/8 x 3/4 5-3/4 7-3/8 11-1/4 9-3/8 8 15-1/43/4 6-1/8 7-3/4 11-5/8 9-3/8 8-3/8 15-5/8

1 & 1 x 1-1/4 7-1/2 9-1/8 13 11-3/16 9-3/4 171-1/2 9-1/8 10-3/8 14-1/4 12-3/4 11 18-1/4

2 10-3/4 12-1/4 16-1/8 14-3/8 12-7/8 20-1/8

PERFORMANCE

Accuracy: ± 1.5%Repeatability: ± 0.5%Max. Operating Pressure: 150 PSI

MeterModel

M25M25M35M40M70

M120M170

Dimensions in inches (Without Register)

PRESSURE LOSS CHARTIndustrial Disc Meters

Rate of Flow in Gallons Per Minute

Model 25, 35 & 70 Model 120 & 170

SPECIFICATIONS

MATERIALS OF CONSTRUCTION

High Temp.Cold and/or

Liquid Chemical UnitsUnits Models 25, 70 & 120

Housing: BZ or PL BZ - 250° FPL - 100° F

Chamber: Noryl LCPDisc: SAN LCPCrossbar: Nylon UltemMagnetic Assembly: Nylon UltemChamber Retainer: Polyethylene Metal ClipScreen: Polypropylene None

BadgerMeter,Inc.

Repair Parts

Bulletin No. IRP-104-05Part No. 53401-104

January 2000

Models 25, 35, 70, 120 and 170

5/8" - 2" Industrial Disc Meters – Bronze

BadgerMeter,Inc.P.O. Box 245036 Milwaukee, WI 53224-9536Telephone: (414) 355-0400Fax: (414) 355-7499

All rights reserved.Due to continuous research, product improvements

and enhancements, Badger Meter reserves the right tochange product or system specifications without notice.

Model 25 Model 35 Model 70 Model 120 Model 170

1/2" Top Top

& 3/4" 1" Load Load

Item Description 3/4" 1 1/2" 2"

1 Shroud Assembly, Plastic.................... 62416-001 62416-001 62416-001 62416-001 62416-001

(Cover, top & roll pin) (No btm.)

2 Register Assembly, (up to 120° F)

U.S. Gallons ............................. 33626-002 33626-060 33626-068 33626-011 33626-057

Cubic Meters ............................ 33626-007 33626-062 33626-070 33626-014 33626-059

Register Assembly, (up to 250° F)

U.S. Gallons ............................. 58932-002 -------------- 58932-007 58932-017 --------------

Liters ........................................ 58932-005 -------------- 58932-009 58932-018 --------------

3 Shroud Assembly, Plastic.................... 62696-001 62696-001 62696-001 62696-001 62696-001

(Cover, top, btm. & roll pin)

3a Screw, Tamper-Resistant ....................... 62335-001 62335-001 62335-001 62335-001 62335-001

3b TORX® Seal Screw Driver & Bit (Stubby) .. 62658-001 62658-001 62658-001 62658-001 62658-001

3c TORX® Seal Screw Driver & Bit (Long) ..... 62658-003 62658-003 62658-003 62658-003 62658-003

4 Pulse Transmitter / Register, RTR......... Please advise meter size, model and unit of measure.

7 Coupling (Series 76 Reg.) .................. 56646-001 56646-001 56646-001 56646-001 56646-001

8 Change Gear, Driver .......................... -------------- -------------- -------------- -------------- --------------

9 Change Gear Driven .......................... -------------- -------------- -------------- -------------- --------------

10 Retaining Ring................................... 1013-000 1013-000 1013-000 1013-000 1013-000

11 Gear Train (234:1).............................. 56065-004 56065-004 56065-004 56065-004 56065-004

11 Gear Train (30:1)............................... 56065-005 56065-005 56065-005 56065-005 56065-005

12 Housing, Mach.................................. 58091-002 58091-002 58091-002 58091-002 58091-002

13 Gear Train Assy. (234:1).................... 56066-004 56066-004 56066-004 56066-004 56066-004

13 Gear Train Assy. (30:1) ..................... 56066-005 56066-005 56066-005 56066-005 56066-005

14 Chamber & Disc Assy., Std .................. 33334-009 33334-029 33334-016 33334-017 33334-028

Chamber & Disc Assy., LCP

(Coated Magnet) Viton Seals ................ 58908-006 -------------- 63079-002 63175-002 --------------

Chamber & Disc Assy., LCP

(Coated Magnet) EPR Seals ................. 58908-010 -------------- -------------- -------------- --------------

15 Chamber Retainer Strap ..................... 58540-001 58540-001 56188-001 -------------- 56188-001

(Low Temp. Only)

16 Spring Clip (High Temp. Only)(2 Reqd.) 62695-001 -------------- 62695-002 62695-002 --------------

17 Screen (Low Temp. Only).......................34333-001 59805-001 56182-001 62172-001 59720-001

18 Housing Gasket , EPR .................... 11071-033 59782-001 58769-001 59239-001 59722-001

(Low Temp. Only)

Housing Gasket, Viton........................ 11071-045 -------------- 58769-002 62171-002 --------------

19 Housing Bottom.................................. 62635-001 59784-001 59733-001 -------------- --------------

19A Washers (6 needed)..............................-------------- -------------- 24991-044 -------------- --------------

20 Housing Bolt.......................................62777-001 62777-001 59733-001 55029-089 55029-089

21 Conn. Assembly (2) 1/2"..................... 7557-002 -------------- -------------- -------------- --------------

Conn. Assembly (2) 3/4"..................... 7559-002 7559-002 -------------- -------------- --------------

Conn. Assembly (2) 1" ....................... -------------- -------------- 7561-002 -------------- --------------

Conn. Assembly (2) 1 1/2".................. -------------- -------------- -------------- 7563-000 --------------

Conn. Assembly (2) 2" ....................... -------------- -------------- -------------- 7564-000 7564-000

22 Conn. Washer (1) 1/2" ....................... 11012-001 -------------- -------------- -------------- --------------

Conn. Washer (1) 3/4" ....................... 14143-000 14143-000 -------------- -------------- --------------

Conn. Washer (1) .............................. -------------- -------------- 18177-000 1331-000/ 1359-000

1359-000

23 Housing Top....................................... -------------- -------------- -------------- 62176-001 59719-001

ORDER INFORMATION: This repair parts bulletin shows an exploded view of the product with specific reference to those itemsavailable for replacement. The item number and part number may change at any time; therefore, it is important when placing anorder that a complete description of the part, meter size, model and serial number be provided.