manual de usuario granalladora (2).pdf

7/30/2019 MANUAL DE USUARIO GRANALLADORA (2).pdf

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LLhee l a b r a t o r••• •••• GROUP

Wheelabrator Group

1219 Corporate Drive

Burlington, Ontario L7L 5V5

T: 905-319-7930

T: 800-845-8508

F: 905-319-7561

F: 800-571-5637

vmw.wheelabratorgroup.com

WARRANTY 3463

Gunderson-Gimsa

Purchase Order Number GGOS747-1

Seller warrants that the equipment described herein will be free from defects in material

and workmanship for a period of twelve (12) months from delivery ("Warranty Period").

Ifwithin the Warranty Period Seller receives written notice promptly after the discovery

of any defect in the material or workmanship Seller shall correct each such defect FOB

point of manufacture. Seller shall undertake its warranty obligation of repair,

replacement within a reasonable time of receiving actual notice ofthe warranty defect.

Seller shall be fully compensated for expenses of travel and for job time (at Seller's thenprevailing per diem rates for straight time and premium time, as applicable) of its service

representatives who inspect warranty claims that are not warranty issues. Buyer shall

issue a purchase order for these expenses prior to Seller's representatives arrival on site

Purchaser has no right to and may not backcharge Seller for warranty claims without prior

approval. Normal wear parts and labor are not included. The liability of Seller to

Purchaser/Buyer arising out of or the supplying of the equipment whether under warranty,

tort, contract, negligence, strict liability or otherwise, shall not in any case exceed the cost

of correcting defects in Equipment and l,1ponthe expiration of said warranty, all such



Operation &

Maintenance

ManualLlheelabrator

••••• GROUP

Customer: Gunderson GIMSAS. de R.L. de C.V. Date: Mar. 17/08

City: Frontera, COAH State: Mexico

Machine Style: 4Wheel Plate Descaling Machine

Machine Serial No.: J 3463

Dust Collector: 5D15L Dust Collector

Dust Collector Serial No.: n/a

If you need any assistance, please do not hesitate to call and we will gladly assist you.



Operation &

Maintenance

Manual

u.heelabrator••• GROUP

See 0 1 Int tQduction l i t . . • . • . • . • . • . • . " . . . . . . • . • . • . • . • . • . ' I I • . • . • . • . • . • . • . • . I I I . . . . . . . . . . . . . . • . • . • . • . • . • . 11

I. 2 1ft truetteA GAdWambtg Syfftbols.. •.••. •.•.•.•.•.••..•.•.•.•••••••••. •. .••.1.2

1.2.1 Read! 12

1.2.2 Caution! 12

1.2.3 Warning! 12

1.2.4 Danger! 12

1.2.5 Electrical Hazard! 12

I. 3 lftstmetioAs... 1.2

1.3.1 Reading about Equipment 12

1.3.2 Understanding the Equipment 13

1.3.3 Equipment Operators & Maintenance Personnel Qualifications 13

1.3.4 Warnings & Precautions 13

1.3.5 Receipt of Equipment 13



Operation &

Maintenance

Manualuheelabrator

•••••••• GROUP

3.4.1 Control Panel 22

3.4.2 Electrical Motors 22

3.4.3 Equipment Installation Wiring 23

3.4.4 Equipment SafetyGrounding 23

3.5.1 Installation 24

3.5.1.1 Lift points 24

3.5.1.2 Tipping Hazard 24

3.5.1.3 Equipment Placement 24

3.5.2 Items to bechecked and completed before start-up 25

3 .4 5 ctf t.iCClI ~Oft •.•.•.• .•.•.•.•.•.• •.•.•.•.•.••.•.•.•.• .•.•.•.•.•.• .•.•.• .•.•.•.•.•".. .• .•.•25

3.6.1 Mechanical Do's &Don'ts Items: 26

~.. ~car~.. .. .. lt~

3.7.1 Caution Signs 28

3.7.2 Warning Signs 30

3.7.3 DangerSigns 32



Operation &

Maintenance

Manualu.heelabrator

•• • _GROUP

ec: 0 Ii System " ,. .

~.. •.•.•.•.•.•.•..•.•.•.•.•.•. •.•.•.•. •.•.•. •. •.•.•.•.•.•.•.•.•.•.•. J[

5.1.1 Types of Lower Reclaims: 51

5.1.1.1 Full Gravity Reclaims: 51

5.1.1.2 Lower Screw Conveyor Reclaims: 51

5.1.1.3 Shaker Conveyor Reclaims: 56

•.2 hfteUoft. q f ' t l t e Bueke .1:1 r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .• . • . • . • . • . • . • . • . • . • . • . • . . . • . • . • . • . • . • . • .'

5.2.1 Elevator HeadSection 58

5.2.2 Elevator Boot Section 60

5.2.3 Elevator BeltAssembly 61

5.3.1 Types of Upper Reclaims: 63

5.3.1.1 Full Gravity Reclaims 63

5.3.1.2 Upper Screw Conveyor Reclaims 63

c ~. SepaNto 70

5.4.1 Types of Separators: 70



Operation &

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Manualuheelabrator

•••••• GROUP

6.2.1 Shaker Bag Style 95

6.2.1.1 Elements of a Typical Shaker Bag Style Dust Collector: 96

6.2.1.1.1 Shaker Mechanism 96

6.2.1.1.2 Filter Bags 96

6.2.1.1.3 Cell Plate 96

6.2.1.1.4 Inlet Vent 97

6.2.1.1.5 Baffle PlatelLiner 97

6.2.1.1.6 Fan Outlet Vent 97

6.2.2 Pulse BagStyle 98

6.2.2.1 Elements of a Typical Pulse Bag Style Dust Collector: 99

6.2.2.1.1 Inlet Vent 99

6.2.2.1.2 Baffle PlatelLiner 99

6.2.2.1.3 Filter Bags 100

6.2.2.1.4 Compressed Air Reservoir 100

6.2.2.1.5 Air Manifold 100

6.2.2.1.6 Multi-Stage Nozzles 100



Operation &

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ManualLlheelabrator

••••••••• GROUP

6.2.3.1.9 Fan Outlet Vent 103

6..3 Di hragrftVa usedOftPulseBag••Cartridge

Pressure Gages sedOftAll ftree Sf\vles ~ Collectors ......•......•..........Ot

6.4.1 Manometer Unit 104

6.4.2 Magnehelic® Differential Pressure Gage 105

6.4.3 Photohelic® Differential Pressure Gage 105

fS..S Bx:h tPiptng COftstruetioft •••••••••••••••••••••••••••••••••••••••••••05

ec on 7 Opera.tion "" ".." " ,." " " " 'II •• " ••••• ••••••• ••••••••• •• 1 07

7.1

7.1.1

7.1.2

7.1.3

7.1.4

7.1.5

7.1.6

7.1.7

Wheel RPM 107

Wheel Amps 107

Abrasive Run Hours 107

Blast Timer 107

Control Power On Light 107

Master Start Pushbutton 107

Emergency Stop Pushbutton 108



Operation &

Maintenance

ManualLlheelabrator

••• GROUP

7.3.3 BlastWheel 112

7.3.4 MediaHandling System 112

1 Y I ~ • . , I ~ l r l ~ " ~ . ~~~~. ~~~~~~~~~~~• • • • • . " " '• • • • • •' • • . " " ' . " ' ,• • •. . . . . . . .~

&1 1ft tio~ ReJKdrlReplacelMftt ofPalts & CofltlM)fteftts...•......•....13

8.1.1 BlastWheel Assembly 113

8.1.1.1 Liners 114

8.1.1.2 Wheel Housing 114

8.1.1.3 Wheel Blades, Control Cage & Impeller 114

8.1.1.4 Removal and Replacement ofBlast Wheel Impeller Bolt 115

8.1.2 CabinetAssembly 116

8.1.3 Work Conveyor Assembly 116

8.1.4 Work Conveyor DriveAssembly 116

8.1.5 Abrasive Recycling System 116

8.1.5.1 Abrasive Hopper 117

8.1.5.2 Elevator Belt Assembly 117

8.1.5.3 Elevator Drive 119



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Operation &

Maintenance

Manual

u .hee lab ra to r•••• GROUP

Section1 Introduction

1.1 Statement

This manualwill benefityou inseveral ways:

1. Itwill provide youwith safetywarnings

andinstructions to protectyouandyour

equipment frominjuries ordamage.

2. Itwill assist you inkeeping this equipment

inthebest possible mechanical condition

atall times.

3. Itwill helpyouobtainthemaximumperformancefromyour equipment.

Theinstructions andsuggestions contained

inthis manual arebaseduponpractical

operating experience. If followed theywill

help yougetthemost production and

satisfaction fromtheequipment.

Everyoneresponsible for theoperation and



Oper at ion &

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Manual

u .hee l ab ra t o r••• o••• GROUP

1.2 Instruction andWarning Symbols

In this operation and maintenance manual the following symbols areused to identify important operation, maintenance and safety

instructions:

e.2.1 Readl

This sign I?dlcates advice regarding operation and maintenance.

&.2.2 Caution! I A CAUTION I Yellow background with black text

o This sign indicates rules and guidelines for a potentially hazardousg situation which, if not avoided, may result in minor or moderate

injury. It may also be used to alert against unsafe practices.

1.2.3 Warning! I A WARNING I•• Orange background with black text

This sign indicates rules and guidelines for a potentially hazardoussituation which, if not avoided, could result in death or seriousinjury.

1.2.4 Danger! A . DANGERRed background with black text

This sign indicates rules and guidelines for an imminently

J

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Operat ion &

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Manualuhee l a b r a t o r

•••• GROUP

o1.3.2 Understanding the Equipment

Before attempting to operate, service or maintain the equipment,

personnel should thoroughly familiarize themselves with thephysical make-up of the equipment, be familiar with the major

components of the equipment, and have a general understandingof overall operations.

1.3.3 Equipment Operators & Maintenance Personnel Qual if icat ions

1. Person must be of legal age for the location to operate and/orservice equipment.

2. Person must be able to read and understand the Englishlanguage to operate and/or service equipment.

3. Person must read and understand operation and maintenance

manual before operating and or servicing the equipment.

4. Person must be trained in the operation and safety of the

equipment before operating.

5. Only qualified maintenance personnel may service thisequipment.



Operation &

Maintenance

ManualL l hee lab r a t o r

r . . • . .. .• • • • GROUP

1.4 Equipment Parameters

Equipment Type: I Plate

Work Handling System: Roll._._._.__.__ . j

Y 4 x 10' w Plateork Descr., . . _ ~ ~ . . ~ . •. ~ M .. . . . . . . . . . . . . . .. . M . . ' . •• •". ~ . . . . . . .. . . . .• _ , _ _ . • • . , _ .

Work Size: 3/16 - 1% Thick. ~ ;---_.. ._--------_._--_._-

! X 10'-0" widei

I plate

~~-·-··T··---·~----Temoereture o f W~r k; A;;-bient--'-'-

f-------.-----.-

................................. ................................................ ............................... .......................,...

Maximum Work Weight or Volume: 1000 Ibs./ft. Linear

~ ~

, Work Loading: I Roll Conveyor '. .- - - - , - - : . . . . - - " .. . - . .- - . ~ - ~ ' . , .. . . - - . .- .. - - - - - ~ - ~ .. - + - . . . . . ; .- pope 4

••••••••••••••••••••••••••••• _" ••••••••••••••••••• - ••••••••••••••••• _ •••••_ ••_ ••••••_HH •••••••• ••••, ••••••••••t : _- · · HH•••

; Work Unloading: Roll Conveyor i

I 'M" I-1-- _ .- -.-.----. .!-..._---_ ....-- --_ .

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Operation &

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u.heelabrator•••• GROUP

" - . . . - /

1.5 Equipment Component Specifications

,---__-----

Component Specification

Blast Wheel ---~--··T-·--······-~m Quantity: T 4 ITy.e.e: ! 25 EZE 270

Speed(RP~):1 1800Power (HP): I 40 HP 1

jlow Rate~er Wheel: ! 894Total Flow Rate: I 3576

i Blast Wheel · · - - - · - · · · - T - · - ·= = -= ~ · - - Q i i a n t i ~ : T - - - - - - I

~.-- .- - - .-.-T . y . e .~;J..-..---.- .-~- - ----.-JI Power (HP1 : i - !-_ •••••• _ •••••••••••••••••••••••••••••••••••••••••••••••••••••• m••• m••••••••••••••••••••••••••••••••••••••••••••••••••••••• .[ ••••••••••••••••••••••••• _ •••••••••••••••••• _ •••••••••••••••••••••• _ ••••••••••• _ •

i L . . . . . . . . . . _ . . . . § . ~ ~ ~ q ( f .! :~ M l ; J . . m . . . . _ . . . . . . . . m _ . . . .I I Flow Rate per Wheel: Ir - m .. . . .. . . . . . .. . . . . . . . .. . . . .. . m . . . . . . . .m . I . . m . . . . .T o t a l . i = i o w " / : j i J t e . : I . .m . . . . . . . . . . .. . . . . . . . . . . . . . . m

r - I ~ o w e r R e c f a i m = " ' " · · · · · ' · r · · · · · = · ~ ~ : : '· :. = . · . : " : " : ~ . · · ~ · - · . : : : ~ ~ f i ~ ~ i t ~ ~ ~ ~ ~ · - ·. - ·. •· : ~ · - · · ·- · ~ - " " · -- """~~·~=:. ii i Size: I 16" I

!------_ _ .._.. .~----.-. ---~

L--.-. Power (HP): I5 HP II Speed(RP~):146

~ __ .__.. ! d" ,



•

Operat ion &

Maintenance

Manual


Section 2 Warranty

WARRANTY 3463

Gunderson-Gimsa

P.urdlas.e Order Number GG05747·1

Seller warrants that the equipment described herein will be free from defects in materialand workmanship for a period of twelve (12) months from delivery ("Warranty Period").

If within the Warranty Period Seller receives written notice promptly after the discovery

of any defect in the material or workmanship Seller shall correct each such defect FOBpoint of manufacture. Seller shall undertake its warranty obligation of repair,replacement within a reasonable time of receiving actual notice of the warranty defect.

Seller shall be fully compensated for expenses of travel and for job time (at Seller's thenprevailing per diem rates for straight time and premium time, as applicable) of its service

representatives who inspect warranty claims that are not warranty issues. Buyer shallissue a purchase order for these expenses prior to Seller's representatives arrival onsite Purchaser has no right to and may not backcharge Seller for warranty claimswithout prior approval. Normal wear parts and labor are not included. The liability of

-.,. Seller to Purchaser/Buyer arising out of or the supplying of the equipment whether

under warranty, tort, contract, negligence, strict liability or otherwise, shall not in anycase exceed the cost of correcting defects in Equipment and upon the expiration of said

warranty, all such liability shall terminate. This warranty is conditioned upon theEquipment being handled, operated, and maintained in accordance with written



Operation &

Maintenance

Manualuheelabrator

•••• GROUP

Section 3 Safety - Warnings & Precautions

3.1 LockoutlTagout

One of the most widely applicable industrial safety principles is

Lockoutrragout. The Occupational Safety and Health Administration

(OSHA) and the American National Standards Institute (ANZI) haveboth addressed the requirement for LockouUTagout. OSHA requires

that each employer formulates a written procedure for implementing aLockouUTagout safety program, including training employees to assure

that it is properly utilized. The following are a few important points to

keep in mind.

1. The principle of LockouUTagout is to protect personnel from the

unexpected energization, start up, or release of stored energy from

the equipment or process.

2. The LockouUTagout principle requires that locks and tags be

affixed to the point where energy can be disconnected from the

equipment or process.

3. Sources of energy are not restricted to electrical; that is,

disconnecting the main power switch may not eliminate all sourcesof unexpected activation. While electrical power always should be

disconnected, a person knowledgeable about the equipment or



Operation &

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Manualuheelabrator

•••• GROUP

e

3.2 MediaWarnings

3.2.1 Highly Explosive Dust

Products (parts), which produce highly explosive

dust, such as Magnesium Titanium Zirconium Thorium etc.,should not be processed in this equipment, unless appropriatesafety measures are followed (consult expert authority). Obtain

approval of your plant safety director and comply with applicableNFPA (National Fire Protection Association) guidelines.

Note: Personnel should not smoke. usematches nor have

open flames around this equipment during operation.

3.2.2 Alumnum Media & Parts

Comply with all applicable sections of NFPA guidelines for

processing or handling of aluminum dust and fines that may bepertinent to your specific operation.

In applications involving the use of dry type bag or cartridge dustcollector system and Aluminum Media or surface blasting of

Aluminum Parts, precautionary measures must be taken tominimize the risk of dust collector fires and/or explosions. The

following procedures should be followed.

~

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Operation &

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Manualu.heelabrator

.oo•••••• GROUP' - - - - - '

3.2.2.3 DuctworkVelocity- AlumnumApplications

Maintain ductwork air velocity of not less than 4500 FPM.

3.3 MaintenanceWarning- Electrical

WARNING



Operati on &

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Manual

L l hee l ab r a t o r•••• ,...,.,••• G RO U P

3.4 Electrical Precautions

Throughout this manual are safety warnings and precautions that mustbe obeyed by maintenance and operating personnel. Although the

precautions which follow may seem to be over simplified, they shouldbe included in the "Buyer's Safety Program." These are minimumsafety requirements for this equipment and any additional plant safety

requirements for your facility shall also be obeyed.

3.4.1 Control Panel

1. DO NOT operate the equipment with the

control panel door open.

2. DO NOT use oversized fuses or bypass

any fuses. Refer to Electrical Drawing.

3. DO verify the correct thermal overload(s)

are installed for the motor starter(s) for the

full load amp rating of the motor(s) as shownon the motor nameplate.

4. DO verify the set point knob on motor J

starter overload relay(s) are set to match

amperage called out for on electrical drawing



Operat ion &

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Manual

uheelabrator.lvv"•••• _GROUP

' - - -

5. DO verify the motor's nameplate before starting the motor(s), to

ensure that the correct power supply (voltage, frequency, and

phase) is being used and that the motor(s) is/are connected

according to the connection diagram on the nameplate. Verifythat the motor is connected properly for the correct rotation. If

motor(s) rotate in the wrong direction, a qualified electrical

person may interchange any two line leads at the starter in thecontrol panel. (Ref.2-3.2)

6. DO NOT use the eyebolt on the motor(s) to lift the motor with

any additional equipment attached to the motor(s).

3.4.3 Equipment Instal lat ion Wiring

DO verify the equipment is wired and connected with wire of the

correct size and correct insulation.

3.4.4 Equipment Safety Grounding

1. DO verify the equipment, as installed, is effectively grounded.

2. DO verify the equipment is grounded in accordance with NEe

and any other applicable state or local codes.



Operation &

Maintenance

Manualuheelabrator

••••••••• GROUP <

3.5 Maintenance Warning -Mechanical

3.5.1 Installation

3.5.1.1 Lift points

Safety during installation and start up requires placing the

equipment without damage or injury and proper hook up tothe required utility service.

The equipment may be lifted using the

designated lift points that are located at abalance point. Be sure to lift the load with

a proper size lifting device and followsafe rigging practices when performing

this work. The proper lift points aredesignated on the equipment by thefollowing sign.

LIFTHERE04 98216

3.5.1.2 Tipping Hazard

Some equipment may have work doors that may cause a Jchange in the equipment's center of gravity when opened.Make sure all doors are securely closed before lifting and

make sure equipment is securely anchored before doors are



Operation &

Maintenflnce

Manual

L1heelabrator•••• GROUP

"'--"'

3.5.2 Items to be checked and completed before start-up

1. Install breathers on speed reducers.*a.) Remove solid fill plug(s) located at the highest position and

on the slow (output) side of each reducer. Ensure oillevel(s)

is/are correct with recommended lubricant(s). (See

lubrication chart in Section 5)

b.) Replace solid fill plug with breather plug(s) which is/are

enclosed in packet inside electrical panel.

*Note: Some units may be equipped with combination plugsthat do not require replacement. Check for air/pressure

vent hole in plug before removing. Only un-vented

plugs need to be changed.

2. Check motor rotation on all drives.

3. This equipment is normally wired to operate from 460V AC, 3

Phase, and 60 HZ electrical supply. Factory supplied options

for 575V AC, 3 Phase, 60 HZ or 230V AC, 3 Phase, 60 HZ

operation are available.

4. Before starting the equipment, check that the equipment is



Operation &

Maintenance

Manual.u.heelabrator

•••• GROUP

3.6.1 Mechanical Do's &Don'ts Items:

1. DO Achieve Zero Mechanical State (ZMS) before performingmaintenance on the equipment.

a.) DO lockout every power source that can produce mechanicalmovement.

b.) DO lockout shut off valves for pressurized fluid (air, oil or other).

c.) DO reduce all accumulators and air surge tanks to atmospheric

pressure.

d.) DO achieve the lowest practical value for mechanical potential

energy for all portions of the equipment.

Example: A belt and bucket elevator system that has stoppedwith the buckets containing abrasive may reversefrom the weight of the abrasive in the buckets.

e.) DO achieve the lowest practical value for kinetic energy of the

equipment members. Loose or freely movable equipment

members and parts must be secured against accidental

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Operation &

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Manualuheelabrator


'- . . - - -

5. DO NOT wear loose fitting clothes, jewelry and watches, while

working near belts, chains, sprockets, shafts or other components

that are movable.

6. DO keep the areas around all equipment clean. Loose abrasive

media and dust can cause hazardous conditions.

7. DO immediately correct any condition(s) that may result indamage to the equipment or cause injury to personnel.

8. DO NOT use your hands to remove excess abrasive from the

elevator boot section, rotary screen, screw conveyor or shakerconveyor. Always use a scoop or scraper for removing this

abrasive.

9. DO NOT attempt to adjust the feed spout, or other wheel parts

while the blast wheel is operating or rotating.

10. DO NOT attempt to adjust the component parts of the abrasive

recycling system or the work parts conveyor system while any partof the blast equipment is in operation.



Operation &

Maintenance!

ManuaJ

u .hee lab ra to r••• GROUP

o3.7 Safety Signs

The following safety and danger signs may appear on and around theequipment, it is important that their meaning is fully understood by all

operators and maintenance personnel who will come in contact withthe equipment:

3.7.1 Caution Signs I A CAUTION ICaution Sians I Descrintlon

Part Number: 498276

Location: This sign is located on liftinglugs and or points on the

equipment where the

equipment can be lifted.

J



Operation &

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Manual

l .JJ lee labra to r••• GROUP

<:»

3.7.2 Warning Signs A WARN I NG

A W A R N I N G

Descrlntion

Part Number: 494043

Location: This sign is located at eye

level on all inspection,access and work doors on

the equipment.

Meaning: This sign warns the operator

or service personnel to wearsafety glasses with side

shields when servicing or I J

operating the equipment.



Operation &

Maintenance

Manual\...--

uheelabrator•••••• GROUP

I Caution Signs I Description

Part Number: 674983

Location: This sign is located on all

access panels and cover

CAUTION plates on the equipment.DO NOT OPERATE MACHINE iWITH COVER REMOVED :

Meaning: This sign cautions theH II MACHINE Will HOTOP!II.t.TE PAOPElt Ly UNLU_ CLOUO

operator to verify that all

access panels and coverplates are secured beforeoperating the equipment.

CAUTIONPart Number: 677122

Buckets must Location: This sign is located on LEMbe aligned with dust collector chamber near

bottom openings dust collection buckets.



Operation &

Maintenance

ManualL l hee l ab ra t o r

•••• GROUP

J

3.7.2 Warning Signs I A WARN ING I

Warn in

A W A R N IN G

Location: This sign is located at eyelevel on all inspection,access and work doors on

the equipment.


or service personnel to wear

safety glasses with side

shields when servicing or! J

operating the equipment.

Descrlntlon

Part Number: 494043



Operation &

Maintenance

Manual\ . . . . . . . - - -

u.heelabrator••••• GROUP

I I Caution Signs I Description

Part Number: 674983

Location: This sign is located on all

access panels and cover

CAUTION plates on the equipment.DO NOT OPERATE MACHINE iWITH COVER REMOVED •

Meaning: This sign cautions theHl t MACHINE WIU HOTOP!IIAU " ,O PE IILV UHLI" CLOIID

operator to verify that all

access panels and coverplates are secured beforeoperating the equipment.

CAUTIONPart Number: 677122

Buckets must Location: This sign is located on LEMbe aligned with dust collector chamber near

bottom openings dust collection buckets.



Operation &

Maintenance

Manual

L l hee l ob ro t o r••• GROUP

J

3.7.2 War ni ng Si gn s A WARN I NG

Warn in

A W A R N I N G

Location: This sign is located at eyelevel on all inspection,

access and work doors on

the equipment.

Meaning: This sign warns the operatoror service personnel to wear

safety glasses with side

shields when servicing or I Joperating the equipment.

Descriotion

Part Number: 494043



Operation &

Maintenance

ManualL l hee l ab ra t o r•••••••••• GROUP

Warnin

Watchyour step.

Keepareaclear

of debris.

494045

ns Descriotion

Part Number: 494045

Location: This sign is located at eyelevel on ladders to service

platforms, at the operator'sstation and all access doorson the equipment.

Meaning: This sign warns the operatoror service personnel to

watch their step around the

equipment due to possible

media on floor.

Part Number: 494749



Operation &

Maintenance

ManualL1hee lab ra to r

••• GROUP

Warning Signs Description

Part Number: 677128

WARNINGI Location: This sign is located at

1. Donot open work dooroperator's station and door

during blast cycle. on manually controlled

2. Waitapprox. 30 seconds tumbler type equipments.after blast cycle Is

complete before openingMeaning: This sign warns the operatorork door.

3. Operate "mill forward" to allow the wheels to stoppushbutton before before opening the workclosing work door to

allow mill to pull door and to run the millrubber shed Into

forward before closing theabinet.

.1112.' work door on the

equipment.

3.7.3 Danger Signs A DANGER

-"

-...-/

J



Operation &

Maintenance

Manualuheelabrator

.O•••• GROUP

I I

Warning Signs I Description I

Part Number: 677128

WARNING Location: This sign is located at

1. Donot open work dooroperator's station and door

during blast cycle. on manually controlled

2. Waitapprox. 30 seconds tumbler type equipments.after blast cycle Is

complete before openingMeaning: This sign warns the operatorork door.

3. Operate "mill forward" to allow the wheels to stoppushbutton before before opening the workclosing work door to

allow mill to pull door and to run the millrubber shed into

forward before closing theabinet.

In 12.1 work door on the

equipment.

3.7.3 Danger Signs ,A DANGER

-.../

J



Operation &

Maintenance

Manual

uheelobrotor•• o>••...•...,•• GROUP

Warnin

Watchyourstep.

Keepareaclear

of debris.

'94046

Descriotion

Part Number: 494045

Location: This sign is located at eye

level on ladders to service

platforms, at the operator'sstation and all access doorson the equipment.


or service personnel to

watch their step around the

equipment due to possible

media on floor.

Part Number: 494749



Operation &

Maintenance

Manual

' - - - -

u .h e e l a b r a t o r••••••••• GROUP

Lethal Voltage.

Authorized

access only.

494041

Part Number: 494041

Location: This sign is located on

junction box covers and

main control panel on theequipment.

Meaning: This sign warns there is a

danger of electrical shock

and only authorized

personnel shall gain access

to the junction boxes and




Operation &

Maintenance

Manualu J l e e l a b r a t o r

•••• GROUP

Part Number: 494150


junction box covers and




and to lock out power

before opening the junction

box or main control paneldoors on equipment.

Part Number: 494388

J



Operation &

Maintenance

Manual

" - - - -

u .h e e l a b r a t o r•••• GROUP

Part Number: 494390


tumbler type equipment

operator's station,pushbutton panel, main

door, sides of loader bucket

and side frame of loader onthe equipment.


danger and to stay clear of

this area around theequipment when operating

door or loader on theequipment.



Operation&

Maintenance

ManualuJ leelabrator

•••• GROUP

Stay clearof

pinchpoints.

".4750

Part Number: 494750

Location: This sign is located nearpinch points on theequipment.

Meaning: This sign warns that there is

a danger and stay clear

pinch points in this area onthe equipment.

A DANGER

J



Operation &

Maintenance

ManualL L h e e l a b r a t o r

r . .r ." " , ... ., ... ., ... ,, . •• _GROUP

3.7.4 Miscellaneous Signs

Part Number: 472553


motors on the equipment.

Meaning: This sign identifies the

proper rotation of the


SAFETYINSTRUCTIONS

1. Keep dust bags I I

and hoppers

clean.

2. Empty hoppers

after each

Part Number: 495075

Location: This sign is located on bag

style dust collectors.

Meaning: This sign contains safety

J

J



Operation &

Maintenance

Manualuheelobrotor

••••••••• GROUP

Part Number: 499946

Location: This sign is located on the

main electrical control panelfor the equipment.



and to ground the

equipment per the National

Electrical Code Article 250.

I" , " " , • •

::f' Thl. machine •••••t ••

•tfectly~y grounded

forop«ator H'.ty.

s.. Nattonal Elect,leal

COOe Artic le 250

Part Number: 715426A DANGER


after filter housing transition

for the dust collector on theLEM equipment.


danger and equipment or



Operation &

Maintenance

Manualuheelabrator

•••• GROUP

3.7.4 Miscellaneous Signs

Part Number: 472553



Meaning: This sign identifies the

proper rotation of themotors on the equipment.

SAFETYINSTRUCTIONS

1. Keep dust bags I I

and hoppers

clean.

2. Empty hoppers

after eachshift.

Part Number: 495075

Location: This sign is located on bag

style dust collectors.

Meaning: This sign contains safety

J

J



Operation &

Maintenance

Manual

L l h e e l a b r a t o r•••• GROUP

I " "" • •

: : r -

Th ,. ••• chino •••••••••

eff ec ti ve ly grounded

for operator Ntely.

Se. Na tt onal Electrical

Code Article 250

A DANGERLocation: This sign is located on the

after filter housing transition

for the dust collector on theLEM equipment.


danger and equipment or

Part Number: 499946


main electrical control panelfor the equipment.



and to ground the

equipment per the National

Electrical Code Article 250.

Part Number: 715426



Operation &

Maintenance

Manual

"--

L i h e e l a b r a t o r••••• GROUP

P a r t N u m b e r : 499414

L o c a t io n : T h i s s i g n i s l o c a t e d o n t h e

m a in e l e ct ri c a l c o n t r o l p a n e l

o n t h e e q u i p m e n t .

M e a n i n g : Th i s s i g n i d e n t i f i e s t h eo p e r a t i n g v o l t a g e o f t h e

e q u i p m e n t .

~~ 't~,

4 ,~A - ~- ; . ',~ , . . " -

S A F E TY INS TR U C TIO NSThis machine must be effectively grounded for operator safety (see NEe ART 250.)

Grounding shall beaccomplished by providing a ground path from the machine to a

grounding electrode with agrounding electrode conductor.

The grounding electrode conductor shall be 8 AWG copper or larger, (size in ac-

cordance with NEe TABLE 250-66.) Attachment shall be made using pressure

type cable connectors (no solder) secured to asurface that is free of dirt and

paint inan area protected from physical damage and from being disconnected

during maintenance and servicing.

Operation &



Maintenance

ManualLiheelabrator


Keep hands outside the elevator casing.If an elevator stalls:

1. Shut off abrasive feed to the Wheelabrator.

2. Tum off and lock out power at theelectrical panel

3. Youmay now remove the inspection plateat the elevator boot.

~ 1 4 . The elevator belt is stretched and as the

~ abrasive jam is corrected, belt tension willcause the boot pulley to rotate. Stay clearof this dangerous condition.

5. Use a scoop to clear abrasive from the boot.

See Maintenance Manual for detailed instructions.

495079

Part Number: 495079

Location: This sign is located above all elevator boot access andclean-out doors on the elevator casing not to be

attached to the clean-out door on the equipment.

Meaning: This sign contains safety instructions for servicing the

elevator boot section of the equipment.

AWARNING

DUST

In appicatons In't'olving theuse ot alumnummedia or surface

blastng of alumnumparts, precauUon8fy rnea.ur •• must be

J

'---.-)

Operation &



Maintenance

Manual

ulleelabrator••• GROUP

Section 4 Blast Wheel

4.1 25 EZEFIT Blast Wheel

4.1.1 How the Blast Wheel Works

&)

Media from an overhead storage hopper is metered to the center of the wheel

unit that is rotating at high speed. A feed spout provides a smooth transition from

the feed line to the impeller rotating with the wheel. The impeller moves the

media through its multiple tapered openings and out through the single stationary

opening in the control cage. Controlled quantities of media are then distributed

onto the rotating blade surface at precisely the right time. The media particles

picked up on the inner ends of the blade's throwing face are rapidly accelerated

as they move to the end of the blades at the outer edge of the wheel. Media then

leaves the wheel in the form of a pattern with a narrow width and variable length

that must be properly focused on the work surface for the desired results.

Motor

Motor Adapter Flange

- - - - - - - - - - - - - - .Rear Hub Liner

Operation &



Maintenance

Manualuheelabrator

r..",..., •.....•.....••• GROUP

4.1.2 Bi-Directional Blast Wheel Parts

The Wheelabrator Bi-Directional Wheel consists of the following

main components (see Figure 4-1)

1. Motor - powers the wheel.

2. Motor Adapter Flange - aligns and mounts the motor to the

wheel housing.

3. Rear Hub Seal- patented labyrinth seal configuration,

effectively minimizes media leakage.

4. Rear Liner - Seals the opening in the wheel housing and

protects the motor adapter flange.

5. Hub Seal - seals around the hub to prevent media leakage.

6. Single Sided Wheel Assembly - provides rugged bladeretention in abusive applications.

7. Wheel Blades - accelerates the media out of the blast wheel

towards the work.

8. Centering Plate - secures the impeller into wheel assembly for

accurate media timing.

J

Operation &



Maintenance

Manual

uheelobrotor•••••••• GROUP




8











Motor


- - - - - - - - - - - - - - .Rear Hub Liner

Operation &



Maintenance

ManualLlheelabrator

••• GROUP

4.1.2 Bi-Directional Blast Wheel Parts

The Wheelabrator Bi-Directional Wheel consists of the following




wheel housing.





5. Hub Seal- seals around the hub to prevent media leakage.



towards the work.



J

Operation &



Maintenance

Manualuheelobrctor

•••• GROUP


4.1 25 EZEFIT BlastWheel


8











Motor


- - - - - - - - - - - - - - .Rear Hub Liner

Operation &



Maintenance

Manual

u.heelabrator••• GROUP

4.1.2 Bi·Directional Blast Wheel Parts

The Wheelabrator Bl-Dlrectlonal Wheel consists of the following




wheel housing.





5. Hub Seal - seals around the hub to prevent media leakage.



towards the work.



J

Operation &



Maintenance

Manual

uheelabrator•••••••• GROUP

\.......- '




&)











Motor

Motor Adapter Flange - - - - - - - - - - - - .Rear Hub Liner

Operation&



Maintenance

Manualuheelobrotor

rv rv r-; , •••• GROUPv

4.1.3 Setting and Adjustment

The setting and adjustment of your Blast Wheel is important for

the performance and life of your machine. You will not accomplish

the surface preparation of your work if you are not hitting it! Not

only will your blast time increase, but you are accelerating wear on

the insides of your machine. A properly set control cage can

prevent this.

o

4.1.4 Wheel Direction

A Blast Wheel can be run in a, clockwise (CW) or counter-

clockwise (CCW) direction, depending upon the design requirement

of a given wheel. Care should be taken, particularly during start-up

that a Blast Wheel is running in the proper direction. The direction

will be clearly identified on the Blast Wheel housing by a directional

arrow. To maintain optimum performance during the life of yourblast machine, it is vital that the wheel direction remain as originally

designed byWheelabrator.

Direction of the BlastWheel should bedetermined by

looking at thewheel from the feed spout side of the

BlastWheel.

Operation &



Maintenance

Manual

u.heelabrator•••• C•••• GROUP

blast pattern may be aimed to the exact position necessary toproduce the optimum results for your surface preparationrequirement.

WheelBlade

9:00$43«(

MediaPointof

ReleaseDiameter

£ ~ i I I ! / l rL Blast I Blast I I Blast

Pattern-L-Pattern~ Pattern

Tailings HotSpot Headings

Clockwise Blast Wheel @ 3600RPMLeading Edge@ 11:30

Figure 4-2

WheelBlade

) 1 f 1 r . Rotation3:00 I

,j~

MediaPointof...../. I .~t,:\Release Diameter -:~.'~~~~~~\

~ , p % ; ; t [ " l f . l } ,Llast I Blast I I Blast

Pattern-L Pattern-U-attern

Tailings HotSpot Headings

9 : 0 ~ « - f

Clockwise Blast Wheel @ 3600 RPM

Leading Edge @ 12:00

Figure 4-3

WheelBlade

J

J

Operation &



Maintenance

Manual\.J

uheelobrotor••••• GROUP

4.1.6 The "Hot Spot"

1. The areas in Figures 4-2, 4-3, 4-4 and 4-5 referred to as a

"Hot Spot" are characteristic of all blast wheels and are in the

areas of the blast where about 70% of the blast intensity is

contained. The position of the "Hot Spot" is therefore very

important in terms of surface preparation efficiency.

2. By using the arrows marked on the face of the control cage, you

may roughly set the control cage position. These arrows identify

the location of the opening in the control cage and it is this

opening that controls the point where the media is picked up by

the blades. The arrows identify the leading and trailing edges or

points where the media starts and stops leaving (exiting) the

control cage.

3. For a clockwise blast wheel, the arrow on the left is the leading

edge and for a counter-clockwise blast wheel the arrow on the

right is the leading edge. The remaining arrow indicates the

trailing edge for each direction.

4. When reference is made to "hour" settings while discussing the

control cage settings, it is important that 12:00 is understood to

Operation &



J

Maintenance

Manualuheelabrator

•••• GROUP

2. The actual check of the blast pattern of the wheel should bemade when the machine is put into operation. The check should

be repeated when any decrease in blast efficiency is noted and

the control cage opening reference mark information has been

lost. The blast pattern checked should also be repeated if a

change is made in the size or type of abrasive media used and

if the RPM (speed) of the wheel is changed.

3. To check the blast pattern, secure a piece of 12-guage sheet

metal about 12" x 48" (called a target plate) in the same relative

position to the wheels, as the component to be cleaned would

be. This plate should be held rigid.

4.1.7.1 To Check Blast Pattern

&)1. Turn main disconnect off and follow lock out/tag out

procedures.

2. Gain access to the blast chamber area.

3. Secure target plate in front of the wheel you are checking

4. Verify target plate is positioned at 90° to blast flow and ,J

perpendicular to the wheel.

5. Turn main disconnect on following lock out/tag out

Operation &



Maintenance

Manualuheelobrotor

•••• GROUP

4.1.6 The "Hot Spot"

1. The areas in Figures 4-2, 4-3, 4-4 and 4-5 referred to as a

"Hot Spot" are characteristic of all blast wheels and are in the

areas of the blast where about 70% of the blast intensity is

contained. The position of the "Hot Spot" is therefore very

important in terms of surface preparation efficiency.

2. By using the arrows marked on the face of the control cage, you

may roughly set the control cage position. These arrows identify

the location of the opening in the control cage and it is this

opening that controls the point where the media is picked up by

the blades. The arrows identify the leading and trailing edges or

points where the media starts and stops leaving (exiting) the

control cage.

3. For a clockwise blast wheel, the arrow on the left is the leading

edge and for a counter-clockwise blast wheel the arrow on the

right is the leading edge. The remaining arrow indicates the

trailing edge for each direction.

4. When reference is made to "hour" settings while discussing the

control cage settings, it is important that 12:00 is understood to

Operation &

Maintenance



J

Manualuheelabrator

•••• GROUP

2. The actual check of the blast pattern of the wheel should bemade when the machine is put into operation. The check should

be repeated when any decrease in blast efficiency is noted and

the control cage opening reference mark information has been

lost. The blast pattern checked should also be repeated if a

change is made in the size or type of abrasive media used and

if the RPM (speed) of the wheel is changed.

3. To check the blast pattern, secure a piece of 12-guage sheet

metal about 12" x 48" (called a target plate) in the same relative

position to the wheels, as the component to be cleaned would

be. This plate should be held rigid.

4.1.7.1 To Check Blast Pattern

81. Turn main disconnect off and follow lock out/tag out

procedures.

2. Gain access to the blast chamber area.

3. Secure target plate in front of the wheel you are checking

4. Verify target plate is positioned at 90° to blast flow and J

perpendicular to the wheel.

5. Turn main disconnect on following lock out/tag out

Operation &



Maintenance

Manualu.heelabrator

•••• GROUP~

The zone of effective cleaning (Blast Pattern) will be evident

on the target plate. If the blast pattern is not satisfactory, the

control cage setting must be re-adjusted. Adjustments to the

control cage should be no more than 3/8" to 3/4" based on

the notches at a time. If the control cage setting is re-

adjusted, you must repeat steps 5-10 to confirm the newadjustment.

Once the control cage is properly adjusted, the position of

the blast pattern will not change substantially until the

internal wheel components wear.

An increase in the percentage of fines remaining in the

abrasive can also cause the blast pattern to move and

lengthen.

4.1.7.2 HowtoRotatetheControl Cage

1. Remove feed spout and feed spout clamps as shown in

Figure4-7.

2. Loosen the two (2) control cage clamps as shown in

Figure 4-6&4-7.

Operation &

Maintenance



Manual

L 1 h e e l a b r a t o r•••• GROUP

Control

Cage

Clamp

~

Rotate

Control Cage

Control Cage

Control

CageClamp

J

Operation &

Maintenance



Manual

L l h e e l a b r a t o r•••••••••• GROUP

FeedSpoutSeal

Curved

FeedSpout

FeedSpoutClamp

Control CageClamp

Control Cage

~

contrOlfl .•Cage .•~

Adapter Control

CageFeedSpout Clamp

Clamp

Straight

FeedSpout

Operation &

Maintenance



Manualuheeloorotor


Section5 MediaHandlingSystem

5.1 Functionof theLowerReclaim:

The lower reclaim function is to collect contaminants spent media

thrown by the blast wheels. The media and contaminants are then

delivered by the lower reclaim to the bucket elevator boot section. The

lower reclaim is part of a total media recovery system to clean and

recycle media back to the blast wheel.

5.1.1 Typesof LowerReclaims:

5.1.1.1 FullGravityReclaims:

a. Gravity hoppers are used for directing spent media

directly to the bucket elevator boot section.

b. Gravity hoppers are generally used on small equipment.

c. There are no drives or mechanical moving parts in gravity

reclaims.

5.1.1.2 LowerScrewConveyorReclaims:

Operation &

Maintenance L1heelabrator



Manual •••• GROUP

Gearmotor

Adapter Plate

Gearmotor

Drive Shaft

Bearing

Shaft Seal

Screw Adapter Housing

Screw Conveyor Trough

Screw Conveyor

End Shaft

Shaft Seal

Bearing

illical Lower Screw Conveyor Components

Figure 5-1

J

Operation &

Maintenance ulleelabrator




Section 5 MediaHandling System

5.1 Function of the Lower Reclaim:

The lower reclaim function is to collect contaminants spent media

thrown by the blast wheels. The media and contaminants are then

delivered by the lower reclaim to the bucket elevator boot section. The

lower reclaim is part of a total media recovery system to clean and

recycle media back to the blast wheel.

5.1.1 Types of Lower Reclaims:

5.1.1.1 Full Gravity Reclaims:

a. Gravity hoppers are used for directing spent media

directly to the bucket elevator boot section.

b. Gravity hoppers are generally used on small equipment.

c. There are no drives or mechanical moving parts in gravity

reclaims.

5.1.1.2 Lower Screw Conveyor Reclaims:

Operation &

Maintenance L l h e e l a b r a t o r



Manual ••••••••• GROUP

' - . . . . -

4. Screw Adapter Housing - joins the screw conveyortrough to the elevator boot or cabinet. This may not

be required on all applications.

5. Drive Shaft - fixed to the screw conveyor and

mounted through the bearing to drive the conveyor.

6. End Shaft - fixed to the screw conveyor and mounted

through the bearing to support the conveyor oppositethe drive.

7. Shaft Seals - prevents media leaking out the ends of

the conveyor and protects the bearings from the

media. (see Figures 5-2 & 5-3)

8. Bearings - supports ends of the screw conveyor.

9. Bearing Adapter Plate - closes the end of the

conveyor and supports the bearing.

10. Gearmotor Adapter Plate - closes the end of the

conveyor and supports the bearing and Gearmotor.

Operation &

Maintenance Llheelabrator



Manual •• GROUP

Spacer Bars < _

!mical ShaftSealAssembly

Figure 5-2

d. A typical shaft seal assembly for a lower screw conveyor

is shown in Figure 5-2.

J

J

Operation &

Maintenance uheelcorotor



Manual •••• GROUP'\.......-

4. Screw Adapter Housing - joins the screw conveyortrough to the elevator boot or cabinet. This may not

be required on all applications.

5. Drive Shaft - fixed to the screw conveyor and

mounted through the bearing to drive the conveyor.

6. End Shaft - fixed to the screw conveyor and mounted

through the bearing to support the conveyor oppositethe drive.

7. Shaft Seals - prevents media leaking out the ends of

the conveyor and protects the bearings from the

media. (see Figures 5-2& 5-3)

8. Bearings - supports ends of the screw conveyor.

9. Bearing Adapter Plate - closes the end of the

conveyor and supports the bearing.


conveyor and supports the bearing and Gearmotor.

Operation &

Maintenance uheelobrotor



Manual .( n•• GROUP

Spacer Bars < _

Imical ShaftSealAssembly

Figure 5-2

d. A typical shaft seal assembly for a lower screw conveyor

is shown in Figure 5-2.

J

J

Operation &





Bearing Mounting Plat,

UHMW Shot Dis

v Bearing Spacers

Imical Shaft Seal Assembl'l.

Figure 5·3

e. Another variation of a shaft seal assembly for a lower

Operation &

Maintenance Llheelabrator




5.1.1.3 Shaker Conveyor Reclaims:

a. Shaker conveyors are used when full gravity is not

feasible and the product application contains significant

tramp metal material entering the reclaim.

b. Shaker conveyors are able to separate large trash from

the media to prevent it entering the remaining media

handling system components and causing damage or

jams.

c. Shaker conveyors are generally self cleaning.

Mounting Base Preforated Area

Media Flow.

-~

J

Operation &




Manual-:

••••••••• GROUP

Bearing Mounting Plat,

UHMW Shot Cis

v Bearing Spacers

illical Shaft SealAssemblx

Figure 5-3

e. Another variation of a shaft seal assembly for a lower

Operation &

Maintenance

Manualuheelobrotor



•••• GROUP

5.1.1.3 Shaker Conveyor Reclaims:

a. Shaker conveyors are used when full gravity is not

feasible and the product application contains significant

tramp metal material entering the reclaim.

b. Shaker conveyors are able to separate large trash from

the media to prevent it entering the remaining media

handling system components and causing damage or

jams.

c. Shaker conveyors are generally self cleaning.

Mounting Base Preforated Area

Media Flow ••

'--J

J

Operation &

Maintenance u .hee lab ra to r




5. Mounting Base - supports the shaker conveyor andsecures it to the foundation.

6. Hanger Springs - are sized to control stroke,frequency and angle of attack designed to proper

conveying action for type media.

7. Conveyor Dr ive - powers the shaker conveyor.

5.2 Function of the Bucket Elevator

a. The belt and bucket centrifugal discharge elevator lifts the abrasive

material from the boot (lower) section to the head (upper) section.The contaminated abrasive material is discharged from the headsection of the elevator, and then delivered to the separator.

INTERMEDIATESECTION WI VENT

Operation &

u .hee lab ra to raintenance

Manual r-, ,-.. ~ ....,·••• GROUP



J

b. A typical elevator arrangement is shown in Figure 5-5.

1. Head Section - This is the upper section of the bucket elevatorcasing. It usually contains the elevator drive.

2. Intermediate Section with Vent - This is the part of theelevator casing that contains the vent box.

3. Vent Box - This is the outlet to remove the dust from of the

elevator casing. It can usually be mounted on either side of theintermediate section depending on the vent piping requirement.

4. Vent Cover - Covers the opening in the intermediate section

opposite the vent box when part of design.

5. Intermediate Section without Vent - This is the part of the

elevator casing used to increase the height of the elevator. This

section is not always required.6. Boot Section - This is the lower section of the bucket elevator

casing. This section receives the spent media from the blastchamber and lower reclaim.

J

7. Elevator Belt Assembly - This bucket and belt assembly

transports the abrasive media from the boot section to the headsection and discharges it to the upper reclaim system.

Operation &

Maintenance

Manualu.heelabrator



.Lvv ••••• GROUP

Shedder (only somedesigns)/ TopCover \

~ TakeUpBolt ,\, j

Shaft

Pulley', IIh

Gearmotor

Bearing &ShaftSeal I III I III '

TakeUpAssembly l I I I I I '

Weldment

IYPical HeadSection ArrangementFigure 5-6

b. A typical elevator head section arrangement is shown in Figure

5-6.

1. Weldment - is a fabricated housing that the head section

components mount to.

Operation &

Maintenance

ManualWleelabrator

•••• GROUP



7. Bearing - supports ends of the elevator head section shaft.

8. Gearmotor - is mounted to the head section shaft to powerthe elevator.

9. Top Cover - is the access cover to the elevator headsection and a safety cover to guard against the rotatingcomponents inside the elevator head section weldment.

10. Shedder - is a wear component to assist in delivery ofabrasive media and contaminants to the upper reclaim

system. This is only used on some designs of elevator head

sections.

5.2.2 Elevator Boot Section

a. The boot section is the lower section of the bucket elevator

casing. It receives the abrasive media and contaminants from

the lower reclaim of the equipment and moves the media andcontaminants to the head section with the elevator belt

assembly.

Boot Section Weldment

J

J

Operation &

Maintenance

ManualLlheelabrator



•••• GROUP

b. A typical elevator boot section arrangement is shown in Figure5-7.

1. Boot Section Weldment - is a fabricated housing that the

boot section components mount to.

2. Adjustment Plate - supports the bearings, shaft seals, shaftand pulley on the boot section weldment. There are usually

two of these plates per boot section.

3. Pulley - provides a rotating surface for the elevator beltassembly to ride on.

4. Shaft - supports the elevator boot section pulley.

5. Shaft Seal - prevents media leaking around the shaft and

protects the bearings from the media.

6. Bearing - supports ends of the elevator boot section shaft.

Note: SeeSection 5.1.1.2(d&e) for the two

types of typical shaft seal assemblies. Also see

Operation &

Maintenance

Manualuheelabrator

••• GROUP



Elevator Bolt&NutBuckets

Typical Elevator Belt Assembly

with Dutchman SpliceTypical Elevator Belt Assembly

with Oil Well Splice

Figure 5-9igure 5-8

b. Typical elevator belt assemblies are shown in Figure 5-8with

a Dutchman splice and Figure 5-9with a Oil Well splice.

1. Elevator Belt - is manufactured from a multi-ply rubberbelting material with an abrasive resistant top cover forprotection against abrasion and cutting. The elevatorbuckets and splice are mounted to the belt.

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Operation &

Maintenance

Manual

L lhee lab ra to r



•••• GROUPx..>

5.3 Functions of Upper Reclaims

The upper reclaim function is to collect media and contaminants

delivered from the elevator. Media and contaminants are then

conveyed by the upper reclaim to the media separator. The upperreclaim is a part of a total media recovery system to clean and recyclemedia back to the blast wheel.

5.3.1 Types of Upper Reclaims:

5.3.1.1 Full Gravity Reclaims

a. Gravity reclaims are used for transferring media directlyfrom the elevator head section to the separator.

b. There are no drives in upper gravity reclaims.

5.3.1.2 Upper Screw Conveyor Reclaims

a. Upper screw conveyors are used to reduce systemheight when full gravity is not feasible.

Operation &

Maintenance

Manual

u .hee lab ra to r,..,••• GROUP



Geannotor

AdapterPlate

ScrewAdapterHousing

ScrewConveyorTrough

Separator

ScrewConveyor TrashChute

Bearing

EndShaft

Ref.Separator

I I

~ - - - - - - - - - - - - - - - - - - - - - - - - - - - ~TrashTubing

Typical Upper Screw Conveyor Components

Figure 5-10

ScrewAdapterHousing

ScrewConveyorTrough

Separator

J

J

Operation &

Maintenance

Manual

u.heelabrator•••• GROUP



Screw Adapter Housing Separator Trash Chute

with Overflow Housing

Screw Conveyor Trough

ScrewConveyor

Bearing

End Shaft

Trash Chute

Adapter

Trash Tubing

Typical Upper Screw Conveyor Components

with Rotary Screen and Trash Chute with Overflow Housing &Hose

Figure 5-12

d. The following are typical components of an upper screw

conveyor reclaim are shown in Figure 5-10 upper

Operation &

LLheelabratoraintenance..-

Manual '.~••••••••• GROUP- .. .



J

. .. 3. Screw Conveyor Trough - connects and encloses

the screw conveyor between the bucket elevator andthe separator.

4. Screw Adapter Housing - joins the screw conveyor

trough to the elevator head section.

5. Separator Trash Chute - the rotary screen emptiesthe large trapped particles into this housing.

6. Separator Trash Chute with Overflow Housing-

when there is a surge of media the media isoverflowed into the first compartment of the housing.The rotary screen empties the large trapped particlesinto the second compartment of the housing.

7. Overflow Hose - directs the overflow media back tolower reclaim to be recycled.

8. Trash Chute Curtain - allows access to clean outany trapped particles that are clogging the entrance to ' - o Jthe trash tube.

Warning: DONOT clean out separator trash

Operation &

Maintenance

Manual

uJ lee lab ra to r ~ i ~ ~••••• GROUP -



<.;

13. Shaf t Seals - prevents media leaking out the ends ofthe conveyor and protects the bearings from themedia.

14. Bearings - supports both ends of the screw

conveyor.

15. Bearing Adapter Plate - mounts to the separator

trash chute for mounting the bearing. _


conveyor and for mounting the bearing and

gearmotor.

17. Gearmotor - mounted on drive shaft to power screwconveyor.

Operation &

Maintenance

Manualuheelobrotor

o ••• GROUP-



-

SpacerBars" _

-

illical ShaftSeal Assembly

Figure 5-13

e. A typical shaft seal assembly for an upper screw

conveyor is shown in Figure 5-13.

J

J

Operation &

Maintenance

Manual

u .hee lab ra to r••••••••• GROUP



Bearing Mounting Plat

UHMW Shot Dis

v tsearing Spacers

.!mical Shaft Seal Assembly

Figure 5-14

f. Another variation of a shaft seal assembly for an upper

Operation &

Maintenance

Manualuheelabrator

••(r••GROUP



5.4 Functions of aSeparator

The separator receives contaminated abrasive media from the upperreclaim. In the separating process, the abrasive media is spread out for

uniform distribution through the separator to remove the contaminants

from the abrasive media. The abrasive contaminants are delivered tothe refuse side of the separator. These contaminants are conveyed tothe customer's refuse container by means of flexible tubing with adribble valve.

5.4.1 Types of Separators:

5.4.1.1 Gravity CFS Separator

(Figure 5-15)

a. The gravity CFS (Compensating Flow Straight) separator

receives the abrasive media and contaminants from the

head section of the elevator.

b. The large contaminants are screened out through astationary screen.

c. The usable abrasive media is separated from the fine

J

J

Operation &

Maintenance

Manualuheelabrator

•••• GROUP<.



Trough Design Separator CasingSwinging Baffle Alternate

Screen

LocationJ Sliding Baffle

Swinging Baffle

Cou nterweightsVent

Outlet" -Trough Desi~

Counterwei9!!!Separator Screen

Adjustable Lip -}3~

Ref. Abrasive Media /Storage Hopper ~:~__ I~ - - - - - - - - ~

Fines

Sand &Scale' ---Discharge

IYPical Gravity CFS Separator Arrangement

Figure 5·15

- _ .. Operation &

uheelobrotoraintenance

Manual n·••••••••• GROUP

. ... .:»



.. Make sure the swinging baffle will not stick on the..

- _ . ends near the vertical housing wall. Grind the edgesfor clearance if required. The vertical back of theswinging baffle should be perpendicular with the edgeof the adjustable lip. Use the slotted holes for the

bearing mounts to adjust the position of the baffle asrequired. The bottom edge of the baffle should clear

.. the adjustable lip by approximately 1/8". This gap may.'. ..

change, based on the size abrasive used, to prevent

sticking of the baffle on the horizontal lip. Correctclearance allows the baffle to push against the build

up of abrasive on top of the lip and prevent any partial

curtain leakage of abrasive.

4. Counterweights - are used to adjust the swingingbaffle to obtain a full width curtain. By moving the

adjustable counterweights up and back on the rod or

adding or removing abrasive from the troughdesigned counterweights the thickness and width ofthe abrasive curtain of abrasive can be adjusted .

.J. Adjustable Lip - is adjusted back about %" behind

-,-",. the vertical fall line from the upper lip that swinging

baffle closes on. The lower lip may need additional

adjustment depending on the size, weight and volume

Operation &

Maintenance

Manual

u.heelabrator .-~••••• GROUP



c. The usable abrasive media is separated from the fine

abrasive media, sand and scale.

• This is achieved by pulling air through a curtain of

abrasive media.

• This curtain is maintained across the full width of theseparator by a sliding baffle and counterweightedswinging baffle system.

d. The screened usable abrasive media is directed to the

storage hopper.

e. The fines, sand and scale are directed to the buyer'sreceptacle at floor level.

Trough Design

Swinging Baffle

Separator Casing Cover

~

' - - - -Trough DesignedCounterweight

Vent

Outlet

Separator

Casing

Operation &

Maintenance

Manual

u .hee lab ra to r•••• C•••• GROUP

.:»



1. Separator Casing - is used to mount the separator

components and retain the abrasive media andcontaminants to be cleaned.

2. Separator Casing Cover - is for access to the upperscrew conveyor and rotary screen.

Warning: DO NOT remove separator casing

cover with power on the equipment

or with the screw conveyor or

screen running.

3. Sliding Baff le - is adjustable and regulates thevolume of abrasive media and contaminants flowingto the swinging baffle.

4. Swinging Baff le - is the mechanism which controls

the flow of contaminated abrasive media in a thincurtain across the entire width of the separator at thepoint of separation.

Make sure the swinging baffle will not stick on the

ends near the vertical housing wall. Grind the edges

for clearance if required. The vertical back of the

swinging baffle should be perpendicular with the edge

J

Operation &

Maintenance

Manual

u.heelobrotor -~~•••• GROUP



C. The usable abrasive media is separated from the fine

abrasive media, sand and scale.

• This is achieved by pulling air through a curtain of

abrasive media.

• This curtain is maintained across the full width of theseparator by a sliding baffle and counterweightedswinging baffle system.

d. The screened usable abrasive media is directed to the

storage hopper.

e. The fines, sand and scale are directed to the buyer's

receptacle at floor level.

Trough Design

Swinging Baffle

Separator Casing Cover

~,- -Trough Designed

Counterweight

Vent

Outlet

Separator

Casing

Operation&

Maintenance

ManualLLheelabrator - : ~ ; f s :. .

••••• GROUP ...- -' - . . . . . -



.. ::'::;;::"'.-6. Upper Adjustable Lip - is adjusted to keep the back

face of the swinging baffle vertical and parallel withthe air opening behind the abrasive media curtain.

7. Lower Adjustable Lip - is adjusted back about %"

behind the vertical fall line from the upper lip that

swinging baffle closes on. The lower lip may need

additional adjustment depending on the size, weightand volume of contaminants.

8. Separator Screen - stops large contaminants before

they can get to the wheel unit. The screen should be

cleaned daily to assure unrestricted abrasive flow to

the wheels. Care should be taken when cleaning the

screen to assure the contaminants do not fall into theabrasive storage hopper.

5.4.1.3 LP Magnetic Separators

The LP (Low Profile) series of magnetic separators provide asignificant improvement in operating efficiency and costreduction for blast cleaning equipment in a typical foundry.

Using a two (2) stage approach, the LP units remove coarse

:~~·-'.::0~:...

.- .

-

- - Operation &

L lhee lab ra to r,

- -Maintenance

Manual ,'ro.,..... •..•.,... r . . . - . , . • • • GROUP

•.. .- .. --...J



---." .-c__ =The achievement of these benefits and the safe

and efficient operation of the LP system units

are dependent on the complete understanding

and ~er use of the information in this manual.

5.4.1.3.1 Primary LP Magnet ic Separators

-(See Figure 5-17)

-

a. A mixture of ferrous abrasive media and sandenters the primary LP magnetic separator unit

from an upper screw conveyor and rotary screen.

b. The rotary screen removes oversize contaminants- -_ . . . . . .

from the mixture and directs this material to a. suitable customer provided floor level container

~ through a flexible steel tube.

C )Note: Overflow material can bypass the

system through a separate overflow pipe

and be recycled.J

c. The ferrous abrasive media and sand mixture that

passes through the rotary screen is spread acrossthe width of the separator by the external screw

Operation &

Maintenance

Manualuheelabrator .~.

.C'••• GROUP' - - . . . -

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6. Upper Adjustable Lip - is adjusted to keep the back

face of the swinging baffle vertical and parallel withthe air opening behind the abrasive media curtain.

7. Lower Adjustable Lip - is adjusted back about %"behind the vertical fall line from the upper lip that

swinging baffle closes on. The lower lip may needadditional adjustment depending on the size, weight

and volume of contaminants.

.-

~~

8. Separator Screen - stops large contaminants beforethey can get to the wheel unit. The screen should be

cleaned daily to assure unrestricted abrasive flow to

the wheels. Care should be taken when cleaning thescreen to assure the contaminants do not fall into theabrasive storage hopper.

5.4.1.3 LP Magnetic Separators

The LP (Low Profile) series of magnetic separators provide asignificant improvement in operating efficiency and costreduction for blast cleaning equipment in a typical foundry.

Using a two (2) stage approach, the LP units remove coarse

Operation &

Maintenance

Manual

u .hee lab ra to r .••••••.... r-"\0"'" ••• G RO U P

'•.



. '.

g. The retained magnetic (ferrous) particles are

released from the face of the drum at the end ofthe magnetic field.

h. The released sand with some magnetic particles

passes to the Secondary LP separator.

i. Released metallic particles are directed to the airwash separator section for classification and

operating mix control.

j. This uniform curtain of material from the magneticdrum falls onto the sloped surface behind the air

wash separator swinging baffle.

k. When the abrasive particles build up to the proper

height behind the swinging baffle (and adjustablebaffle if so equipped) to overcome the resistance

of the counter -weights, the swinging baffle willopen and permit a uniform thickness curtain ofabrasive to flow over the entire edge of the

adjustable lip. [See Figure 5-17 (8-8)]

Note: A properly adjusted air wash

. '1 . . , -,.-

Operation &

Maintenance

Manual

uheelabrator :'~•••• GROUP

'- - '" .



Sliding Baffle

--------",-- --~-- " " -

Burden Plate

Magnetic Drum,

\,,\,

iI

\ ~ )~~~ / Media &Fines

\~,\\~' ''''ir~~~b//Sand '--.: '-'._,~M'~~,' I 1 \ . . . • . . . . . . .> '

-~~i~1~~LJ._~~:~

VIEW A-AFigure 5-17 (A-A)

Swinging Baffle &

Counterweights

-

-: :

Operation &

Maintenance

Manualu.heelabrator

••• GROUP

- - ~~~~~~~~~~~~~~~~~~~~~ J



p. Key components will require adjustment to

achieve the expected operating efficiency in a safeand reliable manner. Reference Figures 5-17,

5-17 (A-A) and 5-17 (B-B).

1. Sliding Baffle - The sliding baffle must bepositioned to control the thickness of the

abrasive and sand mixture from the rotaryscreen so it flows onto the outer surface of the

rotating stainless steel drum without flooding oroverloading the magnetic field.

[See Figures 5-17 & 5-17 (A-A)]

2. Burden Plate - keeps the falling mixture ofabrasive and sand close to the rotating drumsurface and in the magnetic field of the

alternating pole magnet system.

[See Figures 5-17 &5-17 (A-A)]

30° Scribe Line

Coincides with

Drop off Point of

the Discharge

- - - - - - - - -, - - - ~~-~'

"

Rotary Drum

Square Shaft

J

.. . . ;;;-.

Operation &

Maintenance

ManualuJ 1eelabrator~

••••• GROUP .::-::~:-



3. Alternating Pole Magnetic Drum - The

magnetic drum system requires properpositioning of the fixed alternating pole magnet

inside the rotating stainless steel drum (Refer

to Figure 5-17). Using an adjustable wrench __

on the square end shaft, align the upper end of '::L

the scribe mark on the end of the shaft with thelonger scribe mark on the face of the locking

collar. Record the short scribe mark referencepoint from the locking collar. This will position

the upper magnet edge with the drop off point

of the discharge. The initial setting may needfurther adjustment to use the magnetic field tominimize the impact of the falling abrasive andsand on the drum surface and maintain a good

discharge arc for the metallic particles under

the drum.[See Figures 5-17, 5-17 (A-A) and 5-18] 'C-

4. Swinging Baffle &Counterweights -The

swinging baffle should swing freely but remainclosed until sufficient abrasive material builds

up behind the baffle to insure the flow of a full

- - - " ~~.

Operation &

Maintenance

Manualuheelobrotor

•••• GROUP

- -.J



. . ': ,"

Correct clearance allows the baffle to push

against the build up of abrasive on top of the lipand prevent any partial curtain leakage ofabrasive.

[See Figures 5-17 and 5-17 (8-8)]

5. Adjustab le Lip - can be adjusted along withthe swinging baffle adjustment to achieve theposition and relationships described in

paragraph 4 above.[See Figures 5-17 and 5-17 (8-8)]

6. Lower Adjustable Lip - Establish a minimum

gap of %' between the top front edge of this lip

and the back edge of the falling abrasive mix.

Additional adjustments of this lip may berequired in conjunction with adjustments in air

flow through the separator and size, weight &volume of contaminants. An air gap isnecessary to allow some horizontal movementof usable abrasive particles as the horizontalair stream carries the lighter weight

contaminants and unusable metallic fines out

of the abrasive mix.

J

Operation &

Maintenance

Manual~

Llheelabrator ~~~•••• GROUP ': :~t

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3. Alternating Pole Magnetic Drum - The

magnetic drum system requires properpositioning of the fixed alternating pole magnet

inside the rotating stainless steel drum (Refer

to Figure 5-17).Using an adjustable wrench~,:-;

on the square end shaft, align the upper end of ...:-:..

the scribe mark on the end of the shaft with the

longer scribe mark on the face of the locking

collar. Record the short scribe mark referencepoint from the locking collar. This will position

the upper magnet edge with the drop off point

of the discharge. The initial setting may needfurther adjustment to use the magnetic field tominimize the impact of the falling abrasive andsand on the drum surface and maintain a good

discharge arc for the metallic particles under

the drum.[See Figures 5-17, 5-17(A-A) and 5-18]

4. Swinging Baffle &Counterweights -The

swinging baffle should swing freely but remainclosed until sufficient abrasive material builds

up behind the baffle to insure the flow of a full

..~=-

-

::;".~-'

-. . . . • .-

:

Operation &

u.heelabrator;~aintenance

Manual ":)•••••••• GROUP

" -



.. . - 'c. The sand and metallic material is allowed to build

up in the upper casing to an optimum level foreffective operation of the fixed pole magnet ,~...

-

system..-

d. When the abrasive particles build up to the proper .•.-

height behind the swinging baffle to overcome the

resistance of the counter -weights, the swingingbaffle will open and permit a uniform thickness

curtain of abrasive to flow over the entire edge ofthe upper casing.

0-

Note: A properly adjusted swinging_"H_

baffle permits only a full width curtain to

be presented to the magnetic drum

through the separator.::...z;

""~;i,:',:' ::~;:~~

e. The flowing curtain of material passes between

the adjustable burden plate and the rotating drum-"

with its internal hemispherical (-225 degree)

section fixed pole adjustable magnet system.. •. . . .

f. Sand flows directly off the drum into a hopper and

. - .. - -: : : : . ;~. = . ~ : . ' "

Operation &

Maintenance

Manualuheelabrator

••••••••• GROUP

;. ::~::~l!!!!.~~~~~~~~~~~~~~~~~~~~~~..:: .•:~*.~ .: ~==.:.."- .:- . : : : . : : : : : : : .. :~

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. - . . . : :. : . . ::

--.- . . . . .

~~. - . :: :=~:.

- ~.. - :: : " ~' : :::

- , _ .. . .. •

Feedfrom

Primary Separator

Magnetic

Drum

Adjustable

Angle

Swinging Baffle

• I , I & Counterweights7 j1 .,, "

Burden Plate

ii

/\ ,

SeeViewA-A .':::::'-"":~"-:-;.~"";

,

~.---- I• •• •

TYPical Secondary LP Magnetic Separator

Figure 5-19

Swinging Baffle

J

Operation &

Maintenance

Manual

L lhee lab ra to r•••• GROUP -

, , - - - . -,-.~..~-.



i. Key components will require adjustments to

achieve the expected operating efficiency in a safeand reliable manner. Reference Figures 5-19,

5-19 (A-A) and 5-19 (B-B).

1. Swinging Baffle & Counterweights -Theswinging baffle should swing freely but remainclosed until sufficient abrasive material builds

up behind the baffle to insure the flow of a fullwidth curtain. The counterweights must be

positioned to hold the baffle closed without

causing an overflow or partial curtain condition.

Make sure the swinging baffle will not stick onthe ends near the vertical housing wall. Grind

the edges for clearance if required. The verticalback of the swinging baffle should be

perpendicular with the edge of the uppercasing lip. Use the slotted holes for the bearingmounts to adjust the position of the baffle as

required. The bottom edge of the baffle shouldclear the upper casing lip by approximately1/8". This gap may change, based on the size

abrasive used, to prevent sticking of the baffle

Operation &

Maintenance

Manualuheelabrator

••• GROUP



::

Locking Collar

20° Scribe LineCoincides withDrop off Point ofthe Discharge

Rotary DrumSquare Shaft

Locking Collar

Rotary Drum Square Shaft(Scribe Lines Represent

Edges of Magnets)

To Insure Proper Magnet Location in Drum LockingCollar must be Installed with Bolt Facing Upward.

PositioningU~er MagnetEdge

Figure 5-20

Operation &

Maintenance

Manual

L lhee lab ra to r•••• GROUP



This top setting will provide immediate

attraction to the small quantities of magneticmaterial mixed inwith the sand. The bottomsetting insures effective discharge of metallicparticles into the waste hopper area.

4. Adjustable Angle - The adjustable angle mustbe located to allow all metallic particles todischarge from the magnetic drum without

contaminating the reclaimed sand material.Moving of the angle will be dependent on theresults of a screening and magnetic content

analysis of the discharged reclaimed sand.

[See Figures 5-19 and 5-19 (A-A)]

c: ,r sf Dribble Valve

Assembly·

Customer's TrashReceptacle

-

' - . . . . -

Operation &

Maintenance

Manual

uJ lee lab ra to r•••••••• GROUP



b. Adjustable abrasive control valves are provided to regulate the flow

of abrasive to the wheels. An air cylinder or magnetic control unitopens and closes each valve. Cylinders are adjustable to obtain thespecified flow with different types and sizes of abrasive. Magneticcontrols provide variable flow adjustment. This meters the abrasive

from the storage hopper to the wheels.

Abras ive Cont ro ls Assembly with

Butterfly Type Abrasive Control Valve

« - - . . . . . . - - - - ~ - - - - ~- . ' . I ' - : : J / - - - - Ref. Storage Hopper

Fl ' ~ Abrasive Slide Valve

Abrasive Control Valve

MaleHoseAdapter

U-8olt Hose Clamp

FeedHose

Female HoseAdapteri V

j I ') , j ~ Ref. FeedSpout

l,\J ))'-+

Ref. Storage Hopper

~ ! L -=;:t--- Abrasive Slide Valve

Abrasive Control Valve

U-8olt Hose Clamp

FeedHose

Female Hose Adapter

Abras ive Cont ro ls Assembly with

Dipper Type Abras ive Cont ro l Valve

Operation &

uheelabratoraintenance

Manual " ,... ro. ,.,. ,... ••..••••••• G RO U P

_ .r "~J



c. The following are common components of a typical abrasivecontrols assembly as shown in Figures 5-21 , 5-22 and 5-23.

1. Abrasive Slide Valve - This is a manually operated slide valve

to open or close the media flow from the storage hopper to theblast wheel. This valve makes it possible to close off the flow of

media to perform repairs and maintenance on the abrasivecontrols system with have to drain the storage hopper.

Do not use slide valve to meter abrasive

-- I - , media flow.. '_ .

2. Abrasive Control Valve - This meters the abrasive from thestorage hopper to the wheels. There are three (3) types of

abrasive control valves.

[See Figures 5-21, 5-22 and 5-23]

.:. Butterfly Type - An air cylinder opens and closes a wafer

type paddle valve. The cylinder is adjustable to obtain thespecified flow with different types and sizes of abrasive. '-...J

.:. Dipper Type - An air cylinder opens and closes a totally

enclosed dipper cup type valve. An adjustable stop, with

Operation &

Maintenance

Manual

~

uheeloorotor..~•••• GROUP::;~

~~~~~~~~~~~~~~~~~~~~~: ....-



5. Feed Hose - This conveys the abrasive media from the

abrasive control valve to the blast wheel. There are two (2)

types of feed lines .

•:. Abrasive Resistant Rubber Hose - This consists of

abrasive resistant rubber hose and is the most common feedline type. It is flexible and easy to install.

.:. Hard Piping - This consists of a network of hard pipe and

weld elbows to feed the wheels.

-"" . -'- ~ :: - ~ . .. :

6. Female Hose Adapter - This is used to attach rubber hose typefeed lines to the feed spout of the blast wheel.

Operation &

Maintenance

Manual

I Ineelobrotor :~~~J I ----.,--...~,•••• GROUP:~~::::c;- .

~



Section 6 Ventilation

A properly sized and efficiently operating dust collector system is requiredfor effective control of dust and separation and collection of broken downabrasive media and contaminants generated by the blasting action. See

Figure 6·1 for typical ventilation arrangement.

Each ventilation point requires a specific volume and velocity of air to keep.~;.:¥:::;:.~:.:~

particulates suspended in the air stream; avoid dusting at the machine and "--

provide adequate separation of contaminants. A reduction in surface ..=:-"-preparation effectiveness and gradual process degradation will occur .:~~.

without proper ventilation. _ ..

After effective operation of ventilation system has been confirmed, airvolume and velocity readings should be taken at each vent point and

recorded as the standard. Periodic checks should be made to watch forchanges in these readings that would indicate potential ventilation

problems.

~. - ,,- - .:: ,. ,=: - : :

Clean Air SideDuct Usually

Same Size

As Fan Inlet

Dust Collectors :: := ':: ;;:-~. - ;.

Operation & I Ih I b tMaintenance UJ lee a ra ·o r

~::=:~. Manual ., r,....,- . " .- . ,. .., ,.. ., •• • G RO U P

. jt i~=~~~~··~ -~~~~~~~~~~~~~~~ .:»



6.1 Dust Collectors

Dust collectors provide three very important functions related to theclean and efficient operation of a blast cleaning machine.

1. The dust collector exhaust fan maintains a steady air flow throughthe separator, required for the air wash operation. The air flow pulls

dust, fines and other contaminants from the thin curtain of abrasive

media that falls over the lip of the separator. Operating properly, adust collector will take out only unusable fines.

-"--"2. The dust collector exhauster provides a negative pressure in the

blast cabinet. This is needed to keep dust from puffing out of the

blast machine. The puffing effect is caused by the air pump actionfrom blast wheel units ...-

By creating a negative pressure and controlling the flow of air to thedust collector, air outside the cabinet is dawn into the cabinet,rather than air and dust inside the cabinet being forced out.

-/

~

- . . .. -...--.. ~"

:~~~; .uheelobrotor~f:

••••• GROUP::~~?: .,..:~~'.~=:

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Operation &

Maintenance

Manual



SH A K ER

M EC H A NISM

ClEAN AIR

SIDE

. . . . • .:".

6.2 ThreeTypesof DustCollectors

6.2.1 ShakerBagStyle - : : J g ~ =The shaker bag style dust collector is an intermittent duty, ~~~~::.".:automatic or manual shaker type unit. Its construction incorporates:j¥~;:":'-~;

multiple tubular bags with internal access required for maintenance __ .

and inspections. Dust particles are captured on the inner surfaces ::=~~:~of the inflated bags when the fan is operating. Bags may be made : =:

of various fabrics with the most common being cotton sateen or

polyester for blast equipment applications. Incoming air is diverted ~=:::

by a baffle and slowed via expansion into the hopper. Large ~ : f ; : : = ' - : :contaminants drop into the hopper and finer material is collected on.::~~··"f~:

the inside of the bags. Cleaning is performed by stopping the fan to .._ ..allow the bags to go slack before shaking them for a specificinterval, usually about three minutes. This action removes most of _..:::::::-:,.:

the dust from the inner surface of the bags so the dust can then fall ' L ~ ~ '~:into the hopper. See Figure 6-2for Typical Shaker Bag Style Dust ':::--'~:. :~Collector. : : : : . - = : : : : ' ~ -

--'''.

- : ~ ~ ' ~ - * ~ ~ ~ : : ' ~, . - .. ".--,-~.~ .,

.. , .. ,-_ . ._-,..". - . - - .. .~ . .'-.

Operation &

Maintenance

Manual

L lhee lab ra to r• ••• GROUP

. .-.

.•.__ .~~~~~~~~~~~~~~~~~~~~!!i!i!ll!i!i!

6.2.1.1 Elements of a Typical Shaker Bag Style Dust Collector:

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. - - '" : :: =. "~ :.

'-" . . . .--~.- '. • _ . _ - " .

: : . : - : - . = - ~ -.

: '- ~ ~ ~ ~ - ' : l "

: : : : : = : " - = : ~ X ":~:;:::.~.~ . . ,,- .

: : ~ : : l ~ : -= : ~ ~ : : · :.,-- . . • .~ . . •- '.

_~:7'::.::.~~~~:.-

- -

6.2.1.1.1

6.2.1.1.2

Shaker Mechanism

Dustubes are cleaned by the

gentle but highly efficientmotion of the shaker

mechanism which is driven by

a totally enclosed motorlocated at the clean air side or

outside the dust collector. Theshaker provides a gentle wave-

like action from top to bottom

of each bag. The motion issimilar to the action obtainedby hand shaking a rug.

Filter Bags

Filter bags areusually madeof cottonsateen fabric,making them

inexpensive

~

Operation &

Maintenance

Manual\ . . . . . . . . -

LLhee labra tor••••• GROUP



- - - - - -

6.2.1.1.4

6.2.1.1.5

6.2.1.1.6

Inlet Vent

The dust-laden air enters the dust collector from theequipment vent piping through the inlet vent as shown

in Figure 6-2.

Baffle Plate/Liner

The dust-laden air entering the dust collector strikesthe baffle platelliner where the sudden change in

direction and reduction in air velocity cause heavierparticles to drop out immediately into the hopper. All

materials large enough to wear the filter fabric dropout of the air stream so only the small dust particles

reach the filter bags as shown in Figure 6-2.

Fan Outlet Vent

The cleaned air from the dust collector is exhausted

through the fan outlet vent to the atmosphere as

shown in Figure 6-2.

':~:::

::

=

Operation &

Maintenance

Manual


6.2.2 Pulse Bag Style- - · : . ; : ; .. . . ~ w

J



The pulse bag dust collector is a continuous, automatic, pulse-typeunit. Its construction incorporates multiple tubular bags supported

by tubular steel wire cages. Access may be from outside or from anintegral enclosure on the roof. Dust particles are effectively

captured on the outer surface of the tubular bags as the air flowsthrough the material into the center of the cage frames. The bags

may be made of various fabrics with the most common being cottonsateen or polyester for blast equipment applications. Cleaning isperformed by various venturi systems using periodic metered

pulses of high pressure air down the center of the wire cages. Thisreverse air pulse halts the inflow of air and releases the collected

dust from the outer surface of the bags. Each pulse sequence freesthe dust particles to work their way down the bags and into thehopper.

-

COMPRESSEDAIR RESERVOIR

J

uheelobrotor•••• GROUP

Operation &

Maintenance

Manual

,._.



P R I MARYNOZZLE

T h U a ::tY - ' . 'S ECONDARYj J NOZzlE

Cleaning ,Position

Figure 6·5



Operation &

Maintenance

Manualuhee l o b r o t o r

••••• GROUP. . . . . . . - '

6.2.2.1.8 Fan Outlet Vent



The cleaned air from the dust collector is exhaustedthrough the fan outlet vent to the atmosphere as

shown in Figure 6-3.

6.2.3 Cartr idge Style

A cartridge style collector is a continuous, automatic, pulse-typeunit. Its construction offers a compact design with ease of servicing.

Dust particles are effectively captured on the outer surfaces ofcartridge filter elements made of various materials appropriate to

the individual applications. Cleaning is performed by various venturi

systems using periodic metered pulses of high pressure air into thecenter of the cartridges. This reverse air pulse halts the inflow of airand releases the collected dust from the outer surface of thecartridge. Each pulse sequence frees the dust particles to work

their way down the side of the cartridge into the waste hopper and

container. (See Figure 6-6)

Operation &

Maintenance

Manual


6.2.3.1 Elements of a Typical Cartridge Style Dust Collector:

,-.J



6.2.3.1.1

6.2.3.1.2

6.2.3.1.3

Inlet Vent

The dust-laden air enters the dust collector from theequipment vent piping through the inlet vent.

Baffle Plate/Liner

The dust-laden air entering the dust collector strikesthe baffle plate/liner where the sudden change indirection and reduction in air velocity cause heavier

particles to drop out immediately into the hopper. Allmaterials large enough to wear the filter fabric dropout of the air stream so only the small dust particlesreach the cartridge filters.

Typical Cartr idge with Clamping Plate

Thecartridgeclamping

plate asshown here O

·. .

. .

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Operation &

Maintenance

Manual

" - - - - '

u .hee lab ra to r.uuu ••••• GROUP



6 . 2 . 3 . 1 . 5 Compressed Ai r Reservoir0:

The compressed airreservoir stores

compressed air to

insure minimumpressure drop and

maximum air storage

for each valve.;

6 . 2 . 3 . 1 . 6 Air Manifold

The air manifold distributes the air from thecompressed air reservoir evenly to the multi-stagenozzles to clean the filter bags. _ . - -

•.

Note: Similar to Figure 6-3.. ,..,.

6 . 2 . 3 . 1 . 7 Nozzles'-- - -

A controlled blast of compressed air is released fromthe nozzle into the throat of the venturi nozzle. Thevolume of air is magnified by the addition of the

secondary and tertiary air being drawn into the dust-laden cartridge filter.

Operation &

Maintenance

Manual

uheelobrotor••• GROUP

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-:6.3 Diaphragm Valve used on Pulse Bag & Cartridge Style

The reverse pulse diaphragm

valve delivers a short high

pressure pulse of compressed air,

reversing the air flow through a

cartridge filter or filter bag. This

action removes particulate fromthe filter surface, allowing the dust to fall towards the dust hopper.

The valve relies on system pressure acting on a flexible diaphragmmembrane to maintain a closed condition against the valve seat. The

pressurized cover chamber above the diaphragm is exhausted when

an electrical signal is supplied to the solenoid operator of the directpilot operator (CA). This lowers the pressure differential about the

diaphragm and allows the diaphragm to lift off the valve body seat.Compressed air is discharged through the valve outlet. When the

electrical signal is switched off the valve exhausts are closed, thepressure differential is balanced by air bleeding from the body to coverthe chamber and the diaphragm membrane moves back onto the valve

body seat shutting down the sir flow.

Operation &

Maintenance

Manual

uheelobrctor'.•••• GROUP

'--



6.4.2 Magnehel ic@ Differential Pressure Gage

The Magnehelic gage gives a continual reading

of the differential air pressure across the dustcollector filter

elements formonitoring the build

up of dust and theneed for cleaning or

replacement of filter elements.

, FLOW

--T i:ieC A G E

6.4.3 Photohelic@ Dif ferential Pressure Gage

The Photohelic pressure cage gives a

continual reading of the differential airpressure across the dust collector filterelements and electronically controls thecleaning cycle for the dust collector

Operation &

Maintenance

Manual

L lhee lab ra to r•••• GROUP

" - -

Section 7 Operations



7.1 Functions of Cont rol Panel Ins truments

EXAMPLES:

7.1.1 Wheel RPM

The wheel RPM displays the rotations per minute that the blast

wheel is turning.

7.1.2 Wheel Amps

The ammeter measures the amperage that the blast wheel motor isdrawing. (Amperage is an indicator of amount of abrasive flow)

7.1.3 Abrasive Run Hours

The hour meter records blast time usage on the machine.(Preventive and predictive maintenance activity should be

scheduled based on hours of blast time)

7.1.4 Blast Timer

.s:

~

.:

Operation &

Maintenance

Manualuheelabrator

- -••• •••• GROUP

7.1.7 Emergency StopPushbutton

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=

The emergency stop pushbutton shuts down the entire machine.(Stops the machine functions immediately)

Note: This is a push-pull maintained type button,

which is pushed for stopping and pulled to reset.

7.1.8 MotorOverload FaultLight

When this light is illuminated, a motor overload has tripped out.

7.1.9 Blast Start Pushbutton

Press the Blast Start pushbutton and the following occurs:

A. The door locks and the wheel starts.

B. After a small delay, abrasive begins to flow.

C. Blast timer begins to time.

D. When the timer times out, the wheel stops and abrasive

continues to flow to "brake" the wheel and the post tumble timer

begins to time.

I

.:»

Operation &

Maintenance

Manualuheelabrator

••••• GROUP~

7.1.12Wheel Start Pushbutton

'. ._ . .- ,-- - - -_ ." -



This pushbutton starts the blast wheel running when the equipmentis in the manual mode.

7.1.13Wheel Stop Pushbutton

This pushbutton shuts down the blast wheel when the equipment is

in the manual mode.

7.1.14 Blast Test Pushbutton

This pushbutton is used to take a blast pattern test.

7.1.15Abrasive Control Selector Switch

This selector switch enables or disables the flow of abrasive to theblast wheel.

7.2 Sequence of Operations

J an. 15,2007

J 3463 GUNDERSON-GIMSA

. -- - . . . . - ..

. . . . . . - -'" Operation &

Maintenance

Manual •••• ••• GROUP

uhee l ab ra t o r"', _ ., .- ' ..

5. Load the part on the entrance conveyor and press the "Conveyor Forward"push button. When the part is detected by the "Part detect" sensor located in

J



.-. "". front of the entrance vestibule the part tracking starts. If the part is inside theblasting zone the abrasive will turn on/off accordingly. If the part is inside thebrush-off zone the brush will turn on/off accordingly. If the part is inside theblow-off zone the blowers will turn on/off accordingly.

6. When the part reaches the "Over Travel" sensor located at the end of the exitconveyor, stops for unloading.

7. After unloading the blasted part and loading a new part, operator needs to

press the "Conveyor Forward" push button to continue the blasting.8. If for any reason the cabinet conveyor is stopped during the blast/brushprocess and restarted in reverse the part tracking is lost. The part must be

fully moved to the entrance conveyor and then sent back through the

machine.To run the part back to the entrance, operator can jog reverse the conveyor using

the entrance remote push button or the HMI screen button.9. When the reclaim system is running, if abrasive level is low in the upper

storage hopper, the abrasive adder control valve opens automatically to feedthe reclaim.

1D.lf the machine is on but no part is detected for an x time, the machine will shutdown automatically. The value of the auto shut down time is adjustable andpassword protected.

.. - , . _ - ..

IN MANUAL MODE (SET UP OR MAINTENANCE MODE):

J

Operation &

Maintenance

Manualuheelabrator

•••L••••• GROUP" - - - - - '

• There are two "Conveyor interrupt" push buttons located at entrance and

exit conveyors, for operator to stop the conveyors at any time without



disturbing the part tracking. The button which is pressed gets illuminated(flashing) while the other button stays solid on. To restart the conveyor,the button which is flashing has to be pressed again.

• If a motor overload is tripped, or any fault occurs the WHOLE MACHINE

WILL SHUT DOWN AND A FAULT MESSAGE WILL BE DISPLAYEDON THE HMI SCREEN.

7.3 Start-Up and Checkout

Before putting the equipment into operation, the following must beperformed:

1. Remove all foreign objects that might have been dropped or left inthe equipment such as the hoppers, elevator boot, inside the wheel

assembly, etc.2. Make sure that all covers, drive guards, inspection plates, etc. are

securely in place.

3. Check oil level of all the gear reducer drives. If required, fill with

manufacturer's recommendation listed on the reducer nameplate.

-

. • . . .

- •.- •.. ;.:::~:.

.,•. _ .. .:':~~:.. . . . . . . . • • . . _ . .

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Operation &

Maintenance

Manualu.heelabrator

•••• GROUP

..- _ .•. .. ; : : : :=

7.3.2 Charge the Eguipment with Media

-- - -- ./



. - ? :~ :~ :~ .

.. - .. .-~.

.--

-,_.'-

- ~ -.-

Before charging the Equipment, the blast gates on vent line fromthe cabinet, separator and elevator, should be set to one-half (1/2)open position. Final adjustment of the blast gates can be done later

when the ventilation system is balanced. Charge the equipmentwith the desired type and size of media. Load the abrasive material(media) slowly into the equipment.

After the media has been added, operate the blast wheel and

abrasive cycling system for 2 to 3 minutes. Stop blasting and letreclaim system return all the abrasive media to the storage hopper.If required add abrasive media until the level in storage hopper is 6"

to 8" below the adjustable lip under the swinging baffle in the

separator. As the equipment operates, check to insure that onlyfines, sand and/or scale is coming out of the dribble valve on the

separator refuse spout. If usable abrasive media is coming out ofthe dribble valve, verify correct (full curtain) operation of the

separator and adjust the blast gate in the vent line to reduce the airflow through the separator slightly. Also check for abrasive leakagearound the equipment.

7.3.3 Blast Wheel

See Section 4, Blast Wheel, for setting up and operation of the

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Operation &

Maintenance

Manualuheeloorotor

••• GROUP

Section 8 Maintenance



8.1 Inspection, Repair/Replacement of Parts & Components

For the blast equipment to perform efficiently, periodic inspection and

preventive and predictive maintenance must be accomplished througha regular maintenance program, "Have a Good program and PracticeIt." The purpose of this program is:

1) To detect minor necessary repairs and prevent major ones.

2) To anticipate repairs by locating probable causes - i.e., p..reventive·t ~main enance.

3) To plan repairs for convenient times (pre

4) To prevent breakdowns.

5) To be certain that the machine is being operated safely and at the

highest possible efficiency level.6) To keep an accurate record of maintenance activity and

replacement parts usage in order to manage the spare partsinventory and monitor operating and maintenance costs.

CAUTION: When performing inspection and

: .-

.. ::

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-

-----,,,- Operation &

L1hee labra to r- -

Maintenance

- Manual .......•......................,......,.n.GROUp

,J

: : : .

8.1.1.1 Liners-z,



The liners should be inspected and replaced before anyholes are worn through. All liners are easy to replace. When

installing liners in the wheel housing, it is vitally importantthat the liner pieces fit up against one another as tightly as

. possible to minimize housing wear from the blast.

_ . _ . -8.1.1.2 Wheel Housing

- During replacement of liners, the housing should beinspected for wear. A defective housing should be repaired

or replaced promptly to prevent the escape of abrasive

media.

8.1.1.3 Wheel Blades, Control Cage & Impeller•..- - .

The wheel parts should be inspected at the same time thatliner inspection is made. Parts should be replaced whenworn in accordance with the following criteria:

-- One of the main objects of wheel assembly inspection and

maintenance is to keep the wheel in balance. Severe

vibration can be a major cause of motor bearing failure.

Operation &

Maintenance

Manual

_ ..

uheelobrotor••••• GROUP

" - . , . /

To replace the control cage and impeller, remove the feed

spout and control cage clamps. Remove impeller cap screw



and impeller. Withdraw the control cage and fit the new one,

make sure that the opening of the new control cage isreplaced in exactly the same position as the old one. Re-

clamp and replace the impeller and feed spout.

8.1.1.4 Removal and Replacement of Blast Wheel Impeller Bolt ." _.__

&)

When removing and/or replacing the impeller cap screw, it isvery important that the following procedure be implemented

to prevent wheel parts from coming loose and a wheel failure

from occurring. This pertains to all blast wheels containing athreaded insert in the wheel shaft.

After removing impeller cap screw from the wheel assembly,

check the threaded insert in the wheel shaft to assure that itis fully seated (below the surface of the end of the shaft). If

the insert screws out of the shaft when removing the impeller

cap screw, replace both the cap screw and

threaded insert. Do not reuse the threaded insert

that has been removed from the shaft. If the

threaded insert must be reused, apply loctite #242 threadlocker (or equal) to the external threads of the insert prior to

. -~-= - ::--~.,---..,..

"-~:,:=~:::

Operation &

Maintenance

Manual

ulleelabrator•••• GROUP

._- -. __.' iii!iiiiiiii~~~~~~~~~~~~~~~~~~~!!ii!l

8.1.2 Cabinet Assembly

J



At regular inspection intervals, the inside surfaces of the cabinetshould be inspected to detect any wear points that could lead to

structural damage or abrasive leakage. If abnormal wear occurs,

immediate action should be taken to determine the cause and

make necessary repairs/replacement. All liners should be inspectedand replaced before any holes are worn through. Any worn or

damaged components should be replaced to prevent structuraldamage and leakage of abrasive.

8.1.3 Work Conveyor Assembly

Regular inspection should be given to the work conveyor structure,bearings, and alignment.

8.1.4 Work Conveyor Drive Assembly

The work conveyor drive should be checked for alignment andproper operation. The gear motor should be checked for oil level.If required, refer to gear motor's instruction sheet in Commercial

Parts Manuals, Section 10 for proper lubricant. Refer to Section 8,

Paragraph 8.2 for recommendations on lubricating machine

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Operation &

Maintenance

Manual


" - - -

8.1.5.1 Abrasive Hopper



Inspection of the sloping sides of the hopper should be madeat regular intervals to detect any wear points. Immediaterepair/replacement of sections worn away or damaged is

necessary to minimize loss of abrasive and any disruption incycling of the abrasive. Periodically, clean the hopper screen

of accumulated objects and debris.

8.1.5.2 Elevator Belt AssemblyThe elevator belt assembly should be checked for wear or

damage to the belt, worn or damaged buckets, propertension of the belt and proper alignment on the head pulley.

Normally, a new belt assembly is required to replace a wornor damaged elevator belt assembly.

Buckets are the bolt-on type and easily replaced. Check

condition of bolt heads for damage and wear. Badly wornbolt heads can lead to the buckets pulling off of the belt. All

buckets should be inspected periodically for wear or

damage. They should be replaced when the front lip of thebuckets wear down 3/4 inch.

Operation &

u .hee lab ra to raintenance..-'

Manual ~., , . . . . . . . , . . . . , . . . , . . . . t

••• GROUP

- J

- When a worn elevator belt needs replacement, remove theelevator side panel at the boot of the elevator to undo the



- - splice and carefully take out the old belt. You may use theold belt to help pull in the new belt if desired. See note

-- below. Since every belt is "tailor" fitted to each individual

elevator assembly, the new belt supplied will probably be 4":.

to 8" longer than needed. To determine the correct beltlength required, measure the distance of the path of the belt

__ "M

around both top and bottom pulleys. Make sure that the.- head pulley is lowered to the lowest position at the time of

. - measurement. Cut-off must be square. This will result in a

tight belt to begin with and allow ample take-up for future

needed tension. After the belt is cut, punch in the holes for

.- the splice and bolt the splice on one end of the belt only.

-- , Note: While the belt is out of the machine, inspect the bootpulley and head pulley and bearings for wear or damage.Replace any defective parts. The belt assembly can be fed

into the elevator housing through the bottom panel openingand pulled up and over the top pulley (use the old belt or

,- rope wrapped over the top (head) pulley), making sure thatJthe buckets are headed in the proper direction for discharge

- of abrasive into the elevator from the top and fed down thesides of the head pulley. After the belt is "hung" on the top

Operation &

L1hee labra toraintenance

Manual ·" ......•...••••••• GROUP~/

.•

.-

Belt tension can be adjusted by the screw take-uparrangement at the head section of the elevator. The



head pulley can be raised or lowered, within the_ . 4 .

mechanical take-up limits, by the take-up bolts. .-

Inspection of the elevator belt alignment is veryimportant. If the belt is permitted to run off center and rub

against the elevator housing, the abrading action will

eventually damage the elevator housing and belt. Also,

an overload is put on the drive motor, which may causethe overload relays to kick out. A take-up screw is

provided on each side of the head shaft for maintaining.-.

proper alignment. When aligning the elevator belt, make

only a slight adjustment at a time, raising the head shafton the side toward which the belt is riding. Using caution

and keeping hands away from top opening, the top coverplate can be removed to permit viewing the belt

alignment on the head pulley while the belt is running. . -.Refer to Section 9 "Troubleshooting" for elevatormalfunctions and suggested remedies.

8 . 1 . 5 . 3 Elevator Drive

The gear motor for the elevator drive should be checked for

Operation &

Maintenance

ManualLlheelabrator


8.1.5.6 Bearings

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e

-

-

The bearings should be checked for wear. If serious bearingwear is evident the bearings should be replaced. Most

bearings are lubricated for life and do not require

lubrication.

8.1.5.7 CFS Separator Assembly

The purpose of the separator is to remove scale, dust and

other fine materials from the usable shot (media). Thisseparation is extremely important, since failure to removethese contaminants from the media will not only decrease

the productivity (cleaning capability) of the machine, but willalso increase the rate of wear on the machine and maycause dust build up on parts.

The satisfactory performance of the machine is dependent

on the proper adjustment and maintenance of the separator.It is of utmost importance that the operation be constantly

checked. Particular attention should be given to the flow ofabrasive as it passes through the separator baffle assembly.The separator assembly should be adjusted so that auniformly thick falling stream of abrasive material is spread

across the full width of the separator. This insures that the

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·. . .. . .. .

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uJ lee lab ra to raintenance

Manual .. "r.,... •.....r -, •• •• • GROUP

' - - - - - "

The components of the separator are subject to very little

wear. However, they should be inspected periodically and



any damaged components should be repaired or replaced." . .-

Refer to Section 9.3 "Troubleshooting" for separator . M . .• _ '

malfunctions and remedies.

WARNING: If tramp metal or large

particles fall into the storage hopper and

enter the wheel, the wheel components

may shatter and clause severe damage or

possible injury.

8.1.6 Ventilation System - Provided by customer or as an option

-.-The ventilation system requires regular inspection of parts andcomponents to insure design performance, and to insure that an --adequate flow of air exists and is maintained.

The vent piping from the machine to the dust collector should be ..

checked periodically for wear and leaks. Replace or repair defective-.

Operation &

Maintenance

Manual

uheelcorotor•••• GROUP

.-

. . _ ••. . f ! ! ! ! . ~~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~~ ~~ ~ ~ ~ ~ ~

For the machine to perform efficiently, the electrical equipmentmust undergo periodic inspection to detect any wear conditions,

J



-:

physical damage, loose connections or component failure. Refer toSection 9 ''Troubleshooting'' for electrical equipment malfunctions

and remedies. Regular maintenance inspections should beperformed with particular emphasis on the following:

8.1.7.1 Control Panel

Check out electrical wires and connections for looseness,

damage and proper insulation. Tighten, repair or replace.

8.1.7.2 Electric Motors

Periodically inspect the motors for excessive dirt, vibration,

or abnormal conditions. Clean, correct, or replace asnecessary. Keep the ventilation openings of the motor clearto allow free passage of air.

If excessive friction and overheating of bearings is noted, it isusually caused by the following factors:

1) Bent motor shaft

2) Poor alignment

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Operation &

Maintenance

Manual

uheeloorotor:"- ./

••••••••• GROUP .:

8.2 Lubricat ion-Oi l & Grease



o

The life and performance of many components of the equipment aredependent on proper lubrication of components. Most bearings are

lube for life and do not require lubrication. Only electric motors and

reducers will require lubrication. Thorough lubrication, performed at

regular intervals will aid greatly in prolonging the life of the machinecomponents and in improving efficiency of operation.

Note: The intervals of lubrication are based on normal

operating conditions. If severe operating conditions

exist, such as extremely dusty conditions or an abnormal

amount of stopping and starting, it may be necessary to

perform the lubrication more frequently.

While lubrication of the required components is essential, lubrication ofsome drive components of blast cleaning equipment can be

detrimental. For example, chains and sprockets should not be

lubricated with petroleum base material because the lubricant tends to

accumulate metallic dust in the environment. This causes excessive

wear on the chains and sprockets.

The following recommendations should be followed when lubricating

Operation &

Maintenance

Manual

uheelobrotor.•••• GROUP

Section-9 Troubleshooting

Before attempting any troubleshooting, maintenance personnel and . _ -



eoperating personnel should become thoroughly familiar with theequipment.

Follow your Lockout/Tagout procedure (See Safety -

Warning & Precautions Section)

Before making any repair or replacement of defective parts, it is very

important that the reason for the original failure be determined and

corrected. A failure to correct the cause of the problem will inevitably lead

to a reoccurrence of the problem, etc.

Blast equipment will often continue to operate and will do an acceptable

job even though some of the mechanisms or components are not

functioning properly causing a decrease in efficiency. It is important formaximum efficiency, that troubleshooting be performed if either of the

following is noted:

1) Increase in abrasive consumption,

2) Decrease in cleaning efficiency.

Operation &

Maintenance

Manual

u .hee lab ra to r••• •••• GROUP

-.-..~~~~~~~~~~~~~~~~~~~~~._ -

Trouble Probable Cause Possible Remedy

.-....../ .



- . .. . -

@ Broken or chipped @ This condition will

blades. throw the wheel

permanently out of

balance and cause

damage to other partsof the unit. Replace

broken blades

immediately using full

set of new blades.

Retrieve all brokenparts before operatingthe equipment.

@ Improperly mounted @ Wheel must bewheel. squarely mounted and

evenly tightened ontohub or motor shaft -

check wheel for

wobble.

® Drop in blast wheel @ Not enough abrasive @ Check the level of

amperage. getting to the blast abrasive in thewheel. storage hopper. If the

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Operation &

Maintenance

Manual

L1hee labra tor••••••••• GROUP




@ Loose bolts or @ Make certain that all

misalignment components are firmly

secured.

@-D~f~-~ti~~-b~-~~~~~------ -@--Ch~-~k-th~-~~t;ti~~-~---

the unit bearing or the

drive motor. Both

should rotate freely

and smoothly. Repairor replace bad

bearings or motors.

® Increased Cleaning @ Improper abrasive @ If an ammeter check

Time feed to wheel. indicates a lowerampere reading than

the normal full load

rating, check:

a) Quantity of

abrasive and add if

level is low.

b) Abrasive control

valve adjustment

Operation &

Maintenance

Manual



@ Loss of Directional @ Conduct a blast

J



Control of Blast pattern test. Make

Pattern. Abrasive will certain that you have

strike sections of the definitely located the

wheel housing, or usable blast pattern.

cabinet components Adjust control cage

other than work to be accordingly so that the

blasted. This blast pattern is

increases cleaning directed onto the work

time, wear and most effectively.maintenance.

® Blast wheel shutdown @ Abrasive valve worn @ Replace the worn

causing overload. abrasive valve parts.

® Abrasive Leakage @ Improper sealing. @ Check wheel housing

and motor shaft seal.

9.2 Elevator


Operation &

Maintenance

ManualL lhee lab ra to r

•••••••••• GROUP~

Trouble I Probable Cause I Possible Remedy



@ Worn pulleys, travel of @ Rubber lagging on

belt and rotation of pulley may be worn.

boot pulley are erratic. Replace or re-Iag

pulley.

® J ammed Elevator Belt @ Foreign objects in @ Inspect and clean

elevator boot jam boot section

against buckets and periodically.casing causing stall.

Follow safety

instructions sign

when working on

elevator. Reference

Safety - Warning &

Precaution, Section

3, 3.7.4 Safety

Instruction Sign,Part No. 495079

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --@--R;~;~~-b-~~k;t~:-if----@ Worn buckets-

Elevator buckets are belt showsworn so that they no considerable wear,

longer carry the pre- replace complete

determined load. assembly.

Operation &

Maintenance

Manual

L ihee lab ra to r•••••• GROUP


@ Abrasive control valve @ Lack of air pressure to

J



leaks abrasive keep valve closed.

@ Worn parts. Check

and replace worn

parts.

® Elevator Belt Failure @ Belt too tight - @ Belt should bebreakage may occur adjusted to properat splice tension. When belt is

under proper tension,

splice is not

overstressed.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -@ Foreign objects in @ Sudden jams should

boot cause sudden be avoided. Keep

jamming, belt boot section clean;stretches and breaks. remove foreign

objects.

Follow safety

instructions sign

when working on

elevator. Reference

Operation &

Maintenance

Manual

u .hee lab ra to r••••• GROUP

"- -


@ Worn crown on head @ Check head pulley.




® Removing good @ Too much air on @ Adjust blast gateabrasive separator setting.

pulley causes belt to These are crown faceride on one side or the pulleys. If crown isother. worn, replace pulley.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -(f·C·h~~k·~;~~~I·-·-·-·-----@ Belt cannot be aligned

properly although all alignment of head and

components seem to boot pulley by

be in proper condition. dropping plumb linefrom top to bottom -

realign if necessary.

9 . 3 Separator

To determine if the separator is functioning properly, make a visualanalysis of the abrasive after separation and of the material from the:::

separator refusedischarge spout.~:~~

Operation &Maintenance

Manualuheelabrator

•••••••• GROUP

. _ . . ~!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i ii! i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!!i!ii i i i i!i!!!!i!ii!!i!!i!


® Contaminated @ Insufficient flow of air @ Adjust blast gate

J



Abrasive. delivered by setting.

ventilation.

@ Check line for

blockage.

@ Check fan output.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

@ Full curtain is not @ Check stationarymaintained across baffle and swingingseparator. baffle operation.

Adjust baffles asneeded to obtain a full

curtain.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -@ Fines hopper and tube @ Clean out tube and

are plugged. fines hopper.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -@ Magnets on drum not @ Confirm proper

properly positioned. position and secure(This is only on mounting of magnetmagnetic separator assembly using

designs.) external scribe mark

reference guides on

Operation &

Maintenance

Manual" - - - - "

uheelobrctor.••••• GROUP

Trouble Possible Remedyrobable Cause

@ Magnets on drum not @ Confirm proper



properly positioned.

(This is only on

magnetic separator

designs.)

position and secure

mounting of magnet

assembly usingexternal scribe mark

reference guides on

shaft end and lockingcollar.

@ -·B~-;d~-~-P l~t~-~-~t·i~·-·-·-@ -·V~~ify-~~~iti~~-~f·-·-·-·-proper position. (This burden plate to insure

is only on magnetic effective retention of

separator designs.) abrasive and sand

mixture against

rotating drum.

-

Ventilation System

Proper maintenance of the ventilation system is just as important asthe servicinq of other elements of the blastequipment.

The following troubleshooting chart is provided as an aid formaintaining adequate and efficient ventilation.

9.4


Manual

L1hee labra to r••••• GROUP

-- .....~~~~~~~~~~~~~~~~~~~!!!l!!


@ Check dust collector

-J



discharge container -

every shift. Emptybefore container is full.

® Contaminated @ Insufficient flow of air @ Check exhaust fan

abrasive - fines and through separator to rotation.

contaminants not collector.

properly removed from @ Open blower exhaustabrasive. damper if present.

@ Check Magnehelic

reading.

@ Check pulse or shakeroperation of collector

and increase, if

necessary.

@ Replace filters, if

necessary.

9.5 Electrical Equipment

Operation &

Maintenance

ManualuJ1ee labra to r

••••••••• GROUp·:


@ Check main power® Electric Motors do not @ Main power cable



cable at electrical

source. Must be 230,

460 or 575 volt, 60hertz, 3 phase

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - _@ Blown Fuses I I @ Check fuses. Replace

if defective.

@ Applicable motor I I @ Reset starter.

starter overload relaytrips out.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - - - - - - . _ - - - - - _ . _ . - . . . . -@ One fuse blown in @ Check all fuses.

disconnect box. Replace as required. I"~

Start disconnected at

electrical source.

@ All phases of 230 or

460-volt supply not

connected properly.

® Electric Motors do not

Come Up to Speed,

Run Slow

9.5.2 Starters and Contro l Panel

@ Recheck wiring for

loose or improperconnections.


Manualuheelcbrotor


---".~~~~~~~~~~~~~~~~~~~~~~ii!i!i!!!i!!i!


® Fuse Protection @ Fuses blow. @ For the occasional

<:»



"blow", fuses may be

loose in fuse holders,

or temporarilyoverloaded. If

persistent, check for

grounded circuit, barewire.

® Overload Relays Trip @ Overload in circuit low @ Shut down particular

continuously power. circuit. Check power

source for proper

voltage.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -@ Broken, damaged or @ Inspect wiring for

loose wiring. broken, cut wires and

loose terminals.

Replace/repair as

required.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - . - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -@ Dirt or contaminants at @ Clean contacts and

terminals. terminals.

Operation &

Maintenance

Manual

ulleelabrator•••••••• GROUP

Probable Cause

9.5.3 Cont ro l Accessories - Operator's Control Panel

Trouble Possible Remedy



@ Buttons stick.

@ Dirty

@ Failure

® Pushbuttons

.. _ - - - - - - - - - - - - - - - - - - - - - _ . _ . _ - - ) _ . _ - - - - - - - - - _ . _ - - - _ . - . _ . _ . _ . _ . _ . - . -

@ Erratic Operation @ Check contacts for

dirt, springs broken orout of place.

@ Probable cause -abrasive dust.

Remove cover and

clean .

1

_:

,-

® Ammeter-

· - · - - - · - · - · - · - · - · - · - · - · - - - - - - - - - n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - . -

@ Inaccurate reading i@ Bent indicator pointer.Replace meter.

@ Carefully clean

ammeter with a fine

brush.

@ Replace meter.

Commercial LocationPart Model on Web Address for Manual

Operation &

Maintenance

Manual

Llheelabrator ~ =••••••••• GROUP

~. - _ . •. . . _ -

Section-10 Commercial Parts Manuals



No. Machine

BaldorBlast

http://www.baldor.com/Wheel

NordLower

http://www.nord.com/mainlindex.cfmReclaim

SEW- Lower http://www.sew-

Eurodrive Reclaim eurodrive.de/englisch/index.en.html

Reliancehttp://www.reliance.com/

Electric

Boston Gear http://www.bostongear.com/

Browning http://www.emerson-ept.com/

Operation &

Maintenance

Manualuheelabrator -

O •••• GROUP" - - -

Section-11 Recommend Spare Parts

11-1 Wheel Unit Spare Parts



DescriptionUnit Total

Qty. Cat. No.Cost Cost

1 738875 Bare Wheel

1 736807 Feed Spout Seal

3 C104905 *Blade Set

1 731156 Centering Plate

1 Control Cage Adapter

3 737720 *Control Cage

3 Control Cage Adapter Clamp

3 737661 *Impeller1 683487 *Hi Collar Lock Washer

1 682988 *Impeller Cap Screw

1 471181 Feed Spout

::


Manual


- -

11-2 Lower Reclaim Assembly

:: Qty. Cat. No. Description Unit TotalCost Cost

J



1 C205336 Reducer, 5 HP

1 C168695 Bearing, 2" End Plate

1 C82733 Shot Disc

1C1132 Flange Bearing, 1 ' Y : z "

2 C41924 Rubber Buffer

11-3 Elevator Assembly

r

Qty. Cat. No. DescriptionUnit Total

Cost Cost

1 746089 Boot Pulley

1 746089 Head Pulley

2 458667 Bearing

2 685995 Shaft Seal

J

Operation &

Maintenance

Manualuheelobrotor

•• ("r;n•••• G RO U P" - -

11-4 Upper Reclaim &Separator Assembly




Cost Cost

I752001 Base Screw R.H.

1 720490 Base Screw Screen

2 678619 Shaft Seal

2 280800 Bearing

1 720490 Separator Screen

1 747800 Gearmotor

11-5 Dust Collector V

Qty. Cat. No. Description Unit Total ICost Cost

15 C179907 Cartridge Filter

1 C179643 Photohelic Gauge

- _ . - -_ . Operation &Maintenance

Manualulleelabrator

••• GROUP

-.- ..=::~--: : : : i i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i i i i i i i i ii i i i i i i i i i i i i ! ! !i ! ! ! i i i ! ! !i!

11-7 Liners in Line


Cost Cost



- -

39 223306Liner (12" x 12")

1 234096Liner (6 3/8" x 12")

1 C228696Cut Liner

1 C228695 Cut Liner

1 C228694Cut Liner

1 C228693 Cut Liner

1 C228691 Cut Liner

1 C204121 Cut Liner

1 C228699 Cut Liner•. .:'~.:;,. - ::

-

Operation &

Maintenance

Manual


Section-12 Machine Drawings

12-1 Base Machine

The following drawings, listed in the order of insertion, are considered



necessary for ordering replacement and spare parts, propermaintenance and operation:

Drawing GroupTitle

Number Number

A1-97282 22 General Arrangement

A1-97287 22 General Arrangement -

A1-97279 92 Design Criteria

A1-95907 03 Reclaim Screw Arrangement

~

A2-51526 03 Rebound Screw Assembly:

A3-18649 03 Shot Disc Assembly

A2-21720 03 Torque Bracket Assembly..

_ .. . -.Operation &Maintenance

Manualu .hee lab ra to r

• : : : J • • G RO U P

c.: : : : :: :~: i i i i i ! i i ! ! i ! ii l i i i i i ! i i ! !i ! i i l i i i i i ! i i! ! i ! i i l i i i i i! i i ! ! i ! i i li i i i i ! i i ! ! i ! i il i i i i i ! i i ! !i ! i i l i i ! i i i i i ii i i i i i i i ! i i i i i i i i i ii i i i ! i i i i i i i i i i i i i i !i i i i i i i i i i i i i i ! i ii i i i i i i i i i i i ! i i i i i ii i i i i i i i ! i i i i i i i i i ii i i i ! i i i i i i i i i i i i i i !i i i i i i i i i i i i i i ! i ii i i i i i i i i i i i ! i i i i i ii i i i i i i i ! i i i i i i i i i ii i i i ! i i i i i i i i i i i i i i !i i i i i i i i i i i i i i ! i ii i i i i i i i i i i i ! i i i i i ii i i i i i ! i i i ! ! i !! !

-

Drawing GroupTitle

Number Number

0600790 09 Head Section Assembly



0600808 09 Elevator Belt Assembly

0700764 10 Upper Reclaim Arrangement

0600780 10 60" Separator Assembly

0700763 10 Rotary Screen Assembly

A1-97373 15 Motor List

A1-97409 19 Oucting Arrangement

A1-96286 20 Blast Wheel Arrangement

0500320 20 Blade Selection Chart

A1-97454 23 Foundation Footprint

A1-96333 24 Superstructure Arrangement

.~=~: .. : - : : : :~ :


Manualuheelcorotor:

.J••••GROUP" - - - -

Drawing GroupTitle

Number Number

A2-49185 35 Torque Bracket Assembly



-- -- . . " ,

A4-15783 36 Entrance Conveyor Arrangement

A4-15783 37 Exit Conveyor Arrangement

A1-96416 41 Vestibule Seal Arrangement

A1-96515 58 Zero Speed Switch Arrangement

A1-95663 64 Exit Vestibule Arrangement

A1-96352 68 Abrasive Removal System

A1-96502 68 Abrasive Removal System

A2-45963 68 Machine Screw Actuator

A2-46294 68 Limit Switch Flat Arrangement

A2-46296 68 Seal Assembly

-::::::=='::::~:.'~-.---."

. .. _-- • ..-. - - - - ~ , .. .-.--~- - . . -.. .. . _ ..~ :- -" .. •.::~:

-.~ _ . .._".


Manualu .hee lab ra to r

••••••••• GROUP.,._ .,

-~~~7.~~'::

Drawing GroupTitle

Number Number

A3-53398 96 Contro l Schemat ic #4

~



: : : - - : : ~ : : :. : : :

~.. _ .._ , ._ _ .. .

A3-53399 96 Control Schematic #5

A3-53400 96 Photohelic Schematic

A3-53401 96 Frequency Drive Schematic

A3-53402 96 Pneumatic Schematic

A3-53403 96 Main Panel Layout

A3-53404 96 Remote Panels Layout

J

--@NORTHERN Fan Data Sheet CMLN~~~~:,'g~~~~~~~C

BWWER@o Winnipeg, MB. R2C 2Z8Phone: ( 2 0 4 ) 2 2 2 - 4 2 1 6~ ~~~~~~~~ F _ a X _ ( ~2 M_ ) ~2 _ 2 2 _ - 7_0 1

~STOMER: Fox Tech Inc.

SOLD BY: C.B. Airtech Ltd / BobG

TAG:

ORDER #: A56948

CUSTOMER PO: 3463301

LINE ITEM #: 56948.01

Qty 1 Square Fan - BI, Design 7620, Size 2450, Class 2, 90% SISW, Arr 9, Rot CCW, Discharge DB, Mtr Psn Right



Maximum allowable fan speed 2206 RPM at 70 F

Condition Volume SP OV RPM Power Temp Altitude

Operatin'g 8700 CFM 10inWG 2583 FPM 2112 RPM 17.4 BHP O ft

Density

0.075 Ib/cu ft

Features

•Access Door - Position: 12 o'clock, Quick Release

•FanType - Type: Gusset Base

•Motor and Drive Mounting

•Nameplate - Quantity per fan: 1, Type: Standard

•Punched Flanged Outlet(4sided)

•Slip Fit Inlet

Paint Specification

Paint Spec: Interior & Exteriorurface prep: SSPC-SP1 & SP2 cleaned surfaces.rimer: 1 coat alkyd primer.Total OFT 1.5 mils finish.

Guard Color: Safety Yellow

70 F

•Belt Guard

•Mechanical Run Test•Motor Base - Type: J ackscrew

•Percent Width

•Shaft & Bearing Guard w/ access to bearing zerks

•Flat inlet plate 51" x 51"; 12-5/16" hole spacing

Color: Black

~- - - - - - - - H- - - - - - - - ~

- - - - u- - - - ~i l - - - D- - -

Ir-1

B

E



IS J \

~ Y HO LES, 9/ 16 D lA .

f k ~ Y w o . y

CC\J - DB

1

~ ~

/ Qg~1r4lM O T O R P O S I T I O N : R IG H T L r -~ ::; ! J

I.....

"'===1 : "'~ /',v

:/Rti"-----

'Q J', . ,.

FI

DI"enslons noted wl1:h • Q re QdJ ustE'cI for Y o width

SIzE? Sh.ft Diu Keywo..y SIze A B C D E F G H J K L . , N P Q R

r:-'" 2450 Iii ~ X Ii 23~ 19i 22~ 19~ 42i 2BB 11M" 44~

51 42 32/1;- 12 4 12t1;

*262

s T U IN X YD[SCHIIR~ B[ LlU -Ij r,l lnfRN

Size Dtlo£t.r: sml'tA lL TD..[R.-NC:l: I: us

r---AA-DD - n GGSPACE1f -DD

Iii •• CNTRS _cc

NORTHERN BLOWER LUBRICATION INSTRUCTION INDEX ENGLISH

BEARING

DESCRIPTION MFR NB PUBLICATION BEARING SERIES

F4B-DL-000 Dodge

F4B-DL-100 Dodge

F4B-DL-200 Dodge

F4B-SC-000 Dodge

F4B-SC-100 Dodge



F4B-SC-200 Dodge

P2B-DL-000 Dodge

P2B-DL-100 Dodge

P2B-DL-200 Dodge

P2B-GT-000 Dodge

P2B-GT-100 Dodge 01228 200 Series Ball Bearings (Page 2)

P2B-GT-200 Dodge

P2B-SC-000 Dodge

P2B-SC-100 Dodge

P2B-SC-200 Dodge

FYOOO SKF

FY100 SKF

FY200 SKF

SYOOO SKFSY100 SKF

SY200 SKF

F-U300 Linkbelt01229 300 Series Ball Bearings (Page 3)

P-U300 Linkbelt

FB22400 Dodge01230 22400 Series Double Row Spherical Roller Bearings (Page 4)

@NORTHERNSWWER®

l u b r i c a t i o n I n s t r u c t i o n s200 Series Ball Bearings

Procedure For Applying Lubricant To Bearings

Apply sufficient grease when lubricating to cause some purging of grease at the seals.



,Lubricant

Use a multi-purpose ball bearing grease of NLGI Grade 2 with rust inhibitors and antioxidantadditives. An oil viscosity of 100 cSt at 40° C is recommended. Grease for high speed applications

should be dynamically stable and must not churn or whip. It is not good practice to mix greases

with different oil bases as the results are unpredictable.

Several suitable products are: Shell Alvania #2, Exxon (Imperial Oil) Unirex N2, Texaco Premium

RB, Chevron SRI #2, and Mobile Mobilux #2. For fans with vertical shafts, consider using a NLGI

Grade 3 grease such as Shell A1vania3 or Exxon Unirex N3. Do not use long fibered greases.

Consult CML Northern Blower on proper lubrication if bearings are subjected to temperatures

below -10°C (15°F) or above 80°C (175°F).

Lubrication Interval Table

RELUBRICATION INTERVAL IN MONTHS OF OPERATION

SHAFT SHAFT SPEED IN RPM

DIAMETER 1000 1500 1800 2000 2500 3000 3500 4000

3/ 4 12 12 12 12 12 12 10 10

r:

@NORTHERNSIDWER®

l u b r i c a t i o n I n s t r u c t i o n s300 Series Ball Bearings


Apply sufficient grease when lubricating to cause some purging of grease at the seals.



Lubricant

Use a multi-purpose ball bearing grease of NLGI Grade 2 with rust inhibitors and antioxidant'additives. An oil viscosity of 100 cSt at 40° C is recommended. Grease for high speed applications

should be dynamically stable and must not churn or whip. It is not good practice to mix greases

with different oil bases as the results are unpredictable.

Several suitable products are: Shell Alvania #2, Exxon (Imperial Oil) Unirex N2, Texaco PremiumRB, Chevron SRI #2, and Mobile Mobilux #2. For fans with vertical shafts, consider using a NLGIGrade 3 grease such as Shell Alvania 3 or Exxon Unirex N3. Do not use long fibered greases.

Consult CML Northern Blower on proper lubrication if bearings are subjected to temperaturesbelow -10°C (15°F) or above 80°C (175°F).




DIAMETER 500 1000 150 0 2000 2500 3000 3500 4000

1-3/16 6 6 6 4 4 4 2 2

1-7/16 6 6 6 4 4 4 2 2

@NORTHERNBI .DWER®

l u b r i c a t i o n I n s t r u c t i o n s22400 Series Double Row

Spherical Roller Bearings




Apply sufficientgreasewhen lubricatingto causesome purgingofgreaseatthe seals.

LubricantUse a multi-purpose ball bearing g-easeof NLGI Grade 2 with rust inhibitors and antioxidantadditives. An oil viscosity of 100cStat40° C is recommended. Grease for high speed applicationsshould be dynamically stable and must not churn or whip. It is not good practice to mix greaseswith differentoil bases as the results are unpredictable.

Several suitable products are: Shell Alvania #2, Exxon (Imperial Oil) UnirexN2, Texaco PremiumRB,ChevronSRI#2, andMobileMobilux#2. Do not use long fibered greases.

Consult CML Northern Blower on proper lubrication if bearings are subjected to temperaturesbelow-10°C (15°F) or above BO °C (176°F).




DIAMETER 500 1000 1500 2000 22 00 2700

1-11/16 6 4 2 2 1 1

@NORTHERNBI.DWER®

This Lubrication Instruction is for 22500series

bearing assemblies utilizing the 22200seriesbearings only.

l u b r i c a t i o n I n s t r u c t i o n sSplit Pillow Block Bearings22500 Series Double Row Spherical

Roller Bearings

Re-pack the pillow block as described above.

Lubricant

Use a multi-purpose ball bearing grease of NLGI



Procedure ForApplying Lubricant To Bearings

And PillowBlocks

Bearing and housing must be clean.Pack each bearing full of grease by swiveling theouter ring open, rotating it as necessary to inject thegrease, then swiveling the outer ring closed, being

careful not use force in the event a roller end catchesthe corner of the outer ring sphere.

Before assembling the pillow block cap to the base,and after completing bearing and base assembly, fillthe pillow block base to the bottom of the shaft withthe same lubricant that was used to pack the bearing.

Prior to mounting the cap to the base, lightly coat the

interior of the cap with grease.

r For bearings with contact seals, smear a liberalamount of grease on the contacting surface of theseals.

Relubrication Of Bearings Supplied With

Grade 2 with rust inhibitors and antioxidant additives.An oil viscosity of 100 cSt at 40° C is recommended.Grease for high speed applications should bedynamically stable and must not churn or whip. It isnot good practice to mix greases with different oilbases as the results are unpredictable.

Several suitable products are: Shell Alvania #2, Exxon(Imperial Oil) Unirex N2, Texaco Premium RB,Chevron SRI #2, and Mobile Mobilux #2.

Do not use long fibered greases.

Consult CML Northern Blower on proper lubrication ifbearings are subjected to temperatures below -30°C

(-22°F) or above so -c (176°F).

Notes:

1. Increase the frequency or lubrication in conditionsof high vibration, or abnormal temperature,moisture, or dirt.

Table 1

RELUBRICAT ION INTERVAL IN H OUR S O F O PER AT IO N

SHAFTDIA . S HA FT S P EE D (rpm)

IN CHES 500 700 900 1200 1400 1600 1800 2000 2200 2400 2600 3000 3600

1 3/ 16 8900 6200 5000 3800 3250 2650 2250 1950 1650 1450 1250 1050 825

1 7 / 16 7500 5300 4300 3000 2650 2050 1750 1500 1250 1150 950 800 580

1 11/ 1 6 7000 5050 4050 2800 2350 1850 1625 1400 1200 1000 900 700 520

1 15 / 1 6 6600 4800 3900 2650 2100 1750 1500 1250 1100 875 800 625 460

2 3/ 16 6100 4500 3500 2250 1850 1500 1300 1100 900 750 600 480 300

2 7 / 16 5800 4350 3250 2050 1650 1400 1150 92 0 725 585 500 350 200

2 11/ 16 5700 4200 3100 1950 1600 1250 975 840 650 550 440 310 150

2 15/ 16 5600 4100 3000 1900 1500 1200 925 775 590 500 400 250



3 3/ 16 5400 4000 2900 1800 1400 1150 90 0 710 560 450 350

3 7 / 16 5200 3800 2750 1650 1300 1000 800 610 510

3 15/ 16 4900 3550 2500 1500 1150 860 650 525

4 3/ 16 4700 3200 2250 1300 950 700 540 400

4 7 / 16 4400 2950 2000 1150 750 580 450

415/ 16 4150 2600 1700 1000 710 490 3705 3/ 16 3950 2300 1500 850 575 420

5 7 / 16 3400 2150 1400 750 510 310

515 / 1 6 3200 1900 1200 590 420

6 7 / 16 2800 1650 1000 530 340

615/ 1 6 2500 1500 90 0 450

Lubricants deteriorate in time, and the rate of deterioration is a function of the lubricant used at the operating conditionsencountered. Table 1 is based on the use of an age-resistant, average quality grease and is valid for bearing temperatures

of 70°C (158°F) measured on the outer ring. The intervals should be halved for every 15°C (2rF) increase above 70°C, butthe maximum permissible operating temperature for the grease should obviously not be exceeded. Conversely, if theoperating temperatures are lower than 70°C, the intervals can be lengthened to about twice for operating temperatures of50°C (122°F) and below.

Where there is risk of the grease becoming contaminated, the relubrication intervals should be reduced.

Table 2

@NORTHERNSWWER®

This Lubrication Instruction is for 1500and

2500series bearing assemblies utilizing the

1200and2200series bearings only.

Procedurefor applying lubricant to bearings

l u b r i c a t i o n I n s t r u c t i o n sSplit Pillow Block Bearings1500 & 2500 Series Double Row Bearings

If it is not practical to swivel the outer ring open,purge the old grease from the bearing by forcing

freshgrease throughthe bearing.

Re-pack the pillowblockas describedabove.



andpillowblocks

.Bearingand housingmustbe clean.Pack each bearing full of grease by swiveling theouter ring open, rotating it as necessary to injectthe grease, then swiveling the outer ring closed,beingcareful not use force in the eventa rollerendcatchesthe corner of the outer ringsphere.

Beforeassembling the pillowblockcap to the base,and after completing bearing and base assembly,fill the pillow block base to the bottomof the shaftwith the same lubricant that was used to packthebearing.

Priorto mounting the cap to the base, lightly coatthe interiorof the capwith grease.

For bearings with contact seals, smear a liberalamountof grease on the contacting surface of the

Lubricant

Use a multi-purpose ball bearing grease of NLGIGrade 2 with rust inhibitors and antioxidantadditives. An oil viscosity of 100 cSt at 40° C isrecommended. Grease for high speed applicationsshould be dynamically stable and must not churnor whip. It is not good practice to mix greases withdifferentoil bases as the results are unpredictable.Several suitable products are: Shell Alvania #2,Exxon (Imperial Oil) Unirex N2, Texaco PremiumRB, ChevronSRI#2, andMobileMobilux#2.

Donotuse long fibered greases.

ConsultCML NorthemBloweron properlubricationif bearings are subjected to temperatures below -30°C (-22°F) orabove BO °C (176°F).

Notes:

Table 1

DOUB LE R OW B ALL B EAR IN G S

SHAFTDIA . SHAF T SP EED (rpm)

INCHES 5 0 0 7 0 0 9 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 0 2 0 0 0 2 2 0 0 2 4 0 0 2 6 0 0 3 0 0 0 3 6 0 0

1·3/16 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 0 0 0 7 0 0 0

1·7/16 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 4 0 0 7 8 0 0 7 0 0 0 5 8 0 0

1 ·11/16 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 5 0 0 8 0 0 0 7 4 0 0 6 4 5 0 5 0 5 0

1·15/16 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 2 0 0 7 6 0 0 7 0 0 0 4 5 0 0 3 5 0 0



2·3116 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 1 0 0 7 5 0 0 6 8 0 0 6 0 0 0 4 8 0 0 3 0 0 0

27/16 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 3 0 0 7 4 0 0 6 6 0 0 5 8 5 0 4 8 5 0 3 5 0 0 2 0 0 0

2·11/16 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 0 0 0 7 1 0 0 5 4 5 0 4 9 0 0 4 4 0 0 2 9 0 0 1 5 0 0

2·15/16 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 5 0 0 7 7 0 0 6 8 0 0 5 9 0 0 4 9 0 0 3 9 0 0 2 5 0 0 9 0 0

3·3116 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 4 0 0 7 5 0 0 6 4 0 0 5 4 0 0 4 5 0 0 3 5 0 0 2 0 0 0 5 8 0

3·7/16 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 0 0 0 7 0 0 0 5 9 0 0 4 6 0 0 3 7 5 0 2 5 0 0 1 2 0 0 1 8 0

3·15/16 8 7 6 0 8 7 6 0 8 7 6 0 8 7 6 0 8 4 0 0 7 2 5 0 6 2 0 0 5 0 0 0 3 8 0 0 2 6 5 0 1 7 5 0 7 5 0 .

Lubricants deteriorate in time, and the rate of deterioration is a function of the lubricant used at the

operating conditions encountered. Table 1 is based on the use of an age-resistant, average quality grease

and is valid for bearing temperatures of 70°C (158°F) measured on the outer ring. The intervals should be

halved for every 15°C (2rF) increase above 70°C, but the maximum permissible operating temperature

for the grease should obviously not be exceeded. Conversely, if the operating temperatures are lower than

/" 70°C, the intervals can be lengthened to about twice for operating temperatures of 50°C (122°F) and~ below.

Where there is risk of the grease becoming contaminated, the relubrication intervals should be reduced.

@NORTHERNBI.DWER® l u b r i c a t i o n G u id e" M " Se r i e s B a l l B e a r i n g s

Dodge SeM, SKF SYM & FYM

Procedure For Applying Lubricant To BearingsApply sufficient grease when lubricating to cause some purging of grease at the seals.



Lubricant

. Use a multi-purpose ball bearing grease of NLGI Grade 2 with rust inhibitors and antioxidant

additives. An oil viscosity of 100 cSt at 40°C is recommended. Grease for high speed applications

should be dynamically stable and must not churn or ship. It is not good practice to mix grease with

different oil bases as the results are unpredictable.

Several suitable products are: Shell Alvania #2, Exxon (Imperial Oil) Unirex N2. Texaco Premium

RB, Chevron SRI #2, and Mobile Mobilux #2. For fans with vertical shafts, consider using a NLGI

Grade 3 grease such as Shell Alvania 3 or Exxon Unirex N3. Do not use long fibered greases.

Consult CML Northern Blower on proper lubrication if bearings are subjected to temperatures

below -10°C (15°F) or above 80°C (176°F)

Lubricat ion Interval Table

r: RELUBRICATION INTERVAL IN MONTHS OF OPERATION


DIAMETER 1000 1500 1800 2000 2500 3000 3500 4000

1-3/16 12 12 12 12 10 8 8 6

F A N E Q U I P M E N TO P E R A T I O N

M A N U A L



Fan Ser ial No. _

L

T A B L E O F C O N T E N T S

STANDARD TERMS AND CONDITIONS and WARRANTy 4

Standard Terms and Conditions 4

Warranty 5

OPERATION MANUAL - FAN EQUIPMENT 6



SAFETY PRECAUTIONS 6

INSTALLATION, OPERATION & MAINTENANCE

OF CML NORTHERN BLOWER FAN EQUIPMENT 7

Introduction 7

Shipment & Receiving 7

Handling 7

Storage 8

Installation of Fan Equipment.. 8

V-Belt Drive Installation 9

Operation of Fan Equipment 10

Maintenance of Fan Equipment 11

C M L N O R T H E R N B L O W E R I N C .

S T A N D A R D T E R M S A N D C O N D I T I O N S a n d W A R R A N T Y

STANDARD TERMS AND CONDITIONS

TERMS OF PAYMENT: Terms of payment are net thirty (30) days

subject to the prior approval of the CML Northern Blower Inc. ("CML

Northern") Credit Department. Notwithstanding such approval, if in

CML Northern's judgement the customer's financial condition does

notwarrant the continuation ofproduction orshipment onthe original

FREIGHT CLAIMS: Unless otherwise expressly agreed inwriting,

delivery of the product is made FOB CML Northern Plant. The

liability and responsibility of CML Northern for the product ceases

upon delivery of the product ingood order to the carrier. All claims

for damage and shortage in transit are the customer's respon-

sibility and the customer must file the claim against the carrier.



terms, CML Northern reserves the right to request payment in

~dvance. Overdue accounts will bear interest atthe prevailing bank

rate charged to CML Northern.

ACCEPTANCE AND PRICES: Prices quoted for products manu-

factured by CML Northern are subject to acceptance by the pur-

chaser no later than thirty (30) days from the date of the Quotation -

Proposal.

Prices quoted for items which are notmanufactured byCML Northern

such asmotors and drives, etc. are subject to change atany time the

cost of such items charged to CML Northern changes.

Prices onorders for products manufactured byCML Northern are firm

provided approval and release for production and shipment is re-

ceived from the customer within ninety (90) days of the date of CML

Northern's receipt of the customer's order and the products are

shipped within twelve (12) months of the date of CML Northern's

receipt of the customer's order. When such approval and release for

production and shipment is received after ninety (90) days ofthe date

of CML Northern's receipt of the customer's order or products are

shipped after twelve (12) months of the date of CML Northern's

Claims for factory shortage will not be recognized unless such

alleged shortage is reported to CML Northern inwriting within ten

(10) days after receipt of the product.

TAXES: The amount ofany present or future taxes shall be added

to the price contained herein and shall be paid by the customer in

the same manner and with the same effect as if originally added

thereto.

DELAYS: CML Northern shall notbe liable to the customer orto any

third party for anydelays caused by riots, strikes,lockouts, weather,

fire, floods, lack of transportation, accidents, the failure of CML

Northern's suppliers to meet their contractual obligations, break-

downs, or any other contingency beyond CML Northern's reason-

able control and receipt of the product by the customer shall

constitute a waiver of all claims for loss or damage due to delay.

PRODUCT CHANGES: CML Northern reserves the right to

change or modify the product in the interest of continuous product

improvement without liability.

WARRANTY

CML Northern Blower Inc. (the "Seller") warrants products of its

manufacture (the "product", "equipment" or "fan") to be free of

defects inmaterial and workmanship ifproperly installed, and cared

for, and operated under normal conditions, and with competent

supervision, all in accordance with the Seller's Operation Manual.

If any questions exist as to whether the proposed operation of the

Seller's equipment iswithin "normal conditions" for such equipment,

details ofsuch proposed operation should beprovided to the Sellerat its Winnipeg factory. The Seller will review the proposed opera-

tion ofthe equipment (at a fee) and advise ifthe proposed operation

is acceptable.

(5) The performance of the Seller's fan equipment outside of the

laboratory may vary widely and differ from the performance

specifications contained in its sales literature. Therefore, the

Seller cannot and does not guarantee orwarrant the perform-

ance of its fan equipment at the Purchaser's location.

(6) ALL WARRANTIES OF THE SELLER, EXPRESS OR IM-

PLIED, WITH RESPECT TO MOTORS, SWITCHES, CON-

TROLSOR OTHER ACCESSORIES NOT MANUFACTUREDBY THE SELLER, INCLUDING WARRANTIES OF MER-

CHANTABILITY, QUALITY OR FITNESS FOR ANY PAR-

TICULAR PURPOSE, ARE HEREBY EXCLUDED.



(1) The Seller's obligation under this warranty is limited to the

repair or replacement, at its option at its Winnipeg factory, of

any defective part orparts which shall within one (1) year after

shipment thereof to the original purchaser (the "Purchaser"),

be returned to itsWinnipeg factory with transportation chargesprepaid bythe Purchaser and upon such repair or replacement

the Seller shall have fulfilled all its obligations to the Purchaser.

The Seller will notbe liable, inany circumstances, for costs or

expenses incurred by the Purchaser or any person claiming

through the Purchaser in the removal or replacement of

equipment alleged to be defective. Except as specifically

provided herein, the Seller will not be liable, in any circum-

stances, for any loss or damage of whatever nature or kind

(including, without limiting the generality of the foregoing,direct, indirect, incidental or consequential loss ordamage or

damage resulting frombusiness interruption) should the equip-

ment be so defective as to preclude the remedy ofwarranted

defects by repair or replacement. In such event, the Pur-

chaser's sole and exclusive remedy shall be the refund of the

purchase price paid by the Purchaser for all the defective

(7) The Seller shall have no liability under the terms of this

Warranty or otherwise where the Purchaser undertakes the

responsibility of mounting the fan wheel directly to the motor

orturbine shafts withoutthe Seller having inspected and tested

the assembled unit (at a fee) before the fan isoperated inanyfashion. Ifthe Seller does not inspect and test the assembled

unit within ten (10) days of being requested to do so by the

Purchaser and receipt ofpayment of the aforementioned fee,

the Seller shall be deemed to have waived its requirement to

inspect and test the assembled unit.

(8) The Seller shall have no liability under the terms of this

warranty or otherwise until the Purchaser has made full

payment totheSeller forthe product orequipment to which this

warranty is to apply.

(9) NOWARRANTIES WHATSOEVER, EXPRESS OR IMPLIED,

INCLUDING WARRANTIES OF MERCHANTABILITY,

QUALITY OR FITNESS FOR ANY PARTICULAR PUR-

POSE, ARE MADE BY THE SELLER EXCEPT AS EX-

The user should make all personnel who operate or main-

tain the fan equipment aware of all possible hazards.

C M L N O R T H E R N B L O W E R I N C .O P E R A T I O N M A N U A L - F A N E Q U I P M E N T

SAFETY PRECAUTIONS

FAN EQUIPMENT CAN BECOME A SOURCE OF

INJURY AND DEATH IF NOT PROPERLY INSTALLED,

OPERATED OR MAINTAINED. Do not exceed the

maximum operating temperature or speed limits for which

the fan equipment was designed. Limits for some lines of

fan equipment are given inCML Northern Blower Inc. ("CML

THE RESPONSIBILITY FOR PROVIDING SAFETY

ACCESSORIES FOR FAN EQUIPMENT SUPPLIED BY

CML NORTHERN IS THAT OF THE USER OF THE FAN



Northern") catalogues. Limits for non-catalogued lines of

fan equipment should be obtained in writing from the CML

Northern Winnipeg factory and not otherwise. Do not rely

on limits obtained in any other manner.

EQUIPMENT. CML Northern sells its fan equipment with

or without safety accessories, and accordingly, it can

supply standard safety accessories upon receipt of an

order. Ensure that all necessary safety accessories have

been installed before operation of the fan equipment.

The warning notice set out below should be affixed upon the fan equipment:

CML NORTHERN BLOWER INC.

W A R N I N GThis fan has rotating parts and may be hot. Keep body, hands and foreign objects away from inlet and outlet.

Do not touch fan or motor during operation.

Operate, install and maintain Q D J ¥ in strict accordance with safety practices and instructions in manufacturer's

Operation Manual. Do not exceed the maximum operating temperature, speed,or vibration level identified in the

manufacturer's catalogues and Operation Manual. Untrained personnel should never operate, install, adjust or

maintain fan or motor.

ADDITIONAL SAFETY ACCESSORIES FOR THE FAN EQUIPMENT ARE AVAILABLE FROM THE

MANUFACTURER. THE RESPONSIBILITY FOR PROVIDING SUCH ADDITIONAL SAFETY ACCESSORIES

INSTALLATION, OPERATION & MAINTENANCEOF CML NORTHERN FAN EQUIPMENT

INTRODUCTION

The purpose of this section is to aid in the proper installa-

tion, operation, and maintenance of CML Northern fan

equipment. These instructions are intended to supplement

good general practices and are not intended to cover

detailed instruction procedures.

The receipt, handling, installation, operation and mainte-

nance of CML Northern fan equipment is the responsibility

of the user. It is important that the installation and start-up

Centr ifugal fans are best lifted using straps attached to

structural base members of the fan. DO NOT LIFT

CENTRIFUGAL FANS BY THE FAN SHAFT, IMPELLER,

FLANGES OR INLET SUPPORTS.

Roof venti lators should be lifted by using straps attached

to lifting lugs or base only. Spreader bars should also be

used to avoid damage to the butterfly damper assembly or

the weatherhood. DO NOT LIFT ROOF VENTILATORS



of the fan equipment be supervised or inspected by person-

nel experienced in such work and equipment. Trained

personnel are available from CML Northern, and arrange-

ments for such supervision and inspection (at a fee) should

be made through your local CML Northern representative

or at CML Northern's head office. Failure to arrange for

such supervision or inspection may affect or void the CML

Northern Warranty (please refer to paragraph 7 of CML

Northern's Warranty).

SHIPMENT & RECEIVING

CML Northern has thoroughly inspected the fan equipment

at its factory and has prepared the fan equipment for

shipment in accordance with the uniform freight classifica-

tion followed by all carriers. The fan equipment should be

in perfect condition when received, unless damaged in

transit. Upon acceptance by the carrier, as evidenced by

a signed bill of lading, the carrier accepts responsibility for

all shortages or damage, whether concealed or evident.

Claims covering shortages or damage must be made to the

carrier by the purchaser. Any shortages or damage should

be noted by the user on the delivery receipt.

BY THE BUTTERFLY DAMPER ASSEMBLY OR

WEATHERHOOD.

Cen tr if ugal r otor assembl ies (i.e. impeller and shaft

assemblies) have been designed to be supported by the

shaft, and should be lifted by slings around the shaft as

close as possible to the hub on each side of the impeller

(wheel). Slings should not press against the side plates of

the wheel as this may damage and distort the wheel. A

spreader bar should be used when lifting the rotor assembly

(Figure 1). The wheel should never rest on the side plates

or blades, nor should the rotor assembly be lifted by any

components of the fan wheel. To do so may damage the

rotor assembly and destroy the dynamic balance that is

necessary for low vibration operation. If this balance is

destroyed, rebalancing of the rotor assembly will be neces-

sary. Ifthe wheel and shaft have not been assembled, the

fan wheel may be lifted by a timber or wrapped bar of

sufficient strength passed through the hub. The finished

bore of the hub and the bearing surfaces of the shaft must

also be protected from damage.

(4) Ducts must be independently supported, and must

never be supported by the fan. Use flexible duct

connections wherever possible. The independent

mounting of stacks and ducts to the fan will ensure

that the fan will not be twisted or deformed with the

addition of external loads.

(5) It is recommended that access doors be placed in

ductwork just ahead of the fan inlet and just behind

the fan outlet for ease of inspection and mainte-

nance. IN ORDER TO AVOID EQUIPMENT DAM-

AGE AND PERSONAL INJURY ACCESS DOORS

IN A DUCT SYSTEM SHOULD BE SECURELY

CLOSED AND SHOULD NEVER BE OPENED WITH

lei

L L

A B

1) Dimensions 'A' & '8'

must be measured at



THE FAN RUNNING.

(6) Lubricate fan bearings in strict accordance with

bearing manufacturer's recommendations. Lubri-

cate bearings upon receipt of fan. Do not over-

lubricate. Bearings should be locked to the shaft.

Ensure that locking mechanisms on bearings are in

correct position and that locking mechanisms are

fastened before operation of fan.

(7) Flexible couplings must be installed and maintained

in accordance with the coupling manufacturer's

instructions. Refer to fan submittal drawings for

details of drive arrangements and the generalloca-

tion of the coupling halves on the fan and motor

shafts.

V-BELT DRIVE INSTALLATION

V-belt drive systems are the most common type of belt

systems used to drive fan equipment. Other types of belt

systems are used ("cog", belts etc.) but are ne t discussedin this manual.

"'~'\ u

I- ,

I I/

))

~

~

right angles to the fan

shaft.

2) Dimension 'C' should

be as large as

physically possible to

allow for an accuratedetermination.

Fig. 2 Determination of parallel shafts.

_____ Straightedge

" : : : : : - - j A ---=-=- - - - . . ; , . - -:::::-- - - -- -- - - : :: : -

/ TooTight

--........--==---~ --.--



Proper Tension - - - = - - ~(Slight Bow) Too Loose

Fig. 4 Belt tension.

Always use matched v-belts and never mix new and used

v-belts on a drive. Install v-belts correctly:

(i) Shorten the center distance between the

driven and driver sheave so the v-belts can

be slipped into the sheave groove without

damage. While the v-belts are still loose on

the drive, rotate the drive until all the slack

is on one side. Then increase the center

distance until the v-belts are snug (Figure

4). NOTE: Never "roll" or "pry" the v-belts

into the sheave grooves. This can damage

the v-belt cords and lead to v-belt turnover,

short life, or actual breakage. Moreover, it

is both difficult and unsafe to install v-belts

(iii) Check the tension on a new drive fre-

quently during the first day of operation by

observing the slack side span. After a few

days of operation the belts will seat them-

selves in the sheave grooves and it may

become necessary to readjust so that the

drive again shows a slight bow in the slack

side.

OPERATION OF FAN EQUIPMENT

(1) Lock out all power sources.

(2) Ensure that bearings are properly aligned

and lubricated with special attention to the

(9)

(10)

Ifthe fan is equipped with damper or variable

inlet vane, close same to lessen starting load

on motor. Ensure any dampers or variable

inlet vanes furnished with the fan, or used in

conjunction with the fan, do not stick or bind.

Ifan automatic control mechanism is used to

operate the damper or variable inlet vane,

adjust the limits of travel of the automatic

control mechanism in accordance with the

control manufacturer's instructions to avoid

putting force on the damper or variable inlet

vane when it is fully opened or fully closed.

If the fan is driven by an electric motor, read

instructions of motor and starter manufac-

(15) Apply power to the driver momentarily (i.e.

"bump") to check for proper rotation. Any

dampers or other air control devices in the

system should be at least partially closed

during starting periods to reduce power re-

quirements. Damper closure is particularly

important in the case of a fan designed for

high temperature operation being "run in" at

a temperature less than design temperature.

(16) Apply power to the driver and allow the fan to

come up to design speed. Turn off. Look and

listen for any unusual noise or mechanical

action while the impeller isstill spinning. Ifany



(11)

(12)

turer. Ensure that the motor and starter are

set up in compliance with the motor and

starter manufacturers' instructions prior to

any application of electric power. Ifthe fan is

powered by some other form of driver, read

the manufacturer's instructions prior start-

up.

If the fan is equipped with water cooled

bearings turn on the water supply to the

bearings prior to starting the fan. Consult the

water cooled bearing manufacturer's instruc-

tions.

If the fan is to handle a "hot gas" (i.e. a gas

with a temperature greater than 150°F [65°C))

itis imperative that the fan be subject to only

a slow gradual rate of gas temperature

change, not to exceed a rate of 15°F/minute

(8°C/minute). When the fan is being Q l.!1J !l

operation the temperature of the gas must

D .. Q 1 rise at a rate greater than 15°F/minute

(8°C/minute). ~ subject a "cold" fan to a

are noticed, lock out all power sources, locate

cause and correct.

(17) Lock out all power sources and recheck

tightness of all set screws, keys, foundation

bolts and any other hardware. The initial start

up will tend to relieve their tightness and they

may require re-tightening.

(18) Reconnect all power sources.

(19) It is recommended that upon fan installation,

the operating vibration levels be checked to

ensure that the levels do not exceed the

levels indicated on the inspection sheets

shipped with the fan and/or the vibration

levels set forth in the "Vibration" section of

this manual.

Once it has been determined that the fan equipment is

operating satisfactorily, it should be operated, if practical,

for at least eight (8) continuous hours. Operation should be

monitored at least once each hour during this period.

MANUFACTURER'S INSTRUCTIONS TO DETERMINETHE TYPE AND FREQUENCY OF BEARING LUBRICA-

TION REQUIRED.

THE MOTOR BEARINGS SHOULD BE LUBRICATED IN

ACCORDANCE WITH MOTOR MANUFACTURER'S LU-

BRICATION INSTRUCTIONS AND RECOMMENDATIONS

SHOULD BE FOLLOWED CLOSELY.

Bearing failure may be caused by failure to lubricate as

often as required, use of an excessive quantity of lubricantor the use of incompatible lubricants. Excessive vibration,

especially if the bearing is not rotating, will also cause

bearings to fail. Bearings must also be protected from

Periodic checks of voltage, frequency and current of a

motor while in operation are recommended. Such checks

ensure the correctness of frequency and voltage applied to

the motor and yield an indication of the fan load. Compari-

son of this data with previous data will give an indication of

the fan performance. Any serious deviations should be

investigated and corrected.

Spare Parts

Spare parts may be ordered through your CML Northernsales office by providing the following information:

(1) Part name (e.g. impeller, shaft, motor, bear-



water and moisture to avoid internal corrosion.

Bearings are susceptible to damage from exposure to

excess shaft heat transfer which may occur when a fan

operating at a temperature greater than 200°F (93°C) is

shut down without a sufficient period of gradual tempera-

ture reduction. See section (12) of "Operation of FanEquipment" set forth on page 11 of this manual.

Bearing Replacement

Replacement of fan bearings should not be required for

many years if cared for strictly in accordance with bearing

manufacturer's instructions. The procedure used to re-

place fan bearings will vary depending on the type of fan

and the type of bearing. It is important that the replacement

of bearings be supervised or inspected by personnel

experienced in such work and equipment. Trained person-nel are available from CML Northern and arrangements for

such supervision or inspection (at a fee) should be made

through your local CML Northern representative or atCML

Northern's head office.

Var iab le In let Vane

ing, etc).

(2) Fan Serial Number from the nameplate.

(3) If possible, the fan shaft diameter or bearing

size together with the fan class specified on

the nameplate.

DUE TO THE SMALL NUMBER OF PARTS REQUIRED,

SPARE PARTS LISTS ARE NEITHER NECESSARY NOR

AVAILABLE.

Vibration

A vibration analyzer must be used to accurately determine

the level of fan vibration. Vibration readings should be

taken by personnel experienced with vibration analysis and

vibration analysis equipment. Trained personnel are avail-able from CML Northern, and arrangements for vibration

analysis (at a fee) may be made through your local CML

Northern representative or at CML Northern's head office.

The fan should I lQ1 be operated unless the vibration

velocity of the fan is less than 0.20 inches per second.

6050

40

30

ooC')

oo 0 0o0 0e x ) e n

ooioC\I

ootoC')

oooC')

ooC\I

ooio

o0o0e x ) 0

C\I

oo. " .

ooio

o 0o 0to f'.

«Values are for filtered LU

n,readings taken on the ,fan bearing caps. o

LUC J )'<

Z



20

~ 15-cLUq.

100I-8~

« 7LU 6,

5C J )-l 4~

I- 3zLU

~ 2LUo

1.5: 5o,C J )

1 5 1.0z 0.80

0.7

-> -t::o0

r-. IJ-l

t.LU

>

• Z< r••~ 0I- - . . . . • • • • • ••• r - - , i=< 'II • . - , . . . . • . . «

<• • • • • • . . .~

~a:

< C O

' " "I. • . , . s. . •.

~I,\< ~J FI~). ."~( ' ~

~~

< . . . . . . • • ..,(

.~' C ; : ~ • . • . . .

r-,•IA~•... <, .c v : ~

<r-,

~ i'--0.20IN/SEC

PAOBA8 l ECAUSES

F A N T R O U B L E - S H O O T IN G C H A R T

INSUFFICIENT

AIR FLOW

duct elbows near fan inlet or outlet

restricted fan inlet or outlet

impeller rotating in wrong direction

fan speed lower than designsystem resistance higher than design

dampers shut

faulty ductwork



dirty or clogged filters and/or coils

inlet or outlet screens clogged

EXCESSIVE

AIR FLOW

system resistance less than design

fan speed too highfilters not in place

registers or grilles not installed

improper damper adjustment

EXCESSIVE HORSEPOWER

DRAW

fan speed higher than design

gas density higher than design

impeller rotating inwrong direction

static pressure less than anticipatedfan size or type not appropriate for application

EXCESSIVE

VIBRATION

accumulated material on impeller

worn or corroded impeller

O T H E R IN S T R U C T IO N S a n d U T E R A T U R E

FAN EQUIPMENT SERIAL No. MAY CONTAIN COMPO-

NENTS MANUFACTURED BY MANUFACTURERS OTHER THAN CML NORTHERN.

SUCH MANUFACTURERS MAY HAVE FURNISHED INSTRUCTIONS AND/OR OTHER

LITERATURE CONCERNING THEIR COMPONENT. A LIST OF SUCH INSTRUCTIONS

AND/OR OTHER LITERATURE FORWARDED WITH FAN EQUIPMENT

SERIAL No. IS GIVEN BELOW.



(1) CML NORTHERN BEARING LUBRICATION INSTRUCTIONS:

CJLUBRICATION INSTRUCTIONS FOR DOUBLE ROW SPHERICAL ROLLER

BEARINGS 22500 SERIES SPLIT PILLOW BLOCK.

LUBRICATION INSTRUCTIONS FOR SERIES 22400 SERIES DOUBLE ROW

SPHERICAL ROLLER BEARINGS.J

CJ

CJ

LUBRICATION INSTRUCTIONS FOR 300 SERIES BALL BEARINGS.

LUBRICATION INSTRUCTIONS FOR 200 SERIES BALL BEARINGS.

(2) BEARING MANUFACTURER'S INSTRUCTIONS:

(YES) (_N_O_-.J

(3) MOTOR MANUFACTURER'S INSTRUCTIONS:

E.ALDORMOTORS AND DRIVES



Integral Horsepower

AC Induction MotorsOOP,WPI, WPII Enclosure

Table of Contents

Section 1

General Information

Overview 1-1

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Receiving ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Unpacking 1-4

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4.



Section 2

Installation & Operation 2-1

Overview 2-1

Location 2-1

Mounting 2-1

Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Doweling & Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Power Connection 2-2

Conduit Box 2-2

AC Power 2-2

First Time Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Coupled Start Up 2-4

J ogging and Repeated Starts .

Section 3

Maintenance & Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Section 1

General Information

Important:

This manual contains general procedures that apply to Baldor Motor products. Be sure to read and ~

understand the Safety Notice statements in this manual. For your protection, do not install, operate orattempt to perform maintenance procedures until you understand the Warning and Caution statements. A

Warning statement indicates a possible unsafe condition that can cause harm to personnel. A Caution

statement indicates a condition that can cause damage to equipment.

This instruction manual is not intended to include a comprehensive listing of all details for all

procedures required for installation, operation and maintenance. This manual describes generalguidelines that apply to most of the motor products shipped by Baldor. If you have a question

about a procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldordistributor for more information or clarification.

Overview



Before you install, operate or perform maintenance, become familiar with the following:

• NEMA Publication MG-2, Safety Standard for Construction and guidefor Selection, Installation and Use of Electric Motors and Generators.

• The National Electrical Code

• Local codes and Practices

Limited Warranty

1. Baldor Electric motors are warranted for a period of one (1) year, from date of shipment from the factory or factory

warehouse against defects in material and workmanship. To allow for stocking and/or fabrication period and to

provide one year of actual service, the warranty period is extended for an additional period of six (6) months for atotal of eighteen (18) months from the original date of shipment from the factory or factory warehouse stock. In no

case will the warranty period be extended for a longer period. Baldor extends this limited warranty to each buyer

of the electric motor for the purpose of resale and to the original purchaser for use.

2. Baldor will, at its option repair or replace a motor which fails due to defects in material or workmanship during thewarranty period if:

a. the purchaser presents the defective motor at or ships it prepaid to, the Baldor plant in Fort Smith, Arkansaor one of the Baldor Authorized Service Centers and

b. the purchaser gives written notification concerning the motor and the claimed defect including the datepurchased, the task performed by the Baldor motor and the problem encountered.

9ty Notice: This equipment contains high voltage! Electrical shock can cause serious or fatal injury.

Only qualified personnel should attempt installation, operation and maintenance ofelectrical equipment.

Be sure that you are completely familiar with NEMA publication MG-2, safety standards

for construction and guide for selection, installation and use of electric motors and

generators, the National Electrical Code and local codes and practices. Unsafe

installation or use can cause conditions that lead to serious or fatal injury. Only qualifiedpersonnel should attempt the installation, operation and maintenance of this equipment.

WARNING: Do not touch electrical connections before you first ensure that

power has been disconnected. Electrical shock can cause serious



WARNING:

WARNING:

WARNING:

WARNING:

or fatal injury. Only qualified personnel should attempt the

installation, operation and maintenance of this equipment.

Be sure the system is properly grounded before applying power.

Do not apply AC power before you ensure that all grounding

instructions have been followed. Electrical shock can cause

serious or fatal injury. National Electrical Code and Local codes

must be carefully followed.

Avoid extended exposure to machinery with high noise levels. Be

sure to wear ear protective devices to reduce harmful effects to

your hearing.

This equipment may be connected to other machinery that has

rotating parts or parts that are driven by this equipment. Improper

use can cause serious or fatal injury. Only qualified personnelshould attempt to install operate or maintain this equipment.

Do not by-pass or disable protective devices or safety guards.

Safety features are designed to prevent damage to personnel or

equipment. These devices can only provide protection if they

remain operative.

Safety Notice Continued

WARNING:

WARNING:

Caution:

Motors that are to be used in flammable and/or explosive

atmospheres must display the UL label on the nameplate.

Specific service conditions for these motors are defined in

NEC 70-599.

UL rated motors must only be serviced by authorized BaldorService Centers if these motors are to be returned to a flammable

and/or explosive atmosphere.

To prevent premature equipment failure or damage, only qualified



Caution:

Caution:

Caution:

Caution:

maintenance personnel should perform maintenance.

Do not lift the motor and its driven load by the motor lifting

hardware. The motor lifting hardware is adequate for lifting only the

motor. Disconnect the load from the motor shaft before moving the

motor.

If eye bolts are used for lifting amotor, be sure they are securely

tightened. The lifting direction should not exceed a20° angle from

the shank of the eye bolt or lifting lug. Excessive lifting angles can

cause damage.

To prevent equipment damage, be sure that the electrical service is

not capable of delivering more than the maximum motor rated amps

listed on the rating plate.

If a HI POT test (High Potential Insulation test) must be performed,follow the precautions and procedure in NEMA MG-1and MG-2

standards to avoid equipment damage.

Ifyou have any questions orare uncertain about any statement or procedure, or if you

Section 2

Instal lation & Operation

Installation should conform to the National Electrical Code as well as local codes and ~

practices. When other devices are coupled to the motor shaft, be sure to installprotective devices to prevent future accidents. Some protective devices include,

coupling, belt guard, chain guard, shaft covers etc. These protect against accidentalcontact with moving parts. Machinery that is accessible to personnel should providefurther protection in the form of guard rails, screening, warning signs etc.

The motor should be installed in an area that is protected from direct sunlight, corrosives,harmful gases or liquids, dust, metallic particles, and vibration. Exposure to these canreduce the operating life and degrade performance. Be sure to allow clearance for

ventilation and access for cleaning, repair, service and inspections. Ventilation isextremely important. Be sure the area for ventilation is not obstructed. Obstructions will

Overview

Location



Mounting

limit the free passage of air. Motors get warm and the heat must be dissipated to prevent

damage.

These motors are not designed for atmospheric conditions that require explosion proof

operation. They must NOT be used in the presence of flammable or combustible vapors

or dust.1. OOP motors are suitable only for indoor applications.

2. TEFC and WPII motors are suitable for indoor or outdoor standard service

applications.

The motor must be securely installed to a rigid foundation or mounting surface to

minimize vibration and maintain alignment between the motor and shaft load. Failure to

provide a proper mounting surface may cause vibration, misalignment and bearing

damage.

Foundation caps and sole plates are designed to act as spacers for the equipment theysupport. Ifthese devices are used, be sure that they are evenly supported by the

foundation or mounting surface.

After installation is complete and accurate alignment of the motor and load isaccomplished, the base should be grouted to the foundation to maintain this alignment.

The standard motor base is designed for horizontal or vertical mounting. Adjustable or

vel ing & Bol ting After proper alignment is verified, dowel pins should be inserted through the motor feet

into the foundation. This will maintain the correct motor position should motor removal be

required. (Baldor motors are designed for doweling.)

1. Drill dowel holes in diagonally opposite motor feet in the locations provided.

2. Drill corresponding holes in the foundation.

3. Ream all holes.

4. Install proper fitting dowels.

5. Mounting bolts must be carefully tightened to prevent changes in alignment.

Use a flat washer and lock washer under each nut or bolt head to hold the

motor feet secure. Flanged nuts or bolts may be used as an alternative to



Power Connection

Conduit Box

AC Power

washers.

Motor and control wiring, overload protection, disconnects, accessories and grounding

should conform to the National Electrical Code and local codes and practices.

For ease of making connections, an oversize conduit box is provided. The box can berotated 3600 in 900 increments. Auxiliary conduit boxes are provided on some motors for

accessories such as space heaters, RTD's etc.

Connect the motor leads as shown on the connection diagram located on the name plate

or inside the cover on the conduit box. Be sure the following guidelines are met:

1. AC power is within ±10% of rated voltage with rated frequency. (See motor

name plate for ratings).

OR

2. AC power is within ±5% of rated frequency with rated voltage.

OR

3. A combined variation in voltage and frequency of ±10% (sum of absolute

values) of rated values, provided the frequency variation does not exceed ±5%

of rated frequency.

Performance within these voltage and frequency variations are shown in Figure 2-1.

+20

+15

' ; € +10-1oeco

E +5L-

0

Figure 2-1 Motor Per formance VS Voltage Var iations

/Maximum

Full-Load

'"Torque

Current

- , V 'r-,,

Full-LoadPower / curr~Factor - - - - -. " - /



't:41c . .

0-

0-0~c : - 5!II41Clc:co

- 10c:0

- 15

- 20

/'- -~ V '.

.-/

-- - ,/ --

-.• . "' . . . . - - -- - - - - - . . . • . . . . . •

Efficiencyv " " -

/. . . .

. . Efficiency

/. . . . . . . . . .

/'. . . .

. .

/. . . . . . . . . .

/'. . . .

/ PowerMaximum Factor

Torque

- 15 +10 +1510 - 5 o +5

Voltage Variations (%)

+20

+15

~ +10.. . . .

Q)(.)

eco

E +5. . .0

Figure 2-1 Motor Performance VS Voltage Var iations

/Maximum

Full-Load

~

TorqueCurrent

- .

,

r-,, Full-Load

Power / curr~Factor --. ... . . . . • • . • . • /...



't:Q)

Il.

0. .0-0:!e - 5II)Q)

Olc:c o

- 10c:0

- 15

- 20

/'~ V'.

.,/

-- - /. --

-'. . . . . . . - -

-, •. •. - - . . . . . . . . .

EfficiencyV " " -

/•. •.

•. Efficiency

/•. •. •. • . •.

~•. • .

• .

/• . •. •. •.

. •.

/'.• .

.•.

/ PowerMaximum Factor

Torque

- 15 o +10 +1510 - 5 +5

Voltage Variations (%)

'tTimeStart Up Be sure that all power to motor and accessories is off. Be sure the motor shaft is

disconnected from the load and will not cause mechanical rotation of the motor shaft.

1. Make sure that the mechanical installation is secure. All bolts and nuts are

tightened etc.

2. If motor has been in storage or idle for some time, check winding insulationintegrity with a Megger.

3. Inspect all electrical connections for proper termination, clearance, mechanicalstrength and electrical continuity.

4. Be sure all shipping materials and braces (if used) are removed from motor

shaft.



Coupled Start Up

5. Manually rotate the motor shaft to ensure that it rotates freely.

6. Replace all panels and covers that were removed during installation.

7. Momentarily apply power and check the direction of rotation of the motor shaft.

8. Ifmotor rotation is wrong, be sure power is off and change the motor lead

connections. Verify rotation direction before you continue.

9. Start the motor and ensure operation is smooth without excessive vibration or

noise. Ifso, run the motor for 1 hour with no load connected.

10. After 1 hour of operation, disconnect power and connect the load to the motor

shaft. Verify all coupling guards and protective devices are installed. Ensure

motor is properly ventilated.

This procedure assumes a coupled start up. Also, that the first time start up procedurewas successful.

1. Check the coupling and ensure that all guards and protective devices areinstalled.

2. Check that the coupling is properly aligned and not binding.

3. The first coupled start up should be with no load. Apply power and verify thatthe load is not transmitting excessive vibration back to the motor though the

Section 3

Maintenance & Troubleshooting

WARNING: UL rated motors must only be serviced by authorized Baldor

Service Centers if these motors are to be returned to a flammable

and/or explosive atmosphere.

Inspect the motor at regular intervals, approximately every 500 hours of operation or

every 3 months, whichever occurs first. Keep the motor clean and the ventilation

openings clear. The following steps should be performed at each inspection:

WARNING: Do not touch electrical connections before you first ensure thatpower has been disconnected. Electrical shock can cause serious

or fatal injury. Only qualified personnel should attempt the

installation, operation and maintenance of this equipment.

1. Check that the motor is clean. Check that the interior and exterior of the motor

General Inspection



is free of dirt, oil, grease, water, etc. Oily vapor, paper pulp, textile lint, etc. can

accumulate and block motor ventilation. If the motor is not properly ventilated,

overheating can occur and cause early motor failure.

2. Use a "Megger" periodically to ensure that the integrity of the winding insulation

has been maintained. Record the Megger readings. Immediately investigate

any significant drop in insulation resistance.

3. Check all electrical connectors to be sure that they are tight.

Bearing grease will lose its lubricating ability over time, not suddenly. The lubricating

ability of a grease (over time) depends primarily on the type of grease, the size of the

bearing, the speed at which the bearing operates and the severity of the operatingconditions. Good results can be obtained if the following recommendations are used in

your maintenance program.

A high grade ball or roller bearing grease should be used. Recommended grease forstandard service conditions is Polyrex EM (Exxon Mobil).

Equivalent and compatible greases include:

Texaco Polystar, Rykon Premium #2, Pennzoil Pen 2 Lube and Chevron SRI.

Lubrication & Bearings

Type of Grease

- Maximum operating temperature for standard motors = 110° C.

Table 3-2 Service Condit ions

Severity of Service Ambient Temperature Atmospheric Type of Bearmg

Maximum Contamination

Standard 40° C Clean, Little Corrosion Deep Groove Ball Bearing

Severe 50° C Moderate dirt, Corrosion Ball Thrust, Roller

Extreme >50° C* or Severe dirt, Abrasive dust, All Bearings

Class H Insulation CorrosionLow Temperature <-30° C **

* Special high temperature grease is recommended (Dow Corning DC44). Note that Dow Corning DC44 grease does

not mix with other grease types. Thoroughly clean bearing & cavity before adding grease.



** Special low temperature grease is recommended (Aeroshell 7).

Table 3-3 Lubricat ion In terval Multi pl ier

Severity of Service Multiplier

Standard 1.0Severe 0.5

Extreme 0.1

Low Temperature 1.0

Table 3-4 Bearings Sizes and Types

Frame Size Bearing Description

NEMA (IEC) (These are the " Large" bearings (Shaft End) in each frame size)

Bearing 00 Width Weight of Volume of grease

Omm Bmm Grease to to be addedi.--

add * in.) tea-

- oz (Grams) spoon

Up to 210 incl. (132) 6307 80 21 0.30 (8.4 ) 0.6 2.0

Over 210 to 280 incl. (180) 6311 120 29 0.61 (17 ) 1.2 3.9

Over 280 to 360 incl. (225) 6313 140 33 0.81 (23 ) 1.5 5.2

Be sure that the grease you are adding to the motor is compatible with the grease alre<">

in the motor. Consult your Baldor distributor or an authorized service center if a qrease

other than the recommended type is to be used.

Caution: To avoid damage to motor bearings, grease must be kept free of dirt.

For an extremely dirty environment, contact your Baldor distributor or

an authorized Baldor Service Center for additional information.

With Grease Outlet Plug1. Clean all grease fittings.

2. Remove grease outlet plug.

3. If motor is stopped, add the recommended amount of grease.

Lubrication Procedure



If motor is to be greased while running, a slightly greater quantity of grease will

have to be added. Add grease slowly until new grease appears at shaft hole in

the endplate or purge outlet plug.

4. Re-install grease outlet plug.

Without Grease Outlet Plug

1. Disassemble motor.

2. Add recommended amount of grease to bearing and bearing cavity. (Bearing

should be about 1/3 full of grease and outboard bearing cavity should be about

1/2 full of grease.)

Note: Bearing is 1/3 full when only one side of bearing is completely full of grease.

3. Assemble motor.

Sample Lubrication Determination

Assume - NEMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an amble

temperature of 43° C and the atmosphere is moderately corrosive.

1. Table 3-1 list 9500 hours for standard conditions.

2. Table 3-2 classifies severity of service as "Severe".

~essories The following is a partial list of accessories available from Baldor.

Contact your Baldor distributor for availability and pricing information.

Note: Space heaters and RTD's are standard on some motors.

Bearing RTD

RTD (Resistance Temperature Detector) devices are used to measure or

monitor the temperature of the motor bearing during operation.

Bearing Thermocouples

Used to measure or monitor bearing temperatures.

Bearing Thermostat

Temperature device that activates when bearing temperatures are excessive.

Used with an external circuit to warn of excessive bearing temperature or to



shut down a motor.

Condui t Boxes

Optional conduit boxes are available in various sizes to accommodate

accessory devices.Cord & Plug Assemb ly

Adds a line cord and plug for portable applications.

Drains and Breathers

Stainless steel drains with separate breathers are available.

Drip Covers

Designed for use when motor is mounted in a vertical position. Contact your

Baldor distributor to confirm that the motor is designed for vertical mounting.

Fan Cover & Lint ScreenTo prevent build-up of debris on the cooling fan.

Nameplate

Additional stainless steel nameplates are available.

Roller Bearings

Recommended for belt drive applications with a speed of 1800 RPM or less.

Table 3-5 Troubleshooting Chart

Symptom Possible Causes Possible Solutions

Motor will not start Usually caused by line trouble, such Check source of power. Check overloads, fuses,as, single phasing at the starter. controls, etc.

Excessive humming High Voltage. Check input line connections.

Eccentric air gap. Have motor serviced at local Baldor service center.

Motor Over Heating Overload. Compare actual amps Locate and remove source of excessive friction in(measured) with nameplate rating. motor or load.

Reduce load or replace with motor of greater capacity.

Single Phasing. Check current at all phases (should be approximately. equal) to isolate and correct the problem .



Improper ventilation. Check external cooling fan to be sure air is movingproperly across cooling fins.Excessive dirt build-up on motor. Clean motor.

Unbalanced voltage. Check voltage at all phases (should be approximately

equal) to isolate and correct the problem.Rotor rubbing on stator. Check air gap clearance and bearings.

Tighten 'Thru Bolts".

Over voltage or under voltage. Check input voltage at each phase to motor.

Open stator winding. Check stator resistance at all three phases for balance.

Grounded winding. Perform dielectric test and repair as required.

Improper connections. Inspect all electrical connections for propertermination, clearance, mechanical strength and

electrical continuity. Refer to motor lead connection

diagram.Bearing Over Heating Misalignment. Check and align motor and driven equipment. ,,-

Excessive belt tension. Reduce belt tension to proper point for load.

Excessive end thrust. Reduce the end thrust from driven machine.

Excessive grease in bearing. Remove grease until cavity is approximately 3h filled.

Insufficient grease in bearing. Add grease until cavity is approximately 3/4 filled.

1gested bearing and wind ing RTD set ti ng guidel ines

Most large frame AC Baldor motors with a 1.15 service factor are designed to operate

below a Class B (80°G) temperature rise at rated load and are built with a Class H

winding insulation system. Based on this low temperature rise, RTD (Resistance

Temperature Detectors) settings for Class B rise should be used as a starting point.

Some motors with 1.0 service factor have Class F temperature rise.

The following tables show the suggested alarm and trip settings for RTDs. Properbearing and winding RTD alarm and trip settings should be selected based on these

tables unless otherwise specified for specific applications.

If the driven load is found to operate well below the initial temperature settings under

normal conditions, the alarm and trip settings may be reduced so that an abnormal



machine load will be identified.

The temperature limits are based on the installation of the winding RTDs imbedded in the

winding as specified by NEMA. Bearing RTDs should be installed so they are in contact

with the outer race on ball or roller bearings or in direct contact with the sleeve bearing

shell.

Wind ing RTDs - Temperature Limi t In °C (40°C Maximum Ambient)

Cl ass B Temp Rise :s 80°CClass F Temp Rise :s 105°C Class H Temp Rise :s 125°C

Motor Load (Typical Design)

Alarm Trip Alarm Trip Alarm Trip

:s RatedLoad 130 140 155 165 175 185RatedLoad 140 150 160 165 180 185to1.15S.F.

Note: •WindingRTDs are factory production installed, notfromMod-Express.

•WhenClass H temperatures are used, consider bearingtemperatures and lubrication requirements.r:

Bearing RTDs - Temperature Limit In OC with 40°C Max Ambient

Bear ing Type Antt-Frfctlon Sleeve

Oi l or Grease Alarm Trip Alarm Trip



1 The S-VECO brush is self cleaning!

The S-\l:U i's ultra high brush SIWt'd cn'ilks

l't'lltrifugal Inn'c' which comhinr-d with tilt'

OPC'llillg of tilt' brush pat tr- ru L IS the brush

,'ours('s around the sheaves. aids the brush

ill t luowuu; off all of tilt' rt'ftl.-;t' or parttrul.ite



it hdS swept across tilt' object ht'illg t'lt'ililed.

This is the only true self Clt'allillg brush in

oxistencc.

.•. S-VECO eliminates re-deposit & carry hack! Because this isitself cle<tlling brush. it clot's not IDAD-UP like other brushes

or wipers do. thus it does not re-deposit particulate.

Cornblntug this aspect with the fad that S-VF.CO is d linear

transverse cleaner, (which uu-aus that the brush swee-ps

across the ohjed Iwillg cleaned) carry-back is e luuiua te -cl.

.•. Aggres.<;ive yet friendly! The fiber of the S-VEC() brushes will

Ilt' selected to meet the application without use-rworry of

damage to conveyor helting, or tn the object beillg cleaned.While aggrl'ssiv(~ brushing takes place. the transverse linear

hrushuu] action sweeps dUOSS any Il('11splices. rather than

into th('111so there is 110damage done to the splice or to tile

brush.

_\

\

\._.~.J \

i\

C\' .\

\,

t.



A. fLE VATING SCREWS

AllS-VECOlinear brushing machines incorporate some

formof elevating or lifting and lowering device.

Standardunits areequipped with elevating screws and

handwheels. Special units areavailable with manual or

electric lift jacks. The electronic type canbecycled

with amanually operated switch or tied into acontroller.

3. : iA ND CRA'NN TUFT CONSTRUCTION

Theseunique linear brushes of the S-VECObrushing

machinesaremade by hand sewingeach tuft into

D . HIG H SHED, SE LF CLE ANIN G 8RUSHE S

The S-VECObrushes are commonly filled with stainless

steel or nylon fiber. However. many other fibers are

available to suit the application. These brushes art'

driven atspeedsup to l,toOSFM,which helps to make

these brushes the only self cleaning brushes available,

£. BRUSH STABILITY

Idler sheavesare located at regular.intervals between

the Driven andNon-Driven brush sheaves.These idlers

areadjustable upor down to insure constant brush

contact across the entire brush length, evenwhen

' \ l l ' '~lJCA'r30'''1 S'f - J fI '. ',<" " .~"

J•. , ,.l, ~ .,.• ~, .." '., '., . i~Ji~

.'

\It'diulll and Heavy Duty S-VEC() units art' providing

apositive effect to the bottom line.

Lower Operating and ~aintenance Costs

•Reduce lost material clue to carryback

•Reduce carrvback clean up time

•Reduce belt and idler wear

•Reduce belt cleaner system maintenance time due

to S-VETOfeatures and benefits

t':<)~l:'·~oa~{

There are many standard and special S-VEC< rs at



work ill foundries around the world, helping to lower

operating and maintenance costs while increasing

production rates.

Effective Cleaning

•Mold Car Tops

•Hottorn Boards

•SandConveyors

• Recovery SandConveyors

V'JOOO '..YORKING PLANTS

S-VECO , combined with a dust collection system has

proven to be an effective way to do light to mediumsanding and dusting operations.

•Door plants

•Paneling plants

•Plywood plants

Extra-H e a" , DutyL in ear Bru sh ing Mach in e

HD·D

Fe u r e s• NEW '- ligh t w eigh t, f ie ld te sted de sign

• En ergy e f f ic ie n t, e le c tric mo to rs -.e-~~

• A ll · s eale d b eari n gs



• L arge se le c t ion o f ste e l &

syn the tic brush f ibe rs

• C on tour idle rs

• H igh to rque , pow er cog drive be lts

• D ire ct drive syste m

• M an y option s availabl e

B e n e f i l s• Short e st ove rall le n gth available

t' • as e o f In stallation

/. L ow main t e nan ce costs

• Excep t iona l c l ean ing

• P ro ve n de sign

s· C MD·Ixtra-Heavy Duty linear 8ruslting Macltine

TOP V IEW

TAKEU P O PT 1O ~S

~~ ~

Standa~dE q u i p m e n t1. HEAVY DUTY BRUSHES

M o d e l R M H D - D u t i l i z e s t h r e e D s e c t i o n b e l t b r u s h e s .

E a c h b r u s h i s t i t l e d w i t h t w o r o w s o f b r u s h f i b e r f r o m

a w i d e as so rtm en t o f m a t e r ia l t y p e s a n d s i z e s . B r u s h e s

w i l l b e ma de t o s u it t h e applic ati on .

S tan dard t r im l e n g t h ( b r i s t l e le n g t h ) is 3- 1/2", a n d t h e

a p p r o x im a t e f a c e w id t h o f t h r e e b r u s h e s i s 3 " . O t h e r

t r im l e n g t h s a r e a v a il a b le .



FRONT V IEW

A

B

C

f----------sr_D tWe-V4----------I

.-JMODI l NUMIEI tfN. 1 4 - 30· 36: ,42 i 48 5.( 6~ .72 84 96 101 120

A -E f f t c tive B rv ih in g Ar ea U' . 30" : 36 ' 4 2' 48' 55' 62 ' 72' 88 ' 9 6 ' 109 ' 124 ". .

I-W r!h S t an d ard 3 -1 /2" Brv ih T rim : 39' : 4 5" : 51 " 57 ' • 63 ' 70' 7 l " 8 l " 103 ' 1 11 ' 124 139':

CTot al Fr am . Length 4 3" : 4 9" 55 " 61 " : 67 ' 74 ' 81 ' 91 ' 107' liS' 128 ' 1 4 3'

2. BRUSHTENSIONING DEVICEA m a n u a l l y o p e r a t e d s c r e w a n d s li d e a s s e m b l y t o w h i c h

t h e b ru sh s h e a v e i s m o u n t e d p r o v id e s t h e m e a n s t o r

t e n s i o n i n g o r r e l a x i n g t h e b r u s h .

m CAUTION: P r o p er b ru sh t e n s i o n i s c r i t ic a l t o b r u s h

li f e a n d p e r f o r m a n c e . T h is s u b j e c t i s c o v e r e d c o m p l e t e l y

i n t h e I n s t a ll a t i o n a n d O p e r a t in g I n s t r u c t i o n s t h a t are

s u p p l ie d w it h e a c h u n i t .

3. CONTOUR IDLERSHEAVESF u l l b r u s h c o n t a c t a n d s t a b il i t y a re a c h i e v e d , e v e n o n

non- fla t s u r f a c e s , t h r o u g h t h e p r o p e r p o s i t io n i n g o f t h e

c o n t o u r i d l e rs . T h e s e c a n b e a d ju st e d u p o r d o w n t o

f o r c e t h e b r u s h t o c o n f o r m t o t h e s u r f a c e b e i n g

b r u s h e d , t h u s i n s u r i n g p r o p e r c le a n i n g a n d c h a t t e r f r e e

h i g h s p ee d b ru sh i n g .

4. HEIG HTADJ USTMEN TDEVICE( E le va ti n g S c r e w s l

"

CAUTION!BRUSH BELTS MUST NOT

BE OVERTIGHTENED!THESE BELTS DO NOT



TRANSMIT ANY POWER.

HEAVY PRESSURE WILLDESTROY THE UNIT

BEARINGS.

S i n c e 1905

w w w .s c h a e f e r b r u s h . c o m

MODEL RMHD-DDIRECT DRIVE UNIT



S-VECO LINEAR CLEANER

INSTALLATIONS & OPERATING INSTRUCTIONS

s -VECO LINEAR CLEANER

Installation and Operating Instructions

S-VECO Model RMHD-D

Direct Drive Unit

UNPACKING:

Remove all components from shipping crate and set in an area where the unit can be

properly supported so the various components such as motor, gearbox, and idler

assemblies are protected. Make sure the unit is stable and will not tip or fall.



LOCATION:

The S-VECO should be located or positioned so that the particulate being removed can

fall into a discharge or dribble chute if one is available.

For conveyor belt cleaning, the best place to mount the unit is as close to the conveyor

head pulley as possible in order to brush the belt while it is flat and stable. This insures

a clean belt with no particulate transfer to snubber pulleys or return idlers.

Provision should be made to deflect the removed particulate within a confined area,while providing sufficient clearance around the S-VECO to permit the material to fall

clear of the machine and the conveyor belt or other object being cleaned. In conveyor

applications, as well as many other applications, a primary scraper located just ahead of

the S-VECO will improve cleaning efficiency by removing large lumps and by

POSITION UNIT

Position the S-VECO unit under or over conveyor or other object being cleaned.

Whether your application calls for the S-VECO to be mounted under a conveyor belt or

over some other object to be cleaned, care must be taken to position the unit properly in

order to avoid damage to the unit. Position the S-VECO so that the brush is traveling at

a right angle to the direction of the travel of the object being cleaned. Also, the object

being cleaned must enter the brush at the front side of the unit. This means the

conveyer belt will pass over the brush before it passes over the gearbox and motor.

Failure to position the unit in this way will cause excessive pressure on the sheave

bearings, which will result in bearing and shaft failure. If there is any question as to



where the front side of the unit is, please refer to the drawing that accompanies these

instructions. Clamp the mounting brackets (Item 16) to your existing support structure

such as the conveyor frame or other machine support, l-beam, head pulley housing, etc.For best results, this position should be at a point where the conveyor belt, or other item

being cleaned, is as flat and stable as possible. Conveyor belt bounce will minimize the

brushes ability to clean properly and will cause premature wear or damage to the brush.

The unit should be positioned so the center line of the driven sheave, the one on the

motor end, is at the very edge of the conveyor belt, or other object being cleaned. The

S-VECO unit should be positioned so that the brush is centered over or under the object

being cleaned.

IMPORTANT: When installing the unit, be sure there is at least 4" of clearance

between the O.D. of the sheaves and the surface to be cleaned. NOTE: You must also

be sure that you have enough elevating screw travel to provide sufficient adjustment to

Turn the brush take-up device in a clock-wise direction until the handle spins free. At

this point you will have reached the proper torque on the brushes. Tighten the four nuts

on the take-up block. (Item 12)

NOTE: After the first week or two of running the brushes might need to be re-tightened

due to belt stretch. Before turning the brush tightening device handle be sure to loosen

the four nuts at the back of the brush take-up block (Item 12), then tighten brushes andre-tighten the four nuts.

CAUTION: DO NOT OVER TENSION BRUSHES!!!



FINAL MOUNTNG ADJUSTMENTS

1. Turn elevating screws (Item 15) to bring both ends of brushes into slight contact

with surface to be cleaned. (Maximum 1/8" bristle deflection). NOTE: It may be

necessary to re-center the unit on the conveyor at this time (Refer back to "Position

Unit"). Check alignment of idler support bracket attaching screws and raising or

lowering brackets as necessary, then tighten attaching screws.

2. Re-check centering of S-VECO brush to conveyor or other object being cleaned and

if correct, weld mounting brackets (ItemI6) in position. Mounting brackets can bebolted instead of welded in place if you prefer. Use two 1/2" bolts per bracket.

CAUTION: DO NOT allow weld splatter to damage brush.

3. Adjust elevating screws (Item 15) until full brush contact is made with item being

caused by excessive pressure on the bristles when brush is stationary. An electronic

delay might be necessary to accomplish this.

SPEED REDUCER

The FALK 2.552: 1 speed reducer (Item 3) has been filled with the type and amount of

lubrication that is recommended by the manufacturer. Please refer to themanufacturer's instructions that are included with this packet.

. .STARTUP



Re-check to be certain that the S-VECO motor is wired into the conveyor drive circuit,

then start conveyor and S-VECO unit, check for proper brush adjustment and adjust

elevating screws (Item 15) as necessary.

NOTE: The rotation of the brush is optional.

ADJUSTMENTS

1. After initial break-in time it may be necessary to adjust the S-VECO brushes forproper tension on the sheaves, loosen the pinch point guard attaching screws and the

4 take-up block nuts (on Item 12). Adjust brush as needed and re-tighten all screws

and nuts.

CAUTION!

Brush belts must not be over-tightened. These belts do not transmit any power.

NOTE: Over-tightening will cause the drive components to fail.

The brush adjustment clutch which is located on the brush adjustment device (Item 10

or 11 on drawing RNIHD-D-A) has a factory pre-set torque load. When the brush is

adjusted to the proper torque the clutch will break free and the handle will spin free.



DO NOT change the torque pre-set in the clutch assembly! Contact Schaefer Brush

Product Engineering @ 1-888-547-3500.

Replacement parts and brushes can be obtained by calling your local distributor.

Limited Warranty

Schaefer Brush Manufactwing Company Incorporated (the Company) warrantsthat all S-Veco linear brushing machines shall be free from defects in Schaefer

Brush workmanship and materials for a period of six (6) months from the date of

shipment from the Company.



Excluded from this warranty will be bearings and brushes, which are considered

wear items and are therefore replaceable maintenance items, and purchased

components such as motors, drives, and any electronic or mechanical devices that

are not manufactured by the Company.

If a Schaefer Brush Mfg. C O 'TInc. pr.oduct is defective due to Schaefer Brush Mfg.

Co., Inc. workmanship or materials, and the defect occurs during the warranty

period, then Schaefer Brush Mfg. Co., Inc. will either repair or replace the product,

which ever Schaefer Brush Mfg. Co., Inc. believes- to be appropriate under thecircumstances. Schaefer Brush Mfg. -Co., Inc. is not-responsible for removal "Or

shipping of the product to the company, the reinstallation of the product upon its

return to the customer, or any incidental or consequential damages, resulting from

TROUBLESHOOTING GUIDE - S-VECO LINEAR CLEANERS

PROBLEM PROBABLE CAUSE REMEDY

Conveyor not being cleaned. r Cleaner not operating. Start cleaner. Check drive

belt for slippage or breakage.

2. Brush not contacting Adjust elevating screws.3. Brush worn beyond Replace S-VECO brush.

effective cleaning point.

Conveyor not being cleaned r . Brush not contoured to belt. Adjust idler sheaves.

across entire surface. 2. Conveyor belt grooved. Check skirtboarding, return



idlers, or other conveyor

components which could

cause mechanical damage to

belt. In some cases, grooves

can be cleaned by idler

adjustment or additional

idlers.~

Excess slack in conveyor Adjust belt take up..

belt.

Belt cleaning erratic. r S-VECO brush or drive Adjust brush/drive be...

belt slip.2. Wrong size or type bristles Contact factory for their

in S-VECO brush. assistance regarding bristles

3. Excess slack in conveyor Adjust belt take-up.

belt.

IN STA L L A TIO N A N D R EMO VA L IN STR UC TIO NS FO R

B·LOOM L OC K IN G A SSEMB LY SER IES 81 06 & 8103

Thank you for purchasing a B-LOCTM Keyless Frictional Locking Device.

~-LOCTt. keyless connectors provide a high capacity, zero-backlash

afVhub or coupling connection by means of a mechanical interference

'. • Please follow these INSTALLATION AND REMOVAL INSTRUCTiONS

carefully to ensure proper performance of this B-LOCTM unit.

When installing or removing B-LOC''' products, always adhere tothe following

safety standards:

1. 8e sure that all power switches are locked out before installing or removing

B-LOC'M products.

2. Eye protection is required when installing or removing B-LOC'M products

. please wear safety glasses and protective clothing.

INSTALLATION

(Refer to Figure 1)

B-LOCTA·Series 8103 and 8106 Locking Assemblies are supplied lightly oiled and



readyfor installation. They are seIf-centeringand fitstraight-thru hub bores. Note that

Series 8103 units permit axial hub movement during installation. In contrast. the

extended flange on Series 8106 units results in an axially fixed hub position during

assembly. When reinstalling a used unit, make sure that all slits are aligned. Thefrictionaltorquecapacityofthese devioes isbased on a coefficientof frictionof0.12 for

lightlyoiled screw.taper. shaft andbore contact areas.

7. Reset torque wrench to specified torque (MA) and check all locking screws.

No screw should tum at this point, otherwise repeat Step 6 for 1 or 2 more

passes. It is not necessary to re-check tightening torque after equipment hasbeen in operation.

'OTE: The torque capacity ofthese units can beincreased byapproximately 25% by

ttooroughlycleaning the shaft and Locking Assemb1y boreof any lubricant. In

applications subject to extreme corrosion, the slits in all collars should be

sealed with a suitable caulling compund or equivalent. Likewise, push-off

threads should be protected from corrosion.

INSTALLATION OF B-LOC"" LOCKING

ASSEMBLIES OVER SHAFT KEYWAYS

The Locking Assembly should be positioned so that slits in Locking Assembly

collars that contact the shaft are located approximately opposite the keyway.

In addition, a locking screw should be centered directly over the keyway.

When tigptening locking screws, it is important to foltow the installation

procedure outlined above, which specifies equal 1/4 turns of each locking

screw. Failure to follow these instructions could result in excessive tightening

of the screw over the keyway, possibly causing permanent deformation of the



Locking Assembly collars. Even after 1/4 turns can no longer be achieved, it

is important to continue to use equal turning angles for every screw until the

specified tightening torque is reached.

REMOVAL

(Refer to Figure 2)

Prior to initiating the following removal procedure, check to ensure that

no torque or thrust loads are actl"g on the Locking Assembly, shaft or

any mounted components.

IMPORTANT! Make sure ends of lockingscrews used for removal are ground flat

andare slightlychamfered to preventdamage to screw and COllarthreads during

push-off.r:

Check to ensure that axial

movement of collars - necessary

for release of connection - is not

restricted. Likewise, ensure that

push-off threads are in good

("1 \-

WHEELABRATOR

AIR FORCE 1 BLOW OFF SYSTEMS - SPARE PARTS LIST

PURCHASE ORDER # J3463012

Part# Description

AF1-WC-4 1"Wall Clamp

AF1-CC-4 1"Crossover Clamp

AF1 Stocked Parts AF1-MT60 Replacement Filter Cartridge 17.625" x 16"

AF1-FLEX-4 4" Diameter Flexible Hose

AF1-HAS-64 4" Gear Clamp SS

AF 1-AC125-4 Air Cannon Anodized, 4" Diameter Connection

Special Order PartsAF1-DCF100-61 Air Knife, 4" Diameter Double Centre Feed Connection

AF1-CF100-24 Air Knife, 4" Diameter Centre Feed Connection

AF 1-KECS20-CW Replacement Blower Wheel 13" x4" x 1-5/8" CW Rotation Coated Steel



Air Force 1 Blow Off Systems Inc.

AIR FORCE 1

BLOW OFF5

Chemical Composition Limits per ASTM B 26-98

Si Fe Cu Mn Mg Ti Other AI



0.2 0.15 0.05 0.10-0.25 6.2-7.5 0.01-0.25 0.15 Remainder

Typical Mechanical Propert iesTemper Ultimate Yield Elongation Shear Compressive Brine)) Endurance

Strength Strength Strength Yield Strength Hardness Limit

(ksi) (ksi) (% in 2 in.) (ksi) (ksi) (ksi)

F 40 20 13 27.45 24 70 10

(35 min.) (18min.) (9 min.) (70 min.) ASTM B26-98

• Thermal Conductivity (@ 77F, SI unites): 0.24 cal/cm*s*K• Heat Treatment - Achieves its physical and mechanical properties as-cast (F).

This eliminates the time and cost of heat treating.

• Machinability - Excellent Machinablility as-cast, excellent surface finish, and high demensional stability.

Corrosion Resistance - Highest of any cast alloy.

AIR FORCE 1

BLOW OFF SYSTEMS INC.

Blow Off System Installation/Operation/MaintenanceThe following general information has been prepared toassist you in installing, operating and maintaining yourAir Force 1Blow Off System. By following theinstructions, you will prolong the life of the equipment

HANDLING

Blowers should be handled carefully and lifted only bylifting eyes in larger blowers, lifting holes or by the base



and enhance performance while preventing unexpecteddown time.

The scope of this manual covers our standardarrangement 4 (direct drive) product line and is notintended to cover specially engineered equipment.

AF1-FRP SERIES BLOWERS

Lowmaintenance direct drive, FRP housing and powdercoated steel motor base includes reverse inlet venturi.

Inletair temperature is not to exceed 160° F (72°C).

SILENCERIINLET GUARD

Powder coated acoustically lined casing with drumdesign inlet guard. Includes stainless steel mountingbracket and hardware.

SILENCER/FIL TER

on smaller units. Nc. .'.1 by the shaft, motor, silencercasing or housinq. P:ecauuon should be taken to avoiddropping orjarring equipment as this can cause damageto motor shaft or wheel which may not be visible butwhich can result invibrations.

INSTALLATION

Blower wheels are dynamically balanced whenfabricated. Complete fans are test run at operatingspeeds (3600rpm motors) to check entire assembly forconformance to vibration limits. Ductwork feedingblower or on discharge side of blower should be

independently supported.

Lifting holes are provided on the motor and blower motorbase to assist in handling the fan assembly.

Fans and motors should be mounted on structurally

3) Motor - Check electrical wiring to motor. The

current characteristics of the supply line must agree

with the motor nameplate ratings. Motor should be

wired in accordance with all national and local

electric codes. All motors are ULlCSA certified.

Typical wiring is Delta Run.

4) Duct/Flex Hose Connection - Hard line duct should

never be supported by fan only. Rigid/Spiral hardline duct connections should be sealed to prevent air

leaks. To minimize sound resonating through duct,

connect rigid duct to blower inlet/outlet by means of

•flex hose/rubber connection. There should be a

minimum of three duct diameters of straight duct

prior to any elbows or transitions into or from the

blower inlet and outlet.

ELECTRICAL DISCONNECTS

Every motor driven fan should have an independent

disconnect switch to isolate the unit from electrical

supply. It should be near the fan and must be capable of

being locked out during maintenance and servicing.

NOTES:

Check amperage draw of system to motor rating (seemotor plate F.L.A.) when distribution plenum, duct, Air

Cannons and/or Air Knives have been installed and

connected. Opening dampers and/or opening Air Knife

slots will increase the impact of the nozzles, but will

increase the amperage used by the blower's motor.

Adding additional Air Knives and Air Cannons will also



5) Install blower inlet duct, inlet guard or filter.

TO ENSURE PERSONNEL OR PROPERTY

PROTECTION, DO NOT OPERATE BLOWER

WITHOUT AN INLET GUARD.

STARTUP

r:

1) Check to make sure no objects have fallen into fan

housing.

2) Start and stop the motor for a second to check

proper wheel rotation. Arrow on fan housing

indicates the proper direction of wheel rotation.Listen for anything unusual such as vibration,

rubbing or banging that may indicate a problem such

as an object in the duct or fan housing.

3) Fan may now be brought up to speed Again, listen

increase the amperage used by the blower's motor.

MAINTENANCE

1) Weekly, check inlet guards and/or filters for any

signs of restriction due to such things as dirt. In

most cases, 3 drop in amperes will be noticed as the

restrictions increase.

2) Weekly, check the condition ot any hose and replace

any that have holes or are worn.

3) Lubricate larger motors with grease at least every

3000 hours of use - more often if in harshenvironments.

*****VERY IMPORTANT*****

Every 8-10 weeks: check/tighten motor 1710' intino

AIR FORCE 1


B lo w O f f Sy st e m In s t a l l a t i o n /O p e r a t i o n /Ma in t e n a n c e

RECOMMENDED AF1 SAFETY PRACTICES



1. Comply with all regional and company requlations, such as AMCA and OSHA requlauo: I.:> "uvenng air

movement devices. AF1 explicitly disclaim responsibility for compliance of the systems in which our products

are components with local, national safety or electrical codes (this being outside our control).

2. 8e certain that the appropriate guard assembly for all exposed moving parts is securely in place prior to and

during use.

3. The safe operation of the AF1 blower is dependent upon proper installation, regu:., i,,~_0ctJ n and

maintenance including any system related associated components, such as filters.

4. The system supplier and or installer must consider the inclusion of necessary guord.., fa, < : : ;; ' J and oil exposed

fan related moving parts and a warning of high-velocity air streams.

5. Do not use the blower if damage is evident or suspected.

6. Always read the equipment operator's manual before use.

7. Ensure that the blower impeller is properly secured on the appropriate sized motor shaft and adequate

clearance is maintained between the impeller and blower housing.

8. Do not exceed maximum operation speed (RPM) and full load amperes (FLA) marked on the blower motor.

9. Always use OSHA approved ear and eye protection when blower is operating.

10. Inspect the blower and impeller regularly for signs of fatigue or vibration.

11. Do not operate the fan in temperatures in access of 160°F unless designed to do so and authorized in writing

'" '~' .L " lF 1 .

r:

AIR FORCE 1


• Excellent chemicalresistance



.,... w'-

• SUPSl.~! ..~

fatigue r " ; : ,; 3 U : , , .c ..,

• Excellent tear andpuncture resistance

antoprene®

2"-24"IDizes

Std. Lengths 25 Ft.

Colours Black

• Good abrasionresistance

• Superior resistance to

Installation, Operation and

Maintenance Instructions

for AC Induction Motors56- 6800 Frames (NEMA)

63 - 280 Frames (IEC)



_ . . . . . D N @IIEiiII-IEii1II.::-rllm··~1I1II.::

A REGAL-BELOIT COMPANY

MARATHON ELECTRIC

i INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER'S USE

I OWNER: READ AND SAVE THESE INSTRUCTIONS

SAFETY INSTRUCTIONS



A This is the safety alert symbol. It is used to alert you to potential personal

injury hazards. Obey all safety messages that follow this symbol to avoidpossible injury or death.

A WARNING

Before installing, using, or servrcmq this product, carefully read and fully

understand the instructions including all warnings, cautions, & safety notice

statements. To reduce risk of personal injury, death and/or property damage,

fol low all inst ructions for proper motor instal lat ion , operat ion and maintenance.

These instructions are not intended as a complete listing of all details for

instal lat ion, operat ion, and maintenance. If you have any questions concerning

any of the procedures, STOP, and call the appropriate Regal-Beloit motor

company.

4.1.1 Ventilation

4.1.2 Insulation

4.1.3 Electrical Connections

4.2 Lubrication and Bearings4.2.1 Grease Type

4.2.2 Bearing Operating Temperature

4.2.3 Lubrication Interval

4.2.4 Lubrication Procedure

4.2.5 Lubrication Example

4.3 Trouble Shooting4.3.1 General Trouble-Shooting Warnings

4.3.2 Trouble-Shooting Cause / Corrective Action

1.0 INSTALLER/OWNER/OPERATOR RESPONSIBILITY:

1.1 ELECTRICAL SAFETY

A WARNING: ELECTRICAL SHOCK HAZARD

Electrical connections shall be made by a qualified electrical personnel in

accordance with all applicable codes, ordinances and sound practices.

Failure to follow these instructions could result in serious personal injury,

death and/or property damage. Only qualified personnel who are familiar

with the applicable National Code (USA = NEC) and local codes should

install or repair electrical motors and their accessories.

motor is suitable for use on Pulse Width Modulated (PWM) type VFD

power. In addition, the nameplate must be marked with the inverter

rating; for example, "2:1 CT", "2 to 1 Constant Torque", etc.

2.0 RECEIVING AND INSPECTION

2.1 INITIAL INSPECTIONS

2.1.1 CHECK PACKING LIST AND INSPECT the



A WARNING: ELECTRICAL LIVE CIRCUIT HAZARD

Do not touch electrically live parts. Disconnect, lockout and tag input

power supply before installing or servicing motor (includes accessorydevices). Use a voltmeter to verify that power is off before contacting

conductors.

A WARNING: ELECTRICAL GROUNDING HAZARD

Failure to properly ground motors, per the National Electrical Code (NEC)

Article 430 and local codes may cause serious injury or death to

personnel. For general information on grounding refer to NEC Article

250. (Also see "Ground Connections section 3.4.4").

A WARNING: AUTOMATIC RESET PROTECTOR HAZARD

Do not use automatic reset protectors if automatically restarting the motor

will place personnel or equipment at risk .. Failure to follow this instruction

could result in serious personal injury, death and/or property damage

A WARNING: MANUAL RESET PROTECTOR HAZARD

If a tripped manual reset thermal protector is exposed to a temperature

less than -rc (20°F) it may reset and restart the motor automatically. If

an application requires a motor with a manual reset thermal protector that

will be operated at temperatures less than -rc (20°F) contact the

packaging to make certain no damage has occurred in shipment. If

there is visible damage to the packaging, unpack and inspect the

motor immediately. Claims for any damage done in shipment mustbe made by the purchaser against the transportation company.

2.1.2 TURN MOTOR SHAFT by hand to be certain that it

rotates freely. Note: Shaft seals and bearing seals may add drag.

2.1.3 CHECK NAMEPLATE for conformance with purchase

order requirements and compliance with power supply and control

equipment requirements.

2.2 HANDLING:

A WARNING: FALLING OBJECT HAZARD

Eyebolts or lifting lugs, where provided, are intended for lifting

only the motor and accessories mounted by the motor

manufacturer (unless specifically stated otherwise on the motor).

Utilizing the motor lifting provision to lift other components such as

pumps and gear boxes could result in serious personal injury, death

2.3.1 BEARING LUBRICATION: Bearings are grease packed

at the factory; relubrication upon receipt of motor or while in storage

is not necessary. If stored more than one year, add grease per

lubrication instructions (Table 4-4) before start-up.

2.3.2 SHAFT ROTATION: It is recommended that the motor

shaft be rotated 5 to 10 rotations every three months to distribute the

grease in the bearings. This will reduce the chance for corrosion to

form on the bearing rolling elements and raceways. Note: Shaft

seals and bearing seals may add drag.

2.3.3 DAMP OR HUMID STORAGE LOCATIONS: Treat

unpainted flanges, shafts, and fittings with a rust inhibitor. Apply

appropriate power to the motor's space heaters (if so equipped)

3.0 INSTALLATION AND OPERATION

A WARNING: Only qualified personnel who are familiar with the

appropriate national code, local codes and sound practices should install

TEFC (Totally Enclosed Fan Cooled) motors must meet a

minimum distance of Y, the shaft height between the fan guard

grill openings and the nearest obstruction.

3.1.3.3 HAZARDOUS LOCATIONS MOTORS: Hazardous

Locations motors are intended for installations in accordance with ~

NEC Article 500. For all installations involving Hazardous

Locations motors, consult the applicable national codes, local

codes, and the authority having jurisdiction.

Division 1 Installations - includes Class I & II: Use only

motors that are UL Listed and CSA Certified or UL Listed and

UL Certified for Canada. These motors bear a separate

nameplate that includes the UL Listing Mark and CSA

Certification Mark or includes the UL Listing Mark and the UL

Mark for Canada. This plate also bears the phrase: " Electricmotor for Hazardous Locations" and is marked with the Class,

Group and Operating Temperature Code.

Division 2 Installations - Class I only: Use only motors that

are CSA Certified and bear the CSA Certification Mark.

These motors include a phrase on the main motor nameplate

that indicates the motor is CSA Certified for Class I, Division 2

/ Zone 2 locations.

Division 2 Installation - Class II only: Use only Class II

motors as described above under "Division I Installations".



or repair electrical motors and their accessories. Installation should

conform to the appropriate national code as well as local codes and

sound practices. Failure to follow these instructions could result in seriouspersonal injury, death and/or property damage.


Do not touch electrically live parts. Disconnect, Lockout and Tag input

power supply before installing or servicing motor (includes accessory

devices). Use a voltmeter to verify that power is off before contacting

conductors.

3.1 LOCATION

3.1.1 SELECTING A LOCATION: Consideration should be

given to environment and ventilation. Motors should be installed inan area that is protected from direct sunlight, corrosives, harmful

gases or liquids, dust, metallic particles, and vibration. A motor with

the proper enclosure for the expected operating condition should be

selected. Provide accessible clearance for cleaning, repair, service,

and inspections (See section 3.1.3 for construction clearances).

The location should be considered for possible future motor removal

A WARNING: EXPLOSION HAZARD

A motor should never be placed in an area with a hazardousprocess or where flammable gases or combustible materials may

be present unless it is specifically designed and nameplated for

this type of service. Hazardous Locations motors are intended for

installations in accordance with NEC Article 500. For all

installations involving Hazardous Locations motors, consult the

NEC, local codes, and the authority having jurisdiction. Failure to

follow these instructions could result in serious personal injury,

death and/or property damage. (For other limitations see section

1.3)

3.2 MOUNTING MOTOR:

3.2.1 RIGID BASE (FOOTED): The motor must be securely

installed to a rigid foundation or a mounting surface to minimize

vibration and maintain alignment between the motor shaft and the

load's shaft. The mounting surfaces of the four mounting pads must

be flat within 0.01 inches for 210 frame & smaller; 0.015 inches for

Figure 1 3.3.4.4 Bel t Tension

ACAUTION: Equ ipment Fai lu re Caut ion

Belt tensioning by feel is NOT acceptable. Tensioning by "feel" can ~

be very misleading, and can damage motor and equipment.

It is normal for V-belts to squeal initially when line starting a motor.

In general, belt tensions should be kept as loose as possible while

still transmitting the required torque without slipping. Belt tensions

must be measured with a belt tension gage. These inexpensive

gages may be obtained through belt manufacturers, or distributors.

Shaft RPM x 3.14 x Sheave Dia (inches)BELT SPEED (Ft lmin) =-----------

12

Proper belt tension is determined by measuring the force required to

deflect the center of the belt a given distance. The proper deflection(in inches) is determined by dividing the belt span in inches by 64.

Calculate the proper deflection and then see Table 3-3 for the

required "Deflected Force" to achieve that deflection.

After tensioning the belt, rotate the sheaves for several rotations or

operate the system for a few minutes to seat belts into the grooves,

then re-tension the belts. New belts will stretch during use, and

should be retensioned after the first eight hours of use.

3.~.4.2 Number of Belts

In general, use the fewest number of belts that will transmit the

required torque without slipping. See Table 3-3 for recommended

maximum number of belts. Each belt adds to the tension in the

system, which increases load on the shafts and bearings. Belts are

most efficient when operated at or near their rated horsepower.



If the sheaves have more grooves than the number of belts required,

use the grooves closest to the motor.

3.3.4.3 Sheave Locat ionInstall sheaves as close to the housing as possible to increase the

bearing life of the motor and driven equipment

Fi gu re 2

Avoid Desired

Figure 1 3.3.4.4 Belt Tensi on

ACAUTION: Equ ipmen t Fai lu re Cau ti on

Belt tensioning by feel is NOT acceptable. Tensioning by "feel" can ~

be very misleading, and can damage motor and equipment.

It is normal for V-belts to squeal initially when line starting a motor.

In general, belt tensions should be kept as loose as possible while

still transmitting the required torque without slipping. Belt tensions

must be measured with a belt tension gage. These inexpensive

gages may be obtained through belt manufacturers, or distributors.

Shaft RPM x 3.14 x Sheave Dia (inches)BELT SPEED (Ftlmin) =------------

12

Proper belt tension is determined by measuring the force required to

deflect the center of the belt a given distance. The proper deflection(in inches) is determined by dividing the belt span in inches by 64.

Calculate the proper deflection and then see Table 3-3 for the

required "Deflected Force" to achieve that deflection.

After tensioning the belt, rotate the sheaves for several rotations or

operate the system for a few minutes to seat belts into the grooves,

then re-tension the belts. New belts will stretch during use, and

should be retensioned after the first eight hours of use.

3.~.4.2 Number of Belts

In general, use the fewest number of belts that will transmit the

required torque without slipping. See Table 3-3 for recommended

maximum number of belts. Each belt adds to the tension in the

system, which increases load on the shafts and bearings. Belts are

most efficient when operated at or near their rated horsepower.



If the sheaves have more grooves than the number of belts required,

use the grooves closest to the motor.

3.3.4.3 Sheave LocationInstall sheaves as close to the housing as possible to increase the

bearing life of the motor and driven equipment

Fi gu re 2

Avoid Desired

Table 3-3 Recommended Minimum Sheave Diameters, Belt vpe, um er 0 e ts an e ecte orce

1200 rpm 1S00 rpm 3600 rpmMin Max Avg. Min Max Avg. Min Max Avg.

Sheave # Deflected Sheave # Deflected Sheave # Deflected

Dia (in) Belt of Force Dia (in) Belt of Force Dia (in) Belt of ForceMotor Hp Tvpe Belts (lbs) Tvpe Belts (ibs) Type Belts (Ibs)

('\ -r c

"" ""'V . " . "" ""'V ."" ""

"\IV . ."1 2.4 3VX 1 4.0 2.2 3VX 1 3.1 2.2 3VX 1 1.6

1.5 2.4 3VX 2 3.1 2.4 3VX 2 2.1 2.2 3VX 1 2.5

2 2.4 3VX 3 2.8 2.4 3VX 2 2.9 2.4 3VX 1 2.7

3 3.0 3VX 2 3.3 2.4 3VX 3 2.9 2.4 3VX 2 2.3

5 3.0 3VX 3 4.0 3.0 3VX 3 3.7 2.4 3VX 3 2.5

7.5 3.8 3VX 4 4.7 3.0 3VX 4 4.1 3.0 3VX 2 4.2

10 4.4 3VX 4 5.4 3.8 3VX 4 4.3 3.0 3VX 3 3.815 4.4 3VX 5 5.4 4.4 3VX 4 5.4 3.8 3VX 3 4.4

20 5.2 3VX 6 ·6.0 4.4 3VX 6 4.8 4.4 3VX 3 5.0

25 6.0 3VX 7 5.6 4.4 3VX 7 5.2 4.4 3VX 4 4.71n F ; R '>,\1)( 7 <; Q <; ? '>,\1)( 7 <;'>,

40 6.8 5VX 4 11.6 6.0 3VX 7 6.0

50 8.2 5VX 4 14.6 6.8 3VX 8 5.9

60 8.2 5VX 5 14.1 7.4 5VX 4 13.3

75 10.0 5VX 5 14.5 8.6 5VX 4 14.3

Contact Motor00 10.0 5VX 6 16.0 8.6 5VX 6 13

T N b f B I d D fl d F



125 12.0 5V 7 14.1 10.5 5V 6 13.1Manufacturer50 13.2 5V 7 15.4 10.5 5V 7 13.4

200 15.0 5V 8 16.0 13.2 5V 8 13.1 when Belting250 15.0 8V 6 27.6 14.0 5V 9 13.8

300 16.0 8V 7 27.1 14.0 5V/SV 11 1 7 23.4 3600 rpm Motors350 16.5 8V 7 30.3 14.5 5V/SV 12/7 26.0

400 17.5 8V 8 29.1 15.0 5V/SV 13/S 25.7 Greater than 25 HP450 18 8V 8 31.6 16.0 5V/SV 14/9 25.2

500 18.5 8V 9 30.7 16.5 5V/SV 15 /9 26.9

600 17.5 8V 11 26.3

700 19.0 8V 12 27.3

800 20.0 8V 13 28.2

Notes:

1. Horsepower is the nameplate motor horsepower, and RPM is the motor (driver) speed.2. Minimum sheave diameters are from NEMA standards where applicable.

3. For variable speed applications or values outside these recommendations, consult motor manufacturer.

4. Selections are based on a 1.4 service factor, 5 to 1 speed ratio and various Power Transmission Manufacturers' catalogs.

5. These selections are for Narrow V-belt sections only. Consult manufacturer for details on conventional V-belt sections (A, B, C, D and E), or other

belt types.

6. "Average Deflected Force is per section 3.3.4.4 of this document and is the force required to deflect the center of a belt 1/ 64 of the belt span

to Table 3-5 values. Definite purpose VFD motors may

accommodate longer cable lengths. For additional

information contact motor manufacturer.

Table 3-5 Max Cable Lengths General Purpose MotorsThese values are based on 3 kHz carrier frequency. Add

suitable VFD output-side filters when exceeding the listed

values

Frame Size 230V 460 V 575 V

NEMA56-320 600 ft. 125 ft. 40 ft.

NEMA 360-5011 1000 ft. 225 ft. 60 ft.

IEC 80-200 180 m. 40m. 12 m.

IEC 225-280. 300m. 70m. 18 m.

3.3.5.3 VFD Grounding: Equipment grounding conductors

may be run in the same conduit as the AC motor power leads.

This wire must be used as the equipment ground for the motor and

not as the fourth current carrying wire of a "WYE" motor circuit.

The grounded metal conduit carrying the output power conductors

can provide EMI shielding, but the conduit does not provide an

adequate ground for the motor; a separate grounding conductor

must be used. Grounding the motor neutral (WYE) of a VFD

General Information: When thermal protection is provided, one of

the following will be stamped on the nameplate:

1. "THERMALLY PROTECTED" This motor has built in thermal

protection. Thermal protectors open the motor circuitelectrically when the motor overheats or is overloaded. The ~

protector cannot be reset until the motor cools. If the

protector is automatic, it will reset itself. If the protector is

manual, disconnect motor from power supply. After protector

cools (five minutes or more) press the reset button and

reapply power to the motor. In some cases a motor is marked

"Auto" and the connection diagram on the motor will identify

T'Stat leads - see "2 "below. (See warnings on Manual and

Automatic reset protectors - section 1.1)

2. "WITH OVERHEAT PROTECTIVE DEVICE": This motor isprovided with an overheat protective device that does not

directly open the motor circuit. Motors nameplated with this

phrase have either thermostats, thermisters or RTD's. The

leads to these devices are routed into the motor conduit box

or into an auxiliary box. The lead markings are defined on the

nameplate (normally "P1", "P2") . The circuit controlled by the

overheat protection device must be limited to a maximum of

600 volts and 360 volt-amps. See connection decal provided

inside the terminal box cover. Failure to connect these over



powered motor may result in a VFD ground fault trip. Improper

grounding of an inverter fed motor may result in frame voltages in

excess of 500 Volts. Refer to Grounding section 3.4.4

3.3.5.4 VFD - Single Phase:

CAUTION: SINGLE PHASE MOTOR FAILURE:

S ingle Phase motors are NOT suitable for use on VFD power.

Connecting a Single Phase Motor to a VFD voids the warranty.

3.3.5.5 Stray Voltage on Accessory Leads:

VFD's will couple stray (common-mode) voltage to motor-

mounted RTDs, thermistors, thermostats and space

heaters. The leads of these elements must be properly

insulated and control input circuits must be designed towithstand this common-mode voltage.

3.3.6 ACCESSORIES I PROVISIONS:

3.3.6.1 General: Carefully read and understand the accessory

manufacturer's instructions, supplied with motor. Contact the

temperature devices (when provided) will void the warranty.

A WARNING: EXPLOSION HAZARDFor Hazardous Locations motors provided with thermostats

UL and the NEC require connection of thermostat leads into

the control portion of a manual reset start circuit. Failure to

follow this instruction could result in serious personal injury,

death and/or property damage

Resistance Temperature Detectors (RTD): When winding

and/or bearing RTDs are provided the RTD lead markings are

defined on the nameplate. (Normally "R1", "R2", "R3" etc.)

3.3.6.5 RTD Alarm & Trip Settings: ~Tables 3-6 & 3-7 are suggested initial RTD alarm and trip settings.

For motors found to operate significantly below these values the

settings may be reduced accordingly.

Table 3-6 Winding RTD - Temperature Limit (0C)

3.4 ELECTRICAL CONNECTIONS:

A WARNING: ELECTRICAL HAZARDS

Before proceeding read Section 1-1 on Electrical Safety. Failure to

follow the instructions in Section 1-1 could result in serious personal

injury, death and/or property damage

3.4.1 POWER SUPPLY I BRANCH CIRCUIT

A WARNING: POWER SUPPLY INCOMPATIBILITY HAZARD

Check power supply to make certain that voltage, frequency and

current carrying capacity are in accordance with the motor

nameplate. Failure to match motor nameplate values could result in

serious personal injury, death and/or property damage

A WARNING: BRANCH CIRCUIT SUPPLY HAZARD

Motor and control wiring, fusing, overload protection, disconnects,

accessories and grounding must always conform to the applicable

electrical codes as well as local codes and sound practices.

3.4.1.1 Branch Circuit Supply to a motor should include a

disconnect switch, short circuit current fuse or breaker protection,

motor starter (controller) and correctly sized thermal elements or

(3) Machined Surface Gap (Hazardous Locations Terminal

Boxes): The gap between mating surfaces with the machined

terminal box MUST BE LESS THAN 0.002 inches. This gap must

be checked with a feeler gage along the entire perimeter. If there isvisible damage to the mating surfaces, or if the gap between these

surfaces exceeds 0.002 inches, DO NOT complete the installation

and contact the motor manufacturer. Failure to follow these

instructions could result in serious personal injury, death and/or

property damage

3.4.3 LEAD CONNECTIONSElectrical connections to be made per nameplate connection diagram

or separate connection plate. In making connections follow the

applicable electrical code as well as local codes and practices.

A WARNING: ELECTRICAL CONNECTION HAZARD

Failure to correctly connect the motor leads and grounding

conductor can result in injury or death. Motor lead connections can

short and cause damage or injury if not well secured and insulated.

3.4.3.1 Wire Size (Single Phase) RequirementsThe minimum wire size for Single Phase, 115 & 230 Volt Circuits

must meet table 3-8 for a given distance between motor and

either Fuse or Meter Box.



overload relay protection.

3.4.1.2 Fuses, Breakers, Overload RelaysShort Circuit Current Fuses or Breakers are for the protection of the

branch circuit. Starter or motor controller overload relays are for the

protection of the motor. Each of these should be properly sized and

installed per the applicable electrical codes as well as local codes

and practices.

A WARNING: PROTECTIVE DEVICE DISABLED HAZARD

DO NOT bypass or disable protective devices. Protection removal

could result in serious personal injury, death and/or propertydamage

3.4.1.3 AC Power Supply LimitsMotors are designed to operate within the following limits at the

motor terminals:

1- AC power is within +- 10 % of rated voltage with rated

frequency applied. (Verify with nameplate ratings) OR

2- AC power is within +- 5% of rated frequency with rated voltage

Table 3·8 Minimum Wire Gage Size Single Phase

115 & 230 Volt CircuitsDistance (Feet) - Motor to Fuse or Meter Box

Motor 100 Ft. 200 Ft. 300 Ft. 500 Ft.

HP 115 230 115 230 115 230 115 230

1/4 14 14 10 12 8 10 6 8

1/3 12 14 10 12 6 10 4 8

1/2 10 12 8 10 6 8 4 6

3/4 10 12 6 10 4 8 2 6

1 8 10 6 8 4 6 4

1 1/2 4 10 0 8 6 4

2 8 6 4 23 8 6 4 2

5 6 4 2 0

3.4.3.2 Extension Cords (Single Phase Motors):Where an extension cord(s) is utilized to provide power to the

A WARNING: LOOSE & ROTATING PARTS HAZARD

Before proceeding read Section 1-2 on Mechanical Safety. Failure to

follow the instructions in Section 1-2 could result in serious personal

injury, death and/or property damage

A WARNING: EXCESSIVE SURFACE TEMPERATURE

HAZARD

Motors with the temperature code stated on the nameplate are

designed to operate within this limit. Improper application or

operation can cause the maximum surface temperature to be

exceeded. A motor operated in a Hazardous Location that exceeds

this surface temperature limit increases the potential of ignitinghazardous materials. Therefore, motor selection, installation,

operation, and maintenance must be carefully considered to ensure

against the following conditions: (1) Motor load exceeds service

factor value, (2) Ambient temperature above nameplate value, (3)

Voltages outside of limits (3.4.1.3), (4) Loss of proper ventilation, (5)

VFD operation exceeding motor nameplate rating, (6) Altitude above

3300 feet /1000 meters, (7) Severe duty cycles, (8) Repeated starts,

(9) Motor stall, (10) Motor reversing, and (10) Single phase

operation. Failure to follow these instructions could result in serious

Do not start more than twice in succession under full load.

Repeated starts and/or jogs of induction motors can cause

overheating and immediate failure. Contact the motor manufacturer

if it is necessary to repeatedly start or jog the motor.

4.0 MAINTENANCE:

A WARNING: Hazardous Locations Motor Repair HAZARD:

Division 1 Hazardous Locations motors can only be modified or repaired

by the manufacturer or a facility that is Listed under UL's category

"Motors and Generators, Rebuilt for use in Hazardous Locations". Failure

to follow these instructions could result in serious personal injury, death

and/or property damage.

A WARNING: ELECTRICAL SHOCK HAZARD

Electrical connections are to be made by qualified electrical personnel inaccordance with all applicable codes, ordinances and sound practices.

Failure to follow these instructions could result in serious personal injury,

death and/or property damage. Only qualified personnel who are familiar

with the applicable national codes, local codes and sound practices

should install or repair electric motors and their accessories.


Do not touch electrically live parts. Disconnect, lockout and tag input

power supply before installing or servicing motor (includes accessory



personal injury, death and/or property damage.

A CAUTION: HOT SURFACE

Normal motor surface temperatures may exceed 90 ° C (194° F).

Touching the motor frame may cause discomfort or injury. Surface

temperatures should only be measured with suitable instruments and

not estimated by hand touch.

3.4.5.1 Start Up - No Load Procedure

1. Check Instructions: Before startup carefully read and fully

understand these instructions including all warnings, cautions,

and safety notice statements.

2. Motor out of storage after more than three months:

Check winding insulation integrity with a Megger. If winding

resistance to ground is less than 1.5 Meg-ohms consult the local

authorized service shop before energizing the motor.

3. Check Installation: Mechanical - Check tightness of all

bolts and nuts. Manually rotate the motor shaft to ensure motor

shaft rotates freely. Note: Shaft & bearing seals will add drag.

Electrical - Inspect all electrical connections for proper

devices).

4.1 GENERAL INSPECTION

Inspect the motor approximately every 500 hours of operation or every

three months, whichever occurs first. Keep the motor clean and the

ventilation and fin openings clear. The following steps should be

performed at each inspection:

4.1.1 VENTILATION: Check that the ventilation openings and/or

exterior of the motor is free of dirt, oil, grease, water, etc, which can

accumulate and block motor ventilation. If the motor is not properly

ventilated, overheating can occur and cause early motor failure.

~4.1.2 INSULATION: Use a "Megger" periodically to ensure that

the integrity of the winding insulation has been maintained. Record

the Megger readings. If winding resistance to ground is less than 1.5

Meg-ohms consult the local authorized service shop before re-

energizing the motor.

Nameplate Ambient Temperature above 65°C (150°F): Dow

Corning DC44 or equivalent, a special high temperature grease is

required. Note that Dow Corning DC44 grease does not mix with

other grease types.

For RTD settings see Table 3-7.

4 . 2 . 2 BEARING OPERATING TEMPERATURE:

A CAUTION: HOT SURFACE

The external surface temperature of the end shield (bracket) bearing

hub may reach 100° C (212° F) during normal operation. Touching

this surface may cause discomfort or injury. Surface temperatures

should only be measured with suitable instruments and not estimated

by hand touch.

4 . 2 . 3 LUBRICATION INTERVALS: (For motors with regreasing provisions)

Eq.4.2 Lubrication Interval = [(Table 4-1) hrs] x [Interval Multiplier (Table 4-2)] x [Construction Multiplier (Table 4-3)]

Table 4 - 1 Lubrication Intervals (Hours) These values are based on average use.

Operating Speed - RPM (See Table 3 . 4 for Maximum Operating Speed)

NEMA I [IEC] Frame Size <7 2 0 0 <5 4 0 0 < 4 5 0 0 < 3 6 0 0 < 1 8 0 0 < 1 2 0 0

56-180 [80-110] 2500 Hrs. 4000 Hrs 5000 Hrs 6000 Hrs. 17000 Hrs. 20000 Hrs.



210-250 [130-160] 2500 Hrs 4000 Hrs 5000 Hrs. 12000 Hrs. 16000 Hrs.

280 [180] 2000 Hrs 3000 Hrs 4000 Hrs. 10000 Hrs. 14000 Hrs.320 [200] 2000 Hrs 3000 Hrs. 9000 Hrs. 12000 Hrs.

360 [225] 1500 Hrs 2000 Hrs. 8000 Hrs. 10000 Hrs.

400-440 [250 - 280] 1500 Hrs. 4000 Hrs. 7000 Hrs.

>440 [>280] 1000 Hrs. 3000 Hrs. 5000 Hrs.

Seasonal Service: Ifmotor remains idle for more than six months, Lubricate at the beginning of the season, then follow lubrication interval.

Do not exceed maximum safe operating speed Table 3-4 without manufacturer's approval

Table 4 - 2 Service Conditions

Use hiqhest level Multiplier: Maximum Ambient Temperature and Contamination are independent factorsSeverity of Maximum Ambient

Atmospheric Contamination MultiplierService Temperature

Standard Less than 40° C (104° F) Clean, Slight Corrosion, indoors, less than 16 hrs per day1.0

SevereAbove 40° C (104° F) to 50° Moderate dirt or Corrosion or outdoors or more than 16 hrs

4.2.4 LUBRICATION PROCEDURE:(For Motors with Regreasing Provisions)

CAUTION: BEARING DAMAGE WARNING

Added grease must be compatible with the original equipment's

grease. If a grease other than those stated in 4.2.1 is to be utilized

contact the motor manufacturer. Nameplate information

supersedes section 4.2.1 (GREASE TYPE). New grease must be

free of dirt. Failure to follow these instructions and procedure

below may result in bearing and/or motor damage.

For an extremely dirty environment, contact the motor

manufacturer for additional information.

LUBRICATION PROCEDURE:

1..Clean the grease inlet plug or zerk fittings prior to regreasing.

2. (If present) Remove grease drain plug and clear outlet hole

blockage.

CAUTION: GREASE DRAIN PLUGGED:

Old grease may completely block the drain opening and must be

1. Table 4-1 list 10,000 hours for standard conditions.

2. Table 4-2 classifies severity of service as "Severe" with a

multiplier of 0.5.

3. Table 4-3 lists a multiplier value of 0.5 for "Vertical"4. (Eq.4.2) Interval = 10,000 hrs x 0.5 x 0.5 = 2500 hrs

3

Table 4-4 shows that 1.5 in of grease is to be added.3

Relubricate every 2,500 hrs of service with 1.5 in of

recommended grease.

4.3 TROUBLE-SHOOTING

A WARNING: READ INSTRUCTIONS:

Before trouble-shooting a motor, carefully read and fully understand

the warnings, cautions, & safety notice statements in this manual.

A WARNING: Hazardous Locations Motor Repair:

Motors nameplated for use in Division 1 Hazardous Locations can

only be disassembled, modified or repaired by the plant of

manufacturer or a facility that is Listed under UL's category "Motors

and Generators, Rebuilt for use in Hazardous Locations". Failure to

follow these instructions could result in serious personal injury,

death and/or property damage

CAUTION: DISASSEMBLY APPROVAL REQUIRED:



mechanically removed prior to regreasing. Forcing a blocked

drain open by increased greasing pressure may collapse bearing

shields and / or force excess grease through the bearings and

into the motor.

3. Add grease per Table 4-4

4. Re-install grease inlet and drain plugs (if removed).

A WARNING: EXPLOSION HAZARD

Do NOT energize a Hazardous Locations motor without all grease

fittings properly installed.

4.2.5 EXAMPLE: LUBRICATIONAssume - NEMA 286T (IEC 180),1750 RPM Vertical motor driving

an exhaust fan in an ambient temperature of 43° C and the

atmosphere is moderately corrosive.

Motor disassembly must be performed by a party approved by the

motor manufacturer. To disassemble the motor without approval

voids the warranty.

4.3.1 GENERAL TROUBLE-SHOOTING WARNINGS1. DISCONNECT POWER TO THE MOTOR BEFORE

PERFORMING SERVICE OR MAINTENANCE.

2. Discharge all capacitors before servicing motor.

3. Always keep hands and clothing away from moving

parts.

4. Be sure required safety guards are in place before

starting equipment.

5. If the problem persists contact the manufacturer.

432 M t T bl h t" C IC t" A t " T bl 45. o or rou e-s oOlng ause orrec rve cion - a e -Issue: Likely Cause: Corrective Action:

Motor fails to start upon init ial installat ion:

A.)Supply voltage is too low or is severely unbalanced (one (1) Check power supply fuses (2) Match motor lead wiring to nameplate connection

phase is low or missing). diagram and supply voltage (3) Ensure that steady state supply voltage at motor

terminals is within limits (see section 3.4.1.3). Correct as needed (4) Obtain correc

B.) Motor leads are miswired at conduit box. motor to match actual supply voltage.

C.) Driven load exceeds motor capacity(1) Verify that motor & load turn freely (2) Disconnect motor from load & ensure

motor turns freely. Note: Roller bearings make noise when motor is uncoupled and

D.) Load is jammed.shaft is rotated (3) Verify that motor starts when disconnected from load (4)

Remove excessive / bindinq load if present.

E.) Fan guard is bent and making contact with fan Replace fan guard & fan (if blades are damaged)

F.) VFD with power factor capacitors installed Remove power factor correction capacitors if equipped

G.) VFD with motor neutral lead grounded Ensure that motor neutral lead is ungrounded

(1) Repeat checks listed above (2) Verify that VFD current limit and starting boost

H.) VFD programmed incorrectlyare set correctly (5) Double-check motor and feedback parameter settings and

VFD permissives (6) Repeat autotune (for vector drives) procedure (7) Consult

VFD supplier.



Motor has been running, then slow down, stalls, or fails to restart:

(1) Replace fuse or reset circuit breaker. Allow motor to cool down before resetting

Supply voltage has drooped or has become severelymanual protector on motor. Warning s - See section 1.1 for automatic and manual

A.)unbalanced

reset protector warnings (2) Verify that rated and balanced supply voltage has

been restored before restarting motor. Measure voltage during restart. Ensure that

steady state supply voltage at motor terminals is within limits (see section 3.4.1.3).

B.) Motor is overloaded(1) Verify that motor & load turn freely. Repair binding components as needed (2)

C.) Motor bearings are seized Reduce driven load to match motor capacity or increase motor size to match load

D.) Load Is jammed.requirements.

r:(1) Check fault codes on VFD and follow VFD troubleshooting procedures (2)

E.) VFD will not restart motor after tripping Verify that VFD input voltage is balanced and within limits (3) Remove excessive

mechanical load if present.

F.) Capacitor failure on single phase motor (if equipped) Warning: Potential Shock Hazard: Contact service shop to check capacitor.

Motor takes too long to accelerate:

E.) Motor is started too frequently See section 3.4.5.3

(1) Ensure that steady state supply voltage at motor terminals is within limits (see

F.) Supply voltage too low, too high, or unbalanced section 3.4.1.3) Correct as needed (2) Reconnect motor per input voltage (3)Obtain correct motor to match power supply.

Motor Vibrates

A.) Motor misaligned to load. Realign load

(1) Ensure that load is dynamically balanced: (2) Remove motor from load and

B.) Load out of balance (Direct drive application)inspect motor by itself. Verify that motor shaft is not bent. Rule of thumb is 0.002"

runout for shafts extension lengths up to 3.00". Add 0.0005" per every additional

inch of shaft lenoth bevond 3.00".

C.) Uneven tension on multiple belts

Mixing new with used belts. Replace multiple belt applications with a complete set

of matched belts.

(1) De-energize motor and record vibration as load coasts from 100% speed to 0

RPM. If vibration drops immediately, vibration source is electrical. If levels do no.Driven load operating at resonant point / natural drop immediately, source is mechanical (2) Redesign system to operate below the

D .)frequency. resonant point (3) On VFD-driven loads, program skip frequencies to bypass

resonant points (4) Increase carrier frequency to obtain <3% THD current (5) On

variable torque loads reduce volts/hertz below base speed.

E.) VFD torque pulsations(1) Adjust VFD to obtain <3% THD current @ rated motor current (2) Adjust VFD



stability for smooth operation. Vector drives may be unstable at light load.

F.) Motor miswired at terminal box Match motor lead wiring to nameplate connection diagram.

G.) Uneven, weak or loose mounting support. Shim, strengthen or tighten where required.

Test motor by itself. If bearings are bad, you will hear noise or feel roughness.

Roller bearings are normally noisy when operated without load. If sleeve bearing,

H.) Motor bearings defective add oil per nameplate instructions. For motors with regreasing provisions, add

grease per relubricating instructions (see section 4.2.3). If noise persists contac

warrantv service.

Disconnect from load. Set motor on rubber pads on solid floor. Secure a Y,height

I.) Motor out of balancekey in shaft keyway and energize from balanced power supply @ rated voltage.

Record vibration levels and compare with appropriate standards. If excessive

vibration persists contact motor manufacturer.

Bearings repeatedly fail.

(1) If belt drive check system per section 3.3.4. (2) Other than belting, check



P.O. Box 8003

VVausau, VVI54401-8003

PH:(715) 675-3311

Model #256TTFNA4001

Winding: K2562124

NP HP: 20

NP VOLTS: 460

NP AMPS: 23.5

NP RPM: 3530

NP EFF: 90.2%

NP PF: 87.5%

GTD EFF: 88.5%

Certification Data Sheet(DA TA IS BASED ON 460 VOL TS)

Outline Drawing: B-SS2030 15-1225

Connection Diagram: A-EE7308

DESIGN: B Frame: 256T

Max Load

FREQ: 60 HZ Inertia: 58 (Ib ft2)

Approx Mtr

LR CODE: G Wgt: 334

95% PF Corr: 5 Rotor Inertia: 1 (Ib ft2)

Sound@ 1M: 78 dBA Starts/Hour: 2 (NEMA VVK2)

Ambient 40 C Stall Time: 20 See

Service Factor: 1.15 Insulation: F



ThermalProtection: NONE Duty: CONTINUOUS

--,-- -

EQUIVALENT WYE CKT. PARAMETERS (OHMS PER PHASE)

R1 R2 X1 X2 XM

0.26838 0.2201 1.09198 0.923 38.624

RM

88.8

ZREF XR TO TOO

14.2 5.2 0.02 0.477

I KW RPM TQ(lb-ft) I EFF(%) I PF(%) RlR(C)-~ - - ----.- - ---- --_. .--!

________ -+~_AM~~

THREE A HA SEHIG H VOLTAGE DUAL VOLTA~E MOTOR

- r

T1 • L1

T2 • L 2

T3 • L 3

T4

T7 >T5

TB>

T6

>9

LOW VOLTAGE

T1L1

E E 7 3 0 8

T1

T4

T9

T7

TB

T6

T5

T2

T3



T7

T2TB

T3

T9

T4

T5

T6

---->---

----y----- L 2

VIEW O F TER~INAL END

----~»--3REF.

W IND ING D IAGRAM

TB Y , T2Y , T28L , T48X, T2EC, T2G (T68Z, T28, T68L , T4A V, T68, T4B

<___7

OPT IONA L CORDCONNECTION

L 1 WHITE

L 2 RED

L3~LACK

DRAWN RIll 11/20/18110

••. 11/21/18110

APPD $AS 04 - /24,SCALE 1-1

REF-MF-REY

S~E IDRAWING ~E7;~~EOF

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1 I REDRAYitl IRM 11/20/1990I I . x x x x i ±OOD5 IMAn

No,l REVISION I BY & DATE I CHK I ANG I ±7'30" IFINISH

THIS DRAWING IN DESIGN AND DErAil IS OUR PROPERTY AND MUST NOT BE USED EXCEPT I RFP ICAD FilE f'-- IIN CONNECTION WITH OUR WORK ALL RIGHTS OF DESIGN AND INVENTION ARE RESERVED

THIS IS AN ELECTRONICALLY ~ENERATED DOCUMENT - 00 NOl SCALE THIS PRINT 015T ~

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