Manufacturers O and M Manual for Actiflo Mixers Pumps ...

Actiflo OMKRUGER I Kru er Incg

TABLE OF CONTENTS

CiICDSECTION DESCRIPTION ico

QIIUUlO1 Contact List

2 Process O M

3 Mixers

CoagulationInjection Mixer

Maturation Mixer

4 Sand RecirculationSlurry Pumps

5 Settling Tank Scraper

6 Hydrocyclones

7 Pressure Instruments

Pressure GaugePressure Switch

8 Valves

9 Lamella Tubes

1 Microsand

11 Bill of Materials Drawings

12 Warranty

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Project42470003 PortAngeles WAVEOIIA

Actiflo OM

January 2009Ss Thg

Actiflo OMKRlCER I Kruger Inc

SECTION 1

Contacts

Project 42470003 Port Angeles WA Q VEOIIAActiflo OM wArER

January 2009Salutions Technologies

Actiflo OMU I Kruge Inc

KRUGER PARTS AND SERVICE

UNDER WARRANTY CONTACT

Timothy Platt Project ManagerPh 9196778310

Fax 9196770082

Direct 9196534510

Emailtimplatt@veoliawatercomAFTER

WARRANTY CONTACT Bryan

Hewitt AftermarketSales Manager Ph919 6778310Direct

919 6534521Cell

919 3491616Email

bryan hewitt@veoliawatercomProject42470003

Port Angeles wAo VEOl1A ActifloOM WATERJanuary2009

Solutions Technologies

KR GER Actiflo OMU L Kruger Inc

1

SECTION 2

Process OM

Project 42470003 Port Angeles WA OVELAActiflo OM

January 2009WLITER

Solutions iehnologies

ACTIFLO PROCESS

O 8 M MANUAL

Port Angeles WA

Olympic National Park

ElwhaIiver Restoration

January 30 2009

I KRUGER Inc

401 Harrison Oaks BlvdSuite 100

Cary NC 27513

Phone 919 6778310

Fax 919 6770082

Kruger Project Number 42470003

RI Kruger Incorporated ACTIFLO OM Manual

Port Angeles WA

Date January 30 2009

Revision 0

TABLE OF CONTENTS

1 INTROUCTION4

AIBACKGROUND J

B OBJECTIVES OF TIIG MANUAL

C GENGRAL PROCESS DESCRPTION 51 Coagulation lnjection and Maturation Tanks 6

2 Settling Tank 7

3 Sand Recirculation System 7

2 DESCRIPTION OF EQUPMENT8

A ACTILO CLARIFICATION SYS7EM 91 Functional Characteristics 9

2 General Description 93 Coagzrlation Tnnks 94 Injection Tanks l0S Maturation Tanks 106 Settling Tanks l I

7 MicrosandRecirculation Circuits 12

8 Microsand 3

9 Coagulant l4

10 Coagzlant Metering Pumps BY OTHGRS 14ll Polymer Preparation Sysem BY OTHERS 4

2 Polymer Metering Pumps BYOTHERS lSB CONTROL PANEL 15

1 General lS

2 PC Control Panel Descripion l5

3 STARTUP OPERATION AIVD MOIYITORING1G

A START 17

1 Preliminary nerifications l7

2 Debris removalfrom process tanks l7

3 Loading ofmiaosand l813 NORMAL OPERAIION I 3

Sand loss estimation l82 Sand concentratron nzonitoring 193 Sand addition

214 Hydrocyclones 21S Polyme dosing 246 Coagulant Dosrng 24

7 Calibiation ofCoagzdant nnd Polymer posing Pumps 25

4 PERFORn4ANCE MONITORIIYCOPTIMIZAfION AND TROUBLE SHOOTINC GUIDELINES28

A PROCESS PERPORMANCG MONIIORING 291 Recommendednon moniloring schedrde 29

B OPTIMIZATION3

Bnckground and initial informatron 302 Peocess parameter considerations 33 Oplimiaionprocedure 35

C TROUBLE SHOOTING GUIDG 39

5 JAR TEST PROCEDURE41

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A ACTIFLO JAR T6ST PROCEDURE VITH MICROSAND FOR DRY NOLYMGR 42

1 PreJar Testing Chemical Preparation Calculations and Recommendations 42

2 JarIesting Procedure 43

B ACTIFLO JAR TESf PROCEDURL WTFIMCROSAND FOR GMULSfON POLYMER 45

I PreJar Testing Chemical Preparation Calculations and Recommendations 4

2 Jar Testing Procedure 6

6 MAINTENANCE48

A GGNERAI MAINTENANCE 49

IIamellar tubes 49

2 Mixers SO

3 Scrapers 5

4 Sand Pumps Sl

i Hydrocyclones SI

B INTERMITTENIUSE PROCLDURIS 52

I Shor Term StandByAtode Wet Slorage 52

2 LongIerm Shutclown and Freee Yrotection 3

3 lnstrumentation Nlaintenance 53

4 Chenica Feed Maintenance 59

7 APPENDICES5

A ACTIFLOPROCGSS CONIROLS DESCRIPTION J6

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ACTIFLO OM Manual

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1 INTRODUCTION

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A Historical Background

The US National Parks Service has mandated I Kruger Incorporated for the supply of

an ACTIFLO System for the Elwha River Restoration Project in Port Angeles WA

The ACTlFLO clarification system has been designed far a total treatment capacity of

11 MGD consisting of 2 x 55 MGD process trains

Kruger lnc supplied components of the ACTIFLO System for the Elwha River

Restoration Project This equipnent is of superior quality and its proven design will

ensure years of low maintenance operation However in order to obtain a continuous

and efficient performance from the system it is important that the operators follow

the preventative measures and operating procedures described in this manual

To obtain any additional information concerning the characteristics andor the

functioning of this equipment or if a problem persists please contact

I Kruger Incorporated401 Harrison Oaks Boulevard

Suite 100

Cary NC 27513

Phone 919 6778310

Fax 919 6770082

Each request will need to be accompanied by the following information

Project Name Port Angeles WA

Kruger Project1iumber 42470003

B Objectives of the Manual

The goal of this manual is to

Describe and explain the functioninb of the various components of the

ACTIFLO SystemDescribe the procedures for startup standard operation and shut down of the

systenDocnnent preventative maintenance measures and describe procedures for

maintaining the equipment properly

C General Process Description

The ACTIFLO Process is a compact high perfonnance water clarification systemthat combines the advantages of microsand enhanced flocculation wit11 lamellar plate

settlin 1he addition of microsand serves as a flocculation aid and ballasting agent

allowing for an overflow rate of 20 gpmft2 for the Port Angeles WA ACTIFLO

project These high overflow rates result in system footprints that are between 5 and

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25 times smaller than conventional clarification systems of similar capacityACTIFLO treatment is accomplished through a series of consecutive process steps

that consist of coagulation microsand and polymer injection injection tank floc

maturation maturation tank settling and sand recirculation Each of these steps is

discussed in greater detail in the paragraphs that follow A graphical presentation of

the ACTIFLO process is provided in the flow diagram presented in Figure 1

Figure 1 ACTIFLO Process Flow Diagram

SW DGEMICROSAND AND SLUDGE

TO HYDROCYCLONE

HYDROCYCLONE

POLYMER ti

MICROSAND

g

CLARIFIED

WATER

ec i ie Eme T ag h s o

COAGULANT t

Y z s rx y

RAWsP d M3

i xWATER c a wr

wa k

INJEC770Ns

COAGULATION MATURATION s

TUBE SETTLER

WITH SCRAPER

1 Coagulation Injection and Maturation Tanks

Chemical coagulant Alum Ferric ACI1 etc is added into the raw water piping

prior to entering the coagulation tank The raw water then enters the coagulationtank Coagulant destabilizes the suspended solids and the colloidal matter in the

influent stream Efficient mixing is provided in the coagulation tank This

mixing thoroughly disperses the coagulant and the destabilized particles into the

raw water over a hydraulic retention time of approximately two minutes The

destabilized particles collide and begin early stage loc formation

The coagulated water then flows over a weir into the injection tank where

flocculant aids polymer and microsand are added to initiate floc fonnation

Here the combination of flash mixing and a hydraulic retention time of

approximately two minutes allow for thorough incorporation of microsand and

polymer into the coagulated water The combination of microsand and polymerserve asaseed for floc formation and development in the next process step

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ACTIFLO treatment continues as water passes through the underflow passage

from the injection tank into the maturation tank Although chemical floc

formation actually begins with the addition of polymer and microsand in the

injection tank the majority of ballasted floc formation occurs during the

maturation process step Gentle mixing and an increased hydraulic retention time

of approximately six minutes provides ideal conditions for the formation of

polymer bridges between the microsand and the destabilized suspended solids

The large specific surface area of the microsand provides enhanced opportunityfor polymer bridging and enmeshment of microsand and floc already in

suspension further augment this process

2 Settling Tank

The fiilly formed ballasted flocs leave the maturation tank and enter the settlingtank Fere the ballasted flocs rapidly settle and are removed from the treated

water via lamellar settling Laminar up flov through the lamellar settling zone

provides rapid and effective removal of the microsandsludge floc Clarified

water exits the ACTIFLO system via a series of collection troughs oc weirs for

subsequent filtration disinfecting and delivery to the distribution network

3 Sand Recirculation System

The ballasted floc sandsludge miture is collected at the bottom of the settlingtank and withdrawn using a rubberlined centrifugal surry pump The sand

sludge mixture is then pumped to the hydrocyclone for separation Lnergy from

pumping is effectively converted to centrifuga forces within the body of the

hydrocyclone causing chemical sludge to be separated from the higher densitymicrosand Once separated the microsand is concentrated and discharged from

the bottom of the hydrocyclone and reinjected into the ACTIFLO process for

reuse The lighter density sludge is discharaed out of the top of the hydrocycloneand sent for thickening or final disposaL

y

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2 DESCRIPTION OF EQUIPMENT

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A ACTIFLO Clarification System

The purpose of this section is to provide a functional description of each majorcomponent in the ACTIFLO Process

1 Functional Characteristics

The ACTIFLO system for Port Angeles WA has been designed to treat a raw

water flow rate of I 1 million gallons per day

2 General Description

The ACTIFLO clarifier consists of a coagulation tanlc with nixer an injectiontank with mixer a maturation tank vith mixer a settling tank with a sludgescraper lamellar tube modules effluent collection troughs chemical feed

equipment dry polymer preparation system and microsand recirculation circuits

with pumps piping valves hydrocyclones etc The system is monitored and

controlled via a PLC controf panel

3 Coagulation Tanks

Length 9 10

Width 7 8

Sidewater Depth 16 10

Detention Time 2 ininutes at nominal flow

This rapidmixing tank is used for the coagulation of raw water The coagulant is

injected directly into the raw water supply prior to entering the coagulation tank

The raw water enters side of the tank via pipe opening with flow directed to the

bottom of the tank

The coagulation tank is equipped with a mixer assembly consisting of a shaft with

an axial flow impeller a 5 HP TEFC motor a helical gear reducer and a constant

speed drive The shaft and impeller are made of 304 stainless steeL The motor

requires an electric power suppfy of 460 V 3 ph 60 hz The shaft is designedwith a key way to allow for adjustment of the impeller position

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4 Injection Tanks

Length 9 10

Width 7 8


Detention Time 2 minutes at nominal f7ow

Coagulated water flows from the coagulation tank to the injection tank where

flocculation is initiated through the addition of polymer and microsand The

polymer is injected into the tank along with the recirculated microsand via the

hydrocyclone underflow collection box The destabilized suspended solids then

bind to the microsand particles through polymer bridges creating extremely dense

floc

The injection tank is equipped with a miYer assembly consisting of a shaft with an

axial flow impeller a 5 HP TEFC motor a helical gear reducer and a constant

speed drive The shaft and impeller are made of 304 stainless steeL The motor

requires an electric power supply of 460 V 3 ph 60 hz The shaft is designedwitll a keyway to allow for adjustment of the impeller position

The injection tank can be drained via the 6drain located in the maturation tank

The concrete walkway above the injection tank has an access area that can be

used to enter the tank for inspection and maintenance purposes

5 Maturation Tanks

Length 13 9

Width 16 S


Detention Time 6 minutes at nominal flow

The water from the injection tank is a suspension of microsandbailasted flocs

This water enters the maturation tank through an opening at the bottom of the

common wall between the injection and maturation tank In this tank the

conditions of mixing allow for the optimal growth of a large amount of highdensity flocs which will settleqiickly in the settling tank

The maturation tanlc is equipped with a mixer assembly consisting of a shaft with

an axial flow impeller a 75 HP TEFC inverter duty motor a helical gear reducer

and a variable frequency drive The shaft and impeller are made of 304 stainless

steel The motor requires an electric power supply of 460 V 3 ph 60 hz The

shaft is designed with a key way to allow for adjustment of the impeller position

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The mixer is vertically mounted and its rotating speed can vary between 45 and

60I1z adjusted with a variable frequency drive for optimum floc formation

The maturation tank has a 6 drain with a mud valve controllable from the

concrete walkway above the maturation tank

The maturation tank is covered with concrete walkways and open areas for

process observation The open areas are also used to gain access into the

maturation tank for inspection and maintenance purposes

6 Settling Tanks

Length 16 S

Width 16 S


Rise Rate 20 gpmft Ntaximum at desibn flow

The settling tank is composed of a circular sandsludge scraper a sandsludgecollection pit lamellar tube modules and effluent collection troughs

The water from the maturation tank is a suspension of highdensity microsand

ballasted flocs This water flows Crom the maturation tank into the settling tank

where the ballasted flocs settle to the bottom fhe scraper continuously rakes the

sandsludge slurry towards the sandsludge collection pit located at t11e center of

the settling tank A center pit scraper is provided to keep the sandsludge slurryfiom compacting in the pit prior to bing removed by lhe sandsludge pumps

a Sludge collection pit

Located at the center of the bottom of the settling tank is a sludge collection

pit The bottom of the pit is covered with a stainless steel wear plate designedto prevent deterioration of the concrete due to abrasion The sandsludge slurryis continuously pumped from the bottom of the sludge collection pit

b Lamellar tubes

The settling tank is provided vith lamellar tube modules made of polystyreneThe lamellar tubes are inclined at an angle of 60 degrees with respect to the

horizontal axis They have a vertical heighc of 4 The modules are supportedfrom the bottom with a series of 304 stainless steel beams


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c Effluent Collection Troughs

Clarified water is collected in a series of stainless steel rectangular effluentcollection troughs located above the lamellar tube modules The collection

troughs are provided with adjustable rectangularnotch weirs which can beleveed to ensure equal distribution of the flow

7 Microsand Recirculation Circuits

The microsand is recirculated from the bottom of the settling tank back to the

injection tank This is accomplished through the microsand recirculation circuitEach ACTIFLO train is provided with one microsand recirculation circuit Thereis a common standby unit shared by the two trains Each microsand recirculationcircuit consists of 304 stainless steel piping 1 100 rubber lined sandslurrypump 1 suction side flush connections 1 isolation plug valve 1 dischargeside plug valve and l 1ow pressure switch There are two 2 hydrocyclones pertrain one duty and one standby

a Sand pumps

The sand pumps are centrifugal rubber lined slurry pumps with Vbelt drivesEach pump is provided with a 10 HP TEFC motor and a pumping capacity oCl 15 gpm at a discharge pressure of 3040 psi The impeller and the inside ofthe housing shell are rubberlined which is resistant to the microsand abrasionThe motor requires an electric power supply of 460V 3 ph 60 hz The sand

pumps are supplied with a hydrostatic seal but a minimum amount of sealwater must be fed to each pump at a sufficient rate to keep the packinglubricated

The sand pump must operate at a constant discharge pressure A suddendecrease in pressure may be caused by a blockage in the discharge or suction

piping To monitor this condition there is a lowpressure switch located at the

pump discharge If the measured pressure becomes too low the PLC will stopthe lead pump alarm the operator to the problem and the lag pump will startIf both the lead and lag pump pressure become too low the train will shutdown

b Hydrocyclones

The Krebs U6 hydrocyclones with an inlet orifice of22 sq in a vortex finderof 175 and an apex of 10 are completely molded in food grade urethane

Refer to Figure 2 Each train is designed with two 2 hydrocyclones The

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sandsludge slurry is pumped to the hydrocycones where the microsand and

sludge are separated The underflow from each hydrocyclone is then returned

to the injection tank

The hydrocyclones separate the sandsludge slurry by utiizing the force of the

feed stream generated by the sand recirculation pumps The hydrocyclone feed

creates a vortex effect that exerts a centrifugal force on the mixture of particlesThe microsand grains which are denser than the sludge particles are forced to

the outer wall of te hydrocyclone The sludge particles are discharged out of

the hydrocyclone overflow while the microsand is discharged by gravity out

of the underflow

Figure 2 Hydrocyclone Schematic Diagram

OVERFLOW

VORTEX

FINDER

FEED STREAM

I adiry t

cr f

APEX

ORIFICE

UNDERFLOW

8 Microsand

The microsand is NSF approved silica sand with an effective size of 134 150

m It is injected into the injection tank through the hydrocyclone underflow

The microsand serves as a seed for floc fonnation and increases the collision

frequency between particles which contributes to the short flocculation time in

the maturation tank In addition the microsandballasted flocs have a higherdensity and a much higher settling velocity than conventional floc thus hibh rise

rates can be achieved in the settling tank

Kruger recommended supplierManley Brothers of Indiana Inc

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PO BOX 8O

300 South Vermillion St

Troy Grove Illinois 613727741

Telephone1800237SAND or18155397486

Fax18155397741

The microsand for Port Angeles WA is Manley Brothers Grade 80

9 Coagulant

The coagulant is injected directly into raw water influent pipe The coagulantcauses particle destabilization by neutralizing the particles present in the raw

water Also by reacting with alkaline components in the raw water the coagulantwill form the precipitation of inetal hydroxides Both charge neutralization and

precipitation contribute to coagulation

10 Coagutant Metering Pumps BY OTHERS

Kruger lnc is not supplying the chemical feed systems for this project

11 Polymer Preparation System I3Y OTHERS

Kruger Inc is not supplying the chemical feed systems for this project

Figurc 3 Microsand floc

Microsand

Microsand Particle

Particle

FOCSMicrosand

Particle

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12 Polymer Metering Pumps BY OTHERS

Kruger Inc is not supplying the chemical feed systems for this project

B Control Panel

1 General

The electrical circuit of the control panel integrates the necessary functions for

fully automatic operation and equipment protection of the ACTIFLO process

The control panel gives the operator access to every mechanical component of the

system Moreover the control panel gathers the alarms of the system and warns

the operator of an equipment failure or problem

2 PLC Control Panel Description

Panel Type NEMA 12 Steel Panel with back panel

On the Face of the PaneL

Reset pushbuttonAcknowledge alarm pushbuttonOperator Interface

Inside panel120 VAC Surge arrestor

DC power suppliesAnalog isoation

Analog surge suppressionControl relaysPLC equipmentPLC Power supply24 VDC Discrete nput Cards

24 VDC Discrete Output Cards

Analog Output Cards

Analog Input Cards

Circuit breakers

Terminals

Ground Fault Circuit InterrupterEthernet Switch

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3 STARTUP OPERATION AND

MONITORING

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A StartUp

1 Preliminary verifications

Prior to system startup the operators must ensure that

all tanks in the ACTIFLO clarifier are completely cleanall tanks in the ACTIFLO clarifier are compfetely filled with water

the manual valves at the suction and discharge of the sandsluny recirculation

pumps must be fully openthe seal water for the sandslurry punps is functionalthe coagulant and polymer dosing equipment ie pumps valves etc is

operationalthe coagulant storage tank is full to sufficient capacitythe polymer solution is wellmixed and aged properlythe coagulant and polymer metering pumps are calibrated and adjusted to

provide the f7owrates required to obtain the right dosage in the system These

can however be adjusted once the system is operational

2 Debris removal from process tanks

If there is any debris left in the process tanks after the startup of the ACTIFLOsysten the debris may enter the hydrocyclones and clog the hydrocyclone apexIf the apex becomes clogged microsand will be forced out of the systemTherefore it is extremely important to ensure a debrisfree condition in the

process tanks before the system startup This includes nails screvs bolts

cigarettes concrete chunks and general construction debris The contractor

should drain the settling tank if necessary and inspect the tank bottom for debris

by physically climbing inside the tank and perforining a walkthrough As a tinal

check the following procedure should be followed to remove any smallsized

debris that may have been overlooked during the tank inspection and cleaning

1 Remove the apex of the hydrocyclone in order to allow the debris to flow

through the hydrocyclone

2 Place a fine screen in the hydrocyclone underflow collection box to remove

the debris

3 Run the system for at least 20 minutes

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3 Loading of microsand

The system is designed for a sand concentration in the injection and maturation

tanks of a minimum of2 6 gL Based on experience it is recommended that

800 pounds of sand per million gallons of capacity be added to initially charge the

ACTIFLO process Assuming that there is no sand in the system the initial

loading should be 55 MGD x 800 pounds or about4400 Ibs per train

PLEASE PERFORM REQUII2EMENTS OF SECTION3A2 BEFORE

INITIAL SAND LOADING

In actual operation some sand may settle in the corners of the maturation tank

Therefore the required sand amount may be higher than the above estimated

number Thus it is recommended that the above quantity of sand be added at

startup Then after 20 to 30 minutes of operation the concentration of sand

should be measured at east three times over a 30 minute period in accordance

with Section 3B2 The results should be averaged to estimate the actual

concentration Should additional sand be needed add in increments of 200 500

Ibs to increase the sand to the concentration desired After each sand additionwait 30 minutes and recheck the concentration in accordance with proceduredescribed above

B Normal Operation

1 Sand loss estimation

Microsand losses occur because tlle hydrocyclone recovery is not 00 efficient

As an eYample based on the estmated microsand loss of 3 mg1 per day per trainwe can estimate the mass M of microsand required to compensate these losses per

day

M 3 mg1 x 55 MGDtrain24 IbsMGD 55 MGDtrain132 Ibsdaytrain

On a weekly basis this is a loss of 924 Ibs for one train

Microsand is essential for the satisfactory operation of the process however it

does not require an accurate dose to operate correctly The latitude on the

microsand concentration in the process is significant and a 30o change in

microsand concentration is not detrimental to process performance

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Sand concentration monitorin

Although a minor amount of microsand is constantly discharged out of the

process and a sand concentration as low as 2 gI is sufficient for satisfactoryoperation of the ACTIFLO process the microsand concentration should alwaysbe maintained at recommended levels 2 6 gL Therefore the operators shouldmonitor the microsand concentration 23 times per day The concentration can

easily be estimated using the following method

a Sampling system concentration from sand recirculation pipe vertical

a VeriFy that each operatinb hydrocyclone has an uninterrupted conicald ischarge

b Obtain a 10002000 ml graduated mhoff Cone to take samples Fill the

cylinder as close to the 1000 ml or 2000 ml mark as possible ithout over

spilling Caution The 1000 ml cylinder may ill quickly and with force

c Allow the sample to settle for 3 minutes

d Record the volume of the settled sand V in ml along vith the total

sample volume T in ml See figure below

r

m T r

i

e Repeat steps b through d on the same recirculation line two more times

f Use the same sampling procedure as you did on the first hydrocyclone and

repeat steps b through d for all hydrocyclones in operation on the systemFor example if you have two hydrocyclones operating on a given systemyou should have six values for Is and six values for V

g To determine the concentration of sand in the entire system you must next

average all collected values of Us Also average all collected values of V

Now you can use the following two equations provided in section 3 and 4

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below to first determine Cm the microsand concentration in the

ACTIFLO system

Note For the most accurate determination of microsand in any givensystem the sampling procedure above should be performed three

times throughout a 24hour period Three separate values of Cm

should be averaged to determine one final microsand concentration

for the day It is also important to record and trend the Cnal dailyvalue of Cm to give indication of microsand loss over an extended

period of time

Hydrocyclone

Sample port

Sand pump

Imhoff cone discharge pipe

j J

s y

i jrj

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b Sand Concentration of sand recirculation piping

C Vm

xTrain

C Microsand concentration in tanks gLQ Microsandsurry recirculation rate gpm 1 15 gpmQTa Influent flow rate gpmN No of hydrocyclones in operationV Volume of sample collected in cylinder mL

V Volume of settled microsand mL

1700 Conversion factorBulk Densityb 17gmL x 1000 mLL

2 Sand addition

Microsand is to be added into the injection tank of each train Fine particles are

always present in raw microsand therefore it is normal that the turbidity of the

clarified water increases slightly following the addition of new sand

Note The sand concentration in the ACTIFLO system should bc

maintained within the recommended operating range of 3 to 6 gIIt should never be allowed to exceed 10 gI which could overload

the scraper Concentrations greater than 6 gI can increase the

sand loss rate out with the sludge by over loading the hydrocyclonebut will not harm the nrocess performance High sand

concentration vill naturally decrease over time until the 36 gIrnge is once again achieved

3 Hydrocyclones

Numerous factors influence the operation of a hydrocyclone The followinb is a

brief discussion of some factors influencing hydrocyclone operation The

operator is normally able to control these facors vhile the cyclone is operatin

a Feed solution

Ihe concentration of the hydrocyclone feed solution has a breat influence on

the microsand recovery of the hydrocyclone The more diluted the feed

solution the better the sand recovery through the hydrocyclone Thereforeeven though the system is capable of maintaining high sand concentrations in

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order to minimize the sand losses of the hydrocyclone it is not recommended

to overload the system with microsand

b Underflow

Normally the apex produces a 2030 degree cone discharge Under the

condition of extremely high underflow solid concentration the apex will create

aroping discharge Arope is an indication that the apex is not allowing all

of the coarse solids out and consequently some are being forced out the

cyclone overfiow In addition the operator must make sure at all times there is

no obstruction at the apex of the hydrocycones If the apex becomes cloggedmicrosand will be forced out of the system

c nlet Pressurc

The pressure at the inlet of the hydrocyclone should be approximately 20 to 30

psi to ensure an efficient microsandsludge separation

d Overflow

It is important to verify on a daily basis that there is no detectable presence of

microsand in the overflow of the hydrocyclone To do this the operator inust

take a sample of the overflow with a gradaated cylinder and measure the

microsand concentration following a settling time of one minute Normallythe presence of any significant microsand in the overflow should not be

detectable

e Clogging

There are four areas of a hydrocyclone that can hold debris and need to be

inspected if higher than expected sand usage rates are experienced They are

listed as follows

Note All four inspection arcas should be inspected regardless of findingdebris in other areas Multiple obstructions are possible

Apex Tin The apex tip is the most obvious area to notice if debris is presentAs described in our operator training presentation the underflow from the

hydrocyclone should be a uniform shape throughout the entire spray area

When a portion or the entire underflow spray pattern is irregular this is a goodindication of debris lodged in the apex tip Removal of this debris is done bytaking the hydrocyclone out of service and disassembling the lowest section o1

the hydrocyclone body and inspecting the interior portion for debris

Hydrocyclone Body Depending on the size of the obstruction it could be

lodged in any portion of the hydrocyclone body without showing any irregular

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underflow spray patterns The best way to inspect the body is to take the

hydrocyclone out of service by performing proper locktag out procedures ofthe sand pump that supplies slurry to the hydrocyclone to be inspected andremove the lower portion of the hydrocyclone body Inspect the removedsection along with the upper portion of the hydrocyclone body still attached

Any debris in these areas should be easy to remove Any debris found shouldbe identified and noted in case similar material is found in subsequentinspections If the same type of debris is responsible for reoccurringobstructions steps should be taken to nininize or eliminate the source andorthe entrance ofthis debris to the ACTIFLO process trains Once the

hydrocyclone has been inspected and all obstructions been removedreassemble the flange connection

Hydrocvclone overflowvortex finder Obstructions in the area will not

create irregular underflow spray patterns so higher than normal sand usage is a

good guide To inspect this area the hydrocyclone should be taken out ofservice by performing proper locktag out procedures of the sand pump that

supplies slurry to the hydrocyclone to be inspected and the overflov pipeshould be removed The overflow pipe is connected in two locations One is a

coupling on top of the vortex finder on the hydrocyclone The other is a clampconnected to the overflow piping which is connected to the overflow pipeheader This clamp does not need to be completely removed just loosened

enough to allow the overflow pipe itself to rotate Once there is a clear viewinto the vortex finder inspect for obstructions

Iydrocyelone Inlet Obstructions in the area will notceate irregularmderflow spray patterns so higher than normal sand usage is a good guide To

inspect this area the hydrocyclone should be taken out of service byperfonning proper locktag out procedures of the sand pump that suppliesslurry to the hydrocyclone to be inspected and the inFluent piping to the

hydrocyclone should be disconnected fi the inlet to the hydrocycloneDependinb on the method the hydrocyclone influent piping is assembled andthe entire inlet head of the hydrocyclone may need to be removed in order to

inspect the inlet area To remove the inlet head the overflow pipe should be

removed as described above in the vortex finder inspection process Once this

is done remove each of the bolts used to connect the upper portion of the

hydrocyclone to the hydrocyclone support stand Once these bolts are removed

and the influent and overf7ov piping are disconnected the inlet head assemblyshould be easily removed Once removed inspect the inlet chamber of the

hydrocycfone for debris

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4 Polymer dosing

The polymer is dosed into the ACTIFLO process at three different points the

injection tank the inlet ta the maturation tank and at the maturation tank baffles

Under certain conditions such as low raw water temperatures in the winter the

system may prefer a longer coagulation detention time The operators can control

the polymer split to deliver more polymer directly to the injectionmaturationtanks so that the coagulant would have more reaction time before reacting with

the polymer

The polymer stock solution and feed solution should not be prepared over the

recommend maximum concentrations which is 05 o 5 gI for the Ciba LT

series The in line dilution is a very important factor for the efficiency of the

polymer since it increases its dispersion into the ACTIFLO process

The optimum dose of polymer for the ACTIFLO process is adjusted in

accordance with three different parameters

Raw water turbiditySettled water turbidityFilter run time

The raw water turbidity is the factor with the most influence on the polymerrequirement After accumulating enough operation experience with different raw

water characteristics operators should be able to generateaturbidity matria

guide for polymer dosage control

5 Coagulant Dosing

The coagulant causes particle destabilization by neutralizing the particles presentin the raw water Also by reacting with alkaline components in the raw waterthe coagulant will form the precipitation of inetal hydroxides Both chargeneutralization and precipitation contribute to coagulation

The optimum dose of coagulant for the ACTIFLO process is adjusted in

accordance with the raw water turbidity and color After accumulating enoughoperation experience with different raw water characteristics operators should be

able to produceaturbidity matrix guide for coagulant dosabe control

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6 Calibration of Coagulant and Polymer posing Pums

Kruger did not provide the chemical feed systems for this project The

following section is included as a general guide for chemical feed pump

calibration however the equipment manafacturers recommended

guidelines should be followed

Calibration of the coagulant and polymer dosing systems is required to ensure that

the system will provide the required amount of chemicals The system must be

calibrated prior to startup and possibly abain if there is a significant increase or

decrease in average flow rate such that the current settings of the dosing systemwill not meet the expected peak or minimum dosage requirements

During system calibration the objective for diaphragm pumps is to first set the

pump stroke length manually This should allow change in the pump speedcontrol to cover the expected range of ra water Flow to be treated These

settings are usually determined at startup and may not need to be determined

again until a significant increase or decrease in the longtenn average dailyinfluent flow occurs For automatic dosing control via the PLC the pump

capacity must be determined at a predetermined stroke length setting at the 100

percent speed setting Capacities are determined manually using the manual

stroke length control knob and the manual pump speed control on the local

control panel and the calibration cylinder located at the metering pumps For each

combination of settings the time required to pump out a known volue of liquidfrom the calibration cylinder is recorded

The stroke length wili typically be set betveen 20 and 80 of its maimum

setting As a general rule of thumb select a stroke length that will allow the

metering piunp to run at 50 speed for the required dosage at the average dailyflow rate This should allow the PLC to automatically provide the requireddosage over the expected range of flows encountered on a daily basis The onlyinputs to the PLC that may need to be updated are the desired dosage and the

solution strength If the daily average flow changes significantly the proceduremay need to be repeated for a new stroke length settinb

The procedure is outlined stepwise below

1 Have a stopwatch and notepad available

2 Determine the metering capacity in milliliters per minute or gallons per hour

required to provide the expected dosage at the average daily Flow rate

3 Turn the selector switch for the pump on the local control panel to the HAND

position

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4 Manually select a stroke length via the knob on the metering pump

Depending upon the required metering capacity this will typically be between

20 and 80 of its maximum setting

NOTE Only adjust the stroke ength when the pump running

5 Adjust the speed control at the locai controi panel to its 100 setting6 Fill the calibration cylinder with chemical such as coagulant or polymer7 Ensure that all valves on the metering pump system are in the proper position

to allow the metering pump to draw chemical from the calibration cylinderand pump it to the ACTIFLO

8 The liquid level in the calibration cylinder should be dropping as it is pumpedout

9 Record the time required to pump a known volume of iquid from the

cylinder10 Shut off the metering pump by turning the selector switch to the OrF position1 l Calculate the metering capacity of the pwnp for the selected stroke length

using the following formula

QVTx60

Where

Q is the metering rate in milliliters per minute or gallons per minuteV is the volume in milliliters or gallons pumped from the cylinderT is the time required to pump the volume in seconds

NOTE At this point you may want to repeat Steps 5 through 1 1 at least once

to verify that you have estimated the pumping rate correctly

12 If the required metering capacity determined in Step 2 is between 40 and 60o

of the metering capacity calculated in Step 1 1 Go to Step I5

13 f the required metering capacity determined in Step 2 is less than 40 of the

metering capacity determined in Step I1 then increase the stroke lengthsetting If the required metering capacity is greater than 60 of the meteringcapacity determined in Step 1 l then decrease the stroke length setting How

much you increase or decrease the settinb depends upon how much that you

need to increase or decrease the metering capacity14 Go back to Step 6 and repeat through Step 12

15 Ensure all valves are returned to the proper position to allow the meteringpump to pump chemical from the storage tank to the ACI

16 Input into the PLC the calculated value for pump capacity Q at the current

stroke length setting and the 100 speed settingl7 Check and correct if required the input values in the PLC for required

dosage and solution strength

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18 Return control of the ACTIFLO system to the PLC and return the Selectorswitch at the local pump control panel to the AUTO position

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4 PERFORMANCE MONITORING

OPTIMIZATION AND TROUBLE

SHOOTING GUIDELINES

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A Process Performance Monitoring

1 Recommended noninclusive monitoring schedule

The process performance monitoring and analysis to be carried out at

minimum is as follows

Hourly Every Daily Weekly4 hours

Influent

Flowrate

Color

TurbidityAlkalinitypHTemperature

Effluent

Daily Total Flowrate

Color

TurbidityAlkalinitypH

E uipment VFD Fre uency

Maturation Mixer

Sludge Scraper

Scra er

Torque

Sand PumpsSeal Water Pressu Rate

Discharge Pressure

No Sand Spraying Out

HydrocycloncInlet Pressure 27 to 30 psiUnderflow Flowrate

Underflow Spray Pattern

Chemical Dosin

Alum Feed Rate and DosagePolymer Feed Rate and DosageAcid Feed Rate and DosageBase Feed Rate and Dosage

System Sand Concentration

2 to 6 g1 I

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B Optimization

The following outline describes the ACTIFLO system optimization procedure and treatment

considerations

1 Background and initial information

a Treatment Objectives

Removal ofturbidity color suspended solids and other parameters from

the influent raw water

Efficient usage of chemicals

Proper maintenance of ACTIFLO equipment

b ACTlFLO Optimization

The process used to identify and select the process variables and operatingparameters which give the best ACTIFLO perfonnanceTypical Process Parameters Variables

o Flow Rate

o pHo Coagulant type and dose

o Polymer type and dose

o Alkalinityo Temperatureo Time of day week month

o Etc

c Performance Criteria For Optimization

Parameters monitored could include

o Turbidityo Total Organic Carbon TOCo Color

o Algaeo Total Suspended SolidsIo Oil and Grease OGo Metals

o Trihalomethanes THMo Haloacetic acids HAA

cl Optimization Sequence

1 Determine the pH of Coagulation2 Optimize coagulant dose at the optimum pfI3 Optimize polymer dose at the optimum coagulant dose and pH

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e Other Considerations

Prior to optimization verify proper operation of all ACTIFLO related

equipment instruments chem feed etc

Change only one variable at a time

Wait a minimum of two hydraulic retention times before recording data or

making another changeRecord influent water data and perfornance for future reference when

similar conditions exist

2 Process parameter considerations

a Fully Formed Ballasted Floc Iilustration

j4o

i4

e 1C 1 i rtiz r

K 1t f 4j xt

1 it

fi zr

a S rx 3 i

s a 4 t a F

1 4rF r are Aa h 4 s

rJ s a

tr sa a i

b r Ei

V lb IIIla

py

ti

rT

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b Insufficient Polymer pose

Coagulated particles in the raw water will not fully attach to the microsand

to enhance settling and may result in carryover in the settling tank

Generally you will not see a well defned floc in the maturation tank

Pin floc carryover in the settling tank

c Insfficient Polymer pose Illustration

O i

i

jt

S3

S 0 l y12

33

Ya

3vI

43 m

is

e 9

w r sa ey d 3 p

h

Si wt r v f

w i Y

xi

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d Insufficient Influent Water Coagulation

Raw water particles not fully destabilized resulting in decreased settled

water qualityCloudy appearance in the settling tank

Clear ribbons or marbling not seen in maturation tank

e Insufficient Influent Water Coagulation Illustration

fI

e r 4m P Lc

Zt y

tE mS

xr

z

a u z a r s zA b r g z sv u

yt

ea R

3 k f v v 3ir s

n tirr uaru r

n 441

r a ull i

4 x fxR f Y j l

x L

u F Y

kwc

Y 1Y

sF 2r i

1llk E w y

t q q4fr A

gT f

y

c s

1t

iJx

e o ot

g T3

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f Low Microsand Concentration

High Effluent turbidityClear ribbons or marbling not seen in maturation tank

Potential floc carryover

Lower floc density in thematuration tank

g Low Microsand Concentration Illustration

A

A r

n sz

3

fr I as

4

S yt1 a 2

t

p T

F

g 4 g1 x

f a n Y 4 a 5 tr zZ t

s r ql sf x 7F Jii r 4

y

o YIF ti

r

rr

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3 Optimization procedure

a Step One

With a predetermined starting point based on prior treatment experienceset the initial parameters and let system operate for at least 2 hydraulicretention times

o Ex flow rate coagulant type and dose polymer type and dose pHRecord ACTIFLO process variables and performance criteria for bothinfluent and effluento Ex Time Flow Alkalinity plI urbidity color afgae TOC THM

etc

b Step Two

Select the process variable to be investigated Hold all other variablesconstant except this one

o Ex select coagulant dose for optimizationHold the flow rate polymer pH etc constant

Vary the coagulant dose increasing the dosage l0 or in 5 I 0 mgLincrements around the start pointIf increasing the coagulant dose improves the settled water qualitycontinue to increase the coagulant until treatment no longer improvesKee in mind that you will reach a point in which adding additional

coagulant may only slightly increase settled water quality and it may not

be beneficial to overdose chemicals the operator must determine whatthe best coagulant dosage will be

If increasing the coagulant dose does not increase treatment try loweringthe dosage until the optimal coagulant dose has been determined

Record the effect of the variations in coagulant dose on ACTIFLOPerformance

o Ex turbidity color albae TOC etc

c Step Three

Plot the effect of the process variable on ACTIFLO performanceIdentify and select the Optimum setting for the variable beinginvestigatedThis will be the point on the curve where the slope of the curve changes or

where the curve begins to plateau

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Illustration of Coagulant dosage optimization

PGTiFLO Pilol SWtly Wilzonville OR

Feb11 Mar10I00

Efect ofAUM Dose On Settled Water Turbidity Anionic Polymer

Rise Coagulant Polymer pH TurbidityRate

gpmsf Type mgl Type mgI Raw Coag Raw Settl

30 ALUM 3000 LT25 030 693 628 169 277

2000 696 638 165 122

1500 725 660 162 059

1200 750 709 166 056

1000 697 652 166 057

500 741 709 163 228

Raw Water NTU 162 169

300

zso Oplimum DosagePint

NTU 200

urbl

d

t50

n

w

a i o0

aso

o00

0 5 10 15 20 25 30 35

11um Oose mg71

d Step Four

Select the next process variable to be investigated Ex polymerHold the previously selected variable in this case coagulant dose at its

optimum settingHold all other process parametersNow vary the polymer dose increasing the dosage 10 or in 01 mgLincrements around its starting pointRecord the effect of the variations in polymer dose on ACTIFLO

Perfonnance

o Turbidity color algae TOC

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e Step Five

Plot the effect of the process variable on ACTIFLO performanceIdentify and select the Optimum setting for the variable beinginvestigated

Illustration of Polymer dosage optimization

Effect of Pofymer on Settled Water Turbidity Raleigh NC

Plow Rise Rate Coa ulant Pol mer H Turbidi NTU

m msf T e mL T e ml Raw Coa Raw Settled

22 20 Fe SO 75 LT22S 0OS 663 454 76 170

010 661 453 76 052

015 659 457 76 033

020 650 450 76 028

Turbitlity vs Polymer pose

1 8

Li6

I

1 4

z Optimum DosagePnini

Z o i

iv i

08

Fi

06 I

i04 I i

02i

i

00I

005 007 009 011 013 015 017 079

Polymer Oose mgl1

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Step Six

Repeat the previous variable optimization steps for any other parametersunder investigationExampleso pHo Microsand Concentration

o Microsand Size

o Polymer Injection Point Locationso Coagulant Typeso Polymer Types and Chargeso Alkalinityo Maturation Mixer Speed

Illustration of pH optimiztion

E ffe c t o f p H o n S e ttle d W a te r A p p a re n t C o lo r

2 8N o v0 1

Flow Rise Rate Coagulant Polyme pH ColorACU

gpm gpmsf lype mgL Type mgL Ra Co a g R a w 5 e t I e d220 20 f e iS O a 85 LT22 S 020 661 551 1 O S 1 0

6 6 7 4 7 7 9 5 56 6 4 4 1 7 9 5 7

a

C o 1 o r v s p Hio

g

6

Y

iUa

OplimumOperating Point

4 K

59

2a

0 E

4 0 0 4 2 5 4 5 0 4 7 5 5 0 0 5 2 5 5 5 0 5 7 5 6 0 0

pH

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C Trouble Shooting Guide

Problem Possible Cause Necessary Check Remedies

Elevated clarilied Change in raw water Check raw water quality I Perforni jar testing to

water turbidity quality predetermine the optimumcoagulant dosage and polymerdosage

2 Adjust coagulant dosage and

polmier dosage

Loss of coagulant Check coagulant dosage Resume normal coagulant dosing

Loss ofpolymer I Check polymer dosage Rcsumc normal polymer dosing

2 Check polymer diffuser to

verify thal thc polymersolution is delivering

Low sand I Check system sand l If sand concentration is less than 3

concentration concentration gI and there is no noticeable sand

loss increase sand concentration to

be within 3 6 gI range

2 If de sand concentration is 2 Ifsand loss is occurring remove

significantly lower than thc thc hydrocyclone ape and clean

normal range perform the out the obstruction Add microsand

following sand loss checkinb to increase sand concentration to 3

procedures 6 dIrnge

a Checkhdrocyclonc apex

to see if there is any

obstruction Corcing sand

ou of systemb Check hydrocyclone

overFlow to verify no

detectable presence of

microsand

3 Check to ensure tlat the 3 a Restart stopped Iiquipmentinjectionmaluration tank b After 30 minutes check sand

mixers and the sludge scraper concentration and adjustare operating correctl accordingly

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Problem Possible Cause Necessary Check Remedies

Scraper High 1 Check general mechanical 1 Refer to scraper suppliersTorque Alarm condition of scSaper and the Operation and Maintenance Manual

lubricating oil level of for remedy information

scra er

2 Check if a foreign object has 2 t will be necessary to drain the

fallen into the tank tank if the item cannot be fished

out

3 Check if the system is 3 If the system is overload with

overloaded with microsand microsand contact Kruger lnc

4 If the cause cannot be

determined do ot attempt to

restart it until the tank is

drained and cleaned

Low Pressure Pump inlet pipe Check pump inlet pipe to make Perform suctiot pipe flusltingAlarm for Sand clogging sure there are no obstructions proceduresPump Pressure a Close the disdiarge side plugSwitch valve

b Connect the flush line

c furn on water for continuous

five minutes

d Put the equipment back into

normal operatione Restart thc pump

Sand Leakage Mechanical Seal Check general mechanical Refer co pump supplicrsOperationfrom Sand Pump Failure condition of sand pump and Maintenance Manual for remedy

information

Sand Loss from Coss of Treatment Check tha chemical dosages are Resurne normal polyner and coagulantthe system correct and that chemicals are dosing

actually being iqjected into system

Clog in hydrocycione Check for underFlow blockage Ifobstruction is present remove apexunderflow tip clean replace and restart system

Loss of Make sure tnjectionMaturation Correct if failure exists and resume

lnjectionMaturation Mixers and Settling tank scraper is normal operationMixer and or Settting operating check ifshafts are

tank Scraper rotating clockwise

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J JAR TEST PROCEDURE

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A ACTIFLO Jar Test Procedure with Microsand for Dry Polymer

1 PreJar Testing Chemical Preparation Calculations and

Recommendations

l Prepare polymer solutions at 01 1 gL concentration as follows

Very slowly add 1 g of dry polymer to l liter of tap water in a container under vigorous mixingwith a mechanical mixer jar test mixer at 100200 rpm can be used to prepare the polymersolution Continue mixing for another 30 to 60 minutes until all of the dry polymer is dissolved

A new polymer solution should be mixed every 6 to 8 hours

Note Polymer solutions can be prepared in any volume and at any concentrationhowever for jar testing it is recommended that a 01 solution be used

The following table can be used to determine the amount of dry polymer to add to the dilution water

to obtain a given polymer concentration

Grams of Dry Polymer to Add to Obtain a Given PolymerVolume of Solution ml Cocentration

01 02 03

500 05 1 15

1000 1 2 3

2000 1 4 452 Polymer posing Calculations

Volume of Polymer to Add to Jar mTest Jar Volume ml x Desired Dosage mgL

Polymer Concentration x 10000

The following table can be used to determine the volume of prepared polymer to add to the test jar to obtain a

desired polymer dosage

Test Jar Polymer Milliliters of Pol mer to Add to Test Jar to Obtain a Desired Dosa e

Volume Concentration

m01 mL 02 mL 03 mL 04 mL 05 mL 06 mL

1000 01 010 020 030 040 050 060

1000 02 005 010 015 020 025 030

1000 03 003 007 010 013 017 020

2000 01 020 040 060 080 I00 120

2000 02 010 020 030 040 050 060

2000 03 007 013 020 027 033 040

3 Coagulant Dosing Calculations

Volume of Coagulant to Add to Jar mlTest Jar Volume ml x Desired Dosage mgL

Coagulant Specific Gravity x Coagulant Percent Activity x 10000

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4 Since jar testing with microsand is very rapid approx 5 minutestest it is recommended to run

only one jar at a time Therefore in order to ensure consistent raw water quality a largecontainer should be filled with raw water This container should be stirred each time before a

sample is taken for jar testing In this way testing can be performed while avoiding anyinconsistencies that can be caused by varying raw water characteristics

5 For best results test parameters in the following sequencea At optimum coagulant dose and pH from previous experience check the different polymers

at 020 mgI polymer to find which polymer works bestb With best polymer at 020 mgI and optimum coagulant dose try different pH of coagulationc With best polymer at 020 mg1 and optimum pH of coagulation try different coagulant

dosages to fine tune coagulant dose

d With best polymer at 020 mg1 and optimum coagulant dose try different pH of coagulatione At optimum coagulant dose pH and polymer type try various polymer dosagesie005010030 etc

2 Jar Testing Procedure

1 Fill a square beaker with raw water Typically 2000 or 1000 ml of raw water is used for jartesting

Note square beakers are recommended for jar testing round jars can be usedbut the results may not properly reflect actual ACTIFLO operation

2 Add 5 grams of microsand per liter raw water in the test beaker

a Add 5 grams for a 1000 ml 1 L sampleb Add 10 grams for a 2000 ml 2 L sample

3 At time 0 add the coagulant into the vortex around the shaft of the mixer in order to ensure

better and instantaneous mixing and mix at maximum speed 300 rpm for 20 minutes If plfadjuscment is needed add alkali before coagulant addition

Note

To ensure the desired pH of coagulation is achieved following coagulant addition it is

recommended to use a titration method to figure out the required amount of pHadjustment In a separate jar add the desired amount of coagulant into a raw water

sample and mix for 15 minutes Record the pH of the sample and record In the same

coagulated water samplejar add a specific amoint of p1 adjustment and mix After

about 30 seconds measure the pH of the solution once aain and record Continue to do

this until a correlation can be drawn between the amount of pH adjustment added and its

effect on the coagulated water pH This may require 5 10 attempts before a goodcorrelation can be drawn The following table shows the recommended pH ranges to tryfor the corresponding type of coagulant

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Coagulant Type pH Range Recommended Increments to Test

Aluminum Based 55 70 05 H units

Iron Based 40 70 05 pH units to begin and 02 pH units to

further o timize

If a previously established optimum pH of coagulation is know for the water source being

jar tested it is recommended to maintain this pH of coagulation through the jar tetirtgprocedure until an optimum polymer type and coagulant dose is established Once these

two chemicals have been optimized us to chart above to perform pH of coagulationoptimization If a pH is shown to perform better than established pH of coagulationmaintain this new pH andreoptimize the coagulant dose

4 At time 120 sec add polymer in the corner of the beaker in order to avoid wrapping of the

polymer around the shaft of the mixer and continue mixing at maximum speed 300 rpm for 15

seconds

5 At time 135 sec reduce the mixing intensity to approx 200 rpm and continue mixing for 45

seconds so that there is just enough energy to keep the microsand in suspension This is a critical

step in jar testing with microsand There needs to be enough mixing to keep the sand in

suspension but too much mixing could damage the microsand balasted floc

6 At time 180 sec stop all mixing and allow the floc to settle for 2 minutes

7 Sample settled water for turbidity TOC and any other parameters of concern

8 Repeat procedure for all dosages and parameters

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B ACTIFLO Jar Test Procedure with Microsand for Emulsion Polymer

1 PreJar Testing Chemical Preparation Calculations and

Recommendations

1 Prepare polymer solutions at 02 2gL concentration as follows

Very stowly add 2 milliliters of neat polymer to l liter of tap water in a container inder vigorousmixing with a mechanical mixer jar test mixer at 00200 rpm can be used to prepare the

polymer solution Continue mixing until the al of the polymer is incorporated into the water A

new potymer solution should be mixed every 6 to 8 hours

Note Emulsion polymer solutions can be prepared in any volume and at anyconcentration however for jar testing it is recommended that 02 solution be used

The following table can be used to determine the amount of neat polymer to add to the dilution water

to obtain a given polymer concentration

Milliliters of Neat Polymer to Add to Obtain a Given PolymerVolume of Solution ml Concentration

01 02 03

500 05 1 l 5

1000 1 2 3

1500 15 3 45

2000 2 4 6

2 Polymer posing Calculations

Volume of Polymer to Add to Jar mlTest Jar Volume ml x Desired Dosage mgL

Polymer Concentration x 10000

The following table can be used to determine the volume of prepared polymer to add to the testjar to obtain a

desired polymer dosage

Test Jar Polymer Milliliters of Pol mer to Add to Test Jar to Obtain a Desired Dosa e

Volume Concentration

m025 mgL 05 mgL 075 mgL 10 mgL 15 mgL 20 mg1L

1000 01 025 050 07 100 150 200

000 02 013 025 038 050 075 100

1000 03 008 017 025 033 050 067

2000 01 050 100 150 200 300 400

2000 02 025 050 075 100 150 200

2000 Q3 017 033 050 067 100 133

3 Coagulant Dosing Calculations

Volume of Coagulant to Add to Jar nlTest Jar Volume ml x Desired Dosage mgL

Coagulant Specific Gravity x Coagulant Percent Activity x 10004

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4 Since jar testing with microsand is very rapid approx 5 minutestest it is recommended to run

only one jar at a time Therefore in order to ensure consistent raw water qualityaarge container

should be filled with raw water This cantainer should be stirred each time before a sample is taken

for jar testing ln this way testing can be performed while avoiding any inconsistencies that can be

caused by varying raw water characteristics

5 For best results test parameters in the following sequencef At optimum coagulant dose and pH from previous experience check the different polymers

at 020 mg1 polymer to find which polymer works best

g With best polymer at 020 mg1 and optimum coagulant dose try different pH of coagulationh W ith best polymer at 020 mgI and optimum pH of coagulation try different coaguant

dosages to finetme coagulant dose

i With best polymer at 020 mg1 and optimum coagulant dose try different pH of coagulationj At optimum coagilant dose pH and polymer type try various polymer dosages ie005010 030 etc

2 Jar Testing Procedure

6 Fill a square beaker with raw water Typically 2000 or 1000 ml of raw water is used for jar testing

Note square beakers are recommended for jar testing round jars can be usedbut the results may not properly reflect actual ACTIFLO operation

7 Add 5 grams of microsand per liter raw water in Yhe test beakera Add 5 grams for a 1000 ml 1 L sampLeb Add 10 grams for a 2000 ml 2 L sample

8 At time 0 add the coagulant into the vortex aroind the shaf of the mixer in order to ensure

better and instantaneous mixing and mix at maximum speed 300 rpm for 20 minutes If pHadjustment is needed add alkafi before coagulant addition

Note o ensure the desired pH of coagulation is achieved followingcoagulant addition it is recommended to use a titration merhod to figure out

the required amount of pH adjustment In a separate jar add the desired

amount of coagulant into a raw water sample and mix for 15 ininutes Record

the pH of the sample and record In the same coagulated water sample jaradd a specific amount of pH adjustment and mix After about 30 secondsmeasure the pH of the solution once again and record Continue to do this

until a correlation can be drawn between the amount of pH adjustment added

and its effect on the coagulated water pH This may require 5 10 attemptsbefore a good correlation can be drawn The following table shows the

recommended pH ranges to try for the corresponding type of coagulant

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Coagulant Type H Range Recommended lncrements to Test

Aluminum Based 55 70 05 H units

Iron Based 40 70 05 pH units to begin and 02 pH units to

further optimize

If a previously established optimum pH of coagulation is know for the water source beingjar tested it is recommended to maintain this pH of coagulation through the jar testing

procedure until an optimum polymer type and coagulant dose is established Once these

two chemicals have been optimized us to chart above to perfarm pH of coagulationoptimization If a pH is shown to perform better than established pH of coagulationmaintain this new pH andreoptimize the coagulant dose

9 At time 120 sec add polymer in the corner of the beaker in order to avoid wrapping of the

polymer arolind the shaft of the mixer and continue mixing at maximum speed 300 tpm for I S

seconds

10 At time 135 sec reduce tlie mixing intensity to approx 200 rpm and continue mixing for 45

seconds so that there is just enough energy to keep the microsand in suspension This is a critical

step in jar testing with microsand There needs to be enough mixing to keep the sand in

suspension but too much mixing could damage the microsand ballasted floc

1 l At time 180 sec stop all mixing and allow the floc to settle for 2 minutes

12 Sample settled water for turbidity TOC and any other parameters of concern

13 Repeat procedure for all dosages and parameters

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6 MAINTENANCE

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A General Maintenance

1 Lamellar Tubes

Properly cleaned lamella tubes are essential for the proper operation of the

ACTIFLO process In order to properly maintain the tubes the followingcleaning procedures need to be performed

The frequency and duration of each cleaning procedure will vary dependingupon the raw water quality and the amowlt and types of chemicals used in the

ACTIFLO The following are recommendations on the frequency of each

lamella cleaning procedure

Estimated frequency to Estimated duration of

Cleanin Procedure erform rocedurc each rocedure

Type1 1 3 veeks 1 3 hours

Type2 2 6 weeks 4 8 hours

Type3 3 6 rnonths 8 12 hours

Type1 cleaning is done on an as needed basis depending upon the visual

appearance of the tubes However Type2 and Type3 cleaning should be done

regularly within the estimated time periods regardless of the appearance of the

tubes since material tnay get caughl on the bottoms of the tubes where it may not

be readily visible Also please note that rebularly performing Type l cleaningmay reduce the duration of Type2 and Type3 cleaning

Type1 Cleanin Procedure

To perform this cleaning procedure the influent flow to the train should be

stopped and the liquid level in the ACTIFLO settling tank should be drained

to a point that there is 2 3 inches of water above the tops of the tubes Once

this is accomplished the operator should use a water hose with no more than

40 60 psi of water pressure and spray off the tops of the tubes It is

important to ensure that all areas of tle tube tops are thoroughly rinsed

Following this cleaning the ACTIFLO hain can be placed back into service

Iype2Cleanin Procedure

To perform this cleaning procedw the influent flow to the train should be

stopped and the liquid level in the ACTIFLO settling tank should drained to

a point that is at least two feet below the bottom of the lamella tubes Once

this is accomplished the operator should use a water hose with no more than

40 60 psi of water pressure and spray off the tops of the tubes It is

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important to ensure that all areas of the tube tops are thoroughly rinsed

Following this the operators should clean out the tube sections that have

noticeable amount of flocculated material still contained in them following the

initial tube top cleaning Cleaning the lower portion of the tubes can be

accomplished by attaching a long piece of PVC pipe 12 to 34 in diameterto the head ofa water hose with a valve and use this apparatus to force the

flocculated material out For areas under the collection troughs andor scraper

support bridge a short section of pipe can be used to prod the individual

tubes Following this cleaning the ACTIFLO train can be placed back into

service

Type3 Cleanin Procedure

To perform this cleaning procedure the operator should perfortn the Bi

weekly procedures first and then clean the entire underside of the lamella

tubes This can be accomplished by shutting off the influent flow to the train

draining the ACTIFLO settling tank to the level that would allow a person to

waik around the bottom of the settlng tank and then hose off the material

collected on the bottom of the tubes by using a water hose with no more than

40 60 psi of water pressure

After iinishing this cleaning procedure it is recommendelthat the operatorinspect the underside of the lamella tubes to ensure all tube packs are still in

the proper placement are supported correctly and are not dainaged

2 Mixers

ensure that the drive remains cleancheck the oil Ieve1 in the drive on a regular basis

change gear oil every six months or2500 hours wllichever occurs first refer

to Mixer OM for exact instructions

grease bearings when changing oil

keep motors clean and drytighten terminal connections assembly screws bolts and nuts as requiredcheck insulation resistance of motors periodicallykeep external airway on aircooled motors clear as obstructions will restrict air

passagerefer to the Mixer Section of the Mechanical Operation and Maintenance

Manual for further information

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3 Scrapers

ensure that the drive remains clean

inspect oil level in the variable speed reducer every weekinspect all reducers every ten years or as indicated by gearbox manufactureroverhaul as requiredkeep motors clean and drytighten terninal connections assembly screws bolts and nuts as requiredcheck insulation resistance of motors periodicallykeep external airway on aircooled motors clear as obstructions will restrict air

passage refer to the scraper suppliers Operation and Maintenance Manual for

further information

4 Sand Pumps

refer to the Pump Section of the Mechanicaf Operation Maintenance Manual

for further information

ensure that the drive remains cleangland leakage should be checked periodically to ensure that adequatelubrication water is being provided to the sealtake oil sample every month and change when necessary

grease bearings monthly at a minimum

keep motors clean and drytighten tenninal connections assembly screws bolts and nuts as requiredcheck insulation resistance of motors periodicallykeep external airway on aircooed motors clear as obstructions will restrict air

passage

refer to the pump suppliers Parts List and Operating Instructions for further

information

5 Hydrocyciones

inspect cyclone on a monthly basismaintain smooth surfaces on the interior of the cyclonereplace parts when interior surfaces become worn or uneven

reptace apex tip when wear exceeds 18check cone for wear while replacing apex tip to make sure that internal

surfaces are smooth and a lip does not occtr

refer to the hydrocyclone section of the Mechanical Operation Maintenance

Mamal for further information

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B Intermittent Use Procedures

The purpose of this section is to provide information on the proper proceduresrequired when the ACTIFLO process is operated intermittently The ACTIFLOprocess has the unique ability to operate under repeated start and stop operationswithout effecting process performance or the equipment supplied with it This type of

operation is typical for the ACTIFLO process and provides the ability to

successfully treat events within 10 15 minutes of system startup The ACTIFLOsystem intermittent use procedures is described in the following pages as pertaining to

a single ACTIFLO train

1 Short Term StandBy Mode Wet Storage

StandBy Mode is defined as a shutdown where sand and water are retained in the

ACTIFLO system for purposes of keeping the system active and ready for an

event Nearly all ACTIFLO instalations use the wet storage standby mode

during offline conditions This method is recommended by Kruger in lieu of drysystem storage since it allows for fast system startup allows for all mechanical

equipment to be exercised under full loadbiweekly and does not require sand

removal from the system

The StandBy Mode consists of two parts

Flushing the system with clean chlorinated water

Kruger recommends maintaining a small 12 mgL CI residual in the processtanls fo prevent biological growth and provide added odor control Several

options exist for system maintenance following a shut down The system can

be flushed continuously with either a small flow of potable water or

chlorinated secondary effluentreuse water An intermittent flush may be on

option as well as long as a CI residual is maintained in between flushes

Iffieezing conditions are not expected the system can be drained down to a

level just above the lamella tubes A flush with potable water or chlorinated

secondary effluent may not be required if septic conditions or odor is not an

issue Minimal sand wiI be lost when the system is drained mainly in the

area directly around the drains

Biweekly exercisinb of the mechanical equipment

It is recommended that the equipment be exercised every 14 days for 30

minutes This keeps the gears and bearings freshly lubricated with oil and

grease and provides for onger equipment life The microsand that is

inventoried in the system will be unaCfected and will remain inventoried in the

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bottom of the process tanks During equipment exercising and system startupthe microsand will be readilyresuspended

2 Long Term Shutdown and Freeze Protection

If the ACTIFLO system will be out of service for periods longer than two

months Kruger recommends either of the following methods

1 Continuous cycle of a small flow of potable water treated secondary effluent

or nonpotable vater through the system This will allow for periodicexercising of the equipment and will control any odor or growth issues that

may arise

2 Complete drain of the tanks f desired all sand can be removed from the

system by bypassing the hydrocyclones and sending the sand pump dischargeto drain or a hopper Please keep in mind that the cost of sand is minimal on a

per ton basis

Freeze protection requirements vary by location Various methods are employedat existing installations Local site conditions operation frequency and

economics need to be analyzed in order to determine the best method of freeze

protection

A method of freeze protection which is common for ACTIFLO systems located

at existing wastewater plants is to continuously flow a portion of treated

secondary eFfluent troubh the system For remote site not located at the W WTPtreated reuse or potable water can be used as the flush

Another method of freeze protection that may be more benefcially in extreme

cold climates especially durinb the time period when the system is not eYpectedto run is to completely drain the system and store the equipment during the

winter months according to long tenn equipment storage instructions Prior to

draining the system the microsand can be easily removed from the system bysimply bypassing the hydrocyclones and sending it to the existing sewer system or

trash hoppec

3 Instrumentation Maintenancc

pH Meters Steps need to be taken to ensure that the pH probes are not

allowed to dry out Ihe plI meters supplied are the immersion or insertion

type so as lonb as the water surface elevation remains above the pH probesthis will not be an issue If the pII probes are to remain dry for any period of

time they should be placed in a container with distilled water For

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recommendations on proper long term and shortterm storage of the pHprobes please reference the manufacturersinstrument manual

Turbidity Meters The turbidity meters supplied are also the immersion or

insertion type It is recommended that each turbidity meter both influent and

effluent be cleaned and wiped down at the beginning of each shutdown

period This will help to prevent any type of biological growth or buildup on

the sensor Longterm storage of these instruments shall be in accordance

with the manufacturersrecommendations as stated in the instrument manual

4 Chemical Feed Maintenance

All chemical feed equipment should be flushed with water if it is not anticipatedthe system will be used again in the next few days This is easily accomplished on

all Kruger supplied chemical feed pump skids since they are supplied with a flush

water connection and each piup has a dedicated calibration column

It is a good procedure to operate all chemical feed equipment during the bi

weekly exercise If a dry polymer systen is used it is suggested that water is run

through the system and punps as opposed to polyner This will prevent the need

flushing and cleaning the polymer

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7 APPENDICES

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A ACTIFLO Process Controls Description

s

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I Kruger InC TELEPHONE 9196778310

401 Harrison Oaks Blvd FACSIMILE 9196770082

Ste 100

Cary NC 27513

ACTIFLO Process Controls DescriptionPort Angeles WA

The following descriptions will describe a Standard ACTIFLO train operation consisting of standard

instrumentation coagulation injection and maturation mixers a sandsludge scraper and microsand

recirculation pumps This document describes the operation instruinentation and equipment required fora single Standard ACTIFLO Train Additional trains may be added requiring additional

instrumentation and equipment but operation would be consistent to this description

Coagulant is added to the influent water through static induction or inechanical mixing prior to enteringthe coagulation tank The coagulated water then enters the coagulation tank Coagulant destabilizes the

suspended solids and colloidal matter in the influent stream Efficient inixing is provided in the

coagulation tank to thoroughly disperse the coagulant over a hydraulic retention time of approximatelytwo minutes The destabilized particles collide and begin early stage floc fonnation

The coagulated water then flows over a weir into the injection tank where flocculent aid polyiner and

microsand are added to initiate floc formation Here the combination of flash mixing and a hydraulicretention time of approximately two minutes allow for thorough incorporation of microsand and

polymer into the coagulated water The combination of microsand and polymer serve asaseed for

floc formation and development in the next process step

ACTIFLO treatment continues as water passes through the underflow passage from the injection tank

into the maturation tank Although chemical floc formation actually begins with the addition of polymerand microsand in the injection tank the majority of ballasted floc formation occurs during the

maturation process step Gentle mixing and increased hydraulic retention time of appreximately six

minutes provide ideal conditions for the formation of polymer bridges between the nlicrosand and the

destabilized suspended solids The large effective surface area of the microsand provides enhanced

opportunity for polymer bridging and enmeshment of microsand and floc already in suspension

The fully formed ballasted floc leave the maturation tank and enter the settling tank Here the ballasted

flocs rapidly settle and are further removed from the treated water via lamella settling Here laminar

upflow through the lamellasettling zone provides rapid and effective removal of the microsandsludgefloc Clarified water exits the ACTIFLO system via a series of collection troughs or weirs for

subsequent filtration disinfecting and delivery to the distribution network

The ballasted floc sandsludge inixture is collected at the bottom of the settling tank moved to the center

collection pit via a scraper mechanism and withdrawn using a rubberlined centrifugal slurry pump The

sandsludge inixture is then pumped to the hydrocyclone for separation Energy from pumping is

effectively converted to centrifugal forces within the body of the hydrocyclone causing the sludge to be

separated from the higher density microsand Once separated the microsand is concentrated and

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discharged from the bottom of the hydrocyclone andreinjected into the ACTIFLO process for reuse

The lighter density sludge is discharged out the top of the hydrocyclone and sent for thickening or final

disposal

10 Instrumentation

Description Signal Type Scale Resolution

Influent Turbidity Transmitter Analog 0 4000 NTU Hundredths

Effluent Turbidity Transmitter Analog 0 10 NTU Hundredths

PreCoagulant pH Transmitter Analog 014 Hundredths

PostCoagulant pH Transmitter Analog 014 Hundredths

Influent Flow Control Valve by others Analog TBD TBD

Influent Flow Transmitter Analog TBD Hundredths for

MGD Whole

Numbers for

GPM

Scraper Alarm Tor ue Switch Discrete NA NA

Scraper Cutout Torque Switch Discrete NA NA

Sand Pump 1 Low Discharge Pressure Discrete NA NA

Switch

Sand Pump 2 Low Discharge Pressure Discrete NA NA

Switch

20 Description of Opea

Equipment can be started manually at the Local Control Panels LCPs or Motor Control Centers

MCCs using the Hand position of the HandOffAutoHOA or Local position of the LocalOff

RemoteLOR selector switches For the remainder of this document only LCP and HOA will be

used to describe the various local controls Placing all respective equipmentHOAs in Auto enables

automatic sequence control of all respective equipment All startup sequences are described below

Where applicable SCADA controls can perform two modes of operation AutoManual when all

respective HOAselector switches are in the Auto position Each ACTIFLO train and its associated

equipment are controlled as an independent system by the PLC This Docuinent addresses the operationa single train Each additional train will follow the same controls description

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Should a maturation or injection tank mixer fail at any time during operation or startup the PLC willissue an alarm and will initiate the Shutdown Sequence No system shutdown is associated with a

coagulation mixer failure but the PLC will issue an alarm

Should the scraper fail at any time during operation or startup the PLC will issue an alarm and willinitiate the Shutdown Sequence Since the scraper will not be operational the Shutdown Sequence willconsist of the sand recirculation pumps running for the durations as described in section 40 Shutdown

Should a lead sand pump fail the PLC will issue an alarm and sequentially initiate operation of a lagpump if available If all sand pumps fail the PLC will initiate an immediate shutdown of all

equipment

If the maturation tank inixer injection tank mixer or scraper is reinoved from Auto at the LCP while thePLC is in automatic control of the ACTIFLO system the PLC will initiate the Shutdown Sequence As

long as one sand pump is in Auto at the LCP and has not failed the PLC will not initiate the shutdown

sequence though failure alarms may exist on other sand pumps

Manual control of the ACTIFLO process can be assumed by switching the HOA selector switches at

the LCPs to the Hand position for each piece of equipment

30 StartUp

Permissives to initiate the automatic start sequence are

HOA selector switches for all mixers scraper and at least one sand pump are in Auto

Mixers scraper ad at least one sand pump do not have existing fail alanns

If all permissives are present and no equipment alarms exist the OIT will display Train Ready Tlle

Startup Sequence can be initiated via the OIT

Note To prevent damage to the equipment the Train should have water in the tanks above the

mixer impeller elevations prior to Startup In addition the water level in the settling tank should

be greater than the NPSHR for the microsand recirculation pump

To start the train when Train Ready is displayed on the OIT the operator selects Train Start

The system displays Train Starting at the OIT The system then automatically cycles through the stepslisted below

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1 Lead Sand Pump Recirculation System Startup Initiated

a Start Lead Sand Pumpb If the Duty Pump Running signal not seen within 5 seconds issue alarm Sand Pump

Fail To Start

c If the Duty Pump Motor Overload has tripped issue alarm Sand Pump Fault

d If the Duty Pump Discharge Pressure is not within acceptable limits within 30 seconds

issue alarm Sand Pump Low Pressure

If a failure oceurs the lead pump will be locked out in the PLC and the system will shut down This is

due to the fact that there is one common backup pump but no automated valves to allow for the backuppump to serve either train

2 Lead Sand Recirculation Pump successfully started

a Delay 30 seconds

b Start the Settling Tank Scraperc If the Scraper Running signal is not seen within 5 seconds issue alarm Scraper Fail To

Start

d If the Scraper Variable Frequency Drive VFD has tripped issue alann Scraper Fault

If a Scraper failure occurs initiate a Shutdown Sequence

3 Scraper successfully started

a Delay 5 seconds

b Start the Maturation Injection and Coagulation tank mixers These mixer starts are

respectively staggered by 5 seconds

c If the Maturation Tank Mixer Running signal is not seen within 5 seconds issue alarm

Maturation Tank Mixer Fail To Start

d If the Maturation Tank Mixer VFD has tripped issue alann Maturation Tank Mixer

Fault

e If the Injection Tank Mixer Running signal is not seen within 5 seconds issue alarm

Injection Tank Mixer Fail To Start

f If the Injection Tank Mixer Motor Overload has tripped issue alarm Injection Tank

Mixer Fault

g If the Coagulation Tank Mixer Running signal is not seen within 5 seconds issue alann

Coagulation Tank Mixer Fail To Start

h If the Coagulation Tank Mixer Motor Overload has tripped issue alarm CoagulationTank Mixer Fault

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If a Maturation or Injection Tank Mixer failure occurs initiate a Shutdown Sequence No systemshutdown is associated with a Coagulation Mixer failure

4 All Tank Mixers successfully started

a Delay 5 seconds

b Start the Chemical Feed Pumpsb If the Duty Polymer Feed Pump Running signal is not seen within 5 seconds issue alarm

Polymer Pump Fail To Start

c If the Duty Coagulant Feed Pump Running signal is not seen within 5 seconds issue

alarm Coagulant Pump Fail To Start

d If the Duty Caustic Feed Pump Running signal is not seen within 5 seconds issue alann

Caustic Pump Fail To Start

e If the Duty Sulfuric Acid Feed Puinp Running signal is not seen within 5 seconds issue

alann Acid Pump Fail To Start

If any Duty Chemical Feed Pump is taken out of the AUTO position at the LCP while in operation the

standby pump shall be initiated The duty pump will not be locked out so when the pump is placed back

into the AUTO position it will resume operation Duty chemical feed pump alternation is manual onlyat the Operator interface panel

5 Chemical Feed Pumps successfully started

a Open the Influent Water Valve

The Operator will have the option to terminate startup at the OIT at any point in the sequence byselecting Train Stop If the startup fails at any point the sequence will initiate a train shutdown The

operator can correct the failure and then resuine the startup sequence from the current step

40 Shutdown

When in automatic the operator inay iinplement the Shutdown Sequence at any time at the OIT Duringshutdown the OIT will display Train Stopping

Train Started the operator selects Train Stop and the system displays Train Stopping at the OIT

The system then automatically cycles through the steps listed below

l Influent Valve closes

2 Shut down the Chemical Feed Pumps

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3 Shut down the Coagulation Injection and Maturation Tank Mixers

4 AfteraOperator Adjustable delay 1030 minutes shut down the Settling Tank Scraper5 After 5 minutes shut down the LeadDuty Sand Pump

NOTE This delay allows purging of sand and sludge contained in the settling tank and

piping andredeposits it back into the injection tank

The Operator can initiate the Train Auto startup sequence at the OIT at any point during the shutdown

sequence by selecting Train Start This initiates the immediate Startup Sequence of equipinent from

the current sequence step

50 Individual Equipment Operation

Coagulation Tank Mixer

Each coagulation tank is equipped with a constant speed mixer assembly consisting of a constant speedmotor gearbox output sllaft and hydrofoil impeller

Mixer operation is controlled through an HOA selector switch In Auto the mixer operation is

controlled by the PLC and will come on after the start sequence is initiated at the OIT and the duty sand

pump and scraper are verified to be running Operating statuses displayed at the OIT for the mixer are

Ready Running and Failure AReady status indicates that theHOA is in Auto no failures

exist and the mixer is available for operation from the OIT should a start sequence be initiated A

Running status indicates that the PLC has verified that a Run Signal is being received from the motor

starter AFailure status or condition occurs when the ACTIFLO system is in operation and the PLC

is unable to confirm a Run Signal or an overload condition exists IfaFailure condition occurs the

PLC will issue an alarm No shufdowns are associated with this mixer

Injection Tank Mixer

Each injection tank is equipped with a constant speed inixer assembly consisting of a constant speedmotor gearbox output shaft and hydrofoil impeller

Mixer operation is controlled through an HOA selector switch In Auto the mixer operation is


pump and scraper are verified to be running Operating statuses displayed at the OIT for the inixer are

Ready Running and Failure AReady status indicates that the HOA is in Auto no failuresexist and the mixer is available for operation from the OIT should a start sequence be initiated A

Running status indicates that the PLC has verified that a Run Signal is being received from the motor

starter AFailure status or condition occurs when the ACTIFLO system is in operation and the PLC

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is unable to confirm a Run Signal or an overload condition exists IfaFailure condition occurs the

PLC will issue an alarni and initiate the shutdown sequence Conditions that would cause the PLC to

initiate the shutdown sequence are

Loss of Motor Power which can result froin

o Loss of Electrical Service

o Motor Overload Device Trippedo Motor Disconnect Switch Off

HOA Selector Switch Reinoved From Auto Position

Maturation Tank Mixer

Each inaturation tank is equipped with a variable speed mixer assembly consisting of an inverter dutyrated motor gearbox output shaft and hydrofoil impeller

The operator can chane mixer speed at the OIT This only affects the speed when theHOAis in the

Auto position Generally the optiinum mixer speed is determined during start up and commissioningand generally it does not require to be changed during normal process operations When under Hand

control the mixer speed can be controlled by the operator at the LCP

Mixer operation is controlled through anHOA selector switch In Auto the mixer operation is


pump and scraper are verified to be running Operating statuses displayed at the OIT for the mixer are

Ready Running and Failure AReady status indicates that theHOAis in Auto no failures

exist and the mixer is available for operation from the OIT should a start sequence be initiated A

Running status indicates that the PLC has verified that a Run Signal is being received from the VFD

AFailure status or condition occurs when the ACTIFLO system is in operation and the PLC is

unable to confirm a Run Signal or a VFD fault condition exists IfaFailure condition occurs the

PLC will issue an alarm and initiate the shutdown sequence

Note The operator adjustable setpoint for the maturation tanlc mixer speed is 70 to 100 speed42 to 60 Hz

Conditions that would cause the PLC to initiate the shutdown sequence are

Loss of Motor Power which can result from


o VFD Fault

o Motor Disconnect Switch Off

HOA Selector Switch Removed From Auto Position

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Settling Tank Scraper

The scraper drive mechanism consists of a an inverter duty motor a gearbox a vertical rotating shafttwo truss rake arms with ralce blades and a center pit scraper During automatic startup via the PLC the

scraper will come on after the start sequence is initiated and 5 seconds after the duty sand pump isverified to be running With the HOAin Auto the scraper speed can be adjusted manually at the OITThis only affects the speei when theHOAis in the Auto position Generally the optimum scraperspeed is determined during start up and commissioning and generally it does not require to be changedduring normal process operations When under Hand control the scraper speed can be controlled by the

operator at the LCP

Note The operator adjustable setpoint for the scraper speed is 75 to 100 speed 45 to 60 Hz

The scraper drive is equipped with torque overload protection When the torque exceeds the continuous

operating torque the PLC will issue a warning alarm The torque monitoring device is also interlockedwith the scraper at the LCP and when the torque exceeds the maximuin operating cutout torque the

scraper will shutdown the PLC will issue a second alarm scraper fail and initiate the ACTIFLOshutdown sequence These alarm settings are field adjustable at the device however modification ofthese settings without consulting Kruger is not recommended and may void any warranty associatedwith the equipment

Scraper operation is controlled through an HOA selector switch In Auto the scraper operation iscontrolled by the PLC and will come on after the start sequence is initiated at the OIT and the duty sand

pump is verified to be running Operating statuses displayed at the OIT for the scraper are ReadyRunning and Failure AReady status indicates that the H0A is in Auto no failures zxist andthe scraper is available for operation from the OIT should a start sequence be initiated A Runningstatus indicates that the PLC has verified that a Run Signal is being received from the VFD AFailurestatus or condition occurs when the ACTIFLO system is in operation and the PLC is unable to confirma Run Signal or a VFD fault condition exists IfaFailure condition occurs the PLC will issue an

alarm and initiate the shutdown sequence




o VFD Fault

o Motor Disconnect Switch Off

Torque load equal or exceeding the Cutout Torque Limit settingHOA Selector Switch Removed From Auto Position

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Sand Recirculation Circuits

There are a total of 3 sand pumps provided Each train has one duty pump and they will share a

common standby pump The sand recirculation pumps are centrifugal rubber lined slurry pumps with V

belt drives The impeller and the inside of the housing shell are rubberlined or hard metal both of

which are resistant to the microsand abrasion The control scheme for microsand recirculation pump

operation is described below

One Duty One StandbyIn this configuration a duty pump plus a standby pump are supplied for each ACTIFLO process

train Only the duty pump runs during train operation The standby pump is changed to the dutyposition either if a duty pump failure occurs or the operator manually alternates the pumps at the

OIT Duty and standby pumps are alternated as described below

The lead sand pump will be altenlated by the PLC according to one of the three methods below

1 End of cycle The lead pump will be automatically alternated at the end of cycleShutdown Sequence to the next sequentially available pump Note This is the method

of pump alternation preferred by Kruger2 Manual alternation The operator selects the duty pump manually at the OIT

Note This method provides the ability for the Operator to switch sand pumps

without shutting down the system but does not purge the pump discharge lines as

recommended by Kruger

In the event of a dutylead pump failure the PLC will issue an alarm and the standby pump will be

alternated to dutylead status However the train will shut down upon failure of the lead pump The

pump circuits are supplied with manual valves so it will be the operators responsibility to detennine

the correct valve positions If both the duty and standby pump have failed the ACTIFLO PLC will

initiate an immediate system shutdown

Sand pump operation is controlled through an HOA selector switch In Auto the sand pump operationis controlled by the PLC and will come on after the start sequence is initiated at the OIT Operatingstatuses displayed at the OIT for the sand pump are Reaciy Running and FailureAReadystatus indicates that theHOA is in Auto no failures exist and the sand pump is available for operationfrom the OIT should a start sequence be initiatedARunning status indicates that the PLC has verified

that a Run Signal is being received from the motor starter AFailure status or condition occurs when

the ACTIFLO system is in operation and the PLC is unable to confirm a Run Signal or an overload

condition exists IfaFailure condition occurs the PLC will issue an alarm and initiate the shutdown

sequence

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o Motor Overload Device Trippedo Motor Disconnect Switch Off

Low Discharge Pressure At The PumpHOA Selector Switch Removed From Auto Position

The PLC will not attempt to bring any pump into service that is in a fail condition until the operatorresets the alarm If all pumps in a train enter into a fail condition the PLC will initiate an immediate

ACTIFLO shutdown

Each sand pump has a pressure switch installed on the discharge line This switch is input to the PLCwhich will stop the pump after a 30 second delay if the pressure is not greater than the preset ininimum

pressure field adjustable at the device If the pump is shut down by low pressure the control systemwill automatically shut down the ACTIFLO train If the pump is manually started in Hand at the LCP a

lowpressure condition will not shut down the pump and will not annunciate the alarm

Most alarms have associated time delays to allow the PLC todebounce the signal from the respectivealarm signal thus eliminating inadvertent shutdowns Only motor overloads or VFD fault indications do

not have associated time delays

60 Chemical Metering Pump Calculations and Control Descriptions

The ACTIFLO PLC calculates the chemical feed rates and controls the chemical metering purnps usingthe following procedure The chemical feed rate is based on

1 The influent raw water flow rate

2 The chemical dose

3 The physical properties of the chemicals

4 The capacity and settings of the metering pump5 The raw water turbidity

The influent raw water flow rate is obtained through tlle raw water flow meter which sends a signal to

the PLC

The influent raw water turbidity rate is obtained through the raw water turbidimeter and the coagulatedwater pH is obtained through the coagulated water pH meter

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The chemical dose physical properties and metering pump capacity are input by the useroperator intothe PLC

The basic equation for the chemical feed rate is

Chemical feed rateinfluent flow rate x chemical dose

stock chemical concentration

This equation is the general form for all chemical feed rates that use flow pacing control includingcoagulant caustic and polymer The specific equations with typical units are as follows

Coagulant feed rate equation

Q x 263 x 10 x Dci1e11 PercentActiveFeie1n Cci1e11 x SGeite1n x 1000ing x 1000nl1

CChem

1 O

Where

Qif Influent raw water flow to ACTIFLO MGD263 x 10 Conversion factor MGD to tnlminDcie Dose ofcoagulantacidcaustic required to treat The raw water mg1Ccie Concentration of stock coagulantacidcaustic solution to be fed mgIPercent Active Percent activity of the coagulantacidcaustic solution typically found on MSDS

sheetsSGcte Specific gravity of the coagulantacidcaustic solution typically found on MSDS

sheets ingmlFcien Flow of stock coagulantacidcaustic solution fed to ACTIFLO inlmin

Polynerfeed rate eyuation

Q 1iex 263 x 1 O x D M

FYC x 1000

CyV

i oi wae

Where

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Q Influent raw water flow to ACTIFLO MGD263 x 10 Conversion factor MGD to mlmin

Dp Dose of polymer required to treat raw water mg1

CP Concentration of stock polymer solution to be fed g1

M Mass of dry polymer used to prepare solution guwac Volume of water used to prepare polnner solution I

F Flow of stock polymer solution fed to ACTIFLO mlmin

Flow Pacing Control

The way the PLC uses these calculations to determine the chemical inetering pump output is

1 The chemical feed rate equations are programmed into the PLC by a Kruger instruinentation and

controls engineer2 The useroperator inputs the chemical dose physical properties and maximum chemical

metering puinp capacity at the OIT on the ACTIFLO control panel The PLC calculates the

specific chemical feed rate based on the useroperator inputs and the influent raw water flow to

the train

3 The calculated feed rate is then converted by the PLC into a percent speed based on the

maximuin capacity of the metering puinps This signal is then sent to the metering pump

Turbidity Pacing Control

Turbidity pacing control is in addition to the flow pacing control described above The turbidity pacingcontrol screen has a matrix that covers 5 different turbidity levels Each level has operator adjustabiesetpoints for coagulant polymer and the corresponding turbidity threshold For example level one may

have a coagulant dosage of 20 mgL and a polyiner dosage of 01 mgL with a threshold value of 20

NTU If the raw water NTU signal is greater than or equal to 20 NTU and less than level two the

coagulant and polymer dosages will be 20 and 01 mgL respectively If the raw water NTU is greaterthan the level two threshold value the con dosages shall be set by the operator setpoints for

level two

Flow Pacing Control Example

Assume

a You have a 0 to 40 MGD raw water flow meter

January 2009 j 2VEOIfAWATER

soia sraoFEs

e


401 Harrison Oaks Blvd FACSIMIE si960082

Ste 100

Cary NC 27513

b You have an ACTIFLO train running at 20 MGD

c The specific gravity of ferric chloride is 14

d The percent activity of the ferric chloride is 43

e The dose required is 15 mg1The maximum capacity ofthe metering pump is 5000 mlmin

The PLC calculation process is

a A 50 signal is sent to the PLC from the raw water flow meter

b The PLC converts this value to 20 MGD based on the predefined scaling of the raw water

flow meter 0 to 40 MGD 0 MGD 0 and 40 MGD 100c This 20 MGD value is input into the programmed chemical dosing equation in the PLC

d The programmed equation then calculates the ferric chloride feed rate required

PercentActive

Ca100

X SG x 1000mg g x 1000ml 1

CCa100

X 14ginl x 1000mgg x 1000ml1

C 602 000 m 1Coag

Q 1iex 263 x l O x D

co

FcoCco

20 MGD x 263 x 10 x 15 mg1F

602000 mg1

Fcoab 13106mlmin

e With the ferric chloride flow rate calculated by the PLC the PLC then calculates the pump

speed percentage based on the maximum pump capacity input by the useroperator

January 2009 13o VEOIIA

YtdAE R

seino 1zdomgEs



Ste 100

Cary NC 27513

Coagulant Pump SpeedFca

x 100PumpMax

Coagulant Pump Speed 13106mlminX 100

5000 mlmin

Coagulant Pump Speed 262

Once the pump speed is calculated the PLC sends a signal to the metering pump motor to

operate at that speed

January 2009 14ELAWATER

sisraoogts

KFUGER Actiflo OML Kruger Inc

SECTION 3

Mixers

CoagulationInjection Mixer

Maturation Mixer

Project 42470003 Port Angeles wA OVEOIAActiflo OM

warER

January 2009Solutions Technalogies

I Kruger Inc

401 Harrison Oaks Blvd TELEPHONE 9196778310

sw Ste 100 FACSIMILE 919

p Cary NC 27513

Project Name Port Angeles WA Project Number 42470003Date5108 Author MDCRevision 1 Equip Tag Number M411 M421

Coa ulation Tank Mixer S ecification Sheet

Manufacturer Philadel hia

Mig Model Number 4040Order Quantity Two 2Motor

T e 360230460HP 5

RPM 1750

EnclosureTy e IEFC

Service Factor 115

nsulation NEMA Class p

Gearbox

Gearbox Service actor I5

AGMA B10 Life 50000 hrs

Pedestal Mount Yes

Out ut RPM 56

Tank

To of Slab or Beam Height ft 185 el 24300Pad lus Grout Hei ht inch To beam

Total Mountin Height ft gs

Baffles No

Wetted Parts

Material of Construction 304 SS

No Im ellers i

Shaft Length inch 201

Shaft Diameter inchm eller Diameter inch 55

Im eller Distance from Bottoir inch 43

Additional Items

Pedestal bases includedOne set of bearings and seals required as a spare common for both coag and injectionmixersOne gallon of gear oil per mixer to be provided

I Kruger Inc


Ste 100 FACSIMILE 9196770082az r Cary NC 27513

Project Name Port Angeles WA Project Number 42470003

Date5108 Author MDC

Revision 1 Equip Tag Numbcr M412 M422

Inection Tank Mixer S ecification Sheet


Mfg Model Number 4040

Order Quantity Two 2Motor

T e 360230460

HP 5

RPM 1750

EnclosureType TEFC

Service Factor 11 S

Insulation NEMA Class F

Gearbox

Gearbox Service Factor 15


Pedestal Mount Yes

Output RPM 56

Tank

To of Slab or 3eam Hei ht ft 185 el 24300Pad plus Grout Height inch To beam

Total Mounting Height ft 185

Baffles No

Wetted Parts


No Impellers 1

Shaft Length inch 20l

Shaft Diameter inchIm eiler Diameter inch 55

Impeller Distance from Bottom inch 43

Additional Items

Pedestal bases includedOne set of bearings and seals required as a spare common for both coag and injectionmixersOne gallon of gear oil per mixer to be provided

INSTALLATION OPERATING AND

MAINTENANCE MANUAL

Project Name

Port Angeles WTP

Customer

i Kruger Inc

Customer PO No

27540

Equipment Tag No

Coagulation

PMSL Order No 42114

Serial No 08UDK01162

1221 East Main Street Palmyra PA 170789518

i j Phone 7178322800 Fax 7178321740

Q Philly OnCall Services18007331341

EMail phillyoncallaphilamixerscomwwwphilamixerscom

LtlT11VS


MAINIENANCE MANUAL

Project Name

Port Angeles WTP

Customer

I Kruger Inc

Customer PO No

27540

Equipment Tag No

Injection

PMSL Order No 42114

Serial No 08UDK01182


0jjPhone 7178322800 Fax 7178321740

y rr Philly OnCall Services18007331341EMail phillyoncallaphilamixerscom

wwwphilamixerscomP

iS

s F

e

TABLE OF CONTENTS

Service

Parts

Maintenance

Rigid Coupling

Impeller

Motor

Flexible Coupling

Drawings

m

3 P1fiI111X

Service

PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040SM 2 SECTION Introduction

Current INTRODUCTION PAGE 00

Volume 1 ISSUED 30 SEP 98

REVISION 30 APR 00

This Service Manual covers Philadelphia UniFirst 4000 Series Mixer Drives a high qualitymixer drive designed in accordance with the Standards of the American Gear Manufactur

ers Association Certain precautions and procedures however must be observed in

handling installing and servicing the mixer drive and accessories

This manual contains general installation operating maintenance and troubleshootinginstructions for your mixing equipment Also special instructions applicable to specificmixer drives may be included Should questions arise that are not covered additional

information can be obtained by contacting your local representative or Customer Service

at Philadelphia Mixing Solutions Palmyra PA Telephone 717 8381341 FAX 717 832

1740email philamixers@philadelphiamixerscomNOTE

All inquiries must be accompanied by the following information which can be

obtained from the nameplate on the mixer drive Mixer

Drive Size and Type or Model PhiladelphiaMixing Solutions Order Number Serial

Number Orders

for renewal parts must include description and part number shown on

parts list in addition to the above information See Parts Section of this

manual for specific parts ordering procedure and order form Copyright0

Philadelphia Mixing Solutions Specifications subject to change without notice

ISM ZOOOPHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040

SECTION SafetyCurrent SAFETY WARNING PAGE 200

Volume I mportant Safety Instructions ISSUED 15 SEP 98

REVISION 15 MAR 02

WARNING

In the installation operatiort and maintenance of gear drives SAFETY comes firstUse proper clothing tools and methods of handling to prevent serious accidentsThe safety precautions listed in this manual MUST be followed by all personnelworking on equipment otherwise serious injury may result

This manual lists a number of safety precautions Follow them and insist that those

working on this equipment do the same An accident is usually caused by neglect or

oversight

Adequate installation maintenance and safety instructions must be given by the user to

personnel directly responsible for the operation of the mixer drive and accessory equipment In addition the procedures set forth in the operating instructions must be carefullyfollowed

Guards alarms heaters and safety devices which may be furnished by Philadelphia MixingSolutions must be installed by the user

The user is also responsible for furnishing and installing any guards or other safety equipment needed to protect operating personnel as required by the Occupational Safety andHealth Administration OSHA Standards or other applicable safety regulations Thisequipment normally is not furnished by Philadelphia Mixing Solutions except when specifiedas part of the order In all cases however the user has the responsibility of complying with allapplicable safety regulations when installing the equipment

SAFETY PRECAUTIONS

TO AVOID SERIOUS BODILY INJURY OR POSSIBLE DEATHTHE FOLLOWING PRECAUTIONS MUST BE FOLLOWED

ONLY AUTHORIZED PERSONS MAY OPERATE THIS

Ii EQUIPMENTAdequate installation maintenance and safety

instructions must be given by the user to personnel directlyresponsible for the safe operation of the mixer or aerator and

accessory equipment In addition the procedures set forth in theService Instructions must be carefully followed Use qualified andskilled tradespersons to perform each work discipline when

installing inspecting or servicing this equipment All personnel mustbe required to remain a safe distance from rotating shafts couplingsimpellers clutches etc

Copyright0 Philadelphia Mixing Solutions Specificalions subject to change without notice

PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040ISM 2000 SECTION Safety

Current SAFETY WARNING PAGE 300

Volume I ISSUED 15 SEP 98

REVISION 15 MAR 02

READ SERVICE MANUAL BEFORE LIFTING OR MOVING

EQUIPMENTAttach lifting devices to the equipment only as directed in the

Service Instructions and only to designated lifting points Particular care must

be exercised to watch out for pinch or catch points in installation assembly or

disassembly Pieces should be supported to eliminate sudden shifting or

movement

DO NOT OPERATE UNLESS ALL SAFETY GUARDS AND DEVICES ARE

IN PLACE AND ADJUSTED PROPERLYThe user is responsible forr

furnishing and installing additional guards or other safety equipment neededv

to protect operating personnel as required by local or individual safetystandards or regulations This equipment usually is not furnished byPhiladelphia Mixing Solutions except when specified as part of the order In all

cases however the user has the responsibility of complying with all

applicable safety regulations when installing and operating the equipment

throughout the life of the mixer Guards alarms heaters and safety devices

which may be furnished by Philadelphia Mixers must be installed and

maintained by the user

LOCK OUT AND DEPRESSURIZE BEFORE SERVICING

EQUIPMEN7Before closely inspecting repackaging or replacing mixer

shaft seals in mixer assemblies for closed tank operation specialprecautions are mandatory Even if the gas or vapor contained within the

pressure vessel is innocuous rapid release of the pressure can cause bodily

injury or damage to equipment Plant standard depressurizing andor

decontaminating procedures for the vessel must be completed with adequatetime allowed for mixer and vessel to cool sufficiently for safety of service

personnei prior to starting work in mixer shaft seal area

DISCONNECT AND LOCK OUT THE PRIME MOVER AND ITS CONTROL

u CIRCUITS BEFORE INSPECTING OR SERVICING THIS EQUIPMENTDo

not connect the prime mover to its power source until all equipment isN

properly installed lubrication added bolts torqued and safety devices installed

and approved by qualified tradespersons Prior to servicing or closely

inspecting any mixer or aerator that has been installed and made ready for

operation or actually put into an operating mode disconnect and lock out

prime mover power source

DO NOT EXCEED DESIGN LIMITATIONSDo not operate sealingdevices above their rated temperatures or pressures specified on nameplatesor drawings Do not exceed any design limitations or make modifications to

this equipment without first consulting Philadelphia Mixign Solutions

Copyright0 Philadelphia Mixing Solutions Specifications subject to change without notice

PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040M 20 SECTION Service

Current SERVICE INSTRUCTIONS PAGE a00

Volume I GeneralissuE 15 SEP 98

REVISION 15 MAR 02

1 Any apparent or suspected damage sustained by equipment manufactured or fur

nished by Philadelphia Mixers during transport from the factory to the user should be

reported in writing immediately to both Philadelphia Mixing Solutions and the Carrier

2 Upon delivery all equipment furnished must be carefully inventoried against shippingpapers to determine whether any shortages exist in delivered materials Any such

shortages must be immediately reported in writing to both Philadelphia Mixing Solutions

Customer Service Department and the Carrier if a timely claim is to be made

3 The mixer has been protected for limited term storage Inspect mixer drive and anyother equipment furnished by Philadelphia Mixers for corrosion If corrosion is presentnotify in writing Philadelphia Mixing Solutions Customer Service Department

4 The installation of most mixers does not usually require the services of a factory engineer These services are not included in the selling price of the equipment unless

specifically agreed upon in writing between the seller and the purchaser In applications requiring a more complex arrangement of components consideration should be

given to the use of a factory engineer for construction supervision or inspection of the

installation These services are available from Philadelphia Mixing Solutions bycontacting our Customer Service Department

5 The Sellers Warranty applies insofar as the unit is operated within the rating and

service conditions for which it was specificaliy sold The purchaser must prevent the

existence of any destructive external conditions which might typically include vibratoryloads due to critical speeds severe shock loading mechanical or thermal overloads or

other conditions which may adversely affect the operation The mixer mst be installed

and maintained in accordance with instructions provided in this manual

6 In the event of malfunction within the warranty period Philadelphia Mixing Solutions must

be notified promptly in writing within thirty 30 days if it is intended that the warranty is to

cover the incident

7 Adequate installation maintenance and safety instructions must be given by the user

to personnel directly responsible for the operation of the mixer and accessory equipment In addition the procedures set forth in the operating instructions must be care

fully followed

8 Guards alarms heaters and safety devices which may be furnished by PhiladelphiaMixing Solutions must be installed by the user

9 The user is also responsible for furnishing and installing any guards or other safetyequipment needed to protect operating personnel as required by Occupationai Safetyand Health Administration OSHA standards or other applicable safety regulations In


ISM ZOOOPHILADELPHIAMIXINGSOLUTIONS TAB UniFirst4040

SECTION ServiceCurrent

SERVICE INSTRUCTIONSPAGE 500

Volume I GeneralISSUED 15 SEP 98

REVISION 15 MAR 02

all cases however the user has the responsibility of compiying with all safety regulationswhen installing the equipment

10Mixers equipped with electrical controi devices must be wired and checked for

proper operation

11Before startup all Philadelphia mixer drives must be filled with the type and gradeof oil specified

12A11 unauthorized personnel must be required to remain a safe distance from rotatingshafts couplings agitators etc

INSTALLATION

The basic mixer drive is shipped completely assembled Mating gears and pinions are

carefully assembled at the factory to provide proper tooth contact Nothing must be done todisturb this setting Single mechanical seals may be shipped with seal face apart Consultsection Shaft Seal Information for instruction on proper setting

HANDLING See Gearbox Handling Procedure Tab

When handling a UniFirst 4000 Philadelphia Mixer care must be taken to avoid supportingor lifting in a manner that would place excessive stress on parts that are not designed to

support the weight

The UniFirst mixer drive must be lifted with the three shoulder eyebolts provided at the topof the mixer drive The mixer must not be lifted by the motor eyebolt Lifting slings shouldbe used to distribute load evenly When using lifting slings exercise caution to avoid dam

aging any external piping or gauges

Never drag the mixer drive This will mar the machined mounting surfaces and may dam

age the housing

RUST PREVENTION

When the mixer drive is shipped the internal parts are protected with a film of rust preventive which protects the gear drive during shipment This film is soluble in the recommendedlubricant and does not have to be flushed before filling Inspect mixer drive and any other

equipment furnished by Philadelphia Mixing Solutions If corrosion is present notifyPhiladelphia Mixing Solutions Customer Service Department in writing immediately

CopyrightOO Philadelphia Mixing Solutions Specifications subject to change without notice


CurrentGeneral

PAGE s00


REVISION 15 MAR 02

PROLONGED STORAGE

If installation of the mixer drive and operation is to be delayed for more than one 1month after shipment see Section Long Term Storage Instructions The manufacturers

warranty on mixer drives held in prolonged storage must be covered by a special agreement reflecting the storage conditions In order to validate warranty storage must be as

per Long Term Storage Instructions

If prolonged storage is necessary it should be indoors and preferably in a dry area hav

ing a relatively constant temperature When outdoor storage is unavoidable mixer drivesshould be stored on their shipping skids and covered by a tarpaulin or an equivalentcovering Seal all openings with plugs vapor inhibitor paper or caps Also mixer drivesshould be filled to the proper level with a mixture of oil and vapor phase rust preventativeSee Long Term Storage Instructions Exterior exposed metal parts should be coatedwith a heavy duty rust preventive such as Houghton Cosmoline 1102 or equivalent

The mixer drives and any associated equipment must be inspected periodically to ensure

there is still an effective coating of rust preventative on the internal parts The coatingshould be replaced as required

Remove motor fan cover and rotate motor fan weekly to prevent the forming of flat spotson bearings and to refresh coating of gears and bearings with oil mixture Motor fans mustbe rotated until the output shaft completes one revolution Reinstall motor fan cover

SHIPPIIVG COVERS

All protective shipping covers must be removed from the mixer drive The shaft extensions and outside machined surfaces are protected during shipment by a rust inhibitingcompound This compound should be removed by using a solvent if the mixer is

equipped with a mounting flange gently scrape do not scratch clean the surface Use a

solvent or approved plant cleaner to remove any remaining residue

ACCESSORIES

Any field installed straight bore interference fit couplings must be installed carefully to

provide good contact on the driving keys as well as to prevent cocking on the shaft extensions Since an endwise blow on the shaft may damage gears and bearings theseattachments must not be hammered into position but heated to approximately 375F and

sfipped onto shafts

All electric control or monitoring devices must be wired and checked for proper operation

When prolonged storage is anticipated consult Philadelphia Mixing Solutions Long Term Storage Instructions for more detailed information



SECTION Service

Current PAGE 700

Volume I General ISSUED 15 SEP 98

REVISION 15 MAR 02

HIGH SPEED MOTOR COUPLING

The mixer has been shipped with a factory installed flexible high speed motor coupling Nolubrication or adjustment is required

RIGID COUPLING

In many mixer applications the fower agitator shaft as weil as the mixer drive output shaftare shipped with rigid coupling halves and impeller hubs fixed in their proper positionsBefore assembly in tank make certain that the rabbet faces of the rigid couplings are freeof all foreign matter nicks or burrs

FOUNDATIONS

The foundation must be rigid enough to maintain proper alignment with connected machin

ery The foundation must have a flat mounting surface to ensure uniform support for themixer drive If the mixer drive is installed on a surface which is other than horizontalconsult Philadelphia Mixing Solutions to ensure that design provides for proper tooth contact

and adequate lubrication

Customer designed fabricated pedestals or baseplates must be carefully analyzed to deter

mine that they are sufficiently rigid to withstand operating vibrations The mixer

support structure is to be designed so that dynamic angular deflection of the mixer islimited to 025 degree in any direction using the mixer support loads provided on theOutline Installation Drawing supplied with this manual

When installing the mixer drive on structural steel the use of a rigid baseplate is stronglyrecommended Bolt mixer drive and baseplate securely to steel supports with proper

shimming technique to ensure a level surface

If the mixer drive is to be installed on a concrete foundation allow the concrete to cure

properly before bolting down the mixer drive For best installation grout structural steel

mounting pads into the concrete base rather than grouting the mixer drive directly into the

concrete

LEVELING

When shims are used to level or align the mixer drive they must be distributed around the

base under all mounting pads to equalize the support load and avoid distortion of the

housing and high localized stresses

Use a feeler gauge to determine thickness of required shims All pads must be squarelysupported to prevent distortion of the housing when the gear drive is bolted down



Current PAGE 800

Volume I General ISSUED 15 SEP 98

REVISION 15 MAR 02

MOUNTING BOLTS

It is essential that the mixer drive be securely bolted to its foundation utilizing bolts of the

proper diameter to match its mounting holes Bolts should be SAE Grade5 or equivalentApproximate boit torque values are as foliows

Bolt Size Approximate Torque Value

Inches Foot Pounds

1 2 45

58 95

34 150

7 200

300

1 1 4 660

1 1 2 1060

Copyright0 Philadelphia Mixing Solutions Specifications subject to change withoul notice


Current PAGE 900

Volume I Lubrication ISSUED 15 SEP 98

REVISION 15 MAR 02

The UniFirst 4000 Series bearings are all oil bath lubricated The motor bearings are

grease lubricated

The mixer drives are shipped without oil They must be filled with the proper

lubrication before startup

The recommended type of oil for use in the UniFirst mixer drive is an extreme pressure

EP oil

Oil volume is approximately 5 gallonsAGMA Lube No Tem erature Ran e Lubricant

4 EP 15F to 50F Mobilgear0 629 or

9C to 16C Mobilgear SHCO 150

6 EP 50F to 125F Mobilgear 6320 or


Grease for bearings and Mobilith0 AW 2 or

seals when required Mobilith SHCO 220

v

FILLING MIXER DRIVE WITH OIL

1 The mixer drive can be filled with oil in 2 places the fill plug or the dipstickbreather2 Remove dipstickbreather from top of mixer drive housing and wipe clean

3 Fill mixer drive with recommended lubricant through breather hole Fill mixer until oil

level falls between the two lines scribed on dipstick Make sure dipstick is fully seated in

determining oil measurement Do not under fill or overfill The scribed lines representminimum and maximum levels

4 Install dipstickbreather

LOW TEMPERATURE OPERATION

Philadelphia Mixers must be advised if the mixer will be started up in temperatures less

than 10F above the pour point of oil used in the mixer Refer to oil manufactures data

sheet for pour point temperatures

OIL CHANGES

After the initial two weeks of operation of the mixer the original oil should be changed while

the equipment is at operating temperature CAUTION take necessary precautions when

handling hot oil This oil may be strained and used again Consult your oil supplier for

proper filter size Often due to the wearingin process small metal particles will appear in

the oil this is not abnormal

Flush the mixer drive housing thoroughly after the original oil has been drained Fill the

housing to the required level with SAE 10 straight mineral flushing oil Start mixer drive


PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040M2 SECTION Service

Current PAGE 1000

Volume I Lubrication ISSUED 15 SEP 98

REVISION 15 MAR 02

and bring up to operating speed preferably without load and immediately shut down

Drain flushing oil and fill with recommended operating lubricant to the proper leve Oil

should be changed after each subsequent2500 hours of operation or six months of

normal operation whichever occurs first

Unusual environmental or load conditions may require replacement of oil as frequently as 1

to 2 month intervals as determined by field inspection of the oil Special attention must be

given to the inspection of lubricants when the conditions exist

1 High operating temperatures resulting from heavy intermittent loads causing the

temperature of the mixer drive housing to rise rapidly and then cool

2 Ambient temperature conditions which could cause sweating on the inside walls of themixer drive housing

3 Operating oil temperatures that exceed 200 F

4 When the mixer drive is exposed to an unusually moist or dusty atmosphere or corro

sive or reactive vapors

SYNTHETIC LUBRICANTS

Synthetic lubricants have been used very successfully in mixer applications offering the

advantages of longer usable life better stability and operation over a wide temperaturerange In some cases installed in outdoor service summerwinter changeout of oil can beeliminated Do not misinterpret longer service fife for lack of attention Unless field experience with a specific synthetic lubricant is availble use must be closely monitoreu forbehavior in the presence of moisture and chemicals Use should be coordinated betweenthe user the lubricart supplier and Philadelphia Mixers

Only synthesized hydrocarbon fluids should be selected It should be high grade and

specifically formulated for industrial gear use It should be a nonreactive oxidation resis

tant formulation noncorrosive to gears and bearings It should have good defoamingproperties Viscosity should be equal to recommended oils shown in Synthetic Oil table

Synthetic Oil Oil volume is approximately 5 gallonsSummer Ambient 50 to 125F 10 to 50C AGMA 6S or ISO 320 Mobilgear SMC 2200Winter Ambient 15 to 50F 10 to 10C AGMA 4S or ISO 150 Mobilgear SHC 1500

After initial startup using synthetic lubricants sample lubricant after the first three 100 hour

periods of operation thereafter take samples every 2500 hours of operation or six monthswhichever occurs first Draw a onequart sample when mixeraerator is shut down and

analyze Change lubricant whenever sample reveais incipient deterioration

If changing from mineral oil to synthetic lubricant for best results flush mixer drive

Copyright0 Philadelphia Mixing Sofutions Specifications subject to change without notice


Current fPAGE 1100


REVISION 15 MAR 02

PRELIMINARY CHECKS

When starting up any new equipment it is best to proceed cautiously Even though the

installation instructions are followed the existence of errors or omissions is always possible Before initial startup review the following

1 Have all separatelypacked parts been installed Often it is necessary to packagesmall or fragile parts separately

2 Are mounting bolts secure Check all external bolts screws accessories etc to

ensure they have not loosened during shipment or handling3 Are all couplings installed on shaft extensions with keys and fasteners in place4 Has mixer drive been filled with oil to indicated level All mixer drives are shipped

without oil Before startup all Philadelphia Mixing Solutions drives must be filled with the

type and grade of oil specified5 Have all inspection covers on mixer drive been closed and secured

6 Have required electrical connections been made

7 Have required piping connections been made

8 Are all pipe connections tight Tighten all pipe connections to ensure they have not

loosened during shipment or handling9 Will impelter blades clear all tank projections when mixer is operating Manually rotate

the mixer impellers through 360 to check clearance

STARTUP PROCEDURE

1 If the mixer drive is equipped with a heater for low temperature operation turn on the

heater and allow oil temperature to rise to at least 40F

2 Start the mixer drive under as light a load as possible It is recommended that the

mixing assembly be initially operated without liquid in the mixing tank in order to

observe the direction of rotation and clearances of impeller blades

OPERATIONAL CHECKS

1 The mixer drive must be checked for unusual sounds excessive vibration excessive

heat or oil leakage If any of these problems develop the mixer must be stopped

immediately and the cause determined and corrected The operating temperaturemust not exceed 200F at any location in the mixer drive

2 If possible the mixer should be operated under a light load approximately halfloadfor one 1 or two 2 days to allow final breakin of gears After this period the mixer

can be operated under normal load



SECTION Service

Current Maintenance Instructions PAGE 1200

Volume I for a Ratio Change ISSUED 30 APR 00

REVISION 15 MAR 02

1 LockOutTagOut Procedure

a Open the disconnect on the motor control panelb Hang a lock and warning tag on the control panel handlec Try to start the motor If it starts there is a remote starter somewhere locate

it and lock it

2 Remove the bolts 224 and lockwashers 225 securing motor 220 to the highspeed cartridge Remove the motor 220 and high speed coupling 221 from the

input shaft Proceed to remove the hardware 142 and 143 securing the clamp ring141 to housing and set aside

3 Carefully remove the high speed cartridge 140 so as not to break the fange when

removing it off the dowel pin 146 Removel dowel pin 146

4 When replacing new high speed cartridge 140 refer to the drawing for proper location of the dowel pin 146 for that ratio

5 Carefully install high speed cartridge 140 so as not to damage the gearing Rotatethe high speed cartridge 140 to correctly mesh the tooth contact Reinstall the dowel

pin 146 into the correct hole Apply Hylomar Superflex or equal on the split to prevent oil leakage

6 Reinstall the clamp ring 141 and secure with the proper hardware 142 143 and

torque to specifications

7 Carefuliy turn the input shaft 152 by hand to be sure the mixer turns freely

8 Reinstall the high speed coupling 221 on the input shaft 152 and proceed to installthe motor 220 with correct hardware 224 225 and torque

9 Remove the lock and warning tag and proceed to just bump the mixer first Mixer isnow ready to go back into service

aCopyright0 Philadelphia Mixing Solutions Specifications subject to change without notice


SECTION Service

Current HS Cartridge Assembly PAGE o

Volume I for Varous Ratios ISSUED 30 APR 00

REVISION 15 MAR 02

Direction of

Rotation for Dowei Pin

Meshing Gears Holes

o For Ratio 1709

PLAN VIEW SINGLE pFor Ratio 1395

For Ratio 1139REDUCTION CART a For Ratio 93

p For Ratio 759

For Ratio 62R

0 For Ratio 506

t3t

I4

Use This Dowel Pin Hole

f O afor Single Reduction Cart

Q

0

i a

c PLAEJ

VIItV

HSG

TQI

c CGVEFa

o o

Q Use This Dowel Pin0

Hole for poublefl Q

Reduction Cartf

t3 qp

p

Direction of

Rotation for

PLAN VIEW DOUBLE O Meshing Gears

REDUCTION CART

For Ratios 2563

3844 5767 865

For Ratios 2093 Dowel Pin

3144708 7063 Holes


SM ZOOOPHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040

SECTION WarrantCurrent WARRANTY PAGE 1400


REVISION 15 MAR 02

For a period of one year after date start up or eighteen months after delivery to Customer whichever comes first Seller warrants that the products sold to Customer will be free from defects inmaterials and workmanship and will perform the paticular function for which they are intendedMixers and aerators are warranted to be fit to perform the function for which they are intendedwhen operated under the specified mixing or design conditions provided accurate and necessarydata have been furnished to Seller in writing by Customer Seller assumes no responsibility for theaccuracy or reliability of specifications design conditions or other furnished by or on behalf ofCustomer or the ultimate user Customer selected materials are warranted only to conform withCustomer specifications Materials not specified by Customer shall be Sellers standard materialsof construction for out of tank components Material exposed to process are not warranted againstcorrosion or other deterioration due to exposure to vessel contents

These warranties shall not be effective if the product or part is not used strictly in accordance withall instructions as to storage handling maintenance lubrication installation startup operation andsafety set forth in the manuals and instruction sheets furnished by Seller

The standards of the American Gear Manufacturers Association will be used and shall governwhere applicable in the manufacture of gears and gear drive assemblies unless Seller expresslyagrees otherwise in writing

The foregoing limited warranties are exclusive and are in lieu of all other warranties express andimplied including but not limited to implied warranties of inerchantability or fitness for a particularpurpose

LIMITATION OF REMEDIES

Customers remedy for breach of any of the forgoing warranties shall be limited to replacement or

repair by Seler oi any defective equipment or parts discovered during the 1 year warranty periodSuch products or parts shall be shipped to Seller FOB Sellers plant orFOB at such otherlocation as may be designated by Seller Seller shall have the right at its sole discretion to refundthe purchase price paid by Customer in lieu of repair or replacement Without limiting the foregoing under no circumstances shall Seller be liable for any expenses for removal of allegedly defective equipment or parts or for installation costs of repaired or replaced equipment or parts

All claims for breach of any Sellers warranties shall be barred unless Customer notices Seller ofsuch breach in writing within 30 days of discovery of the breach

LIMITATION OF LIABILITIESSeller shall not be liable for any liquidated consequential or incidental damages due to defects inmalfunctions or failure of its products to perform late delivery of loss of use nor shall Sellers totalliability under any circumstances exceed the purchase price of the products sold Seller shall notbe liable for any damage resulting from improper storage or handling following shipment Sellershall not be responsible for repairs performed by others outside Sellers plant unless such repairsare authorized by Seller in writing in advance Seller shall not be responsible for any defects in anycomponents such as gears shafts bearings or motors furnished by others

CopyrightO Philadelphia Mixing SolutionsSpecifications subject to change without notice

PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040ISM 2000 SECTION Shaft Handling

Current PAGE 1500

Volume I A9itator Shaft Lifting Procedure issuE 15 SEP 98

REVISION 15 MAR 02

Caution Only trained professionals experienced in the handling rigging and

lifting of heavy machinery should be employed to install or remove

mixer components

Warning Never lift the agitator shaft from the horizontal position with one end of

the shaft on the ground Lifting in this manner may bend the shaft asin Figure 1A

NOTE In certain applications the impeller hubs may have to be removed

from the agitator shaff prior to insfalling the agitator shaft into the

vessel

Handling and Lifting

Handling and lifting of mixer components like all heavy machinery can be dangerous and

proper methods may depend upon the particular instailation Philadelphia Mixers recom

mends that only trained professionals perform these tasks during installation or removal of

the mixers and assumes no responsibility for injury to persons or property that may occur

during these activities

1 Attach one lifting sling at or near the coupling at the top of the agitator shaft Use onlyproperly rated new nonmetallic slings See Outline Installation drawing for weights

2 Attach a second lifting sling approximately onethird of the length of the shaft from the

bottom See Figure 1 B

3 Lift the agitator shaft horizontally to a sufficient height so that the impeller end of the

shaft will not contact the ground when the shaft is moved into a vertical position

4 Continue to lift the agitator shaft from the coupling end sling only until the shaft is

vertical

5 When the agitator shaft is vertical remove the impeller end sling and use the couplingend sling to lower the shaft into the mixing vessel



SECTION Shaft HandlingCurrent Agitator Shaft Lifting Procedure PAGE 1600


REVISION 15 MAR 02

Figure 1A

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1Copyright0 Philadelphia Mixing Solutions Specifications subject to change without

notice


SECTION Gear Box Handlin

Current PAGE

Volume IRECEIPT AND HANDLING ISSUED 15 SEP 98

REVISION 15 MAR 02

Receipt and Inspection

1 UniFirst Series mixers are generally shipped bolted to a hardwood pallet Remove any

packaging material from around the mixer and carefully examine it for evidence of

damage during shipping If damage is found retain the damaged material and contact

Philadelphia Mixing Solutions ProTech Services at18007331341 for guidance

2 Inventory the equipment against the shipping papers to verify that the correct components have been received If any components appear to be missing contact Philadel

phia Mixing Solutions or your sales representative for guidance

3 Inspect the mixer drive and other components for evidence of rust or corrosion particularly if there are areas of chipped paint due to handling damage If corrosion is presentcontact Philadelphia Mixing Solutions ProTech Services at18007331341 for further

instructions



SECTION Gear Box Handlin

Current PAGE 1800

Volume I RECEIPT AND HANDLING ISSUED 15 SEP 98

REVISION 15 MAR 02

Caution Only trained professionals experienced in the handling rigging and liftingof heavy machinery should be employed to install or remove mixer components


Handling and lifting of mixer componentslike all heavy machinerycan be dangerousand proper methods may depend upon the particular installation Philadelphia Mixing Solutions recommends that only trained professionals perform these tasks during installation or

removal of the mixers and assumes no responsibility for injury to persons or property that

may occur during these activities

In addition the following general guidelines should be observed when moving or lifting themixer

1 Keep the mixer drive in the upright position

2 Never support the mixer by the output shaft

3 When the mixer is to be placed on the ground put blocks under the mounting surfaces

4 Never drag the mixer This will damage the machined mounting surfaces and could

damage the housing

5 There are eyebolts on both the mixer drive housing and the motor housing Do not liftthe mixer drive by the eyebolts on the motor housing Lift the mixer gear drive by the

eyebolts attached to the top of the drive housing Use lifting slings to distribute the load

evenly Make sure the slings are positioned so they do not place a load on external

components pipes gauges etc when the mixer is lifted

6 Never shock the mixer by snapping loose lifting rigging

7 Never lift a fully assembled mixer weighing over 1200 Ibs including the gear drivemotor agitator shaft and impellers Refer to Outline Installation Drawing for each

components weight

8 The 4040 mixer is shipped on two or more skids One skid will contain the mixer drivewhich is positioned horizontally or vertically and the other skids will contain the agitator shaft andor additional components Remove all shipping restraints Two hoists or

cranes are necessary to lift the mixer and agitator parts LIFT THE MIXER DRIVE BYITSELF DO NOT ATTACH THE AGITATOR SHAFT



SECTION Gear Box Handling

Current PAGE 1900

Volume I RECEIPT AND HANDLING ISSUED 16 MAR 01

REVISION 15 MAR 02

9 The mixer drive must be carefully lifted and positioned into a vertical position to be

installed correctly by using the three lifting eyebolts Using two shackles cables and

a nylon strap wrapped around the drivestand see picture lift the mixer drive usingtwo cranes When it reaches the appropriate height lower the crane with the strap Be

sure to support the mixer drive with the two shackles and cables Disconnect the strapand replace it with a shackle and cable Proceed to position the mixer drive in the

vertical position and locate on blocking Reposition allthree shackles and cables on

one crane for a correct vertical lift DO NOT USE THE EYEBOLT LOCATED ON THE

MOTOR FOR LIFTING PURPOSES

10 Lift and position the agitator shaft into the tank and secure the agitator shaft flangewith biocking Be sure two bolt holes 180 degrees opposite each other are acces

sible The face and tenon of all rigid couplings must be perfectly clean and free of

nicks Refer to Page 200 Shaft Handling

11 Carefully lift the mixer drive and lower it over the agitator shaft DO NOT ALLOW

THE COUPLING FACE TO MAKE CONTACT Insert two coupling bolts 180 degreesapart and carefully tighten them to engage the tenon and pull the coupling faces

together Insert the remaining coupling bolts and tighten being suretotorque thebolts to the value specified Remove the shaft blocking Refer to Page 200 Shaft

Handling

12 Lower the mixer onto the tank with the proper holddown hardware It is essential that

the mixer drive be securely bolted to its foundation utilizing bolts of the proper diam

eter to match its mounting holes Bolts should be SAE Grade 5 or equivalent Shear

blocks are recommended if gear drive has a heavy overhung load in a direction that

would place the bolts in shear Approximate bolt torque values are as follows

Bolt Size Approx Torque Value

inches Foot Pounds

1 2 45

58 95

34 150

78 200

1 300

1 1 4 660

1 1 2 1060


PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040SM 20 SECTION Gear Box Handling

Current PAGE 2000

Volume I RECEIPT AND HANDLING ISSUED 16 MAR 01

REVISION 15 MAR 02

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PHILADELPHIA MIXING SOLUTIONS TAB UniFirst 4040SM 20 SECTION Lon Term Stora e

Current PAE Z00

Volume 1 GENERALISSUED 15 SEP 98

REVISION 15 MAR 02

These procedures are designed to protect your mixers or aerators from atmospheric corro

sion or other harmful effects during storage or periods of inactivity The critical periods are

before the new mixer is ever run and prolonged idle periods thereafter

The storage instructions for gear drive protection can be valid for periods as long as two yearsfor equipment stored under best conditions Longer term storage is acceptable provided

necessary procedures are followed contact the Service Department of Philadelphia MixingSolutions for additional information Any costs for storage materials or labor required after shipment will be paid by the customer unless specifically contracted for by Philadelphia Mixers at

the time of purchase

Specific storage procedures to be followed are meant to maintain the Mixers or Aerators as

nearly as possible to their as shipped condition Failure to properly store and protect the

equipment as outlined may void any warranty either expressed or implied It is advisable

for the user to keep a detailed log to record the results of inspections and maintenance

performed on each Aerator or Mixer

We recommend that the gear reducers and motors be kept in a dry temperaturecontrolledindoor area We do not recommend outdoor storage There may be some instances where

indoor storage is impossible Storage of special equipment supplied by Philadelphia MixingSolutions such as motors control panels etc is to be in accordance with the manufacturers

recommendations included with this manual

Copyright0 Philadelphia Mixing Solutions Specifications subject lo change wiihout notice

PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040SM 2000 SECTION Long Term Storage

Current PAE z200

Volume I RECEIVING THE EQUIPMENT ISSUED 15 SEP 98

REVISION 15 MAR 02

1 Check impellers and impeller shafts for obvious shipping damage Should such

damage be found immediately report the details to the carrier that delivered the

equipment and the Philadelphia Mixing Solutions Service Department

Carefully move these components to a storage area where they will be least likelyto be damaged by contact with fork trucks etc Carbon steel components whether

painted or not should be protected Protective coatings against atmosphericcorrosion as applied for shipping should be checked for damage and renewed or

patched as necessary Periodic checks preferably at no more than 30day inter

vals should be made to assure that no rusting or other damage has occurred

Should such be noted corrective action should be quickly initiated Contact Phila

delphia Mixers Service Department for guidance2 Carefully check before putting drives into storage to assure that the plugs are

installed in place of breathers and all other openings to the atmosphere are

sealed

3 If the duration of storage in any of 3 environments to be defined in the followingwill not exceed six months for a newlymanufactured drive the gear reducer if

properly prepared will not require additional protective procedures Inspect the

drive to assure that longterm preservation procedures were applied at the factoryThis is indicated by a tag attached to the drive which will say This mixeraerator

has internal rust protection which is considered adequate under normal INDOOR

storage conditions FOR SIX 6 TO TWELVE 12 MONTHS from date of preservation application The date of the preservation application appears on the tag

PHONE 7178322800

FAX 7178328802

Philly OnCall Services18007331341


PHILADELPHIA MIXING SOLUTIONS TAB UniFirst 4040ISM ZOOO SECTION Long Term Storage

Current PAGE

Volume GENERAL ISSUED 15 SEP 98

REVISION 15 MAR 02

Field Application of Corrosion Protection

If field application of longterm internal corrosion protection to a miXer drive is necessaryfor any reason arrangements should be made with thePhladelphia Mixing SolutionsService Department for a factory representative to be on hand if possible while the

preservation procedure is carried out The first step is to inspect the drive to assure that a

damaging degree of corrosion does not exist If existing corrosion or other damage doesnot require attention proceed as follows

To coaf all internal surfaces with a protective compound such as HoughtonCosmoline 1902 fill the gear drive to its normal operafing level with the com

pound To insure complete coating the drive must be rotated using the electricmotor to splash all internal surfaces for one to three minutes Caution Onlvctualified electrical and mechanical personnel should perform this operationContact the factory if assistance is reguired Drain the excess rusfprevenfivecompound Sea all drive openings with plugs paper impregnated with vaporizing corrosion inhibitor caps etc

Further prepare the drive motor for storage as described by the storage location

according to the appropriate following procedures

Storing in 3 Types of Locations

Please note that there are 3 basic types of storage locations and environments forAerators and Mixers Storage procedures are different for each Use the procedurewhich applies to your drive

A Indoor Storage in a Dry TemperatureControlled Area

The preferred storage environment for Mixers or Aerators is a dry area with relativelyconstant temperature prevent condensation The use of a mechanical dehumidifyingsystem with controls to maintain the atmosphere at 40 relative humidity or lower is

recommended

If automatic humidity control is unavailable and conditions become extreme it may be

necessary to use trays of renewable desiccant such as silica gel or portable dehu

midifiers to remove moisture from the air in the enclosed storage area in order to

properly maintain necessary relative humidity levels

Each gear reducer should be stored in its normal operating position and then filled to

normal operating oil level with the recommended oil see Operating and MaintenanceInstructions for the specific Aerator or Mixer Add NoxRust VCI10 or equal volatile corrosion inhibitive oil at the rate of 2 of sump capacity added to the conven

tional oil used Replace oil fill plug when finished Assure that all other openings in


IS ZOOOPHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040

SECTION Lon Term Stora e

Current PAGE 2400

Volume I GENERAL ISSUED 15 SEP 98

REVISION 15 MAR 02

the gear drive are closed to the atmosphere Rotate shaft several times by removingmotor fan cover and rotating fan by hand Reinstall fan cover At six month intervalsdrain 2 of sump capacity and replace with NoxRust

If the furnished motors have motor heaters connect these to a proper power source

immediately upon putting into storage

Motor shafts in storage should be rotated at regular intervals We recommend 5 com

plete rotations of the shafts Foilow motor manufacturer recommendations for storageMotors supplied with breathers and drains must be inspected for operability Motor

bearings must be greased per instructions from the manufacturer of the motor supplied These recommendations have been supplied with this manual

B Indoor Storage No Temperature Nor Humidity Control

Motors must be stored with all breathers and drains operable and motor heaters if

any connected If motor heaters are furnished they must be connected to a properpower source upon placement in storage regardless of the duration of storage Covereach motor but do not seal it off as this might trap moisture

If no motor heaters are supplied motors must be securely wrapped in plastic withdesiccant bags placed inside Replace the desiccant bags at 30day intervals


plete rotations of the shafts Follow motor manufacturer recommendations for storageMotors supplied with breathers and drains must be inspected for operability Motor

bearings must be greased per instructions irom the manufacturer of the motor supplied These recommendations nave been supplied with this manuai

Each gear reducer should be stored in its normal operating position and then filled tonormal operating oil level with the recommended oil see Operating and MaintenanceInstructions for the specific Aerator or Mixer Add NoxRust VCI10 or equai volatile corrosion inhibitive oil at the rate of 2 of sump capacity added to the conven

tional oil used Replace oil fill plug when finished Assure that all other openings in the

gear drive are closed to the atmosphere Rotate Shaft several times by removingmotor fan cover and rotating fan by hand Reinstall fan cover At six month intervalsdrain 2 of sump capacity and replace with NoxRust

Product of Daubert Chemical Company Chicago IL


PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040

SM 200 SECTION Lon Term Stora e

CurrentGENERAL

PAGE 2500


REVISION 15 MAR 02

C Outdoor Storage Not Recommended

PROCEDURES TO FOLLOW WHEN OUTDOOR STORAGE IS UNAVOIDABLE

All Aerator or Mixer components must be kept off the ground Storage should be on

skids or platforms and protected with a tarpaulin or other waterproof covering If this

equipment is mounted for storage in its eventual operating location on top of tanks or

wastewater treatment basins the equipment should be protected by a tarpaulin or

other waterproof covering



If no motor heaters are supplied motors must be securely wrapped in plastic with

desiccant bags placed inside Replace the desiccant bags at 30day intervals


plete rotations of the shafts Follow motor manufacturer recommendations for storageMotors supplied with breathers and drains must be inspected for operability Motor

bearings must be greased per instructions from the manufacturer of the motor sup

plied These recommendations have been supplied with this manual


normal operating oil level with the recommended oil see Operating and Maintenance

Instructions for the specific Aerator orIllixer Add NoxRust VCI10 or equal vola

tile corrosion inhiitive oil at the rate of 2 of sump capacity added to the conven

tional oil used Replace oil fill plug when finished Assure that all other openings in the

gear drive are closed to the atmosphere Rotate Shaft several times by removingmotor fan cover and rotating fan by hand Reinstall fan cover At six month intervals

drain 2 of sump capacity and replace with NoxRust

NOTE In the event that the Aerafors or Mixers are fully installed and secured

in their eventual operating location with full power available and a standard

startup procedure possible revert to Operating and Maintenance Instruc

tions manual for filling each drive with proper lubricant and conducting a

thorough startup check and initial startup fo prepare the equipmenf for later

normal operation Having done this it is absolutely mandatory that each

Aerator or Mixer must be run twice a week for a period of one hour

Note once operated the corrosionprotective coatrng on drive internals has

been removed by operating with normal lubricant the internals are




SECTION Long Term StorageCurrent

GENERALPAGE 2s00

VOIUfYI@ I ISSUED 15 SEP 98

REVISION 15 MAR 02

now subject to atmospheric corrosion more than ever Experience hasshown that failure to follow the operatetwiceaweek instruction betweendate of installing and testing a drive and the start of continuous operationcan be the most critical period for potential damage by atmospheric corro

sive attack

From Storage Into Service

All applicable portions ofthe Operating and Maintenance Instructions should be re

viewed for special instructions relative to handling of the assemblies and storage procedures to follow for motors coupiings or special auxiliary equipment supplied in each

assembly

Preparing StoredAeratorsMixers for Service

1 Wipe off any dust and other accumulated dirt or grime from the exterior of each drive

assembly Inspect both interior and exterior of the gear drive for any rusting If rust or

other damage is noted contact Philadelphia Mixing Solutions Service Department

2 Remove motor coverings or wrappings and any desiccant bags that may have beenplaced inside the wrappings Be sure that motor breathers and drains are operable

Remove plugs from breather holes on gear drives and install the breather shipped withthe drive

CopyrightOO Philadelphia Mixing Solutions Specifications subject to change without notice

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SECTION PartsCurrent PAGE

Volume I4040 Common Parts Drawing ISSUED 15 SEP 98

REVISION 15 MAR 02

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CopyrightOO Philadelphia Mixing SolutionsSpecifications subject to change without notice

PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040ISM 2000 SECTION Parts

Current PAGE 5300

Votume 1 4040 Common Parts List ISSUED 15 SEP 98

REVISION 15 MAR 02

Spare Bubble Number Part Number Description Qty101 402000711 Housing 1

102 330003877 Hex Head Cap Screw 18

104 330003875 Lock Washer 18

105 330000158 Dowel Pin 2

106 310000136 Bearing Cone 1

107 310000136 Bearing Cone 1

110 404700989 Output Shaft 1


112 360002135 Oil Seal 1

120 401400399 Low Speed Gear Spider 1

121 401052157 ow Speed Gear 1

122 310000135 Bearing Cup 1

123 310000135 Bearing Cup 1

130 400850195 Low Speed Bearing Retainer 1


132 360000885 O Ring 1

133 402250755 Shim Set 1

140 400450396 High Speed Cartridge 1

141 400750025 Clamp Ring 1


143 330003875 Lock Washer 8

146 330000147 Dowel Pin 1

205 350000245 Pipe Plug 1

206 340002578 Shoulder Bolt 3

220 See Motor Data Motor 1

221 See Motor Data Coupling Hub 1

223 See Motor Data Motor Adapter 1

224 See Motor Data Hex Head Cap Screw 4

225 See Motor Data Lock Washer 4

226 See Motor Data Hex Head Cap Screw 8

227 See Motor Data Lock Washer 8

228 902550154 Pipe Nipple 1

229 350002192 DipstickBreather 1

230 350000241 Oil Drain Piug 1



SECTION Parts

Current PAGE 6200

Volume I 4040 Double Reduction Drawing ISSUED 15 SEP 98

REVISION 15 MAR 02

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CopyrightOO Philadelphia Mixing Soiutions Specifications subject to change without notice


Current PAGE 6500

Volume I4040 Double Reduction 3141 Parts List ISSUED 15 SEP 98

REVISION 25 AUG 05

Bubble Number Part Number Descri tion Qt140 400450394 High Speed Cartridge 1

145 310000472 Bearing Cup 1

147 310000472 Bearing Cup 1

150 403651405 Input Pinion Shaft 1

151 310000473 Bearing Cone 1

152 See Motor Data Key 1

153 Not Required Bearing Spacer154 310000473 Bearing Cone 1

160 400450395 Input Cartridge 1


162 402250758 Shim Set 1

163 310000472 Bearing Cup 1

170 404251361 Intermediate Pinion Shaft 1

171 340002565 Key 1

172 401052160 High Speed Gear 1

173 403151338 Bearing Spacer 1

174 310000473 Bearing Cone 1

175 310000473 Bearing Cone 1

180 400450395 Cartridge Bearing 1


182 402250758 Shim Set 1

183 310000472 Bearing Cup 1

221 See Motor Data Coupling Hub 1

222 See Motor Data Coupling Spacer 1

SPARE 1212540402 Rebuild Kit 1

Copyright0 Philadelphia Mixing Solutions Specifications subject lo change without notice


Current PAGE s00

VOIU111e I Mofor Parts 180 C Parts List ISSUED 15 SEP 98

REVISION 15 MAR 02

Refer to page 3 of the Parts Section for the drawing 4040 Common Parts

Bubble Number Part Number Description Qt

152 340000053 Key 1

220 Consult Factory Motor 1

221 323001173 Coupling Hub Input Shaft 1

221 320000109 Coupling Hub Motor 1

221 320000438 Coupiing Flex Assembly 1

222 403151343 Coupling Spacer 1

223 400050204 Motor Adapter 1


225 330001050 Lock Washer 4


227 330001012 Washer 8

CopyrightO Philadelphia Mixing Solutions Specifications subject to change without notice

PHILADELPHIA MIXING SOLUTIONS TAB UniFirst 4040ISM 2000 SECTION Parts

Current PAGE 13000

Volume 1 PTO DS 25 30 Drawing ISSUED 15 SEP 98

REVISION 15 MAR 02

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PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040M 2000 SECTION Parts

Current PAGE 13100

Volume IPTO DS 25 8 30 Parts List ISSUED 15 SEP 98

REVISION 15 MAR 02

Bubble Number Part Number Description Qty110 404700989 Output Shaft 1

301 800000008 Coupling Adapter 1

302 330003883 Socket Head Cap Screw 6


314 806150547 Drive Stand 1


317 330004020 Lock Washer 8


320 330001107 Lock Washer 8

321 330001113 Flat Washer 8



CurrentpARTS

PAGE 5000


REVISION 15 MAR 02

Parts Order Procedure

This manual includes the information necessary to assist you in ordering replacement parts for

your Philadelphia Mixing Solutions UniFirst Mixer Drive Please use the followirg procedure for ease

in meeting your mixer parts requirements

The parts order procedure will be simplified if you use the following 3 reference materials

included in this manual

1 Parts QuoteOrder Form

2 Parts List

3 Drawings bubble

Find a copy of the Parts QuoteOrder Form on page 2 of this section Please make a copv

of this form for your transmittal

Use the Parts QuoteOrder Form when requesting quote information from PhiladeiphiaMixers Upon completion of all information this form can be used as an order submittal

along with a copy of your authorized purchase order form

Please fill in the serial number order number model customer name requisitioner return

fax number and all information for parts required bubble item description and quan

tity requested Fill in this information completely for easy cross reference to the specificpiece of equipment

The identification information for the particular mixer drive referenced can be found on the

Outline installation Drawing cover page of this manual andor the nameplate attached to

the mixer drive

This manual has a complete parts list for your specific gear drives and related accesso

ries to assist you in ordering replacement parts

Bubble number drawings are enclosed for your reference Use these for easy identification

of the required replacement parts

s Please make any notes or comments on the bottom of the Parts QuoteOrder Form bottom

in the space provided

Upon completion of all information FAX the Parts QuoteOrder Form to your local sales

representative or the Parts Department at Philadelphia Mixing Solutions at7178321746 for

your quote and delivery schedule Your quote will be returned as soon as possible so you can

proceed with your order processing Remember this form can then be used as an order sub

mittal along with a copy of your authorized purchase order form



CurrentQuofeOrder Form

PAGE 5100


REVISION 15 MAR 02

QUOt@

Serial Number Customer

Order Number Requisitioner

Model Return Fax Number

Fax to Philadelphia Mixing Solutions Parts Sales 717 8321746

or Fax to your local sales representative

Bubble Part Number Description Qty Price Each Total Price Delivery

NotesCommentsCustomer

NotesCommentsPMSL


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Mintenance


SECTON Maint Trouble

CurrentMAINTENANCE TROUBLESHOOTING

PAGE 200

Volume i ISSUED 15 SEP 98

REVISION 15 MAR 02

Preventive Maintenance Schedule for UniFirst Series Mixers

PM Interval Required Preventive Maintenance

Daily Inspect mixer drive for unusual sounds or oil leaks

Weekly Check oil level on dipstick Mixer must be off

Record level and add oil as necessary

Monthly Check oil for contamination

Check operation of guards alarm systems gaugescontrols and other safety devices in accordance withOwners Plant Safety Operating Procedures

Six Month or 2500 Hour Intervals Refer to Motor Service Instructions for GreasingInstructions

Change oil in mixer drive

Inspect impeller for evidence of erosion and

corrosion

Check hardware tightness Retorque to originalspecifications

Extended Shutdown Periods See appropriate Long Term Storage InstructionsGreater than 1 Week Run mixer for approx 1 hour twice a week to coat

gears and bearings with oil and to prevent rust due

to moisture condensation

Note These Philadelphia Mixing Solution Procedures are for mixers installed in theirnormal operating position See Philadelphia Mixing Solutions LONG TERM STORAGEINSTRUCTIONS for additional information on storage of mixers


PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040SM ZOOO SECTION

Current MAINTENANCE 8 TROUBLESHOOTING 28100Trouble

PAGE


REVISION 15 MAR 02

TROUBLESHOOTING

Warning Lock out the mofor and remove all external oads before servicing the mixer

or accessories Refer fo the safety precautionsTrouble What to Inspect Action

Motor Determine whether the specific gravity or viscosity of the

Overload process has changed from that originally anticipatedInspect impellers for material buildupHave additional baffles been added to the vessel or the

size of the baffles increased

Check for proper impeller rotation as shown on the outline

installation drawingCheck the outline installation drawing for proper impellerlocation and proximity to intank appurtenances

Overheating Oil level too low Shut off mixer and check the oil level on dipstick

Breather Breather must be open and clean Clean breather

regularly

Grade of oil Oil must be of the grade specified in the lubrication instruc

tions If it is not flush mixer and refill with the correct gradeof oil

Condition of oil Check to see if the oil is oxidized dirty or of a high sludgecontent Flush and change the oil per the lubrication instruc

tions

Stuffing box Stuffing box gland must not be overtightened See

if supplied Packing Procedure for proper packing and breakin Included if applicable

Are bearings prop Adjustable tapered bearings must be set at proper lateral

erly adjusted ClearanCe or preload Call Philadelphia Mixing Solutions ProTech

Services18007331341 Emaii protech@philamixerscomRust

formation in Make necessary provisions to prevent entrance of water mixer

due to the Use lubricant with good rust inhibiting properties Make sure entrance

of water or oil level is correct See Long Term Storage Instructions humidity

Are

bearings and Abrasive substance will cause excessive gear and bearing gearsexposed to an wear Make necessary provisions to prevent entranceof abrasive

substance abrasive substance Clean and flush mixer drive thoroughlyegdusty atmo and refill with new oil Revise maintenance practices to sphere

include more frequent oil changes Copyright0

Philadelphia Mixing Solutions Specifications subject to change without notice

PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040SM 20 SECTION Maint Trouble

Current MAINTENANCE TROUBLESHOOTINGPAGE 2s00


REVISION 15 MAR 02

Trouble What to Inspect Action

Noise Coupling wear Check input coupling for wear Replace if worn


erly adjusted clearance or preload Call Philadelphia Mixing Solutions ProTech

Services18007331341 Email protech@philamixerscomAre

bearings and Shut off mixer and check the oil level on dipstick gearsproperly Oil must be of the grade specified in the lubrication instruc lubricatedtions If it is not flush mixer drive and refill with the correct grade

of oil Hardware

tight Be certain that all mounting and coupling hardware is enedtightened to the correct wrench torque Mixer

support Does the mounting arrangement for the mixer provide structuresufficient support to prevent wobblingor vibrationof the assembly

See Outline Installation Drawing for criteria Vibration

Agitator Shaft Agitator shaft should not be bent The rigid coupling halves mustbe connected according to the instructions Critical

SpeedIf the shaft and or impellers are supplied by others check fora critical speed condition Vibrations can occur througha particular

speed range Steady

bearing Has excessive wear occurred to the steady bearing Is the if

applicable bearing securely bolted to the vessel and is it properly alignedInspect

hardware Is all blade hardware and extension arm hardwareif applicable

properly torqued Including agit shaft couplings andmounting hardware Oil

Leakage Plug at drain and Apply pipe joint sealant or equal and tighten fittings standardpipe fittingsHousing

and caps Tighten capscrews or bolts to proper torqueIf not entirely effectiveremove housing cover and caps Clean mating surfacesand apply new sealing compound gasket Mixer

output shaft Has the recommendedoil level been exceeded Check oil levelon the dipstick Drain oil to the correct level Breather

open Breather must be open and clean PHONE

717 8381341FAX 717 8321740ProTech

Services1 8007331341E

mailprotech@philamixerscomCopyright0PhiladelphiaMixing Solutions Specifications subject to change without notice

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a

PHILAQELPHIA MIXERS SECTiON Cou lin s

erVICB PAGE i00

Manual 2900 SERIES RIGI COUPLINGissu 01 JAN 99

Welded Design REVISION

In many mixer applications the agitator shaf as well as the mixer drive output shaft are

shipped with rigid coupfing halves fixed in their proper positions Before assembly into the

tank make certain that the rabbet faces of the rigid coupling are free of at foreign matternicks or burrs

The mating faces must be positioned evenly and squarely together Gradually tightenopposing bolts until wrench torque speced on the drawing below fails to tum ay boitThese torques should be rechecked after three months of operation for tightness and at

each scheduled shutdawnI

I

Hold Hold

f

II II C 7II II

II I 11 11 1 II

li 11 1 II

I I 11 11 I II

p u

I ry n

4 II II I 11

A 1 tar usA tor ue f pp y qP y q

to this nutto this nut

I This nut is

jammed

Stainless Steel and other

metals hardware

double nut design

Coupling 2902 2903 2904 2905 2906 2907 2908 2909 2910 2911Sizes

No and Size of NoBBolts Inches

Recommended FtIbs

Wrench Torque

Coupling 2912 2913 2914 2916 2918 2920 2922 2924 2926 2928Sites

No and Size of NoB 634Bolts Inches

Recommended FtIbs 142

Wrench Torque

Copyfightm Philadelphia Mixers S eclficatlons subject to change wiUout noUce

E

aa e

aw LtTl1

P

Impeller

PHILADElPH1AMIXERSSCIOI M1I

Type MAlNTNANCE INSTRUCTlONS PAGE 107

E HYDROFOIL 9MPELLER ISSUED 1 JAN 1982

4 BLADED BOLTED GONSTRUCTION REVIStON A 15 AUG 1990

i

378

i

I 376

i

Ii

1380 I

379

377

PART NO DESCRIPTION

376 IMPELLER HUB

377 IMPEILER BIADE

378 BOLT NUT AND LOCKWASHER

379 HOOK KEY

380 SET SCREW

Copyright 1990 Philaddphia Mixcrs

PHILADELPHIAMIXERSSECTION MI

TypIMPELLERINSTRUCTIONS

PAGE 200

ISSU ED 20 AUG 1974

CARBONSTAINLESSSTEEL REVISION E 02 DEC 1996

G ENE RAL Liberally coat the shait with lubricant such as molybdenumImpellers from Philadelphia Mixers are normally shipped disulphide paste for ease of slidingwith hubs mounted on the agitator shaft and with blades Back oft ail setscrews Rock the hub to loosen and firrnlyshipped loose Blades should be installed in strict accor slide the hub away from pin applying an even load ondance with matchmarks if any and with bolts tightened to

opposite ears The hub may be tapped lightly through athe torque listed below

wooden block to aid in this movement Heavier hammerREPOSITIONING OR REMOVAL blows may cause the bore to close in and grab the shaft

Due to adjustment requirements or special installationen hub slides clear remove hook key

procedures it may be necessary to relocate or even remove Stop the hub at the first signoibinding on the shaft Forcingthe impeller hub from the shaft Your Philadelphia Mixeis tie hub may induce galling in some materials makingimpeller hub to shaft clearance is optimized to provide emoval even more difficult Back off from the bindingmaximum adjustability and support with a minimum of spot determine the cause and correct it berore conlinuingfretting therefore even slight distortions and scratches

If needed moderate heat of about 300350l ligYit strawmay cause the hab to hangup

temper color may be applied to the hub OD which willIf more than one hub is to be removed check the shaft and

expand the bore for removal over high spots Heat concenhub for matchmarks lf none mark ciearly with a non trated on ttie thinner hub sec6on over the keyslot is mostremovable indicator noting wtuch side of the hub is to face effective Never allow the temperature to rise above 450F

dark straw to bluish temper color Wtien using heatIt is safest to remove or relocate hubs while the shaft is in handle the hub only with heat protecting glovesthe horizontal position belore installation If they are to be

movedwhiletheshaftishungverticallyasafetyropemust REPLACEMENTANDSECURWG

be tied securely through one or more boltholes and tethered Before replacing the hub onto the shatt check the bore forzrom above t prevent dropping or sudden movement burrs or scratches Coat the bore and shaft with molybdeBefore proceeding remove all scratches and burrs from the num disulphide paste Ifthe shaft is hung vertically attach

shaft over which the hub must pass as well as the hub bore asafety tether securely through one or more boltholes ii the

Do not use tools wluch might contaminate special agitator hub and support from above Install the hub wiLh lhe side

materials such as metal files on stainless steel Polish the up as indicated by matchmarks It is usually although not

shaft with emery cloth necessarily assembled chamferred side t7rst

Slide the hub to a point above its required position and

replace the hookkey onto the shaf Gently lower thc hub

onto the key until it seats against tlte pin Do noc dropagainst the pin Tighten set screws to torque listed below

Install blades and tighten bolts to torques IisCed below

Torque values shown are good for standard carbon and

stainless steel hex head bolts as well nickel monet

o inconel and Alloys T3C and 20 and are based on bolts

a e lightly lubricated in the as received condition If lubri

cated with molybdenum disulphide paste on threads and

nut bearing face bolt torques must be reduced to 750 of

those tabulated

A11 bolfs should be tightened byhrning nut side only

q g All boits should be retightened within 1 month after

statup and at each scheduled shutdown

O OIMPELLERBLADEBOLTTORQUES SLI SCREV TOIL UES

DIA 2 58 34 78 1 118 1141t2 DIA 1A 516 38 12 58 34 78 7

TORQUE FT LB 43 85 130 200 270 400 S00 730 TORQUE FT LB 58 11 19 42 82 140 330 460

Copyright0 1996 Fhiladclphia Mixers

PHILADELPHIA MIXERS SECTION M1IType

MAINTENANCE INSTRUCTIONS PAGE 202HYDROFOILIMPELLER INSTRUCTIONS

Series ISSUED 26 AUG 1983HYDROFOIL

REVISION 15 SEP 1986

GENERAL EROSION

ThePhiladelphiaMixersHydrofoillmpeflerisavailable As a standard preventive maintenanceprocedurein a wide variety of materials including welded and impeller blades should be inspected AT ONE

bolted constructions The hydrofoil is a highly efficient MONTH after startup and whenever the basin is

impellerwhichimpartspredominantlyaxialflowtothe drained thereafter but not to exceed SIX MONTH

surrounding fluid It is widely used in slurry or aerator INTERVALS for signs of erosion or corrosion dam

usually in a draft tube down pumping above an air age Be sure to inspect the bottom as well as the topsparge service of the impeller

BALANCING Abrasive particles in slurry applications or the corro

sive properties of the fluid itselfl cause wear charac

When the agitator shaft rotates at greater than 100 terized by smooth craters and channels in the metal

RPM the impeller is balanced at the factoryCavitation occurs when air or gas bubbles entrapped

Do nof attempt to rebafance in the fietd by adding in the process liquid expand due to the rapid pressure

compensation weights to the hydrofoil blades Fluid drop in the fluid passing over the blade surface

flow across the blade is sensitive to any bladeto

blade geometry variation and operation may be These voids may collapse at the blade surface pro

greatly altered Consult factory when any rebalance ducing localized shock loads The aggregate of theseis contemplated shocks produces pulsations great enough to be felt

throughout the drive and support system and mayFor bolted designs the blades and hub ears are cause erosion of the blade surface This erosive wear

matchmarked and must be posifioned in accordance is characterized by surface pitting especially in areas

with the numerical matchmarks stamped on them at along the tips and leading edgethe factory

In both abrasive and cavitation cases the highestWith multiple impellers mounted on one shaft or on erosion normaHy occurs in areas of low stress and isseveral mixers the match marks run consecutively not a cause of concern but because of the unpredict

able nature of hydraulic flow interaction this erosion

Balancing of overhung shafts should be considered a should be monitored Indications of severe erosion

perishable quantity affected by handling during ship greaterthan15ofbladethicknessoccurringontheping and installation Therefore the initial operation inner half of the blade should be repaired This can beshould be monitored carefully and any undue move done without removal of the impeller by cleaning the

ment or vibrations reported to the factory Note affected area fill welding grinding to a smooth finish

however that since these impellers are used in rug comparable to the finish of the blades as they were

ged duty applications some vibrations are expected originally manufactured and repainting as requiredand considered norma to the process and adjustment may not be required

CopyrightOPhiladelphia MixersSpecifications subject to change

Motor

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iRELi PHASE

SO j FRAME HP i TYPE RPM VOLTSHERTZ

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L184T 5 P 360 1750 i 230460I

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AMB C I NEMA CODEAMPS DUTY i ENCL

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DESIGN LETTER

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13266 CONT 40F 115 B J FCXE

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TEST TEST i STATOR RES@25 CS ROTOR iI 50 DATE OHMS BETWEEN LINES

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535479 418424052FE 646258I

PERFORMANCE

I e I

LOAD HP AMPERES j RPM i POWER FACTOR i EFFICIENCY

INO LOAD 0 i 30 1800 652 0

i

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14 125 34 i 1789 I 408 846i i I

i24 250 42 j 1777 I 623 894

l34 375 53 1765 I 736

I901

ii

44 500 66 i 1752 797 895

ii

54 625 79 1737 835 883

SPEED TORQUE

TORQUE TORQUERPM

FULL LOAD LBFTAMPERES

LOCKED ROTOR 0 239 359 460

PULL UP 275 223 335 450

BREAKDOWN 1396 329 493 281

FULL LOAD 1752 100 150 66

AMPERES SfiOWN FOR460 VOLT

CONNECTION IF OTHER VOLTAGE CONNECTIONS ARE AVAILABLE THE

AMPERES WILL VARY INVERSELY WITH THE RATED VOLTAGE

REMARKS CALCULATED DATA

NEMA NOM EFF 895 PCT

i DR BY W L SMITHA MOTOR

T iCK BY JJHARRISON

E02665DN001L APP BY w L sMZTx PERFORMANCESALDQR DOE RELlANGPI

DATE 1031OS DATA ISSUE DATE 1031OS

Printed on 111307 803 usmghengdev

REL SO RPM 1750 SF 115 ROTOR 416424052FE

FxAME L184T vOLTS 230460 xartA DESZGN B TEST So CALCULATED DATA

HP S AMPS 13266 CODE LETTER J TEST DATE

TYPE P DUTY CONT ENCLOSURE FCXE STATOR RES @25C6462

58PHASE HERTZ3 60 AMB40 FE S 535479 OHMS BETWEEN

LINES

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NOMEFF Sy S PCT i I i r

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i AMPERES SHOWN FOR 4G0VOI 1 CONNECTION ZF OTHER VOLTAGE CONNECTIONS ARE AVAILABLE

THE AMPERES WILL VARYZN VERSELY WZTH THE RATED

VOLTAGE DR BYS TF A C

MOTORBAL O CK BY

JJJiARRISON L ppp Hy us T PERFORMANCEG02665D

N001SAS DGRDE RELIANGEt DATE10I 0 CURVES ISSUE DATEpJ

pS Printed on1113 078 04

usmghengdevl

DIST LODE w

DUTY MASTER ALTERNATING CURRENT MOTORSSQUIRRELCAGE INDUCTION

XT CONSTRUCTIONNCLOSURE TOTALLY ENCLOSED COOLING FAN COOLEDMOUNTING FOOT NEMA C FACE

FRAMES 180TC THRU 210TC

BF TAP4 HOLESP

AB

BS

FVBB AC

MIN 45T

AH

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AA 1PIPEFNFW

NWTAP

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SUPPLIED ONLY IJHEN gREQUIRED

STANDARD FRAMES HAVE 8 HOLES FORDUAL MUNTING AND F2CNVERSION

LONG FRAMES HAVE 6 HOLES FR DUALFOR F2 MTG MOUNTING NT SUITABLE FOR F2180210 FRAME NLY CONVERSION

ONE SIZE LAF2GER 6CAST IRON TERM B

FRAME AA AB AC AF

180TCL180TC 11 894 694 250

210TCL2107C 11 981 781 2501

DIMENSIONS ARE IN INCHES SEE SHEET 2 FOR DIMENSIONS IN MILLIMETERS

CAST IRON TERM BOX MINTAP

FRAME A D 3 E G H J 0 P T AA AB AC AF BA BB BD 8f DEPTH AJ AK 4180TCL180TC 900 450 375 44 44 175 988 950 200 1 844 669 212 350 25 900 7 213 75 725 8500210TCL210TC 1050 525 425 44 44 200 1725 1100 200 1 931 756 272 425 25 900 1 213 75 725 8500

1

FRAME FOOT MT BE SHAFT AND KEY FRONT END SHAFT AND KEY WOGHTSIZE PROV C BS B 2F 2F AH N N U 2 V SQ LGiH F1J FNFW FU 2 FV SQ LGTH LBS 5

180TC 184T 1638 275 700 4 550262 300 275 11250 250 250 175 319 225 8750 200 188 138

95

100

L180TCL184T

g8 350 850450

550z62 300 275 11250 250 250 175 319 225 8750 200 188 138

25

130

210TC 25T 2006 350 850 312 362 338 13750 312 312 238 375 275 11250 250 250 17514

155785L210TC

15T2094 394 912 550 700

312 362 738 13750 312 312 238 375 275 17250 250 250 775195

1

1 SPECIAL DIMENSIONS ON THIS LINE STANDARD DOUBLE SHAFT SUPPLIED ONLYVHEN SPECFIED

2 U AND FU MAY VARY 0000 0005

3 D MAY VARY 00 03TERMINAL BX LOCATED ON OPPOSITE SIDE NHEN F2 N1

4 AK MAY VARY 000 003W N5 V7 R C1 MOUNTING IS SPECIFIED

FACE RUNOUT AND 004 MAX T I R MAXIMUM PERMISSIBLE SHAFT RUNOUT IIHEN MEASURED ATECCENTRICITYEND OF STANDARD SHAFT EXTENSION IS 002 T I R

S MTR NEIGHTS MAY VARY BY 15FR NONSTANDARD RATINGS IF MOUNTING CLEARANCE DETAILS ARE REQUIRED CNSULT

6 ONE SIZE LARGER TERMINAL BXFACTORY

SUPPLIED ONLY VHEN SPECIFIED

FRAME 7YPE CERTIFIED FOR

ORDER ITEN HP RPM PH HZ VLT

LIANCE SALES ORDER APPROVED HY DATE

f7ELA1VCE er K THOMAS

ELECTl9C BY R L BROWN D I M E N S I 0 N 61 3 0 51 5 0 4tap arG KILBORN SHEET ISSUE DATE APRIL 26 1995

CLEVELAND OHI 44117 U S A nnTE 3486SHEET I OF 2

CR 293454 331585 1054100 10541OS EDSAC613051504SH1DlIG

DIST CODE w

DUTY MASTER ALTERNATING CURRENT MOTORSSQUIRRELCAGE NDUCTION

XT CONSTRUCTIONNCLOSURE TOTALLY ENCLOSED COOLING FAN COOLEDMOUNTING F00T NEMA C FACE


CHF TAP4 HOLES

P

ABFN BS

BBAC

FVMIN 45

T

AH

I t N

AF

F VU AK 1

AJD

AA 1PIPE

FNFW

IBA

NuTAP

J IE

G

H DIA

3816UNC 2F qGRUND SCREIJ HOLESUPPLIED NLY WHEN

I Ig

REQUIRED

STANDARD FRAMES HAVE 8 HOLES FOR

DUAL MOUNTING AND F2 CONVERSIN

LONG FRAMES HAVE 6 HOLES FOR DUAL

FOR F2 MTG MOUNTING NOT SUITABLE FOR F21802L0 FRAME ONLY CONVERSION

ONE SIZE LARGER 6CAST IRON TERM BdX

FRAME AA 7 AB AC AF

780TCL180TC 11 2271 1763 635

210TCL210TC 11 2492 1984 635

1

OIMENSIONS ARE IN MILLIMETERS SEE SHEET 2 FOR DIMENSIONS IN INCHES

CAST IRON TERM BOXMINTAP

FRAME A D 3 E G H J 0 P T AA 7 AB AC A BA BB BD BF DEPTH AJ AK 4

180TCL180TC 2286 1143 953 112 t12 445 2510 2413 508 1 2744 7699 538 889 635 2286 1 21 191 1842 21590

210TCL210TC 2667 1334 1080 112 112 508 2858 2794 508 7 2365 1920 538 1080 635 2286 1 21 191 1842 27590

1

FRAME F00T MT BE SHAFT AND KEY FRONT END SHAFT AND KEY WEIGHT

SIZE PROV C BS B 2F 2F AH N NW U 2 V SQ LGTH FN FNFW FU 2 FV SQ LG7H L85 5

180TC182T

4161 699 778 665 762 699 28575 635 635 445 810 572 22225 508 478 35143

184T 1397 45

L180TC 4542 889 159114

665 762 699 28575 635 635 445 870 572 22225 508 478 35157

L184T 1397 5

210TC21

095 889 1599

792 919 859 34925 792 792 605 953 699 28575 635 635 445 60215T 1778

1210TCL213T

5319 1001 2316139

792 919 859 34925 792 792 605 953 699 28575 635 635 44584

L215T 177B 8B

1

C1 SPECIAL DIMENSIONS ON THIS LINE STANDARD DDUBLE SHAFT SUPPLIED ONLYVHEN SPECIFED


C3 MAY VARY 00 76 TERMINAL BX LOCATED N OPPOSITE SIDE NHEN F2 u1

4 AK MAY VARY 000 076u N5 W7 OR C1 MDUNTING IS SPECIFIED

FACE RUNUT AND 101 MAX TIR MA7IMUM PERMISSIBLE SHAFT RUNUT WHEN MEASURED ATECCENTRICITY END F STANDARD SHAFT EXTENSION IS O50 T I R

CS MOTOR WEIGHTS MAY VARY BY 15

FORNNSTANDARD RATINGS IF MOUNTING CLEARANCE DETAILS ARE REOUIRED CONSUIT

6 NE SIZE LARGER TERMINAL BOXFACTORY

SUPPLIE NLY VHEN SPECIFIED

FRAME TYPE CERTIFIED FOR

RDER ITEM HP RPM PH HZ VLTS

LIANCE SALES ORDER APPROVED BY DATE

RELANCEBY K THMAS

ELECTRCBY R BRWN D I M E N S I 0 N 61 3 0 51 5 0 4

nPp arG KILBORN SHEET ISSUE DATE APRIL 26 1995

CLEVELAND HI 44117 U S A nnT 3486SHEET 2 OF 2

CR 293454 331585 1054100 10541OS EDSAC613051504SH2DUG

A C M OTOR

CONNECTION DIAGRAMSTANDARD 9 EAD Y CONNECTED

T1

T4

T7

T6 Tg T8 T5

T3 T2

T4 TS T6 T4 T5 T6

T7 T9 IT7 IT8 IT9

T1 T2 T3 Tt T2 T3

L1 L2 L3 L1 L2 L3

LOW VOLTS HIGH VOLTS

NP 1575

CUSTOMER RELIANCECUSTOMER ORDER N0 SO N0

RELANCE DRBNwCONNECTIONELECTRC K BYY 416 8 201

APP BY HE D I A G R A MCLEVELAND OHIO 441 17 RAG Dn7E 03OSf76 ISSUE DATE JUNE 15 1976

EW RAG 1054103

AL170IVIOTORS AND DRIVES

Integrae HorsepowerAC Induction Motors

ODP Enclosure

TFCErclosure

Explosion Proof

Installation Operating Manual

701 MN400

Table of Contents

Section 1

Generalinformation 11

Overview 11

LimitedWarranty 11

SafetyNotice 12

Receiving 14

Storage 14

Unpacking 14

Handling 14

Section 2

Installation Operation 21

Overview 21

Location 21

Mounting 21

Alignment 2t

Doweling Bolting 22

PowerConnection 22

ConduitBox 22

ACPower 22

FirstTime Start Up 24

CoupledStart U p 24

Jogging and Repeated Starts 24

Section 3

M aintenance Troubleshooting 31

Generallnspection 31

Lubrication Bearings 31

Typeof Grease 31

Lubricationlntervals 31

Lubrication Procedure 33

Accessories 34

Troubleshooting Chart 35

MN400 Table of Contents i

Section 1

Generai Information

Overview 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 or

attempt 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 Cautionstatement indicates a condition that can cause damage to equipment

Important 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 questionabout a procedure or are uncertain about any detail Do Not Proceed Please contact your Baldordistributor for more information or clarification

Before you install operate or perform maintenance become familiar with the followingNEMA Publication MG2 Safety Standard for Construction and guide

for Selection Installation and Use of Electric Motors and Generators

The National Electrical Code

Local codes and Practices

Limited Warrantv

1 Baldor Electric motors are warranted for a period of one 1 year from date of shipment from the factory or factorywarehouse against defects in material and workmanship To allow for stocking andor fabrication period and to

provide one year of actual service the warranty period is extended for an additional period of six 6 months for a

total 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 buyerof 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 the

warranty period if

a the purchaser presents the defective motor at or ships it prepaid to the Baldor plant in Fort Smith Arkansas

or one of the Baldor Authorized Service Centers and

b the purchaser gives written notification concerning the motor and the claimed defect including the date

purchased the task performed by the Baldor motor and the problem encountered

3 Baldor vill not pay the cost of removal of any electric motor from any equipment the cost of delivery to Fort SmithArkansas or a Baldor Authorized Service Center or the cost of any incidental or consequential damages resultingfrom the claimed defects Some states do not allow the exclusion or limitation of incidental or consequentialdamages so the above exclusion may not apply to you Any implied warranty given by laws shall be limited to

the duration of the warranty period hereunder Some states do not allow limitations on how long an impliedwarranty lasts so the above limitation may not apply to you

4 Baldor Authorized Service Centers when convinced to their satisfaction that a Baldor motor developed defects in

material or workmanship within the warranty period are authorized to proceed with the required repairs to fulfill

Baldors warranty when the cost of such repairs to be paid by Baldor does not exceed Baldors warranty repairallowance Baldor will not pay overtime premium repair charges without prior written authorization

5 The cost of warranty repairs made by centers other than Baldor Authorized Service Centers WILL NOT be paidunless first authorized in writing by Baldor

6 Claims by a purchaser that a motor is defective even when a failure results within one hour after being placed into

service are not always justified Therefore Baldor Authorized Service Centers must determine from the condition

of the motor as delivered to the center whether or not the motor is defective If in the opinion of a Baldor

Authorized Service Center a motor did not fail as a result of defects in material or workmanship the center is to

proceed with repairs only if the purchaser agrees to pay for such repairs If the decision is in dispute the

purchaser should still pay for the repairs and submit the paid invoice and the Authorized Service Centers signedservice report to Baldor for further consideration

7 This warranty gives you specific legal rights and you may also have other rights which vary from state to state

Note that Baldor SuperEO Premium Efficiency electric motors are warranted for a period of three 3 yearsAll other terms and conditions of the Limited Warranty statement apply

MN400 General Information 11

Saety Notice This equipment contains high voltage Electrical shock can cause serious or fatal injuryOnly qualified personnel shouid altempt instailation operation and maintenance of

electrical equipment

Be sure that you are completely familiar with NEMA publication MG2 safety standards

for construction and guide for selection installation and use of electric motors and

generators the National Electricai Code and locai 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

or fatal injury Only qualified personnel should attempt the

instalation operation and maintenance of this equipment

WARNING Be sure the system is properly grounded before applying powerDo not apply AC power before you ensure that all groundinginstructions have been followed Electrical shock can cause

serious or fatal injury National Electrical Code and Local codes

must be carefully followed

WARNING Avoid extended exposure to machinery with high noise levels Be

sure to wear ear protective devices to reduce harmful effects to

your hearing

WARNING This equipment may be connected to other machinery that has

rotating parts or parts that are driven by this equipment Improperuse can cause serious or fatal injury Only qualified personnelshould attempt to install operate or maintain this equipment

WARNING Do not bypass or disable protective devices or safety guardsSafety features are designed to prevent damage to personnel or

equipment These devices can only provide protection if theyremain operative

WARNING Avoid the use of automatic reset devices if the automatic restartingof equipment can be hazardous to personnel or equipment

WARNING Be sure the load is properly coupled to the motor shaft before

applying power The shaft key must be fully captive by the load

device Improper coupling can cause harm to personnel or

equipment if the load decouples from the shaft during operation

WARNING Use proper care and procedures that are safe during handlinglifting installing operating and maintaining operationsImproper methods may cause muscle strain or other harm

WARNING Before performing any motor maintenance procedure be sure that

the equipment connected to the motor shaft cannot cause shaft

rotation If the load can cause shaft rotation disconnect the load

from the motor shaft before maintenance is performed Unexpectedmechanical rotation of the motor parts can cause injury or motor

damage

WARNING Disconnect all electrical power from the motor windings and

accessory devices before disassembly of the motor Electricalshock can cause serious or fatal injury

WARNING Do not use these motors in the presence of flammable or

combustible vapors or dust These motors are not designed for

atmospheric conditions that require explosion proof operation

12 General Information MN400

Safety Notice Continued

WARNING Motors that are to be used in flammabJe andor explosiveatmospheres must display the UL label on the nameplate

Specific service conditions for these motors are defined in

NEC 70599

WARNING UL rated motors must only be serviced by authorized Baldor

Service Centers if these motors are to be returned to a flammable

andor explosive atmosphere

Caution To prevent premature equipment failure or damage only qualifiedmaintenance personnel should perform maintenance

Caution Do not lift the motor and its driven load by the motor liftinghardware The motor lifting hardware is adequate for lifting only the

motor Disconnect the load from the motor shaft before moving the

motr

Caution If eye bolts are used for lifting a motor be sure they are securelytightened The lifting direction should not exceed a 20 angle from

the shank of the eye bolt or lifting lug Excessive lifting angles can

cause damage

Caution To prevent equipment damage be sure that the electrical service is

not capable of delivering more than the maximum motor rated ampslisted on the rating plate

Caution If a HI POT test High Potential Insulation test must be performedfollow the precautions and procedure in NEMA MG1 and MG2

standards to avoid equipment damage

If you have any questions or are uncertain about any statement or procedure or if you

require additional information please contact your Baldor distributor or an Authorized

Baldor Service Center


Reeivinq Each Baldor Electric Motor is thoroughly tested at the factory and carefully packaged for

shipment When you receive your motor there are several things you should do

immediately

1 Observe the condition of the shipping container and report any damageimmediately to the commercial carrier that delivered your motor

2 Verify that the part number of the motor you received is the same as the partnumber listed on your purchase order

Sta If the motor is not put into service immediately the motor must be stored in a clean dryand warm location Several precautionary steps must be performed taavoid motor

damage during storage

1 UseaMegger periodically to ensure that the integrity of the winding insulationhas been maintained Record the Megger readings Immediately investigateany significant drop in insulation resistance

2 Do not lubricate bearings during storage Motor bearings are packed with

grease at the factory Excessive grease can damage insulation quality3 Rotate motor shaft at least 10 turns every two months during storage more

frequently if possible This will prevent bearing damage due to storage4 If the storage location is damp or humid the motor windings must be protected

from moisture This can be done by appiying power to the motors spaceheater if available while the motor is in storage

Unpackinq Each Baldor motor is packaged for ease of handling and to prevent entry ofcontaminants

1 To avoid condensation inside the motor do not unpack until the motor hasreached room temperature Room temperature is the temperature of the room

in which it will be installed The packing provides insulation from temperaturechanges during transportation

2 When the motor has reached room temperature remove all protective wrappingmaterial from the motor

Handling The motor should be lifted using the lifting lugs or eye bolts provided1 Use the lugs or eye bolts provided to lift the motor Never attempt to lift the

motor and additional equipment connected to the motor by this method The

lugs or eye bolts provided are designed to lift only the motor Never lift themotor by the motor shaft

2 If the motor must be mounted to a plate with the driven equipment such as

pump compressor etc it may not be possible to lift the motor alone For thiscase the assembly should be lifted by a sling around the mounting base Theentire assembly can be lifted as an assembly for installation Do not lift usingthe motor lugs or eye bolts provided

If the load is unbalanced as with couplings or additional attachmentsadditional slings or other means must be used to prevent tipping In any eventthe load must be secure before lifting


Section 2

Installation Operation

Overview Instaliation should conform to the National Electrical Code as well as locai codes and

practices When other devices are coupied to the motor shaft be sure to install

protective devices to prevent future accidents Some protective devices include

coupling belt guard chain guard shaft covers etc These protect against accidental

contact with moving parts Machinery that is accessibie to personnel should providefurther protection in the form of guard rails screening warning signs etc

Location 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 can

reduce the operating life and degrade performance Be sure to allow clearance for

ventilation and access for cleaning repair service and inspections Ventilation is

extremely important Be sure the area for ventilation is not obstructed Obstructions will

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 ODP motors are suitable only for indoor applications

2 TEFC motors are suitable for indoor or outdoor standard service applications

Mountinq 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 bearingdamage

Foundation caps and sole plates are designed to act as spacers for the equipment they

support If these devices are used be sure that they are evenly supported by the

foundation or mounting surface

After installation is compiete and accurate alignment of the motor and load is

accomplished 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

sliding rails are designed for horizontal mounting only Consult your Baidor distributor or

authorized Baldor Service Center for further information

Alignment Accurate alignment of the motor with the driven equipment is extremely important

1 Direct CouplingFor direct drive use flexible couplings if possible Consult the drive or

equipment manufacturer for more information Mechanical vibration and

roughness during operation may indicate poor alignment Use dial indicators to

check alignment The space between coupling hubs should be maintained as

recommended by the coupling manufacturer

2 EndPlay AdjustmentThe axial position of the motor frame with respect to its load is also extremely

important The motor bearings are not designed for excessive external axial

thrust loads Improper adjustment will cause failure

3 Pulley Ratio

The pulley ratio should not exceed 81

4 Belt Drive

Align sheaves carefully to minimize belt wear and axial bearing loads seeEndPlay Adjustment Beft tension should be sufficient to prevent belt slippageat rated speed and load However belt slippage may occur during starting

Caution Do not over tension belts

MN400 Installation Operation 21

Daweling Boiting 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 doweling1 Drill dowel holes in diagonally opposite motor feet in the locations provided2 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 alignmentUse 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

washers

Power ConneCtion Motor and control wiring overload protection disconnects accessbries and groundingshould conform to the National Electrical Code and local codes and practices

Conduit Box For ease of making connections an oversize conduit box is provided The box can be

rotated 360 in 90 increments Auxiliary conduit boxes are provided on some motors for

accessories such as space heaters RTDs etc

AC Power Connect the motor leads as shown on the connection diagram located on the name plateor 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 pfate for ratingsOR

2 AC power is within 5 of rated frequency with rated voltageOR

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 frequencyPerformance within these voltage and frequency variations are shown in Figure 21

22 Installation Operation MN400

Figure 21 Motor Performance VS Voltage Variations

20Maximum

Full Load TorqueCurrent

15

10y FullLoad

Power CurrentFactor

E 5L

O

L

a

0O r

Efficiency Efficiency5

d

c10

U

15Power

Maximum Factor

Torque20

15 10 5 0 5 10 15

Voltage Variations

0MN400 Installation Operation 23

Firsf Time Start Up Be sure that all power to motor and accessories is off Be sure the motor shaft isdisconnected 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 insulation

integrity with a Megger3 Inspect all electrical connections for proper termination clearance mechanical

strength and electrical continuity4 Be sure all shipping materials and braces if used are removed from motor

shaft

5 Manualiy rotate the motor shaft to ensure that it rotates freely6 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 If motor rotation is wrong be sure power is off and change the motor leadconnections Verify rotation direction before you continue

9 Start the motor and ensure operation is smooth without excessive vibration or

noise If so run the motor for 1 hour with no load connected

10 After 1 hour of operation disconnect power and connect the load to the motorshaft Verify all coupling guards and protective devices are insialled Ensuremotor is properly ventilated

Coupled Start U This procedure assumes a coupied start up Also that the first time start up procedurewas successful

t Check the coupling and ensure that aii guards and protective devices are

installed

2 Check that the coupling is properly aligned and not binding3 The first coupled start up should be with no load Apply power and verify that

the load is not transmitting excessive vibration back to the motor though thecoupling or the foundation Vibration should be at an acceptable levei

4 Run for approximately 1 hour with the driven equipment in an unloadedcondition

The equipment can now be loaded and operated within specified limits Do not exceedthe name plate ratings for amperes for steady continuous loads

Joaqing and Repeated Starts Repeated starts andor jogs of induction motors generally reduce the life of the motor

winding insulation A much greater amount of heat is produced by each acceleration or

jog than than by the same motor under full load If it is necessary to to repeatedly start or

jog the motor it is advisable to check the application with your local Baldor distributor orBaldor Service Center

Heating Duty rating and maximum ambient temperature are stated on the motor name

plate Do not exceed these values If there is any question regarding safe operationcontact your locai Baldor distributor or Baldor Service Center

24 Installation OperationMN400

Section 3

Maintenance Troubleshooting




General InspeCtion 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




installation operation and maintenance of this equipment

1 Check that the motor is clean Check that the interior and exterior of the motor

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 UseaMegger periodically to ensure that the integrity of the winding insulation

has been maintained Record the Megger readings Immediately investigateany significant drop in insulation resistance

3 Check all electrical connectors to be sure that they are tight

Lubrication Bearinqs Bearing grease will tose 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

Type of Grease A high grade ball or roller bearing grease should be used Recommended grease for

standard service conditions is Polyrex EM Exxon Mobil

Equivalent and compatible greases include

Texaco Polystar Rykon Premium 2 Pennzoil Pen 2 Lube and Chevron SRI

Maximum operating temperature for standard motors 110 C

Shutdown temperature in case of a malfunction 115 C

Lubrication Intervals Recommended lubrication intervals are shown in Table 31 It is important to realize that

the recommended intervals of Table 31 are based on average use

Refer to additional information contained in Tables 32 and 33

Table 31 Lubrication Intervals

Rated peed RPM

NEMA IEC Frame Size 10000 6000 3600 1800 1200 900

Up to 210 incl 132 2700 Hrs 5500 Hrs 12000 Hrs 18000 Hrs 22000 Hrs

Over 210 to 280 incl 180 v 3600 Hrs 9500 Hrs 15000 Hrs 18000 Hrs

Over 280 to 360i 225 xr e

2200 Hrs 7400 Hrs 12000 Hrs 15000 Hrs

Over 360 to 5800 incl 300 2200 Hrs 3500 Hrs 7400 Hrs 10500 Hrs

Lubrication intervals are for ball bearings For roller bearings divide the listed lubrication interval by 2

For 6205 and 6806 bearings For 6807 bearings consult oil mist lubrication MN401Relubrication interval for 6205 bearing bearing is 1550Hrs using grease lubricationRelubrication interval for 6806 bearing bearing is 720Hrs using grease lubrication

0

MN400 Maintenance Troubleshooting 31

Table 32 Service Conditions

everity of ervice Ambient emperature Atmospheric Type of BearingMaximum Contamination

Standard 40 C Clean Little Corrosion Deep Groove Ball BearingSevere 50 C Moderate dirt Corrosion Ball Thrust Roller

Extreme 50 C or Severe dirt Abrasive dust All BearingsClass H Insulation Corrosion

Low Temperature 30 C

Special high temperature grease is recommended Dow Corning DC44 Note that Dow Corning DC44 grease doesnot mix with other grease types Thoroughly clean bearing cavity before adding grease

Special low temperature grease is recommended Aeroshell 7

Table 33 Lubrication Interval Multiplier

everty of ervice MultiplierStandard 10

Severe pg

Extreme 01

Low Temperature 1p

Table 3 Bearings Sizes and TypesFrame Size Bearing pescriptionNEMA IEC These are the Large bearings Shaft End in eac frame size

Bearing OD Width Weight of Volume of greaseD mm B mm Grease to to be added

add tea

oz Grams j spoonUp to 210 incl 132 6307 80 21 030 84 i 06 20

Over 210 to 280 incl 180 6311 120 29 061 17 12 39Over 280 to 360 incl 225 6313 140 33 081 23 15 52Over 360 to449 incL 280 NU319 200 45 212 60 41 134

Over 5000 to 5800 incl 355 NU328 300 62 470 130 92 300Spindle Motors

76 Frame 6207 72 17 022 61 044 1477 Frame 6210 90 20 032 90 064 2180 Frame 6213 120 23 049 140 099 33

Weight in grams 005 DB

32 Maintenance Troubleshooting MN400

Lubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease alreadyin the motor Consult your Baldor distributor or an authorized service center if a greaseother 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 Plug

1 Clean all grease fittings2 Remove grease outlet plug

3 If motor is stopped add the recommended amount of grease

If motor is to be greased while running a slightly greater quantity oi grease will

have to be added Add grease slowly until new grease appears at shaft hole in

the endplate or purge outlet plug4 Reinstall grease outlet plug

Without Grease Outlet Plug1 Disassemble motor

2 Add recommended amount of grease to bearing and bearing cavity Bearingshould be about 13 full of grease and outboard bearing cavity should be about

12 full of grease

Note Bearing is 13 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 ambient

temperature of 43 C and the atmosphere is moderately corrosive

1 Table 31 list 9500 hours for standard conditions

2 Table 32 classifies severity of service as Severe

3 Table 33 lists a multiplier value of 05 for Severe conditions

4 Table 34 shows that 12 in or 39 teaspoon of grease is to be added

Note Smaller bea ings in size category may require reduced amounts of grease

0MN400 Maintenance Troubleshooting 33

Accessories The following is a partial list of accessories available from Baldor

Contact your Baldor distributor for availability and pricing information

Note Space heaters and RTDs 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 ThermocouplesUsed to measure or monitor bearing temperatures

Bearing Thermostat

Temperature device that activates when bearing temperatures are excessiveUsed with an external circuit to warn of excessive bearing temperature or toshut down a motor

Conduit Boxes

Optional conduit boxes are available in various sizes to accommodate

accessory devices

Cord Plug AssemblyAdds 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 yourBaldor distributor to confirm that the motor is designed for vertical mounting

Fan Cover Lint Screen

To prevent buildup of debris on the cooling fan

NameplateAdditional stainless steel nameplates are available

Roller BearingsRecommended for belt drive applications with a speed of 1800 RPM or less

Rotation Arrow Labels

Rotation arrows are supplied on motors designed to operate in one direction

only Additional rotation arrows are available

Space Heater

Added to prevent condensation of moisture within the motor enclosure duringperiods of shut down or storage

Stainless Hardware

Stainless steel hardware is available Standard hardware is corrosion resistantzinc plated steef

Winding RTD


monitor the temperature of the motor winding during operation

Winding ThermocouplesUsed to measure or monitor winding temperatures

Winding Thermostat

Temperature device that activates when winding temperatures are excessiveUsed with an external circuit to warn of excessive winding temperature or toshut down a motor

Note On some motors leads for accessory devices are brought out to a separateconduit box located on the side of the motor housing unless otherwisespecified

34 Maintenance 8 Troubleshootin g MN400

Table 35 Troubleshooting Chart

Symptom Possible Causes Possible Solutions

Motor will not start Usually caused by line troubie such Check source of power Check overloads fusesas single phasing at the starter controls etc

Excessive humming High Voltage Check input line connections

Eccentric air gap Have motor servic at local Baldor service center

Motor Over Heating Overload Compare actual amps Locate and remove source of excessive friction in

measuredj with nameplate rating motor or load

Reduce load or replace with motor of greater capacitySingle Phasing Check current at all phases should be approximately

equa to isolate and correct the problemImproper ventilation Check external cooling fan to be sure air is moving

properly across cooling fins

Excessive dirt build on motor Clean motor

Unbalanced voltage Check voltage at all phases should be approximatelyequal to isolate and correct the problem

Rotor rubbing on stator Check air gap clearance and bearingsTighten Thru Bolts

Over voltage or under volt Check input voitage 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 requiredImproper connections Inspect all electrical connections for proper

termination ciearance mechanical strength and

I electrical continuity Refer to motor lead connection

diagramBearing 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 bear Remove grease until cavity is approximately 3 fiiled

Insufficient grease in bearing Add grease un cavity is approximately 3J4 filled

Dirt in bearing Clean bearing cavity and bearing Repack with correct

grease until cavit is approximately 3 filled

Vibration Misalignment Check and align motoranddriven equipment

Rubbing between rotating parts and fsolate and eliminate cause of rubbingstationary partsRotor out of balance Have rotor balance checked are repaired at your


Resonance Tune system or contact your Baldor Service Center for

assistance

Noise Foreign material in air gap or Remove rotor and foreign material Reinstall roior

ventilation openings Check insulatio integrity Cleanventilation openingsGrowling or whining Bad bearing Replace bearing Clean all grease from cavity and new

i bearing Repack with correct grease until cavity is

approximately 3l4 filled


SALL70RMOTORS AND DRIVES

BALDOR ELECTRIC COMPANY

PO Box 2400

Ft Smith AR 729022400

501 6464711

Fax 501 6485792

O Baldor Electric Company Printed in USAMN400 701 CJ10000

m wwaaMT

M r

3

LtVfs

e

Flexible Coapling

ox


SECTION Motor Cou linCurrent MOTOR COUPLING PAGE 3400

Volume I mportant Safety InstructionsSSUED 15 SEP 98

REVISION 15 MAR 02

Warning

During start up and operation of power transmission product avoid sudden shockloads Coupling assembfy shouid operate quietly and smoothly If coupling assem

bly vibrates or makes bearing sound shut down immediately and recheck alignment Shortly after initial operation and periodically thereafter where appiicableinspect coupling assemblyforalignment wear of elastomeric element bolt torquesand flexing elements for signs of fatigue Do not operate coupling assembly if

alignment is improper or where applicable if elastomeric element is damaged or

worn beyond 25o of its original thickness

Coupling mounting as easy as 1 2 3

f euzC

s

4 Fi r I

i

r

rs

tx x

Mount both coupling halves Insert the flexible spider and Ch2ckalignment between theincluding keys if any on their bring coupling halves together two halves using a steel straightrespective shafts leaving approximately 116 edge across the top of both

space in between the ends of the coupling halves

jaws Spacer dots molded onto

spiders provide a guide for

correct spacing

Misalignment Capability

max MaX Standard Materials

Torque Range Angular Parallel

Model InLbOffset rf5et Body

Flexible

Degrees inctes Member

L Up to 4600 015 Sintered Iron NBR Rubberand Cast Iron

2 Sintered IronL Up to 6240 010 and Cast ron Hytrel


PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040M 200 SECTION Motor CouplingCurrent MOTOR COUPLING

PAGE 3500


REVISION 15 MAR 02

Lovejoy elastomeric jaw type flexible

couplings do not require lubrication and are the

accepted industry standard They offer ease of

assembly or disassembly permit visual inspection3r J3t of the flexible element wear members and allows

for their remova without disturbing the motor or

tcouit pump alignment in most applications

Lovejoy spider type individual load cushions and snap wrap spiders satisfy all stan

dard application requirements as well as combinations of low speedhigh torquelow speedhigh temperature high torque and other special conditions Lovejoys one

piece spider construction also includes raised spacer dots on each side of the cushion

to give premeasured separaton between the jaws of each coupling half See diagrambelow

C

CI

ii iiI i n

nIiiu

1tL y

AE A

I L

iti trniu un u

u nnl

D DB B

aCopyright0 Philadelphia Mixing Solutions Specifications subject to change without notice

PHILADELPHIAMIXINGSOLUTIONS TAB UniFirst 4040ISM 2000 SECTION R d cou nn

Current MOTOR COUPLINGPAGE 3600

Volume 1 ISSUED 15 SEP 98

REVISION 15 MAR 02

Dimensional Data

Type L Flexibie Couplings

Dimension in Inches Moment

Distance of InertiaBore Outside Overall Between Length Hub Approx Weight wR2

Coupling Style Diameter Length Flanges Thru Bore DiameterPounds LBINZ

Number No Min Max A B C D E Solid Max Bore SolidL075 1 14 78 134 21 8 12 1316 134 10 8 388L090 1 14 78 2764 21 8 12 1316 2764 15 12 772

L095 1 716 118 2764 212 12 1 2764 18 13 890L100 1 12 138 21732 312 34 138 21732 35 25 2783

L110 1 58 158 3516 414 78 11116 3516 66 50 8993L150 1 58 178 334 412 1 134 334 91 70 11477

L190 2 34 218 412 514 1 218 4 17 13 39256

Performance Data

Horsepower Capacity at Varying SpeedRated Torque RPM

CouplingInLbs HP100 RPM NBR Rubber

Number NBR Rubber Hytrel NBR Rubber Hytrel 300 1200 1800 3600 Max BoreL075 756 12 36 144 216 432 78

L090 1260 20 60 24 36 72 1L095 1760 28 84 336 504 1008 118

L100 3780 1130 60 18 18 72 108 216 138L110 6930 2079 11 33 33 132 198 396 158

L150 10710 3213 17 51 51 204 306 612 178L190 13860 4158 22 66 66 264 396 792 21 8


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I Kruger Inc


Ste 100 FACSIMILE 9196770082

Cary NC 27513

Project Name Port Angeles WA Project Number 42470003

Date5108 Author MDC

Revision 1 Equip Tag Number M13 M423

Maturation Tank Mixer S ecification Sheet


Mfg Model Number 3855

Order Quantity Two 2

Motor

T e 360230460 nverter Dut

HP 75

RPM 1750

EnclosureType TEFC

Service Factor 115

Insulation NEMA Class F

Gearbox

Gearbox Service Factor 15


Pedestal Mount Yes

Output RPM

Tank

To of Slab or Beam Height ft 185 el 24300

Pad lus Grout Height inch To beam

Total Mounting Height ft 85

Wetted Parts


No I mpel lers

Shaft Length inch gg

Shaft Diameter inch

Impeller Diameter inch 95

lmpeller Distance from Bottom inch 4

Additional Items

Pedestal bases includedOne set of bearings and seals required as a spare

One gallon of lubricant per mixer to be included


MAINTENANCE MANUAL

Project Name

Port Angeles WTP

Customer

I Kruger I nc

Customer PO No

27540

Equipment Tag No

Maturation

PMSL Order No 42114

Serial No 08DEN01202


n Phone 7178322800 Fax 7178321740


JjEMail phillyoncallaphilamixerscom

E11 wwwphilamixerscom

r

TABLE OF CONTENTS

Service

Pa rts

Maintenance

Rigid Coupling

Impeller

Motor

Flexible Coupling

Drawings

m

ctu

3 wmwms uewr wov

HgAXeh

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R i

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SGVIC

PHILADELPHIAMIXERS INDEX 3850Series

ISM 2000 SECTION Introduction

Current INTRODUCTIQN PAGE 100

Volume I ISSUED o urv 2002

REVISION A 01 MAY 2003

This Service Manual covers Philadelphia 3850 Series Mixer Drives a high quality mixer drive

designed in accordance withthe Standards of the American Gear Manufacturers Associa

tion Certain precautions and procedures however must be observed in handiing installingand servicing the mixer drive and accessories

This manual contains general installation operating maintenance and troubieshooting in

structions for your mixing equipment Also special instructions applicable to specific mixer

drives may be included Should questions arise that are not covered additional information

can be obtained by contacting your local representative or Customer Service at PhiladeiphiaMixers Palmyra PA Telephone 717 8322800 FAX 717 8321746email

protech@philamixerscomNOTE

All inquiries must be accompaniedby the foilowing information which can be

obtained from the nameplate on the mixer drive Mixer

Drive Size and Type or Mode PhiladelphiaMixer Order NumberO

SerialNumberOrders

for renewal parts must include description and part number shown on

parts list in addition to the above information See Parts Section of this

manual for specific parts ordering procedure and order form Copyright0

Philadelphia Mixers Specifications subject to change without notice

PHILADELPHIA MIXERS INDEX 3850 Series

ISM 2000 SECTION Safety

Current SAFETY WARNING PAGE 200

Volume I ISSUED 01 JUN 2002


WARNING

In the installation operation and maintenance of gear drives SAFETY comes first Use

proper clothing tools and methods of handling to prevent serious accidents The

safety precautions listed in this manual MUST be followed by all personnel working on

equipment otherwise serious injury may result

This manual lists a number of safety precautions Follow them and insist that those working on

this equipment do the same An accident is usually caused by neglect or oversight

Adequate installation maintenance and safety instructions must be given by the user to person

nel directly responsible for the operation of the mixer drive and accessory equipment In addi

tion the procedures set forth in the operating instructions must be carefully followed

Guards alarms heaters and safety devices which may be furnished by Philadelphia Mixers

must be installed by the user

The user is also responsible for furnishing and installing any guards or other safety equipmentneeded to protect operating personnel as required by the Occupational Safety and Health

Administration OSHA Standards or other applicable safety regulations This equipmentnormally is not furnished by Philadelphia Mixers except when specified as part of the order In

all cases however the user has the responsibility of complying with all applicable safety regulations when installing the equipment

SAFETY PRECAUTIONS

TO AVOID SERIOUS BODILY INJURY OR POSSIBLE DEATH

THE FOLLOWING PRECAUTIONS MUST BE FOLLOWED

ONLY AUTHORIZED PERSONS MAY OPERATE THIS

EQUIPMENTAdequate installation maintenance and safety instructions

must be given by the user to personnel directly responsible for the safe

operation of the mixer or aerator and accessory equipment In addition

the procedures set forth in the Service Instructions must be carefully fol

lowed Use qualified and skilled tradespersons to perform each work

discipline when installing inspecting or servicing this equipment All per

sonnel must be required to remain a safe distance from rotating shafts

couplings impellers clutches etc

OCopyright0 Philadelphia Mixers Specifications subject to change without notice

PHILADELPHIAMIXERS INDEX 3850 Series

2 SECTION SafetyCurrent

SAFETY WARNING PAGE s00

Volume I iSSUE 01 JUN 2002

REVISION A OA1 MAY200

READSERVICE MANUAL BEFORE LIFTING OR MOVING

EQUIPMENTAttach lifting devices to the equipment only as directed in the

Service Instructions and onlyto designated lifting points Particularcare must

be exercised to watch out for pinch or catch points in installation assembly or

disassembly Pieces should be supported to eliminate sudden shifting or

movement

DO NOT OPERATE UNLESS ALL SAFETY GUARDS AND DEVICES AREIN PLACE AND ADJUSTED PROPERLYThe user is responsible for fur

nishing and installing additional guards or other safety equipment needed to

protect operating personnel as required by local or individual safety standardsor regulations This equipment usually is not furnished by Philadelphia Mixers

except when specified as part of the order In all cases however the user

has the responsibility of complying with all appiicable safety regulations when

installing and operating the equipment throughout the life of the mixer Guardsalarms heaters and safety devices which may be furnished by PhiladelphiaMixers must be installed and maintained by the user

LOCK OUT AND DEPRESSURIZE BEFORE SERVICINGEQUIPMENTBefore closely inspecting repackaging or replacing mixershaft seals in mixer assemblies for cosed tank operation special precautions are mandatory Even if the gas or vapor contained within the pressurevessel is innocuous rapid release of the pressure can cause bodily injury or

damage to equipment Plant standard depressurizing andor decontaminat

ing procedures for the vessel must be completed with adequate time allowedfor mixer and vessel to cool sufficiently for safety of service personel prior to

starting work in mixer shaft seal area

DISCONNECT AND LOCK OIJT THE PRIME MOVER AND ITS CONTROLCIRCUITS BEFORE INSPECTING OR SERVICING THISEQUIPMENTDo not connect the prime mover to its power source until all

equipment is properly installed lubrication added bolts torqued and safetydevices installed and approved by qualified tradespersons Prior to servicingor closely inspecting any mixer or aerator that has been installed and made

ready for operation or actually put into an operating mode disconnect andlock out prime mover power source

DO NOT EXCEED DESIGN LIMITATIONSDo not operate sealingdevices above their rated temperatures or pressures specified on nameplatesor drawings Do not exceed any design limitations or make modifications tothis equipment without first consulting Philadelphia Mixers

CopyrightOO Philadelphia Mixers Specifications subject to change without notice


M 20 SECTION Service

CurrentSERVICE PAGE 400

Volume iGENERAL ISSUED o uN 2002


1 Any apparent or suspected damage sustained by equipment manufactured or furnished byPhiladelphia Mixers during transport from the factory to the user should be reported in

writing immediately to both Philadelphia Mixers and the Carrier

2 Upon delivery all equipment furnished must be carefully inventoried against shipping papersto determine whether any shortages exist in delivered materials Any such shortages must

be immediateVy reported in writing to both Philadelphia Mixers Customer Service Department and the Carrier if a timely claim is to be made

3 The mixer has been protected for limited term storage Inspect mixer drive and any other

equipment furnished by Philadelphia Mixers for corrosion If corrosion is present notify in

writing Phiadelphia Mixers Customer Service Department

4 The installation of most mixers does not usually require the services of a factory engineerThese services are not incfuded in the selling price of the equipment unless specificallyagreed upon in writing between the seiler and the purchaser in applications requiring a

more complex arrangement of components consideration should be given to the use of a

factory engineer for construction supervision or inspection of the installation These services

are available from Philadelphia Mixers by contacting our Customer Service Deartment

5 The Sellers Warrantv applies insofar as the unit is operated within the rating and service

conditions for which it was specifically sold The purchaser must prevent the existence of

any destructive external conditions which might typicaily include vibratory foads due to

critical speeds severe shock loading mechanica or thermal overloads or other conditions

which may adversely affect the operation The mixer must be installed and maintained in

accordance with instructions provided in this manual

6 In the event of malfunction within the warranty period Philadelphia Mixers must be notified

promptly in writing within thirty 30 days if it is intended that the warranty is to cover the

incident

7 Adequate installation maintenance and safety instructions must be given by the user to

personnel directly responsible for the operation of the mixer and accessory equipment In

addition the procedures set forth in the operating instructions must be carefully followed

8 Guards alarms heaters and safety devices which may be furnished by Philadelphia Mixers

must be installed by the user

9 The user is also responsible for furnishing and installing any guards or other safety equipment needed to protect operating personnel as required by Occupational Safety

Copyright0 Philadelphia Mixers Specifications subject to change without notice


M 2 SECTION Service

CurrentSERVICE

PAGE 500Volume I issuE

GENERAL 01 JUN 2002

REVISION q 01 MAY 2003

and Health Administration OSHA standards or other applicabie safety regulations In all

cases however the user has the responsibility of complying with all safety regulations when

instaliing the equipment

10Mixers equipped with electrical control devices must be wired and checked for

proper operation

11Before startup all Philadelphia Mixers drives must be filled with the type and gradeof oil specified

12A11 unauthorized personnel must be required to remain a safe distance from rotatingshafts couplings agitators etc

INSTALLATION

The basic mixer drive is shipped completely assembled Mating gears and pinions are care

fully assembled at the factory to provide proper tooth contact Nothing must be done to disturbthis setting Single mechanical seals may be shipped with seai face apart Consult sectionShaft Seal information for instruction on proper setting

HANDLING See Gearbox Handling Procedure Tab

When handling a 3850 Series Philadelphia Mixer care must be taken to avoid supporting or

lifting in a manner that would place excessive stress on parts that are not designed ta supportthe weight

The 3850 Series mixer drive must be lifted with the three shoulder eyebolts provided at the topof the mixer drive The mixer must not be lifted by the motor eyebolt Lifting slings should beused to distribute load evenly When using lifting slings exercise caution to avoid damagingany external piping or gauges

Never drag the mixer drive This will mar the machined mounting surfaces and may damagethe housing

RUST PREVENTION

When the mixer drive is shipped the internal parts are protected with a film of rust preventivewhich protects the gear drive during shipment This film is soluble in the recommended lubricant and does not have to be flushed before filling Inspect mixer drive and any other equipmentfurnished by Philadephia Mixers If corrosion is present notify Philadelphia Mixers CustomerService Department in writing immediately

Copyright0Philadelphia Mixers Specifications subject to change without notice


M 2 SECTION Service

CurrentSERVICE

PAGE 600

Volume I issuE 01 JUN 2002


PROLONGED STORAGE

If installation of the mixer drive and operation is to be delayed for more than one 1 month

after shipment see Section Long Term Storaqe Instructions The manufacturers warranty on

mixer drives heid in prolonged storage must be covered by a special agreement reflecting the

storage conditions In order to validate warranty storage must be as per Long Term StorageInstructions

If prolonged storage is necessary it should be indoors and preferably in a dry area having a

relatively constant temperature When outdoor storage is unavoidable mixer drives should be

stored on their shipping skids and covered by a tarpaulin or an equivalent covering Seal all

openings with plugs vapor inhibitor paper or caps Also mixer drives should be filled to the

proper level with a mixture of oil and vapor phase rust preventative See Long Term Storaqeinstructions Exterior exposed metal parts should be coated with a heavy duty rust preventivesuch as Houghton Cosmoline 1102 or equivalent

The mixer drives and any associated equipment must be inspected periodically to ensure

there is still an effective coating of rust preventative on the internal parts The coating should

be replaced as required

Remove motor fan cover and rotate motor fan weekly to prevent the forming of flat spots on

bearings and to refresh coating of gears and bearings with oil mixture Motor fans must be

rotated until the output shaft completes one revolution Reinstall motor fan cover

SHIPPING COVERS

All protective shipping covers must be removed from the mixer drive The shaft extensions

and outside machined surfaces are protected during shipment by a rust inhibiting compoundThis compound should be removed by using a solvent If the mixer is equipped with a mount

ing flange gently scrape do not scratch clean the surface Use a solvent or approved plantcleaner to remove any remaining residue

ACCESSORIES

Any field installed straight bore interference fit couplings must be installed carefully to pro

vide good contact on the driving keys as well as to prevent cocking on the shaft extensions

Since an endwise blow on the shaft may damage gears and bearings these attachments

must not be hammered into position but heated to approximately 375F and slipped onto

shafts

When prolonged storage is anticipated consult Philadelphia Mixers Long Term Storage Instructions for

more detailed information



M 2Q0 SECTION Service

CurrentSERVICE

PAGE 700



HIGH SPEED MOTOR COUPLING

The mixer has been shipped with a factory installed flexible high speed motor coupling

RIGID COUPLING

In many mixer applications the lower agitaor shaft as weli as the mixer drive output shaft are

shipped with rigid coupling halves and impeller hubs fixed in their proper positions Before

assembly in tank make certain that the rabbet faces of the rigid couplings are free of all

foreign matter nicks or burrs

FOUNDATIONS

The foundation must be rigid enough to maintain proper alignment with connected machineryThe foundation must have a flat mounting surface to ensure uniform support for the mixer drive

If the mixer drive is installed on a surface which is other than horizontal consult PhiladelphiaMixers to ensure that design provides for proper tooth contact and adequate lubrication

Customer designed fabricated pedestals or baseplates must be carefully analyzed to deter

mine that they are sufficiently rigid to withstand operating vibrations The mixer support struc

ture is to be designed so that dynamic angular defiection of the mixer is limited to 25 degreein any direction using the mixer support loads provided on the Outline Installation Drawingsupplied with this manual

When installing the mixer drive on structural steei the use of a rigid basepiate is stronglyrecommended Bolt mixer drive and baseplate securely to steel supports with proper shim

ming technique to ensure a level surface

If the mixer drive is to be installed on a concrete foundation allow the concrete to cure properlybefore bolting down the mixer drive For best installation grout structural steel mounting padsinto the concrete base rather than grouting the mixer drive directly into the concrete

LEVELING

When shims are used to level or align the mixer drive they must be distributed around the

base under all mounting pads to equalize the support load and avoid distortion of the housingand high localized stresses

Use a feeler gauge to determine thickness of required shims All pads must be squarelysupported to prevent distortion of the housing when the gear drive is bolted down

Copyrighl0 Philadelphia Mixers Specifications subject to change without notice



Current PAGE

VolumeSERVICE s00

GENERALISSUED

01 JUN 2002


MOUNTING BOLTS

It is essential that the mixer drive be securely bolted to its foundation utilizing boits of the

proper diameter to match its mounting holes Botts should be SAE Grade 5 or equivalentApproximate bolt torque values are as follows

Bolt Size Approximate Torque Valueinches Foot Pounds

1 2 45

58 95

34 150

78 200

300

1 1 4 660

1 1 2 1060




Current SERVICE PAGE 900

Volume I LUBRICATION ISSUED 10 JAN 2003


The mixer drives are shipped without oil They must be filled with the properlubrication before startup

The recommended type of oil for use in the 3850 series mixer drive is an extreme pressure

EP oif

AGMAlube No Tem erature Ran e Lubricant

3 EP 15F to 50F Mobilgear0 627 or


5 EP 50F to 125F Mobilgear 6300 or


Grease for bearings and MobilithOAW 2 or

seals when required Mobilith SHCO 220

Approximate Oil Capacity and Weight

3853MS2 3855MS2 3857MS2 3859MS2 3861 MS2

Oil Capacity 3 gallon 7 gallon 8 gallon 16 gallon 35 gallonWeight 450 bs 820 Ibs 1100 Ibs 1870 Ibs 37200 Ibs

3853MS3 3855MS3 3857MS3 3859MS3 3861 MS3

Oil Capacity 3 gallon 7 gallon 8 gallon 16 gallon 35 gallonWeight 4951bs 9051bs 11901bs 20051bs 39601bs

FILLING MIXER DRIVE WITH OiL

1 The mixer drive can be filled with oil in 2 places the breaher or the high speed gearinginspection cover

2 Remove dipstickbreather from top of mixer drive housing and wipe clean

3 ill mixer drive with recommended lubricant through breather hole Fill mixer until oil level

falls between the two lines scribed on sightgass Do not under fili or overfill The scribedlines represent minimum and maximum levels

4 After start up grease bearing at oil change intervals or every 6 months

LOW TEMPERATURE OPERATION

Philadelphia Mixers must be advised ifthe mixerwill be started up in temperatures less than10F above the pour point of oil used in the mixer Refer to oil manufactures data sheet for

pour point temperatures

OIL CHANGES

After the initial two weeks of operation of the mixer the original oil should be changed while the

eguipment is at operating temperature CAUTION take necessary precautions when handlinghot oil This oil may be strained and used again Consult your oil supplier for proper filtersize Often due to the wearingin process small metal particles will appear in the oil this is not

abnormal



M 2 SECTION Service

CurrentSERVICE PAGE 1000

Volume ILUBRICATION ISSUED 10 JAN 2003


Flush the mixer drive housing thoroughly after the original oil has been drained Fili the housingto the required level with SAE 10 straight mineral flushing oil Start mixer drive and bring up to

operating speed preferably without load and immediately shut down Drain flushing oil andfill with recommended operating lubricant to the proper level Oil should be changed after each

subsequent2500 hours of operation or six months of normal operation whichever occurs first

If changing from EP oil to synthetic lubricant for best results flush mixer drive Unusual environmental or load conditions may require repacement of oil as frequently as 1 to 2 month intervalsas determined by field inspection of the oil Special attention must be given to the inspection oflubricants when the following conditions exist

1 High operating temperatures resulting from heavy intermittent loads causing the temperature of the mixer drive housing to rise rapidly and then cool

2 Ambient temperature conditions which could cause sweating on the inside walis of themixer drive housing

3 Operating oil temperatures that exceed 200 F

4 When the mixer drive is exposed to an unusually moist or dusty atmosphere or corrosiveor reactive vapors

SYNTHETIC LUBRICANTS Consult FactorySynthetic lubricants have been used very successfully in mixer applications offering the

advantages of longer usable life better stability and operation over a wide temperature rangeIn some cases installed in outdoor service summerwinter changeout of oil can be eliminatedDo not misinterpret longer service life for lack of attention Unless field experience with a

specific synthetic lubricant is available use must be closely monitored for behavior in the

presence of moisture and chemicals Use should be coordinated between the user thelubricant supplier and Philadelphia Mixers

Only synthesized hydrocarbon fluids should be selected It should be high grade and

specifically formulated for industriai gear use It should be a nonreactive oxidation resistant

formulation noncorrosive to gears and bearings It should have good defoaming propertiesViscosity should be equal to recommended oils shown in Synthetic Oil table

Synthetic Oil Consult FactorySummer Ambient 50 to 125 10 to 50 AGMA 5EP or SO 320 Mobifgear0 220

Winter Ambient 15 to 50 10 to 10 AGMA 3EP or ISO 150 Mobilgear0150

After initial startup using synthetic lubricants sampie lubricant after the first three 100 hour

periods of operation thereafter take samples every2500 hours of operation or six monthswhichever occurs first Draw a onequart sample when mixeraerator is shut down and

analyze Change lubricant whenever sample reveals incipient deterioration



M 2QQQ SECTION Service

CurrentSERVICE

PAGE 1100

Volume I issuEO o utv 2002StartUp


PRELIMINARY CHECKS

When starting up any new equipment it is best to proceed cautiously Even though the installa

tion instructions are followed the existence of errors or omissions is always possible Before

initial startup review the following

1 Have ail separatelypacked parts been installed Often it is necessary to packagesmall or fragile parts separately

2 Are mounting bolts secure Check aI externa bolts screws accessories etc to ensure

they have not loosened during shipment or handling3 Are all couplings installed on shaft extensions with keys and fasteners in place4 Has mixer drive been filied with oil to indicated level All mixer drives are shipped

without oil Before startup all Philadelphia Mixers drives must be filled with the type and

arade of oil specified5 Have all inspection covers on mixer drive been closed and secured

6 Have required electrical connections been made

7 Have required piping connections been made

8 Are all pipe connections tight Tighten all pipe connections to ensure they have not loos

ened during shipment or handling9 Will impeller blades clear all tank projections when mixer is operating Manually rotate the

mixer impellers through 360 to check clearance

STARTUP PROCEDURE

1 If the mixer drive is equipped with a heater for low temperature operation turn on the

heater and allow oil temperature to rise to at least 40F

2 Start the mixer drive under as light a load as possible It is recommended that the mixingassembly be initially operated without liquid in the mixing tank in order to

observe the direction of rotation and clearances of impeller blades

OPERATIONAL CHECKS

1 The mixer drive must be checked for unusual sounds excessive vibration excessive heat

or oil leakage If any of these problems develop the mixer must be stoppedimmediately and the cause determined and corrected The operating temperaturemust not exceed 200F at any location in the mixer drive

2 If possible the mixer should be operated under a light load approximately halfloadfor one 1 or two 2 days to allow final breakin of gears After this period the mixer can

be operated under normal load

Copyright0 Philadelphia Mixers Specifications subject to change without nofice


ISM 2000 SECTION WarrantyCurrent wqRRqNT PAGE 200

Volume I ssuE o uN 2002


For a period of one year after date start up or eighteen months after delivery to Customer whichevercomes first Selier warrants that the products sold to Customer will be free fromdefects in materiais and workmanship and will perform the particularfunction for which theyare intended Mixers and aerators are warranted to be fit to perForm the function for which they are

intended when operated under the specified mixing or design conditions provided accurate and

necessary data have been furnished to Seller in writing by Customer Seller assumes no responsibility for the accuracy or reliability of specifications design conditions or other furnished by or on behaffof Customer or the ultimate user Customer selected materials are warranted only to conform withCustomer specifications Materials not specified by Customer shall be Sellers standard materials ofconstruction for out of tank components Material exposed to process are not warranted againstcorrosion or other deterioration due to exposure to vessel contents

These warranties shall not be effective if the product or part is not used strictly in accordance with allinstructions as to storage handling maintenance lubrication instaNation startupoperation and safety set forth in the manuals and instruction sheets furnished by Seller

The standards of theAmerican Gear ManufacturersAssociation will be used and shall govern where

appiicabfe in the manufacture of gears and gear drive assemblies unless Seller expressly agreesotherwise in writing

The foregoing limited warranties are exclusive and are in lieu of al other warranties express and

implied including but not limited to implied warranties of inerchantability or fitness for a particularpurpose

LIMTATION OF REMEDIES

Customers remedy for breach of any of the forgoing warranties shall be limited to replacement or

repair by Seller of any defective equipment or parts discovered during the 1 year warranty periodSuch products or parts shall be shipped to SellerFOBSelers plant orFOB at such other locationas may be designated by Seller Seller shall have the right at its sole discretion to refund the purchaseprice paid by Customer in lieu of repair or replacement Without limiting the foregoing under no

circumstances shall Seller be liable for any expenses for removal of allegedly defective equipment or

parts or for installation costs of repaired or replaced equipment or parts

All claims for breach of any Sellerswarranties shall be barred unless Customer notices Seller ofsuch breach in writing within 30 days of discovery of the breach

LIMITATION OF LIABILITIES

Seller shall not be liable for any liquidated consequential or incidental damages due to defects inmalfunctions or failure of its products to perform late delivery of loss of use nor shall Sellers totai

liabifity under any circumstances exceed the purchase price of the products sold Seiler shall not beliable for any damage resulting from improper storage or handling following shipment Seller shall not

be responsible for repairs performed by others outside Sellers plant unless such repairs are authorized by Seller in writing in advance Seller shall not be responsible for any defects in any componentssuch as gears shafts bearings or motors furnished by others



ISM 2000 SECTION ShaftHandlin

C u r re n tSHAFT HANDLING PAGE 1300

Volume ISSUED 01JUN2002


Agitator Shaft Lifting Procedure

Caution Only trained professionals experienced in the handling rigging and

lifting ofheavy machinery should be employed to instal or remove

mixer components

Warning Never lift the agitator shaft from the horizonfal position with one end of

the shaft on the ground Lifting in this manner may bend the shaft asin Fiaure 1A

NOTE In certain applications the impellerhubs mayhave to be removed

from the agitatorshaft prior to installing the agitaforshaff into the

vesse


Handling and lifting of mixer components like ail heavy machinery can be dangerous and

proper methods may depend upon the particular installation Philadelphia Mixers recom

mends that only trained professionals perform these tasks during installation or removal of the

mixers and assumes no responsibility for injury to persons or property that may occur duringthese activities

1 Attach one lifting sling at or near the coupling at the top of the agitator shaft Use oniyproperly rated newnonmetallic slings See Outline Installation drawing forweights

2 Attach a second lifting sling approximately onethird of the length of the shaft from the

bottom See Fiqure 1 B

3 Lift the agitator shaft horizontally to a sufFcient height so that the impeller end of the shaft

will not contact the ground when the shaft is moved into a verticai position

4 Continue to lift the agitator shaft from the coupling end sling only until the shaft is vertical

5 When the agitator shaft is vertical remove the impeller end sling and use the coupling end

sling to lower the shaft into the mixing vessel



fSM 2000 SECTION ShaftHandlin

C u rren t SHAFT HANDLING PAGE 1400



Shaft Lifting Procedure Diagram

Figure 1A

fi

is

f

i

Ir

Figure



SM 2Q SECTION Gear Box Handlin

CurrentRECEIPT AND HANDLING

PAGE 1500

Volume ISSUED 01 JUN2002


Receipt and Inspection

1 3850 Series mixers are generally shipped bolted to a hardwood pallet Remove any

packaging material from around the mixer and carefully examine it for evidence of dam

age during shipping If damage is found retain the damaged material and contact Phiia

delphia Mixing Solutions Philly OnCall Services at18007331341 for guidance

2 Inventory the equipment against the shipping papers to verify that the correct componentshave been received If any components appear to be missing contact Philadelphia Mixers

or your sales representative for guidance

3 Inspect the mixer drive and other components for evidence of rust or corrosion particularlyif there are areas of chipped paint due to handling damage If corrosion is present contact

Philly OnCall Services at18007331341 for further instructions



SM 20 SECTION Gear Box Handling

CurrentGEAR BOX HANDLING PROCEDURES

PAGE 1600

VolumeRECEIPT AND HANDLING

issuEO o uN2oo2

REVISION 01 MAY 2003

Caution Only frained professionals experienced in the handling rigging and lifting of

heavymachineryshould be employed to install orremove mixercomponents


Handling and lifting of mixer componentslike ail heavy machinerycan be dangerous and

proper methods may depend upon the particular installation Philadelphia Mixers recommends

that only trained professionals perform these tasks during installation or removal of the mixersand assumes no responsibility for injury to persons or property that may occur during these

activities

In addition the foliowing genera guidelines should be observed when moving or lifting the

mixer

1 Keep the mixer drive in the same position as shipped from factory

2 Neversupport the mixer by the output shaft

3 When the mixer is to be placed on the ground put blocks under the mounting surfaces

4 Neverdrag the mixer This will damage the machined mounting surfaces and could dam

age the housing

5 There are eyebolts on both the mixer drive housing and the motor housing Do not lift the

mixer drive by the eyebolts on the motor housing Lift the mixer gear drive by the eyeboltsattached to the top of the drive housing Use lifting slings to distribute the load evenly Make

sure the slings are positioned so they do not place a load on external components pipesgauges etc when the mixer is lifted

6 Nevershock the mixer by snapping loose lifting rigging

7 The 3850 series mixer is shipped on two or more skids One skid wiil contain the mixer

drive which is positioned horizontally or vertically and the other skids will contain the

agitator shaft andor additional components Remove all shipping restraints Two hoists or

cranes are necessary to lift the mixer and agitator parts LIFT THE MIXER DRIVE BY

ITSELF DO NOT ATTACH THE AGITATOR SHAFT


PHILADELPHIAMIXERS N 3850 Series

SM 2 SECTION Gear Box Handling

Current PAGE 1700

Volume I RECEIPT AND HANDUNGissuo ouN2oo2


9 The mixer drive must be carefully lifted and positioned into a vertical position to be installed

correctly by using the eyebolts provided Using two shackles cables and a nylon strapwrapped around the drivestand lift the mixer drive using two cranes When it reaches the

appropriate height lower the crane with the strap Be sure to support the mixer drive with

the two shackles and cables Disconnect the strap and replace it with a shackle and cable

Proceed to position the mixer drive in the vertical position and locate on blocking Reposition all three shackles and cables on ore crane for a correct vertical lift DO NOT USE

THE EYEBOLT LOCATED ON THE MOTOR FOR LIFTING PURPOSES

10 Lift and position the agitator shaft into the tank and secure the agitator shaft flange with

blocking Be sure two bolt holes 180 degrees opposite each other are accessible The

face and tenon of all rigid coupings must be perfectly clean and free of nicks Refer to

Page 200 Shaft Handling

11 Carefully lift the mixer drive and lower it over the agitator shaft DO NOT ALLOW THE

COUPLING FACE TO MAKE CONTACT Insert two coupling bolts 180 degrees apartand carefully tighten them to engage fhe fenon and pull the coupling faces together Insert

the remaining coupling bolts and tighten being sure to torque the bolts to the value specified Remove the shaft blocking

12 Lower the mixer onto the tank with the proper holddown hardware It is essential that the

mixer drive be securely bolted to its foundation utilizing bolts of the proper diameter to

match its mounting holes Bolts should be SAE Grade 5 or equivalent Shear blocks are

recommended if gear drive has a heavy overhung load in a direction that would place the

bolts in shear Approximate bolt torque values are as follows

Bolt Size Approx Torque Value

Inches Foot Pounds

1 2 45

58 95

34 150

78 200

1 300

1 1 4 660

1 1 2 1060



SM 20 SECTION Long Term Stosage

C u rren t PAGE 2400

Volume iLONG TERM STORAGE

ISSUED 01 JUN2002


These procedures are designed to protect your mixers or aerators frorn atmospheric corrosionor other harmful effects during storage or periods of inactivity The critical periods are before thenew mixer is ever run and prolonged idle periods thereafter

The storage instructions for gear drive protection can be valid for periods as long as two yearsfor equipment stored under best conditions Longer term storage is acceptable provided

necessary procedures are followed contact the Service Department of Philadelphia Mixers foradditional information Any costs for storage materials or labor required after shipment will be

paid by the customer unless specifically contracted for by Philadelphia Mixers at the time of

purchase

Specific storage procedures to be foilowed are meant to maintain the Mixers or Aerators as

nearly as possible to their as shipped condition Failure to properly store and protect the equipment as outlined may void any warranty either expressed or implied It is advisable for theuser to keep a detailed log to record the results of inspections and maintenance performed on

each Aerator or Mixer

We recommend that the gear reducers and motors be kept in a dry temperaturecontrolledindoor area We do nt recommend outdoor storage There may be some instances whereindoor storage is impossible Storage of special equipment supplied by Philadelphia Mixers

such as motors control panels etc is to be in accordance with the manufacturers recommen

dations included with this manuai



SM 2000 SECTION Long Term Storage

Current PAGE Zs00

Volume 1LONG TERM STORAGE

Receiving the EguipmentISSUED o uN2oo2

REVISION q Q1 MAY 2003

1 Check impellers and impeller shafts for obvious shipping damage Shouid such

damage be found immedtately report the details to the carrier that delivered the

equipment and the Philadelphia Mixers ServiceDartment

Carefully move these components to a storage area where they will be least likely to

be damaged by contact with fork trucks etc Carbon steel components whether

painted or not should be protected Protective coatings against atmospheric corro

sion as applied for shipping should be checked for damage and renewed or

patched as necessary Periodic checks preferably at no more than 30day intervalsshould be made to assure that no rusting or other damage has occurred Should such

be noted corrective action should be quickly initiated Contact Philadelphia Mixers

Service Department for guidance2 Carefully check before putting drives into storage to assure that the plugs are instailed

in place of breathers and ali other openings to the atmosphere are sealed

3 If the duration of storage in any of 3 environments to be defined in the following will

not exceed six months for a newlymanufactured drive the gear reducer if properlyprepared wili not require additional protective procedures Inspectthe drive to assure

that longterm preservation procedures were applied at the factory This is indicated

by a tag attached to the drive which will say This mixeraerator has internal rust

protection which is considered adequate under normal INDOOR storage conditionsFOR SIX 6 TO TWELVE 12 MONTHS from date of preservation application The

date of the preservation application appears on the tag

PHONE 7178322800

FAX 7178321746


Email protech@philamixerscomCopyright

0Philadelphia Mixers Specifications subject to change without notice


SM 200 SECTION Long jerm Storage

Current PAGE 2s00

Volume ILONG TERM STORAGE

ISSUED 01 JUN202


Field Application of Corrosion Protection

If field application of longterm internal corrosion protection to a mixer drive is necessaryfor any reason arrangements should be made with the Philadelphia Mixers Service

Department for a factory representative to be on hand if possible while the preservationprocedure is carried out The first step is to inspect the drive to assure that a damagingdegree of corrosion does not exist If existing corrosion or other damage does not re

quire attention proceed as follows

To coat all internal surfaces with a protective compound such as Cosmoline 1102 aproduct of Houghton International Inc Valley Forge PA spray or brush areas above oil

level thru the access windows and fill the gear drive to the proper oil level with the com

pound To insure complete coating rotate the motor coupling a sufficient number of timesfor two complete revolutions of the drive output shaft Drain therustpreventative com

pound Seal all drive openings with plugs paper impregnated with uapor phase corrosion

inhibitor caps etc Alternatively or if no access openings exist the procedure below maybe used

If the gear drive is supplied with an external pump lubrication system DO NOT PUMP

COSMOLINE THRU THE PIPING SYSTEM because Cosmoline contains solids which

may clog small orifices and spray nozzles Instead fill the gearbox to just below the

proper low oil level with about 1 part Rust Veto Concentrate a product of HoughtonInternational Inc Valley Forge PA to 9 parts of a standard gear or motor oil of the recom

mnded viscosity To this mixture add about 2 of NOX Rust VCI10 a product of

Daubert Chemical Co Chicago IL volatile corrosion inhibitive oil Run drive unloaded

including the lubrication pump for about one hour then seal afl openings as above Unit

does not need to be drained if it is not to be moved during the length of storage Every 6

months unseal the drive drain just enough oil to add 2 capacity of NOX Rust to main

tain the proper oif level run the drive and pump for one hour and reseal This procedurecan be repeated for up to 3 years of storage Drain oil completely and flush drive before

adding the recommended operating oil and placing into service

Further prepare the drive motor for storage as described by the storage location

according to the appropriate following procedures

Storing in 3 Types of Locations

Please note that there are 3 basic types of storage locations and environments for Aera

tors and Mixers Storage procedures are different for each Use th procedure which

applies to your drive



SM ZQQQ SECTlON Long Term Storage

CurrentLONG TERM STORAGE

PAGE 2700

Volume ISSUED 01 JUN2002

REVISION q 01 MAY 2Q03

A Indoor Storage in a Dry TemperatureControlled Area

The preferred storage environment for Mixers orAerators is a dry area with relativelyconstant temperature prevent condensation The use of a mechanical dehumidifyingsystem with controls to maintain the atmosphere at 40o relative humidity or lower is

recommended

If automatic humidity control is unavailable and conditions become extreme it may be

necessary to use trays of renewable desiccant such as silica gel or portable dehumidifi

ers to remove moisture from the air in the enclosed storage area in order to properlymaintain necessary relative humidity levels


normai operating oil level with the recommended oi see Oqerating and Maintenance

Instructions for the specificAerator or Mixer Add NoxRust VCI10 or equal volatile

corrosion inhibitive oil at the rate of 2 of sump capacity added to the conventional oii

used Replace oil fill plug when finished Assure that all other openings in the gear drive

are closed to the atmosphere Rotate shaft several times by removing motor fan cover

and rotating fan by hand Reinstall fan cover At six month intervals drain 2 of sump

capacity and replace with NoxRust



Motor shafts in storage should be rotated at regular intervals We recommend 5 completerotations of the shafts Foow motor manufacturer recommerdatonsfor torage Motors

supplied with breathers and drains must be inspected for operability Motor bearingsmust be greased per instructions from the manufacturer of the motor supplied These

recommendations have been supplied with this manual

B Indoor Storage No Temperature Nor Humidity Control

Motors must be stored with all breathers and drains operable and motor heaters if anyconnected If motor heaters are furnished they musf be connected to a proper power

source upon placement in storage regardless of the duration of storage Cover each

motor but do not seal it off as this might trap moisture

If no motor heaters are supplied motors must be securely wrapped in plastic with desic

cant bags placed inside Replace the desiccant bags at 30day intervals



PHILADELPHfA MIXERS N 3850 Series

SM 20 SECTION Long Term Storage

CurrentLOiVG TERM STORAGE

PAGE Zs00

Volume 1SSUED 01 JUN2002


Motor shafts in storage should be rotated at regular intervals We recommend 5 compieterotations of the shafts Follow motor manufacturer recommendations for storage Motors

supplied with breathers and drains must be inspected for operability Motor bearings must

be greased per instructions from the manufacturer of the motor supplied These recommen

dations have been supplied with this manual

Each gear reducer should be stored in its normal operating position and then filled to nor

mal operating oil level with the recommended oil see Operatinq and Maintenance Instruc

tions for the specificAerator or Mixer Add NoxRust VCI10 or equal vofatile corrosion

inhibitive oil at the rate of 2 of sump capacity added to the conventional oil used Replaceoil fill plug when finished Assure that all other openings in the gear drive are closed to the

atmosphere Rotate Shaft several times by removing motor fan cover and rotating fan byhand Reinstail fan cover At six month intervals drain 2 of sump capacity and replace with

NoxRust

C Outdoor Storage Not Recommended

PROCEDURES TO FOLLOW WHEN OUTDOOR STORAGE IS UNAVOIDABLE

All Aerator or Mixer components must be kept off the ground Storage should be on skids or

piatforms and protected with a tarpaulin or other waterproof covering If this equipment is

mounted for storage in its eventual operating location on top of tanks or wastewater treat

ment basins the equipment should be protected by a tarpaulin or other waterproof cover

ing

If the furnished motors have motor heaters connect these to a proper power source immedi

ately upon putting into storage

If no motor heaters are supplied motors must be securely wrapped in plastic with desiccant

bags ptaced inside Replace the desiccant bags at 30day intervals

Motor shafts in storage should be rotated at regular intervals We recommend 5 completerotations of the shafts Follow motor manufacturer recommendations for storage Motors

supplied with breathers and drains must be inspected for operability Motor bearings must

be greased per instructions from the manufacturer of the motor supplied These recommen

dations have been supplied with this manual

Each gear reducer should be stared in its normal operating position and then filled to nor

mal operating oil levef with the recommended oil see Operating and Maintenance



PHILADELPHIAMIXERS NDEX 3850 Series

SM 200 SECTION Lon Term Stora e

C u rrent PAGE Zs00

Volume ILONG TERM STORAGE

ISSUED 01 JUN 2002


Instructions for the specificAerator or Mixer Add NoxRust VCl10 or equal volatile corro

sion inhibitive oii at the rate of2 of sump capacity added to the conventional oil used Re

place oil fill plug when finished Assure that all other openings in the gear drive are closed to

the atmosphere Rotate Shaft several times by removing motor fan cover and rotating fan byhand Reinstall fan cover At six month intervals drain 2 of sump capacity and replace with

NoxRust

NOTE In the event that the Aerators or Mixers are fully installed and secured in

their eventual operating location with full power available and a standard startupprocedure possible revert to Operating and Maintenance lnsfructions manual for

filling each drive with proper lubricant and conducting a thorough startup check

and initial startup to prepare the equipment for later normal operation Havingdone this it is absolutely mandatory that each Aerator or Mixer must be run

twice a week for a period of one hour Note once operated the corrosionprotective coating on drive internals has been removed by operating with normal lubri

cant the internals are now subject to atmospheric corrosion more than everExperience has shown that failure to follow the operatetwiceaweek instruction

between date of installing and testing a drive and the start of continuous operationcan be the most critical period for potential damage by atmospheric corrosive

attack

From Storage Into Service

All applicable portions ofthe Operating and Maintenance Instructions should be reviewed for

special instructions relative to handling of the assemblies and storage procedures to followfor motors couplings or special auxifiary equipment supplied in each assembly

Preparing StoredAeratorsMixers for Service

1 Wipe off any dust and other accumulated dirt or grime from the exterior of each drive as

sembfy Inspect both interior and exterior of the gear drive fior any rusting f rust or other

damage is noted contact Philadelphia Mixers Service Department

2 Remove motor coverings or wrappings and any desiccant bags that may have been

placed inside the wrappings Be sure that motor breathers and drains are operable

Remove plugs from breather holes on gear drives and install the breather shipped with the

drive



ISM 2000 SECTION Ratio

CurrentqINTENANCE INSTRUCTIONS

PAGE ao00

Volume I3855MS3 Q3 RATIO CHANGE DRAWING ISSUED 01 JUN2002


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Copyright0 Phifadelphia Mixers Specifications subject to change without nolice



Current PAGE 4100

Volume I3855M TRIPLE REDUCTION

SSUEDDISASSEMBLY INSTRUCTION 01 JUN2002


Maintenance Instructions for Ratio Change

NOTE ALL HARDWARE IS METRIC

1 Lock out tag out procedure

a Open the disconnect on the motor control panelb Place a lock and warning tag on the control handle

c Try to start the motor if it starts there is a remote starter somewhere locate and

lock it out

2 Drain the oil from the mixer

3 Remove the bolts 82 and remove the triple reduction adapter 80 and the highspeed input shaft 93 Remove the bolts 87 72 and remove the thru cap high speed

4 Remove the retainer ring 69 and using a gear puller with a rose bud tip graduallyheat the high speed gear 90 from the outside diameter into the inside diameter and

remove same Remove the bolts 74 73 72 and carefully remove the high speed end

cover 70 Remove the bolts 77 securing the retainer plate 75 to the high speedend cover 70 and remove

5 Remove the bolt and thrust plate 57 securing the intermediate gear 60 to the bevel

pinion shaft 55 Using a gear puller and a torch with a rose bud tip gradually heat the

intermediate gear 60 from the outside diameter in to the inside diameter and remove

same

6 Remove all bearing cups and cones 67 68 95 96 oil seal 84 and any gasketsand shims 81 85 76 Carefully ciean all items




Current PAGE 4200Volume I

3855M TRIPLE REDUCTIONASSEMBLY INSTRUCTION SSUED olUN2oo2


1 Secure the intermediate shaft 63 and install the outboard bearing cone 68 usingheat induction heater small oven heat the intermediate pinion 61 and place on theintermediate shaft 63 and install the inboard bearing cone 67 If the intermediateshaft is an integral just instail the inboard and outboard bearing cones 67 68

2 Carefully position andtap the inboard bearing cup 67 into the housing 10 checkwith a feeler gage behind the bearing cup 67 to be sure it is seated correctly

3 Heat the intermediate gear 60 and carefully position on the bevel pinion shaft 55Position the hex head cap screw and thrust plate 57 and secure the intermediate gear60 to the bevel pinion shaft 55 using loctite 242 torque to specifications Positionthe intermediate shaft assembly 63 into the housing 10

4 Coat the housing end with black permatex 2 install two dowel pins 375 diameter intothe housing 10 and position the housing cover high speed end 70 on the housing10 Install ten lockwashers 72 ten hex head cap screws 73 and four socket head

cap screws 74 and torque to specifications

5 Install the outboard intermediate shaft bearing cup 68 in the housing cover highspeed end 70 and gently tap into position until it just barely touches the outboard

bearing cone 68 Place the retainer plate 75 on the housing cover high speed end

70 and using a feeler gage check the dimension between the retainer plate 75and the high speed end cover 70 and record Add an additional 010 to the re

corded dimension secure this amount of shims 85 and position over the outboard

bearing cup 68 Install the retainer plate 75 over the outboard bearing cup 68 position four hex head cap screws 52 and torque to the required specification

6 Using a magnetic based indicator to check the endplay of the intermediate shaft 63Shims will need to be added or removed to reach the correct endplay setting After the

correct endplay setting is accomplished remove the four hex head cap screws 52apply loctite 242 to the hardware replace and torque to specifications

7 Secure the high speed input shaft 93 and install the outboard bearing cone 96Using heat induction heater small oven heat the high speed pinion 91 and positionon the high speed input shaft 93 place the high speed pinion shaft spacer 94 on the

high speed input shaft 93 and install the inboard bearing cone 95 If the high speedshaft is an integral just install the inboard and outboard bearing cones 95 96

8 Carefully position and tap the inboard bearing cup 95 into the housing cover high




Current PAGE 4300

Volume I3855M TRIPLE REDUCTION

ASSEMBLY INSTRUCTION continuedSSUED o utv2oo2


speed end 70 check with a feeler gage behind the inboard bearing cup 95 to be sure

it is seated correctly

9 Heat the high speed gear 90 and carefully position on the intermediate shaft 63 and

install the retainer ring 69 Position the high speed shaft assembly 93 into the inboard

bearing cone 95 and mesh the teeth with the high speed gear 90 Position the gaskethigh speed adapter 81 on the housing cover high speed end 70 Position the tripiereduction adapter 80 on the housing cover high speed end 70 and secure usingseven socket head cap screws 82

10 Carefully position and tap the outboard bearing cup 96 into the triple reduction adapter80 until itjust barely touches the outboard bearing cone 96 Place the thru cap highspeed 83 and using a feeler gage check the dimension between the thru cap highspeed 83 and the triple reduction adapter 80 and record Add an additional 010 to

the recorded dimension secure this amount of shims 76 and position over the out

board bearing cup 96 Position the lockwashers 72 and hex head cap screws 87and torque to specifications Using a magnetic based indicator check the endplay of the

high speed input shaft 93 Shims will have to be added or removed to reach the correct

endplay setting Instalt the oil seai 84 after the correct endplay setting is accomplished

11 Reinstall the high speed couping 209 on the input shaft 63 and proceed to install the

motor mounting spooi 200 and motor 220 with the correct hardware and torque to

specifications


n

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P

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Pa rts


ISM 2000 SECTION Parts

Current PAE 6600

Volume I QuofeOrderForm ISSUED 01 JUN2002


QUOt@

Serial Number Customer

Order Number Requisitioner

Model Return Fax Number

Fax to Philadelphia Mixers Parts Sales 717 8321746

or Fax to your local sales representative

Bubble Item Number Description Qty Price Each Total Price Delivery

NotesCommentsCustomer

NotesCommentsPM




Current3855MS3 COMPOSITE PARTS DRAWING

PAGE 7300



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Copyrfght0 Philadelphia Mixers Specifications subject to change without notice



Current3855MS3 COMPOSITE PARTS L1ST

PAGE a00



Bubble Qty Part No Description Bubble Qty Part No DescriptionNo

10 1 802050060 Housing 61 1 Consut Factory Intermediate Pinion11 1 802930019 Drywell 62 1 340000067 Key12 1 350000658 Breather 63 1 consuit Factory Intermediate Shaft13 3 340002716 I Bolt Shoulder 64 1 ConsultFactory Int Pinion Shaft Spacer20 1 800400259 Cap Thru Pug 65 1 803150375 HS Pin Shft Spacer

21 a sets 360000391 Shim Set 66 1 803150377 Int GearSpacer22 8 330004596 Lockwasher 67 1 310000083 Bearing Cup23 7 330004600 Hex Head Cap Screw 67 1 310000084 Bearing Cone26 1 800250143 Blind Cap 68 1 310000617 Bearing Cone27 1 802250254 Gasket 68 1 310000018 Bearing Cup

28 4 330004492 Lockwasher 69 1 340000288 Retainer Ring29 4 330004594 Hex Head Cap Screw 70 1 801650182 HS End Cover30 1 804850094 Drive Sleeve 71 2 330000159 Dowel Pin31 2 310000265 Bearing Cone 72 16 330004593 Socket Hd Cap Screws31 2 310000811 Bearing Cup 75 1 800400266 IPS Thru Cap

33 1 801250040 Spiral Bevel Ring Gear 76 a sets 802250176 Shim Set34 1 360000454 O Ring 77 4 330003879 Hex Head Cap Screw35 1 340000041 Key 78 1 340000088 Key36 2 330004600 Hex Head Cap Screw 80 1 801650187 Triple Red Adapter37 1 800850041 Thrust Plate 81 1 802250217 HS Adapter Gasket

38 4 330003879 Hex Head Cap Screw 82 6 330004020 Lockwasher40 1 800400143 Cap Thru 83 6 330004591 Hex Head Cap Screw41 a sets 360000347 Shim Set 84 2 330004592 Socket Hd Cap Screw42 1 360000042 Oil Seal 85 1 800400265 HS Thru Cap43 6 330004596 Lockwasher 86 a sets 360000332 Shim Set

44 6 330004600 Hex Head Cap Screw 87 1 360000016 Oil Seal45 1 806800088 SplitAdapterRing gg 4 330002688 Lockwasher46 4 330004623 Hex Head Cap Screw 8g 4 330004612 Hex Head Cap Screw47 1 800850127 Retainer Plate 90 1 Consuit Factory High Speed Gear48 1 340002729 Retaining Ring Spirolox 91 1 Consuit Factory High Speed Pinion

50 1 800450115 Spiral Bevel Pin Cartridge 92 1 340000067 Key51 a sets 360000342 Shim Set 93 1 consuit Factory High Speed Input Shaft52 6 330004599 Hex Head Cap Screw g4 1 Consult Factory Spacer53 1 310000167 Bearing Cone 95 1 310001399 Bearing Cone53 1 310000166 Bearing Cup g 1 310001398 Bearing Cup

54 1 310000031 Bearing Cup gg 1 310000617 Bearing Cone54 1 310001431 Bearing Cone 96 1 310000018 Bearing Cup55 1 8Q4400027 Spiral Bevel Pinion Shaft 9g 1 360000766 Sleeve Speedi56 1 330000392 Bearing Lockwasher 100 1 340000086 Key56 1 330000045 Bearing Locknut 101 1 800550102 Cover Inspection

57 1 806750102 Thrust Piate 102 1 802250273 Gasket58 1 330004598 Hex Head Cap Screw 103 4 330004492 Lockwasher59 1 340000556 Key 104 4 330004594 Hex Head Cap Screw60 1 Consult Factory Intermediate Gear



M 20 SECTION Parts

Current PARTS PAGE 6500

Volume I ISSUED 01 JUN2002


Parts Order Procedure

This manual includes the information necessary to assist you in ordering replacement parts for

your Philadelphia Mixers 3850 Series Mixer Drive Please use the following procedure for ease in

meeting your mixer parts requirements

The parts order procedure will be simplified if you use the following 3 reference materials included

in this manual

1 Parts QuoteOrder Form

2 Parts List

3 Drawings bubble

Find a copy of the ParsQuoteOrder Form on page 2 of this section Please make a coav of

this form for your transmittal

Use the Parts QuoteOrder Form when requesting quote information from Philadelphia Mixers

Upon compfetion of a1f information this form can be used as an order submittal along with a

copy of your authorized purchase order form

Please fill in the serial number order number model customer name requisitioner return fax

number and all information for parts required bubble item description and quantity re

quested FiH in this information completely for easy cross reference to the specific piece of

equipment

The identification information for the particular mixer drive referenced can be found on the

Outline Installation Drawing cover page of this manual andorthe nameplate attached to the

mixer drive

This manual has a complete parts list for your specific gear drives and related accessories to

assist you in ordering replacement parts

Bubble number drawings are enclosed for your reference Use these for easy identification of

the required replacement parts

o Please make any notes or comments on the bottom of the Parts QuoteOrder Form bottom in

the space provided

Upon completion of all information FAX the Parts QuoteOrder Form to your local sales repre

sentative or the Parts Department at Philadelphia Mixers at7178321746 for your quote and

delivery schedule Your quote will be returned as soon as possible so you can proceed with

your order processing Remember this form can then be used as an order submittal along with

a copy of your authorized purchase order form


A

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F 4

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k

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Maintenance


SM 200 SECTION MaintTrouble

CurrentMAINTENANCE AND TROUBLESHOOTING

PAGE 00



Preventive Maintenance Schedule for 3850 Series Mixers

PM Intervai Required Preventive Maintenance

Daily Inspect mixer drive for unusual sounds or oil leaks

Weekly Check oil level on dipstick Mixer must be off Record

level and add oil as necessary

Monthly Check oil for contamination

Check operation of guards alarm systems gaugescontrols and other safety devices in accordance with

Owners Piant Safety Operating Procedures

Six Month or 2500 Hour Intervals Refer to Motor Service Instructions for Greasinginstructions

Change oil in mixer drive

Inspect impeller for evidence of erosion and

corrosion

Check hardware tightness Retorque to originalspecifications

Extended Shutdown Periods See appropriate Long Term Storage Instructions

Greater than 1 Week Run mixer for approx 1 hour twice a week to coat

gears and bearings with oii and to prevent rust due to

moisture condensation

Note These Philadelphia Mixers Procedures are for mixers installed in their normal

operating position See Philadelphia Mixers LONG TERM STORAGE INSTRUC

TIONS for additional information on storage of mixers




CurrentMAINTENANCE AND TROUBLESHOOTING

PAGE 1900

Volume I ISSUED 01 JUN2002


TROUBLESHOOTING

Warning Lock out the motorand remove all external loads before servicing the mixer

or accessories Refer to the safety precautionsTrouble What to Inspect Action

Motor Determine whether the specific gravity or viscosity of the

Overload process has changed from that originally anticipatedInspect impellers for material buildupHave additional baffles been added to the vessel or the

size of the baffles increased

Check for proper impeller rotation as shown on the outline

installation drawingCheck the outline installation drawing for proper impellerlocation and proximity to intank appurtenances

Overheating Oil level too low Shut off mixer and check the oil level in sightglass

Breather Breather must be open and cfean Clean breather

regularly

Grade of oil Oil must be of the grade specified in the lubrication instruc

tions If it is not flush mixer and refill with the correct gradeof oil

Condition of oil Check to see if the oil is oxidized dirty or of a high sludgecontent Flush and change the oil per the lubrication instruc

tions

Stuffing box Stuffing box gland must not be overtightened See Pack

if supplied ing Procedure for proper packing and breakin Included if

applicable

Are bearings prop Adjustabfe tapered bearings must be set at proper lateral

erly adjusted clearance or preload Call Philadelphia Mixers ProTech

Services18007331341 Email protech@philamixerscomRust

formation in Make necessary provisionsto prevent entrance of water mixer

due to the Use lubricant with good rust inhibiting properties Make sure entrance

of water or oil level is correct See Lona Term Storagef nstructions humidity

Are

bearings and Abrasive substance will cause excessive gear and bearing gearsexposed to an wear Make necessary provisionsto prevent entranceof abrasive

substance abrasive substance Clean and flush mixer drive thoroughlyegdusty atmo and refill with new oil Revise maintenance practices to sphere

include more frequent oil changes Copyright0

Philadelphia Mixers Specifications subject to change without notice


SM 2 SECTION Maint Trouble

C u rrent PAGE 2000

Volume IMAINTENANCE AND TROUBLESHOOTING

ISSUED 01 JUN2002


Trouble What to Inspect Action

Noise Coupiing wear Check input coupling for wear Replace if worn


erly adjusted clearance or preload Call Philadelphia Mixers ProTech

Services18007331341 Email protech@philamixerscomAre

bearings and Shut off mixer and check the oil level at sightglass gearsproperly Oil must be of the grade specified in the lubrication instruc lubricatedtions If it is not flush mixer drive and refill with the correct grade

of oil Hardware

tightenedBe certain that all mounting and coupling hardware is tightened

to the correct wrench torque Mixer

support Does the mounting arrangement for the mixer provide structuresufficient support to prevent wobblingor vibrationof the assembly

See Outline Installation Drawing for criteria Vibration

Agitator Shaft Agitator shaft should not be bent The rigid coupling halves mustbe connected accordingto the instructions Critical

Speed If the shaft and or impellers are supplied by others check for

a critical speed condition Vibrations can occur througha particular

speed range Steady

bearing Has excessive wear occurredto trie steady bearing Is the if

applicable bearing securely bolted to the vessel and is it properly alignedInspect

hardwareIs all blade hardware and extension arm hardwareif applicable

properly torqued Including agit shaft couplings andmounting hardware Oil

Leakage Plug at drain and Apply pipe joint sealant or equal and tighten fittings standardpipe fittings Housing

and caps Tighten capscrewsor bolts to proper torqueIf not entirely effectiveremove housing cover and caps Clean mating surfacesand apply new sealing compound gasket Mixer

output shaft Has the recommendedoil level been exceeded Check oil levelat sightglass Drain oil to the correct level Breather

open Breather must be open and clean PHONE

717 8381341FAX 717 8321746ProTech

Services1 8007331341E mailprotech@philamixers comCopyright0PhiladelphiaMixers Specifications subject to change without notice


SM 2 SECTIONMaintTrouble

Current PAGE 2100

Votume i MAINTENANCE INSTRUCTIONS iSSUED 01 JUN 2002


A

Spiral Bevel Gears

Typical Preferred Tooth Contact

Pinion Member Left Hand in All Cases Shown

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Central Toe

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Bottom Side

Central Toe

Contact

Bottom Side Top Side

Central Toe Central Toe

Contact Contact

BProfile Error

Profile Error

To Correct move out on pinion coneTo Correct move in on pinion cone

Mti

ERROR 4

ERRORs Top Side Low Top Side High

E Heel Contact Toe Contact

ri

T

Bottom Side Low Bottom Side HighToe Contact Heel Contact

Bottom Side High Top Side High Bottom Side Low Top Side LowToe Contact Heel Contact Heel Contact Toe Contact



SM 200 SECTIONMaintTrouble

Current MAINTENANCE iNSTRUCTIONS PAGE 2200

VOIU111@ I Diagnosing Causes ofISSUED

Helical Gear Tooth Damage01 JAN 2001


Shown here are typical illustrations of the five basic3causes of gear tooth failures although this is an y

a

oversimplification of gear tooth failures it might be

of some value in solving problems in the field The

five basic causes are

1 Original surface roughness 32 Foreign matter in the lubricant E3 Mechanical damage t r a4 Metal failure

5 Lubrication failure yPhiladelphia Mixers has a competent staff of

engineers to furtheranalyze yourgearproblems5

Foreign Material in the Lubricant

This failure shows upon the surface as wearr

f scratches or dents When contaminating mate

s rial is of a fine nature a lapping or polishingoccurs however tooth profiles also show wear

f s

Scratches of this nature are most prominent at

root and tip of teeth where sliding is greatestS M h

1 aa32

Thorough flushing of the mixer drive and replacement of the lubricant will eliminate this cause of

g failure

Original Surface Roughness 4F

No matter how smooth a surface may appear to

the eye it is comparatively rough when viewed 4under the microscope Usually lubricatonwill

provide a thin film for protection however under wn

borderline conditions these high spots will be

more highly stressed than adjacent areas Thus

pitch line pitting occurs

Improvement of finish such as shaving grindingor lapping will help this condition Mechanical Damage

This sort of damage includes bent broken or

scarred teeth In most cases when damage first

occurs only one or two teeth are affected ff teeth

are completely cracked off an examination of the

broken surface will usually indicate whether the

break is due to sudden impact overload or from

fatigue Impact overload condition will be dull in

color and crystallike structure


PHILADELPHIA MIXERS n1 3850 Series


Current MAINTENANCE INSTRUCTIONS PAGE 2300

VOIUtII@ I Diagnosing Causes of ISSUED 01 JUN2002Helical Gear Tooth Damage


f one or two teeth are damaged but not brokenq

ethose teeth then scar or scuff all teeth with which z Y

z

they mesh Smoothing of any damaged tooth or

teeth will prevent any further damageA Z 3

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3

Metal Failures

The Spalling type of failure usually occurs first

e

y below the pitch line of the pinion and is due to

fatigue failure of the surface metal

Metal Failures Fundamentally fatigue is a metallurgical problem Increasing the hardness of the metal in

When elastic limit is too low to carry the surface overloaded teeth will minimize the problem of

loads failure occurs comparatively quickly and surface fatigue

permanent plastic deterioration takes place TheA fatigue fracture is smooth and sometimes

metal flows and rolls to create feather edges atshows a series of concentric rings around a

tips of teethcentral starting point and is usually shiny in color

k

Et3t 3

v Y t

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Fk

ah cr 2s y wc

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T i p r

r w x aahy aY

a s

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ras vA s

Metal Failures Lubrication Failure

Shock loads beyond the elastic limit squeezesInsufficient lubrication is the fifth basic cause of

metal out at the tooth ends often referred to asfailure Both meshing gear surfaces are scarred

PeeningFirst signs of lubricant failure will be noticed at or

close to the tooth tips A well iubricated steel

tooth has a dull grey color less efficiently lubricated teeth are brighter and may have been

burnished to a mirror finish Illustration shows a

ridge along the pitch line due to advanced lubri

co ht0 Philadel hia Mixerscation failure

PY 9 p Specifications subject to change without notice

Ew

y j J

5d

a 4u

Rigid Coulingo

3ac

PHiL4DELPHlA MIXERS SECTON Cou Ilh s

Service PAGE i00

Manual 2g00 SERIES RiGlD COUPLlNGssUo 01 JAN 99

Welded Design REVlSION

In many mixer appfications the agitator shaft as well as the mixer drive output shaft are

shipped with rigid coupling halves fixed in their proper positions Befare assembly into the

tank make certain that the rabbet facss of the rigid coupling are free of a foreign matternicks or burrs

The mating faces must be positioned evenly and squareiy togethar Gradually tightenopposing bolts until wrench orque specifidon th drawing below fails to tum any boitThese torques should be rechecked after three rnonths of operatian for tightness and at

each schedufed shutdownI

I

Hold Hold

IpCY

i

i

ry u ry 1 II

11 II II II

II I II I I II

11 II I II

I 1 II I II 1 II

IAPply torque

Apply forque to this nuto this nut

I This nut is

jammed

Stainlss Steel and other

metals hardwaredouble nut design

Coupling 2902 29b3 2904 2905 2906 29Q7 2908 2909 2910 291iSizes

No and Size of NoBBolts Inches

Recommended FtIbs

Wrench 7orgue

Coupling 2912 2913 2914 2916 2918 2920 2922 2924 2926 2928Sizes

No and Size of tVo 878Bolts Inches

Recommended FtIbs 194

Wrench Torque

CopyrlghKD Philadeaphia Miuers Specifications subject to change without notice

p

wM W

s

cY

Ei

Impelle

Q

PHIIADELPHIA MIXERS SECTION M1I

Typ MAfNTENANCE dNSTRUCTIONS PAGE 124

ITYDROFOIL IMPELLER ISSUED 1 JUL 1989

3 BLADED BOLTED CONS7RUCTION REVISIOfV A 15 AUG 1990

if

t

i

378

376

1

380j

379

I

i oF gi

eJ

1ii

PAR7 NO DESCRIPTION

376 1MPELLER MiJB

377 IMPELLER 6lADE

378 BOLT NUT AND LOCKWASHER

379 HOOK KEY

380 SET SCREW

Copyright t990 Philadelphia Mixcrs

PHILADELPHIAMIXERSSECTION M1I

TypeIlV1PELLERIIVSTRUCTIQNS

PAGE 200

ISSUED 20 AUG 1974CARBONSTAINLESSSTEEL REVISION E 02 DEC 1996

G E N E R AL Liberall y coat the shaft with lubricant such as molybdenumImpellers from Philadelphia Mixers are normally shipped disulphide paste for ease of slidingwith hubs mounted on the agitator shaft and with blades Back off all setscrews Rock the hub to loosen and firmlyshipped loose Blades should be installed in strict accor slide the hub away from pin appying an even load ondance with matchmarks if any and with bolts tightened to

opposite ears The hub may be tapped lightly through athe torque listed belowwooden block to aid in this movement Heavier hammer

REPOSITIONING OR REMOVAL blows may cause the bore to close in and grab the shaft

Due to adjustment requirements or special installationen hub slides clear remove hook key

procedures it may be necessary to relocate or even remove StoQ the hub at the first sign of binding on the shaft Forcingthe impeller hub from the shaft YourPhiladelphia Mixers the hub may induce galling in some materials makingimpeller hub to shaft clearance is optimized to provide removal even more difficult Back off from the bindingmaximum adjustability and support with a minimum of spot determine the cause and correct it before continuingfretting theretiore even slight distortions and scratches

If needed moderate heat of about 300350F li ht strawmay cause the hub to hangup gtemper color may be applied to the hub OD which willIf more than one hub is to be removed check the shaft andexpand the bore for removal over high spots Heat concenhub for matchmarks If none mark clearly with a non trated on the thinner hub section over the keyslot is inost

removable indicator noting wiiich side of the hub is to face effective Never allow the temperature to rise above 450Fp dark straw to bluish temper color When using heatIt is safest to remove or relocate hubs while the shaft is in handle the hub only with heat protecting glovesthe horizontal position before insCallation If they are to be

movedwhiletheshaftishungverticallyasafetyropemust REQLACEMENTANDSECURINGbe fied securely through one or more bolt holes and tethered Before repiacing the hub onto the shaft check the bore forfrom above to prevent dropping or sudden movement buns or scratches Coat the bore and shaft with niolybdeBefore proceeding remove all scratches and burrs from the num disulphide paste If the shaft is hung vertically attach

shaft over which the hub must pass as well as the hub bore a safety tether securely through one or mare boltholes in the

Do not use tools which might contaminate special agitator hub and support from above Install the hub with the side

materials such as metal files on stainless steel Polish the up as indicated by matchmarks Itis usually aithough not

shaft with emery cloth necessarily assembied chamferred side tirst

Slide the hub to a point above its required position and

replace ttie liook key onto the staft Gently lower the hub

onto the key unti it seats against the pin Do not dropagainst the pin Tighten set screws to torque listed below

Install blades and fighten bolts to torques listed below

Torque values shown are good for standard carbon andstainless steel hex head bolts aS well as nickel monel

e inconel and Alloys BC and 20 and are based on bolts

a e lightly lubricated in the as received condition If lubri

cated with molybdenum disulphide paste on ttueads and

nut bering face bolt torques must be reduced to 75 ofthose tabulated

Ail bolts should be 6ghtened by turning nut side onlyq g All bolts should be reflghtened within 1 month after

startup and at each scheduled shutdown

0 0IMPELLERBLADEBOLTTORQUES SET SCREW TOR UE5

DIA z 58 34 78 i 118 114 1i2 DIA 14 516 38 12 58 34 78 1

TORQUE FT LB 43 85 130 200 270 400 500 730 TORQUE FT LB 58 1 1 19 42 82 140 330 460

Copyright0 1996 Philadelphia Mixers

PHILADELPHIA MIXERS SECTION M1I

TypeMAINTENANCE INSTRUCTlONS PAGE 202

HYDROFOILIMPELLER fNSTRUCTiQNS ISSUED 26 AUG 1983

Series HYDROFOILREVISION 15 SEP 1986

GENERAL EROSION

The Philadelphia Mixers Hydrofoil lmpefleris available As a standard preventive maintenance procedurein a wide variety of materials including welded and impeller blades should be inspected AT ONE

bolted constructions The hydrofoil is a highlyecient MOIVTFf after startup and whenever the basin is

impellerwhichimpartspredominantlyaxialflowtothe drained thereafter but not to exceed SIX MONTH

surrounding fluid It is widey used in slurry or aerator INTERVALS for signs of erosion or corrosion dam

usually in a draft tube down pumping above an air age Be sure to inspect the bottom as well as the top

sparge service of the impeller

BALANCING Abrasive particles in slurry applications or the corro

sive properties of the fluid itselfl cause wear charac

When the agitator shaft rotates at greater than 100 terized by smooth craters and channels in the metal

RPM the impeller is baanced at the factory

Cavitation occurs when air or gas bubbles entrapped

Do nof attempt to rebalance in the field by adding in the process liquid expand due to the rapid pressure

compensation weights to the hydrofoil blades Fluid drop tn the fluid passing over the blade surface

flow across the blade is sensitive to any bladeto

blade geometry variation and operation may be These voids may collapse at the blade surface pro

greatly altered Consult factory when any rebalance ducing localized shock loads The aggregate ofthese

is contemplated shocks produces pulsations great enough to be felt

throughout the drive and support system and may

For bolted designs the blades and hub ears are cause erosion of the blade surface This erosive wear

matchmarked and must be positioned in accordance is characterized by surface pitting especially in areas

with the numerical matchmarks stamped on them at along the tips and leading edgethe factory

In both abrasive and cavitation cases the highestWith multiple impellers mounted on one shaft or on erosion normally occurs in areas of low stress and is

several mixers the match marks run consecutively not a cause of concern but because of the unpredictable nature of hydraulic flow interaction this erosion

Balancing of overhung shafts should be considered a should be monitored Indications of severe erosion

perishable quantity affected by handling during ship greaterthan 15ofbladethickness occurring on the

ping and installation Therefore the initial operation inner half of the blade should be repaired This can be

should be monitored carefully and any undue move done without removal of the impeller by cleaning the

ment or vibrations reported to the factory Note affected area fill welding grinding to a smooth finish

however that since these impellers are used in rug comparable to the finish of the blades as they were

ged duty appications some vibrations are expected originally manufactured and repainting as requiredand considered normal to the process and adjust

ment may not be required

CopyrightOO PhiladelphiaMixers Specifications subjectto change

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REL I I PHASEI

SO II FRAME HP TYPEHERTZ I RPM VOLTS

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L213T 75 P 360 I 1765 I 230460I j I i

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AMPS DUTY SF i ENCLj INSUL DESIGN LETTER i

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TEST i TEST i STATOR RES25 CES I ROTOR iI SO DATE i OHMS BETWEEN LINES

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f t534693 i 418425053JE i I I 376150

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PERFORMANCE

1

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LOAD

I HPAMPERES RPM

II ji i

NO LOAD 0 41 1800 I 532 0

14 i 188 47 1792 422 878

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i24 375 60 i 1784 i 644 I 917

i34 562 76 1776 i 755 I 922

I i44 750 94 j 1767 I 812 917

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54 937 114 1757 846 907I

6

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JSPEED TORQUE

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FULL LOAD I LBFT iAMPERES

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ILOCKED ROTOR I 0 215 480 635i

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PULL UP j 360 175 390 613

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BREAKDOWN 1551 309 690 385i

FULL LOAD 1767 100 223 94

AMPERES SHOWN FOR460 VOLT

CONNECTION IF OTHER VOLTAGE CONNECTIONS ARE AVAILABLE THE

AMPERES WILL VARY INVERSELY WITH THE RATED VOLTAGE

REMARKS CALCULATED DATA

XE MOTOR NEMA NOM EFF 917 MIN9020

i DR BY W L SMITAA MOTOR

IICR BY JJHARRISON i

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BALDQRDfJ3ERLIANGE iiDATE 1213OS DATA ZSSUE DATE 1213OS

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REL SO RPM 1765 SF 115 ROTOR 418425053JE

FRAME L213T VOLTS 230460 NEMA DESIGN B TEST SO CALCULATED DATA

HP 75 AMpS 16894 CODE LETTER H TEST DATE

TYPE P DUTY CONT ENCLOSURE FCXE STATOR RES @25c376150PHASE AERTZ3 60 AMB40 FE S 534693 OHMS BETWEEN

LINES IFF9I MIN902rb IIII I a I I I I I I I iI

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VOLTAGE I DR BY WL SMITH A C

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soN pERFORMANCEE02672BE001I APP BY W L

SYIITHHAL LIORD04CE RELfANCEI DATEI13 OS CURVES ISSUE DATE1213

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DIST CODE w


XT CONSTRUCTIONNCLOSURE TOTALLY ENCLOSED COOLING FAN COOLEDMOUNTING FOOT NEMA C FACE


BF TAP4 HOLESP

AB

BS

BBAC

FVMIN 45

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3816UNCH DIA

GRUND SCREW HOLE Ii2F A

SUPPLIED ONLY WHEN gREQUIRED

STANDARD FRAMES HAVE 8 HLES FORDUAL MOUNTING AND F2CNVERSION

LONG FRAMES HAVE 6 HOLES FR DUALFR F2 MTG MUNTING NOT SUITABLE FR F2180210 FRAME ONLY CONVERSIN

ONE SIZE LARGER 6CAST IRON TERM BbX

fRAME AA AB AC AF

180TCL180TC 11 894 694 250

210TCL210TC 11 981 781 250

1

DIMENSIONS ARE IN INCHES SEE SHEET 2 FOR DIMENSIONS IN MILLIMEIERS

CAST IRON TERM BOX MINTAP

FRAME A D 3 E G H J 0 P T AA AB AC AF BA BB BD BF DEPTH AJ AK 4180TCL180TC 900 450 375 44 44 175 988 950 200 1 844 669 212 350 25 900 1 213 75 725 8500210TCL210TC 1050 525 425 44 44 200 1125 1100 200 1 931 756 212 425 25 900 1 213 75 725 8500

1

FRAME FOOT MT BE SHAFT AND KEY FRONT END SHAFT AND KEY WqGHTSIZE PROV C BS B 2F 2F AH N N U 2 V SQ tGTH FN FNFW FU 2 FV SQ IGTH LBS 5

95180TC 8 1638 275 700 450 55D262 300 275 11250 250 250 175 319 225 8750 200 188 138

L180TCL184T

88 350 850 4S0 550262 300 275 11250 250 250 175 319 225 8750 200 188 138

ZS

130

210TC Z 2006 350 850700

312 362 338 13750 312 312 238 375 275 11250 250 250 17545

155

L270TCL215T

2094 394 912550

700 312 362 338 13750 312 372 238 375 275 71250 250 250 17585

195t

ll SPECIAL DIMENSIONS N THIS LINE STANDARD DOUBLE SHAFT SUPPLIED NLYVHEN SPECIFIED


C3 D MAY VARY 00 03 TERMINAL BX IOCATED N PPOSITE SIDE uHEN F2 V114 AK MAY VARY 000 003

W 115 W7 OR C1 MOUNTING IS SPECIFIE

FACE RUNOUT AND 004 MAX TIR MAXIMUM PERMISSIBLE SHAFT RUNOUT YHEN MEASURED ATECCENTRICITY END F STANDARD SHAFT EXTENSIN IS 002 T I R

5 MTOR WEIGHTS MAY VARY BY 15FOR NONSTANDARD RATINGS IF MOUNTING CLEARANCE DETAILS ARE REQUIRED CNSUT

6 NE SIZE LARGER TERMINAL BaXFACTORY

SUPPLIED ONLY YHEN SPECFIED


RDER ITEM HP RPM PH HZ VOLT

LIANCE SALES RDER APPRaVED HY DATE

RELANCEBY K THOMAS

ELECTRCB R L BROWN D I M E N S I 0 N 61 3 0 51 5 0 4

rwP arG KILBRN SHEET ISSUE ATE APRIL 26 1995CLEVELAND pHI 44117 U S A narE 34A6

SHEEr t F 2

CR 2934541 331585 1054100 10541OS EDSAC613051504SH1UG

DIST CODE w


XT CONSTRUCTIONENCLOSURE TOTALLY ENCLOSED COOLING FAN COOLEDMOUNTING FOOT NEMA C FACE


BF TAP4 HLESP

AB

FN BSAC

HBFV

MIN 45T

AH

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AF

FU

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AA 1PIPE

FNFM

IBA

Nu

TAP

JE

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IiZF A

GRUND SCREW HOLESUPPLIED ONLY WHEN gREQUIRED

STANDARD FRAMES HAVE 8 HLES FR

DUAL MUNTING AND F2 CONVERSION

LONG FRAMES HAVE 6 HOLES FOR DUALFR F2 MTG MDUNTING NOT SUITABLE FOR F2180210 FRAME NLY CONVERSION

ONE SIZE LARGER 6CAST IRON TERM BbX

FRAME AA 7 AB AC PF

180TCL180TC 11 2271 1763 635

210TCL210TC 11 2492 1984 635

1

DIMENSIONS ARE IN MILLIMEiERS SEE SHEET 2 FOR DMENStONS IN 1NCHES

CAST IRON TERM BOXMINTAP

FRAME A D 3 E G H J 0 P T AA 7 AB AC AF BA B8 BD BF DEPTH AJ AK 4

180TCL180TC 2285 143 953 112 112 445 2510 2413 508 1 2744 1699 538 889 635 2286 1 21 191 1842 21590

210TCL210TC 2667 1334 1080 112 112 508 2858 2794 508 1 2365 1920 538 1080 635 2286 1 21 191 1842 21590

1

FRAME F007 MT BE SHAFT AND KEY FRONT END SHAFT AND KEY WEIGHT

SIZE PROV C BS B 2F 2F AH N NW U 2 V SQ LGTH FN FNFW FU 2 FV SQ LGTH LBS 54

180TC182T

4161 699 778 665 762 699 28575 635 635 445 810 572 22225 508 478 3514

184T 1397 45

L180TCL784T

4542 889 159 114 1397665 762 699 28575 635 635 445 870 572 22225 508 478 351 59

210TC23T

095 869 159139

792 919 859 34925 792 792 605 953 699 28575 635 635 44566

215T 1776 70

L270TCL215T

5319 1001 2316t39

B792 919 859 34925 792 792 605 953 699 28575 635 635 445

84

88

1

ll SPECIAL DIMENSIONS N THIS LINE STANDARD BQUBLE SHAfT SUPPLIED NLY

NHEN SPECIFIED


C3 D MAY VARY 00 76 TERMINAL BOX LOCATED N OPPSITE SIDE WHEN F2 LI1N4 N5 W7 OR C1 MDUNTING IS SPECIFIED

C 4 AK MAY VARY 000 076

FACE RUNOUT AND 101 MAX TIR MAXIMUM PERMISSIBLE SHAFT RUNOUT NHEN MEASURED ATECCENTRICITY END F STANDARD SHAF7 EXTENSION IS O50 T I R

5 MOTR MEIGHTS MAY VARY BY 15FRNNSTANDARD RATINGS IF MOUNTING CLEARANCE DETAILS ARE REQUIRED CNSULT

6 NE SIZE LARGER TERMINAL BOXFACTORY

SUPPIED ONLV VHEN SPECIFIED


RDER ITEM HP RPM PH HZ VOLT

ZELIANCE SALES ORDER APPROVED BY DATE

RELANCEBY K THOMAS

EcrRc gY RLBROWN DIMENSION 61 3051 504aaa BrGKILBORN SHEET ISSUE DATE APRIL 26 1995

CLEVELAND OHI 44117 U S A nnTE 3486SHEET 2F 2

CR 293454 331585 1054100 0541OS EDSAC613051504SH2DVG

AC MOTOR

CONNECTION DIAGRAM

STANDARD 9 LEAD DELTACONNECTED

T1

T9 T4

T6 T

T3 T8 T5 T2

T4 T5 T6 T4 T5 T6

T7 T8 T9 T7 T8 T9

T1 T2 T3 T1 T

LTLZ L3L1 L2 3

LOWER VOLTSLINEHIGHER VOLTS

NP 1575B

N

o CUSTOMER RELIANCE

CUSTOMER ORDER N0 SO N0

iRELANCE DRBYNF CON N ECTI ON 416 8 20 2ELECTRC

CKBYDGYAPP BY HEJ

UCLEVELAND OHIO 44117 DATE3151z6 DIAGRAM ISSUE DATE OCT 30 1986

EWDIAG416820002 RAG 1054106

lNIOTOfS Al1V RIVES

IntegratHrsepowerACIductioa Motors

ODP Ercosure

TEFCEclosure

Explosior Proof

Installation Operating Manual

701 MN400

Table of Contents

Section 1

Generalinformation 11

Overview 11

LimitedWarranty 11

SafetyNotice 12

Receiving 14

Storage 1

Unpacking 14

Handling 14

Section 2

Instatlation Operation 21

Overview 21

Location 21

Mounting 21

Alignent 21

Doweling Bolting 22

PowerConnection 22

Conduit 22

ACPower 22

FirstTime U p 24

Coupled U p 24

Jogging and Repeated Starts 24

Section 3

M aintenance Troubleshooting 31

G enerallnspection 31

Lubrication Bearings 31

Typeof Grease 31

Lubricationlntervals 31

Lubrication Procedure 33

Accessories 34

TroubleshootingChart 35

MN400Table of Contents i

Section 1

General information

Overview 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 instail operate or

attempt 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

Important This instruction manual is not intended to include a comprehensive listing of all details for alt

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 questionabout a procedure or are uncertain about any detail Do Not Proceed Please contact your Baldor

distributor for more information or clarification

Before you install operate or perform maintenance become familiar with the followingNEMA Publication MG2 Safety Standard for Construction and guide

for Selection Installation and Use of Electric Motors and Generators

The National Electrical Code

Local codes and Practices

Limited Warrantv

1 Baldor Electric motors are warranted for a period of one 1 year from date of shipment from the factory or factorywarehouse against defects in material and workmanship To allow for stocking andor fabrication period and to

provide one year of actual service the warranty period is extended for an additional period of six 6 months for a

total 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 buyerof 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 the

warranty period if

a the purchaser presents the defective motor at or ships it prepaid to the Baldor plant in Fort Smith Arkansas

or one of the Baldor Authorized Service Centers and

b the purchaser gives written notification concerning the motor and the claimed defect including the date

purchased the task performed by the Saldor motor and the problem encountered

3 Baldor will not pay the cost of removal of any electric motor from any equipment the cost of delivery to Fort SmithArkansas or a Baldor Authorized Service Center or the cost of any incidental or consequential damages resultingfrom the claimed defects Some states do not allow the exclusion or limitation of incidental or consequential

damages so the above exclusion may not apply to you Any implied warranty given by laws shall be limited to

the duration of the warranty period hereunder Some states do not allow limitations on how long an impliedwarranty lasts so the above limitation may not apply to you

4 Baldor Authorized Service Centers when convinced to their satisfaction that a Baldor motor developed defects in

material or workmanship within the warranty period are authorized to proceed with the required repairs to fulfill

Baldors warranty when the cost of such repairs to be paid by Baldor does not exceed Baldors warranty repairallowance Baldor will not pay overtime premium repair charges without prior written authorization

5 The cost of warranty repairs made by centers other than Baldor Authorized Service Centers WILL NOT be paidunless first authorized in writing by Saldor

6 Claims by a purchaser that a motor is defective even when a failure results within one hour after being placed into

service are not always justified Therefore Baldor Authorized Service Centers must determine from the condition

of the motor as delivered to the center whether or not the motor is defective If in the opinion of a Baldor

Authorized Service Center a motor did not fail as a result of defects in material or workmanship the center is to

proceed with repairs only if the purchaser agrees to pay for such repairs If the decision is in dispute the

purchaser should still pay for the repairs and submit the paid invoice and the Authorized Service Centers signedservice report to Baldor for further consideration

7 This warranty gives you specific legal rights and you may also have other rights which vary from state to state

Note that Baldor SuperEO Premium Efficiency electric motors are warranted for a period of three 3 years

All other terms and conditions of the Limited Warranty statement apply


Safety Notice This equipment contains high voltage Electrical shock can cause serious or fatal injury

Oniy qualified personnel should attempt instaliation operation and maintenance of

electricai equipment

Be sure that you are completely familiar with NEMA publication MG2 safety standards

for construction and guide for selection installation and use of electric motors and

generators the Nationai Electricai 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 instailation operation and maintenance of this equipment





WARNING Be sure the system is properly grounded before applying power

Do not apply AC power before you ensure that all groundinginstructions have been followed Electrical shock can cause

serious or fatal injury National Electrical Code and Local codes

must be carefully followed

WARNING Avoid extended exposure to machinery with high noise levels Be

sure to wear ear protective devices to reduce harmful effects to

your hearing

WARNING This equipment may be connected to other machinery that has

rotating parts or parts that are driven by this equipment Improperuse can cause serious or fatal injury Only qualified personnelshould attempt to install operate or maintain this equipment

WARNING Do not bypass or disable protective devices or safety guards

Safety features are designed to prevent damage to personnel or

equipment These devices can only provide protecteon if theyremain operative

WARNING Avoid the use of automatic reset devices if the automatic restartingof equipment can be hazardous to personnel or equipment

WARNING Be sure the load is properly coupled to the motor shaft before

applying power The shaft key must be fully captive by the load

device Improper coupling can cause harm Yo personnel or

equipment if the load decouples from the shaft during operation

WARNING Use proper care and procedures that are safe during handlinglifting installing operating and maintaining operationsImproper methods may cause muscle strain or other harm

WARNING Before performing any motor maintenance procedure be sure that

the equipment connected to the motor shaft cannot cause shaft

rotation If the load can cause shaft rotation disconnect the load

from the motor shaft before maintenance is performed Unexpectedmechanica rotation of the motor parts can cause injury or motor

damage

WARNING Disconnect all electrical power from the motor windings and

accessory devices before disassembly of the motor Electrical

shock can cause serious or fa1a1 injury

WARNING Do not use these motors in the presence of flammable or

combustible vapors ar dust These motors are not designed for

atmospheric conditions that require explosion proof operation


Safety Notice Continued

WARNING Motors that are to be used in flammable andor explosiveatmospheres must display the UL label on the nameplate

Specific service conditions for these motors are defined in

NEC 70599




Caution To prevent premature equipment failure or damage only qualifiedmaintenance personnel should perform maintenance

Caution Do not lift the motor and itslriven load by the motor liftinghardware The motor lifting hardware is adequate for lifting onfy the

motor Disconnect the load from the motor shaft before moving the

motor

Caution If eye bolts are used for lifting a motor be sure they are securelytightened The lifting direction should not exceed a 20 angle from

the shank of the eye bolt or lifting lug Excessive lifting angtes can

cause damage

Caution 7o prevent equipment damage be sure that the electrical service is

not capable of delivering more than the maximum motor rated ampslisted on the rating plate

Caution If a HI POT test High Potential Insulation test must be performedfollow the precautions and procedure in NEMA MG1 ad MG2

standards to avoid equipment damage

If you have any questions or are uncertain about any statement or procedure or if you

require additional information please contact your Baldor distributor or an Authorized



Reeivinq Each Baldor Electric Motor is thoroughly tested at the factory and carefully packaged for

shipment When you receive your motor there are several things you should do

immediately1 Observe the condition of the shipping container and report any damage

immediately to the commercial carrier that delivered your motor

2 Verify that the part number of the motor you received is the same as the partnumber listed on your purchase order

Storaqe If the motor is not pui into service immediately the motor must be stored in a clean dryand warm location Several precautionary steps must be performed to avoid motor

damage during storage



2 Do not lubricate bearings during storage Motor bearings are packed with

grease at the factory Excessive grease can damage insulation quality

3 Rotate motor shaft at least 10 turns every two months during storage more

frequently if possibie This will prevent bearing damage due to storage

4 If the storage location is damp or humid the motor windings must be protectedfrom moisture This can be done by applying power to the motors space

heater if available while the motor is in storage

UnpBCkinq Each Baldor motor is packaged for ease of handling and to prevent entry of

contaminants

1 To avoid condensation inside the motor do not unpack until the motor has

reached room temperature Room temperature is the temperature of the room

in which it will be installed The packing provides insulation from temperature

changes during transportation

2 When the motor has reached room temperature remove all protective wrappingmaterial from the motor

Handling The motor should be lifted using the lifting lugs or eye bolts provided

1 Use the lugs or eye bolts provided to lift the motor Never attempt to lift the

motor and additional equipment connected to the motor by this method The

lugs or eye boits provided are designed to lift only the motor Never lift the

motor by the motor shaft

2 If the motor must be mounted 10 a plate with the driven equipment such as

pump compressor etc it may not be possible to lift the motor alone For this

case the assembly shoufd be lifted by a sling around the mounting base The

entire assembly can be lifted as an assembly for installation Do not lift usingthe motorIgs or eye bolts provided

If the load is unbalanced as with couplings or additional attachmentsadditional siings or other means must be used to prevent tipping In any eventthe load must be secure before lifting


Section 2

Installation Operation

Overview Installation should conform to the National Eaectrical Code as well as local codes and

practices When other devices are coupled to the motor shaft be sure to install

protective devices to prevent future accidents Some protective devices includecoupling 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

Location The motor should be installed in an area that is protected from direct sunlight corrosivesharmful gases or liquids dast metallic particles and vibration Exposure to these can

reduce the operating life and degrade performance Be sure to ailow clearance forventilation and access for cleaning repair service and inspections Ventilation is

extremely important Be sure the area for ventilation is not obstructed Obstructions wiVllimit the free passage of air Motors get warm and the heat must be dissipated to preventdamage

These motors are not designed for atmospheric conditions that require explosion proofoperation They must NOT be used in the presence of flammable or combustible vaporsor dust

1 ODP motors are suitable oniy for indoor applications2 TEFC motors are suitable for indoor or outdoor standard service applications

Mountinq The motor must be securely installed to a rigid foundation or mounting surface to

minlmize vibration and maintain alignment between the motor and shaft load Failure to

provide a proper mounting surface may cause vibration misalignment and bearingdamageFoundation caps and sole plates are designed to act as spacers for the equipment theysupport If these devices are used be sure that they are evenly supported by thefoundation or mounting surface

After installation is complete and accurate alignment of the motor and load is

accomplished the base should be grouted to the fioundation to maintain this alignmentThe standard motor base is designed for horizontal or vertical mounting Adjustable or

sliding rails are designed for horizontal mounting only Consult your Baldor distributor or

authorized Baldor Service Center for further information

Alignment Accurate alignment of the motor with the driven equipment is extremely important1 Direct Coupling

For direct drive use flexible couplings if possible Consult the drive or

equipment manufacturer for more information Mechanical vibration and

roughness during operation may indicate poor alignment Use dial indicators tocheck alignment The space between coupling hubs should be maintained as

recommended by the coupling manufacturer

2 EndPlay AdjustmentThe axial position of the motor frame with respect to its load is also extremelyimportant The motor bearings are not designed for excessive external axialthrust loads Improper adjustment will cause failure

3 Pulley Ratio

The pulley ratio should not exceed 81

4 Belt Drive

Align sheaves carefully to minimize belt wear and axial bearing loads seeEndPlay Adjustment Belt tension should be sufficient to prevent belt slippageat rated speed and load However belt slippage may occur during starting

Caution Do not over tension belts


Daweling Bolting After proper alignment is verified dowel pins should be inserted through the moor feet

into the foundation This will maintain the correct motor position should motor removal be

required Baldor motors are designed for doweling1 Drill dowel holes in diagonally opposite motor feet in the locaiions provided2 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 alignmentUse 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

washers

Power Connection Motor and control wiring overload protection disconnects aceessories and groundingshould conform ta the National Electrical Code and local codes and practices

Conduit Box For ease of making connections an oversize conduit box is provided The box can be

rotated 360 in 90 increments Auxiliary conduit boxes are provided on some motors for

accessories such as space heaters RTDs etc

AC Power Connect the motor leads as shown on the connection diagram located on the name plateor 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 ratingsOR

2 AC power is within 5 of rated frequency with rated voltageOR

3 A combined variation in voltage and frequency of 1 p sum of absolute

values of rated values provided the frequency variation does not exceed 5

of rated frequencyPerformance within these voltage and frequency variations are shown in Figure 21

22 Instailation Operation MN400

Figure 21 Motor Performance VS Voltage Variations20

Full LoadMaximum

CurrentTorque

15

10

Full LoadPower CurrentFactor

5

oL

aL O00

Efficiency Efficiency5Nd

C

L lOU

15Power

Maximum FactorTorque

20

15 10 5 0 5 10 15

Voltage Variations


First Time Start 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 insulation

integrity with a Megger3 Inspect all electrical connections for proper termination clearance mechanical

strength and electrical continuity4 Be sure all shipping materials and braces if used are removed from motor

shaft

5 Manualiy rotate the motor shaft to ensure that it rotates freely6 Replace all panels and covers that were removed during instailation

7 Momentarily apply power and check the direction of rotation of the motor shaft

8 If motor 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 If so 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

Coupled Start Up 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 are

instailed

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 that

the load is not transmitting excessive vibration back to the motor though the

coupling or the foundation Vibration should be at an acceptable level

4 Run for approximately 1 hour with the driven equipment in an unloaded

condition

The equipment can now be loaded and operated within specified limits Do not exceed

the name plate ratings for amperes for steady contiruous loads

Jogging and Repeated Starts Repeated starts andor jogs of induction motors generally reduce the life of the motor

winding insulation A much greater amount of heat is produced by each acceleration or

jog than than by the same motor under full load If it is necessary to to repeatedly start or

jog the motor it is advisable to check the application with your local Baldor distributor or


Heating Duty rating and maximum ambient temperature are stated on the motor name

plate Do not exceed these values If there is any question regarding safe operationcontact your loca Saldor distributor or Baldor Service Center

24 Installation Operation MN400

Section 3

Maintenance Troubleshooting




General InspeCtion 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 cfear The following steps should be performed at each inspection





1 Check that the motor is cfean Check that the interior ard exterior of the motor

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



3 Check all electrical connectors to be sure that they are tight

Lubrication Bearinqs 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

Type of Grease A high grade ball or roller bearing grease should be used Recommended grease for

standard service conditions is Polyrex EM Exxon Mobil

Equivalent and compatible greases include

Texaco Polystar Rykon Premium 2 Pennzoil Pen 2 Lube and Chevron SRI

Maximum operating temperature for standard motors 110 C

Shutdown temperature in case of a malfunction 115 C

Lubrication Intervals Fiecommended lubrication intervals are shown in Table 31 It is important to realize that

the recommended intervals of Table 31 are based on average use

Refer to additional information contained in Tables 32 and 33

Table 31 Lubrication Intervals

Rated peed RPM

NEMA IEC Frame Size 10000 6000 3600 1800 1200 900

Up to 210 incl 132 2700 Hrs 5500 Hrs 12000 Hrs 18000 Hrs 22000 Hrs

Over 210 to 280 incL 180 3600 Hrs 9500 Hrs 15000 Hrs 18000 Hrs



Lubrication ntervals are for ball bearings or roller bearings divide the iisted lubrication interval by 2

For 6205 and 6806 bearings For 6807 bearings consult oil mist lubrication MN401Relubrication interval for 6205 bearing bearing is 1550Hrs using grease lubricationRelubrication interval for 6806 bearing bearing is 720Hrs using grease lubrication


Table 32 Service Conditions

everity of ervice Ambient emperature Atmospheric Type of BearingMaximum Contamination

Standard 40 C Clean Little Corrosion Deep Groove Ball BearingSevere 50 C Moderate dirt Corrosion Ball Thrust Rolier

Extreme 50 C or Severe dirt Abrasive dust All BearingsClass H Insulation Corrosion

Low 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 33 Lubrication Interval Multiplier

everity of ervice MultiplierStandard 10

Severe 05

Extreme 01

Low Temperature 10

Table 3 Bearings Sizes and Types

Frame Size Bearing DescriptionNEMA IEC These are the Large bearings Shaft End in each frame size

Bearing OD Width Weight of Volume of greaseD mm B mm Grease to to be added

add in tea

i oz Grams spoon

Up to 210 incl 132 6307 8Q 21 030 84 06 20

Over 210 to 280 incl 180 6311 120 29 061 17 12 39

Over 280 to 360 incl 225 6313 140 33 081 23 15 52

Over 360 to 449 incl 280 NU319 200 45 212 60 41 134

Over 5000 to 5800 incl 355 NU328 300 62 470 130 92 300

Spindle Motors

76 Frame 6207 72 17 022 6 i 044 14

77 Frame 6210 90 20 032 90 064 21

80 Frame 6213 120 23 049 140 099 33

Weight in grams 005 DB

32 Maintenance Troubleshootin MN4009

Lubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease alreadyin the motor Consult your Baldor distributor or an authorized service center if a greaseother 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 plug3 If motor is stopped add the recommended amount of grease

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 plug4 Reinstall grease outlet plug

Without Grease Outlet Plug1 Disassemble motor

2 Add recommended amount of grease to bearing and bearing cavity Bearingshoud be about 13 full of grease and outboard bearing cavity should be about12 full of grease

Note Bearing is 13 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 ambient

temperature of 43 C and the atmosphere is moderately corrosive

1 Table 31 list 9500 hours for standard conditions

2 Table 32 classifies severity of service as Severe

3 Table 33 lists a multiplier value of 05 for Severe conditions

4 Table 34 shows that 12 in or 39 teaspoon of grease is to be added

Note Smaller bearings in size category may require reduced amounts of grease


ACCesSOPies The following is a partial list of accessories available frpm Baldor

Contact your Baldor distributor for availability and pricing informationNote Space heaters and RTDs are standard on some motors

Bearing RTD


monitor the temperature of the motor bearing during operation

Bearing ThermocouplesUsed to measure or monitor bearing temperatures

Bearing Thermostat

Temperature device that activates when bearing temperatures are excessiveUsed with an externai circuit to warn of excessive bearing temperature or toshut down a motor

Conduit Boxes

Optional conduit boxes are available in various sizes to accommodate

accessory devices

Cord Plug AssemblyAdds 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 yourBaldor distributor to confirm that the motor is designed for vertical mounting

Fan Cover int ScreenTo prevent buildup of debris on the cooling fan

NameptateAdditional stainless steel nameplates are available

Roller BearingsRecommended for belt drive applications with a speed of 1800 RPM or less

Rotation Arrow Labels

Rotation arrows are supplied on motors designed to operate in one direction

only Additional rotation arrows are available

Space Heater

Added to prevent condensation of moisture within the motor enciosure duringperiods of shut down or storage

Stainless Hardware

Stainless steel hardware is availabie Standard hardware is corrosion resistantzinc plated steei

Winding RTD


monitor the temperature of the motor winding during operation

Winding ThermocouplesUsed to measure or monitor winding temperatures

Winding Thermostat

Temperature device that activates when winding temperatures are excessiveUsed with an external circuit to warn of excessive winding temperature or foshut down a motor

Note On some motors leads for accessory devices are brought out to a separaieconduit box located on the side of the motor housing unless otherwisespecified

34 Maintenance Troubleshooting MN400

Table 35 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 j Check input line connections

Eccentric air gap I Have motor serviced at loca Baldorservice center

Motor Over Heating Overload Compare actual amps I Locate and remove source of excessive friction in

fmeasured with nameplate rating motor or foad

i Reduce load or replace with motor of greater capacity

Single Phasing Check current at all phases should be approximatelyequal to isolate and correct the problem

Improper ventilation Check external cooling fan to be sure air is movingproperly across cooling fins

Excessive dirt build on motor Clean motor

Unbalanced voltage Check voltage at all phases should be approximatelyequai to isolate and correct the problem

Rotor rubbing on stator Check air gapcearance and bearings

Tighten Thru Bolts

Over voltage or under voltage Check input voitage 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 proper

termination clearance mechanical strength and

electrical continuity Refer to motor lead connection

diagramBearing Over Neating Misalignment Check and align motor and driven equipment

Excessive belt tension Reduce belt tension to proper point for toad

Excessive end thrust Reduce the end thrust from driven machine

Excessive grease in bearing Remove grease until cavity is approximately 34 filled

Insufficient grease in beaing Add grease until caviry is approximateiy 34 filled

Dirt in bearing Clean bearing cavity and bearing Repack with correct

grease unti cavit is approximately 34 filled

Vibration M Check and align motor and driven equipment

Rubbing between rotating parts and Isolate and eliminate cause of rubbingstationary partsRotor out of balance Have rotor balance checked are repaired at your


Resonance Tune system or contact your Baldor Service Center for

assistance

Noise Foreign material in air gap or Remove rotor and foreign material Reinstall rotor

ventilation openings Cherk insulatio integrity Clean ventilation openingsGrowling or whining Bad bearing Replace bearing Clean all grease from cavity and new

i bearing Repack with correct grease until cavity is

approximately 34 filled


BALORMOTORS AND DRIiES

BALDOR ELECTRIC COMPANYPO Box 2400

Ft Smith AR 729022400

501 6464711

Fax 501 6485792

O Baldor Electric Company Printed in USA

MN400 701 CJ10000

Flexibfe

Coupling

3

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3


M 200 SECTION MotorCoupling

CUPi@tlt PAGE AppendixBVolume I MOTOR COUPLING

ISSUED 07 JUN 2002

Important Safety lnstructionsREVISION A 01 MAY 2003

Warning For scoop mounted motors only

During start up and operation of power transmission product avoid sudden shock

ioads Coupling assembiy should operate quietly and smoothly If coupling assemblyvibrates or makes bearing sound shut down immediately and recheck alignmentShortly after initial operation and periodicaliy thereafter where applicable inspectcoupling assembly for alignment wear of elastomeric element boit torques and

flexing elements for signs of fatigue Do not operate coupling assembly if alignment is

improper or where applicable if elastomeric element is damaged or worn beyond25o of its origina thickness

Coupling mounting as easy as 1 2 3

z

1 vrr

1

iz

C

Mount both coupling halves insert the flexible spider and bring Check alignment between the two

including keys if any on their coupling halves together leaving halves using a steel straight edgerespective shafts approximately 116 space in across the top of both coupling

between the ends of the jaws halves

Spacer dots molded onto spidersprovide a guide for correct

spacing

Misalignment Capability

MaX max Standard Materials

Torque Range Angular Parallel

Model Inorrset fset

godyFlexible

Degrees Inches Member

L Up to4600 015 Sintered Iron NBR Rubberand Cast Iron

Sintered IronL Up to6240 010 and Cast Iron HYtrel

CopyrightOO Philadelphia Mixers Specrfications subject to change without notice

PHILADELPHIAMIXERS INDEX 3850Series

M 20 SECTION MotorCou lin

Current MOTOR COUPLING PAGE

Volume I mportant Safety InstructionsAppendix B

ISSUED07 JUN 2002


Lovejoy elastomeric jaw type flexible

couplings do nt require lubrication and are the

accepted industry standard They offer ease of

assembly or disassembly permit visual inspection ofh the flexible element wear members and allows for

their removal without disturbing the motor or pump

alignment in most applications

Lovejoy spider type individual load cushions and snap wrap spiders satisfy all standard

application requirements as well as combinations of low speedhigh torquelow speedhigh temperature high torque and other special conditions Lovejoys one

piece spider construction aso includes raised spacer dots on each side of the cushionto givepremeasured separaton between the jaws of each coupling half See diagrambelow

C

I IC

i

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A E A

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D DB B

Copyrfght0 Philadelphia Mixers Specifications subject to change without notice


S 20 SECTION RigidCouplingCurrent MOTOR COUPLING PAGE AppendixD

Volume I Dimensional Data ISSUED 07JUN2002


Dimensional Data

Type L Flexible Couplings

Dimension in Inches MomentDistance of Ineria

Bore putside Overall Between Length Hub Approx Weight WRzCoupling Style Diameter Length Flanges hru Bore Diameter Pounds LBINzNumber No Min Max A B C D E Solid Max Bore SolidL075 1 14 78 134 218 12 1316 134 10 8 388L090 1 14 78 2764 218 12 1316 2764 15 12 772L095 1 716 118 2764 212 12 1 2764 18 13 890L100 1 12 138 21732 312 34 138 21732 35 25 2783L110 1 58 158 3516 414 78 11116 3516 66 50 8993L150 1 58 178 33l4 412 1 134 334 91 70 11477L190 2 34 218 412 514 1 218 4 17 13 39256

Performance Data

Horsepower Capacity at Varying SpeedRated Torque RPM

CouplingnLbs HP100 RPM NBR Rubber

Number NBR Rubber Hytrel NBR Rubber Hytrel 300 1200 1800 3600 Max BoreL075 756 12 36 144 216 432 78L090 1260 20 60 24 36 72 1L095 1760 28 84 336 504 1008 118L100 3780 1130 60 18 18 72 108 216 138L110 6930 2079 11 33 33 132 198 396 158L150 10710 3213 17 51 51 204 306 612 178L190 13860 4158 22 66 66 264 396 792 218

Copyright0 Philadelphia MixersSpecifications subject to change without notice

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