Manual de Usuario Granalladora PDF

LLheelabrator
T: 905-319-7930 T: 800-845-8508 F: 905-319-7561 F: 800-571-5637 vmw.wheelabratorgroup.com
GROUP
Wheelabrator Group 1219 Corporate Drive Burlington, Ontario L7L 5V5
WARRANTY 3463 Gunderson-Gimsa Purchase Order Number GGOS747-1 Seller warrants that the equipment described herein will be free from defects in material and workmanship for a period of twelve (12) months from delivery ("Warranty Period"). Ifwithin the Warranty Period Seller receives written notice promptly after the discovery of any defect in the material or workmanship Seller shall correct each such defect FOB point of manufacture. Seller shall undertake its warranty obligation of repair, replacement within a reasonable time of receiving actual notice ofthe warranty defect. Seller shall be fully compensated for expenses of travel and for job time (at Seller's then prevailing per diem rates for straight time and premium time, as applicable) of its service representatives who inspect warranty claims that are not warranty issues. Buyer shall issue a purchase order for these expenses prior to Seller's representatives arrival on site Purchaser has no right to and may not backcharge Seller for warranty claims without prior approval. Normal wear parts and labor are not included. The liability of Seller to Purchaser/Buyer arising out of or the supplying of the equipment whether under warranty, tort, contract, negligence, strict liability or otherwise, shall not in any case exceed the cost of correcting defects in Equipment and l,1ponthe expiration of said warranty, all such liability shall terminate. This warranty is conditioned upon the Equipment being handled, operated, and maintained in accordance with written instructions provided or approved in writing by Seller. This Warranty is not applicable to commercial items used on Seller's assembled equipment; such issues shall be covered byany terms provided bythe original equipment manufacturer for any respective commercial item. Seller makes no warranties which extend to damage to the Equipment due to deterioration or wear occasioned by chemicals, abrasion, corrosion or erosion, improper erection, operation or maintenance, abnormal conditions of temperature or dirt, or operation of the Equipment, and Purchaser's exclusive remedy shall be limited as above provided. THE WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESSED OR IMPLIED OR STATUTORY, INCLUDING ANY WARRANTY OF MERCHANTABLITY OR FITNESS FOR PARTICULAR PURPOSE. The remedies set forth herein are expressly declared to be the sole and exclusive remedies hereunder. There shall be no liability to anyone for special, incidental or consequential damages with respect to the Equipment or for any related economic loss or property damage.
Wheelabrator
Group (Canada)
Ltd.
Operation & Maintenance Manual
Llheelabrator
GROUP
Customer: City:
Gunderson GIMSA S. de R.L. de C.V.
Date:
Mar. 17/08 Mexico
Frontera, COAH
Style:
State:
Machine Machine
4 Wheel Plate Descaling Machine J3463
Serial No.:
Dust Collector: Dust Collector
5D15L Dust Collector

Serial No.:
n/a
If you need any assistance, please do not hesitate to call and we will gladly assist you.
Canada
Wheelabrator
1219 Corporate Drive Burlington, Ontario L7L SVS Telephone: (800) 84S-8S08 Telephone: (90S) 319-7930 Fax: (90S) 319-7S61 Web Site: www.wheelabratorgroup.com
Created: March 28, 2008 Revision:
Page 1 of148
www.wheeiabratorgroup.com
u.heelabrator
GROUP
See
I. 2
1 Int tQduction
lit.. ...... "...... .....
. 'II ........
III.............. ...... 11
1ft truetteA GAd Wambtg Syfftbols.. .. ...... .. .. . . ..1.2

Read! Caution! Warning! Danger! Electrical Hazard! 12 12 12 12 12
1.2.1 1.2.2 1.2.3 1.2.4 1.2.5
I. 3
lftstmetioAs...
Reading about Equipment Understanding the Equipment Equipment Operators & Maintenance Personnel Qualifications Warnings & Precautions Receipt of Equipment
1.2
12 13 13 13 13
1.3.1 1.3.2 1.3.3 1.3.4 1.3.5
Sectio
,fety - W mings & Preca
ions................. ...................... ............ 19
3.2.1 3.2.2
Highly Explosive Dust. Aluminum Media & Parts Adding Limestone
20 20 Dry Type Collectors
3.2.2.1 3.2.2.2 3.2.2.3
20
20
Dust Collector Hopper(s) Ductwork Velocity - Aluminum Applications
21
Created: March 28, 2008
Page 3 of 148
Revision:
.1
uheelabrator
GROUP 22 22 23 23
3.4.1 3.4.2 3.4.3 3.4.4
Control Panel Electrical Motors Equipment Installation Wiring Equipment Safety Grounding
3.5.1
Installation Lift points Tipping Hazard Equipment Placement
24 24 24 24 25
. ..25
3.5.1.1 3.5.1.2 3.5.1.3 3.5.2
Items to be checked and completed before start-up ctft.iCClI ~Oft

... ...... , .......... ...... ... ..... ""..
3.45
3.6.1
Mechanical Do's & Don'ts Items:
26
~.. ~car~..
3.7.1 3.7.2 3.7.3 3.7.4 Caution Signs Warning Signs Danger Signs
..
..
lt~
28 30 32 38
Miscellaneous Signs
See i n 4 BI t Wh
~1 2
4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7
I~u~~~~ ~~~~ ~~ ~
' l .
Bias
u.....
~~
u
41
41 42 43 43 43 45 45 46 47
How the Blast Wheel Works Bi-Directional Blast Wheel Parts Setting and Adjustment Wheel Direction Control Cage Setting The "Hot Spot" Blast Pattern To Check Blast Pattern How to Rotate the Control Cage
Page 4 of148
www.wheelabratorgroup.com
4.1.7.1
4.1.7.2
Created:
March 28, 2008
Revision:
u.heelabrator
_GROUP
ec:
~..
Ii
System
....... ........... ...
"
,. .
. ..... ...... J[
5.1.1
Types of Lower Reclaims: Full Gravity Reclaims: Lower Screw Conveyor Reclaims: Shaker Conveyor Reclaims:
51
5.1.1.1 5.1.1.2 5.1.1.3
51
51 56
. 2
hfteUoft.
qf'tlte
Bueke .1:1
r........................................................................... 7'
58 60 61
5.2.1 5.2.2 5.2.3
Elevator Head Section Elevator Boot Section Elevator Belt Assembly
5.3.1
Types of Upper Reclaims: Full Gravity Reclaims Upper Screw Conveyor Reclaims
63 63 63
5.3.1.1 5.3.1.2
c
5.4.1 5.4.1.1 5.4.1.2 5.4.1.3
~.
SepaNto
70
70
Types of Separators: Gravity CFS Separator CFS Separator w/Upper Screw Conveyor Reclaim LP Magnetic Separators
70
72 75
5.4.1.3.1 Primary LP Magnetic Separators 5.4.1.3.2 Secondary LP Magnetic Separators

ftm4~Uo 5.5.1
76 82
... .
DriM
..... .. ....... ..
Mounting and locating dribble valve AI"~u:f8e
~.c_".
tro
..
..................
'
.
'
88
Aelras:f8eCo
..88
tCoReeto
Created: Revision: March 28, 2008 Page 5 of 148
.
uheelabrator
GROUP 95
6.2.1
Shaker Bag Style Elements of a Typical Shaker Bag Style Dust Collector: Shaker Mechanism Filter Bags Cell Plate Inlet Vent Baffle PlatelLiner Fan Outlet Vent
6.2.1.1 6.2.1.1.1 6.2.1.1.2 6.2.1.1.3 6.2.1.1.4 6.2.1.1.5 6.2.1.1.6 6.2.2
96
96 96 96 97 97 97 98
Pulse Bag Style Elements of a Typical Pulse Bag Style Dust Collector: Inlet Vent Baffle PlatelLiner Filter Bags Compressed Air Reservoir Air Manifold Multi-Stage N ozzles Venturi Fan Outlet Vent
6.2.2.1 6.2.2.1.1 6.2.2.1.2 6.2.2.1.3 6.2.2.1.4 6.2.2.1.5 6.2.2.1.6 6.2.2.1.7 6.2.2.1.8 6.2.3
99
99 99 100 100 100 100 100 101 101 102 102 102 102 102 103 103 103 103
Cartridge Style Elements of a Typical Cartridge Style Dust Collector: Inlet Vent Baffle PlatelLiner Typical Cartridge with Clamping Plate Typical Cartridge Filters w/o Clamping Plate Compressed Air Reservoir Air Manifold Nozzles Typical Venturi
Page 6 of 148
6.2.3.1 6.2.3.1.1 6.2.3.1.2 6.2.3.1.3 6.2.3.1.4 6.2.3.1.5 6.2.3.1.6 6.2.3.1.7 6.2.3.1.8

Created: Revision:
March 28, 2008
Llheelabrator
GROUP Fan Outlet Vent 103
6.2.3.1.9
6..3 Di
hragrft Va
used Oft PulseBag Cartridge
Pressure Gages sed Oft All ftree Sf\vles ~ Collectors ...................... lOt
6.4.1 6.4.2 6.4.3 Manometer Unit Magnehelic Differential Pressure Gage Photohelic Differential Pressure Gage 104 105 105
fS..S Bx:h
t Piptng
COftstruetioft
....................................... 105
ec on 7 Opera.tion ""
7 .. 1
7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.1.8 7.1.9 7.1.10 7.1.11 7.1.12 7.1.13 7.1.14 7.1.15 Wheel RPM Wheel Amps Abrasive Run Hours Blast Timer
".. " "
,." "
" "
'II "
107
107 107 107 107 107 107 108 108 108 108 108 109 109 109 109
Control Power On Light Master Start Pushbutton Emergency Stop Pushbutton Motor Overload Fault Light Blast Start Pushbutton Auto/Manual Mode Control Selector Switch
Abrasive Light On Wheel Start Pushbutton Wheel Stop Pushbutton Blast Test Pushbutton Abrasive Control Selector Switch
7 .. 2
7.3.1 Motor Rotation Charge the Equipment with Media
Page 7 of148
111 112
r:
J
7.3.2
Revision:
Operation Manual
&
Maintenance
Llheelabrator
GROUP
7.3.3 7.3.4
Blast Wheel Media Handling System
112 112
1YI~ .,I~lrl~"
&1 1ft
8.1.1.1 8.1.1.2 8.1.1.3 8.1.1.4 8.1.2 8.1.3 8.1.4 8.1.5 8.1.1
~.~~~~.~~~~~~~~~~~ " ,.""' " "' ,.""'."', ,........ ~

113 114 114
tio~ ReJKdrlReplacelMftt of Palts & CofltlM)fteftts .............. 113

Blast Wheel Assembly Liners Wheel Housing Wheel Blades, Control Cage & Impeller Removal and Replacement of Blast Wheel Impeller Bolt
114 115
116 116 116 116
Cabinet Assembly Work Conveyor Assembly Work Conveyor Drive Assem bly Abrasive Recycling System Abrasive Hopper Elevator Belt Assembly Elevator Drive Elevator Casing, Dribble Valve & Refuse Tubing Slide Valve Assembly, Control Valve & Feed Hose Bearings CFS Separator Assembly
8.1.5.1
117 117 119

119
8. 1.5.2
8.1.5.3 8.1.5.4 8.1.5.5 8.1.5.6 8.1.5.7 8.1.6 8.1.7
119
120 120 121 121
Ventilation System - Provided by customer or as an option Electrical Control Panel Electric Motors
8.1.7.1
8.1.7.2
122 122
~jlt.,r,~
~I
""""
""""",."
, ~
...................
1)1~~"c)c) illSl............................................
9.. 1 B
4t
9 .. 2
Created: March 28, 2008 Revision: Page 8 of 148
WO;J"onoJiuOlluq8IaaqM"MMM
:UO!S!A;}lI 8t110 6 ;}~~d

800Z
'8Z
q;)UW :P;}J~;}.I;)
S.1
~
...,",..,
"
,', ,"",.,',
.......,
,
,',
..
IlIJlp
l ... ~l
......................................................
UIMJ
a aUI'I:,)
Z~"UOll:l&1
1 ~1
. , , ' ~ lIJ
.,"",., ,",.,
..
,., , ,.".".,.".,",.,
s..a.un~Q
.1.'11
., ..toliaavo:')
.,1
~r
~1
...................................... ~~~II~ ~: .. .. .. . . .. .. . .' . ._ v. ~ lUJ81~_.taefd'a
$'11
11
v..t~J, .- '" lUJDJ-_ ~O'J' D .............. .. ~ ~ ~1t.lI I~~ 1"1
D ............................ ,"""',
.... ... ..... ... -

" ,.,', ,',., ,
e-rr
11
t-tt ~,,~ ~~~~~~~ . ~~ ~ . ~~~~~~~~ . ~~~~~ . ~~~~n . ~n~~~~~~~~~~~~~~S1J.d &.leas puewWOO&~~~"UOll~

s:a,A8d 1.1~.WWO:lO~"UOllas 'S'6 Z'S'6
~'S'6 laued IOJ~UO::> s,Jo~eJado - sa!Jossa:>:>v IOJ~UO::> laued IOJ~UO::> pue SJaJJe~s SJO~Ow
6t~n. nnnnnnnnnnnn~nnnnnnnnnnSI.nU8'"
L ~ S ~
17 ~
~~Jr ,., ,,,,., " ,',., ,.".,",.,"""''""~~lIIc1.t~I~~~I~ ~.~ ~~Jr ,.,.,',.,"',.".,""""""""""""',." Jr~Jr .,., ,""""',.,"", ".,""', ,' ".'.~~ ".,"",., """'."'
lIc.~I~~4l ~.
~'
I'
' ' '." ~
dnO~8
JO~OJqoleelft1
lenuew a:ueuaJu!ew " uO!JeJado
u.heelabrator
GROUP
Section 1
Introduction Statement
1.1
This manual will benefit you in several ways: 1. It will provide you with safety warnings and instructions to protect you and your equipment from injuries or damage. 2. It will assist you in keeping this equipment in the best possible mechanical condition at all times. 3. It will help you obtain the maximum performance from your equipment. The instructions and suggestions contained in this manual are based upon practical operating experience. If followed they will help you get the most production and satisfaction from the equipment. Everyone responsible for the operation and maintenance of your equipment must read and understand this manual before using or working on the equipment. Our interest in the safest and most successful operation of your equipment continues throughout the life of the equipment. We want it to serve you well. For that reason, please feel free to discuss any problems you may have concerning it or the work you are doing. It will be a pleasure to help you.
Addition copies of this manual can be purchased from the equipment manufacturer.
Created: Revision:
March 28, 2008
Page 11 of 148
u.heelabrator o
GROUP
1.2
Instruction and Warning Symbols In this operation and maintenance manual the following symbols are used to identify important operation, maintenance and safety instructions:
e
&
g
1.2.1 Readl
This sign I?dlcates advice regarding operation and maintenance. 1.2.2 Caution!
IA
I
CAUTION
Yellow background with black text
This sign indicates rules and guidelines for a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. 1.2.3 Warning!
WARNING I
Orange background with black text
This sign indicates rules and guidelines for a potentially hazardous situation which, if not avoided, could result in death or serious injury. 1.2.4 Danger!
A. DANGER
J
Red background with black text
This sign indicates rules and guidelines for an imminently hazardous situation which, if not avoided, will result in death or serious injury. It may also be used to alert against unsafe practices 1.2.5 Electrical Hazard! This sign indicates rules and guidelines to prevent possible severe or fatal injuries to the person and/or damage to the equipment by electrical causes. 1.3 Instructions 1.3.1 Reading about Equipment
&)
This manual has been prepared to assist operator and maintenance personnel in understanding the equipment, so that it may be operated safely in the most efficient manner and maintained in the best condition. All personnel responsible for the operation and maintenance of the equipment must read and understand the manual, before using or working on the equipment.
Page 12 of148
uheelabrator
Before attempting to operate, service or maintain the equipment, personnel should thoroughly familiarize themselves with the physical make-up of the equipment, be familiar with the major components of the equipment, and have a general understanding of overall operations.
GROUP
1.3.2 Understanding the Equipment
1.3.3 Equipment Operators & Maintenance Personnel Qualifications

1. Person must be of legal age for the location to operate and/or service equipment. 2. Person must be able to read and understand the English language to operate and/or service equipment. 3. Person must read and understand operation and maintenance manual before operating and or servicing the equipment. 4. Person must be trained in the operation and safety of the equipment before operating. 5. Only qualified maintenance personnel may service this equipment.
1.3.4 Warnings & Precautions

Operating and maintenance equipment. personnel must obey all posted on the
the warnings and safety precautions
Serious injury to personnel or severe are not followed.
damage to the equipment may result if the warnings and precautions
1.3.5 Receipt of Equipment
fJ
Created: Revision: March 28, 2008
Examine the shipment carefully for possible damage in transit. If damage is found, note the damage on the bill of lading, notify the transportation carrier immediately and advise the Wheelabrator Group.
Page 13 of148
Llheelabrator r.. ....

Parameters Equipment Type: Work Handling System: Work Descr.
GROUP
1.4
Equipment
I Plate
Roll
,.._~ ~..~..~ M................. ._._._._ _ _ .. __ . j
Y4 x 10' . w M..'.".~ Plate ............ _

10'-0" wide
,__ .., _
.~;
---_ ...._--------_._--_._-
Work Size:
i
3/16 - 1 % Thick
!X
I
plate
f-------.-----.-
~~--T---~---Temoereture
...................................................................................................................................... !.,...
of W~rk;I A;;-bient--'-'_.HH_ ,.,
Maximum Work Weight or Volume:

_" _. _ _
t : _-
1000 Ibs./ft. Linear

HH
, ;
I
1
:-
..-
-- -,--:....--"...- ..--.~-
~'.,....--
..- ..------~-~
Work Loading:
I Roll Conveyor;...-+-.....
Roll Conveyor
.!-..._---_ .... _----_.
'
pope
Work Unloading:
-.-.----.
H
,--_.
'
'M"
~_.-.H
H H-.-
Abrasive Media Size & Type: S280 H_

_ _ _ -. _ ~_._ _ _ _ _ _. __
'!
I -1
ft
_._
._
,
. .
Ventilation (CFM) Req~i;;;;~t;-r8ifbo Equipment Primary Power Supply:
CFM------
1
'-+--0-- "---~
r.::- ---.-t-_
--- ~ ; ...--1"'
460V 24VDC
_ _ .._._.
60Hz
- ---_
Equipment Secondary Power Supply: . ---..... Total Amps Requirement:
__ ._.........
I .3 Phase ~I Hz I 3 Phase i
-l
299
Created: Revision:
March 28, 2008
Page 14 of 148

"-...-/
u.heelabrator
GROUP
1.5
Equipment Component Specifications
,---_._-----
Component
Blast Wheel
---~--T----~m
Specification
Quantity:
T4
25 EZE 270
I
1
Ty.e.e: ! Power (HP): I Speed(RP~):1 Flow Rate~er Wheel: ! Total Flow Rate:
40 HP
1800 894 3576
i Blast
i
Wheel
-----T--==-=~--Qiianti~:T----- ;-_
~.--. _
Ir-m..
..........................m........ .m.I.. I
L.........._ .... .~~~q(f.!:~Ml;J..m
Power (HP1:
m m
-.-.-T.y.e.~;J..-..---.-.-~i
.[ _ _
----.-J
_.
.... _...... ..m_.... Flow Rate per Wheel: I m... ..Total.i=iow"/:jiJte.:I ..m........... ................m
r-I~owerRecfaim="'"
i
~
'r=~~::'..:
!------_
=..:":":~.~-.:::~~fi~~it~~~~~- .. --.-:~- . -~-""=-"""~~~=: ..

i
I
Elevator'
__ ._._...
L--.-.
d'"
Power (HP): I 5 HP Speed(RP~):146

,
.. _..
Size: .~.----.-. I 16"
---~
=!'
$~
L.
, Upper Reclaim
-.IYye:
_
r_. . __ m _
L.__ ._
1--- _
--"
_-_
Power
,
_-
Size: HP:
._ ,.,
Rota~ Screen 14" 7 1/2 --~

.. ------.,_ , _ _" _
I
J
_ .. _
_.. m.m._.m m
_ _ __
~_ m.mm __ m._...ef!....f!...rJ.{RP~),;..+ 40 RPfvt1 ..__ __ m m_._..

~ _._
I Separator
i
~_ __ _ _
__
._
_"
!--... _
L.-.
_..
_M
"......
ii . _ _
.....................I.Ye~;J.B9.!9.~.~~~~ __ _
_. .. ........... __ ._.......... .. ..... ".. ....... .. ........... _ .......................
Size:
!-'_ _._
I 60"
I I -
"
_ .._._
._ .._ .._. __ .. _
Work Handling
i ,.... ... --.. -... --.----.-.. ----.---
c'
r_
?:r
...,
'.
'r
'=_.. ......
._.._.._~ .._.._.._..
":+.. __ ._._~
__
. _ _ . _
Created: Revision:
March 28, 2008
Page 15 of 148
Operation &
Maintenance Manual
u.heelabrator
GROUP WARRANTY 3463 Gunderson-Gimsa P.urdlas.e Order Number GG057471
Section 2
Warranty
-.,.
Seller warrants that the equipment described herein will be free from defects in material and workmanship for a period of twelve (12) months from delivery ("Warranty Period"). If within the Warranty Period Seller receives written notice promptly after the discovery of any defect in the material or workmanship Seller shall correct each such defect FOB point of manufacture. Seller shall undertake its warranty obligation of repair, replacement within a reasonable time of receiving actual notice of the warranty defect. Seller shall be fully compensated for expenses of travel and for job time (at Seller's then prevailing per diem rates for straight time and premium time, as applicable) of its service representatives who inspect warranty claims that are not warranty issues. Buyer shall issue a purchase order for these expenses prior to Seller's representatives arrival on site Purchaser has no right to and may not backcharge Seller for warranty claims without prior approval. Normal wear parts and labor are not included. The liability of Seller to Purchaser/Buyer arising out of or the supplying of the equipment whether under warranty, tort, contract, negligence, strict liability or otherwise, shall not in any case exceed the cost of correcting defects in Equipment and upon the expiration of said warranty, all such liability shall terminate. This warranty is conditioned upon the Equipment being handled, operated, and maintained in accordance with written instructions provided or approved in writing by Seller. This Warranty is not applicable to commercial items used on Seller's assembled equipment; such issues shall be covered byany terms provided bythe original equipment manufacturer for any respective commercial item. Seller makes no warranties which extend to damage to the Equipment due to deterioration or wear occasioned by chemicals, abrasion, corrosion or erosion, improper erection, operation or maintenance, abnormal conditions of temperature or dirt, or operation of the Equipment, and Purchaser's exclusive remedy shall be limited as above provided. THE WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESSED OR IMPLIED OR STATUTORY, INCLUDING ANY WARRANTY OF MERCHANTABLITY OR FITNESS FOR PARTICULAR PURPOSE. The remedies set forth herein are expressly declared to be the sole and exclusive remedies hereunder. There shall be no liability to anyone for special, incidental or consequential damages with respect to the Equipment or for any related economic loss or property damage.
Page 17 of148
uheelabrator
GROUP
Section 3 3.1
Safety - Warnings & Precautions LockoutlTagout One of the most widely applicable industrial safety principles is Lockoutrragout. The Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANZI) have both addressed the requirement for LockouUTagout. OSHA requires that each employer formulates a written procedure for implementing a LockouUTagout safety program, including training employees to assure that it is properly utilized. The following are a few important points to keep in mind. 1. The principle of LockouUTagout is to protect personnel from the unexpected energization, start up, or release of stored energy from the equipment or process. 2. The LockouUTagout principle requires that locks and tags be affixed to the point where energy can be disconnected from the equipment or process. 3. Sources of energy are not restricted to electrical; that is, disconnecting the main power switch may not eliminate all sources of unexpected activation. While electrical power always should be disconnected, a person knowledgeable about the equipment or process must assess the system for circumstances in which other forms of energy may be stored and released. 4. Personnel who are most vulnerable to injury from the activation of energy are maintenance personnel who must disassemble, expose and work on the equipment in the process of repair or service. The following serves as a reminder to apply this important safety principle when working on the equipment. Disconnect or remove all sources of stored energy before performing maintenance or other service actions. Failure to eliminate or block sources of stored energy can result in unexpected movement of equipment elements and cause serious injury or death. Follow your Lockout/Tagout procedure.
Created: Revision:
March 28, 2008
Page 19 of 148
uheelabrator
GROUP
~
3.2
Media Warnings 3.2.1 Highly Explosive Dust Products (parts), which produce highly explosive dust, such as Magnesium, Titanium, Zirconium, Thorium, etc., should not be processed in this equipment, unless appropriate safety measures are followed (consult expert authority). Obtain approval of your plant safety director and comply with applicable NFPA (National Fire Protection Association) guidelines. Note: Personnel should not smoke. use matches nor have open flames around this equipment during operation. 3.2.2 Aluminum Media & Parts
Comply with all applicable sections of NFPA guidelines for processing or handling of aluminum dust and fines that may be pertinent to your specific operation. In applications involving the use of dry type bag or cartridge dust collector system and Aluminum Media or surface blasting of Aluminum Parts, precautionary measures must be taken to minimize the risk of dust collector fires and/or explosions. The following procedures should be followed. 3.2.2.1 Adding Limestone - Dry Type Collectors No. 200 mesh agricultural limestone (CaC03) should be added to the ventilation system at a continuous rate of 0.2 oz per hour per square foot of filter area. Caution: CaC03 is crushed limestone rock (not to be confused with lime, otherwise known as hot lime, burnt lime or hydrated lime. These highly reactive lime products should not be used). 3.2.2.2 Dust Collector Hopper(s) The dust collector's refuse hopper(s) must be emptied at frequent intervals and at the end of each shift of operation. Collection of more than 1/3 the hopper capacity should not be exceeded. If external containers are used to collect refuse, they must never be allowed to overfill and back up into the collector hopper. All equipment must be grounded in accordance with the National Electrical Codes (NEC) to minimize static electric charges.
Page 20 of 148
www.wheelabratorgroUD.com
'-----'
u.heelabrator .oo
Ductwork Velocity - Aluminum Applications
Maintain ductwork air velocity of not less than 4500 FPM.
GROUP
3.2.2.3
3.3
MaintenanceWarning - Electrical
WARNING
BEFORE ANY MAINTENANCE WORK IS CARRIED OUT ON THIS EQUIPMENT, THE MAIN ELECTRICAL SUPPLY SWITCH MUST BE IN THE "OFF" POSITION. ANY PERSONNEL PERFORMING ANY MAINTENANCE ON THIS EQUIPMENT MUST FOLLOW ALL APPLICABLE PLANT SAFETY
STANDARD OPERATING PROCEDURES SUCH AS LOCK-OUT, TAG-OUT, ETC ...
Page 21 of148
Revision:
Llheelabrator
,...,.,
G RO U P
3.4
Electrical Precautions Throughout this manual are safety warnings and precautions that must be obeyed by maintenance and operating personnel. Although the precautions which follow may seem to be over simplified, they should be included in the "Buyer's Safety Program." These are minimum safety requirements for this equipment and any additional plant safety requirements for your facility shall also be obeyed. 3.4.1 Control Panel
1. DO NOT operate the equipment with the

control panel door open.
2. DO NOT use oversized fuses or bypass

any fuses. Refer to Electrical Drawing.
3. DO verify the correct thermal overload(s)

are installed for the motor starter(s) for the full load amp rating of the motor(s) as shown on the motor nameplate. 4. DO verify the set point knob on motor starter overload relay(s) are set to match amperage called out for on electrical drawing and matches motor nameplate data. 3.4.2 Electrical Motors Only qualified personnel should perform electrical installation, operation and maintenance work.
1. DO verify all power sources are disconnected before attempting

maintenance or repair.
2. DO follow your plants LockoutlTagout procedures. 3. DO NOT come in contact with rotating parts.
4. DO verify motor(s) are effectively grounded. All the motor(s) on this equipment are securely fastened by metal-to-metal contact on the equipment and effectively grounded provided that the equipment is grounded. Refer to Item 3.4.4 on equipment grounding.
uheelabrator
.lvv,"
'---
_GROUP
5. DO verify the motor's nameplate before starting the motor(s), to

ensure that the correct power supply (voltage, frequency, and phase) is being used and that the motor(s) is/are connected according to the connection diagram on the nameplate. Verify that the motor is connected properly for the correct rotation. If motor(s) rotate in the wrong direction, a qualified electrical person may interchange any two line leads at the starter in the control panel. (Ref.2-3.2)
6. DO NOT use the eyebolt on the motor(s) to lift the motor with
any additional equipment attached to the motor(s).
3.4.3 Equipment Installation Wiring
DO verify the equipment is wired and connected with wire of the

correct size and correct insulation.
3.4.4 Equipment Safety Grounding 1. DO verify the equipment, as installed, is effectively grounded. 2. DO verify the equipment is grounded in accordance with NEe
and any other applicable state or local codes.
3. DO verify effective grounding is accomplished by providing a

ground path from the equipment to a grounding electrode with a copper conductor. The ground electrode may be: a.) b.) c.) An underground metal water pipe A grounded metal building frame Other local metallic underground systems, such as tanks, plates, or driven pipe or rod.
4. DO verify the grounding conductor from equipment to grounding electrode is fastened by a pressure type cable connector (no solder) to a surface that is free of dirt and paint. Electrical devices (motors, controls, etc.) securely fastened to the equipment are grounded if the equipment is grounded.
Page 23 of 148
uheelabrator
GROUP
<,
3.5
Maintenance Warning - Mechanical 3.5.1 Installation 3.5.1.1 Lift points Safety during installation and start up requires placing the equipment without damage or injury and proper hook up to the required utility service. The equipment may be lifted using the designated lift points that are located at a balance point. Be sure to lift the load with a proper size lifting device and follow safe rigging practices when performing this work. The proper lift points are designated on the equipment by the following sign. 3.5.1.2 Tipping Hazard Some equipment may have work doors that may cause a change in the equipment's center of gravity when opened. Make sure all doors are securely closed before lifting and make sure equipment is securely anchored before doors are opened. Note: DO NOT open doors on equipment until the equipment is anchored securely. 3.5.1.3 Equipment Placement 1. Be sure to allow sufficient space around the equipment to ensure that operation and maintenance can be performed without endangering personnel. 2. Inspect all access covers to make sure each is in place and secure. 3. Install vent piping to customer's dust collector system or to the dust collector supplied with the equipment. 4. Remove all foreign objects that might have been dropped or left in hoppers, elevator boot, etc.
LIFT
HERE
0498216
Created: Revision:
March 28, 2008
Page 24 of 148
Operation & Maintenflnce Manual

"'--"'
L1heelabrator
Items to be checked and completed before start-up
GROUP
3.5.2
1. Install breathers on speed reducers.
a.) Remove solid fill plug(s) located at the highest position and on the slow (output) side of each reducer. Ensure oillevel(s) is/are correct with recommended lubricant(s). (See lubrication chart in Section 5) b.) Replace solid fill plug with breather plug(s) which is/are enclosed in packet inside electrical panel.
* Note: Some units may be equipped with combination

2. Check motor rotation on all drives.
plugs that do not require replacement. Check for air/pressure vent hole in plug before removing. Only un-vented plugs need to be changed.
3. This equipment is normally wired to operate from 460V AC, 3 Phase, and 60 HZ electrical supply. Factory supplied options for 575V AC, 3 Phase, 60 HZ or 230V AC, 3 Phase, 60 HZ operation are available. 4. Before starting the equipment, check that the equipment is properly wired for the voltage it will operate on. 5. Make sure all drive guards, inspection plates, etc. are in place. 3.6 Mechanical Precautions
Throughout this manual are safety warnings and precautions that must be obeyed by maintenance and operating personnel. Although the precautions that follow may seem to be over simplified, they should be included in the "Buyer's Safety Program." These are minimum safety requirements for this equipment and any additional plant safety requirements for your facility shall also be obeyed.
, Created: March 28, 2?08 Revision:
Page 25 of 148
u.heelabrator
GROUP
.J
3.6.1 Mechanical Do's & Don'ts Items: 1. DO Achieve Zero Mechanical State (ZMS) before performing maintenance on the equipment. a.) DO lockout every power source that can produce mechanical movement. b.) DO lockout shut off valves for pressurized fluid (air, oil or other). c.) DO reduce all accumulators and air surge tanks to atmospheric pressure. d.) DO achieve the lowest practical value for mechanical potential energy for all portions of the equipment. Example: A belt and bucket elevator system that has stopped with the buckets containing abrasive may reverse from the weight of the abrasive in the buckets. e.) DO achieve the lowest practical value for kinetic energy of the equipment members. Loose or freely movable equipment members and parts must be secured against accidental movement. Example: A rotating part, such as an airless blast wheel, will continue to rotate for a period of time after the electrical power has been disconnected.
2. DO keep all guards in place, except during maintenance or repair

work. Remount all guards upon completion of any maintenance or repair work.
3. DO wear safety glasses while working near or on the equipment. 4. DO wear gloves, when applicable, when working near and on the
equipment.

Revision:
Page 26 of 148

'-..---
uheelabrator
GROUP
5.
DO NOT wear loose fitting clothes, jewelry and watches, while

working near belts, chains, sprockets, shafts or other components that are movable.
6.
DO keep the areas around all equipment clean. Loose abrasive

media and dust can cause hazardous conditions.
7. DO immediately correct any condition(s) that may result in

damage to the equipment or cause injury to personnel. 8.
DO NOT use your hands to remove excess abrasive from the

elevator boot section, rotary screen, screw conveyor or shaker conveyor. Always use a scoop or scraper for removing this abrasive.
9.
DO NOT attempt to adjust the feed spout, or other wheel parts

while the blast wheel is operating or rotating.
10. DO NOT attempt to adjust the component parts of the abrasive

recycling system or the work parts conveyor system while any part of the blast equipment is in operation.
11. DO NOT remove access covers or panels while equipment is

operating. Always follow your facility's LockoutfTagout procedures before removing any covers or panels.
12. DO obey all safety signs (caution, warning & danger) and other
precautionary information posted on the equipment or in the equipment operating area.
Page 27 of148
Revision:
Operation & Maintenance

!
ManuaJ
u.heelabrator
GROUP J
3.7
Safety Signs The following safety and danger signs may appear on and around the equipment, it is important that their meaning is fully understood by all operators and maintenance personnel who will come in contact with the equipment:
3.7.1
Caution Signs
I A CAUTION I
I
Caution Sians
Descrintlon
Part Number: 498276 Location: This sign is located on lifting lugs and or points on the equipment where the equipment can be lifted. Meaning: This sign shows points on the equipment where it is safe to lift the equipment.
LIFT
HERE
498276
Part Number: 674982 Location: This sign is located on all blast wheel motors on the equipment. Meaning: This sign cautions the operator to verify that all the blast wheels are rotating per design requirements.
CAUTION CHECK WHEEL MOTOR ROTATION
Created: Revision:
March 28, 2008
Page 28 of 148
___J
l.JJleelabrator
GROUP
<:
3.7.2 Warning Signs
A WARNING
Descrlntion
AWARNING
Part Number: 494043 Location: This sign is located at eye level on all inspection, access and work doors on the equipment. Meaning: This sign warns the operator or service personnel to wear safety glasses with side shields when servicing or operating the equipment.
f
}
~."~.~"I"!!f(~~~~~~,
,;
;~
..' ~
,,~
,
Part Number: 494044 Location: This sign is located on all drive guards on the equipment. Meaning: This sign warns the operator to verify that all drive guards are secured before operating the equipment.
Page 30 of 148
wwwowheelabratorgroupocom

\...--
uheelabrator
GROUP
Caution Signs
Description
Part Number: 674983 Location: This sign is located on all access panels and cover plates on the equipment. Meaning: This sign cautions the operator to verify that all access panels and cover plates are secured before operating the equipment.
CAUTION DO NOT OPERATE MACHINE i WITH COVER REMOVED :

THII MACHINE Will HOT OP!II.t.TE PAOPEltLy UNLU_ CLOUO
CAUTION
Buckets must be aligned with bottom openings before clamping to maintain an air-tight seal for proper dust removal from blast cabinet.
677122
Part Number: 677122 Location: This sign is located on LEM dust collector chamber near dust collection buckets. Meaning: This sign cautions the operator on proper alignment of dust collection buckets before clamping them in place.
Page 29 of 148
Llheelabrator
GROUP
3.7.2 Warning Signs
I A WARNING
Warn in
AWARNING
Descrlntlon
Part Number: 494043 Location: This sign is located at eye level on all inspection, access and work doors on the equipment. Meaning: This sign warns the operator or service personnel to wear safety glasses with side shields when servicing or! operating the equipment.
f_l
0494044
Created: Revision:
March 28, 2008
Page 30 of 148

\.......---
u.heelabrator
GROUP
II
Caution Signs
Description
Part Number: 674983 Location: This sign is located on all access panels and cover plates on the equipment. Meaning: This sign cautions the operator to verify that all access panels and cover plates are secured before operating the equipment.
CAUTION DO NOT OPERATE MACHINE i WITH COVER REMOVED

THlt MACHINE WIU HOT OP!IIAU ",OPEIILV UHLI" CLOIID
CAUTION
Buckets must be aligned with bottom openings before clamping to maintain an air-tight seal for proper dust removal from blast cabinet.
871122
Part Number: 677122 Location: This sign is located on LEM dust collector chamber near dust collection buckets. Meaning: This sign cautions the operator on proper alignment of dust collection buckets before clamping them in place.
Page 29 of 148
Llheelobrotor
GROUP J
3.7.2 Warning Signs
A WARNING
Descriotion
Part Number: 494043 Location: This sign is located at eye level on all inspection, access and work doors on the equipment. Meaning: This sign warns the operator or service personnel to wear safety glasses with side shields when servicing or operating the equipment.
Warn in
AWARNING
,~,+4i.",~1"!'!'t~m'~lf~,
t} ". ,';.
j " ~ '
."t
-.;:_
Created: Revision:
March 28, 2008
Page 30 of 148
Llheelabrator
GROUP
Warnin
ns
Descriotion
Part Number: 494045 Location: This sign is located at eye level on ladders to service platforms, at the operator's station and all access doors on the equipment. Meaning: This sign warns the operator or service personnel to watch their step around the equipment due to possible media on floor.
Watch your step. Keep area clear of debris.

494045
Part Number: 494749 Location: This sign is located near air or hydraulic cylinders, air supply shut-off valves and powered mechanisms on the equipment.
Lock out power and bleed air or hydraulic pressure before servicing.
494749
Meaning: This sign warns the service personnel to lock out power and bleed lines before servicing the equipment.
'-..--
Created: Revision:
March 28, 2008
Page 31 of 148
L1heelabrator
GROUP
-...-/
Warning Signs
WARNING
1. Do not open work door during blast cycle. 2. Wait approx. 30 seconds after blast cycle Is complete before opening work door. 3. Operate "mill forward" pushbutton before closing work door to allow mill to pull rubber shed Into cabinet.
.1112.'
Description
Part Number: 677128 Location: This sign is located at operator's station and door on manually controlled tumbler type equipments. Meaning: This sign warns the operator to allow the wheels to stop before opening the work door and to run the mill forward before closing the work door on the equipment.
3.7.3 Danger Signs
A DANGER
-"
A DANGER
Part Number: 494040 Location: This sign is located on junction box covers and main control panel on the equipment. Meaning: This sign warns there is a danger of electrical shock and to lock out power before opening the junction box or main control panel doors on the equipment.
~*
..... 7
Lock out power at main electrical panel before opening. ~
Page 32 of 148
uheelabrator .O
Warning Signs
WARNING
1. Do not open work door during blast cycle. 2. Wait approx. 30 seconds after blast cycle Is complete before opening work door. 3. Operate "mill forward" pushbutton before closing work door to allow mill to pull rubber shed into cabinet.
In 12.1
GROUP
-.../
Description
Part Number: 677128 Location: This sign is located at operator's station and door on manually controlled tumbler type equipments. Meaning: This sign warns the operator to allow the wheels to stop before opening the work door and to run the mill forward before closing the work door on the equipment.
3.7.3
Danger Signs
,A DANGER
A DANGER
Part Number: 494040 Location: This sign is located on junction box covers and main control panel on the equipment. Meaning: This sign warns there is a danger of electrical shock and to lock out power before opening the junction box or main control panel doors on the equipment.
~*
.~
Lock out power at main electrical panel before opening.

4!M040
Created: Revision:
March 28, 2008
Page 32 of 148
uheelobrotor
o>: ... ,...,
GROUP
Warnin
Descriotion
Part Number: 494045 Location: This sign is located at eye level on ladders to service platforms, at the operator's station and all access doors on the equipment. Meaning: This sign warns the operator or service personnel to watch their step around the equipment due to possible media on floor.
'94046
Watch your step. Keep area clear of debris.
Part Number: 494749 Location: This sign is located near air or hydraulic cylinders, air supply shut-off valves and powered mechanisms on the equipment.
Lock out power and bleed air or hydraulic pressure before servicing.
494749
Meaning: This sign warns the service personnel to lock out power and bleed lines before servicing the equipment.

Revision:
Page 31 of 148
u.heelabrator
GROUP
'----
Part Number: 494041 Location: This sign is located on junction box covers and main control panel on the equipment. Meaning: This sign warns there is a danger of electrical shock and only authorized personnel shall gain access to the junction boxes and main control panel on the equipment.
494041
Lethal Voltage. Authorized access only.
Part Number: 494042 Location: This sign is located on drive guards and cover plate over moving mechanisms on the equipment. Meaning: This sign warns that there is a danger and to turn off and lock out power before servicing this area on the equipment.
Turn off and lock out power at main electrical panel.

494042
,--,
Page 33 of148
uJleelabrator
GROUP
Part Number: 494150 Location: This sign is located on junction box covers and main control panel on the equipment. Meaning: This sign warns there is a danger of electrical shock and to lock out power before opening the junction box or main control panel doors on equipment.
Part Number: 494388 Location: This sign is located on cross channel of loader bucket on tumbler type equipments. Meaning: This sign warns there is a danger and to stay clear of this area around the equipment.
Created: Revision:
March 28, 2008
Page 34 of 148
'-...J
"----
u.heelabrator
GROUP
Part Number: 494390 Location: This sign is located on tumbler type equipment operator's station, pushbutton panel, main door, sides of loader bucket and side frame of loader on the equipment. Meaning: This sign warns there is a danger and to stay clear of this area around the equipment when operating door or loader on the equipment.
Part Number: 494748 Location: This sign is located at eye level at access points to the equipment with screw conveyors. Meaning: This sign warns that there is a danger and to turn off and lock out power before servicing the screw conveyor( s) on the equipment.
Turn off and lock out power at main electrical panel.

494748
Created: Revision:
March 28, 2008
Page 35 of 148
uJleelabrator
GROUP
Part Number: 494750 Location: This sign is located near pinch points on the equipment. Meaning: This sign warns that there is a danger and stay clear pinch points in this area on the equipment.
Stay clear of pinch points.

".4750
A DANGER
Do not open door: 1. If fan is running. 2. If door is hot. 3. If smoke is present.
Part Number: 495076 Location: This sign is located on inspection and access doors on dust collector and fan house. Meaning: This sign warns there is a danger and to not open door under the conditions stated.
495076
Page 36 of148
-:
LLheelabrator
r..r."",....,....,...,,. Miscellaneous Signs
_GROUP
J
3.7.4
Part Number: 472553 Location: This sign is located on motors on the equipment. Meaning: This sign identifies the proper rotation of the motors on the equipment.
SAFETY INSTRUCTIONS
1. Keep dust bags and hoppers clean. 2. Empty hoppers after each shift.
I I
Part Number: 495075 Location: This sign is located on bag style dust collectors. Meaning: This sign contains safety instructions on maintaining the equipment's dust collector.
495075
Part Number: 495605 Location: This sign is located on the main electrical control panel on the equipment. Meaning: This sign identifies the operating voltage of the equipment.
Page 38 of 148
uheelobrotor
Part Number: 499946
GROUP
I","",
::f'
Thl. machine t tfectly~y grounded
Location: This sign is located on the main electrical control panel for the equipment. Meaning: This sign warns there is a danger of electrical shock and to ground the equipment per the National Electrical Code Article 250.
for opator H'.ty.

s.. Nattonal Elect,leal COOe Article 250
A DANGER
Part Number: 715426 Location: This sign is located on the after filter housing transition for the dust collector on the LEM equipment. Meaning: This sign warns there is a danger and equipment or personnel could be damaged or injured if the transition is not removed before opening door.
1~
II
Page 37 of 148
uheelabrator
Miscellaneous Signs
GROUP
J
3.7.4
Part Number: 472553 Location: This sign is located on motors on the equipment. Meaning: This sign identifies the proper rotation of the motors on the equipment.
SAFETY INSTRUCTIONS
1. Keep dust bags and hoppers clean. 2. Empty hoppers after each shift.
I I
Part Number: 495075 Location: This sign is located on bag style dust collectors. Meaning: This sign contains safety instructions on maintaining the equipment's dust collector .
.95075
Part Number: 495605 Location: This sign is located on the main electrical control panel on the equipment. Meaning: This sign identifies the operating voltage of the equipment.
Page 38 of148
Revision:
Llheelabrator
Part Number: 499946
GROUP
I"""
::r
Th,. chino effectively for operator Se. grounded Ntely.
Location: This sign is located on the main electrical control panel for the equipment. Meaning: This sign warns there is a danger of electrical shock and to ground the equipment per the National Electrical Code Article 250.
Nattonal Electrical
Code Article 250
A DANGER
Part Number: 715426 Location: This sign is located on the after filter housing transition for the dust collector on the LEM equipment. Meaning: This sign warns there is a danger and equipment or personnel could be damaged or injured if the transition is not removed before opening door.
71542'
Created: Revision:
March 28, 2008
Page 37 of 148
Operation & Maintenance Manual "--
Liheelabrator
GROUP Part Number: 499414 Location: This sign is located on the main electrical control panel on the equipment. Meaning: This sign identifies the operating voltage of the equipment.
~~
't ~
4 -;.
,~A
',~
,..
"
~-
SAFETY INSTRUCTIONS
This machine must be effectively grounded for operator safety (see NEe ART 250.) Grounding shall be accomplished by providing a ground path from the machine to a grounding electrode with a grounding electrode conductor. The grounding electrode conductor shall be 8 AWG copper or larger, (size in accordance with NEe TABLE 250-66.) Attachment shall be made using pressure type cable connectors (no solder) secured to a surface that is free of dirt and paint in an area protected from physical damage and from being disconnected during maintenance and servicing. The grounding electrode may be: (a) an underground metal water pipe, (b) metal frame of the building or structure, (c) concrete-enclosed electrode, (d) ground ring, (see NEe ARTICLE 250-50.) Electrical devices which have metal to metal contact with a grounded machine and are securely fastened to that machine are effectively grounded.
494751
Part Number: 494751 Location: This sign is located near grounding lug on the equipment. Meaning: This sign contains instructions to properly ground the equipment.
Page 39 of 148
Liheelabrator
Keep hands outside the elevator casing. If an elevator stalls: 1. Shut off abrasive feed to the Wheelabrator. 2. Tum off and lock out power at the electrical panel
GROUP
~ ~
14. The elevator belt is stretched and as the abrasive jam is corrected, belt tension will
cause the boot pulley to rotate. Stay clear of this dangerous condition. 5. Use a scoop to clear abrasive from the boot. See Maintenance Manual for detailed instructions.
495079
3. You may now remove the inspection plate at the elevator boot.
Part Number: 495079 Location: This sign is located above all elevator boot access and clean-out doors on the elevator casing not to be attached to the clean-out door on the equipment. Meaning: This sign contains safety instructions for servicing the elevator boot section of the equipment.
AWARNING L
DUST COLLECTOR -l
'---.-)
In applications
In't'olving the use ot aluminum media or surface
blasting of aluminum parts, precauUon8fy rnea.ur must be taken to mlnimtze the risk of dust cOllector fir and or explosions. 1 The dust collector refuse hopperb) or tontalnena) must M
emptied at frequent int&l"vals. Collection of more than 113 the container or hopper capaCity should not be exceeded. 2 rhe blest machfne and dust collector minimize static electric 3 charges. fOIJstbe grounded to
No. 200 MeSh Agricultural Limestone (CaCO;tJ should be added to the venUllation system at a conUnuOlJSfate of 0.2 oz. per hour per square toot of
tater
area.
CAUTION: (CaC03)
115 cfushed limestone rock (not to be con-
fused with lime, otherwise known as hot lime. butnt lime, or hydrated 'Une). Under FlOcircumstances shOuld these highly reactive lime products be
UNdo
READ SAFETY INSTRUCTIONS THOROUGHLY
Products (parts) which produce h;ghly explosive dust, such Magneslum, Titanium, Zwconium, ThOrium. ete., should not be proc d In thiI maehkle.
Part Number: 673723 Location: This sign is located above at eye level on dust collector's wall. Meaning: This sign contains safety instructions warning against high explosive dust from media and parts.
Created: March 28, 2008 Page 40 of 148
www.wheelabratorgroup.com <:
Revision:
ulleelabrator
GROUP
Section 4 4.1
Blast Wheel 25 EZEFIT Blast Wheel 4.1.1 How the Blast Wheel Works
Media from an overhead storage hopper is metered to the center of the wheel unit that is rotating at high speed. A feed spout provides a smooth transition from the feed line to the impeller rotating with the wheel. The impeller moves the media through its multiple tapered openings and out through the single stationary opening in the control cage. Controlled quantities of media are then distributed onto the rotating blade surface at precisely the right time. The media particles picked up on the inner ends of the blade's throwing face are rapidly accelerated as they move to the end of the blades at the outer edge of the wheel. Media then leaves the wheel in the form of a pattern with a narrow width and variable length that must be properly focused on the work surface for the desired results.
&)
Motor Motor Adapter Flange Rear Hub Liner
--------------.
Wheel Blades -------.

Target Lock Index Plate
Retaining Ring
AV t:::::/'Y' ~~~--.~ Feed Spout Clamps
Impeller Bolt & Lock Washer O-Ring Feed Spout Seal
Wheelabrator 25 EZEFIT Wheel Components

:
Figure 4-1
uheelabrator
r..",..., .......... Bi-Directional Blast Wheel Parts The Wheelabrator Bi-Directional Wheel consists of the following main components (see Figure 4-1) 1. Motor - powers the wheel. 2. Motor Adapter Flange - aligns and mounts the motor to the wheel housing. 3. Rear Hub Seal- patented labyrinth seal configuration, effectively minimizes media leakage. 4. Rear Liner - Seals the opening in the wheel housing and protects the motor adapter flange. 5. Hub Seal - seals around the hub to prevent media leakage. 6. Single Sided Wheel Assembly - provides rugged blade retention in abusive applications. 7. Wheel Blades - accelerates the media out of the blast wheel towards the work.
GROUP
4.1.2
8. Centering Plate - secures the impeller into wheel assembly for accurate media timing. 9. Control Cage Adapter - provides cage alignment for consistent blast pattern and a positive lock. 10. Control Cage - regulates the flow of media onto the blades for the proper discharge from the blades onto the work. It is available with various openings that control the blast pattern length and direction. 11.lmpeller - times and accelerates the media through the opening in the control cage and onto the blades. 12. Impeller Bolt & Lock Washer - retains impeller and centering plate to the wheel. 13. O-Ring Feed Spout Seal - reduces noise and prevents dust and media leakage. 14. Feed Spout - funnels the media into the center of the impeller for distribution through the opening in the control cage onto the blades of the blast wheel.
uheelobrotor
GROUP
Section 4 4.1
--------------.
Control Cage Adapter Centering Plate Retaining Ring
Impeller Bolt & Lock Washer O-Ring Feed Spout Seal Feed Spout Clamps

.'
Figure 4-1
Page 41 of 148
Llheelabrator
Bi-Directional Blast Wheel Parts The Wheelabrator Bi-Directional Wheel consists of the following main components (see Figure 4-1) 1. Motor - powers the wheel. 2. Motor Adapter Flange - aligns and mounts the motor to the wheel housing. 3. Rear Hub Seal- patented labyrinth seal configuration, effectively minimizes media leakage. 4. Rear Liner - Seals the opening in the wheel housing and protects the motor adapter flange. 5. Hub Sealseals around the hub to prevent media leakage.
GROUP
4.1.2
6. Single Sided Wheel Assembly - provides rugged blade retention in abusive applications. 7. Wheel Blades - accelerates the media out of the blast wheel towards the work. 8. Centering Plate - secures the impeller into wheel assembly for accurate media timing. 9. Control Cage Adapter - provides cage alignment for consistent blast pattern and a positive lock. 10. Control Cage - regulates the flow of media onto the blades for the proper discharge from the blades onto the work. It is available with various openings that control the blast pattern length and direction. 11.lmpeller - times and accelerates the media through the opening in the control cage and onto the blades. 12. Impeller Bolt & Lock Washer - retains impeller and centering plate to the wheel. 13. O-Ring Feed Spout Seal - reduces noise and prevents dust and media leakage. 14. Feed Spout - funnels the media into the center of the impeller for distribution through the opening in the control cage onto the blades of the blast wheel.
Revision:
uheelobrctor
GROUP
Section 4 4.1
--------------.
Wheel Blades ---------.

Target Lock Index Plate
Retaining Ring
Impeller Bolt & Lock Washer O-Ring Feed Spout Seal Feed Spout Clamps

Figure 4-1
u.heelabrator
GROUP BiDirectional Blast Wheel Parts The Wheelabrator Bl-Dlrectlonal Wheel consists of the following main components (see Figure 4-1) 1. Motor - powers the wheel. 2. Motor Adapter Flange - aligns and mounts the motor to the wheel housing. 3. Rear Hub Seal- patented labyrinth seal configuration, effectively minimizes media leakage. 4. Rear Liner - Seals the opening in the wheel housing and protects the motor adapter flange. 5. Hub Seal - seals around the hub to prevent media leakage. 6. Single Sided Wheel Assembly - provides rugged blade retention in abusive applications. 7. Wheel Blades - accelerates the media out of the blast wheel towards the work. 8. Centering Plate - secures the impeller into wheel assembly for accurate media timing. 9. Control Cage Adapter - provides cage alignment for consistent blast pattern and a positive lock. 10. Control Cage - regulates the flow of media onto the blades for the proper discharge from the blades onto the work. It is available with various openings that control the blast pattern length and direction. 11.lmpeller - times and accelerates the media through the opening in the control cage and onto the blades. 12.lmpeller Bolt & Lock Washer - retains impeller and centering plate to the wheel. 13.0Ring Feed Spout Seal - reduces noise and prevents dust and media leakage. 14. Feed Spout - funnels the media into the center of the impeller for distribution through the opening in the control cage onto the blades of the blast wheel.
4.1.2
Created:
March 28, 2008
Page 42 of 148
Revision:

\.......-'
uheelabrator
GROUP
Section 4 4.1
&)
------------.
Control Cage Adapter Centering Plate Retaining Ring
Impeller Bolt & Lock Washer
O-Ring Feed Spout Seal Feed Spout Clamps

Figure 4-1
~ Created: March 28, 2008 Revision: Page 41 of 148
uheelobrotor
rv rv r-; ,
GROUP
4.1.3 Setting and Adjustment The setting and adjustment of your Blast Wheel is important for the performance and life of your machine. You will not accomplish the surface preparation of your work if you are not hitting it! Not only will your blast time increase, but you are accelerating wear on the insides of your machine. A properly set control cage can prevent this. 4.1.4 Wheel Direction A Blast Wheel can be run in a, clockwise (CW) or counterclockwise (CCW) direction, depending upon the design requirement of a given wheel. Care should be taken, particularly during start-up that a Blast Wheel is running in the proper direction. The direction will be clearly identified on the Blast Wheel housing by a directional arrow. To maintain optimum performance during the life of your blast machine, it is vital that the wheel direction remain as originally designed by Wheelabrator.
Direction of the Blast Wheel should be determined by looking at the wheel from the feed spout side of the Blast Wheel.
4.1.5 Control Cage Setting 1. The control cage setting is one of the most important adjustments that can be made on your machine. A properly adjusted blast pattern will give you an effective and economical surface preparation machine. A pattern that is improperly set will cause premature wear inside the blast cabinet and on the wheel housing liners. 2. To better understand this important setting, please study the sketches shown in Figures 42, 43, 44 and 45. Figures
42 and 43 show a clockwise blast wheel with control cage in

two different locations. Notice the shift in the blast pattern from right to left as the control cage is rotated in a clockwise direction. In a similar way, Figures 44 and 45 show a counter-clockwise blast wheel and the shift in the pattern from left to right as the control cage is rotated counter-clockwise. Therefore, by rotating the control cage in either direction, the
Revision:
Page 43 of148
Operation Manual
&
Maintenance
u.heelabrator
C GROUP
blast pattern may be aimed to the exact position necessary to produce the optimum results for your surface preparation requirement.
WheelBlade
Wheel Blade
9:00$43(
MediaPoint of ReleaseDiameter
9:0~-f
Media Point of...../.
I
)1f1r.
,j~
.
Rotation 3:00
~t,:\
~iII!/lr
L
Blast Pattern Tailings Hot Spot
Release Diameter
I Pattern Blast -L~
~,p%;;t["lf.l},
L
Blast Pattern Tailings
-:~:.'~~.~~~~\\
Blast Pattern Headings
-L I
Blast Pattern Hot Spot
I I -U-
Clockwise Blast Wheel @ 3600 RPM Leading Edge @ 11:30
Clockwise Blast Wheel @ 3600 RPM Leading Edge @ 12:00
Figure 4-2
Figure 4-3
J
Wheel Blade
Rotation
\9:0~~
'i"":'~~
.) 4gg;fih:oo
,-Media Point of
fi;ffif.ti&~~~}~_~
Blast Pattern Headings Blast Pattern Hot Spot
ReleaseDiameter
I Pattern Blast --lTailings
'jlWi}jl!l!!J!Jlfj];if"~
I I -!.......!-
Blast Pattern Hot Spot
I -I-
Blast Pattern Tailings
-l I
Counter-Clockwise Blast Wheel @ 3600 RPM Leading Edge @ 12:30
Counter-Clockwise Blast Wheel @ 3600 RPM Leading Edge @ 12:00
Figure 4-4
Figure 4-5
Created: Revision:
March 28, 2008
Page 44 of 148
Operation Manual
&
Maintenance
\.J
uheelobrotor
The "Hot Spot" 1. The areas in Figures 4-2, 4-3, 4-4 and 4-5 referred to as a "Hot Spot" are characteristic of all blast wheels and are in the areas of the blast where about 70% of the blast intensity is contained. The position of the "Hot Spot" is therefore very important in terms of surface preparation efficiency.
GROUP
4.1.6
2. By using the arrows marked on the face of the control cage, you may roughly set the control cage position. These arrows identify the location of the opening in the control cage and it is this opening that controls the point where the media is picked up by the blades. The arrows identify the leading and trailing edges or points where the media starts and stops leaving (exiting) the control cage. 3. For a clockwise blast wheel, the arrow on the left is the leading edge and for a counter-clockwise blast wheel the arrow on the right is the leading edge. The remaining arrow indicates the trailing edge for each direction. 4. When reference is made to "hour" settings while discussing the control cage settings, it is important that 12:00 is understood to be at the top and center of any blast wheel housing, exactly opposite or 180 from the wheel housing opening.
0
5. The best way to locate the Hot Spot is to check and set blast patterns. To eliminate unnecessary work when replacing control cages, the position of the leading edge should be clearly marked to enable the new cage to be placed in the exact same position. 4.1.7 Blast Pattern 1. The abrasive thrown by the wheel must contact the work in order to clean it, therefore the blasting efficiency also depends on the direction the abrasive is thrown, i.e. the direction of the abrasive that is thrown is primarily determined by the position of the control cage.
Created: Revision:
March 28, 2008
Page 45 of 148
uheelabrator
GROUP
J
2. The actual check of the blast pattern of the wheel should be made when the machine is put into operation. The check should be repeated when any decrease in blast efficiency is noted and the control cage opening reference mark information has been lost. The blast pattern checked should also be repeated if a change is made in the size or type of abrasive media used and if the RPM (speed) of the wheel is changed. 3. To check the blast pattern, secure a piece of 12-guage sheet metal about 12" x 48" (called a target plate) in the same relative position to the wheels, as the component to be cleaned would be. This plate should be held rigid. 4.1.7.1 To Check Blast Pattern 1. Turn main disconnect off and follow lock out/tag out procedures. 2. Gain access to the blast chamber area. 3. Secure target plate in front of the wheel you are checking 4. Verify target plate is positioned at 90 to blast flow and perpendicular to the wheel. 5. Turn main disconnect on following lock out/tag out procedures. 6. Press control power 'on' push button and start entire system exceQ! work conveyor. 7. Blast target plate for approximately 45 seconds by setting the cycle timer for 45 seconds or by holding the blast pattern test pushbutton down for 45 seconds. 8. Allow time for dust and abrasive to clear target plate area. 9. Follow shut down, lock out/tag out procedures. 10. Examine target plate for blast coverage. 11.Adjust control cage as required, if needed. 12. Relocate, reposition or replace target plate as required. 13. Repeat this procedure, starting with step #5, for each wheel on the machine.
Created: March 28, 2008 Revision: Page 46 of148
&)
,J
-.J
Operation Manual
&
Maintenance
uheelobrotor
The "Hot Spot" 1. The areas in Figures 4-2, 4-3, 4-4 and 4-5 referred to as a "Hot Spot" are characteristic of all blast wheels and are in the areas of the blast where about 70% of the blast intensity is contained. The position of the "Hot Spot" is therefore very important in terms of surface preparation efficiency.
GROUP
4.1.6
2. By using the arrows marked on the face of the control cage, you may roughly set the control cage position. These arrows identify the location of the opening in the control cage and it is this opening that controls the point where the media is picked up by the blades. The arrows identify the leading and trailing edges or points where the media starts and stops leaving (exiting) the control cage. 3. For a clockwise blast wheel, the arrow on the left is the leading edge and for a counter-clockwise blast wheel the arrow on the right is the leading edge. The remaining arrow indicates the trailing edge for each direction. 4. When reference is made to "hour" settings while discussing the control cage settings, it is important that 12:00 is understood to be at the top and center of any blast wheel housing, exactly opposite or 180 from the wheel housing opening.
0
5. The best way to locate the Hot Spot is to check and set blast patterns. To eliminate unnecessary work when replacing control cages, the position of the leading edge should be clearly marked to enable the new cage to be placed in the exact same position. 4.1.7 Blast Pattern 1. The abrasive thrown by the wheel must contact the work in order to clean it, therefore the blasting efficiency also depends on the direction the abrasive is thrown, i.e. the direction of the abrasive that is thrown is primarily determined by the position of the control cage.
Created:
March 28, 2008
Page 45 of 148
Revision:
uheelabrator
GROUP
J
2. The actual check of the blast pattern of the wheel should be made when the machine is put into operation. The check should be repeated when any decrease in blast efficiency is noted and the control cage opening reference mark information has been lost. The blast pattern checked should also be repeated if a change is made in the size or type of abrasive media used and if the RPM (speed) of the wheel is changed. 3. To check the blast pattern, secure a piece of 12-guage sheet metal about 12" x 48" (called a target plate) in the same relative position to the wheels, as the component to be cleaned would be. This plate should be held rigid. 4.1.7.1 To Check Blast Pattern 1. Turn main disconnect off and follow lock out/tag out procedures. 2. Gain access to the blast chamber area. 3. Secure target plate in front of the wheel you are checking 4. Verify target plate is positioned at 90 to blast flow and perpendicular to the wheel. 5. Turn main disconnect on following lock out/tag out procedures. 6. Press control power 'on' push button and start entire system exceQ! work conveyor. 7. Blast target plate for approximately 45 seconds by setting the cycle timer for 45 seconds or by holding the blast pattern test pushbutton down for 45 seconds. 8. Allow time for dust and abrasive to clear target plate area. 9. Follow shut down, lock out/tag out procedures. 10. Examine target plate for blast coverage. 11.Adjust control cage as required, if needed. 12. Relocate, reposition or replace target plate as required. 13. Repeat this procedure, starting with step #5, for each wheel on the machine.
Revision:
Page 46 of 148~J

~
u.heelabrator
GROUP The zone of effective cleaning (Blast Pattern) will be evident on the target plate. If the blast pattern is not satisfactory, the control cage setting must be re-adjusted. Adjustments to the control cage should be no more than 3/8" to 3/4" based on the notches at a time. If the control cage setting is readjusted, you must repeat steps 5-10 to confirm the new adjustment. Once the control cage is properly adjusted, the position of the blast pattern will not change substantially until the internal wheel components wear. An increase in the percentage of fines remaining in the abrasive can also cause the blast pattern to move and lengthen.
4.1.7.2
How to Rotate the Control Cage

1. Remove feed spout and feed spout clamps as shown in
Figure 4-7.
2. Loosen the two (2) control cage clamps as shown in Figure 4-6 & 4-7. 3. With use of a hammer and a drift pin, punch or similar tool inserted into one of the outer notches, it will be possible to tap the control cage to rotate it in the desired clockwise or counter-clockwise direction. 4. Once the desired position is reached, the control cage clamps are replaced and secured. This locks the control cage in position. 5. Mark the face of the control cage adapter on the wheel housing with the location of the leading and tailing edges of the opening in the control cage. This will enable you to replace the control cage in the correct position every time. 6. Replace feed spout and secure the feed spout clamps.
Page 47 of 148
L1heelabrator
GROUP
Control Cage Clamp
Rotate Control Cage
Control Cage
Control Cage Clamp
Control Cage Adapter
Control Cage Adjustment

Figure 4-6
Created: Revision:
March 28, 2008
Page 48 of 148
Llheelabrator
GROUP
FeedSpout Clamp
Control Cage Clamp Control Cage FeedSpout Seal Curved FeedSpout
~ contrOlfl Cage Adapter Feed Spout Clamp Straight Feed Spout . ~ . Control Cage Clamp
Control Cage Adjustment Components ~lodedView

Figure 4-7
&
"
Created: Revision: March 28, 2008
CAUTION: The cast wear parts for wheels are made of very hard,
longwearing alloys. Use moderate force when tapping the control cage to avoid breaking, cracking or chipping of cage.
Do not use any cast wear parts that show evidence of damage such as chips, cracks or broken sections.
Page 49 of 148
uheeloorotor
GROUP
Section 5 5.1
Media Handling System Function of the Lower Reclaim:

The lower reclaim function is to collect contaminants spent media thrown by the blast wheels. The media and contaminants are then delivered by the lower reclaim to the bucket elevator boot section. The lower reclaim is part of a total media recovery system to clean and recycle media back to the blast wheel.
5.1.1 Types of Lower Reclaims: 5.1.1.1 Full Gravity Reclaims:

a. Gravity hoppers are used for directing spent media directly to the bucket elevator boot section. b. Gravity hoppers are generally used on small equipment. c. There are no drives or mechanical moving parts in gravity reclaims.
5.1.1.2
Lower Screw Conveyor Reclaims:

a. Lower screw conveyors are used when full gravity is not feasible and the product application does not have significant amounts of tramp metal entering the screw area that would otherwise result in jams. Screws may be protected by shed plates, grating and/or screen. b. The volume of media flow determines the size of screw conveyor and horsepower required to move the abrasive to the bucket elevator boot section.
Created:
March 28, 2008
Page 51 of 148
Revision:
L1heelabrator
Screw Adapter Housing Screw Conveyor Trough
GROUP
Gearmotor Adapter Plate Gearmotor
Screw Conveyor
Drive Shaft Bearing Shaft Seal End Shaft Shaft Seal Bearing
illical
Lower Screw Conveyor Components

Figure 5-1
c. Typical components of a lower screw conveyor reclaim are shown in Figure 5-1. 1. Screw Conveyor - flighting and tube construction to deliver media to the bucket elevator boot section. 2. Screw Conveyor Trough - connects and encloses the screw conveyor between the blast chamber and elevator boot. This may not be required on all applications. 3. Shed Plate; Grating; Screen - may be provided to protect the screw from objects that could jam the screw conveyor and also to meter the abrasive to the screw conveyor.
ulleelabrator
GROUP
Section 5 5.1
Media Handling System Function of the Lower Reclaim: The lower reclaim function is to collect contaminants spent media thrown by the blast wheels. The media and contaminants are then delivered by the lower reclaim to the bucket elevator boot section. The lower reclaim is part of a total media recovery system to clean and recycle media back to the blast wheel. 5.1.1 Types of Lower Reclaims: 5.1.1.1 Full Gravity Reclaims: a. Gravity hoppers are used for directing spent media directly to the bucket elevator boot section. b. Gravity hoppers are generally used on small equipment. c. There are no drives or mechanical moving parts in gravity reclaims. 5.1.1.2 Lower Screw Conveyor Reclaims: a. Lower screw conveyors are used when full gravity is not feasible and the product application does not have significant amounts of tramp metal entering the screw area that would otherwise result in jams. Screws may be protected by shed plates, grating and/or screen. b. The volume of media flow determines the size of screw conveyor and horsepower required to move the abrasive to the bucket elevator boot section.
Page 51 of 148
www.wheelabratorl!roup.com
Llheelabrator
4. Screw Adapter Housing - joins the screw conveyor trough to the elevator boot or cabinet. This may not be required on all applications. 5. Drive Shaft - fixed to the screw conveyor and mounted through the bearing to drive the conveyor.
'-....-
GROUP
6. End Shaft - fixed to the screw conveyor and mounted through the bearing to support the conveyor opposite the drive. 7. Shaft Seals - prevents media leaking out the ends of the conveyor and protects the bearings from the media. (see Figures 5-2 & 5-3) 8. Bearings - supports ends of the screw conveyor.
9. Bearing Adapter Plate - closes the end of the conveyor and supports the bearing. 10. Gearmotor Adapter Plate - closes the end of the conveyor and supports the bearing and Gearmotor. 11. Gearmotor conveyor. - mounted on drive shaft to power screw
Created: Revision:
March 28, 2008
Page 53 of 148
Llheelabrator
Spacer Bars
< _
GROUP
!mical
Shaft Seal Assembly

Figure 5-2
d. A typical shaft seal assembly for a lower screw conveyor is shown in Figure 5-2. 1. Shaft Seal Spacer Bars - maintains a space between the adapter plate and the shaft seal retainer for the shaft seal to mount. This allows maintains proper compression of the felt shaft seal. 2. Shaft Seal - prevents media leaking out the ends of the conveyor and protects the bearings from the media. 3. Shaft Seal Retainer - retains the shaft seal between the shaft seal spacer bars. 4. Hex Nut Spacers - maintains a space between the shaft seal retainer and the flange bearing. This allows any media that made it by the shaft seal to drain before contaminating the flange bearing. 5. Bearing - supports ends of the screw conveyor.
Created: March 28, 2008 Revision: Page 54 ofl48
Operation Manual
'\.......-
&
Maintenance
uheelcorotor
4. Screw Adapter Housing - joins the screw conveyor trough to the elevator boot or cabinet. This may not be required on all applications. 5. Drive Shaft - fixed to the screw conveyor and mounted through the bearing to drive the conveyor.
GROUP
6. End Shaft - fixed to the screw conveyor and mounted through the bearing to support the conveyor opposite the drive. 7. Shaft Seals - prevents media leaking out the ends of the conveyor and protects the bearings from the media. (see Figures 5-2 & 5-3) 8. Bearings - supports ends of the screw conveyor. 9. Bearing Adapter Plate - closes the end of the conveyor and supports the bearing. 10. Gearmotor Adapter Plate - closes the end of the conveyor and supports the bearing and Gearmotor. 11. Gearmotor conveyor. - mounted on drive shaft to power screw

Revision:
Page 53 of148
uheelobrotor .( n
Spacer Bars
< _
GROUP
Imical
Shaft Seal Assembly

Figure 5-2
d. A typical shaft seal assembly for a lower screw conveyor is shown in Figure 5-2. 1. Shaft Seal Spacer Bars - maintains a space between the adapter plate and the shaft seal retainer for the shaft seal to mount. This allows maintains proper compression of the felt shaft seal. 2. Shaft Seal- prevents media leaking out the ends of the conveyor and protects the bearings from the media. 3. Shaft Seal Retainer - retains the shaft seal between the shaft seal spacer bars. 4. Hex Nut Spacers - maintains a space between the shaft seal retainer and the flange bearing. This allows any media that made it by the shaft seal to drain before contaminating the flange bearing. 5. Bearing - supports ends of the screw conveyor.
uheelobrotor
Bearing Mounting Plat,
GROUP
UHMW Shot Dis
Bearing Spacers
Imical Shaft Seal Assembl'l.

Figure 53 e. Another variation of a shaft seal assembly for a lower screw conveyor is shown in Figure 53. 1. Bearing Mounting Plate - is the base for mounting the other components of the bearing assembly. 2. UHMW Shot Disc - prevents media leaking out the ends of the conveyor and protects the bearings from the media. 3. Bearing Cover Plate - retains the UHMW shot disc in the bearing mounting plate. 4. Bearing Spacers - maintains a space between the bearing cover plate and the flange bearing. This allows any media that made it by the shot disc seal to drain before contaminating the flange bearing. 5. Flange Bearing - supports ends of the screw conveyor.
Llheelabrator
Shaker Conveyor Reclaims:
GROUP
-~
5.1.1.3
a. Shaker conveyors are used when full gravity is not

feasible and the product application contains significant tramp metal material entering the reclaim. b. Shaker conveyors are able to separate large trash from the media to prevent it entering the remaining media handling system components and causing damage or jams. c. Shaker conveyors are generally self cleaning.
Mounting Base Preforated Area
Media Flow.
Mounting Base ...../
Hanger Springs ~
Mounting Base
Typical Shaker Reclaim Conveyor System

Figure 5-4 d. A typical shaker conveyor reclaim system is shown in Figure 5-4. 1. Conveyor Pan or Deck - controls media and trash while it is being conveyed and reclaimed. 2. Conveyor Pan Liner - protects pan from abrasion and impact. 3. Perforated Area - separates large trash from media before media is delivered to the elevator boot section. 4. Discharge Chute - delivers media to the elevator boot section.
-J

-:
uheelobrotor
Bearing Mounting Plat,
GROUP
UHMW Shot Cis
Bearing Spacers
illical Shaft Seal Assemblx

Figure 5-3 e. Another variation of a shaft seal assembly for a lower screw conveyor is shown in Figure 5-3. 1. Bearing Mounting Plate - is the base for mounting the other components of the bearing assembly. 2. UHMW Shot Disc - prevents media leaking out the ends of the conveyor and protects the bearings from the media. 3. Bearing Cover Plate - retains the UHMW shot disc in the bearing mounting plate. 4. Bearing Spacers - maintains a space between the bearing cover plate and the flange bearing. This allows any media that made it by the shot disc seal to drain before contaminating the flange bearing. 5. Flange Bearing - supports ends of the screw conveyor.
uheelobrotor
Shaker Conveyor Reclaims: a. Shaker conveyors are used when full gravity is not feasible and the product application contains significant tramp metal material entering the reclaim. b. Shaker conveyors are able to separate large trash from the media to prevent it entering the remaining media handling system components and causing damage or jams. c. Shaker conveyors are generally self cleaning.
Mounting Base Preforated Area
GROUP
'--J
5.1.1.3
Media Flow
Mounting
Base .J
Hanger Springs
Mounting
Base
Typical Shaker Reclaim Conveyor System

Figure 5-4 d. A typical shaker conveyor reclaim system is shown in Figure 5-4. 1. Conveyor Pan or Deck - controls media and trash while it is being conveyed and reclaimed. 2. Conveyor Pan Liner - protects pan from abrasion and impact. 3. Perforated Area - separates large trash from media before media is delivered to the elevator boot section. 4. Discharge Chute - delivers media to the elevator boot section.
-J
u.heelabrator
GROUP 5. Mounting Base - supports the shaker conveyor and secures it to the foundation. 6. Hanger Springs - are sized to control stroke, frequency and angle of attack designed to proper conveying action for type media. 7. Conveyor Drive - powers the shaker conveyor.
5.2
Function of the Bucket Elevator a. The belt and bucket centrifugal discharge elevator lifts the abrasive material from the boot (lower) section to the head (upper) section. The contaminated abrasive material is discharged from the head section of the elevator, and then delivered to the separator.
INTERMEDIATE SECTION WI VENT
I"
VENT BOX
INTERMEDIATE SECTION WIO VENT
[[d
II
Typical Elevator Arrangement
Figure 5-5
u.heelabrator
r-, ,-.. ~
....,
GROUP
J
b. A typical elevator arrangement is shown in Figure 5-5.
1. Head Section - This is the upper section of the bucket elevator

casing. It usually contains the elevator drive.
2. Intermediate
Section with Vent - This is the part of the elevator casing that contains the vent box.
3. Vent Box - This is the outlet to remove the dust from of the elevator casing. It can usually be mounted on either side of the intermediate section depending on the vent piping requirement. 4. Vent Cover - Covers the opening in the intermediate section opposite the vent box when part of design.
5. Intermediate
Section without Vent - This is the part of the elevator casing used to increase the height of the elevator. This section is not always required.
6. Boot Section - This is the lower section of the bucket elevator casing. This section receives the spent media from the blast chamber and lower reclaim. 7. Elevator Belt Assembly - This bucket and belt assembly transports the abrasive media from the boot section to the head section and discharges it to the upper reclaim system.
5.2.1 Elevator Head Section

a. The head section is the upper section of the bucket elevator casing. It receives the abrasive media from the boot section of the elevator and discharges the abrasive media into the upper reclaim system.
Page 58 of148
u.heelabrator
.Ltvv
GROUP
Shedder (only some designs) / Top Cover ~ Take Up Bolt Shaft Pulley',
\ ,\,
IIh
Gearmotor Bearing & Shaft Seal Take Up Assembly Weldment

I
III I
III '
II
I I '
IYPical Head Section Arrangement

Figure 5-6 b. A typical elevator head section arrangement is shown in Figure 5-6.
1. Weldment - is a fabricated housing that the head section components mount to. 2. Take Up Assembly - supports the bearings, shaft seals, shaft and pulley on the weldment. They slide up and down to adjust the tension of the elevator belt assembly. There are , two take up assemblies per head section. 3. Take Up Bolts - are the links between the weldment and the take up assemblies. Turning the bolts clockwise will tighten the elevator belt and turning the bolts counterclockwise will loosen the elevator belt. These bolts are also used to adjust the tracking of the elevator belt. 4. Pulley - provides a rotating surface to drive the elevator belt assembly. The pulley is usually crowned and lagged to assist in tracking the elevator belt assembly. 5. Shaft - supports the elevator head section pulley. 6. Shaft Seal- prevents media leaking out from the take up assembly plates and protect the bearings from the media.
Wleelabrator
GROUP J
7. Bearing - supports ends of the elevator head section shaft. 8. Gearmotor - is mounted to the head section shaft to power the elevator. 9. Top Cover - is the access cover to the elevator head section and a safety cover to guard against the rotating components inside the elevator head section weldment. 10. Shedder - is a wear component to assist in delivery of abrasive media and contaminants to the upper reclaim system. This is only used on some designs of elevator head sections. 5.2.2 Elevator Boot Section a. The boot section is the lower section of the bucket elevator casing. It receives the abrasive media and contaminants from the lower reclaim of the equipment and moves the media and contaminants to the head section with the elevator belt assembly. Boot Section Weldment
Cover Plates
(=
+
~ ,
Bearing & Shaft Seal Shaft
II
.
I
II
i
Pulley
TYPical Boot Section Arrangement

Figure 5-7
Llheelabrator
GROUP b. A typical elevator boot section arrangement is shown in Figure
5-7.
1. Boot Section Weldment - is a fabricated housing that the boot section components mount to. 2. Adjustment Plate - supports the bearings, shaft seals, shaft and pulley on the boot section weldment. There are usually two of these plates per boot section. 3. Pulley - provides a rotating surface for the elevator belt assembly to ride on. 4. Shaft - supports the elevator boot section pulley. 5. Shaft Seal - prevents media leaking around the shaft and protects the bearings from the media. 6. Bearing - supports ends of the elevator boot section shaft.
o
5.2.3
Note: See Section 5.1.1.2 (d & e) for the two types of typical shaft seal assemblies. Also see Figures 5-2 and 5-3.
7. Cover Plates - are the access covers to the elevator boot section and a safety cover to guard against the rotating components inside the elevator boot section weldment.
Elevator Belt Assembly a. The elevator belt assembly carries the abrasive media and contaminants in buckets from the elevator boot section to the elevator head section. The belt tracks on the elevator head and boot pulleys.
Created: Revision:
March 28, 2008
Page 61 of 148
uheelabrator
GROUP J
Elevator Bolt & Nut Buckets
Typical Elevator Belt Assembly with Dutchman Splice

Figure 5-8
Typical Elevator Belt Assembly with Oil Well Splice

Figure 5-9
b. Typical elevator belt assemblies are shown in Figure 5-8 with a Dutchman splice and Figure 5-9 with a Oil Well splice. 1. Elevator Belt - is manufactured belting material with an abrasive protection against abrasion and buckets and splice are mounted from a multi-ply rubber resistant top cover for cutting. The elevator to the belt.
2. Buckets - carry the abrasive media. They are usually made out of cast ductile iron for better wear life. 3. Leather Flat Washer - spaces the buckets off the belt to help prevent edge of buckets cutting into the belt. 4. Belt Splice & Splice Bars - joins the two ends of the elevator belt together to make one continuous belt. There are two types of splices. The Dutchman splice is usually used on low temperature belts and in smaller size elevators. The Oil Well splices are usually used on high temperature belts and in larger size elevators.
Page 62 of 148
Revision:

x..>
Llheelabrator
GROUP
5.3
Functions of Upper Reclaims The upper reclaim function is to collect media and contaminants delivered from the elevator. Media and contaminants are then conveyed by the upper reclaim to the media separator. The upper reclaim is a part of a total media recovery system to clean and recycle media back to the blast wheel.
5.3.1 Types of Upper Reclaims: 5.3.1.1

Full Gravity Reclaims a. Gravity reclaims are used for transferring media directly from the elevator head section to the separator.
b. There are no drives in upper gravity reclaims. 5.3.1.2

Upper Screw Conveyor Reclaims
a. Upper screw conveyors are used to reduce system

height when full gravity is not feasible.
b. The volume of media flow determines the size of screw

conveyor and horsepower required to move the abrasive media from the bucket elevator to the separator.
c. There are two styles of upper screw reclaim. One is a

standard screw conveyor and the other is a screw conveyor with a rotary screen. (See Figures 5-10 & 5-11)
Page 63 of148
u.heelabrator
,..,
Screw Adapter Housing
GROUP
Geannotor Adapter Plate
Screw Conveyor Trough Screw Conveyor Separator Trash Chute Bearing End Shaft
Ref. Separator
~---------------------------~
Trash Tubing
Typical Upper Screw Conveyor Components

Figure 5-10
J
Screw Adapter Housing Screw Conveyor Trough Screw Conveyor Separator Trash Chute Bearing End Shaft
Ref. Separator
~-----------------~
Trash Tubing
Typical Upper Screw Conveyor Components with Rotary Screen

Figure 5-11
Created:
March 28, 2008
Page 64 of 148
Revision:
u.heelabrator
GROUP
Screw Adapter Housing Screw Conveyor Trough Screw Conveyor Bearing End Shaft Separator Trash Chute with Overflow Housing
Trash Chute Adapter Trash Tubing
Typical Upper Screw Conveyor Components with Rotary Screen and Trash Chute with Overflow Housing & Hose
Figure 5-12
d. The following are typical components of an upper screw conveyor reclaim are shown in Figure 5-10 upper screw conveyor and Figure 5-11 upper screw conveyor with rotary screen Figure 5-12 upper screw conveyor with rotary screen screw and trash chute with overflow housing & hose. 1. Screw Conveyor - flighting and tube construction to deliver media and contaminants from the bucket elevator to the separator. 2. Rotary Screen - is a scalping drum that allows the abrasive and contaminants to flow through a screen, but holds large tramp material inside the screen where it is conveyed to a trash chute. The rotary screen directs any large particles away from the air wash and discharges them into the trash chute to a refuse container.
Page 65 of148
Revision:
Operation &
..- ...
Maintenance Manual
LLheelabrator
'.~
GROUP
J
3. Screw Conveyor Trough - connects and encloses the screw conveyor between the bucket elevator and the separator. 4. Screw Adapter Housing - joins the screw conveyor trough to the elevator head section. 5. Separator Trash Chute - the rotary screen empties the large trapped particles into this housing. 6. Separator Trash Chute with Overflow Housingwhen there is a surge of media the media is overflowed into the first compartment of the housing. The rotary screen empties the large trapped particles into the second compartment of the housing. 7. Overflow Hose - directs the overflow media back to lower reclaim to be recycled. 8. Trash Chute Curtain - allows access to clean out any trapped particles that are clogging the entrance to the trash tube. Warning: DO NOT clean out separator trash chute with power on the equipment or with the screw conveyor or screen running. 9. Trash Chute Adapter - attaches the separator trash chute to the trash tubing. 10.Trash Tubing - conveys discharged trash particles from the rotary screen to the buyer's trash receptacle. 11. Drive Shaft - fixed to the screw conveyor and mounted through the bearing to drive the conveyor. 12. End Shaft - fixed to the screw conveyor and mounted through the bearing to support the conveyor opposite the drive.
...
'-oJ
--
uJleelabrator ~i~~
GROUP 13. Shaft Seals - prevents media leaking out the ends of the conveyor and protects the bearings from the media. 14. Bearings - supports both ends of the screw conveyor. 15. Bearing Adapter Plate - mounts to the separator trash chute for mounting the bearing. 16. Gearmotor Adapter Plate - closes the end of the conveyor and for mounting the bearing and gearmotor. 17. Gearmotor - mounted on drive shaft to power screw conveyor.
<.;
Created: Revision:
March 28, 2008
Page 67 of 148

-
uheelobrotor o
Spacer Bars" _
GROUP
illical
Shaft Seal Assembly

Figure 5-13
e. A typical shaft seal assembly for an upper screw conveyor is shown in Figure 5-13.
."
1 Shaft Seal Spacer Bars - maintains a space

between the adapter plate and the shaft seal retainer for the shaft seal to mount. This allows maintains proper compression of the felt shaft seal.
_ ..
2. Shaft Seal - prevents media leaking out the ends of

-' ..
the conveyor and protects the bearings from the media.
...
...
.. ..-
3. Shaft Seal Retainer - retains the shaft seal between

the shaft seal spacer bars .
4. Hex Nut Spacers - maintains a space between the

shaft seal retainer and the flange bearing. This allows any media that made it by the shaft seal to drain before contaminating the flange bearing.
5. Bearing - supports both ends of the screw conveyor.

--.J
u.heelabrator
GROUP
Bearing Mounting Plat
UHMW Shot Dis
tsearing Spacers
.!mical Shaft Seal Assembly

Figure 5-14 f. Another variation of a shaft seal assembly for an upper screw conveyor is shown in Figure 5-14.
1. Bearing Mounting Plate - is the base for mounting the other components of the bearing assembly. 2. UHMW Shot Disc - prevents media leaking out the ends of the conveyor and protects the bearings from the media. 3. Bearing Cover Plate - retains the UHMW shot disc in the bearing mounting plate. 4. Bearing Spacers - maintains a space between the bearing cover plate and the flange bearing. This allows any media that made it by the shot disc seal to drain before contaminating the flange bearing. 5. Flange Bearing - supports ends of the screw conveyor.
~
Created: March 28, 2008 Page 69 of148
Revision:
uheelabrator ( r
GROUP
J
5.4 Functions of a Separator The separator receives contaminated abrasive media from the upper reclaim. In the separating process, the abrasive media is spread out for uniform distribution through the separator to remove the contaminants from the abrasive media. The abrasive contaminants are delivered to the refuse side of the separator. These contaminants are conveyed to the customer's refuse container by means of flexible tubing with a dribble valve. 5.4.1 Types of Separators: 5.4.1.1 Gravity CFS Separator (Figure 5-15) a. The gravity CFS (Compensating Flow Straight) separator receives the abrasive media and contaminants from the head section of the elevator. b. The large contaminants are screened out through a stationary screen. c. The usable abrasive media is separated from the fine abrasive media, sand and scale. This is achieved by pulling air through a curtain of abrasive media. This curtain is maintained across the full width of the separator by a sliding baffle and counterweighted swinging baffle system. J
d. The cleaned usable abrasive media is directed to the storage hopper. e. The fines, sand and scale are directed to the buyer's receptacle at floor level.
Page 70 of 148
uheelabrator
Separator Casing Sliding Baffle Swinging Baffle Vent Outlet Alternate Screen Location
<..
GROUP
Trough Design Swinging Baffle

J
Cou nterweights
"Trough Desi~
Counterwei9!!!
Separator Screen Adjustable Lip /
-}3~
~--------~
I
Ref. Abrasive Media Storage Hopper ~:~__
Fines Sand & Scale' --Discharge
IYPical Gravity CFS Separator Arrangement

Figure 515 f. The following are typical components of a gravity CFS separator as shown in Figure 515. 1" Separator Casing - is used to mount the separator components and retain the abrasive media and contaminants to be cleaned. 2. Sliding Baffle - is adjustable and regulates the volume of abrasive media and contaminants flowing to the swinging baffle. 3. Swinging Baffle - is the mechanism which controls the flow of contaminated abrasive media in a thin curtain across the entire width of the separator at the point of separation.
__ .t
.--
Page 71 of 148
www.wheelabratorgroup.com ",-
-_ ..
uheelobrotor n
GROUP
....
.:
Make sure the swinging baffle will not stick on the ends near the vertical housing wall. Grind the edges for clearance if required. The vertical back of the swinging baffle should be perpendicular with the edge of the adjustable lip. Use the slotted holes for the bearing mounts to adjust the position of the baffle as required. The bottom edge of the baffle should clear the adjustable lip by approximately 1/8". This gap may change, based on the size abrasive used, to prevent sticking of the baffle on the horizontal lip. Correct clearance allows the baffle to push against the build up of abrasive on top of the lip and prevent any partial curtain leakage of abrasive. 4. Counterweights - are used to adjust the swinging baffle to obtain a full width curtain. By moving the adjustable counterweights up and back on the rod or adding or removing abrasive from the trough designed counterweights the thickness and width of the abrasive curtain of abrasive can be adjusted .
.
'
..
_. ..
..
...
'.'
.
'
-,-".,.
5. Adjustable Lip - is adjusted back about %" behind the vertical fall line from the upper lip that swinging baffle closes on. The lower lip may need additional adjustment depending on the size, weight and volume of contaminants. 6. Separator Screen - stops large contaminants before they can get to the wheel unit. The screen should be cleaned daily to assure unrestricted abrasive flow to the wheels. Care should be taken when cleaning the screen to assure the contaminants do not fall into the abrasive storage hopper. 5.4.1.2 CFS Separator w/Upper Screw Conveyor (Figure 5-16) Reclaim
~ .. ..
,
.
'
a. The CFS (Compensating Flow Straight) separator receives contaminated abrasive media from the upper screw conveyor reclaim . b. The large contaminants are screened out through a rotary screen.
,.'
.:
Operation Manual
&
Maintenance
u.heelabrator .-~
GROUP c. The usable abrasive media is separated from the fine abrasive media, sand and scale. This is achieved by pulling air through a curtain of abrasive media. This curtain is maintained across the full width of the separator by a sliding baffle and counterweighted swinging baffle system.
d. The screened usable abrasive media is directed to the storage hopper. e. The fines, sand and scale are directed to the buyer's receptacle at floor level.
Trough Design Swinging Baffle Separator Casing Cover
'---Trough Designed
Counterweight
Swinging Baffle Upper Adjustable Lower Adjustable Ref. Abrasive Media Storage Hopper \/" lip Lip I /
Vent Outlet
Separator Casing
Yo"
I" -'
Separator Screen
:..t::
C!o.
--J..
Fines "
I
,/
, / C--
,-,,' ".J
'\
Jsand&scaie
, ,
Discharge
illical CFS Separator Arrangement

Figure 5-16
f. The following are typical components found in a CFS

separator with upper screw conveyor reclaim as shown in Figure 5-16.
Created: Revision: March 28, 2008 Page 73 of148
u.heelabrator
C
GROUP
.:
1. Separator Casing - is used to mount the separator components and retain the abrasive media and contaminants to be cleaned. 2. Separator Casing Cover - is for access to the upper screw conveyor and rotary screen. Warning: DO NOT remove separator casing cover with power on the equipment or with the screw conveyor or screen running. 3. Sliding Baffle - is adjustable and regulates the volume of abrasive media and contaminants flowing to the swinging baffle. 4. Swinging Baffle - is the mechanism which controls the flow of contaminated abrasive media in a thin curtain across the entire width of the separator at the point of separation. Make sure the swinging baffle will not stick on the ends near the vertical housing wall. Grind the edges for clearance if required. The vertical back of the swinging baffle should be perpendicular with the edge of the adjustable lip. Use the slotted holes for the bearing mounts to adjust the position of the baffle as required. The bottom edge of the baffle should clear the adjustable lip by approximately 1/8". This gap may change, based on the size abrasive used, to prevent sticking of the baffle on the horizontal lip. Correct clearance allows the baffle to push against the build up of abrasive on top of the lip and prevent any partial curtain leakage of abrasive. 5. Counterweights - are used to adjust the swinging baffle to obtain a full width curtain. By moving the adjustable counterweights up and back on the rod or adding or removing abrasive from the trough designed counterweights the thickness and width of the abrasive curtain of abrasive can be adjusted.

.. Revision:
Page 74 of148
u.heelobrotor -~~~ GROUP

C.
The usable abrasive media is separated from the fine abrasive media, sand and scale. This is achieved by pulling air through a curtain of abrasive media. This curtain is maintained across the full width of the separator by a sliding baffle and counterweighted swinging baffle system.
d. The screened usable abrasive media is directed to the storage hopper. e. The fines, sand and scale are directed to the buyer's receptacle at floor level.
Trough Design Swinging Baffle Separator Casing Cover
Trough Designed Counterweight
,--
Vent Outlet
Separator Casing
Swinging Baffle Upper Adjustable lip Lower Adjustable Lip Ref. Abrasive Media Storage Hopper \ I /
Yo"
I,,",
Separator Screen
-:.t::
/
C!~
" "Js~nd
--lFines & Scale Discharge
\/ ,
/
"
I ''\ , ,
,/
,-""","
C--
"~
TYPical CFS Separator Arrangement

Figure 5-16 f. The following are typical components found in a CFS
separator with upper screw conveyor reclaim as shown in
Figure 5-16.
\.......,/
Page 73 of 148
'-.....-
LLheelabrator
GROUP 6. Upper Adjustable Lip - is adjusted to keep the back face of the swinging baffle vertical and parallel with the air opening behind the abrasive media curtain. 7. Lower Adjustable Lip - is adjusted back about %" behind the vertical fall line from the upper lip that swinging baffle closes on. The lower lip may need additional adjustment depending on the size, weight and volume of contaminants. 8. Separator Screen - stops large contaminants before they can get to the wheel unit. The screen should be cleaned daily to assure unrestricted abrasive flow to the wheels. Care should be taken when cleaning the screen to assure the contaminants do not fall into the abrasive storage hopper.
-:~;fs:..
... =-..::'::;;::"'.:~~,
-'.::0~: ...
.- .
5.4.1.3
LP Magnetic Separators The LP (Low Profile) series of magnetic separators provide a significant improvement in operating efficiency and cost reduction for blast cleaning equipment in a typical foundry. Using a two (2) stage approach, the LP units remove coarse and fine non metallic contaminants from the steel abrasive operating mix and metallic fines from the non metallic waste stream. The primary benefits are: 1. Increased life of wheel components over systems with air;::;~ wash only separators. 2. Reduced maintenance on the blast equipment and dust collector. 3. Reduced loss of usable abrasive and sand. 4. Reduced ventilation air requirement for separators. 5. Reduced metallic content in reclaimed sand.
......
"""'~-"
..
._
..
Created:
March 28, 2008
Page 75 of 148
Revision:
--
--
-,
Llheelabrator r...-.,.
,'ro.,..... ...,...
GROUP
--...J
...- .. ---."
.-c__
=-
The achievement
of these benefits and the safe
and efficient operation of the LP system units are dependent on the complete understanding and ~er use of the information in this manual.
5.4.1.3.1 -
Primary LP Magnetic Separators (See Figure 5-17) a. A mixture of ferrous abrasive media and sand enters the primary LP magnetic separator unit from an upper screw conveyor and rotary screen. b. The rotary screen removes oversize contaminants from the mixture and directs this material to a suitable customer provided floor level container through a flexible steel tube.
--_ ......
.
~'
C)
--
Note: Overflow material can bypass the system through a separate overflow pipe and be recycled. c. The ferrous abrasive media and sand mixture that passes through the rotary screen is spread across the width of the separator by the external screw flighting of the rotary screen. d. This mixture is then metered by a sliding baffle to generate a maximum 3/8 "thick controlled flow of material onto the rotating stainless steel drum. e. The flowing curtain of material passes between the adjustable burden plate and the rotating drum with its internal hemispherical (215 degree) section alternating pole adjustable magnet system. [See Figure 5-17 (A-A)]
.-
f. Alternating pole magnets agitate the mixture of

ferrous abrasive media and sand to achieve the maximum release of sand particles and the maximum retention of ferrous particles on the drum surface. ---.J
Created: Revision:
March 28, 2008
Page 76 of 148
'--...-
uheelabrator .~.
.C' GROUP 6. Upper Adjustable Lip - is adjusted to keep the back face of the swinging baffle vertical and parallel with the air opening behind the abrasive media curtain. 7. Lower Adjustable Lip - is adjusted back about %" behind the vertical fall line from the upper lip that swinging baffle closes on. The lower lip may need additional adjustment depending on the size, weight and volume of contaminants. 8. Separator Screen - stops large contaminants before they can get to the wheel unit. The screen should be cleaned daily to assure unrestricted abrasive flow to the wheels. Care should be taken when cleaning the screen to assure the contaminants do not fall into the abrasive storage hopper.
!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!!i!!!i!!!!!i!!!~~~~~~.-'
.-
~~
5.4.1.3
LP Magnetic
Separators
The LP (Low Profile) series of magnetic separators provide a significant improvement in operating efficiency and cost reduction for blast cleaning equipment in a typical foundry. Using a two (2) stage approach, the LP units remove coarse and fine non metallic contaminants from the steel abrasive operating mix and metallic fines from the non metallic waste stream. The primary benefits are: 1. Increased life of wheel components over systems with air wash only separators. 2. Reduced maintenance on the blast equipment and dust collector. 3. Reduced loss of usable abrasive and sand. 4. Reduced ventilation air requirement for separators.-, 5. Reduced metallic content in reclaimed sand. .-

'
u.heelabrator .
,.... r-"\
0"'"
G RO U P
. '.
g. The retained magnetic (ferrous) particles are released from the face of the drum at the end of the magnetic field. h. The released sand with some magnetic particles passes to the Secondary LP separator.
i. Released metallic particles are directed to the air

wash separator section for classification and operating mix control.
j.
This uniform curtain of material from the magnetic drum falls onto the sloped surface behind the air wash separator swinging baffle.
k. When the abrasive particles build up to the proper height behind the swinging baffle (and adjustable baffle if so equipped) to overcome the resistance of the counter -weights, the swinging baffle will open and permit a uniform thickness curtain of abrasive to flow over the entire edge of the adjustable lip. [See Figure 5-17 (8-8)]
.'1..,,.-
e
I.
Note: A properly adjusted air wash separator permits only a full width curtain to be presented to the air flow through the separator. This air flow passes between the adjustable lip and the lower adjustable lip.
m. Usable abrasive is directed to a stationary tray screen to capture any oversize material that may have by-passed the rotary screen. n. Usable abrasive passes through the tray screen into the storage hopper for the blast wheels. o. The fine metallic waste material and the small amount of sand removed at the air wash separator pass by the lower adjustable lip and drain into a suitable customer provided waste container at floor level.
-=
uheelabrator :'~
GROUP
.-
'--'"
",-Sliding Baffle
-------- --~-"", Magnetic Drum
\,,
\,
Burden Plate
i
I I
\ ~
)~~~
Media & Fines
Sand
\~,\\~' ''''ir~~~b// '>'

'--.: '-'._,~'M'~''~:,'
-~~i~1~~LJ._~~:~
I1\... .......
-::
VIEW A-A
Figure 5-17 (A-A)
Swinging Baffle & Counterweights
'"
Adjustable Lip Lower Adjustable Lip
''\
, ,
:..
\,
\
I I
/ , ,
ri~~.
"---- -----~,' -~
VIEW B-B
Figure 5-17 (B-B)
www.wheelabratorgroup.com .-
Operation Manual
&
Maintenance
u.heelabrator
GROUP
--~~~~~~~~~~~~~~~~~~~~~
p. Key components will require adjustment to achieve the expected operating efficiency in a safe and reliable manner. Reference Figures 5-17, 5-17 (A-A) and 5-17 (B-B). 1. Sliding Baffle - The sliding baffle must be positioned to control the thickness of the abrasive and sand mixture from the rotary screen so it flows onto the outer surface of the rotating stainless steel drum without flooding or overloading the magnetic field. [See Figures 5-17 & 5-17 (A-A)] 2. Burden Plate - keeps the falling mixture of abrasive and sand close to the rotating drum surface and in the magnetic field of the alternating pole magnet system. [See Figures 5-17 & 5-17 (A-A)]
30 Scribe Line Coincides with Drop off Point of the Discharge
/'
,------------
~~-~
"
Rotary Drum Square Shaft
\,
-::
Locking
Collar
\,
"
"<, "
~
;~"
, /
' <,~~-
Locking
Collar
-------- --_/
............. __ ......... '
/ ,
Rotary Drum Square Shaft (Scribe Lines Represent Edges of Magnets)
To Insure Proper Magnet Location in Drum Locking Collar must be Installed with Bolt Facing Upward.
Positioning Upper Magnet Edg~

Figure 5-18
www.wheelabratorl!roup.com
Revision:
....
;;;-.
uJ1eelabrator~
3. Alternating Pole Magnetic Drum - The magnetic drum system requires proper positioning of the fixed alternating pole magnet inside the rotating stainless steel drum (Refer
GROUP .::-::~:-
to Figure 5-17). Using an adjustable wrench

on the square end shaft, align the upper end of the scribe mark on the end of the shaft with the longer scribe mark on the face of the locking collar. Record the short scribe mark reference point from the locking collar. This will position the upper magnet edge with the drop off point of the discharge. The initial setting may need further adjustment to use the magnetic field to minimize the impact of the falling abrasive and sand on the drum surface and maintain a good discharge arc for the metallic particles under the drum.
__ ;
'::L
[See Figures 5-17, 5-17 (A-A) and 5-18]

4. Swinging Baffle & Counterweights -The swinging baffle should swing freely but remain closed until sufficient abrasive material builds up behind the baffle to insure the flow of a full width curtain. The air wash will then flow uniformly through the falling material to remove unusable metallic fines and residual non metallic contaminants. The counterweights must be positioned to hold the baffle closed without causing an overflow or partial curtain condition. Make sure the swinging baffle will not stick on the ends near the vertical housing wall. Grind the edges for clearance if required. The vertical back of the swinging baffle should be perpendicular with the edge of the adjustable lip. Use the slotted holes for the bearing mounts to adjust the position of the baffle as required. The bottom edge of the baffle should clear the adjustable lip by approximately 1/8". This gap may change, based on the size abrasive used, to prevent sticking of the baffle on the horizontal lip.
'C-
---"
~~.
":=.1:"

-
uheelobrotor
GROUP
.J
Correct clearance allows the baffle to push against the build up of abrasive on top of the lip and prevent any partial curtain leakage of abrasive. [See Figures 5-17 and 5-17 (8-8)] 5. Adjustable Lip - can be adjusted along with the swinging baffle adjustment to achieve the position and relationships described in paragraph 4 above. [See Figures 5-17 and 5-17 (8-8)] 6. Lower Adjustable Lip - Establish a minimum gap of %' between the top front edge of this lip and the back edge of the falling abrasive mix . Additional adjustments of this lip may be required in conjunction with adjustments in air flow through the separator and size, weight & volume of contaminants. An air gap is necessary to allow some horizontal movement of usable abrasive particles as the horizontal air stream carries the lighter weight contaminants and unusable metallic fines out of the abrasive mix. [See Figures 5-17 and 5-17 (8-8)]
..
':
,"
5.4.1.3.2
Secondary LP Magnetic Separators (See Figure 5-19) a. A mixture of sand with small amounts of metallic particles enters the secondary LP magnetic separator unit from the primary separator discharge pipe/hose. b. This hose directs the mixture to the top of the separator casing where internal deflector baffles uniformly spread the incoming material out across the width of the separator housing.
Created:
March 28, 2008
Page 82 of 148
,-
Revision:

~
Llheelabrator ~~~ '::~t

GROUP
..- --.
!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!ii!!!ii!!!!!!!!iii!!!!!!!!!!!!
3. Alternating Pole Magnetic Drum - The magnetic drum system requires proper positioning of the fixed alternating pole magnet inside the rotating stainless steel drum (Refer
.. ~=:-
to Figure 5-17). Using an adjustable wrench~,:-; on the square end shaft, align the upper end of ... ::-:.. the scribe mark on the end of the shaft with the longer scribe mark on the face of the locking collar. Record the short scribe mark reference point from the locking collar. This will position the upper magnet edge with the drop off point of the discharge. The initial setting may need further adjustment to use the magnetic field to minimize the impact of the falling abrasive and sand on the drum surface and maintain a good discharge arc for the metallic particles under the drum. [See Figures 5-17, 5-17 (A-A) and 5-18]
4. Swinging Baffle & Counterweights -The swinging baffle should swing freely but remain closed until sufficient abrasive material builds up behind the baffle to insure the flow of a full width curtain. The air wash will then flow uniformly through the falling material to remove unusable metallic fines and residual non metallic contaminants. The counterweights must be positioned to hold the baffle closed without causing an overflow or partial curtain condition. Make sure the swinging baffle will not stick on the ends near the vertical housing wall. Grind the edges for clearance if required. The vertical back of the swinging baffle should be perpendicular with the edge of the adjustable lip. Use the slotted holes for the bearing mounts to adjust the position of the baffle as required. The bottom edge of the baffle should clear the adjustable lip by approximately 1/8". This gap may change, based on the size abrasive used, to prevent sticking of the baffle on the horizontal lip.
::;".~'-'
.--
'"
:J.
......
u.heelabrator;~
":) GROUP
... -'
"-
c. The sand and metallic material is allowed to build up in the upper casing to an optimum level for effective operation of the fixed pole magnet system. d. When the abrasive particles build up to the proper height behind the swinging baffle to overcome the resistance of the counter -weights, the swinging baffle will open and permit a uniform thickness curtain of abrasive to flow over the entire edge of the upper casing.
,~
...
...-
0
f.
Note: A properly adjusted swinging

_"'H'_'
baffle permits only a full width curtain to be presented to the magnetic through the separator. e. The flowing curtain of material passes between the adjustable burden plate and the rotating drum with its internal hemispherical (-225 degree) section fixed pole adjustable magnet system.
.
drum
::.. .. z; ""~;i,:' ,:'::~;: ~

~~-
-"
....
Sand flows directly off the drum into a hopper and then into a discharge container or transporter provided by the purchaser.
..
.
..
g. Metallic particles retained by the magnetic field are released at the rear of the separator unit and pass into a waste metallic container provided by the purchaser. h. An adjustable angle under the magnetic drum is positioned for effective splitting of the sand and metallic discharge material.
-,- .....
'.
-...
~-.-,
... . .'-._-_ ....
:;:: ...
.
.,.
..
Page 83 of 148
._::~:: :-.. :. ... - ~ ... _ .
..._-, ......
.;: ..~::::
-.
Operation
. - .. - -::::.;~. =.~:.'"
&
Maintenance Manual
uheelabrator
GROUP
;. ::~::~l!!!!. ~~~~~~~~~~~~~~~~~~~~~~
..:: ..: ~*
"-
.:-.:::.:::::::..:~
.~.:~==.: ...
,J
.-...::.:.. ::
Feed from Primary Separator
--.-
.....
Magnetic Drum
7j1.,,"
i ,
Swinging Baffle I & Counterweights Burden Plate
i
\
,
~~. - .:::=~': ..
~..-:::"~':: ;::
See View A-A
"
Adjustable Angle .':::::'-"" ":~"-:-;.~"";

,
----
~.
TYPical Secondary LP Magnetic Separator

-,_ .....
Figure 5-19
Swinging Baffle & Counterweights
Magnetic Drum Sand

-.. ~-,.....
Metallics
Adjustable Angle
.""'-"-'
View A-A
Figure 5-19 (A-A)
.::::~: ..
Llheelabrator
,,---.
GROUP
-,-.~ ..
~-.
i. Key components will require adjustments to

achieve the expected operating efficiency in a safe and reliable manner. Reference Figures 5-19, 5-19 (A-A) and 5-19 (B-B). 1. Swinging Baffle & Counterweights -The swinging baffle should swing freely but remain closed until sufficient abrasive material builds up behind the baffle to insure the flow of a full width curtain. The counterweights must be positioned to hold the baffle closed without causing an overflow or partial curtain condition. Make sure the swinging baffle will not stick on the ends near the vertical housing wall. Grind the edges for clearance if required. The vertical back of the swinging baffle should be perpendicular with the edge of the upper casing lip. Use the slotted holes for the bearing mounts to adjust the position of the baffle as required. The bottom edge of the baffle should clear the upper casing lip by approximately 1/8". This gap may change, based on the size abrasive used, to prevent sticking of the baffle on the horizontal lip. Correct clearance allows the baffle to push against the build up of abrasive on top of the lip and prevent any partial curtain leakage of abrasive. [See Figures 4-19 and 4-19 (A-A)] 2. Burden Plate - keeps the falling mixture of metallic particles and sand close to the rotating drum surface and in the magnetic field of the fixed pole magnet system. [See Figures 4-19 and 4-19 (A-A)]
---
Created: Revision:
March 28, 2008
Page 85 of 148
Operation Manual
&
Maintenance
uheelabrator
Locking Collar 20 Scribe Line Coincides with Drop off Point of the Discharge
GROUP
Rotary Drum Square Shaft
Locking Collar
Rotary Drum Square Shaft (Scribe Lines Represent Edges of Magnets) To Insure Proper Magnet Location in Drum Locking Collar must be Installed with Bolt Facing Upward.
Positioning U~er MagnetEdge

::
Figure 5-20 3. Fixed Pole Magnetic Drum - The magnetic drum system requires proper positioning of the fixed pole magnet inside the rotating stainless steel drum (Refer to Figure 5-20). Using an adjustable wrench on the square end shaft, align the upper end of the scribe mark on the end of the shaft with the longer scribe mark on the face of the locking collar. This will position the upper magnet edge directly below the discharge lip drop point below the swinging baffle and the lower edge past the lower hopper adjustable angle. This initial setting may need further adjustment to maintain a good discharge arc for the metallic particles under the drum. [See Figures 5-19, 5-19 (A-A) and 5-20]
www.wheclabratorgroup.com
.... Revision:
Llheelabrator
This top setting will provide immediate attraction to the small quantities of magnetic material mixed in with the sand. The bottom setting insures effective discharge of metallic particles into the waste hopper area.
GROUP
4. Adjustable Angle - The adjustable angle must

be located to allow all metallic particles to discharge from the magnetic drum without contaminating the reclaimed sand material. Moving of the angle will be dependent on the results of a screening and magnetic content analysis of the discharged reclaimed sand. [See Figures 5-19 and 5-19 (A-A)]
c:
,r
sf
Dribble Valve Assembly Customer's Trash Receptacle
-:.
Figure 5-21
uJleelabrator
'-....-
GROUP
b. Adjustable abrasive control valves are provided to regulate the flow of abrasive to the wheels. An air cylinder or magnetic control unit opens and closes each valve. Cylinders are adjustable to obtain the specified flow with different types and sizes of abrasive. Magnetic controls provide variable flow adjustment. This meters the abrasive from the storage hopper to the wheels.
--......
-.'.
----~Fl
I
'
---~ '-::J/ ---~
Ref. Storage Hopper
Ref. Storage Hopper
Abrasive Slide Valve Abrasive Control Valve Male Hose Adapter U-8olt Hose Clamp Feed Hose Female Hose Adapter Ref. Feed Spout
-=:;:t--- Abrasive Slide Valve
Abrasive Control Valve
U-8olt Hose Clamp Feed Hose Female Hose Adapter
i
j
I '
j
),
'-+/ Abrasive Controls Assembly with Butterfly Type Abrasive Control Valve
l,\J))
Abrasive Controls Assembly with Dipper Type Abrasive Control Valve
Figure 5-21
Figure 5-22
Ref. Storage Hopper
: - ..--..--..- ..--~,~
'''--]
I ,
, __ J
Abrasive Slide Valve Abrasive Control Valve
U-8olt Hose Clamp
Female Hose Adapter
jV \. I ,<,
).~i~
1./"
Ref. Feed Spout

-r
Abrasive Controls Assembly with MagnaValve Type Abrasive Control Valve
Figure 5-23
x..> Created: March 28, 2008
Revision:
Page 89 of 148

_.r "
uheelabrator
" ,... ro. ,.,. ,... ..
G RO U P
~J
c. The following are common components of a typical abrasive controls assembly as shown in Figures 5-21 , 5-22 and 5-23. 1. Abrasive Slide Valve - This is a manually operated slide valve to open or close the media flow from the storage hopper to the blast wheel. This valve makes it possible to close off the flow of media to perform repairs and maintenance on the abrasive controls system with have to drain the storage hopper.
-.'_.
Do not use slide valve to meter abrasive media flow.

2. Abrasive
Control Valve - This meters the abrasive from the storage hopper to the wheels. There are three (3) types of abrasive control valves. [See Figures 5-21, 5-22 and 5-23] .:. Butterfly Type - An air cylinder opens and closes a wafer type paddle valve. The cylinder is adjustable to obtain the specified flow with different types and sizes of abrasive. .:. Dipper Type - An air cylinder opens and closes a totally enclosed dipper cup type valve. An adjustable stop, with coarse and fine adjustments, on the valve controls where the cylinder stops to obtain the specified flow with different types and sizes of abrasive . :. MagnaValve Type - This valve is a normally closed magnetic valve suitable for regulation of steel shot and grit. The valve construction includes a permanent magnet for normally closed operation and an electromagnet for controlling shot flow rates. By regulating the voltage to the electromagnetic any desired flow rate may be achieved. When power is off, the valve will hold shot due to the permanent magnet.
'-...J
..:;:--.'~,' ..
3. Male Hose Adapter - This is used to attach rubber hose type

,"
feed lines to the abrasive control valve. 4. U-Bolt Hose Clamp - this secures the rubber hose type feed line to the hose adapter.
Page 90 of 148
-_. -, -- Created: March 28, 2008
<:
Revision:

~
uheeloorotor .. j~
GROUP::;~
....-""
~~~~~~~~~~~~~~~~~~~~~:
5. Feed Hose - This conveys the abrasive media from the abrasive control valve to the blast wheel. There are two (2) types of feed lines . :. Abrasive Resistant Rubber Hose - This consists of abrasive resistant rubber hose and is the most common feed line type. It is flexible and easy to install. .:. Hard Piping - This consists of a network of hard pipe and weld elbows to feed the wheels. 6. Female Hose Adapter - This is used to attach rubber hose type feed lines to the feed spout of the blast wheel.
'-
~::- ...:
~-
.-
,::: ...
Created: Revision:
March 28, 2008
Page 91 of 148
.c;

~
I I
UJ I
neelobrotor -:~~~~ --. ,-.... ~.,

GROUP:~~::::c;- .
Section 6
Ventilation
A properly sized and efficiently operating dust collector system is required for effective control of dust and separation and collection of broken down abrasive media and contaminants generated by the blasting action. See Figure 61 for typical ventilation arrangement. Each ventilation point requires a specific volume and velocity of air to keep.~;.::::;:.~:.:~ particulates suspended in the air stream; avoid dusting at the machine and "-provide adequate separation of contaminants. A reduction in surface .. :=;:-"preparation effectiveness and gradual process degradation will occur .:~~. without proper ventilation. _ .. After effective operation of ventilation system has been confirmed, air volume and velocity readings should be taken at each vent point and recorded as the standard. Periodic checks should be made to watch for changes in these readings that would indicate potential ventilation problems.
Clean Air Side Duct Usually
Same Size ~ ..-,,--.
-
::,.,=:-::
As Fan Inlet
Dust Collectors:::='::;;:-~ .. ;-;. Sized for Tota r:L::;~~L Air Volume -~~~:::~.: From ~:::::::=:-:.~:.::: Blast Machine..:::~::.: ::.:.:.
_. ::-::~
-::::
Blast Gates for Balancing System (should slide horizontally) Velocity in Dusty Air Lines Should Be At Least 3500 FPM Machine Empty Hoppers Often
-_.~ ..
..
~-~
..
...
..---
_.__ ......
_.-- .....
,-...~ ~~.. '.
-"
'
.....
-;".M:::::'::
..... :..
TYPICAL ARRANGEMENT
Figure 61
www.wheelabratorgroup.com .:::-
-._.-- .' -..

-",
~::=::~.
.jti~=~~~~~~~~~~~~~~~~~~~~~
h Ia b ra tor UJlee
I I
., r ,...., r-. " .-. ,..., ,...,
G RO U P
.:
6.1
Dust Collectors Dust collectors provide three very important functions related to the clean and efficient operation of a blast cleaning machine. 1. The dust collector exhaust fan maintains a steady air flow through the separator, required for the air wash operation. The air flow pulls dust, fines and other contaminants from the thin curtain of abrasive media that falls over the lip of the separator. Operating properly, a dust collector will take out only unusable fines.
-"--"
...-
2. The dust collector exhauster provides a negative pressure in the blast cabinet. This is needed to keep dust from puffing out of the blast machine. The puffing effect is caused by the air pump action from blast wheel units . By creating a negative pressure and controlling the flow of air to the dust collector, air outside the cabinet is dawn into the cabinet, rather than air and dust inside the cabinet being forced out. 3. The dust collector retains the fine particles, which otherwise would be exhausted to the atmosphere and cause a potential air pollution problem. Because of the potential environmental problems created by dust and the need for good plant housekeeping and good community relations, it is necessary for all blast equipment to be operated with an efficient dust collector system.
-/
..-
--'.~--:::::.' ~ .. -:::;
-:-~:~-
Created: :::. Revision:
March 28, 2008
Page 94 of 148
.J
'-..... -...--..

~
~~~~~~~~~~~~~~~~~~~~~~!!!!!!!l!!!:
uheelobrotor
GROUP::~-~?: .,.
.
~f:~
.:~~'.~=:
=~:.::_::'
:~~~;.
~"
6.2
Three Types of Dust Collectors
6.2.1 Shaker Bag Style
-::Jg~=
The shaker bag style dust collector is an intermittent duty, ~~~~::.".: automatic or manual shaker type unit. Its construction incorporates:j~;:":'-~; multiple tubular bags with internal access required for maintenance __ . and inspections. Dust particles are captured on the inner surfaces ::=~~:~ of the inflated bags when the fan is operating. Bags may be made :=: of various fabrics with the most common being cotton sateen or polyester for blast equipment applications. Incoming air is diverted ~=:::: by a baffle and slowed via expansion into the hopper. Large contaminants drop into the hopper and finer material is collected on.::~~"f~: the inside of the bags. Cleaning is performed by stopping the fan to .. _ .. allow the bags to go slack before shaking them for a specific interval, usually about three minutes. This action removes most of _ .. ;:::::::-: - ,.: the dust from the inner surface of the bags so the dust can then fall into the hopper. See Figure 6-2 for Typical Shaker Bag Style Dust ':::--'~:. :~ Collector. ::::.-=::::' ~ -
~:f;::=' -::
'L~~'~ -:
SHAKER MECHANISM
.....:".
ClEAN AIR
SIDE
..... :::::;- ..
'::-::: ..
:::~~:~. ~:::
BAfFLE
Pt.ATE
_I
...... ...- ....-. '--' ..

",
::=..
DUSTY AIR SIDE
...
I!;:.f
:I: :f'
HOPPER
":
. ':::::
::.
'"
'-'-'
....
-..-.-......-. -
Typical Shaker Bag Style Dust Collector Figure 6-2

"'--' Created: March 28, 2008 Page 95 of 148
...::=:::- ',:::::'
Revision:
..
.,
-_ ---_._...
..
." '::::::::=:'":':::::'.'_ . ;0._.-- ... . ... .. .... - .......
~ ..:!... - ..-.:~~.~::::: . ...
~.-
_
__
'
__
.,_._.
W"
.:.-
--'''
-:~~'~-*~~~::'~ Maintenance ".--,-~

,
..
Operation & Manual
.-.. .. .. _-,. ."....,-_ -.-- .. ... ..'-.

..~,
,
~,
Llheelabrator
Elements of a Typical Shaker Bag Style Dust Collector: Shaker Mechanism Dustubes are cleaned by the gentle but highly efficient motion of the shaker mechanism which is driven by a totally enclosed motor located at the clean air side or outside the dust collector. The shaker provides a gentle wavelike action from top to bottom of each bag. The motion is similar to the action obtained by hand shaking a rug. 6.2.1.1.2 Filter Bags Filter bags are usually made of cotton sateen fabric, making them inexpensive cloth filters. No metal contacts the filtering area of the cloth filter bags. 6.2.1.1.3 Cell Plate The cell plate retains the bottom or open end of the filter bags that features a sewed-in ring-type spring. This end is folded in half and inserted through a cell plate hole for installation (see picture). When pressure on the hoop spring is released, the tube snaps into place, providing an instant, positive seal with the cell plate surface. 6.2.1.1.1
GROUP J
... __.~~~~~~~~~~~~~~~~~~~~!!i!i!ll!i!i!
..
..
6.2.1.1
.--'" :::=."~: ..
'-" ''
..
.... --~. _._-".
::.:-:-.=-~..
:'-~~~~-':l"
:::::=:"-=:~X"
.
:~:;::: ..~ .
..,,-.
_~:7'::.::.~~~~:.-
::~::l~:-=:~~::: .,--....~ ..-'.
--
-"'"
:~.... ::-:=:~.'
=- .::::=' ::...
Created: March 28, 2008 Revision: _ ..
Page 96 of 148
_.""
Operation & Maintenance

\........-
Manual
LLheelabrator
GROUP
6.2.1.1.4
Inlet Vent The dust-laden air enters the dust collector from the equipment vent piping through the inlet vent as shown in Figure 6-2.
6.2.1.1.5
Baffle Plate/Liner The dust-laden air entering the dust collector strikes the baffle platelliner where the sudden change in direction and reduction in air velocity cause heavier particles to drop out immediately into the hopper. All materials large enough to wear the filter fabric drop out of the air stream so only the small dust particles reach the filter bags as shown in Figure 6-2.
':~::::
6.2.1.1.6
Fan Outlet Vent The cleaned air from the dust collector is exhausted through the fan outlet vent to the atmosphere as shown in Figure 6-2.
------
::
;:
-.
.:
Created: Revision:
March 28, 2008
Page 97 of 148
www.wheelabratorgroup.com -::::~;:: ...
=
u.heelabrator
GROUP J Pulse Bag Style The pulse bag dust collector is a continuous, automatic, pulse-type unit. Its construction incorporates multiple tubular bags supported by tubular steel wire cages. Access may be from outside or from an integral enclosure on the roof. Dust particles are effectively captured on the outer surface of the tubular bags as the air flows through the material into the center of the cage frames. The bags may be made of various fabrics with the most common being cotton sateen or polyester for blast equipment applications. Cleaning is performed by various venturi systems using periodic metered pulses of high pressure air down the center of the wire cages. This reverse air pulse halts the inflow of air and releases the collected dust from the outer surface of the bags. Each pulse sequence frees the dust particles to work their way down the bags and into the hopper.
--
:.;:;....~w
6.2.2
COMPRESSED AIR RESERVOIR
DUSTLADENi AIR INLET I
~DISTRIBUTION BAFFLE
.--
Typical Pulse Bag Style Dust Collector Figure 6-3

Created:
7.
March 28, 2008
Page 98 of 148
.:
Revision:
Operation Manual
&
Maintenance
uheelobrotor
GROUP
,._.
PRIMARY NOZZLE
ThUa::tYj
' .
J
'SECONDARY
NOZzlE
Cleaning ,Position Figure 65
6.2.2.1
Elements of a Typical Pulse Bag Style Dust Collector: Inlet Vent The dust-laden air enters the dust collector from the equipment vent piping through the inlet vent as shown in Figure 63.
6.2.2.1.1
6.2.2.1.2
Baffle Plate/Liner The dust-laden air entering the dust collector strikes the baffle plate/liner where the sudden change in direction and reduction in air velocity cause heavier particles to drop out immediately into the hopper. All materials large enough to wear the filter fabric drop out of the air stream so only the small dust particles reach the filter bags as shown in Figure 63.
'--'
Page 99 of 148
Operation Manual
.......-'
&
Maintenance
uheelobrotor
GROUP
6.2.2.1.8
Fan Outlet Vent

The cleaned air from the dust collector is exhausted through the fan outlet vent to the atmosphere as shown in Figure 6-3.
6.2.3 Cartridge Style

A cartridge style collector is a continuous, automatic, pulse-type unit. Its construction offers a compact design with ease of servicing. Dust particles are effectively captured on the outer surfaces of cartridge filter elements made of various materials appropriate to the individual applications. Cleaning is performed by various venturi systems using periodic metered pulses of high pressure air into the center of the cartridges. This reverse air pulse halts the inflow of air and releases the collected dust from the outer surface of the cartridge. Each pulse sequence frees the dust particles to work their way down the side of the cartridge into the waste hopper and container. (See Figure 6-6)
Typical Cartridge Style Dust Collector Figure 6-6

Revision:
Page 101of 148

wwwowheelabratorgroupocom
u.heelabrator
GROUP
,-.J
6.2.3.1
Elements of a Typical Cartridge Style Dust Collector: Inlet Vent The dust-laden air enters the dust collector from the equipment vent piping through the inlet vent.
6.2.3.1.1
6.2.3.1.2
Baffle Plate/Liner The dust-laden air entering the dust collector strikes the baffle plate/liner where the sudden change in direction and reduction in air velocity cause heavier particles to drop out immediately into the hopper. All materials large enough to wear the filter fabric drop out of the air stream so only the small dust particles reach the cartridge filters.
6.2.3.1.3
Typical Cartridge with Clamping Plate The cartridge clamping . . plate as . . shown here in this sketch is attached to the cartridge filter as shown in this picture. This enables it to be clamped into the tube sheet with the cartridge clamp assembly.
6.2.3.1.4
Typical Cartridge Filters w/o Clamping Plate The dust collector cartridge filter as shown here is composed of cellulose pleated filter with reinforced polyester screen inside and outside encasement.
Created:
March 28, 2008
Page 102 of 148

Revision:
u.heelabrator
.uuu GROUP
"----'
6.2.3.1.5
Compressed Air Reservoir

0:
The compressed air reservoir stores compressed air to insure minimum pressure drop and maximum air storage for each valve.
6.2.3.1.6
Air Manifold The air manifold distributes the air from the compressed air reservoir evenly to the multi-stage nozzles to clean the filter bags. Note: Similar to Figure 6-3
_.-.. .. ..
,
,.
6.2.3.1.7
Nozzles A controlled blast of compressed air is released from the nozzle into the throat of the venturi nozzle. The volume of air is magnified by the addition of the secondary and tertiary air being drawn into the dustladen cartridge filter.
'
---
6.2.3.1.8
T;mical Venturi The Venturi cone shown here helps funnel the pulsed air from the cartridge header into the center of the cartridge filter element. The venturi is dropped into the filter element before clamping and installing the filter element into the tube sheet in the dust collector chamber.
6.2.3.1.9
Fan Outlet Vent The cleaned air from the dust collector is exhausted through the fan outlet vent to the atmosphere.
..
..
'-~..
Page 103 of 148

uheelobrotor
GROUP J
6.3
-:
Diaphragm Valve used on Pulse Bag & Cartridge Style The reverse pulse diaphragm valve delivers a short high pressure pulse of compressed air, reversing the air flow through a cartridge filter or filter bag. This action removes particulate from the filter surface, allowing the dust to fall towards the dust hopper. The valve relies on system pressure acting on a flexible diaphragm membrane to maintain a closed condition against the valve seat. The pressurized cover chamber above the diaphragm is exhausted when an electrical signal is supplied to the solenoid operator of the direct pilot operator (CA). This lowers the pressure differential about the diaphragm and allows the diaphragm to lift off the valve body seat. Compressed air is discharged through the valve outlet. When the electrical signal is switched off the valve exhausts are closed, the pressure differential is balanced by air bleeding from the body to cover the chamber and the diaphragm membrane moves back onto the valve body seat shutting down the sir flow.
6.4
Pressure Gages used on All Three Styles of Collectors
6.4.1
Manometer Unit The manometer is a U-tube type to measure air pressure drop across the dust collector filter elements and indicates a need for cleaning or replacement of filter elements. The manometer should be mounted at a convenient height for reading vertically on dust collector and it must be level.
-L:."

Revision:
Page 104 of 148

uheelobrctor'.
GROUP Magnehelic@ Differential Pressure Gage The Magnehelic gage gives a continual reading of the differential air pressure across the dust collector filter , FLOW elements for monitoring the build up of dust and the need for cleaning or CAGE replacement of filter elements.
'-6.4.2
--Ti:ie
6.4.3
Photohelic@ Differential Pressure Gage The Photohelic pressure cage gives a continual reading of the differential air pressure across the dust collector filter elements and electronically controls the cleaning cycle for the dust collector
6.5
Exhaust Piping Construction The gauge/thickness of material used to fabricate vent piping is critical to the effective life and performance of the vent piping system. Duct routing and intersecting duct construction methods must be compatible with the highly abrasive particulates being carried in the air stream. Follow appropriate guidelines for construction of your exhaust piping system. Contact your blast equipment supplier for copies of the recommended exhaust piping construction information.
.-
'--"
Created: Revision:
March 28, 2008
Page 105 of 148

Operation Manual
&
Maintenance
Llheelabrator
GROUP
"--
Section 7
Operations
7.1
Functions of Control Panel Instruments

.s:
EXAMPLES:
7.1.1 Wheel RPM

The wheel RPM displays the rotations per minute that the blast wheel is turning.
7.1.2
Wheel Amps The ammeter measures the amperage that the blast wheel motor is drawing. (Amperage is an indicator of amount of abrasive flow)
.:
7.1.3
Abrasive Run Hours The hour meter records blast time usage on the machine. (Preventive and predictive maintenance activity should be scheduled based on hours of blast time)
7.1.4
Blast Timer The blast timer controls the selected blast time for a cleaning cycle. (Parts are blasted for the selected time and then the abrasive and wheel are turned off)
7.1.5
Control Power On Light When the control power light is illuminated, the power is on to the control panel.
-.
7.1.6
Master Start Pushbutton Energizes system and starts the reclaim in proper sequence. The Blast Start Pushbutton controls blast wheel and abrasive control valve.
-,
'-....--
Created: Revision:
March 28, 2008
Page 107 of 148

uheelabrator
The emergency stop pushbutton shuts down the entire machine. (Stops the machine functions immediately)
GROUP
-7.1.7 Emergency Stop Pushbutton
Note: This is a push-pull maintained type button, which is pushed for stopping and pulled to reset.
=
7.1.8 Motor Overload Fault Light

When this light is illuminated, a motor overload has tripped out.
7.1.9 Blast Start Pushbutton

Press the Blast Start pushbutton and the following occurs: A. The door locks and the wheel starts. B. After a small delay, abrasive begins to flow. C. Blast timer begins to time. D. When the timer times out, the wheel stops and abrasive continues to flow to "brake" the wheel and the post tumble timer begins to time. E. When the post tumble timer times out, the mill stops and the cycle complete pilot light illuminates. F. The door unlocks.
.:
7.1.10Auto/Manual Mode Control Selector Switch

This selector switch enables the equipment to run in a manual or automatic mode.
7.1.11Abrasive Light On
When this light is illuminated, the abrasive will flow to the blast wheel.

Revision:
Page 108 of148

----_." Operation & Maintenance Manual

~
'
...
_..
,-
uheelabrator
This pushbutton starts the blast wheel running when the equipment is in the manual mode.
GROUP
7.1.12 Wheel Start Pushbutton
7.1.13 Wheel Stop Pushbutton

This pushbutton shuts down the blast wheel when the equipment is in the manual mode.
7.1.14 Blast Test Pushbutton

This pushbutton is used to take a blast pattern test.
7.1.15 Abrasive Control Selector Switch

This selector switch enables or disables the flow of abrasive to the blast wheel.
7.2
Sequence of Operations
Jan. 15,2007
.---....
- ..
J3463 GUNDERSON-GIMSA
1. Perform all machine inspections and safety checks as stipulated in WHEELABRA TOR operations manual and purchaser plant regulations. 2. Close all the machine access doors. 3. Turn panel mounted disconnect to ON position. 4. Press the "Control Power On" push button.
IN AUTO MODE:
From the remote push button station located beside the brush-off, perform the following operations: 1. Manually adjust the Brush/Blower position according to the part thickness. From 2. 3. 4. the HMI Screen perform the following operations: Select "Machine Auto Mode" and "Abrasive Auto Mode". Select the conveyor blast speed by adjusting the speed pot. Press the "Machine Start" push button. The dust collector, reclaim system and blast wheels will start in sequence.
Page 109 of 148
www.wheelabratorgroup.com ....-'
~ .....
......- -'"
uheelabrator
GROUP J
",',
_.,.- ..
'
.-.
"".
. ..-,._- ..
5. Load the part on the entrance conveyor and press the "Conveyor Forward" push button. When the part is detected by the "Part detect" sensor located in front of the entrance vestibule the part tracking starts. If the part is inside the blasting zone the abrasive will turn on/off accordingly. If the part is inside the brush-off zone the brush will turn on/off accordingly. If the part is inside the blow-off zone the blowers will turn on/off accordingly. 6. When the part reaches the "Over Travel" sensor located at the end of the exit conveyor, stops for unloading. 7. After unloading the blasted part and loading a new part, operator needs to press the "Conveyor Forward" push button to continue the blasting. 8. If for any reason the cabinet conveyor is stopped during the blast/brush process and restarted in reverse the part tracking is lost. The part must be fully moved to the entrance conveyor and then sent back through the machine. To run the part back to the entrance, operator can jog reverse the conveyor using the entrance remote push button or the HMI screen button. 9. When the reclaim system is running, if abrasive level is low in the upper storage hopper, the abrasive adder control valve opens automatically to feed the reclaim. 1D.lf the machine is on but no part is detected for an x time, the machine will shut down automatically. The value of the auto shut down time is adjustable and password protected. IN MANUAL MODE (SET UP OR MAINTENANCE MODE): 1. Motors can be turned on and off individually using push buttons on the HMI Screen, provided with necessary interlocks to prevent equipment from being damaged. 2. Blast wheel amps are set manually 3. Abrasive on/off control is by the operator in manual mode Notes:
..,-
All the access doors must be closed when the machine is running. All conveyors run and stop in the same time. There are five E-Stop push buttons to stop the machine for safety purpose.
Created: .Revision:
March 28, 2008
Page 110 of 148

Operation & Maintenance Manual "-----'
uheelabrator
L
GROUP
There are two "Conveyor interrupt" push buttons located at entrance and exit conveyors, for operator to stop the conveyors at any time without disturbing the part tracking. The button which is pressed gets illuminated (flashing) while the other button stays solid on. To restart the conveyor, the button which is flashing has to be pressed again. If a motor overload is tripped, or any fault occurs the WHOLE MACHINE WILL SHUT DOWN AND A FAULT MESSAGE WILL BE DISPLAYED ON THE HMI SCREEN.
7.3
Start-Up and Checkout Before putting the equipment into operation, the following must be performed: 1. Remove all foreign objects that might have been dropped or left in the equipment such as the hoppers, elevator boot, inside the wheel assembly, etc. 2. Make sure that all covers, drive guards, inspection plates, etc. are securely in place. 3. Check oil level of all the gear reducer drives. If required, fill with manufacturer's recommendation listed on the reducer nameplate. 7.3.1 Motor Rotation Check the motors on the equipment for proper rotation. If any of the motors are not rotating in the proper direction, the change must be made by a qualified electrician.
....
=Created: March 28, 2008 Page 111 of 148

Revision:
-.-...;.:::~: ..
:':~~:. ........... _ .. ;--~ ..
.,. ...
u.heelabrator
GROUP
-----./
..-
...;::::=
7.3.2 Charge the Eguipment with Media Before charging the Equipment, the blast gates on vent line from the cabinet, separator and elevator, should be set to one-half (1/2) open position. Final adjustment of the blast gates can be done later when the ventilation system is balanced. Charge the equipment with the desired type and size of media. Load the abrasive material (media) slowly into the equipment. After the media has been added, operate the blast wheel and abrasive cycling system for 2 to 3 minutes. Stop blasting and let reclaim system return all the abrasive media to the storage hopper. If required add abrasive media until the level in storage hopper is 6" to 8" below the adjustable lip under the swinging baffle in the separator. As the equipment operates, check to insure that only fines, sand and/or scale is coming out of the dribble valve on the separator refuse spout. If usable abrasive media is coming out of the dribble valve, verify correct (full curtain) operation of the separator and adjust the blast gate in the vent line to reduce the air flow through the separator slightly. Also check for abrasive leakage around the equipment.
.- ?:~:~: ~~. .. - -~ ..
...
.--
-,_.'-
-~..
J
7.3.3 Blast Wheel See Section 4, Blast Wheel, for setting up and operation of the blast wheels .
..
,,~
~~
:.::.
.~....-...."-_ .
7.3.4 Media Handling System See Section 5, Media Handling System, for setting up and operation of the media handling system.
-,
..
"
Page 112 of 148

uheeloorotor
GROUP
Section 8 8.1
Maintenance Inspection, Repair/Replacement of Parts & Components For the blast equipment to perform efficiently, periodic inspection and preventive and predictive maintenance must be accomplished through a regular maintenance program, "Have a Good program and Practice It." The purpose of this program is: 1) To detect minor necessary repairs and prevent major ones. 2) To anticipate repairs by locating probable causes - i.e., p..reventive t enance. ~ main 3) To plan repairs for convenient times (pre 4) To prevent breakdowns. 5) To be certain that the machine is being operated safely and at the highest possible efficiency level. 6) To keep an accurate record of maintenance activity and replacement parts usage in order to manage the spare parts inventory and monitor operating and maintenance costs.
:...::
-=.
CAUTION: When performing inspection maintenance on the machine, electric must be disconnected gloves should be worn.
and power
and safety glasses and
The components of the machine which require periodic inspection and eventual repair/replacement include, but are not limited to, the following: 8.1.1 Blast Wheel Assembly A basic inspection of the wheel assembly can be made by removing the top cover and top liner and then looking inside the assembly while slowly rotating the bladed-wheel manually. Removing the components from the housing will permit a more detailed inspection. Refer to Section 9.1 Troubleshooting for blast wheel assemblies malfunctions and suggested remedies.
:.
Page 113 of 148

--
----,,,-
L1heelabrator
............................ ,..,......,.n.GROUp
,J
:::.
8.1.1.1
z,
Liners The liners should be inspected and replaced before any holes are worn through. All liners are easy to replace. When installing liners in the wheel housing, it is vitally important that the liner pieces fit up against one another as tightly as possible to minimize housing wear from the blast.
_._.-
8.1.1.2
Wheel Housing During replacement of liners, the housing should be inspected for wear. A defective housing should be repaired or replaced promptly to prevent the escape of abrasive media.
. .-- .
8.1.1.3
Wheel Blades, Control Cage & Impeller The wheel parts should be inspected at the same time that liner inspection is made. Parts should be replaced when worn in accordance with the following criteria: One of the main objects of wheel assembly inspection and maintenance is to keep the wheel in balance. Severe vibration can be a major cause of motor bearing failure. The most frequent cause of vibration is worn, chipped or broken wheel blades. Wear on the wheel blades varies greatly from one installation to another. Blade life is dependent on various operating conditions. Although the wheel blades may be wearing evenly and may not be causing any abnormal vibrations, blades should be replaced before wearing half-way through. Holes in the wheel blade surfaces will cause wear on other parts and disrupt the blast pattern. The edge of the control cage opening and impeller openings will eventually wear and this wear must not be allowed to exceed 1/8" for the impeller and 1/4" for the control cage before replacement. The effect of wear will move the blast pattern and this in turn will cause wear on the machine structure and reduced cleaning of the work.
-~ ..
.---~
.
~
=
4 ~.
--"
-'
Page 114 of 148

www.wheelabrato!J!:roup.com
_J
..
Operation & Maintenance Manual "-.,./
_ ..
uheelobrotor
GROUP
To replace the control cage and impeller, remove the feed spout and control cage clamps. Remove impeller cap screw and impeller. Withdraw the control cage and fit the new one, make sure that the opening of the new control cage is replaced in exactly the same position as the old one. Reclamp and replace the impeller and feed spout.
8.1.1.4
Removal and Replacement of Blast Wheel Impeller Bolt When removing and/or replacing the impeller cap screw, it is very important that the following procedure be implemented to prevent wheel parts from coming loose and a wheel failure from occurring. This pertains to all blast wheels containing a threaded insert in the wheel shaft. After removing impeller cap screw from the wheel assembly, check the threaded insert in the wheel shaft to assure that it is fully seated (below the surface of the end of the shaft). If the insert screws out of the shaft when removing the impeller cap screw, replace both the cap screw and threaded insert. Do not reuse the threaded insert that has been removed from the shaft. If the threaded insert must be reused, apply loctite #242 thread locker (or equal) to the external threads of the insert prior to reinserting. It is very important that the threads of the cap screw and the threaded insert be clean and free of abrasive contaminants. Prior to reinserting cap screw, use an air hose to remove contaminants. (Comply with O.S.H.A. regulations for use of compress air for cleaning.) Make sure the centering plate is correctly positioned on the hub/wheel drive pins and the impeller is securely locked in the centering plate slots when assembled. Use only the special impeller bolt hi-collar lock washer, listed on your wheel assembly drawing. Do not assemble with a standard lock washer. Tighten the impeller cap screw to 100 ftllbs of torque. Ez-Iock insert number 329-12 Wheelabrator part number 294212.
." _. __
&)
Page 115 of 148

www.wheelabratorgroup.com -:
.'~'~:.
.-~ .-= -::

"'-~::,:=~::::
--~.,---.., ...
ulleelabrator
GROUP J Cabinet Assembly At regular inspection intervals, the inside surfaces of the cabinet should be inspected to detect any wear points that could lead to structural damage or abrasive leakage. If abnormal wear occurs, immediate action should be taken to determine the cause and make necessary repairs/replacement. All liners should be inspected and replaced before any holes are worn through. Any worn or damaged components should be replaced to prevent structural damage and leakage of abrasive.
._- -. __.' iii!iiiiiiii~~~~~~~~~~~~~~~~~~~!!ii!l
8.1.2
8.1.3
Work Conveyor Assembly Regular inspection should be given to the work conveyor structure, bearings, and alignment.
8.1.4
Work Conveyor Drive Assembly The work conveyor drive should be checked for alignment and proper operation. The gear motor should be checked for oil level. If required, refer to gear motor's instruction sheet in Commercial Parts Manuals, Section 10 for proper lubricant. Refer to Section 8, Paragraph 8.2 for recommendations on lubricating machine components.
--J
8.1.5
Abrasive Recycling System The abrasive recycling system, cleans the media, removes fines from the abrasive, conditions and returns the reusable abrasive to the wheel, and is designed to adequately handle the abrasive load requirements of the machine. The components of the abrasive recycling system are subjected to wear and damage due to their contact with abrasive material. Regular inspection of the abrasive recycling system components will help detect any wear, physical damage, or component failures. Check the following frequently:
Created: Revision:
March 28, 2008
Page 116 of 148

.... z..
~,
u.heelabrator
GROUP
"--8.1.5.1 Abrasive Hopper

Inspection of the sloping sides of the hopper should be made at regular intervals to detect any wear points. Immediate repair/replacement of sections worn away or damaged is necessary to minimize loss of abrasive and any disruption in cycling of the abrasive. Periodically, clean the hopper screen of accumulated objects and debris.
8.1.5.2
Elevator Belt Assembly

The elevator belt assembly should be checked for wear or damage to the belt, worn or damaged buckets, proper tension of the belt and proper alignment on the head pulley. Normally, a new belt assembly is required to replace a worn or damaged elevator belt assembly. Buckets are the bolt-on type and easily replaced. Check condition of bolt heads for damage and wear. Badly worn bolt heads can lead to the buckets pulling off of the belt. All buckets should be inspected periodically for wear or damage. They should be replaced when the front lip of the buckets wear down 3/4 inch. After a long period of use, the stretching of the rubber belt may cause the belt take-up arrangement to become ineffective, making it necessary to shorten the belt. Remove the side panel located at the bottom section of the elevator in front of the boot pulley for access to the belt and its splice. Make sure that the head pulley is lowered to its lowest position. Undo the belt splice. By measurement, cut off the excess length and punch new holes in the belt for reconnection. Use a belt puller while making the splice. This will result in a tight belt and allow ample take-up for future needed belt tension. Retighten the belt by the take-up screw at the head section.
Page 117 of148

Operation &
..-'
Maintenance Manual
u.heelabrator
~.,,.......,....,...,... .t
--:.
GROUP J
__
"M
.-
When a worn elevator belt needs replacement, remove the elevator side panel at the boot of the elevator to undo the splice and carefully take out the old belt. You may use the old belt to help pull in the new belt if desired. See note below. Since every belt is "tailor" fitted to each individual elevator assembly, the new belt supplied will probably be 4" to 8" longer than needed. To determine the correct belt length required, measure the distance of the path of the belt around both top and bottom pulleys. Make sure that the head pulley is lowered to the lowest position at the time of measurement. Cut-off must be square. This will result in a tight belt to begin with and allow ample take-up for future needed tension. After the belt is cut, punch in the holes for the splice and bolt the splice on one end of the belt only . Note: While the belt is out of the machine, inspect the boot pulley and head pulley and bearings for wear or damage. Replace any defective parts. The belt assembly can be fed into the elevator housing through the bottom panel opening and pulled up and over the top pulley (use the old belt or rope wrapped over the top (head) pulley), making sure that the buckets are headed in the proper direction for discharge of abrasive into the elevator from the top and fed down the sides of the head pulley. After the belt is "hung" on the top pulley, pass one end of it under and around the boot pulley and complete the belt splicing by using a belt puller while making splices. Proper belt tension can be judged by making the following observations: A. The boot pulley should rotate constantly without slipping or hesitation. B. The unloaded belt should run generally on the center of the elevator pulleys with a minimum of movement from side to side. The elevator buckets should not strike the sides of the housing. C. It should be difficult to manually slide the elevator belt back and forth across the face of the boot pulley when the elevator is stopped. The tension of the elevator belt, however, should not be so great that there is danger of tearing out the splice.
--,
,-
.-
--~-.
-
_'M
-. ~.
.=
--
Revision:

~/
L1heelabrator
" .......... Belt tension can be arrangement at the head pulley can be mechanical take-up adjusted by the screw take-up head section of the elevator. The raised or lowered, within the limits, by the take-up bolts.
GROUP
..
.-
_.4.
.-
Inspection of the elevator belt alignment is very important. If the belt is permitted to run off center and rub against the elevator housing, the abrading action will eventually damage the elevator housing and belt. Also, an overload is put on the drive motor, which may cause the overload relays to kick out. A take-up screw is provided on each side of the head shaft for maintaining proper alignment. When aligning the elevator belt, make only a slight adjustment at a time, raising the head shaft on the side toward which the belt is riding. Using caution and keeping hands away from top opening, the top cover plate can be removed to permit viewing the belt alignment on the head pulley while the belt is running. Refer to Section 9 "Troubleshooting" for elevator malfunctions and suggested remedies.
.-..
. ..
8.1.5.3
Elevator Drive
The gear motor for the elevator drive should be checked for oil level. If required, refer to gear motor's instruction sheet in Commercial Parts Manuals, Section 10 for proper lubricant. Refer to Section 8, Paragraph 8.2 for recommendations on lubricating machine components. - ..
8.1.5.4
Elevator Casing. Dribble Valve & Refuse Tubing

Regular inspection of the above parts should be made to detect any wear conditions, physical damage, missing parts or component failure. Repair or replace components as required.
..-.-. ,.-
8.1.5.5
Slide Valve AssemblYI Control Valve & Feed Hose

Regular inspection of the above parts should be made to detect any wear conditions, physical damage or component failure. Repair or replace components as required.
.~:.
'-'"
Page 119 of 148

Llheelabrator
GROUP
.J
e
-
8.1.5.6
Bearings The bearings should be checked for wear. If serious bearing wear is evident the bearings should be replaced. Most bearings are lubricated for life and do not require lubrication.
8.1.5.7
CFS Separator Assembly The purpose of the separator is to remove scale, dust and other fine materials from the usable shot (media). This separation is extremely important, since failure to remove these contaminants from the media will not only decrease the productivity (cleaning capability) of the machine, but will also increase the rate of wear on the machine and may cause dust build up on parts. The satisfactory performance of the machine is dependent on the proper adjustment and maintenance of the separator. It is of utmost importance that the operation be constantly checked. Particular attention should be given to the flow of abrasive as it passes through the separator baffle assembly. The separator assembly should be adjusted so that a uniformly thick falling stream of abrasive material is spread across the full width of the separator. This insures that the abrasive material will be properly exposed to a uniform flow of air through the separator for the air wash separation.
e
NOTE: A full width uniformly thick curtain must be maintained in the separator at all times for proper cleaning of the media. To maintain a uniformly thick full curtain of media across the full width of the separator, the swinging baffle must be properly balanced. This can be accomplished using the counterweight system supplied for the swinging baffle. Be sure the swinging baffle and adjustable lip are straight and have not been damaged in shipment. The blast gate, at the air outlet vent on the separator, can be adjusted to accurately control the size of the abrasive material that will be removed from the good shot (media).
Page 120 of148
......
-...
uJleelabrator
.. "r.,... ..... ,r-,
GROUP
'-----"
The components of the separator are subject to very little wear. However, they should be inspected periodically and any damaged components should be repaired or replaced.
"
..-
Refer to Section 9.3 "Troubleshooting" for separator malfunctions and remedies.
.M.. _'
WARNING: If tramp metal or large particles fall into the storage hopper and enter the wheel, the wheel components may shatter and clause severe damage or possible injury.
8.1.6 Ventilation System - Provided by customer or as an option
.The ventilation system requires regular inspection of parts and components to insure design performance, and to insure that an adequate flow of air exists and is maintained. The vent piping from the machine to the dust collector should be checked periodically for wear and leaks. Replace or repair defective parts. The blast gates that adjust machine ventilation should be inspected regularly and replaced as required. 8.1.7 Electrical
-..
"
--.
-. -
...
DANGER: Before initiating maintenance procedures, be sure that all power sources are disconnected from the machine and accessories to avoid personal injury from electrical power or from rotating parts. This machine operates on 230, 460 or 575 volts, 3 phase, 60 hertz electrical power.
.
Page 121 of 148

-.
Revision:

.. _ .. f!!!!. ~~~~~~~~~~~~~~~~~~~~
uheelcorotor
GROUP J
.-
For the machine to perform efficiently, the electrical equipment must undergo periodic inspection to detect any wear conditions, physical damage, loose connections or component failure. Refer to Section 9 ''Troubleshooting'' for electrical equipment malfunctions and remedies. Regular maintenance inspections should be performed with particular emphasis on the following: 8.1.7.1 Control Panel Check out electrical wires and connections for looseness, damage and proper insulation. Tighten, repair or replace. 8.1.7.2 Electric Motors Periodically inspect the motors for excessive dirt, vibration, or abnormal conditions. Clean, correct, or replace as necessary. Keep the ventilation openings of the motor clear to allow free passage of air. If excessive friction and overheating of bearings is noted, it is usually caused by the following factors: 1) Bent motor shaft 2) Poor alignment 3) Lubrication - over/under The bearings of these motors are pre-lubricated with grease by the Manufacturer and should be lubricated after one year of operation. Refer to the Manufacturer's nameplate for type of lubricant. An accurate greasing program should be followed when greasing motors for it has been determined that the greatest cause of bearing failure in motors is over greasing rather than under greasing. Refer to Section 8, Paragraph 8.2 for recommendations on lubricating machine components.
-:
Created: Revision:
March 28, 2008
Page 122 of 148

J
~
uheeloorotor:
GROUP
"-./
.:
8.2
Lubrication-Oil & Grease The life and performance of many components of the equipment are dependent on proper lubrication of components. Most bearings are lube for life and do not require lubrication. Only electric motors and reducers will require lubrication. Thorough lubrication, performed at regular intervals will aid greatly in prolonging the life of the machine components and in improving efficiency of operation. Note: The intervals of lubrication are based on normal
operating conditions.
If severe operating conditions dusty conditions or an abnormal more frequently.
exist, such as extremely perform the lubrication
amount of stopping and starting, it may be necessary to
While lubrication of the required components is essential, lubrication of some drive components of blast cleaning equipment can be detrimental. For example, chains and sprockets should not be lubricated with petroleum base material because the lubricant tends to accumulate metallic dust in the environment. This causes excessive wear on the chains and sprockets. The following recommendations machine components: should be followed when lubricating
1) Shut off power to machine during lubrication. 2) Clean dust and contaminants from the points of lubrication. 3) Clean up excessive or spilled lubricants from the equipment. 4) Use clean lubricants. 5) Do not over lubricate. This could result in overheating and possible damage of the components. 6) The oil in oil-lubricated devices should be changed if the oil shows traces of dirt or shows the effects of high temperature operation, which is evident, by the discoloration of the oil or odor.
.!.
7) Drain dirty oil while the unit is still warm, examining for
contamination by metal particles. 8) KEEP IT CLEAN & MAINTAIN
\.Created: Revision: March 28, 2008 Page 123 of 148
CLEANLINESS.
--
uheelobrotor.
GROUP
Section-9
Troubleshooting Before attempting any troubleshooting, maintenance personnel and operating personnel should become thoroughly familiar with the equipment.
._-
Follow your Lockout/Tagout
procedure (See Safety -
Warning & Precautions Section)
Before making any repair or replacement of defective parts, it is very important that the reason for the original failure be determined and corrected. A failure to correct the cause of the problem will inevitably lead to a reoccurrence of the problem, etc. Blast equipment will often continue to operate and will do an acceptable job even though some of the mechanisms or components are not functioning properly causing a decrease in efficiency. It is important for maximum efficiency, that troubleshooting be performed if either of the following is noted: 1) Increase in abrasive consumption, 2) Decrease in cleaning efficiency. As an aid to troubleshooting when a deficiency is noted in one of the elements or mechanism of the equipment, the following tables are provided. These tables list the most common troubles, their probable cause and remedies: 9.1 Blast Wheel Assembly Trouble Probable Cause Possible Remedy
Excessive vibration usually indicates that the Wheel Assembly is out of balance. This condition will eventually cause motor or unit bearing failures.
Unevenly worn wheel, blades, hub, and/or impeller.
Replace worn parts and check separator operation for removal of contaminants.
"'x _
"'--'
Created: Revision:
March 28, 2008
Page 125 of 148

www.wheelabratorgroup.com "'7
u.heelabrator
GROUP
.-....../ .
-..-..~~~~~~~~~~~~~~~~~~~~~
.
_-
Trouble
Probable Cause @ Broken or chipped

blades.
Possible Remedy @ This condition will

throw the wheel permanently out of balance and cause damage to other parts of the unit. Replace broken blades immediately using full set of new blades. Retrieve all broken parts before operating the equipment.
-....-
@ Improperly mounted
wheel.
@ Wheel must be
squarely mounted and evenly tightened onto hub or motor shaft check wheel for wobble.
J
Drop in blast wheel amperage.
@ Not enough abrasive

getting to the blast wheel.
@ Check the level of

abrasive in the storage hopper. If the level is low, add abrasive to the system. If the abrasive level seems adequate, check the abrasive valve & blast wheel feed spout for blockage.
Excessive noise besides being undesirable, it may also indicate misalignment of wheel components that cause failures or wear.
@ Improper clearances
between wheel and feed spout, wheel and wheel compartment liner or control cage and impeller.
@ Check alignment and

clearance of components in relation to each other. Allow equal clearances between moving parts to avoid pinch points and prevent contact against one another.
Created: Revision:
March 28, 2008
Page 126 of 148

_J
L1heelabrator
Trouble Probable Cause @ Loose bolts or
misalignment
GROUP
Possible Remedy @ Make certain that all

components secured. are firmly
@-D~f~-~ti~~-b~-~~i~~~------ -@--Ch~-~k-th~-~~t;ti~~-~i--the unit bearing or the drive motor. Both should rotate freely and smoothly. Repair or replace bad bearings or motors.
Increased Cleaning Time
@ Improper abrasive
feed to wheel.
@ If an ammeter check
indicates a lower ampere reading than the normal full load rating, check: a) Quantity of abrasive and add if level is low. b) Abrasive control valve adjustment for proper abrasive flow rate. c) Abrasive may contain a large percentage of fines and other contaminants, which should have been removed by the separator check ventilation system, swinging baffle operation, and abrasive screen analysis. d) Feed line obstructions may cause reduced flow to the wheel, check and clean out.
"--"
Created: Revision:
March 28, 2008
Page 127 of148

u.heelabrator
GROUP
J
Trouble Probable Cause @ Loss of Directional
Control of Blast Pattern. Abrasive will strike sections of the wheel housing, or cabinet components other than work to be blasted. This increases cleaning time, wear and maintenance.
Possible Remedy @ Conduct a blast

pattern test. Make certain that you have definitely located the usable blast pattern. Adjust control cage accordingly so that the blast pattern is directed onto the work most effectively.
Blast wheel shutdown
@ Abrasive valve worn

causing overload.
@ Replace the worn

abrasive valve parts.
Abrasive Leakage
@ Improper sealing.
@ Check wheel housing

and motor shaft seal.
9.2
Elevator
Trouble Probable Cause Possible Remedy @ Tension the belt or
clear the jam. Follow safety instructions sign when working on elevator. Reference Safety - Warning & Precaution, Section 3, 3.7.4 Safety Instruction Sign, Part No. 495079
Elevator shutdown
Loose belt or boot jam
Elevator Belt Slippage
Loose elevator belt.
@ Tighten belt by screw

take-up arrangement at head section. If belt is stretched so that take-up is ineffective, shorten belt.
Created: Revision:
March 28, 2008
Page 128 of 148


~
Llheelabrator
Trouble
GROUP
Probable Cause @ Worn pulleys, travel of

belt and rotation of boot pulley are erratic.
Possible Remedy @ Rubber lagging on

pulley may be worn. Replace or re-Iag pulley.
Jammed Elevator Belt
@ Foreign objects in
elevator boot jam against buckets and casing causing stall.
@ Inspect and clean

boot section periodically. Follow safety instructions sign when working on elevator. Reference Safety - Warning & Precaution, Section 3, 3.7.4 Safety Instruction Sign, Part No. 495079
-------------------------------@ Worn bucketsElevator buckets are worn so that they no longer carry the predetermined load.
-@--R;~;~~-b-~~k;t~:-if---belt shows considerable wear, replace complete assembly. -@--M~-k~-~b;~~-i~;---------(media) additions slowly. Check abrasive control valve flow rate adjustment. DO NOT overload wheel above rated capacity. -@--Ch;~k-t;;lt-~li-~~~-~~-t--to keep elevator belt centered on pulleys.
-------------------------------@ Excessive abrasive

loading
-------------------------------@ Belt rubs casing

causing motor overload relays to kick out.
-------------------------------@ Mechanical bind motor overload relays kick out.
-@--Ch;~k-f~~-~~~h~~i-~~I-binds in motor or gearbox. Check for bad bearings.
~.
Page 129 of 148

Liheelabrator
GROUP
J
Trouble Probable Cause @ Abrasive control valve
leaks abrasive
Possible Remedy @ Lack of air pressure to

keep valve closed.
@ Worn parts. Check

and replace worn parts.
Elevator Belt Failure
@ Belt too tight breakage may occur at splice
@ Belt should be
adjusted to proper tension. When belt is under proper tension, splice is not overstressed.
-------------------------------@ Foreign objects in

boot cause sudden jamming, belt stretches and breaks.
--------------------------------@ Sudden jams should

be avoided. Keep boot section clean; remove foreign objects. Follow safety instructions sign when working on elevator. Reference Safety - Warning & Precaution, Section 3, 3.7.4 Safety Instruction Sign, Part No. 495079
-. -------------------------------@ Badly worn belt may
--------------------------------@ Inspect belt and

splice. Replace when necessary.
suddenly break.
Belt does not run at center of head pulley.
@ Improper adjustment
of head pulley.
@ Realign pulley by
means of the adjusting screws on elevator head section.
-------------------------------@ Improper splicing

results in crooked belt, which rides from side to side on head pulley.
--------------------------------@ Be sure that splice

and belt are squarely assembled.
Created: Revision:
March 28, 2008
Page 130 of 148

u.heelabrator
GROUP Trouble Probable Cause @ Worn crown on head
pulley causes belt to ride on one side or the other.
"--
Possible Remedy @ Check head pulley.

These are crown face pulleys. If crown is worn, replace pulley. -(fCh~~k~;~~~II-------alignment of head and boot pulley by dropping plumb line from top to bottom realign if necessary.
-------------------------------@ Belt cannot be aligned

properly although all components seem to be in proper condition.
9.3
Separator
To determine if the separator is functioning properly, make a visual analysis of the abrasive after separation and of the material from the::: separator refuse discharge spout.~:~~
Trouble Probable Cause @ Too much air on
separator @f'F~li~~rt~i~-i';'~~t'-'-'-'maintained across separator.
Possible Remedy @ Adjust blast gate

setting.
Removing good abrasive
--------------------------------@ Check stationary

baffle and swinging baffle operation. Adjust baffles as needed to obtain a full curtain.
Reduced air flow
@ Air leaks in metal case

or vent piping connections. @-Ai~~~kf~~~------discharge tubing.
@ Repair or replace as
necessary.
-e,-V~~~~-th;d~ibbi~---valve on the fines discharge tube is sealing and in good operating condition.
::".
Page 131 of 148

uheelabrator
GROUP
J
._ .. ~!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!!i!iiiiii!i!!!!i!ii!!i!!i!
Trouble
Probable Cause @ Insufficient flow of air

delivered by ventilation.
Possible Remedy @ Adjust blast gate

setting.
Contaminated Abrasive.
@ Check line for

blockage.
@ Check fan output. -------------------------------@ Full curtain is not

maintained across separator.
--------------------------------@ Check stationary

baffle and swinging baffle operation. Adjust baffles as needed to obtain a full curtain.
-------------------------------@ Fines hopper and tube

are plugged.
--------------------------------@ Clean out tube and

fines hopper.
-------------------------------@ Magnets on drum not

properly positioned. (This is only on magnetic separator designs.)
-.- ..... -.-~ ..
"-'
--------------------------------@ Confirm proper

position and secure mounting of magnet assembly using external scribe mark reference guides on shaft end and locking collar.
-------------------------------@ Burden Plate not in

proper position. (This is only on magnetic separator designs.)
--------------------------------@ Verify position of

burden plate to insure effective retention of abrasive and sand mixture against rotating drum.
Good abrasive in separator fines discharge.
@ Too much air through

separator.
@ Adjust slide gate. @ Check fan output.
-------------------------------@ Hopper overfilled.
--------------------------------@ Control additions.
Created: Revision:
March 28, 2008
Page 132 of 148

uheelobrctor.
GROUP Trouble Probable Cause @ Magnets on drum not
properly positioned. (This is only on magnetic separator designs.)
"----"
Possible Remedy @ Confirm proper

position and secure mounting of magnet assembly using external scribe mark reference guides on shaft end and locking collar.
@-B~-;d~-~-Pl~t~-~-~ti~---@-V~~ify-~~~iti~~-~f---proper position. (This is only on magnetic separator designs.) burden plate to insure effective retention of abrasive and sand mixture against rotating drum.
9.4
Ventilation System
Proper maintenance of the ventilation system is just as important as the servicinq of other elements of the blast equipment. The following troubleshooting chart is provided as an aid for maintaining adequate and efficient ventilation.
Trouble Probable Cause Possible Remedy @ Close cabinet vent
blast gate slightly.
Abrasive carryout to dust collector.
Too much air.
Fines and contaminants not properly removed from abrasive.
Too little air or improper separator adjustments.
@ Open separator blast

gate slightly.
@ Check for build-up of

particles in ductwork, clean out as needed.
-I'
Created: Revision:
March 28, 2008
Page 133 of 148

Operation Manual
&
Maintenance
-- ..... ~~~~~~~~~~~~~~~~~~~~!!!l!!
L1heelabrator
GROUP
-J
Trouble
Probable Cause
Possible Remedy @ Check dust collector

discharge container every shift. Empty before container is full.
Contaminated abrasive - fines and contaminants not properly removed from abrasive.
@ Insufficient flow of air

through separator to collector.
@ Check exhaust fan

rotation.
@ Open blower exhaust

damper if present.
@ Check Magnehelic
reading.
@ Check pulse or shaker

operation of collector and increase, if necessary.
@ Replace filters, if
necessary.
9.5
Electrical Equipment NOTE: DISCONNECT ALL ELECTRICAL POWER SOURCES OR REPAIR.
BEFORE ATTEMPTING 9.5.1 Motors Trouble
MAINTENANCE
Probable Cause @ Overheats and

overloads trip out.
Possible Remedy @ Check for mechanical

binds.
Wheel Motor
Elevator Motor
@ Overheats or motor
stops.
@ Check tightness of
elevator belt and if centered on top pulley.
Page 134 of 148

uJ1eelabrator
Trouble Probable Cause @ Main power cable
disconnected at electrical source.
GROUp:
Possible Remedy @ Check main power

cable at electrical source. Must be 230, 460 or 575 volt, 60 hertz, 3 phase
Electric Motors do not Start
--------------------------------1-----------------------------_ @ Blown Fuses II @ Check fuses. Replace

if defective.
@ Applicable motor
starter overload relay trips out.
II
@ Reset starter.
Electric Motors do not Come Up to Speed, Run Slow
@ All phases of 230 or

460-volt supply not connected properly.
@ Recheck wiring for

loose or improper connections.
--------------------------------~---------------------._-----_._.@ One fuse blown in @ Check all fuses.

disconnect box. Replace as required.
.... I"~;
9.5.2 Starters and Control Panel

Trouble Probable Cause @ Overloads trip out. Possible Remedy
-:=
Overload Relay
Do not increase the overload setting; check load with ammeter; compare with overload relay setting. If load is excessive, determine cause and correct.
Contacts and Contact Springs
@ Contacts badly pitted.
Replace
'-,
Created: Revision:
March 28, 2008
Page 135 of 148


---".~~~~~~~~~~~~~~~~~~~~~~iii!i!i!!!i!!i!
uheelcbrotor
Trouble Probable Cause @ Fuses blow. Possible Remedy @ For the occasional
Fuse Protection
GROUP
<:
"blow", fuses may be loose in fuse holders, or temporarily overloaded. If persistent, check for grounded circuit, bare wire.
Overload Relays Trip continuously
@ Overload in circuit low

power.
@ Shut down particular

circuit. Check power source for proper voltage.
-------------------------------@ Broken, damaged or

loose wiring.
--------------------------------@ Inspect wiring for

broken, cut wires and loose terminals. Replace/repair as required.
------------------------------.-
@ Dirt or contaminants at
terminals.
--------------------------------@ Clean contacts and

terminals.
Wheel Motor Sound Not Continuous
@ Abrasive level low. -------------------------------@ Loose connectors. -------------------------------@ Abrasive system

clogged or damaged.
@ Add abrasive to
specified level.
--------------------------------@ Tighten electrical

connectors.
--------------------------------@ Clean or replace

defective parts.
Page 136 of 148

ulleelabrator
GROUP Control Accessories - Operator's Control Panel Trouble Probable Cause Possible Remedy @ Probable cause abrasive dust. Remove cover and clean .
.
1 _:
9.5.3
Push buttons
Buttons stick.
,-
_._---------------------_._._--)_._---------_._---_.-._._._._._.-.
Erratic Operation
Check contacts for dirt, springs broken or out of place.
Ammeter
Dirty
@ Carefully clean
ammeter with a fine brush.
---------------------n-------------------------------.@ Inaccurate reading i @ Bent indicator pointer.

Replace meter.
@ Failure
@ Replace meter.
--
Page 137 of 148


~
Llheelabrator
GROUP
~=
.
-_ ...._-
Section-10 Commercial Parts Manuals

Commercial Part Model No. Location on Machine Blast Wheel Web Address for Manual
Baldor
http://www.baldor.com/
Nord
Lower Reclaim
http://www.nord.com/mainlindex.cfm
SEWEurodrive
Lower Reclaim
http://www.seweurodrive.de/englisch/index.en.html
Reliance Electric
http://www.reliance.com/
Boston Gear
http://www.bostongear.com/
Browning
http://www.emerson-ept.com/
Cleveland Gear
http://www.clevelandgear.com/
Cone Drives
http://www.conedrive.textron.com/index.htm
Dodge
http://www.dodge-pt.com/
:~~:..
Page 139 of 148

,
.;:.. ..
,:;.-"
_ ..
"."
".,. ,--',
..-.~
..
......- --...---.
uheelabrator O GROUP Spare Parts
"--Section-11 Recommend 11-1
Wheel Unit Spare Parts
Qty.
1 1 3 1 1 3 3 3 1 1 1 1 3 1
Cat. No.
738875 736807 C104905 731156
Description
Bare Wheel Feed Spout Seal
Unit Cost
Total Cost
* * * * * *
Blade Set Plate

::
Centering
Control Cage Adapter 737720 Control Cage
Control Cage Adapter Clamp 737661 683487 682988 471181 736807 737703 739665 739666 738794 740316 Impeller Hi Collar Lock Washer Impeller Cap Screw
Feed Spout Feed Spout O-Ring
Feed Spout Clamp Top Liner End Liner Wheel Motor Wheel Tune-up Kit
4 2
1
I
I
1
Note: Parts with in front their descriptions the wheel tune-up kit.
are included
in
u.heelabrator
GROUP
-11-2
::
J
Lower Reclaim Assembly Cat. No. C205336 C168695 C82733 C1132 C41924 Description Reducer, 5 HP Bearing, 2" End Plate Shot Disc Flange Bearing, 1 'Y:z" Rubber Buffer Unit Cost Total Cost
Qty.
1 1 1 1 2
11-3 Qty.
r
Elevator Assembly Cat. No. 746089 746089 458667 685995 746467 016986 106510 500082 017402 746078 Description Boot Pulley Head Pulley Bearing Shaft Seal Elevator Belt Assembly Elevator Bucket Elevator Bolt Elevator Hex Nut Leather Washer Gearmotor Unit Cost Total Cost
1 1 2 2 1
62 310 11 310
Created: ~Revision:
March 28, 2008
Page 142 of 148

<:
uheelobrotor
(" r; n
"--
G RO U P
11-4 Qty. 1 1
Upper Reclaim & Separator Cat. No. 752001 720490 678619 280800 720490 747800 Dust Collector Cat. No. C179907 C179643 C205013 C102807 C663949 C137436 Work Conveyor Cat. No. C229084 C122086 C3309 C41925 Cartridge Photohelic Diaphragm Filter Clips
Assembly Unit Cost Total Cost
Description Base Screw R.H. Base Screw Screen Shaft Seal Bearing Separator Gearmotor Screen
2
2 1 1 11-5 Qty. 15 1 3 24 6 1 11-6 Qty. 1 12 12 2
Created: Revision:
V
Description Filter Gauge Valve Unit Cost Total Cost
After Filter Veri pack Rotary Air Lock Assembly Description Reducer, 2 HP
;
Unit Cost
Total Cost
~,
Felt Seal Pillow Block Bearing Rubber Buffer

Page 143 of 148
www.wheelabratorgroup.com.=
March 28, 2008
:.
-_. --_
ulleelabrator
GROUP Cat. No. Description Liner (12" x 12") Liner (6 3/8" x 12") Cut Liner Cut Liner Cut Liner Cut Liner Cut Liner Cut Liner Cut Liner Unit Cost Total Cost
-.- ..=.::~-- ::::iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii!!!i!!!iii!!!i!
11-7 Qty.
Liners in Line
39
1 1
223306 234096 C228696 C228695 C228694 C228693 C228691 C204121 C228699
--
1 1 1 1 1
...:'~ ..:;,. -::
Page 144 of 148

u.heelabrator
GROUP
Section-12
Machine Drawings Base Machine The following drawings, listed in the order of insertion, are considered necessary for ordering replacement and spare parts, proper maintenance and operation: Drawing Number A1-97282 A1-97287 A1-97279 A1-95907 A2-51526 A3-18649 A2-21720 A1-95926 A1-83267 A2-8719 A3-17665 A1-83278 A2-51346 A1-96005 0600792 0600791 Group Number 22 22 92 03 03 03 03 05 05 05 05 05 05 07 09 09 Title General Arrangement General Arrangement Design Criteria Reclaim Screw Arrangement
~
12-1
Rebound Screw Assembly Shot Disc Assembly Torque Bracket Assembly
. . Cabinet Door Arrangement Cabinet Door Assembly Micro Switch Assembly Hinge Assembly Labyrinth Seal Assembly Vestibule Door Assembly Plenum Arrangement Elevator Assembly Boot Section Assembly
Page 145 of 148
z
:
.
-
Created: Revision:
March 28, 2008
_ ...
-..
u.heelabrator
:::J
G RO U P Group Number 09 09 10 10 10 15 19 20 20 23 24 25 27 28 28 28 29 30 35 Title Head Section Assembly Elevator Belt Assembly Upper Reclaim Arrangement 60" Separator Assembly Rotary Screen Assembly Motor List Oucting Arrangement Blast Wheel Arrangement Blade Selection Chart Foundation Footprint Superstructure Arrangement
c.:::::::~: iiiii!ii!!i!iiliiiii!ii!!i!iiliiiii!ii!!i!iiliiiii!ii!!i!iiliiiii!ii!!i!iiliiiii!ii!!i!iilii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiiiii!iiiiiiiiiiii!iii!!i!!!
Drawing
.~=~:. :.:-::::~:
Number 0600790 0600808 0700764 0600780 0700763 A1-97373 A1-97409 A1-96286 0500320 A1-97454 A1-96333 A1-96395 A1-96313 A1-96436 A2-51797 A2-49994 A1-96615 3463-30 A1-96305
Storage Hopper Arrangement Liner Arrangement Feed Pipe Arrangement Abrasive Control Valve Assembly Abrasive Control Valve Assembly Field Material & Safety Signs 5015L Oust Collector Work Conveyor Arrangement

::::.::..Revision:
Page 146 of 148

"----
uheelcorotor: .J
GROUP Group Number 35 36 37 41 58 64 68 68 68 68 68 69 71 96 96 96 96 96 96 Title Torque Bracket Assembly Entrance Conveyor Exit Conveyor Vestibule Arrangement
Drawing Number A2-49185 A4-15783 A4-15783 A1-96416 A1-96515 A1-95663 A1-96352 A1-96502
----..",
Arrangement
Seal Arrangement
Zero Speed Switch Arrangement Exit Vestibule Abrasive Abrasive Arrangement
Removal System Removal System
A2-45963 A2-46294 A2-46296 A1-96512 A1-96021 A3-53392 A3-53393 A3-53394 A3-53395 A3-53396 A3-53397
Machine Screw Actuator Limit Switch Flat Arrangement Seal Assembly Abrasive Abrasive Schematic Removal System Blow-Off Adder Arrangement List #1 #2 #1 #2 #3
.::
Power Schematic Power Schematic Control Schematic Control Schematic Control Schematic
---Created: Revision: March 28, 2008 Page 147 of 148

.-: ... , ..-....~ . ~:;::,

.
~.-
-::::::==''::::~::.
'~-.---." ... .. ----~,. .. -.--~ - -..-.. ... .. . ~ :- -" ...::~:
_-..
-.~. _ ..._".
.,._.,
u.heelabrator
GROUP
~
-~~~7.~~ .'::
Drawing Number A3-53398
Group Number 96 96 96 96 96 96 96
Title Control Schematic #4 Control Schematic #5 Photohelic Schematic Frequency Drive Schematic Pneumatic Schematic Main Panel Layout Remote Panels Layout
:::- -::~::: .. :::

~ ... _ _, .__ ...
..
A3-53399 A3-53400 A3-53401 A3-53402 A3-53403 A3-53404
_.
-::-.:::::::.::-
'.- =:= ::..
--_ _._ ...

..
Created:
.-..
March 28, 2008
Page 148 of 148

._.
Revision:
--@NORTHERN
BWWER@o
~ ~~~~~~~~
Fan Data Sheet

ORDER #:
CUSTOMER
CMLN~~~~':,'g~~~~~~I~C Winnipeg, MB. R2C 2Z8 Phone: (204) 222-4216 F_aX_(~2M_)~2_22_-7 __ 001
~STOMER:
Fox Tech Inc.
A56948
PO: 3463301
SOLD BY: TAG:
C.B. Airtech Ltd / BobG
LINE ITEM #: 56948.01

DB, Mtr Psn Right
Qty 1 Square Fan - BI, Design 7620, Size 2450, Class 2, 90% SISW, Arr 9, Rot CCW, Discharge Maximum allowable fan speed 2206 RPM at 70 F Condition Volume SP Operatin'g 8700 CFM 10inWG
OV 2583 FPM
RPM 2112 RPM
Power 17.4 BHP
Temp 70 F
Altitude
Density 0.075 Ib/cu ft
Oft
Features Access Door - Position: 12 o'clock, Quick Release Fan Type - Type: Gusset Base Motor and Drive Mounting Nameplate - Quantity per fan: 1, Type: Standard Punched Flanged Outlet (4 sided) Slip Fit Inlet Paint Specification Paint Spec: Interior & Exterior urface prep: SSPC-SP1 & SP2 cleaned surfaces. rimer: 1 coat alkyd primer. Total OFT 1.5 mils finish. Guard Color: Safety Yellow Motor Data Motor supplied by Customer, mounted by NB 20 HP, 1800 RPM, 3/60/460, Motor Frame 256T TEFC, EPACT Efficiency, VP Conduit Box Position F1 Drive Data Drive supplied by NB, mounted by NB Type: NB Standard, Constant speed Qty: 3 Minimum Service Factor: 1.3 Motor Sheave: 6.6X3B-SD Fan Sheave: 5.4X3B-SD Bearings Inboard Bearing: F4B-SC-111 x 1-11/16 Fan Weight Complete unit shipping weight w/ ace as shipped from r-factory: 1050 Ibs
Belt Guard Mechanical Run Test Motor Base - Type: Jackscrew Percent Width Shaft & Bearing Guard w/ access to bearing zerks Flat inlet plate 51" x 51"; 12-5/16" hole spacing Color: Black
Model:
Manufacturer: NB Standard Drive Belt: B87 Ctr Dist: 35 Motor Bushing: SDx1 5/8 Fan Bushing: SDx1 11/16 Drive Side Bearing: F4B-SC-111 x 1-11/16
1/21/20089:48:45
AM
Change number 00 There are no revisions
Page 1 of 1
Page 2 of 3
~--------H--------~ ----u----~il---D---
I
E
r
-1 B
I
SJ \
~ Y HOLES, 9/16 DlA.
fk~Ywo.y
CC\J
DB
RIGHT
L
MOTOR
POSITION:
t
DI" enslons SIzE? no t ed Sh.ft Diu wl1:h
Q
i 'QJ
I 1 :/Rt
v
' ,
g~ r /Q
M
~ ~
..... : "'~ /',
1"'===
-~ ::;!J
Tr 4l
"-----
. .
, J
re
QdJ ustE'cI
for
Yo width
F
H K
I
L
Keywo..y SIze
.,
r:
-'" 2450
Iii s
T
~ X Ii U
23~
19i X
22~ Y
19~
42i
2BB
11M"
44~
51
42
32/1;D[SCHIIR~
Dtlot.r:sml'tAlL
12
r,llnfRN
I: us TD..[R.-NC:l:
12t1;
Size
IN
B[LlU-Ij
*
-DD
262
r---AADD GG SPACE1f Iii CNTRS
n....
_cc
EE
2~50
a
AA
l/2 DrA VELD NUT~ "" WELDED INS IDE:
23
25
1B~'
DD
25~
16
SIzE?
]B
CC
EE
FF
GG
JJ
KK
LL
MM
PLAT
PLAn:
INLET
MM
HOLES:,
1<1< DIA.
'lJ~1
:\!/ .. -""/1\ ~!:\\ .~ .. . .

.r
"
. ~(1J
t3~
~GB
c~
2450
20~_
28~
~
(ALSO
3!"
REFER
5tt
1~
tt
17!"
22
CNTR LINE OF'" rAN
NOTES
TO FAN DATA SHEET>
REVISION
CUSTOMER: PROJECT: TAGGING:
FOX
TECH
INC,
DESIGN:
CENTRIFUGAL
7620
FAN
SIZE: 2450 CLASS: 2 DISCH.: DB
ITolerance IScalE" NTS

90% WIDTH S,D,#/D\JG,j:j
1/8'
ARRG'T: 9, SISW
ROT.: CCW
9C" Rc,;,u"'1A\u. \"'us1, \'\'
d ..
JjNORTHERH
V~BLOWER
:0;',
\1~"tocc. Q;" ~,~~, RLC ill T00;:'''0''0: :(;4: 2.2-42'6,

Tuot);:
CERTIFIED FOR
By' MS
CONSTRUCTION
:~4:LLi..-7f!::'
Dot",
21-JAN-08
56948,01
Page 3 of 3
NORTHERN BLOWER LUBRICATION INSTRUCTION INDEX ENGLISH

BEARING DESCRIPTION F4B-DL-000 F4B-DL-100 F4B-DL-200 F4B-SC-000 F4B-SC-100 F4B-SC-200 P2B-DL-000 P2B-DL-100 P2B-DL-200 P2B-GT-000 P2B-GT-100 P2B-GT-200 P2B-SC-000 P2B-SC-100 P2B-SC-200 FYOOO FY100 FY200 SYOOO SY100 SY200 F-U300 P-U300 FB22400 PB22400 SAF22500 SAFD22500 SNL22500 SAF1500 SAFD1500 SNL 1500 SAF2500 SAFD2500 SNL2500 F4B-DLM-100 F4B-DLM-200 F4B-SCM-100 F4B-SCM-200 P2B-DLM-100 P2B-DLM-200 P2B-GTM-100 P2B-GTM-200 P2B-SCM-100 MFR Dodge Dodge Dodge Dodge Dodge Dodge Dodge Dodge Dodge Dodge Dodge Dodge Dodge Dodge Dodge SKF SKF SKF SKF SKF SKF Linkbelt Linkbelt Dodge Dodge SKF SKF SKF SKF SKF SKF SKF SKF SKF Dodge Dodge Dodge Dodge Dodge Dodge Dodge Dodge Dodge 01637 "M" Series Ball Bearings (Page 9) 01634 1500 & 2500 Series Double Row Split Pillow Block Bearing (Page 7 & 8) 01231 22500 Series Double Row Spherical Roller Split Pillow Block Bearing (Page 5 & 6) 01230 22400 Series Double Row Spherical Roller Bearings (Page 4) 01229 300 Series Ball Bearings (Page 3) 01228 200 Series Ball Bearings (Page 2) NB PUBLICATION BEARING SERIES
P2B-SCM-200 Dodge **Note. If a two different beanng senes are used on a fan, send the lubricetion Instructions for each type of beanng.
Effective Date: December 20, 2006
Distribution: Customer Drawings
NB Form: 02437
@NORTHERN
SWWER
lubrication Instructions
200 Series Ball Bearings
Procedure For Applying Lubricant To Bearings Apply sufficient grease when lubricating to cause some purging of grease at the seals. ,Lubricant Use a multi-purpose ball bearing grease of NLGI Grade 2 with rust inhibitors and antioxidant additives. An oil viscosity of 100 cSt at 40 C is recommended. Grease for high speed applications should be dynamically stable and must not churn or whip. It is not good practice to mix greases with different oil bases as the results are unpredictable. Several suitable products are: Shell Alvania #2, Exxon (Imperial Oil) Unirex N2, Texaco Premium RB, Chevron SRI #2, and Mobile Mobilux #2. For fans with vertical shafts, consider using a NLGI Grade 3 grease such as Shell A1vania 3 or Exxon Unirex N3. Do not use long fibered greases. Consult CML Northern Blower on proper lubrication if bearings are subjected to temperatures below -10C (15F) or above 80C (175F). Lubrication Interval Table
RELUBRICATION SHAFT DIAMETER INTERVAL IN MONTHS OF OPERATION SHAFT SPEED IN RPM
1000 12 12 12 12 12 12 12 12 12 12
3/4 15/16 1-3/16 1-7/16 1-11/16 1-15/16 2-3/16 2-7/16 2-11/16 2-15/16 Notes:
1500 12 12 12 12 12 12 12 12 10 10
1800 12 12 12 12 12 10 10 10 8 8
2000 12 12 12 12 10 10 10 8 8 6
2500 12 12 12 10 9 8 6 6 6 6
3000 12 10 10 8 8 6 6 4 4 3
3500 10 10 8 8 6 4 4 4 3
4000 10 8 6 6 4 4 3 3
1. Increase the frequency or lubrication in conditions of abnormal temperature, moisture, or dirt. 2. Bearings may run hot for a short time during the "run-in" period, or just after lubricating the bearings. Storage If the fan is to be idle and not operating for an extended period of time, bearings should be protected as recommended by the manufacturer. The bearings should be completely filled with grease and the fan shaft should be turned at frequent intervals to prevent corrosion and damage.
Effective Date: May 23, 2002 NB Publication: 01228
@NORTHERN
r:
SIDWER
300 Series Ball Bearings
Procedure For Applying Lubricant To Bearings Apply sufficient grease when lubricating to cause some purging of grease at the seals. Lubricant Use a multi-purpose ball bearing grease of NLGI Grade 2 with rust inhibitors and antioxidant 'additives. An oil viscosity of 100 cSt at 40 C is recommended. Grease for high speed applications should be dynamically stable and must not churn or whip. It is not good practice to mix greases with different oil bases as the results are unpredictable. Several suitable products are: Shell Alvania #2, Exxon (Imperial Oil) Unirex N2, Texaco Premium RB, Chevron SRI #2, and Mobile Mobilux #2. For fans with vertical shafts, consider using a NLGI Grade 3 grease such as Shell Alvania 3 or Exxon Unirex N3. Do not use long fibered greases. Consult CML Northern Blower on proper lubrication if bearings are subjected to temperatures below -10C (15F) or above 80C (175F). Lubrication Interval Table
RELUBRICATION SHAFT DIAMETER 1-3/16 1-7/16 1-11/16 1-15/16 2-3/16 2-7/16 2-11/16 2-15/16 3-3/16 3-7/16 3-15/16 INTERVAL IN MONTHS OF OPERATION SHAFT SPEED IN RPM
500
6 6 6 6 6 6 6 6 6 6 6
1000
6 6 6 6 6 6
1500
6 6 6 6
2000 4 4 4 4 4 4
2 2 2 1 1
2500 4 4 4 4
2 2 1 1 1
3000 4 4
2 2 1 1 1
3500
2 2 2 2 1 1
4000
2 2 1 1
4 4
2 2 2 2 2
4 4 4 4 4
Notes: 1. Increase the frequency or lubrication in conditions of abnormal temperature, moisture, or dirt. 2. Bearings may run hot for a short time during the "run-in" period, or just after lubricating the bearings. Storage If the fan is to be idle and not operating for an extended period of time, bearings should be protected as recommended by the manufacturer. The bearings should be completely filled with grease and the fan shaft should be turned at frequent intervals to prevent corrosion and damage.
@NORTHERN BI.DWER
22400 Series Double Row Spherical Roller Bearings
Procedure For Applying Lubricant To Bearings Apply sufficient grease when lubricating to cause some purging of grease at the seals. Lubricant Use a multi-purpose ball bearing g-ease of NLGI Grade 2 with rust inhibitors and antioxidant additives. An oil viscosity of 100 cSt at 40 C is recommended. Grease for high speed applications should be dynamically stable and must not churn or whip. It is not good practice to mix greases with different oil bases as the results are unpredictable. Several suitable products are: Shell Alvania #2, Exxon (Imperial Oil) Unirex N2, Texaco Premium RB, Chevron SRI #2, and Mobile Mobilux #2. Do not use long fibered greases. Consult CML Northern Blower on proper lubrication if bearings are subjected to temperatures below -10C (15F) or above BOC (176F). Lubrication Interval Table
RELUBRICATION SHAFT DIAMETER 1-11/16 1-15/16 2-3/16 2-7/16 2-11/16 2-15/16 3-3/16 3-7/16 3-11/16 3-15/16 INTERVAL IN MONTHS OF OPERATION SHAFT SPEED IN RPM
500
6 6 6
1000
4 4 4
2 2 2 2 2 1 1
1500
2 2 2 1 1 1 1 1 1/2 1/2
2000
2 1 1 1
2200
1 1
2700
1
4 4 4 4 4 4 4
Notes: 1. Increase the frequency or lubrication in conditions high vibration, or abnormal temperature, moisture, or dirt. 2. Bearings may run hot for a short time during the "run-in" period, or just after lubricating the bearings. Storage If the fan is to be idle and not operating for an extended period of time, bearings should be protected as recommended by the manufacturer. The bearings should be completely filled with grease and the fan shaft should be turned at frequent intervals to prevent corrosion and damage.
/?
@NORTHERN
BI.DWER
Split Pillow Block Bearings
22500 Series Double Row Spherical Roller Bearings
This Lubrication Instruction is for 22500 series bearing assemblies utilizing the 22200 series bearings only. Procedure For Applying Lubricant To Bearings And Pillow Blocks Bearing and housing must be clean. Pack each bearing full of grease by swiveling the outer ring open, rotating it as necessary to inject the grease, then swiveling the outer ring closed, being careful not use force in the event a roller end catches the corner of the outer ring sphere. Before assembling the pillow block cap to the base, and after completing bearing and base assembly, fill the pillow block base to the bottom of the shaft with the same lubricant that was used to pack the bearing. Prior to mounting the cap to the base, lightly coat the interior of the cap with grease.
Re-pack the pillow block as described above. Lubricant Use a multi-purpose ball bearing grease of NLGI Grade 2 with rust inhibitors and antioxidant additives. An oil viscosity of 100 cSt at 40 C is recommended. Grease for high speed applications should be dynamically stable and must not churn or whip. It is not good practice to mix greases with different oil bases as the results are unpredictable. Several suitable products are: Shell Alvania #2, Exxon (Imperial Oil) Unirex N2, Texaco Premium RB, Chevron SRI #2, and Mobile Mobilux #2. Do not use long fibered greases. Consult CML Northern Blower on proper lubrication if bearings are subjected to temperatures below -30C (-22F) or above (176F).
so-c
For bearings with contact seals, smear a liberal amount of grease on the contacting surface of the seals. Relubrication Of Bearings Supplied With Grease Nipples Refer to Table 1 as a guide for the relubricating interval. The recommended quantity of grease is shown in Table 2. Bearings should be completely repacked at least once every three years. Bearings which are exposed to high temperature or are cperating in a moist or dirty environment should be repacked more often. Relubrication Of Bearings Not Equipped With Grease Nipples Refer to Table 1 as a guide for the relubricating interval. Remove pillow block cap and extract old grease from bearing and pillow block. If it is not practical to swivel the outer ring open, purge the old grease from the bearing by forcing fresh grease through the bearing.
Notes: 1. Increase the frequency or lubrication in conditions of high vibration, or abnormal temperature, moisture, or dirt. 2. Bearings may run hot for a short time during the "run-in" period, or just after lubricating the bearings. 3. If the bearings are equipped with flushable labyrinth seals, the seals should be lubricated once a month. Storage If the fan is to be idle and not operating for an extended period of time, bearings should be protected as recommended by the manufacturer. The bearings should be completely filled with grease and the fan shaft should be turned at frequent intervals to prevent corrosion and damage.
Effective Date: May 23, 2002 NB Publication: 01231 Page 1 of 2
Table 1 RELUBRICATION SHAFTDIA. INCHES INTERVAL IN HOURS OF OPERATION SHAFT SPEED (rpm)
1 3/16 1 7/16 1 11/16 1 15/16 2 3/16 2 7/16 2 11/16 2 15/16 3 3/16 3 7/16 3 15/16 4 3/16 4 7/16 415/16 5 3/16 5 7/16 515/16 6 7/16 615/16
500 8900 7500 7000 6600 6100 5800 5700 5600 5400 5200 4900 4700 4400 4150 3950 3400 3200 2800 2500
700 6200 5300 5050 4800 4500 4350 4200 4100 4000 3800 3550 3200 2950 2600 2300 2150 1900 1650 1500
900 5000 4300 4050 3900 3500 3250 3100 3000 2900 2750 2500 2250 2000 1700 1500 1400 1200 1000 900
1200 3800 3000 2800 2650 2250 2050 1950 1900 1800 1650 1500 1300 1150 1000 850 750 590 530 450
1400 3250 2650 2350 2100 1850 1650 1600 1500 1400 1300 1150 950 750 710 575 510 420 340
1600 2650 2050 1850 1750 1500 1400 1250 1200 1150 1000 860 700 580 490 420 310
1800 2250 1750 1625 1500 1300 1150 975 925 900 800 650 540 450 370
2000 1950 1500 1400 1250 1100 920 840 775 710 610 525 400
2200 1650 1250 1200 1100 900 725 650 590 560 510
2400 1450 1150 1000 875 750 585 550 500 450
2600 1250 950 900 800 600 500 440 400 350
3000 1050 800 700 625 480 350 310 250
3600 825 580 520 460 300 200 150
Lubricants deteriorate in time, and the rate of deterioration is a function of the lubricant used at the operating conditions encountered. Table 1 is based on the use of an age-resistant, average quality grease and is valid for bearing temperatures of 70C (158F) measured on the outer ring. The intervals should be halved for every 15C (2rF) increase above 70C, but the maximum permissible operating temperature for the grease should obviously not be exceeded. Conversely, if the operating temperatures are lower than 70C, the intervals can be lengthened to about twice for operating temperatures of 50C (122F) and below. Where there is risk of the grease becoming contaminated, the relubrication intervals should be reduced. Table 2 SHAFT DlA. INCHES BEARING *NUMBER MAXIMUM SPEED (rpm) GREASE OIL RELUBRICATION QUANITY OZ. GRAMS INITIAL GREASE FILL SNL GRAMS OZ. SAF &SAFD GRAMS OZ.
1 3/16 1 7/16 1 11/16 115/16 2 3/16 2 7/16 2 11/16 215/16 3 3/16 3 7/16 3 15/16 4 3/16 4 7/16 415/16 5 3/16 5 7/16 515/16 6 7/16 6 15/16
22207EKlW33 22209EKlW33 22210EKlW33 22211EKlW33 22213EKlW33 22215EKlW33 22216EKlW33 22217EKlW33 22218EKlW33 22220EKlW33 22222EKlW33 22224EKlW33 22226EKlW33 22228EKlW33 22230EKlW33 22232EKlW33 22234EKlW33 22236EKlW33 22238EKlW33
6300 5300 5000 4500 3800 3400 3200 3000 2600 2200 2000 1900 1800 1700 1600 1500 1300 1300 1200
8000 6700 6300 5600 4800 4300 4000 3800 3400 3000 2800 2600 2400 2200 2000 1900 1700 1700 1600
0.3 0.3 0.4 0.4 0.7 0.7 0.8 1.0 1.1 1.5 1.9 2.2 2.6 3.0 3.5 4.1 4.7 4.9 5.5
8 10 10 13 19 20 23 27 32 41 53 62 74 85 99 116 133 138 156
1.76 2.29 2.64 3.53 6.35 8.11 9.88 11.60 15.20 22.20 30.00 35.30 38.80 49.40 60.00 70.60 84.20 99.00 115.00
50 65 75 100 180 230 280 330 430 630 850 1000 1100 1400 1700 2000 2400 2800 3250
2.50 3.00 4.00 5.00 7.50 9.00 13.00 13.00 14.00 21.00 28.00 40.00 52.00 52.00 60.00 68.00 84.00 96.00 116.00
70 85 113 142 213 255 369 369 397 595 794 1134 1475 1475 1700 1930 2381 2722 3290
*Note: "EK" could be "CCK" for some bearings

Effective Date: May 23, 2002 NB Publication: 01231 Page 2 of 2
@NORTHERN
SWWER
Split Pillow Block Bearings
1500 & 2500 Series Double Row Bearings If it is not practical to swivel the outer ring open, purge the old grease from the bearing by forcing fresh grease through the bearing. Re-pack the pillow block as described above. Lubricant Use a multi-purpose ball bearing grease of NLGI Grade 2 with rust inhibitors and antioxidant additives. An oil viscosity of 100 cSt at 40 C is recommended. Grease for high speed applications should be dynamically stable and must not churn or whip. It is not good practice to mix greases with different oil bases as the results are unpredictable. Several suitable products are: Shell Alvania #2, Exxon (Imperial Oil) Unirex N2, Texaco Premium RB, Chevron SRI #2, and Mobile Mobilux #2. Do not use long fibered greases. Consult CML Northem Blower on proper lubrication if bearings are subjected to temperatures below 30C (-22F) or above BOC (176F). Notes: 1. Increase the frequency or lubrication in conditions of high vibration, or abnormal temperature, moisture, or dirt. 2. Bearings may run hot for a short time during the "run-in" period, or just after lubricating the bearings. 3. If the bearings are equipped with flushable labyrinth seals, the seals should be lubricated once a month. Storage If the fan is to be idle and not operating for an extended period of time, bearings should be protected as recommended by the manufacturer. The bearings should be completely filled with grease and the fan shaft should be turned at frequent intervals to prevent corrosion and damage.
This Lubrication Instruction is for 1500 and 2500 series bearing assemblies utilizing the 1200and 2200 series bearings only. Procedure for applying lubricant to bearings and pillow blocks Bearing and housing must be clean. Pack each bearing full of grease by swiveling the outer ring open, rotating it as necessary to inject the grease, then swiveling the outer ring closed, being careful not use force in the event a roller end catches the corner of the outer ring sphere. Before assembling the pillow block cap to the base, and after completing bearing and base assembly, fill the pillow block base to the bottom of the shaft with the same lubricant that was used to pack the bearing. Prior to mounting the cap to the base, lightly coat the interior of the cap with grease. For bearings with contact seals, smear a liberal amount of grease on the contacting surface of the seals. Relubrication of bearings supplied with grease nipples Refer to Table 1 as a guide for the relubricating interval. The recommended quantity of grease is shown in Table 2. Bearings should be completely repacked at least once every three years. Bearings which are exposed to high temperature or are operating in a moist or dirty environment should be repacked more often. Relubrication of bearings not equipped with grease nipples Refer to Table 1 as a guide for the relubricating interval. Remove pillow block cap and extract old grease from bearing and pillow block.
Effective Date: May 23, 2002 Page 1 of 2 NB Publication: 01634
Table 1
DOUBLE ROW BALL BEARINGS SHAFTDIA. INCHES SHAFT SPEED (rpm)
500 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760
700 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760
900 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760
1200 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760
1400 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760 8400
1600 8760 8760 8760 8760 8760 8760 8760 8500 8400 8000 7250
1800 8760 8760 8760 8760 8760 8300 8000 7700 7500 7000 6200
2000 8760 8760 8760 8760 8100 7400 7100 6800 6400 5900 5000
2200 8760 8760 8500 8200 7500 6600 5450 5900 5400 4600 3800
2400 8760 8400 8000 7600 6800 5850 4900 4900 4500 3750 2650
2600 8760 7800 7400 7000 6000 4850 4400 3900 3500 2500 1750
3000 8000 7000 6450 4500 4800 3500 2900 2500 2000 1200 750
3600 7000 5800 5050 3500 3000 2000 1500 900 580 180
.
13/16 17/16 111/16 115/16 23116 27/16 211/16 215/16 33116 37/16 315/16
/" ~
Lubricants deteriorate in time, and the rate of deterioration is a function of the lubricant used at the operating conditions encountered. Table 1 is based on the use of an age-resistant, average quality grease and is valid for bearing temperatures of 70C (158F) measured on the outer ring. The intervals should be halved for every 15C (2rF) increase above 70C, but the maximum permissible operating temperature for the grease should obviously not be exceeded. Conversely, if the operating temperatures are lower than 70C, the intervals can be lengthened to about twice for operating temperatures of 50C (122F) and below. Where there is risk of the grease becoming contaminated, the relubrication intervals should be reduced. Table 2
SHAFT DIA. BEARING SPEED (rpm) NUMBER GREASE OIL QUANITY OZ. GRAMS BEARING NUMBER SPEED (rpm) GREASE OIL QUANITY OZ. GRAMS OZ. SNH GRAMS SAF & SAFD OZ. GRAMS
13/16 17/16 111/16 115/16 23/16 27/16 211/16 215/16 33/16 37/16 315/16
1207EK 1209EK 1210EK 1211 EK 1213EK 1215K 1216K 1217K 1218K 1220K 1222K
9000 7800 7000 6300 5300 4800 4500 4000 3800 3400 3000
11000 0.2 9000 0.3 8500 7500 6300 5600 5300 4800 4500 4000 3600 0.3 0.4 0.5 0.6 0.6 0.7 0.8 1.1 1.3
6 6 9 11 14 16 18 21 24 31 38
2207EK 2209EK 2210EK 2211 EK 2213EK 2215K 2216EK 2217K 2218K 2220K 2222K
8500.0 7000.0 6300.0 6000.0 5000.0 4500.0 4000.0 3800.0 3600.0 3200.0 2800.0
10000 8500 7500 7000 6000 5300 4800 4500 4300 3800 3400
0.3 0.3 0.4 0.4 0.7 0.7 0.8 1.0 1.1 1.5 1.9
8 10 10 13 19 20 23 27 32 41 53
1.76 2.29 2.64 3.53 6.35 8.11 9.88 11.6 15.2 22.2 30
50 65 75 100 180 230 280 330 430 630 850
.
1.7 1.9 2.5 3.8 4.9 5.8 7 7.2 15 16
.
48 54 71 110 140 165 200 205 425 455
*Note: "EK" could be "CCK" for some bearings
Effective Date: May 23, 2002 Page 2 of 2 NB Publication: 01634
@NORTHERN
BI.DWER
/
lubrication Guide
"M" Series Ball Bearings
Dodge SeM, SKF SYM & FYM
Procedure For Applying Lubricant To Bearings Apply sufficient grease when lubricating to cause some purging of grease at the seals. Lubricant . Use a multi-purpose ball bearing grease of NLGI Grade 2 with rust inhibitors and antioxidant additives. An oil viscosity of 100 cSt at 40C is recommended. Grease for high speed applications should be dynamically stable and must not churn or ship. It is not good practice to mix grease with different oil bases as the results are unpredictable. Several suitable products are: Shell Alvania #2, Exxon (Imperial Oil) Unirex N2. Texaco Premium RB, Chevron SRI #2, and Mobile Mobilux #2. For fans with vertical shafts, consider using a NLGI Grade 3 grease such as Shell Alvania 3 or Exxon Unirex N3. Do not use long fibered greases. Consult CML Northern Blower on proper lubrication if bearings are subjected to temperatures below -10C (15F) or above 80C (176F) Lubrication Interval Table
r:
SHAFT DIAMETER 1-3/16 1-7/16 1-11/16 1-15/16 2-3/16 2-7/16 2-11/16 2-15/16
RELUBRICATION INTERVAL IN MONTHS OF OPERATION SHAFT SPEED IN RPM
1000
12 12 12 12 12 12 12 12
1500
12 12 12 12 10 10 10
1800
12 12 . 12 10
2000
12 10 10
2500
10 9
3000 8 8
6
3500 8
6
,,""',
4000
6
8 8
6 6 6
4 rw 4
8 8 8
6
8 8 8 8
6
4 4 4
-* -
Notes: 1. Increase the frequency of lubrication in conditions of abnormal temperature, moisture, or dirt. 2. Bearings may run hot for a short time during the "run-in" period, or just after lubricating the bearings. 3. Lubrication intervals should be halved for every 15C (27F) increase above 70C (158F), but the maximum permissible operating temperature for the grease must not be exceeded. Storage If the fan is to be idle and not operating for an extended period of time, bearings should be protected as recommended by the manufacturer. The bearings should be completely filled with grease and the fan shaft should be turned at frequent intervals to prevent corrosion and damage.
CML Northern Blower Inc. 901 Regent Avenue, Winnipeg, Manitoba, Canada, R2C 2Z8
FAN EQUIPMENT OPERATION MANUAL

Fan Serial No. _
I----
,
,
57~ REF.
2.9372 2.9355
~VJBLDWER
r-:-: NORTHERN
TABLE OF CONTENTS
STANDARD TERMS AND CONDITIONS Standard Terms and Conditions Warranty and WARRANTy
4
4 5
OPERATION
MANUAL - FAN EQUIPMENT
6
6
SAFETY PRECAUTIONS
INSTALLATION,
OPERATION
& MAINTENANCE 7 7 7 7 8 8 9 10 11
OF CML NORTHERN Introduction Shipment & Receiving Handling Storage
BLOWER FAN EQUIPMENT
Installation of Fan Equipment.. V-Belt Drive Installation Operation of Fan Equipment Maintenance of Fan Equipment
FAN TROUBLE-SHOOTING OTHER INSTALLATION
CHART AND LITERATURE
14 15
INSTRUCTIONS
Published by
CML NORTHERN BLOWER INC.

Telephone 204-222-4216 Telefacsimile 204-222-7601 901 Regent Avenue West WINNIPEG, MANITOBA CANADA R2C 2Z8 1990
CML NORTHERN BLOWER INC. STANDARD TERMS AND CONDITIONS and WARRANTY
STANDARD TERMS AND CONDITIONS
FREIGHT CLAIMS: TERMS OF PAYMENT: Terms of payment are net thirty (30) days Notwithstanding such approval, if in subject to the prior approval of the CML Northern Blower Inc. ("CML Northern") Credit Department. CML Northern's judgement the customer's financial condition does not warrant the continuation of production or shipment on the original terms, CML Northern reserves the right to request payment in Unless otherwise expressly agreed in writing, The delivery of the product is made FOB CML Northern Plant. liability and responsibility for damage and shortage sibility and the customer
of CML Northern for the product ceases in transit are the customer's respon-
upon delivery of the product in good order to the carrier. All claims
must file the claim against the carrier. unless such
Claims for factory shortage will not be recognized
~dvance. Overdue accounts will bear interest at the prevailing bank rate charged to CML Northern.
alleged shortage is reported to CML Northern in writing within ten (10) days after receipt of the product.
ACCEPTANCE
AND PRICES:
Prices quoted for products manuby the pur-
TAXES:
The amount of any present or future taxes shall be added
factured by CML Northern are subject to acceptance Proposal.
to the price contained herein and shall be paid by the customer in the same manner and with the same effect as if originally added thereto. DELAYS: CML Northern shall not be liable to the customer orto any third party for any delays caused by riots, strikes,lockouts, fire, floods, lack of transportation, weather,
chaser no later than thirty (30) days from the date of the Quotation -
Prices quoted for items which are not manufactured by CML Northern such as motors and drives, etc. are subject to change at any time the cost of such items charged to CML Northern changes.
accidents, the failure of CML obligations, break-
Northern's suppliers to meet their contractual Prices on orders for products manufactured by CML Northern are firm provided approval and release for production and shipment is received from the customer within ninety (90) days of the date of CML Northern's receipt of the customer's order and the products are PRODUCT CHANGES: CML Northern shipped within twelve (12) months of the date of CML Northern's receipt of the customer's order. When such approval and release for production and shipment is received after ninety (90) days of the date of CML Northern's receipt of the customer's order or products are RETURNED GOODS: downs, or any other contingency
beyond CML Northern's reasonshall
able control and receipt of the product by the customer
constitute a waiver of all claims for loss or damage due to delay.
reserves
the right to
change or modify the product in the interest of continuous product improvement without liability.
shipped after twelve (12) months of the date of CML Northern's receipt of the customer's order, such prices are subjectto adjustment to CML Northern prices in effect on the date approval and release from customer is received by CML Northern or at time of shipment.
Goods may not be returned except by the
written permission of the President, General Manager or General Sales Manager of CML Northern and when so returned will be subject to a handling charge and transportation costs.
Orders for non-stock equipment released for production and scheduled by CML Northern cannot be rescheduled by the customer unless it is done at least eight (8) weeks before the CML Northern scheduled shipping date. If production is started the customer must accept delivery when the order is ready for shipment.
MODIFICATION:
These Standard Terms and Conditions may not
be modified except by written agreement signed by the President, General Manager or General Sales Manager of CML Northern. The failure of CML Northern to object to provisions customer's purchase orders not be deemed waiver of the Standard contained in the shall or other communications
Terms and Conditions No other terms and
CANCELLATIONS:
Accepted orders cancelled by the customer are The cancellation charges on
hereof or acceptance
of such provisions.
subject to cancellation charges for all expenses incurred and commitments made by CML Northern. completed items will be one hundred (100%) percent of the selling price. The aforementioned cancellation charges shall not in any way whatsoever limit CML Northern's other remedies it may have at law including, without limiting the generality of the foregoing, the ability of CML Northern to claim and recover any amounts or damages to which CML Northern would otherwise be entitled by reason of accepted orders cancelled by the customer.
conditions other than the Standard Terms and Conditions contained herein and those terms and conditions with respect to the description of product, quantity and price contained in the "QuotationProposal" shall be binding upon CML Northern unless made in writing and signed by the President, General Manger or General Sales Manager of CML Northern. Without restricting the generality of the foregoing, agents and sales representatives of CML Northern do not have authority to modify these Standard Terms and Conditions.
WARRANTY
(5) CML Northern Blower Inc. (the "Seller") warrants products of its manufacture (the "product", "equipment" or "fan") to be free of The performance specifications of the Seller's fan equipment outside of the laboratory may vary widely and differ from the performance contained in its sales literature. Therefore, the
defects in material and workmanship
if properly installed, and cared and with competent
Seller cannot and does not guarantee or warrant the performance of its fan equipment at the Purchaser's location. (6) ALL WARRANTIES OF THE SELLER, EXPRESS OR IM-
for, and operated under normal conditions,
supervision, all in accordance with the Seller's Operation Manual. If any questions exist as to whether the proposed operation of the Seller's equipment is within "normal conditions" for such equipment, details of such proposed operation should be provided to the Seller at its Winnipeg factory. The Seller will review the proposed operation of the equipment (at a fee) and advise ifthe proposed operation is acceptable.
PLIED, WITH RESPECT TO MOTORS, SWITCHES, CONTROLSOR OTHER ACCESSORIES NOT MANUFACTURED BY THE SELLER, CHANTABILITY, INCLUDING WARRANTIES OF MER-
QUALITY OR FITNESS FOR ANY PAR-
TICULAR PURPOSE, ARE HEREBY EXCLUDED. under this warranty is limited to the at its option at its Winnipeg factory, of
(1)
The Seller's obligation repair or replacement,
(7)
The Seller shall have no liability under the terms of this Warranty or otherwise where the Purchaser undertakes the responsibility of mounting the fan wheel directly to the motor
any defective part or parts which shall within one (1) year after shipment thereof to the original purchaser (the "Purchaser"), be returned to its Winnipeg factory with transportation charges prepaid by the Purchaser and upon such repair or replacement the Seller shall have fulfilled all its obligations to the Purchaser. The Seller will not be liable, in any circumstances, for costs or
or turbine shafts withoutthe Seller having inspected and tested the assembled unit (at a fee) before the fan is operated in any fashion. If the Seller does not inspect and test the assembled unit within ten (10) days of being requested to do so by the Purchaser and receipt of payment of the aforementioned inspect and test the assembled unit. fee,
expenses incurred by the Purchaser or any person claiming through the Purchaser equipment in the removal or replacement of
the Seller shall be deemed to have waived its requirement to
alleged to be defective.
Except as specifically (8) The Seller shall have no liability under the terms of this warranty or otherwise until the Purchaser has made full
provided herein, the Seller will not be liable, in any circumstances, for any loss or damage of whatever nature or kind (including, without limiting the generality of the foregoing, loss or damage or
payment to the Seller forthe product or equipment to which this warranty is to apply. (9) NOWARRANTIES INCLUDING QUALITY WHATSOEVER, EXPRESS OR IMPLIED,
direct, indirect, incidental or consequential
damage resulting from business interruption) should the equipment be so defective as to preclude the remedy of warranted defects by repair or replacement. In such event, the Pur-
WARRANTIES
OF MERCHANTABILITY, PURAS EX-
chaser's sole and exclusive remedy shall be the refund of the purchase price paid by the Purchaser for all the defective equipment.
OR FITNESS
FOR ANY PARTICULAR EXCEPT
POSE, ARE MADE BY THE SELLER PRESSLY PROVIDED HEREIN.
(2)
The Seller shall not be liable forthe repair or replacement of any such defective part or parts, or for loss, damage, or any
(10) The terms of this warranty may not be modified except by written agreement signed by the President, General Manager or General Sales Manager of the Seller. The Seller's failure to object to provisions contained in the Purchaser's purchase orders or other communications shall not be deemed waiver
expense of repairs when any adjustment, alteration or repair shall have been made or attempted except if such adjustment, is first obtained. alteration outside of its factory, or repair outside its
factory is made or attempted after the Seller's written consent
of the terms and conditions hereof nor acceptance of such provisions. No representations or warranties other than those contained herein shall be binding upon the Seller unless made
(3)
The Seller shall not be liable for any corrosion or fouling caused by any foreign substance deposited in or on the equipment.
in writing and signed by the President, General Manager or General Sales Manager of the Seller. Without restricting the generality of the foregoing, agents and sales representatives
(4)
Because the Seller is unaware of any forms of construction, materials, alloys or coatings which will successfully resist all abrasion, erosion, corrosion, or deterioration from excessive heat, the Seller's warranty does not apply when any of its products or equipment are subjected to conditions which
of the Seller do not have authority to modify the the terms ofthis Warranty or make representations those contained herein. or warranties other than
cause such abrasion, erosion, corrosion or deterioration from excessive heat or any damages similar or related thereto.
CML NORTHERN BLOWER INC. OPERATION MANUAL - FAN EQUIPMENT

SAFETY PRECAUTIONS
FAN EQUIPMENT CAN BECOME A SOURCE OF INJURY AND DEATH IF NOT PROPERLY INSTALLED, OPERATED OR MAINTAINED. Do not exceed the maximum operating temperature or speed limits for which the fan equipment was designed. Limits for some lines of fan equipment are given in CML Northern Blower Inc. ("CML Northern") catalogues. Limits for non-catalogued lines of fan equipment should be obtained in writing from the CML Northern Winnipeg factory and not otherwise. Do not rely on limits obtained in any other manner. The user should make all personnel who operate or maintain the fan equipment aware of all possible hazards. THE RESPONSIBILITY FOR PROVIDING SAFETY ACCESSORIES FOR FAN EQUIPMENT SUPPLIED BY CML NORTHERN IS THAT OF THE USER OF THE FAN EQUIPMENT. CML Northern sells its fan equipment with or without safety accessories, and accordingly, it can supply standard safety accessories upon receipt of an order. Ensure that all necessary safety accessories have been installed before operation of the fan equipment.
The warning notice set out below should be affixed upon the fan equipment:
CML NORTHERN
BLOWER INC.
WARNING
This fan has rotating parts and may be hot. Keep body, hands and foreign objects away from inlet and outlet. Do not touch fan or motor during operation. Operate, install and maintain QDJ in strict accordance with safety practices and instructions in manufacturer's Operation Manual. Do not exceed the maximum operating temperature, speed,or vibration level identified in the manufacturer's catalogues and Operation Manual. Untrained personnel should never operate, install, adjust or maintain fan or motor. ADDITIONAL SAFETY ACCESSORIES FOR THE FAN EQUIPMENT ARE AVAILABLE FROM THE MANUFACTURER. THE RESPONSIBILITY FOR PROVIDING SUCH ADDITIONAL SAFETY ACCESSORIES IS THAT OF THE USER OF THE FAN EQUIPMENT. CONSULT THE MANUFACTURER'S OPERATION MANUAL FOR GUIDANCE. Before starting maintenance work, lock disconnect switch in the off position,de-energize and disconnect all power sources to the motor and to accessory devices and secure fan impeller. Cleanout doors must be secure during operation. Unsecured clean out doors may shoot open during operation because of pressure build up inside the fan. Do not start-up when fan impeller is rotating backwards. FAILURE TO FOLLOW MANUFACTURER'S INSTRUCTIONS AS TO OPERATION, INSTALLATION, ADJUSTMENT, MAINTENANCE, SAFETY EQUIPMENT OR APPROPRIATE OPERATING CONDITIONS COULD RESULT IN DAMAGE TO THIS EQUIPMENT, DAMAGE TO OTHER EQUIPMENT, PERSONAL INJURY OR DEATH.
Should the warning notice not be affixed to the fan equipment purchased, CML Northern will supply such a warning notice upon request made to its head office. The user of the fan equipment, in making its determination as to the appropriate safety accessories to be installed and any additional warning notices to be affixed upon the fan equipment, should consider (1) the location of the installation of the fan equipment, (2) the accessibility of employ-
ees and other persons to the fan equipment, (3) any adjacent equipment, (4) applicable building codes, and (5) applicable health and safety legislation. Users and installers of the fan equipment should read "RECOMMENDED SAFETY PRACTICES FOR AIR MOVING DEVICES"which is published by the Air Movement and Control Association, 30 West University Drive, Arlington Heights, Illinois, 60004.
INSTALLATION, OPERATION & MAINTENANCE OF CML NORTHERN FAN EQUIPMENT

INTRODUCTION The purpose of this section is to aid in the proper installation, operation, and maintenance of CML Northern fan equipment. These instructions are intended to supplement good general practices and are not intended to cover detailed instruction procedures. The receipt, handling, installation, operation and maintenance of CML Northern fan equipment is the responsibility of the user. It is important that the installation and start-up of the fan equipment be supervised or inspected by personnel experienced in such work and equipment. Trained personnel are available from CML Northern, and arrangements for such supervision and inspection (at a fee) should be made through your local CML Northern representative or at CML Northern's head office. Failure to arrange for such supervision or inspection may affect or void the CML Northern Warranty (please refer to paragraph 7 of CML Northern's Warranty).
Centrifugal fans are best lifted using straps attached to structural base members of the fan. DO NOT LIFT CENTRIFUGAL FANS BY THE FAN SHAFT, IMPELLER, FLANGES OR INLET SUPPORTS. Roof ventilators should be lifted by using straps attached to lifting lugs or base only. Spreader bars should also be used to avoid damage to the butterfly damper assembly or the weatherhood. DO NOT LIFT ROOF VENTILATORS BY THE BUTTERFLY DAMPER ASSEMBLY OR WEATHERHOOD. Centrifugal rotor assemblies (i.e. impeller and shaft assemblies) have been designed to be supported by the shaft, and should be lifted by slings around the shaft as close as possible to the hub on each side of the impeller (wheel). Slings should not press against the side plates of the wheel as this may damage and distort the wheel. A spreader bar should be used when lifting the rotor assembly (Figure 1). The wheel should never rest on the side plates or blades, nor should the rotor assembly be lifted by any components of the fan wheel. To do so may damage the rotor assembly and destroy the dynamic balance that is necessary for low vibration operation. If this balance is destroyed, rebalancing of the rotor assembly will be necessary. If the wheel and shaft have not been assembled, the fan wheel may be lifted by a timber or wrapped bar of sufficient strength passed through the hub. The finished bore of the hub and the bearing surfaces of the shaft must also be protected from damage.
SHIPMENT & RECEIVING CML Northern has thoroughly inspected the fan equipment at its factory and has prepared the fan equipment for shipment in accordance with the uniform freight classification followed by all carriers. The fan equipment should be in perfect condition when received, unless damaged in transit. Upon acceptance by the carrier, as evidenced by a signed bill of lading, the carrier accepts responsibility for all shortages or damage, whether concealed or evident. Claims covering shortages or damage must be made to the carrier by the purchaser. Any shortages or damage should be noted by the user on the delivery receipt. The fan equipment may contain components manufactured by manufacturers other than CML Northern. Such other manufacturers may have furnished instructions and/ or other literature concerning their component. A list of such instructions and/or other literature is forwarded with the fan equipment (see page 15 of this manual). If any of the items on the list are missing, please contact your CML Northern representative, CML Northern at it's head office or contact the component's manufacturer directly.
HANDLING The fan equipment should be handled with care. Some fans are provided with lifting lugs or holes for easy handling. Others must be handled using nylon straps or well-padded chains and cables which protect the fan's coating and housing. Spreader bars should be used when lifting large parts. Axial fans should be lifted by using straps around the fan housing only. DO NOT LIFT AXIAL FANS BY THE MOTOR, MOTOR BASE, IMPELLER OR FLANGES.
Fig. 1 Correct use of spreader bar when lifting centrifugal rotor assembly.
(4)
Ducts must be independently supported, and must never be supported by the fan. Use flexible duct connections wherever possible. The independent mounting of stacks and ducts to the fan will ensure that the fan will not be twisted or deformed with the addition of external loads. It is recommended that access doors be placed in ductwork just ahead of the fan inlet and just behind the fan outlet for ease of inspection and maintenance. IN ORDER TO AVOID EQUIPMENT DAMAGE AND PERSONAL INJURY ACCESS DOORS IN A DUCT SYSTEM SHOULD BE SECURELY CLOSED AND SHOULD NEVER BE OPENED WITH THE FAN RUNNING. Lubricate fan bearings in strict accordance with bearing manufacturer's recommendations. Lubricate bearings upon receipt of fan. Do not overlubricate. Bearings should be locked to the shaft. Ensure that locking mechanisms on bearings are in correct position and that locking mechanisms are fastened before operation of fan. Flexible couplings must be installed and maintained in accordance with the coupling manufacturer's instructions. Refer to fan submittal drawings for details of drive arrangements and the generallocation of the coupling halves on the fan and motor shafts.
lei
L L
(5)
B
1) Dimensions 'A' & '8' must be measured at right angles to the fan shaft. 2) Dimension 'C' should be as large as physically possible to allow for an accurate determination.
"'
I
~ ~
(6)
~ '\ u
-,
./
II
) )
(7)
Fig. 2 Determination
of parallel shafts.
V-BELT DRIVE INSTALLATION V-belt drive systems are the most common type of belt systems used to drive fan equipment. Other types of belt systems are used ("cog", belts etc.) but are net discussed in this manual. Proper alignment is essential to long fan bearing, driver bearing, v-belt and sheave life. Ensure that driver and fan shafts are parallel. The most common causes of misalignment are nonparallel shafts and improperly located sheaves. Where shafts are not parallel, v-belts on one side are drawn tighter and pull more than their share of the load. As a result, these v-belts wear out faster, requiring the entire set to be replaced before it has given maximum service. If the sheaves are misaligned, v-belts will enter and leave the grooves at an angle, causing excessive v-belt and sheave wear. Shaft alignment can be checked by measuring the distance between the shafts at two or more locations as shown in Figure 2. If the distances are equal, the shafts are parallel. Check the location of the sheaves on the shaft with a straight edge or a length of string. If the sheaves are properly aligned the string will touch them at the points indicated by the arrows in Figure 3. Rotating each sheave one-half (1/2) revolution will indicate if the sheave is misaligned or the shaft is bent. Correct any causes of misalignment.
_____
Straightedge
If sheaves are straight and aligned the string or straightedge will touch them simultaneously at all four points indicated by the arrows
Fig. 3 Sheave alignment.
......... --==--~
":::::--jA
----..;,.
--
TooTight
-- -- -
--.--
---=-=
Proper Tension (Slight Bow)
- -- --::::- -:::::-=- -~
Too Loose
Fig. 4 Belt tension.
Always use matched v-belts and never mix new and used v-belts on a drive. Install v-belts correctly: (i) Shorten the center distance between the driven and driver sheave so the v-belts can be slipped into the sheave groove without damage. While the v-belts are still loose on the drive, rotate the drive until all the slack is on one side. Then increase the center distance until the v-belts are snug (Figure 4). NOTE: Never "roll" or "pry" the v-belts into the sheave grooves. This can damage the v-belt cords and lead to v-belt turnover, short life, or actual breakage. Moreover, it is both difficult and unsafe to install v-belts this way. Keep takeup rails, motor base, or other means of center distance adjustment free of dirt, rust, and grit. Lubricate adjusting screws and slide rails as required. Operate the drive and fan a few minutes to seat the v-belts in the sheave grooves (operate the fan equipment ~ after following the procedure listed in the "Operation of Equipment" section of this manual). Observe the operation of the drive under its highest load condition (usually starting). A slight bowing of the slack side of the drive indicates proper tension. If the slack side remains taught during peak load, the drive is too tight. Excessive bowing or slippage indicates insufficient tension. If the v-belts squeal severely as the motor comes on or at some subsequent peak load, they are not tight enough to deliver the torque demanded by the fan. The fan should be stopped and the v-belts tightened.
(iii)
Check the tension on a new drive frequently during the first day of operation by observing the slack side span. After a few days of operation the belts will seat themselves in the sheave grooves and it may become necessary to readjust so that the drive again shows a slight bow in the slack side.
OPERATION OF FAN EQUIPMENT (1) Lock out all power sources. (2) Ensure that bearings are properly aligned and lubricated with special attention to the locking mechanisms, cleanliness, and possible corrosion. Bearings showing signs of corrosion must be replaced priorto operation of fan equipment. Check set screws and keys (or taperlock hub if present) in fan impeller, and bolts on cooling wheel. Check foundation for tightness. bolts and other hardware
(ii)
(3)
(4)
(5)
(6) (7)
Ensure that the fan housing, ducts, etc., are free of foreign objects. Ensure that all access doors are secure. Check the impeller to inlet cone and impeller to fan housing clearance to ensure that there is no interference. Turn the impeller by hand, ensuring that it rotates freely. On belt drive fans, check sheave alignment and v-belt tension (refer to the section entitled "V-BELT DRIVE INSTALLATION" on page 9 of this manual).
(8)
10--------------------------------------------------------------
(9)
If the fan is equipped with damper or variable inlet vane, close same to lessen starting load on motor. Ensure any dampers or variable inlet vanes furnished with the fan, or used in conjunction with the fan, do not stick or bind. If an automatic control mechanism is used to operate the damper or variable inlet vane, adjust the limits of travel of the automatic control mechanism in accordance with the control manufacturer's instructions to avoid putting force on the damper or variable inlet vane when it is fully opened or fully closed. If the fan is driven by an electric motor, read instructions of motor and starter manufacturer. Ensure that the motor and starter are set up in compliance with the motor and starter manufacturers' instructions prior to any application of electric power. If the fan is powered by some other form of driver, read the manufacturer's instructions prior startup. If the fan is equipped with water cooled bearings turn on the water supply to the bearings prior to starting the fan. Consult the water cooled bearing manufacturer's instructions. If the fan is to handle a "hot gas" (i.e. a gas with a temperature greater than 150F [65C)) it is imperative that the fan be subject to only a slow gradual rate of gas temperature change, not to exceed a rate of 15F/minute (8C/minute). When the fan is being Ql.!1J!l operation the temperature of the gas must D..Q1 rise at a rate greater than 15F/minute (8C/minute). ~ subject a "cold" fan to a "hot" gas stream. When the fan is being taken out of operation the temperature of the gas must D..Q1 decline at a rate greater than 15F/minute (8C/minute), and when the gas temperature has reached a level of 150F (65C) or less it is imperative that the fan be operated at this temperature for a period of time sufficient to allow the entire fan structure to reach an equilibrium temperature of 150F (65C). Only when the entire fan structure has reached an equilibrium temperature of 150F (65C) or less can the fan be shut off and removed from operation. Failure to follow these instructions may result in damage to the fan equipment. NEVER EXCEED THE MAXIMUM OPERATING TEMPERATURE OR SPEED FOR WHICH THE FAN WAS DESIGNED. Connect the power source. Fan impeller should always be stationary prior to startup. Startup while fan impeller is rotating backwards can cause damage.
(15)
Apply power to the driver momentarily (i.e. "bump") to check for proper rotation. Any dampers or other air control devices in the system should be at least partially closed during starting periods to reduce power requirements. Damper closure is particularly important in the case of a fan designed for high temperature operation being "run in" at a temperature less than design temperature. Apply power to the driver and allow the fan to come up to design speed. Turn off. Look and listen for any unusual noise or mechanical action while the impeller is still spinning. If any are noticed, lock out all power sources, locate cause and correct. Lock out all power sources and recheck tightness of all set screws, keys, foundation bolts and any other hardware. The initial start up will tend to relieve their tightness and they may require re-tightening. Reconnect all power sources. It is recommended that upon fan installation, the operating vibration levels be checked to ensure that the levels do not exceed the levels indicated on the inspection sheets shipped with the fan and/or the vibration levels set forth in the "Vibration" section of this manual.
(16)
(10)
(17)
(11 )
(18) (19)
(12)
Once it has been determined that the fan equipment is operating satisfactorily, it should be operated, if practical, for at least eight (8) continuous hours. Operation should be monitored at least once each hour during this period. Inspection should be made for any change of operation during this period. Some bearings will have to "run in" and will heat up during this period. The maximum bearing temperature should not exceed 200F (93C). It is normal for bearings lubricated with grease to purge a small amount of the grease through the bearing seals during run-in. NOTE THAT ALL BOLTS, SETSCREWS AND V-BELTS SHOULD BE RE- TIGHTENED AFTER TWO (2) DAYS OF INITIAL OPERATION. MAINTENANCE OF FAN EQUIPMENT BEFORE STARTING MAINTENANCE WORK ON FAN EQUIPMENT LOCK MOTOR, LOCK DISCONNECT SWITCH IN THE OFF POSITION, DE-ENERGIZE AND DISCONNECT ALL POWER SOURCES TO THE MOTOR AND TO ACCESSORY DEVICES, AND SECURE FAN IMPELLER. Bearings and Lubrication Selection ofthe correct fan bearing lubricant and lubrication intervals depends on several factors. Extreme high or low temperatures and dirty or damp surroundings are all conditions that will create a requirement for more frequent lubrication or special lubricants. READ THE BEARING
(13) (14)
------------------------------------------------------------11
MANUFACTURER'S INSTRUCTIONS TO DETERMINE THE TYPE AND FREQUENCY OF BEARING LUBRICATION REQUIRED. THE MOTOR BEARINGS SHOULD BE LUBRICATED IN ACCORDANCE WITH MOTOR MANUFACTURER'S LUBRICATION INSTRUCTIONS AND RECOMMENDATIONS SHOULD BE FOLLOWED CLOSELY. Bearing failure may be caused by failure to lubricate as often as required, use of an excessive quantity of lubricant or the use of incompatible lubricants. Excessive vibration, especially if the bearing is not rotating, will also cause bearings to fail. Bearings must also be protected from water and moisture to avoid internal corrosion. Bearings are susceptible to damage from exposure to excess shaft heat transfer which may occur when a fan operating at a temperature greater than 200F (93C) is shut down without a sufficient period of gradual temperature reduction. See section (12) of "Operation of Fan Equipment" set forth on page 11 of this manual. Bearing Replacement Replacement of fan bearings should not be required for many years if cared for strictly in accordance with bearing manufacturer's instructions. The procedure used to replace fan bearings will vary depending on the type of fan and the type of bearing. It is important that the replacement of bearings be supervised or inspected by personnel experienced in such work and equipment. Trained personnel are available from CML Northern and arrangements for such supervision or inspection (at a fee) should be made through your local CML Northern representative or at CML Northern's head office. Variable Inlet Vane Once a year, the variable inlet vane coverplate should be removed and the moving parts re-packed with grease. The lubrication interval should be increased where moisture or particles are present in the airstream. CAUTION: Where automatic control mechanisms are used to operate the variable inlet vane, care should be taken to correctly adjust control mechanism stroke limits as OVERTRAVEL MAY DAMAGE THE VARIABLE INLET VANE OPERATING MECHANISM. Motors DO NOT OPERATE THE MOTOR WITHOUT FIRST READING THE MOTOR MANUFACTURER'S INSTRUCTIONS. OPERATE THE MOTOR ONLY IN ACCORDANCE WITH THE INSTRUCTIONS. The fundamental principle of electrical maintenance is to KEEP THE MOTOR CLEAN AND DRY. This requires periodic inspection of the motor. The frequency of the inspections depends upon the type of motor, the service and the motor manufacturer's instructions.
Periodic checks of voltage, frequency and current of a motor while in operation are recommended. Such checks ensure the correctness of frequency and voltage applied to the motor and yield an indication of the fan load. Comparison of this data with previous data will give an indication of the fan performance. Any serious deviations should be investigated and corrected. Spare Parts Spare parts may be ordered through your CML Northern sales office by providing the following information: (1) Part name (e.g. impeller, shaft, motor, bearing, etc). Fan Serial Number from the nameplate. If possible, the fan shaft diameter or bearing size together with the fan class specified on the nameplate.
(2) (3)
DUE TO THE SMALL NUMBER OF PARTS REQUIRED, SPARE PARTS LISTS ARE NEITHER NECESSARY NOR AVAILABLE. Vibration A vibration analyzer must be used to accurately determine the level of fan vibration. Vibration readings should be taken by personnel experienced with vibration analysis and vibration analysis equipment. Trained personnel are available from CML Northern, and arrangements for vibration analysis (at a fee) may be made through your local CML Northern representative or at CML Northern's head office. The fan should IlQ1 be operated unless the vibration velocity of the fan is less than 0.20 inches per second. If the vibration analyzer being used to measure vibration levels will provide only vibration displacement readings refer to Figure 5. Figure 5 is a graph used to determine whether the vibration velocity of a fan is acceptable or unacceptable if the vibration analyser is capable of measuring only the vibration displacement. To utilize Figure 5 it is necessary to identify the following: (1) the vibration displacement in mils (where 1 mil is equal to 1/1 OOOthof an inch). the vibration frequency in cycles per minute (generally taken as the fan speed in rpm).
(2)
Find the vibration displacement on the left vertical axis of Figure 5, and the vibration frequency on the horizontal axis. DO NOT OPERATE THE FAN if the point of intersection of these values lies in the region labelled "UNACCEPTABLE". All points in the region labelled "UNACCEPTABLE" are indicative of vibration velocities exceeding 0.20 inches per second and corrective action must be taken to reduce the vibration velocity below this value before the fan is returned to normal operation.
12------------------------------------------------------------
o o
C')
o o
60 50 40 30 20 ~
.".
o o io
o o to
0
0 f'.
o 0 o 0 ex) en
o
0 0
o o
C\I
o o io
o o ex)
0 0 0 C\I
o
o io
C\I
o o
o
C')
o o to
C')
Values are for filtered readings taken on the fan bearing caps.
LU
n, ,
o
Z
LU CJ) '<,
,
-c
15 10 8 7 6 5 4 3 2 1.5 ~
>t:: o
LU
q.
~
0
I-
r-.
<,
0 -l
IJ
I--.... <,
t.
LU
~ r
<,
LU
c,
CJ)
-l
r--, .'II
<,
,.. .... ...
~ ~
>
Z
i=
~
CO
~
I-
I, \
z
~
'" .. " ~(
LU
o
CJ)
LU
f'~
.. ,.... "I <, ~J FI~ ) <, ....... .,(

....
a:
'C;: ~~
:5 o,
z
15 1.0
0 0.8 i= 0.7 -c 0.6 a: co 0.5 > 0.4 0.3 0.2
.~ <, A~ ... ,.c v:

r-,
~ ~
<,
r-,i'--
0.20IN/SEC
0.1 VIBRATION FREQUENCY - CPM
Fig. 5 Fan Vibration Severity Chart
--------------------------------------------------------------13
FAN TROUBLE-SHOOTING CHART

PAOBA8lECAUSES
INSUFFICIENT AIR FLOW duct elbows near fan inlet or outlet restricted fan inlet or outlet impeller rotating in wrong direction fan speed lower than design system resistance higher than design dampers shut faulty ductwork dirty or clogged filters and/or coils inlet or outlet screens clogged
EXCESSIVE AIR FLOW
system resistance less than design fan speed too high filters not in place registers or grilles not installed improper damper adjustment
EXCESSIVE HORSEPOWER DRAW
fan speed higher than design gas density higher than design impeller rotating in wrong direction static pressure less than anticipated fan size or type not appropriate for application
EXCESSIVE VIBRATION
accumulated material on impeller worn or corroded impeller bent shaft impeller or sheaves loose on shaft motor out of balance impeller out of balance sheaves eccentric or out of balance bearing or drive misalignment mismatched belts belts too loose or too tight loose or worn bearings loose bearing bolts loose fan mounting bolts weak or resonant foundation foundation unlevel structures not crossbraced fan operating in unstable system condition
INOPERATIVE FAN
blown fuse broken belts loose sheave motor too small wrong voltage
14------------------------------------------------------------
OTHER INSTRUCTIONS and UTERATURE

FAN EQUIPMENT SERIAL No. NENTS MANUFACTURED SUCH MANUFACTURERS BY MANUFACTURERS MAY CONTAIN COMPOOTHER THAN CML NORTHERN.
MAY HAVE FURNISHED INSTRUCTIONS AND/OR OTHER A LIST OF SUCH INSTRUCTIONS
LITERATURE CONCERNING THEIR COMPONENT.
AND/OR OTHER LITERATURE FORWARDED WITH FAN EQUIPMENT SERIAL No.

(1)
IS GIVEN BELOW.
CML NORTHERN BEARING LUBRICATION INSTRUCTIONS:
CJ CJ CJ CJ
(2)
LUBRICATION INSTRUCTIONS FOR DOUBLE ROW SPHERICAL BEARINGS 22500 SERIES SPLIT PILLOW BLOCK.
ROLLER
LUBRICATION INSTRUCTIONS FOR SERIES 22400 SERIES DOUBLE ROW SPHERICAL ROLLER BEARINGS. LUBRICATION LUBRICATION INSTRUCTIONS INSTRUCTIONS FOR 300 SERIES BALL BEARINGS. FOR 200 SERIES BALL BEARINGS.
BEARING MANUFACTURER'S INSTRUCTIONS:

(YES) (_N_O_-.J
(3)
MOTOR MANUFACTURER'S INSTRUCTIONS:

(YES) (NO
(4)
COUPLING INSTRUCTIONS:
CML NORTHERN COUPLING INSTRUCTIONS COUPLING MANUFACTURER'S INSTRUCTIONS (YES) (YES ) (NO) (NO)
(5)
ACTUATOR/CONTROLLER MANUFACTURER'S INSTRUCTIONS:

(YES) (NO)
(6)
OTHER LITERATURE/INSTRUCTIONS:
----------------------------------------------------------15
E.ALDOR
MOTORS AND DRIVES
Integral Horsepower AC Induction Motors OOP, WPI, WPII Enclosure TEFC Enclosure Explosion Proof
Installation & Operating Manual
7/02
MN400
Table of Contents
Section 1 General Information Overview Limited Warranty. .............................................................................. Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receiving ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking 1-1 1-1 1-2 1-4 1-4 1-4 1-4 2-1 2-1 2-1 2-1 2-1 2-2 2-2 2-2 2-2 2-4 2-4 . ................................................................... 3-1 3-1 3-1 3-1 3-1 3-3 3-4 3-5
. Section
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Installation & Operation Overview Location Mounting Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doweling & Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Connection Conduit Box AC Power First Time Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupled Start Up Jogging and Repeated Starts
Section 3 Maintenance & Troubleshooting. Lubrication & Bearings. Type of Grease. Lubrication Intervals
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......................................................................... ...........................................................................
Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories ................................................................................... Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting
MN400
Table 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 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 Caution statement indicates a condition that can cause damage to equipment. This instruction manual is not intended to include a comprehensive listing of all details for all procedures required for installation, operation and maintenance. This manual describes general guidelines that apply to most of the motor products shipped by Baldor. If you have a question about a procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldor distributor for more information or clarification. Before you install, operate or perform maintenance, become familiar with the following: NEMA Publication MG-2, Safety Standard for Construction and guide for Selection, Installation and Use of Electric Motors and Generators. The National Electrical Code Local codes and Practices
Important:
Limited Warranty
1. Baldor Electric motors are warranted for a period of one (1) year, from date of shipment from the factory or factory warehouse against defects in material and workmanship. To allow for stocking and/or fabrication period and to provide one year of actual service, the warranty period is extended for an additional period of six (6) months for 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 buyer of the electric motor for the purpose of resale and to the original purchaser for use. Baldor will, at its option repair or replace a motor which fails due to defects in material or workmanship warranty period if: a. b. during the
2.
the purchaser presents the defective motor at or ships it prepaid to, the Baldor plant in Fort Smith, Arkansa or one of the Baldor Authorized Service Centers and 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 will not pay the cost of removal of any electric motor from any equipment, the cost of delivery to Fort Smith,
Arkansas or a Baldor Authorized Service Center, or the cost of any incidental or consequential damages resulting from 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 implied warranty 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 Baldor's warranty when the cost of such repairs to be paid by Baldor does not exceed Baldor's warranty repair allowance. Baldor will not pay overtime premium repair charges without prior written authorization. The cost of warranty repairs made by centers other than Baldor Authorized Service Centers WILL NOT be paid unless first authorized in writing by Baldor. 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 Center's signed service report to Baldor for further consideration. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Note that Baldor Super-E Premium Efficiency electric motors are warranted for a period of three (3) years \ Baldor IEEE 841 electric motors are warranted for a period of five (5) years. All other terms and conditions of the Limited Warranty statement apply.
5. 6.
7.
MN400
General Information 1-1
9ty Notice:
This equipment contains high voltage! Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt installation, operation and maintenance of electrical equipment. Be sure that you are completely familiar with NEMA publication MG-2, safety standards for construction and guide for selection, installation and use of electric motors and generators, the National Electrical Code and local codes and practices. Unsafe installation or use can cause conditions that lead to serious or fatal injury. Only qualified personnel 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 installation, operation and maintenance of this equipment. Be sure the system is properly grounded before applying power. Do not apply AC power before you ensure that all grounding instructions have been followed. Electrical shock can cause serious or fatal injury. National Electrical Code and Local codes must be carefully followed. Avoid extended exposure to machinery with high noise levels. Be sure to wear ear protective devices to reduce harmful effects to your hearing. This equipment may be connected to other machinery that has rotating parts or parts that are driven by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt to install operate or maintain this equipment. Do not by-pass or disable protective devices or safety guards. Safety features are designed to prevent damage to personnel or equipment. These devices can only provide protection if they remain operative. Avoid the use of automatic reset devices if the automatic restarting of equipment can be hazardous to personnel or equipment. 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. Use proper care and procedures that are safe during handling, lifting, installing, operating and maintaining operations. Improper methods may cause muscle strain or other harm. 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. Unexpected mechanical rotation of the motor parts can cause injury or motor damage. Disconnect all electrical power from the motor windings and accessory devices before disassembly of the motor. Electrical shock can cause serious or fatal injury. 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.
WARNING:
WARNING:
WARNING:
WARNING:
WARNING: WARNING:
WARNING:
WARNING:
WARNING:
WARNING:
1-2 General Information
MN400
Safety Notice Continued WARNING: Motors that are to be used in flammable and/or explosive atmospheres must display the UL label on the nameplate. Specific service conditions NEC 70-599. WARNING: for these motors are defined in
UL rated motors must only be serviced by authorized Baldor Service Centers if these motors are to be returned to a flammable and/or explosive atmosphere. To prevent premature equipment failure or damage, only qualified maintenance personnel should perform maintenance. Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware is adequate for lifting only the motor. Disconnect the load from the motor shaft before moving the motor. If eye bolts are used for lifting a motor, be sure they are securely tightened. 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. To prevent equipment damage, be sure that the electrical service is not capable of delivering more than the maximum motor rated amps listed on the rating plate. If a HI POT test (High Potential Insulation test) must be performed, follow the precautions and procedure in NEMA MG-1 and MG-2 standards to avoid equipment damage.
Caution: Caution:
Caution:
Caution:
Caution:
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.
MN400
General Information 1-3
Section 2 Installation & Operation

Overview
Installation should conform to the National Electrical Code as well as local codes and ~ practices. When other devices are coupled to the motor shaft, be sure to 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 accessible to personnel should provide further protection in the form of guard rails, screening, warning signs etc. The motor should be installed in an area that is protected from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and vibration. Exposure to these 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. 2. OOP motors are suitable only for indoor applications. TEFC and WPII motors are suitable for indoor or outdoor standard service applications.
Location
Mounting
The motor must be securely installed to a rigid foundation or mounting surface to minimize vibration and maintain alignment between the motor and shaft load. Failure to provide a proper mounting surface may cause vibration, misalignment and bearing damage. Foundation caps and sole plates are designed to act as spacers for the equipment they support. If these devices are used, be sure that they are evenly supported by the foundation or mounting surface. After installation is complete and accurate alignment of the motor and load 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 Baldor distributor or authorized Baldor Service Center for further information.
Alignment
Accurate alignment of the motor with the driven equipment is extremely important. 1. 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 to check alignment. The space between coupling hubs should be maintained as recommended by the coupling manufacturer. End-Play Adjustment The 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. Pulley Ratio The pulley ratio should not exceed 8: 1. Belt Drive Align sheaves carefully to minimize belt wear and axial bearing loads (see End-Play Adjustment). Belt tension should be sufficient to prevent belt slippage at rated speed and load. However, belt slippage may occur during starting. Do not over tension belts. Sleeve bearing motors are only suitable for coupled loads. ~
2.
3. 4.
Caution: 5.
MN400
Installation & Operation 2-1
veling & Bolting
After proper alignment is verified, dowel pins should be inserted through the motor feet into the foundation. This will maintain the correct motor position should motor removal be required. (Baldor motors are designed for doweling.) 1. 2. 3. Drill dowel holes in diagonally opposite motor feet in the locations provided. Drill corresponding Ream all holes. Install proper fitting dowels. Mounting bolts must be carefully tightened to prevent changes in alignment. Use a flat washer and lock washer under each nut or bolt head to hold the motor feet secure. Flanged nuts or bolts may be used as an alternative to washers. holes in the foundation.
4. 5.
Power Connection
Conduit Box
Motor and control wiring, overload protection, disconnects, accessories and grounding should conform to the National Electrical Code and local codes and practices. For ease of making connections, an oversize conduit box is provided. The box can be rotated 3600 in 900 increments. Auxiliary conduit boxes are provided on some motors for accessories such as space heaters, RTD's etc. Connect the motor leads as shown on the connection diagram located on the name plate or inside the cover on the conduit box. Be sure the following guidelines are met: 1. AC power is within 1 0% of rated voltage with rated frequency. (See motor name plate for ratings). OR AC power is within 5% of rated frequency with rated voltage. OR A combined variation in voltage and frequency of 1 0% (sum of absolute values) of rated values, provided the frequency variation does not exceed 5% of rated frequency.
AC Power
2. 3.
Performance within these voltage and frequency variations are shown in Figure 2-1.
2-2 Installation & Operation
MN400
Figure 2-1 Motor Performance VS Voltage Variations
+20
Full-Load Current
+15
';
41
o
e co
+10
Power Factor
'"
--Efficiency
-,
E
L-
+5
't:
r-, -. .
/'
V' ,
/
/
.-/
Maximum Torque
L-
41 c..
0 0
c:
!II 41
v""-
-5 -10 -15 -20
--~
- - - "'.
/
- - .. ..
.. .. .. .. .. .. .. ..
Full-Load curr~
V'
,/
/'
........
.. "'
....
-- --- --..
Efficiency
c: co .c:
Cl
/
/'
/
Maximum Torque
.. ..
.. ..
.. ..
..
/
-10
-5
Power Factor
-15
+5
+10
+15
Voltage Variations (%)
MN400
Figure 2-1 Motor Performance VS Voltage Variations
+20
Full-Load Current
+15
~ e.....
Q)
(.)
+10
Power Factor
e co
E ...
0
Q)
+5
--.
-.r-,
/'
/
.,/
Maximum Torque
,
/
't:
Il.
. .... ........
..
~
/
. . . . . . . . . . .
Full-Load curr~
:!
e
II) Q)
0 0
...
0
Efficiency
V""-
-5 -10 -15 -20
-~'
/ ,
V' .
'
/'
.........
........ .
-- -- -.
. . . .
Efficiency
c: co .c:
Ol
/
Maximum Torque
..
..
..
/
-10
-5
Power Factor
-15
+5
+10
+15
Voltage Variations (%)
MN400
't 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. 2. 3. 4. 5. 6. 7. 8. 9. Make sure that the mechanical installation is secure. All bolts and nuts are tightened etc. If motor has been in storage or idle for some time, check winding insulation integrity with a Megger. Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical continuity. Be sure all shipping materials and braces (if used) are removed from motor shaft. Manually rotate the motor shaft to ensure that it rotates freely. Replace all panels and covers that were removed during installation. Momentarily apply power and check the direction of rotation of the motor shaft. If motor rotation is wrong, be sure power is off and change the motor lead connections. Verify rotation direction before you continue. 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 procedure was successful. 1. 2. 3. Check the coupling and ensure that all guards and protective devices are installed. Check that the coupling is properly aligned and not binding. 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. Run for approximately condition. 1 hour with the driven equipment in an unloaded
4.
The equipment can now be loaded and operated within specified limits. Do not exceed the name plate ratings for amperes for steady continuous loads.
Jogging and Repeated Starts
Repeated starts and/or 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 Baldor 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 operation, contact your local Baldor distributor or Baldor Service Center.
2-4 Installation & Operation
MN400
Section 3 Maintenance & Troubleshooting

WARNING: UL rated motors must only be serviced by authorized Baldor Service Centers if these motors are to be returned to a flammable and/or explosive atmosphere.
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: 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 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. Use a "Megger" periodically to ensure that the integrity of the winding insulation has been maintained. Record the Megger readings. Immediately investigate any significant drop in insulation resistance. Check all electrical connectors to be sure that they are tight.
2.
3.
Lubrication & Bearings
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 operating conditions. Good results can be obtained if the following recommendations are used in your maintenance program. A high grade ball or roller bearing grease should be used. Recommended standard service conditions is Polyrex EM (Exxon Mobil). grease for
Type of Grease
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. - Shut-down temperature in case of a malfunction = 115 C.
Lubrication
Intervals
Recommended lubrication intervals are shown in Table 3-1. It is important to realize that the recommended intervals of Table 3-1 are based on average use. Refer to additional information contained in Tables 3-2 and 3-3.
Table 3-1 Lubrication Intervals *

NEMA / (IEC) Frame Size Up to 210 incl. (132) Over 210 to 280 incl. (180) Over 280 to 360 incl. (225) Over 360 to 5800 incl. (300) * ** 10000 ** 6000 2700 Hrs. Rated speed - RPM 3600 1800 5500 Hrs. 12000 Hrs. 3600 Hrs. 9500 Hrs. * 2200 Hrs. 7400 Hrs. *2200 Hrs. 3500 Hrs. 1200 18000 Hrs. 15000 Hrs. 12000 Hrs. 7400 Hrs. 900 22000 Hrs. 18000 Hrs. 15000 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 (MN401). Relubrication interval for 6205 bearing bearing is 1550Hrs. (using grease lubrication). Relubrication interval for 6806 bearing bearing is 720Hrs. (using grease lubrication).
MN400
Maintenance & Troubleshooting
3-1
Table 3-2 Service Conditions

Severity of Service Standard Severe Extreme Low Temperature * ** Ambient Temperature Maximum 40 C 50 C >50 C* or Class H Insulation <-30 C ** Atmospheric Contamination Clean, Little Corrosion Moderate dirt, Corrosion Severe dirt, Abrasive dust, Corrosion Type of Bearmg Deep Groove Ball Bearing Ball Thrust, Roller All Bearings
Special high temperature grease is recommended (Dow Corning DC44). Note that Dow Corning DC44 grease does not mix with other grease types. Thoroughly clean bearing & cavity before adding grease. Special low temperature grease is recommended (Aeroshell 7).
Table 3-3 Lubrication Interval Multiplier

Severity of Service Standard Severe Extreme Low Temperature Multiplier 1.0 0.5 0.1 1.0
Table 3-4 Bearings Sizes and Types

Frame Size NEMA (IEC)
i.--
Up to 210 incl. (132) Over 210 to 280 incl. (180) Over 280 to 360 incl. (225) Over 360 to 449 incl. (280) Over 5000 to 5800 incl. (355) Over 360 to 449 incl. (280) Over 5000 to 5800 incl. (355) Spindle Motors 76 Frame 77 Frame 80 Frame * Weight in grams = .005 DB
Bearing Description (These are the "Large" bearings (Shaft End) in each frame size) Width Weight of Volume of grease Bearing 00 Omm Bmm Grease to to be added in.) add * teaoz (Grams) spoon 0.30 (8.4 ) 0.6 2.0 6307 80 21 1.2 3.9 6311 120 29 0.61 (17 ) 0.81 (23 ) 1.5 5.2 6313 140 33 13.4 2.12(60) 4.1 6319 200 45 4.70 (130) 9.2 30.0 6328 300 62 13.4 NU319 200 45 2.12(60) 4.1 4.70 (130) 9.2 30.0 NU328 300 62 6207 6210 6213 72 90 120 17 20 23 0.22 (6.1) 0.32 (9.0) 0.49 (14.0) 0.44 0.64 0.99 1.4 2.1 3.3
Note: Not all bearing sizes are listed. For intermediate bearing sizes, use the grease volume for the next larger size bearing.
3-2 Maintenance & Troubleshooting
MN400
Lubrication
Procedure
Be sure that the grease you are adding to the motor is compatible with the grease alre<"> in the motor. Consult your Baldor distributor or an authorized service center if a qrease other than the recommended type is to be used. Caution: To avoid damage to motor bearings, grease must be kept free of dirt. For an extremely dirty environment, contact your Baldor distributor or an authorized Baldor Service Center for additional information.
With Grease Outlet Plug 1. 2. 3. Clean all grease fittings. Remove grease outlet plug. 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 plug. 4. Re-install grease outlet plug.
Without Grease Outlet Plug 1. 2. Disassemble motor. Add recommended amount of grease to bearing and bearing cavity. (Bearing should be about 1/3 full of grease and outboard bearing cavity should be about 1/2 full of grease.)
Note: Bearing is 1/3 full when only one side of bearing is completely full of grease. 3. Sample Lubrication Determination Assume - N EMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an amble temperature of 43 C and the atmosphere is moderately corrosive. 1. 2. 3. 4. Table 3-1 list 9500 hours for standard conditions. Table 3-2 classifies severity of service as "Severe". Table 3-3 lists a multiplier value of 0.5 for Severe conditions. Table 3-4 shows that 1.2 in3 or 3.9 teaspoon of grease is to be added. Assemble motor.
Note: Smaller bearings in size category may require reduced amounts of grease.
MN400
3-3
~essories
The following is a partial list of accessories available from Baldor. Contact your Baldor distributor for availability and pricing information. Note: Space heaters and RTD's are standard on some motors. Bearing RTD RTD (Resistance Temperature Detector) devices are used to measure or monitor the temperature of the motor bearing during operation. Bearing Thermocouples Used to measure or monitor bearing temperatures. Bearing Thermostat Temperature device that activates when bearing temperatures are excessive. Used with an external circuit to warn of excessive bearing temperature or to shut down a motor. Conduit Boxes Optional conduit boxes are available in various sizes to accommodate accessory devices. Cord & Plug Assembly Adds a line cord and plug for portable applications. Drains and Breathers Stainless steel drains with separate breathers are available. Drip Covers Designed for use when motor is mounted in a vertical position. Contact your Baldor distributor to confirm that the motor is designed for vertical mounting. Fan Cover & Lint Screen To prevent build-up of debris on the cooling fan. Nameplate Additional stainless steel nameplates are available. Roller Bearings Recommended for belt drive applications with a speed of 1800 RPM or less. 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 during periods of shut down or storage. Stainless Hardware Stainless steel hardware is available. zinc plated steel. Standard hardware is corrosion resistant
Winding RTD RTD (Resistance Temperature Detector) devices are used to measure or monitor the temperature of the motor winding during operation. Winding Thermocouples Used to measure or monitor winding temperatures. Winding Thermostat Temperature device that activates when winding temperatures are excessive. Used with an external circuit to warn of excessive winding temperature or to shut down a motor. Note: On some motors, leads for accessory devices are brought out to a separate conduit box located on the side of the motor housing (unless otherwise specified).
MN400
Table 3-5 Troubleshooting

Symptom Motor will not start Excessive humming Motor Over Heating Possible Causes Usually caused by line trouble, such as, single phasing at the starter. High Voltage. Eccentric air gap. Overload. Compare actual amps (measured) with nameplate rating. Single Phasing. Improper ventilation.
Chart
Unbalanced voltage. Rotor rubbing on stator. Over voltage or under voltage. Open stator winding. Grounded winding. Improper connections.
Bearing Over Heating
Misalignment. Excessive belt tension. Excessive end thrust. Excessive grease in bearing. Insufficient grease in bearing. Dirt in bearing. Misalignment. Rubbing between rotating parts and stationary parts. Rotor out of balance. Resonance.
Vibration
Possible Solutions Check source of power. Check overloads, fuses, controls, etc. Check input line connections. Have motor serviced at local Baldor service center. Locate and remove source of excessive friction in motor or load. Reduce load or replace with motor of greater capacity. Check current at all phases (should be approximately equal) to isolate and correct the problem . Check external cooling fan to be sure air is moving properly across cooling fins. Excessive dirt build-up on motor. Clean motor. Check voltage at all phases (should be approximately equal) to isolate and correct the problem. Check air gap clearance and bearings. Tighten 'Thru Bolts". Check input voltage at each phase to motor. Check stator resistance at all three phases for balance. Perform dielectric test and repair as required. Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical continuity. Refer to motor lead connection diagram. ,,Check and align motor and driven equipment. Reduce belt tension to proper point for load. Reduce the end thrust from driven machine. Remove grease until cavity is approximately 3h filled. Add grease until cavity is approximately 3/4 filled. Clean bearing cavity and bearing. Repack with correct grease until cavity is approximately 3h filled. Check and align motor and driven equipment. Isolate and eliminate cause of rubbing. Have rotor balance checked are repaired at your Baldor Service Center. Tune system or contact your Baldor Service Center for assistance. Remove rotor and foreign material. Reinstall rotor. Check insulation integrity. Clean ventilation openings. Replace bearing. Clean all grease from cavity and new bearing. Repack with correct grease until cavity is approximately 3/4 filled.
Noise Growling or whining
Foreign material in air gap or ventilation openings. Bad bearing.
MN400
3-5
1gested bearing and winding RTD setting guidelines

Most large frame AC Baldor motors with a 1.15 service factor are designed to operate below a Class B (80G) temperature rise at rated load and are built with a Class H winding insulation system. Based on this low temperature rise, RTD (Resistance Temperature Detectors) settings for Class B rise should be used as a starting point. Some motors with 1.0 service factor have Class F temperature rise. The following tables show the suggested alarm and trip settings for RTDs. Proper bearing and winding RTD alarm and trip settings should be selected based on these tables unless otherwise specified for specific applications. If the driven load is found to operate well below the initial temperature settings under normal conditions, the alarm and trip settings may be reduced so that an abnormal machine load will be identified. The temperature limits are based on the installation of the winding RTDs imbedded in the winding as specified by NEMA. Bearing RTDs should be installed so they are in contact with the outer race on ball or roller bearings or in direct contact with the sleeve bearing shell.
Winding RTDs - Temperature Motor Load
:s
Limit In C (40C Maximum Ambient) Class F Temp Rise :s 105C Alarm Trip Class H Temp Rise :s 125C Alarm Trip
Class B Temp Rise :s 80C (Typical Design) Alarm Trip
Rated Load Rated Load to1.15S.F.
130 140
140 150
155 160
165 165
175 180
185 185
r:
Note: Winding RTDs are factory production installed, not from Mod-Express. When Class H temperatures are used, consider bearing temperatures and lubrication requirements.
Bearing RTDs - Temperature Bearing Type Oil or Grease Antt-Frfctlon Alarm
Limit In OC with 40C Max Ambient Sleeve Trip Alarm Trip
Standard* 95 100 85 High Temperature** 110 115 105 Note: * Bearing temperature limits are for standard design motors operating at Class B temperature rise. ** High temperature lubricants include some special synthetic oils and greases.
95 110
Greases that may be substituted that are compatible with Polyrex EM (but considered as "standard" lubricants) include the following: - Texaco Polystar - Rykon Premium #2 - Chevron SRI #2 See the motor nameplate for replacement grease or oil recomendation. application engineering for special lubricants or further clarifications. Contact Baldor
MN400
l3A.LDOR
BALDOR ELECTRIC COMPANY P.O. Box 2400 Ft. Smith, AR 72902-2400 (479) 646-4711 Fax (479) 648-5792
Baldor Electric Company MN400
MOTORS AND DRIVES
Printed in USA
7/02 C&J10000
The S-VECO brush is self cleaning! The S-\l:U i's ultra high brush SIWt'd cn'ilks
l't'lltrifugal Inn'c' which comhinr-d with tilt' OPC'llillg of tilt' brush pattr-ru LIS the brush ,'ours('s around the sheaves. aids the brush ill t luowuu; off all of tilt' rt'ftl.-;t' or parttrul.ite it hdS swept across tilt' object ht'illg t'lt'ililed. This is the only true self Clt'allillg brush in oxistencc.
..
S-VECO eliminates re-deposit & carry hack! Because this is it self cle<tlling brush. it clot's not I DAD-UP like ot he r brushes or wipers do. t hus it does not re-deposit particulate. Cornblntug this aspect with the fad that S-VF.CO is d linear transverse cleaner, (which uu-aus that the brush swee-ps across the ohjed Iwillg cleaned) carry-back is eluuiuate-cl. Aggres.<;ive yet friendly! The fiber of the S-VEC() brushes will Ilt' selected to meet the application without use-r worry of damage to conveyor helting, or tn the object beillg cleaned.
While aggrl'ssiv(~ brushing takes place. the transverse linear hrushuu] action sweeps dUOSS any Il('11splices. rather than into th('111so there is 110damage done to the splice or to tile brush.
..
5IiAP'lv~ 1NSTALLATION .& .;,\OJUS rM:.1

Flexibility of iustallatlon is an important desigll
Ieatun-
of the
S-VECO linear brushillg m.ulune. St.uul.trd units of tilt' various models are qutppcd with rnounthu; brackets that fil('ilit,ltf~ hi.lllgillg the mnchine from conveyor rails or othe-r Illoulltillg
pcnuts to suit the application. (fig. g) Sperially desiglled met hods. such as floor stands arc also available. mouutuu;
Quick adjustment of th brush pressure is <ll'I'(lInplisllt'd through the use of tilt, <:It'valill!..( scre-ws. (fig .. \) Vl.mual c)r clectrouic lilt jacks call Ill' substituted ,II adclit ional cost.
F:ledroni(' controls for brush SPt'('(1. for liftillg :lrt' available. or !c>wl:>rilig of the 1I11it.awl olher Iuuctious
U\5Y .~~rlA ~"dO-tlU~{i

The amount ',,'Ilidl clf 1I1ililllt'II,lIWt' nquired f('atlln's ;1I](1tht' ('<lSt' with svstr-m it is dOIH' are uuport.mt of tlu- S.. YEU)
cI('si~IIS. For ex.u II pip. brush n-pl:lt't'llll'llt <)1't('11SiC)lIill~ is .1(llic:\ . -d bv illC'r.'ly .u ljustuu; tilt 1:\1:1).\1<1)<If ()( "1'1:1) \I~I) hru- l: 'IlSillllilig cI('vi\.'~.(fig. \.'. c)utl)tI.lrci 1\ p .' ~lJm\ II i nrllsll <'11:111:-.(' (lut Oil most uuit s is ;1('('lIlIlplisllcri t iIill' is II IiII i111,\1. \Illillih 11:<11,',' f/cl'linnll'llts. ill ,ll!l;ltt,'r (If ruinut..
"<I
(f,,\\'!1
:11'>' ((f1:ipJl!'rI . trh :-"'di"c! h",iriflgs
[.)1' I'I\\' 'l!.lillk
_\
\
._.~.J
\i
\
C
\
'.
\
,
..t
A. fLEVATING
SCREWS
D.
HIGH SHED, SELF CLEANING 8RUSHES
All S-VECOlinear brushing machines incorporate some form of elevating or lifting and lowering device. Standard units are equipped with elevating screws and hand wheels. Special units are available with manual or electric lift jacks. The electronic type can be cycled with a manually operated switch or tied into a controller.
The S-VECObrushes are commonly filled with stainless steel or nylon fiber. However. many other fibers are available to suit the application. These brushes art' driven at speeds up to l,toOSFM,which helps to make these brushes the only self cleaning brushes available,
BRUSH STABILITY
3.
:iAND
CRA'NN TUFT CONSTRUCTION
These unique linear brushes of the S-VECObrushing machines are made by hand sewing each tuft into standard "S" or --0" section rubber V-belts. This sewing or hand drawing of the brush fiber is the most secure method of setting brush fiber into a core. It is the only method that can be used to minimize tuft loss or "shedding" in these ultra high speed brushes.
Idler sheaves are located at regular. intervals between the Driven and Non-Driven brush sheaves. These idlers are adjustable up or down to insure constant brush contact across the entire brush length, even when brushing a lion-level surface. Proper adjustment of the idler sheaves v.ill insure a clean product and help to eliminate brush chatter.
F.
POWER AND TRANSMISSION
C.
i:lRUS;.e lENSIONING
DEVICE
This device is a screw driven slide assembly. with either an INBOARDor OuTBOARD mounted driver, that positions the non-driven brush sheave for proper tension on the brush, This device also facilitates the process for removing and replacing the brush.
All standard units are powered with electric motors in the 2HP.to SHP.range. Power is transmitted to the brush via a drive belt. or in a direct drive method via a gear box. Motors tire sized to meet the unit size and customer application.
Hand drawn tuft construction
Direct drive
Belt drive
J.,
i~'Ji~' '\ll' '~lJCA'r30'''1 S

. 'f-JfI
~'
'.
',<"
"
.~'"
,.l,
.,.
~,
.."
'.,
'.,
.'
\It'diulll and Heavy Duty S-VEC() units art' providing a positive effect to the bottom line.
Lower Operating and ~aintenance

Costs
Reduce lost material clue to carryback Reduce carrvback clean up time Reduce belt and idler wear Reduce belt cleaner system maintenance time due to S-VETO features and benefits
t':<)~l:'~oa~{
There are many standard and special S-VEC< rs at work ill foundries around the world, helping to lower operating and maintenance costs while increasing production rates.
Effective Cleaning
Mold Car Tops Hottorn Boards Sand Conveyors Recovery Sand Conveyors
V'JOOO '..YORKING
PLANTS
S-VECO, combined with a dust collection system has proven to be an effective way to do light to medium sanding and dusting operations. Door plants Paneling plants Plywood plants Chipboard plants Veneer and Laminate plants Furniture plants Hardwood Floor plants
S-VECOcan be used in many applications to increase productivity, improve quality, and reduce maintenance
l'(
ists.
Reduce conveyor carry back

Taconite Conveyors Coal Conveyors Phosphate Conveyors Cement Conveyors Aluminum Hot Strip 8.:Plate lille Hot Strip Copper Hot Strip .-;tpel Cold Slabs
Remove scale and surface impurities
Extra-He a", Duty Linear Brushing Machine
HDD
Fe ures
NEW'- light weight, field tested design Energy efficient, electric motors -.e-~~ All sealed bearings Large selection of steel & synthetic brush fibers Contour idlers High torque, power cog drive belts Direct drive system Many options available
Benefils
Shortest overall length available
t' Ease of Installation

/. Low maintenance costs Exceptional cleaning Proven design Can be mounted for "top or bottom cleaning" or horizontally mounted
Suggested Applications
Conveyor Belt Cleaning Mold Car Sweep Panel Dusting or Light Sanding Plate & Slab Cleaning
Typical Users
Foundries Mines Steel Mills Furniture Factories Food Processing
llOl South Prairie Ave. Waukesha, WI 53186 1-800-347-3501 414 547-3500 fax 414 547-3927 http://www.~chaeferbrush.com e-rnail: schaeterbrushrs'execpc.corn
s
~~
C Ixtra-Heavy Duty
TAKEUP OPT1O~S
linear
MD 8ruslting Macltine
Standa~d Equipment
1. HEAVY DUTY BRUSHES
Model RMHD-D utilizes three D section belt brushes. Each brush is titled with two rows of brush fiber from a wide assortment of material types and sizes. Brushes will be made to suit the application.
Standard
TOP VIEW
~
trim length (bristle length) is 3-1/2", and the approximate face width of three brushes is 3". Other trim lengths are available.
FRONT VIEW
2. BRUSH TENSIONING DEVICE

A manually operated screw and slide assembly to which
the brush sheave is mounted provides the means tor tensioning or relaxing the brush.
m CAUTION: Proper brush tension is critical to brush

life and performance. This subject is covered completely in the Installation and Operating Instructions that are supplied with each unit.
A
B
C
f----------sr_D tW. + e-V4----------I
3. CONTOUR IDLERSHEAVES
Full brush contact and stability are achieved, even on
non-flat surfaces, through the proper positioning of the
.-J
30 36: ,42i A-EfftctiveBrvihing Area U' . 30" : 36' 42' . . I-Wr!h Standard 3-1/2" Brvih Trim : 39' : 45" : 51" 57' : CTotal Fram. Length 43" : 49" 55" 61" : D-Number of Contour Idlers 1 2 3 2
MODIlNUMIEI tfN.
14-
48 48'
5.( 55' 70' 74'
6~ .72
62' 7l" 81' 5 72' 8l" 91'
6
63' 67' 3
..
84 88' 103' 107'

6
96 101 120 96' 109' 124" 111' 124 139' liS' 128' 143' 7 9 9
contour idlers. These can be adjusted up or down to force the brush to conform to the surface being brushed, thus insuring proper cleaning and chatter free high speed brushing.
4. HEIGHTADJUSTMENT DEVICE(Elevating Screwsl

The amount of pressure being applied by the brush against the object being cleaned is of utmost importance. This pressure is controlled by the operator through the use of the Height Adjustment Device or Elevating Screws. On standard models these are manually operated. load sensing devices (In be installed, which can be wired to a computer .md then to automatic electric lift jacks JS an option. Note: The working part of a brush is the tips of the bristle. Exaggerated bristle deflection caused by excessive pressure will result in premature wear and tJilure. The only exception to this is the use of an abrasive impregnated brush fiber,
Contour idler sheaves shown with optional sheave cleaners.
5. SEALEDBEARINGS
:\11 the standard units feature maintenance tree se-aled ball bearings.
6. POWER SOURCE
The model R.\1HD-D units are po ..ered with
J
high etli-
ciency 1725 RPM, TEFC, 3/60c, 208-220/4-l0V electric
motor, which is mounted directly to J 2.5: I Falk ~rar box. These rwo units are mounted directly in ime wirh the driven brush sheave. with a common shJti jommg ail three parts, thereby forming a direct drive.
7. WelDED ALUMINUM FRAME

All model R.\IHD-D units are assembled on a 't~on~, light weight aluminum extrusion. that h.ls J bick plate welded to it to ~i\e added strength .1OdItabiliry.
"
CAUTION!
BRUSH BEL TS MUST NOT BE OVERTIGHTENED! THESE BELTS DO NOT TRANSMIT ANY POWER. HEAVY PRESSURE WILL DESTROY THE UNIT BEARINGS.
Since 1905
www.schaeferbrush.com
MODEL RMHD-D
DIRECT DRIVE UNIT
S-VECO LINEAR CLEANER INSTALLATIONS & OPERATING INSTRUCTIONS
SCHAEFER BRUSH MANUFAaURING,
INC.
1101 South Prairie Ave. P.O. Box 148 Waukesha, WI 53187 1-888-547-3500 262-547-3500 262-547-3927 fax E-Mail: schaefer@schaeferbrush.com
s- VECO
LINEAR CLEANER
Installation and Operating Instructions S-VECO Model RMHD-D Direct Drive Unit UNPACKING: Remove all components from shipping crate and set in an area where the unit can be properly supported so the various components such as motor, gearbox, and idler assemblies are protected. Make sure the unit is stable and will not tip or fall. LOCATION: The S-VECO should be located or positioned so that the particulate being removed can fall into a discharge or dribble chute if one is available. For conveyor belt cleaning, the best place to mount the unit is as close to the conveyor head pulley as possible in order to brush the belt while it is flat and stable. This insures a clean belt with no particulate transfer to snubber pulleys or return idlers. Provision should be made to deflect the removed particulate within a confined area, while providing sufficient clearance around the S-VECO to permit the material to fall clear of the machine and the conveyor belt or other object being cleaned. In conveyor applications, as well as many other applications, a primary scraper located just ahead of the S-VECO will improve cleaning efficiency by removing large lumps and by decreasing the amount of particulate that must be swept clear. INSTALLATION: next). (IMPORTANT: Complete each step before proceeding to the
PREP UNIT
Remove 3/8"-16 bolt and flat washer from bottom of elevating screw assemblies (Item 15). Screw the assemblies into the large machined steel nuts (Item 14) located on each end of the S-VECO frame (item 1) and reinstall washer and nut. Loosen the 4 nuts on the brush take-up block (Item 12) and adjust the brush take-up device (item 10 or 11) to the full relaxed or inboard position.
SCH8~~al~E~~1~0~~~~S~~U RING, INC.
POSITION UNIT Position the S-VECO unit under or over conveyor or other object being cleaned. Whether your application calls for the S-VECO to be mounted under a conveyor belt or over some other object to be cleaned, care must be taken to position the unit properly in order to avoid damage to the unit. Position the S-VECO so that the brush is traveling at a right angle to the direction of the travel of the object being cleaned. Also, the object being cleaned must enter the brush at the front side of the unit. This means the conveyer belt will pass over the brush before it passes over the gearbox and motor. Failure to position the unit in this way will cause excessive pressure on the sheave bearings, which will result in bearing and shaft failure. If there is any question as to where the front side of the unit is, please refer to the drawing that accompanies these instructions. Clamp the mounting brackets (Item 16) to your existing support structure such as the conveyor frame or other machine support, l-beam, head pulley housing, etc. For best results, this position should be at a point where the conveyor belt, or other item being cleaned, is as flat and stable as possible. Conveyor belt bounce will minimize the brushes ability to clean properly and will cause premature wear or damage to the brush. The unit should be positioned so the center line of the driven sheave, the one on the motor end, is at the very edge of the conveyor belt, or other object being cleaned. The S-VECO unit should be positioned so that the brush is centered over or under the object being cleaned. IMPORTANT: When installing the unit, be sure there is at least 4" of clearance between the O.D. of the sheaves and the surface to be cleaned. NOTE: You must also be sure that you have enough elevating screw travel to provide sufficient adjustment to compensate for brush wear. EXAMPLE: If your brushes have a 3-112" trim (bristle length), you need to provide 3" of travel or adjustment. If the selected mounting location does not allow you to achieve the desired elevating screw travel, put a spacer between the mounting brackets and the mounting support structure.
INSTALL BRUSH Install the S- VECO brush or brushes, (depending on whether your model requires one 3 banded brush or 3 single band brushes, on sheaves (Items 7 & 8) and idlers (Item 9). If difficulty is encountered while installing the brushes, check brush take-up block position as in step 2 of "Prep Unit". After the brushes have been installed, tighten brush, utilizing the brush take-up device (Item 10 or 11). This device has a factory set torque load. When proper torque is achieved the clutch will break free preventing over tensioning of the brushes. (See yellow caution sheet included with this packet).
SCH~~~tLe~}J~tlcM~~Jt'oTsURING, INC.
1101 South Prairie Ave. P.O. gox 148 Waukesha, WI 53187 1-888-547-3500 262-547-3500 262-547-3927 fax E-Mail: schaefer@schaeferbrush.com
Turn the brush take-up device in a clock-wise direction until the handle spins free. At this point you will have reached the proper torque on the brushes. Tighten the four nuts on the take-up block. (Item 12) NOTE: After the first week or two of running the brushes might need to be re-tightened due to belt stretch. Before turning the brush tightening device handle be sure to loosen the four nuts at the back of the brush take-up block (Item 12), then tighten brushes and re-tighten the four nuts.
CAUTION: DO NOT OVER TENSION BRUSHES!!!
FINAL MOUNTNG ADJUSTMENTS 1. Turn elevating screws (Item 15) to bring both ends of brushes into slight contact with surface to be cleaned. (Maximum 1/8" bristle deflection). NOTE: It may be necessary to re-center the unit on the conveyor at this time (Refer back to "Position Unit"). Check alignment of idler support bracket attaching screws and raising or lowering brackets as necessary, then tighten attaching screws. 2. Re-check centering of S-VECO brush to conveyor or other object being cleaned and if correct, weld mounting brackets (ItemI6) in position. Mounting brackets can be bolted instead of welded in place if you prefer. Use two 1/2" bolts per bracket. CAUTION: DO NOT allow weld splatter to damage brush. 3. Adjust elevating screws (Item 15) until full brush contact is made with item being cleaned, and the bristles bow or crush approximately 1/8". This adjustment provides maximum cleaning efficiency and assures maximum brush life. Excessive bristle pressure WILL NOT increase efficiency or cleaning, but WILL increase brush wear. 4. Install brush pinch guard using hardware supplied.
POWER
Wire the S- VECO drive motor (Item 2) into conveyor drive circuit making sure that voltage is correct. CAUTION, the S-VECO unit must operate ONLY when the conveyor belt is moving to prevent damage to the conveyor belt. A manual disconnect switch is recommended to permit servicing of the S-VECO. USE FLEX CONDUIT TO MOTOR TO PERMIT ADmSTMENT FOR BRUSH WEAR.
NOTE: If the conveyor has a long "coast to stop" time, it is recommended that the SVECO continue to run during this time to prevent clogging of the brush, and roll-out
SCH~f~a~~tii~glJf~Q;~RING,
INC.
caused by excessive pressure on the bristles when brush is stationary. delay might be necessary to accomplish this.
An electronic
SPEED REDUCER The FALK 2.552: 1 speed reducer (Item 3) has been filled with the type and amount of lubrication that is recommended by the manufacturer. Please refer to the manufacturer's instructions that are included with this packet.
..
STARTUP Re-check to be certain that the S-VECO motor is wired into the conveyor drive circuit, then start conveyor and S-VECO unit, check for proper brush adjustment and adjust elevating screws (Item 15) as necessary. NOTE: The rotation of the brush is optional.
ADJUSTMENTS 1. After initial break-in time it may be necessary to adjust the S-VECO brushes for proper tension on the sheaves, loosen the pinch point guard attaching screws and the 4 take-up block nuts (on Item 12). Adjust brush as needed and re-tighten all screws and nuts. 2. Adjustment for bristle wear is accomplished by turning elevating screws (Item 15). See step 3 under FINAL MOUNfING ADJUSTMENTS. Intervals between adjustments will vary with each application. It is suggested that the brush be checked daily for the first two weeks of operation to determine the interval. The appearance of the particulate on the object being cleaned, at any time, usually indicates the need for adjustment. The brushes should be replaced when the bristles have been worn down to 3/4", or when satisfactory cleaning can no longer be obtained. 3. Idler sheave adjustment, either up or down, see step 1 under" FINAL MOUNfING ADJUSTMENTS". Main sheave adjustments are performed at the factory before the unit is shipped. Be sure that the attaching screws on the take-up block (Item 12) are tight at all times to maintain alignment and clearance.
SCH~f~AtaBhJ~ti~JJfAg:~RING, INC.
CAUTION!
Brush belts must not be over-tightened.
These belts do not transmit any power.
NOTE: Over-tightening will cause the drive components to fail. The brush adjustment clutch which is located on the brush adjustment device (Item 10 or 11 on drawing RNIHD-D-A) has a factory pre-set torque load. When the brush is adjusted to the proper torque the clutch will break free and the handle will spin free. DO NOT change the torque pre-set in the clutch assembly! Contact Schaefer Brush Product Engineering @ 1-888-547-3500. Replacement parts and brushes can be obtained by calling your local distributor.
SCHW~J;U~AJ~tlM~~UfaQJJRING, INC.
Limited Warranty
Schaefer Brush Manufactwing Company Incorporated (the Company) warrants that all S-Veco linear brushing machines shall be free from defects in Schaefer Brush workmanship and materials for a period of six (6) months from the date of shipment from the Company. Excluded from this warranty will be bearings and brushes, which are considered wear items and are therefore replaceable maintenance items, and purchased components such as motors, drives, and any electronic or mechanical devices that are not manufactured by the Company. If a Schaefer Brush Mfg. CO' Inc. pr.oduct is defective due to Schaefer Brush Mfg. Co., Inc. workmanship or materials, and the defect occurs during the warranty period, then Schaefer Brush Mfg. Co., Inc. will either repair or replace the product, which ever Schaefer Brush Mfg. Co., Inc. believes- to be appropriate under the circumstances. Schaefer Brush Mfg. -Co., Inc. is not-responsible for removal "Or shipping of the product to the company, the reinstallation of the product upon its return to the customer, or any incidental or consequential damages, resulting from the defect, removal, reinstallation, shipment, or otherwise.
T
This warranty is made in lieu of all other warranties,inclucling l~l~~ unpiled Will 11l.l1ties of Merchantability and Fitness.
without limitation
No employee, agent, distributor, or other person is authorized to give any additional warranties on behalf of Schaefer Brush Mfg. Co., Inc. nor to assume for Schaefer Brush Mfg. Co., Inc. any other liability with connection with any of its products, except an officer of the Company by signed writing. -
SCHAEFER BRUSH MANUFACTURING, INC.

TROUBLESHOOTING
PROBLEM Conveyor not being cleaned.
GUIDE - S-VECO LINEAR CLEANERS

PROBABLE CAUSE REMEDY Start cleaner. Check drive belt for slippage or breakage. Adjust elevating screws. Replace S-VECO brush.
r Cleaner not operating.

2. Brush not contacting 3. Brush worn beyond effective cleaning point.
Conveyor not being cleaned across entire surface.
r. Brush not contoured to belt.

2. Conveyor belt grooved.
J.
Excess slack in conveyor belt.
Adjust idler sheaves. Check skirtboarding, return idlers, or other conveyor components which could cause mechanical damage to belt. In some cases, grooves can be cleaned by idler adjustment or additional idlers. Adjust belt take up.
Belt cleaning erratic.
S-VECO brush or drive belt slip. 2. Wrong size or type bristles in S-VECO brush. 3. Excess slack in conveyor belt.
Adjust brush/drive be... Contact factory for their assistance regarding bristles Adjust belt take-up.
Drive belt or brush belt take-up screw difficult to turn.
r Excessive belt tension.

2. Take up block or brush
Adjust properly (See Install Brush & Final Adjustment). Loosen attaching screws.
guard attaching screws not loosened. 3. Threads on take-up screw clogged or corroded. Elevating Screw is difficult to turn (raising cleaner). I. Unit cocked due to uneven adjustment of elevating screw. '-. Dust boot not in position has permitted buildup on threads above take-up nut. ., .1. Brush jammed against conveyor belt. 4 Motor wired with rigid conduit.
')
Clean and relubricate threads.
Adjust screws evenly (2 or 3 turns at a time). Clean and relubricate threads. Position dust boot properly. Adjust brush properly Rewire with flexible conduit
SCHAEFER BRUSH MANUFACTURING, INC.

1101 South Prairie Ave. P.O.Box 148 Waukesha, WI 53187 1-888-547-3500 262-547-3500 262-547-3927 fax E-Mail: schaefer@schaeferbrush.com
INSTALLATION AND REMOVAL INSTRUCTIONS FOR BLOOM LOCKING ASSEMBLY SERIES 8106 & 8103
Thank you for purchasing a B-LOCTM Keyless Frictional Locking Device. ~-LOCTt. keyless connectors provide a high capacity, zero-backlash afVhub or coupling connection by means of a mechanical interference '. . Please follow these INSTALLATION AND REMOVAL INSTRUCTiONS carefully to ensure proper performance of this B-LOCTM unit.
When installing or removing B-LOC''' safety standards:
products, always adhere to the following
1. 8e sure that all power switches are locked out before installing or removing B-LOC'M products. 2. Eye protection is required when installing or removing B-LOC'M products . please wear safety glasses and protective clothing. INSTALLATION (Refer to Figure 1) B-LOCTASeries 8103 and 8106 Locking Assemblies are supplied lightly oiled and ready for installation. They are seIf-centering and fit straight-thru hub bores. Note that Series 8103 units permit axial hub movement during installation. In contrast. the extended flange on Series 8106 units results in an axially fixed hub position during assembly. When reinstalling a used unit, make sure that all slits are aligned. The frictional torque capacity of these devioes is based on a coefficient of friction of 0.12 for lightly oiled screw. taper. shaft and bore contact areas.
Figure 1
Therefore, it is important notto use Molybdenum Disulfide (e.g., Molykote, NeverSeeze or similar lubricants) in any Locking Assembly installation. 1. Make sure that locking screw. taper, shaft and bore contact areas are clean and lightly oiled and that all collar slits are aligned. Loosen all locking screws by a minimum of four (4) turns and transfer at least three (3) screws into push-off threads in order to keep Parts 1 and 2 separated during assembly (see Figure 2). After inserting Locking Assembly into hub bore. relocate locking screws used for separating Parts 1 and 2. Hand tighten locking screws and confirm that collar item 1 is parallel and in full contact with face of part to be attached to shaft. Use torque wrench and set it approximately 5% higher than specified tightening torque MA Tighten locking screws in either a clockwise or counterclockwise sequence (it is not necessary to tighten in a diametrically pposite pattern). using only 1/4 (i.e., 90") turns for several passes until 1/ , turns can no longer be achieved. Continue to apply overtorque for 1 to 2 more passes. This is required to compensate for a system-related relaxation of locking screws since tightening of a given screw will always relax adjacent screws. Without overtorquing. an infinite number of passes would be needed to reach specified tightening torque. 26 Gilbert Street Monroe, NY 10950
2.
3.
4.
5.
6.
B-LOC Corporation
7.
Reset torque wrench to specified torque (MA) and check all locking screws. No screw should tum at this point, otherwise repeat Step 6 for 1 or 2 more passes. It is not necessary to re-check tightening torque after equipment has been in operation.
'OTE: The torque capacity of these units can be increased by approximately 25% by ttooroughlycleaning the shaft and Locking Assemb1y bore of any lubricant. In applications subject to extreme corrosion, the slits in all collars should be sealed with a suitable caulling compund or equivalent. Likewise, push-off threads should be protected from corrosion. INSTALLATION OF B-LOC"" LOCKING ASSEMBLIES OVER SHAFT KEYWAYS The Locking Assembly should be positioned so that slits in Locking Assembly collars that contact the shaft are located approximately opposite the keyway. In addition, a locking screw should be centered directly over the keyway. When tigptening locking screws, it is important to foltow the installation procedure outlined above, which specifies equal 1/4 turns of each locking screw. Failure to follow these instructions could result in excessive tightening of the screw over the keyway, possibly causing permanent deformation of the Locking Assembly collars. Even after 1/4 turns can no longer be achieved, it is important to continue to use equal turning angles for every screw until the specified tightening torque is reached.
REMOVAL (Refer to Figure 2) Prior to initiating the following removal procedure, check to ensure that no torque or thrust loads are actl"g on the Locking Assembly, shaft or any mounted components. IMPORTANT! Make sure ends of locking screws used for removal are ground flat and are slightly chamfered to prevent damage to screw and COllarthreads during push-off. Check to ensure that axial movement of collars - necessary for release of connection - is not restricted. Likewise, ensure that push-off threads are in good condition. 2. Relax all locking screws by approx. four (4) complete turns and transfer screws to all pushoff threads located in flange of collar Item 1. Release connection by evenly tightening all push-off screws (not exceeding 1/4 turns) in a diametrically opposite sequence.
r:
("1\-
3.
Figure 2
LOCKING SCREW SIZES AND SPECIFIED TIGHTENING TORQUE M. TIghtening Torque Metric Series Inch SerIes 8106 20 45 70 100 130 220 280 320 360 Hex Key Size (mm)
M.
(ft-Ibs) 8103 10 25 50 90 135 219 290 420 560
Screw Size
x x x x x x x x x
47 75 110 145 180 285 355 405 455
to to to to to to to to to
40 65 95 120 200 260 300 340 400
x x x x x x x x x
65 95 135 165 260 325 375 425 495
314 1-518 2-11/16 3-15116 4-15/16
to to to to to
1-112 2-9/16 3-314 4-3i4 8
12 30 60 105 166 257 350 500 675 call
M 6 M 8 Ml0 M 12 M14 M16 M18 M20 M22
5 6 8 10 12 14 14 17 17
For technical
assistance,
please
1-800-865-7756
WHEELABRATOR
AIR FORCE 1 BLOW OFF SYSTEMS - SPARE PARTS LIST PURCHASE ORDER # J3463012
Part # AF1-WC-4 AF1-CC-4 AF1 Stocked Parts AF1-MT60 AF1-FLEX-4 AF1-HAS-64 AF 1-AC 125-4 AF1-DCF100-61 AF1-CF100-24 AF 1-KECS20-CW 1" Wall Clamp 1" Crossover Clamp Replacement Filter Cartridge 17.625" x 16" 4" Diameter Flexible Hose 4" Gear Clamp SS Air Cannon Anodized, 4" Diameter Connection Air Knife, 4" Diameter Double Centre Feed Connection Air Knife, 4" Diameter Centre Feed Connection Replacement Blower Wheel 13" x 4" x 1-5/8" CW Rotation Coated Steel Description
Special Order Parts
Air Force 1 Blow Off Systems Inc.
AIR FORCE 1 BLOW OFF 5
Chemical Composition Limits per ASTM B 26-98

Si 0.2 Fe 0.15 Cu 0.05 Mn 0.10-0.25 Mg 6.2-7.5 Ti 0.01-0.25 Other 0.15 AI Remainder
Typical Mechanical Properties

Temper Ultimate Strength Yield Strength Elongation Shear Strength Compressive Yield Strength Brine)) Hardness Endurance Limit
(ksi) F 40 (35 min.)
(ksi) 20 (18 min.)
(% in 2 in.) 13 (9 min.)
(ksi) 27.45
(ksi) 24 70 (70 min.)
(ksi) 10 ASTM B26-98
Thermal Conductivity (@ 77F, SI unites): 0.24 cal/cm*s*K Heat Treatment - Achieves its physical and mechanical properties as-cast (F). This eliminates the time and cost of heat treating. Machinability - Excellent Machinablility as-cast, excellent surface finish, and high demensional stability. Corrosion Resistance - Highest of any cast alloy. Finishing - Produces an excellent surface finish by burnishing or polishing. Anodizes well to a clear-satin finish due to the minimal amount of silicon in the alloy.
"~~~Load Capacity oftEittiiigtS_et1Screws~Whe",Proper:lYJrTorqued~

Std. JPS'Size'Steel
Fitting Size 3/4" 3/4" 1" 1" Torque Ft. Lbs. 13 13 14 14 2 2 1000lbs 1900lbs 1200lbs 1800lbs 3/4" 3/4" 1" 1" 10 10 12 12 9371bs
10061bs 950lbs
1020lbs
Above data compiled by an independent laboratory using the following test procedures: Standard I.P.S.-sized within the vertical barrel of the test fittings, to the torque shown above. A 30,000Ib. Universal testing machine applied vertical load to the pipe member in an attempt to produce pipe slippage. Load capacities listed above are based on a safety factor of 2: 1.
Above data compiled by an independent laboratory using the following procedures: A 30,000Ib. Universal Testing Machine applied vertical load to the pipe member in an attempt to produce pipe slippage through the vertical barrol of the fitting. Load capacities listed above are based on a safety factor of 100%.
AIR FORCE 1 BLOW OFF SYSTEMS INC.

Blow Off System Installation/Operation/Maintenance
The following general information has been prepared to assist you in installing, operating and maintaining your Air Force 1 Blow Off System. By following the instructions, you will prolong the life of the equipment and enhance performance while preventing unexpected down time. The scope of this manual covers our standard arrangement 4 (direct drive) product line and is not intended to cover specially engineered equipment. AF1-FRP SERIES BLOWERS Low maintenance direct drive, FRP housing and powder coated steel motor base includes reverse inlet venturi. Inlet air temperature is not to exceed 160 F (72C). SILENCERIINLET GUARD Powder coated acoustically lined casing with drum design inlet guard. Includes stainless steel mounting bracket and hardware. SILENCER/FIL TER Powder coated acoustically lined casing with 1a-micron paper media filter cartridge. Includes stainless steel mounting bracket and hardware. RECEIVING Most shipments are F.O. B. Waterloo, ON, Canada. It is in the best interest of the buyer to carefully inspect all shipments before they are accepted from the freight carrier. Upon delivery, be sure that all items listed on the bill of lading and packing slip have been received. The blowers are usually completely assembled. They are then skidded, crated or boxed to fully comply with trucking requirements. Any shortage, breakage or damage noticed at the time of delivery should be indicated to the carrier's representative. Damage noticed after delivery should be reported to the carrier at once. Request their inspection of the shipment and fill out a concealed inspection report. Blower wheels are dynamically balanced when fabricated. Complete fans are test run at operating speeds (3600rpm motors) to check entire assembly for conformance to vibration limits. Duct work feeding blower or on discharge side of blower should be independently supported. Lifting holes are provided on the motor and blower motor base to assist in handling the fan assembly. Fans and motors should be mounted on structurally sound foundations. Concrete is the best, however, other structures designed properly are acceptable. Equipment should be leveled on base foundation. As a rule, if vibration isolators are used, the fan should first be bolted to a structural steel base and isolation take place between the structure steel base and the foundation. This prevents the fan base from floating due to uneven distribution and/or drive forces when mounted directly to vibration isolators. PRIOR TO STARTUP - CHECK THE FOLLOWING (make sure all power sources are locked out): 1) 2) Fasteners - all foundation bolts, wheel hub set screw, motor base bolts must be tight. Fan Wheel - Turn/rotate wheel assembly by hand to see that it runs free and does not bind or strike housing or reverse inlet venturi. Clearance should be 1/8-inch to %-inch. If the wheel rubs the fan housing or venturi, check to make sure motor is square to housing or move wheel on the motor shaft. HANDLING Blowers should be handled carefully and lifted only by lifting eyes in larger blowers, lifting holes or by the base on smaller units. Nc. .'.1 by the shaft, motor, silencer casing or housinq. P:ecauuon should be taken to avoid dropping or jarring equipment as this can cause damage to motor shaft or wheel which may not be visible but which can result in vibrations. INSTALLATION
r:

636 Colby Drive Waterloo Ontario Canada N2V 1A2 Phone: (519) 746-5035 Fax: (519) 746-1231
3)
Motor - Check electrical wiring to motor. The current characteristics of the supply line must agree with the motor nameplate ratings. Motor should be wired in accordance with all national and local electric codes. All motors are ULlCSA certified. Typical wiring is Delta Run. Duct/Flex Hose Connection - Hard line duct should never be supported by fan only. Rigid/Spiral hard line duct connections should be sealed to prevent air leaks. To minimize sound resonating through duct, connect rigid duct to blower inlet/outlet by means of flex hose/rubber connection. There should be a minimum of three duct diameters of straight duct prior to any elbows or transitions into or from the blower inlet and outlet. Install blower inlet duct, inlet guard or filter. TO ENSURE PERSONNEL OR PROPERTY PROTECTION, DO NOT OPERATE BLOWER WITHOUT AN INLET GUARD.
ELECTRICAL DISCONNECTS
Every motor driven fan should have an independent disconnect switch to isolate the unit from electrical supply. It should be near the fan and must be capable of being locked out during maintenance and servicing.
4)
NOTES:
Check amperage draw of system to motor rating (see motor plate F.L.A.) when distribution plenum, duct, Air Cannons and/or Air Knives have been installed and connected. Opening dampers and/or opening Air Knife slots will increase the impact of the nozzles, but will increase the amperage used by the blower's motor. Adding additional Air Knives and Air Cannons will also increase the amperage used by the blower's motor. MAINTENANCE 1) Weekly, check inlet guards and/or filters for any signs of restriction due to such things as dirt. In most cases, 3 drop in amperes will be noticed as the restrictions increase. Weekly, check the condition ot any hose and replace any that have holes or are worn. Lubricate larger motors with grease at least every 3000 hours of use - more often if in harsh environments. IMPORTANT*****
1710'
5)
STARTUP 1) Check to make sure no objects have fallen into fan housing. Start and stop the motor for a second to check proper wheel rotation. Arrow on fan housing indicates the proper direction of wheel rotation. Listen for anything unusual such as vibration, rubbing or banging that may indicate a problem such as an object in the duct or fan housing. Fan may now be brought up to speed Again, listen fur anything unusual such as vibratic. v:"-bing or banging and stop the machine if any of these are present.
i, I
2)
2)
3)
r:
3)
*****VERY
Every 8-10 weeks: check/tighten motor hardware" ";v " ,"--'wer base.
intino
4)
Check motor amperage against nameplate amperage (F.L.A.) to make sure motor is not overloading. If overloading is evident, close down dampers or air knife slots. operating temperature of blower 160F
Note: Maximum (72C)
AIR PRESSURE AND SUCTION In addition to the normal dangers of rotating machinery, fans present another hazard from the suction created at the fan/silencer inlet. This suction can draw materials into the fan chamber where they become high velocity projectiles at fan, air knife or air cannon outlets. Fan inlets, even if they are ducked, require inlet guards of some type or proper filters to prevent entry and discharge of solid objects.
AIR FORCE 1
BLOW OFF SYSTEMS INC.

Blow Off System Installation/Operation/Maintenance
RECOMMENDED 1. AF1 SAFETY PRACTICES
Comply with all regional and company requlations, such as AMCA and OSHA requlauo: I.:>, "uvenng air movement devices. AF1 explicitly disclaim responsibility for compliance of the systems in which our products are components with local, national safety or electrical codes (this being outside our control). 2. 8e certain that the appropriate guard assembly for all exposed moving parts is securely in place prior to and during use. 3. The safe operation of the AF1 blower is dependent upon proper installation, regu:., i,,~,_0ctJn and maintenance including any system related associated components, such as filters. 4. The system supplier and or installer must consider the inclusion of necessary guord.., fa, <::;;'J and oil exposed fan related moving parts and a warning of high-velocity air streams. 5. Do not use the blower if damage is evident or suspected. 6. Always read the equipment operator's manual before use. 7. Ensure that the blower impeller is properly secured on the appropriate sized motor shaft and adequate clearance is maintained between the impeller and blower housing. 8. Do not exceed maximum operation speed (RPM) and full load amperes (FLA) marked on the blower motor. 9. Always use OSHA approved ear and eye protection when blower is operating. 10. Inspect the blower and impeller regularly for signs of fatigue or vibration. 11. Do not operate the fan in temperatures in access of 160F unless designed to do so and authorized in writing '"'~' .L"lF1.
AIR FORCE 1
BLOW OFF SYSTEMS INC.
r:

.,...
Excellent chemical resistance Good abrasion resistance Superior resistance to

w'SUPSl.~! .. ~,
Santoprene Sizes Std. Lengths Colours Temp. Range Options 2"-24"ID 25 Ft. Black -60 to 275 F Continu, (intermit. To 300F) Wearstrip available for External abrasion resistance.
JS
fatigue r";:,;3U:,, .c.., Excellent tear and puncture resistance
Applications: Lighter materials handling where extreme flexibility is required. Most all industrial ventilation and light material handling uses. Suited for corrosive solvent ventilation, extreme temperature environments, or continuous flexing.
:i";i
2"
".!
31 24
0/
28 18
17 8
4" 6"
..diifi0.
"1%,,
18 12
8"
Installation, Operation and Maintenance Instructions

for AC Induction Motors 56- 6800 Frames (NEMA) 63 - 280 Frames (IEC)
_.. . .. DN@ IIEii II-IIEii 1II.::-rllm~1I1II.::

A REGAL-BELOIT
MARATHON ELECTRIC
Contact Motor Customer Service at: Phone: (715) 675-3311
COMPANY
www.marathonelectric.com
Form 5554E
i INSTALLER:
I OWNER:
PLEASE LEAVE THIS MANUAL FOR THE OWNER'S USE READ AND SAVE THESE INSTRUCTIONS
SAFETY INSTRUCTIONS
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
A WARNING
Before installing, using, or servrcmq this product, carefully read and fully understand the instructions including all warnings, cautions, & safety notice statements. To reduce risk of personal injury, death and/or property damage, follow all instructions for proper motor installation, operation and maintenance. These instructions are not intended as a complete listing of all details for installation, operation, and maintenance. If you have any questions concerning any of the procedures, STOP, and call the appropriate Regal-Beloit motor company.
Table of Contents
1.0 INSTALLER / OWNER / OPERATOR RESPONSIBILITY 1.1 Electrical Safety 1.2 Mechanical Safety 1.3 Environmental Safety 2.0 RECEIVING & INSPECTION 2.1 Initial Inspection 2.1.1 Packing List & Inspect 2.1.2 Turn Motor Shaft 2.1.3 Check Nameplate 2.2 Handling 2.2.1 Correct Lifting Angles 2.3 Storage 2.3.1 Bearing Lubrication 2.3.2 Shaft Rotation 2.3.3 Damp or Humid Storage Locations 3.0 INSTALLATION AND OPERATION 3.1 Location 3.1.1 Selecting a Location 3.1.2 Ambient Temperature Limits 3.1.3 Construction Selection per Location 3.1.3.1 Dripproof 3.1.3.2 Totally Enclosed 3.1.3.3 Hazardous Locations Motors 3.2 Mounting Motor 3.2.1 Rigid Base (Footed) 3.2.2 Rigid Base Hole Selection -6 or 8 Hole Bases 3.2.3 Vertical 3.3 Application Assembly to Motor 3.3.1 General: Proper Alignment 3.3.2 Direct Coupling 3.3.3 Direct Connected 3.3.4 Belted 3.3.5 VFD Operation 3.3.6 Accessories 3.3.6.1 General 3.3.6.2 Brake Motors 3.3.6.3 Space Heaters 3.3.6.4 Thermal Protection General, Thermostats, Thermisters & RTDs 3.3.6.5 RTD Alarm & Trip Settings 3.3.7 Guards 3.4 Electrical Connections 3.4.1 Power Supply / Branch Circuit 3.4.1.1 Branch Circuit Supply 3.4.1.2 Fuses, Breakers, Overload Relays 3.4.1.3 AC Power Supply Limits 3.4.2 Terminal Box 3.4.2.1 Conduit opening 3.4.2.2 Hazardous Locations 3.4.3 Lead Connections 3.4.3.1 Wire Size Requirements (Single Phase) 3.4.3.2 Extension Cords (Single Phase) 3.4.4 Ground Connections 3.4.5 Start Up 3.4.5.1 Start Up - No Load Procedure 3.4.5.2 Start Up - Load Connected Procedure 3.4.5.3 Jogging and/or repeated starts 4.0 MAINTENANCE 4.1 General Inspection
4.1.1 Ventilation 4.1.2 Insulation 4.1.3 Electrical Connections 4.2 Lubrication and Bearings 4.2.1 Grease Type 4.2.2 Bearing Operating Temperature
4.2.3 Lubrication Interval 4.2.4 Lubrication Procedure 4.2.5 Lubrication Example 4.3 Trouble Shooting 4.3.1 General Trouble-Shooting Warnings 4.3.2 Trouble-Shooting Cause /
Corrective
Action
motor is suitable for use on Pulse Width Modulated (PWM) type VFD power. In addition, the nameplate must be marked with the inverter rating; for example, "2:1 CT", "2 to 1 Constant Torque", etc.
1.0 INSTALLER/OWNER/OPERATOR RESPONSIBILITY: 1.1 ELECTRICAL SAFETY

ELECTRICAL SHOCK HAZARD Electrical connections shall be made by a qualified electrical personnel in accordance with all applicable codes, ordinances and sound practices. Failure to follow these instructions could result in serious personal injury, death and/or property damage. Only qualified personnel who are familiar with the applicable National Code (USA = NEC) and local codes should install or repair electrical motors and their accessories. ELECTRICAL LIVE CIRCUIT HAZARD Do not touch electrically live parts. Disconnect, lockout and tag input power supply before installing or servicing motor (includes accessory devices). Use a voltmeter to verify that power is off before contacting conductors.
A WARNING:
2.0
RECEIVING AND INSPECTION
A WARNING:
2.1 INITIAL INSPECTIONS 2.1.1 CHECK PACKING
LIST AND INSPECT the packaging to make certain no damage has occurred in shipment. If there is visible damage to the packaging, unpack and inspect the motor immediately. Claims for any damage done in shipment must be made by the purchaser against the transportation company. 2.1.2 TURN MOTOR SHAFT by hand to be certain that it rotates freely. Note: Shaft seals and bearing seals may add drag. 2.1.3 CHECK NAMEPLATE
for conformance with purchase with power supply and control
A WARNING:
ELECTRICAL GROUNDING HAZARD Failure to properly ground motors, per the National Electrical Code (NEC) Article 430 and local codes may cause serious injury or death to personnel. For general information on grounding refer to NEC Article 250. (Also see "Ground Connections section 3.4.4").
A WARNING: A WARNING:
-rc
AUTOMATIC RESET PROTECTOR HAZARD Do not use automatic reset protectors if automatically restarting the motor will place personnel or equipment at risk .. Failure to follow this instruction could result in serious personal injury, death and/or property damage MANUAL RESET PROTECTOR HAZARD If a tripped manual reset thermal protector is exposed to a temperature less than (20F) it may reset and restart the motor automatically. If an application requires a motor with a manual reset thermal protector that will be operated at temperatures less than (20F) contact the manufacturer to review the application / motor requirements. Failure to follow this instruction could result in serious personal injury, death and/or property damage
order requirements and compliance equipment requirements.
2.2 HANDLING:
A WARNING:
-rc
FALLING OBJECT HAZARD Eyebolts or lifting lugs, where provided, are intended for lifting only the motor and accessories mounted by the motor manufacturer (unless specifically stated otherwise on the motor). Utilizing the motor lifting provision to lift other components such as pumps and gear boxes could result in serious personal injury, death and/or property damage. FALLING OBJECT HAZARD Before using the lifting provision, check the eyebolts and/or means to assure they are not bent or damaged and are threaded, seated & secured to the motor. Equipment to lift have adequate lifting capacity. While lifting the motor DO under or in the vicinity of the motor. Failure to follow these could result in serious personal injury, death and/or property
A WARNING:
1.2 MECHANICAL SAFETY
A WARNING:
A WARNING:
LOOSE PARTS HAZARD Before starting the motor, remove all unused shaft keys and loose rotating parts to prevent them from flying off. Failure to follow these instructions could result in serious personal injury, death and/or property damage. ROTATING PARTS HAZARD Keep extremities, hair, jewelry and clothing away from moving parts. Failure to follow these instructions could result in serious personal injury, death and/or property damage.
other lifting completely motor must NOT stand instructions damage.
2.2.1 LIFTING ANGLE LIMITATIONS
Ai WARNING:
1.3 ENVIRONMENTAL SAFETY
HAZARDOUS LOCATIONS (1) The NEC and the local authority having jurisdiction must be consulted conceming the installation and suitability of motors for use in Hazardous Locations. The local authority having jurisdiction must make the final determination of what type of motor is required. The application and operation is beyond the control of the motor manufacturer. (2) Division 1 Hazardous Locations motors can only be modified or reworked by the manufacturer or a facility that is Listed under UL's category "Motors and Generators, Rebuilt for use in Hazardous Locations". Failure to follow these instructions could result in serious personal injury, death and/or property damage. (3) Do not use a Hazardous Locations motor with a Variable Frequency Drive (VFD) unless the motor nameplate specifically states that the
2.3 STORAGE:
Motors, not put into service immediately, must be stored indoors in a clean, dry location. Avoid locations with large temperature swings that will result in condensation. Motors must be covered to eliminate airborne dust and dirt. If the storage location exhibits high vibration, place isolation pads under motor to minimize damage to motor bearings.
2.3.1 BEARING LUBRICATION: Bearings are grease packed at the factory; relubrication upon receipt of motor or while in storage is not necessary. If stored more than one year, add grease per lubrication instructions (Table 4-4) before start-up.
It is recommended that the motor shaft be rotated 5 to 10 rotations every three months to distribute the grease in the bearings. This will reduce the chance for corrosion to form on the bearing rolling elements and raceways. Note: Shaft seals and bearing seals may add drag.
TEFC (Totally Enclosed Fan Cooled) motors must meet a minimum distance of Y, the shaft height between the fan guard grill openings and the nearest obstruction. HAZARDOUS LOCATIONS MOTORS: Hazardous Locations motors are intended for installations in accordance with ~ NEC Article 500. For all installations involving Hazardous Locations motors, consult the applicable national codes, local codes, and the authority having jurisdiction. Division 1 Installations - includes Class I & II: Use only motors that are UL Listed and CSA Certified or UL Listed and UL Certified for Canada. These motors bear a separate nameplate that includes the UL Listing Mark and CSA Certification Mark or includes the UL Listing Mark and the UL Mark for Canada. This plate also bears the phrase: " Electric motor for Hazardous Locations" and is marked with the Class, Group and Operating Temperature Code. Division 2 Installations - Class I only: Use only motors that are CSA Certified and bear the CSA Certification Mark. These motors include a phrase on the main motor nameplate that indicates the motor is CSA Certified for Class I, Division 2 / Zone 2 locations. Division 2 Installation - Class II only: Use only Class II motors as described above under "Division I Installations".
3.1.3.3
2.3.2
SHAFT
ROTATION:
2.3.3
DAMP OR HUMID STORAGE LOCATIONS: Treat unpainted flanges, shafts, and fittings with a rust inhibitor. Apply appropriate power to the motor's space heaters (if so equipped)
3.0 INSTALLATION
AND OPERATION
WARNING: Only qualified personnel who are familiar with the appropriate national code, local codes and sound practices should install or repair electrical motors and their accessories. Installation should conform to the appropriate national code as well as local codes and sound practices. Failure to follow these instructions could result in serious personal injury, death and/or property damage.
A WARNING:
ELECTRICAL LIVE CIRCUIT HAZARD Do not touch electrically live parts. Disconnect, Lockout and Tag input power supply before installing or servicing motor (includes accessory devices). Use a voltmeter to verify that power is off before contacting conductors.
3.1 LOCATION SELECTING A LOCATION: Consideration should be given to environment and ventilation. Motors should be installed in an area that is protected from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and vibration. A motor with the proper enclosure for the expected operating condition should be selected. Provide accessible clearance for cleaning, repair, service, and inspections (See section 3.1.3 for construction clearances). The location should be considered for possible future motor removal / handling. The free flow of air around the motor should not be obstructed. 3.1.2 AMBIENT TEMPERATURE LIMITS: The ambient temperatures of the air inlet to the motor should not exceed 40C (104F) or be less than -30C (-22F) unless the motor nameplate specifically states an ambient temperature outside of these limits. The ambient inside an enclosure built around the motor shall not exceed the nameplate ambient. For ambient temperatures outside of these limits consult the motor manufacturer. 3.1.1 3.2
WARNING: EXPLOSION HAZARD A motor should never be placed in an area with a hazardous process or where flammable gases or combustible materials may be present unless it is specifically designed and nameplated for this type of service. Hazardous Locations motors are intended for installations in accordance with NEC Article 500. For all installations involving Hazardous Locations motors, consult the NEC, local codes, and the authority having jurisdiction. Failure to follow these instructions could result in serious personal injury, death and/or property damage. (For other limitations see section 1.3) MOUNTING MOTOR:
3.2.1 RIGID BASE (FOOTED): The motor must be securely installed to a rigid foundation or a mounting surface to minimize vibration and maintain alignment between the motor shaft and the load's shaft. The mounting surfaces of the four mounting pads must be flat within 0.01 inches for 210 frame & smaller; 0.015 inches for 250 frame & larger. [IEC 0.25 mm for 130 frame & smaller, 0.38 mm for 160 frame & larger). This may be accomplished by shims under the motor feet. For special isolation mounting, contact manufacturer for assistance 3.2.2 RIGID BASE HOLE SELECTION -6 OR 8 HOLES Lm'41on 1 aoo :3 hola~ l\..y statfmmes:
INErAA,' 1~, 213, 2:4, 7l34, 914,
8(;4, 404., .14.4, 447 (lEG] , 12S. 1&"'S, 11?{~, 1Ef ..

:1irfA.~. 2!'lDS, 2808 lOC;JlYfl2 !))(,r, are krF", F:;! CDIT~cm ~f pro'itled) LOc:a:iDn 1 ;::nj 4-h:;Ie:-; fer k:rg fram~:;
INEM",) 184,210,2:6,286,
. 4 CAUTION:
INSULATION DEGRADATION WARNING Insulation at high temperatures ages at an accelerated rate. Each 10C increase in temperature reduces the insulation life by one half.
WARNING: HAZARDOUS LOCATIONS AMBIENT LIMIT: Division 1 Hazardous Locations motors shall NOT be operated below -25C (-13F) ambient. (Low temperatures reduce the component mechanical properties.) 3.1.3 CONSTRUCTION SELECTION per LOCATION: 3.1.3.1 DRIPPROOF (OPEN) MOTORS are intended for use
indoors where the atmosphere is relatively clean, dry, and non-corrosive. Recommended a minimum clearance of Y, the shaft height between vent openings and the nearest obstruction.
a<E,
:::'i;Q,4OS,445,449
OEC'j 112111, 1321.1, 160L,1 BO!.. 3:D.... 22et.t, ZGiI, ~
3.2.3
VERTICAL
MOUNTING:
3.1.3.2
TOTALLY ENCLOSED MOTORS are suitable for indoor or outdoor standard service applications. TEAO or AOM (Totally Enclosed Air Over) motors must be mounted in the air stream. When the motor nameplate states a minimum airflow the motor must be mounted in an air stream meeting this minimum value.
ENCLOSURE PROTECTION CAUTION: Most Dripproof rigid base (footed) motors do NOT meet "Dripproof' requirements when mounted vertically. If the motor is located in unprotected environments. the addition of a drip cover may be ~ available. Drip covers not available for cast iron rigid base motors.
CAUTION:
WARNING: FALLING OBJECT HAZARD The lifting provision on standard horizontal footed motors is not designed for lifting the motor in a vertical shaft up or shaft down position. (see 2.2.1 lifting angles). Lifting method / provisions for
Figure 1
3.3.4.4
Belt Tension
CAUTION: Equipment Failure Caution Belt tensioning by feel is NOT acceptable. Tensioning by "feel" can ~ be very misleading, and can damage motor and equipment. It is normal for V-belts to squeal initially when line starting a motor.
In general, belt tensions should be kept as loose as possible while still transmitting the required torque without slipping. Belt tensions must be measured with a belt tension gage. These inexpensive gages may be obtained through belt manufacturers, or distributors. Shaft RPM x 3.14 x Sheave Dia (inches) BELT SPEED (Ftlmin) =-----------12 Proper belt tension is determined by measuring the force required to deflect the center of the belt a given distance. The proper deflection (in inches) is determined by dividing the belt span in inches by 64. Calculate the proper deflection and then see Table 3-3 for the required "Deflected Force" to achieve that deflection. After tensioning the belt, rotate the sheaves for several rotations or operate the system for a few minutes to seat belts into the grooves, then re-tension the belts. New belts will stretch during use, and should be retensioned after the first eight hours of use.
3.~.4.2
Number of Belts In general, use the fewest number of belts that will transmit the required torque without slipping. See Table 3-3 for recommended maximum number of belts. Each belt adds to the tension in the system, which increases load on the shafts and bearings. Belts are most efficient when operated at or near their rated horsepower. If the sheaves have more grooves than the number of belts required, use the grooves closest to the motor.
3.3.4.3 Sheave Location

Install sheaves as close to the housing as possible to increase the bearing life of the motor and driven equipment
Figure 2
Avoid Desired
Figure 1
3.3.4.4
Belt Tension
CAUTION: Equipment Failure Caution Belt tensioning by feel is NOT acceptable. Tensioning by "feel" can ~ be very misleading, and can damage motor and equipment. It is normal for V-belts to squeal initially when line starting a motor.
In general, belt tensions should be kept as loose as possible while still transmitting the required torque without slipping. Belt tensions must be measured with a belt tension gage. These inexpensive gages may be obtained through belt manufacturers, or distributors. BELT SPEED (Ftlmin)
= ------------
Shaft RPM x 3.14 x Sheave Dia (inches) 12 Proper belt tension is determined by measuring the force required to deflect the center of the belt a given distance. The proper deflection (in inches) is determined by dividing the belt span in inches by 64. Calculate the proper deflection and then see Table 3-3 for the required "Deflected Force" to achieve that deflection. After tensioning the belt, rotate the sheaves for several rotations or operate the system for a few minutes to seat belts into the grooves, then re-tension the belts. New belts will stretch during use, and should be retensioned after the first eight hours of use.
3.~.4.2
Number of Belts In general, use the fewest number of belts that will transmit the required torque without slipping. See Table 3-3 for recommended maximum number of belts. Each belt adds to the tension in the system, which increases load on the shafts and bearings. Belts are most efficient when operated at or near their rated horsepower. If the sheaves have more grooves than the number of belts required, use the grooves closest to the motor.
3.3.4.3 Sheave Location

Install sheaves as close to the housing as possible to increase the bearing life of the motor and driven equipment
Figure 2
Avoid Desired
Table
3-3
Recommended
Min Sheave Dia (in)
Minimum
Sheave
Diameters,
Min Sheave Dia (in)
Belt
T vpe,
N um ber
Avg. Deflected Force (ibs)
0f
Be Its
an d
Defl ecte d
Force
1200 rpm Max
#
Belt Tvpe
""'V
Motor Hp
('\ -r c
of Belts
1 1.5 2 3 5 7.5 10 15 20 25 1n 40 50 60 75 100 125 150 200 250 300 350 400 450 500 600 700 800
2.4 2.4 2.4 3.0 3.0 3.8 4.4 4.4 5.2 6.0 F;R 6.8 8.2 8.2 10.0 10.0 12.0 13.2 15.0 15.0 16.0 16.5 17.5 18 18.5
""
Avg. Deflected Force (lbs)
1S00 rpm Max
#
Belt Tvpe
""'V
"
3VX 3VX 3VX 3VX 3VX 3VX 3VX 3VX 3VX 3VX
'>,\1)(
1 2 3 2 3 4 4 5 6 7
7
4.0 3.1 2.8 3.3 4.0 4.7 5.4 5.4 6.0 5.6 <;Q
of Belts
""
2.2 2.4 2.4 2.4 3.0 3.0 3.8 4.4 4.4 4.4 <;? 6.0 6.8 7.4 8.6 8.6 10.5 10.5 13.2 14.0 14.0 14.5 15.0 16.0 16.5 17.5 19.0 20.0
Min Sheave Dia (in)
3600 rpm Max
#
Belt Type
"'\IV
of Belts
'>,\1)(
1 2 2 3 3 4 4 4 6 7
7
""
3.1 2.1 2.9 2.9 3.7 4.1 4.3 5.4 4.8 5.2
<;'>,
2.2 2.2 2.4 2.4 2.4 3.0 3.0 3.8 4.4 4.4
""
Avg. Deflected Force (Ibs) 1.6 2.5 2.7 2.3 2.5 4.2 3.8 4.4
1 1 1 2 3 2 3 3 3 4
."
5.0 4.7
5VX 5VX 5VX 5VX 5VX 5V 5V 5V 8V 8V 8V 8V 8V 8V
4 4 5 5 6 7 7 8 6 7 7 8 8 9
11.6 14.6 14.1 14.5 16.0 14.1 15.4 16.0 27.6 27.1 30.3 29.1 31.6 30.7
3VX 3VX 5VX 5VX 5VX 5V 5V 5V 5V 5V/SV 5V/SV 5V/SV 5V/SV 5V/SV 8V 8V 8V
7 8 4 4 6 6 7 8 9 11 1 7 12/7 13/S 14/9 15/9 11 12 13
6.0 5.9 13.3 14.3 13 13.1 13.4 13.1 13.8 23.4 26.0 25.7 25.2 26.9 26.3 27.3 28.2
Contact Motor Manufacturer when Belting 3600 rpm Motors Greater than 25 HP
Notes: 1. Horsepower is the nameplate motor horsepower, and RPM is the motor (driver) speed. 2. Minimum sheave diameters are from NEMA standards where applicable. 3. For variable speed applications or values outside these recommendations, consult motor manufacturer. 4. Selections are based on a 1.4 service factor, 5 to 1 speed ratio and various Power Transmission Manufacturers' catalogs. 5. These selections are for Narrow V-belt sections only. Consult manufacturer for details on conventional V-belt sections (A, B, C, D and E), or other belt types. 6. "Average Deflected Force is per section 3.3.4.4 of this document and is the force required to deflect the center of a belt 1/64 of the belt span distance. Tolerance on this force is 1 Ibf for forces $10 Ibs, and 2lbs for forces >10 Ibs as measured utilizing a belt tension gage. 7. When more than one belt is required the belts must be a matched set (matched for length). 8. If possible, the lower side of the belt should be the driving side to increase the length of wrap on the sheave). 9. For belted loads do not exceed 125% of 60 Hz operating RPM.
3.3.5 VFD (Variable Frequency Drives) OPERATION:
A WARNING: A
VFD Motors with Reset Thermal Protectors UL Recognition, UL Listing, or CSA certification does not apply to motors that are equipped with a manual or automatic reset thermal protector when the motor is operated on VFD power. Power Factor Correction Power factor correction capacitors should between the drive and the motor.
3.3.5.1
Overspeed Capability:
Belted loads: Do not exceed 125% of 60 Hz operating RPM. Table 3-4 Maximum Safe Continuous Speed (RPM) For Coupled and Direct Connected Loads
WARNING:
Capacitors: never be installed
NEMAI [lEe] Frame Size

56-180 210-250 280 320 360 400-440 >440 [80-110] [130-160] [180] [200] [225] [250-280] [>280]
2-Pole
7200 * 5400 * 5400 * 4500 * 4500 * 3600 3600
4,6, or 8 Pole
5400 * 4200* 3600 3600 2700 2700 1800
CAUTION: VFD I Motor Setup:
It is the responsibility of the startup personnel during set up of the VFD 1 motor system to properly tune the drive to the motor for the specific application per the VFD user manual. The correct voltage boost and volts per hertz settings are application dependent and unique to each motor design. Failure to connect over temperature devices (when provided) will void the warranty.
* - Fan cooled motors (Totally Enclosed & Hazardous Locations Motors) are limited to a maximum safe continuous speed of 4000 RPM For higher speeds or shortened duty cycle contact motor manufacturer
3.3.5.2
Cable Lengths: For optimum insulation life, limit VFD to motor cable lengths of general purpose motors
to Table 3-5 values. Definite purpose VFD motors may accommodate longer cable lengths. For additional information contact motor manufacturer. Table 3-5 Max Cable Lengths General Purpose Motors These values are based on 3 kHz carrier frequency. Add suitable VFD output-side filters when exceeding the listed values Frame Size 230V 600 ft. 1000 ft. 180 m. 300m. 460 V 575 V
NEMA56-320 NEMA 360-5011 IEC 80-200 IEC 225-280.
125 ft. 225 ft. 40m. 70m.
40 ft. 60 ft. 12 m. 18 m.
General Information: When thermal protection is provided, one of the following will be stamped on the nameplate: 1. "THERMALLY PROTECTED" This motor has built in thermal protection. Thermal protectors open the motor circuit electrically when the motor overheats or is overloaded. The ~ protector cannot be reset until the motor cools. If the protector is automatic, it will reset itself. If the protector is manual, disconnect motor from power supply. After protector cools (five minutes or more) press the reset button and reapply power to the motor. In some cases a motor is marked "Auto" and the connection diagram on the motor will identify T'Stat leads - see "2 "below. (See warnings on Manual and Automatic reset protectors - section 1.1) 2. "WITH OVERHEAT PROTECTIVE DEVICE": This motor is provided with an overheat protective device that does not directly open the motor circuit. Motors nameplated with this phrase have either thermostats, thermisters or RTD's. The leads to these devices are routed into the motor conduit box or into an auxiliary box. The lead markings are defined on the nameplate (normally "P1", "P2") . The circuit controlled by the overheat protection device must be limited to a maximum of 600 volts and 360 volt-amps. See connection decal provided inside the terminal box cover. Failure to connect these over temperature devices (when provided) will void the warranty. WARNING: EXPLOSION HAZARD For Hazardous Locations motors provided with thermostats UL and the NEC require connection of thermostat leads into the control portion of a manual reset start circuit. Failure to follow this instruction could result in serious personal injury, death and/or property damage Resistance Temperature Detectors (RTD): When winding and/or bearing RTDs are provided the RTD lead markings are defined on the nameplate. (Normally "R1", "R2", "R3" etc.) 3.3.6.5 RTD Alarm & Trip Settings: ~ Tables 3-6 & 3-7 are suggested initial RTD alarm and trip settings. For motors found to operate significantly below these values the settings may be reduced accordingly. Table 40C Motor 3-6 Winding Class Rise:s; Alarm Up to 1.0 SF >1.0 to 1.15 SF 130 140 RTD Temperature Limit
3.3.5.3 VFD Grounding: Equipment grounding conductors may be run in the same conduit as the AC motor power leads. This wire must be used as the equipment ground for the motor and not as the fourth current carrying wire of a "WYE" motor circuit. The grounded metal conduit carrying the output power conductors can provide EMI shielding, but the conduit does not provide an adequate ground for the motor; a separate grounding conductor must be used. Grounding the motor neutral (WYE) of a VFD powered motor may result in a VFD ground fault trip. Improper grounding of an inverter fed motor may result in frame voltages in excess of 500 Volts. Refer to Grounding section 3.4.4 3.3.5.4 VFD - Single Phase: CAUTION: SINGLE PHASE MOTOR FAILURE: Single Phase motors are NOT suitable for use on VFD power. Connecting a Single Phase Motor to a VFD voids the warranty. 3.3.5.5 Stray Voltage on Accessory Leads: VFD's will couple stray (common-mode) voltage to motormounted RTDs, thermistors, thermostats and space heaters. The leads of these elements must be properly insulated and control input circuits must be designed to withstand this common-mode voltage. 3.3.6 ACCESSORIES
PROVISIONS:
3.3.6.1 General: Carefully read and understand the accessory manufacturer's instructions, supplied with motor. Contact the manufacturer for additional information. 3.3.6.2 Brake Motors:
(0C)
Max Ambient Load B Temp 80C Trip 140 150 Class Rise:s; Alarm 155 160 F Temp 105C Trip 165 165
CAUTION: Vertical Motor Premature Brake Failure Motors with brakes that are designed for vertical applications are equipped with springs to support the brake pressure plate. Mounting a horizontal brake motor vertically shaft up or down may require a pressure plate spring modification. Failure to modify the brake for the vertical application may result in premature brake failure. If in question, consult brake literature or brake manufacturer. Brake Solenoid Wiring: Do NOT connect the brake solenoid to the output of a VFD. The brake solenoids must be wired to 50/60 Hz line power 3.3.6.3 Space Heaters: Motors provided with space heaters have two leads that are brought into the conduit box or into an auxiliary box. These leads are marked "H1", "H2" ("H3", "H4" if a second space heater is supplied). See the space heater nameplate on motor for heater rating. WARNING: DIVISION 2 EXPLOSION HAZARD The space heater temperature rating when used in Class I, Division 2 motors shall NOT exceed 80% of the auto ignition temperature of the hazardous gas or vapor. See the space heater nameplate on motor for heater Temperature Code and heater rating. Failure to follow this instruction could result in serious personal injury, death and/or property damage 3.3.6.4 Thermal Protection:
Table 40C
3-7
Bearing
RTD
Temperature
Limit
(0C)
Max Ambient Ambient Up to 40C > 40C Bearings that are Heat Stabilized to 150C Alarm 95 110 130 Trip 100 115 135
3.3.7
GUARDS:
WARNING: ROTATING PARTS HAZARD When devices are assembled to the motor shaft, be sure to install protective devices such as belt guards, chain guards, and shaft covers. These devices must protect against accidental contact with ~ extremities, hair, and clothing. Consider the application and provide guarding to protect personnel. Remove all unused shaft keys and loose rotating parts to prevent them from flying off and causing bodily injury. Failure to follow this warning could result in serious personal injury, death and/or property damage.
3.4
ELECTRICAL
CONNECTIONS:
WARNING: ELECTRICAL HAZARDS Before proceeding read Section 1-1 on Electrical Safety. Failure to follow the instructions in Section 1-1 could result in serious personal injury, death and/or property damage
3.4.1
(3) Machined Surface Gap (Hazardous Locations Terminal Boxes): The gap between mating surfaces with the machined terminal box MUST BE LESS THAN 0.002 inches. This gap must be checked with a feeler gage along the entire perimeter. If there is visible damage to the mating surfaces, or if the gap between these surfaces exceeds 0.002 inches, DO NOT complete the installation and contact the motor manufacturer. Failure to follow these instructions could result in serious personal injury, death and/or property damage
POWER SUPPLY I BRANCH CIRCUIT
POWER SUPPLY INCOMPATIBILITY HAZARD Check power supply to make certain that voltage, frequency and current carrying capacity are in accordance with the motor nameplate. Failure to match motor nameplate values could result in serious personal injury, death and/or property damage
WARNING:
3.4.3
LEAD CONNECTIONS
Electrical connections to be made per nameplate connection diagram or separate connection plate. In making connections follow the applicable electrical code as well as local codes and practices.
A WARNING:
3.4.1.1
BRANCH CIRCUIT SUPPLY HAZARD Motor and control wiring, fusing, overload protection, disconnects, accessories and grounding must always conform to the applicable electrical codes as well as local codes and sound practices. to a motor should include a disconnect switch, short circuit current fuse or breaker protection, motor starter (controller) and correctly sized thermal elements or overload relay protection.
WARNING: ELECTRICAL CONNECTION HAZARD Failure to correctly connect the motor leads and grounding conductor can result in injury or death. Motor lead connections can short and cause damage or injury if not well secured and insulated. 3.4.3.1 Wire Size (Single Phase) Requirements
Branch
Circuit
Supply
The minimum wire size for Single Phase, 115 & 230 Volt Circuits must meet table 3-8 for a given distance between motor and either Fuse or Meter Box.
3.4.1.2
Fuses, Breakers,
Overload
Relays
Table 38 Minimum Wire Gage Size Single Phase 115 & 230 Volt Circuits
Distance Motor HP 1/4 1/3 1/2 3/4 1 1 1/2 2 3
100 Ft. 115 230
Short Circuit Current Fuses or Breakers are for the protection of the branch circuit. Starter or motor controller overload relays are for the protection of the motor. Each of these should be properly sized and installed per the applicable electrical codes as well as local codes and practices.
(Feet) - Motor to Fuse or Meter Box

200 Ft. 115 230 300 Ft. 115 230 500 Ft. 115 230
A WARNING:
3.4.1.3
PROTECTIVE DEVICE DISABLED HAZARD DO NOT bypass or disable protective devices. Protection removal could result in serious personal injury, death and/or property damage
14 12 10 10 8 4
AC Power Supply
Limits
14 14 12 12 10 10 8 8
10 10 8
6 6
0
12 12 10 10 8 8
6 6
4 4
10 10 8 8
6
4 4 2
8 8
6 6
4 4 2 2 0
6 6
4 4 2
6 6
4
Motors are designed to operate within the following limits at the motor terminals: 1AC power is within +/- 10 % of rated voltage with rated frequency applied. (Verify with nameplate ratings) OR 2AC power is within +/- 5% of rated frequency with rated voltage OR 3A combined variation in voltage and frequency of +/- 10% (sum of absolute values) of rated values, provided the frequency variation does not exceed +/-5% of rated frequency. 4For 3 phase motors the line to line full load voltage must be balanced within 1%. 5If the motor is rated 208-230V, the voltage deviations must be calculated from 230V.
5 3.4.3.2
6 Extension
Cords (Single Phase Motors):
Where an extension cord(s) is utilized to provide power to the motor the extension cord(s) must be ... (1) the proper gauge size per table 3-8, (2) in good working condition (3) properly grounded.
3.4.4
GROUND CONNECTION(S):
CAUTION: Reduced Motor Performance Operation outside of these limits will degrade and increase operating temperature.
motor performance
3.4.2
TERMINAL Conduit
BOX: Opening:
WARNING: ELECTRICAL GROUNDING HAZARD For general information on grounding (USA) refer to NEC Article 250. Improper grounding of an inverter fed motor may result in frame voltages in excess of 500 Volts. In making the ground connection, the installer must make certain that a good electrical connection is obtained between motor and grounding lead. Failure to properly ground motors, per the applicable national code (such as NEC Article 430) and local codes may cause serious injury or death to personnel.
3.4.2.1
For ease of connections, motors are typically provided with large terminal boxes. Most motors have conduit access in 90 degree increments, the terminal box conduit opening is typically provided via knockouts, holes with covers, or the terminal box is rotate-able. Fabricated conduit boxes may have a removable plate for the installer to provide correctly sized hole(s).
3.4.2.2
Hazardous
Locations
Motors:
WARNING: EXPLOSION HAZARDS (1) Terminal Boxes mounted to motor with a pipe nipple: If a pipe nipple mounted terminal box is removed or rotated it must be reassembled with a minimum of five full threads of engagement. (2) Component Removal: Do not set a terminal box component on its machined surfaces. Prior to component reassembly wipe clean all machined surfaces.
Primary "Internal" Ground: A grounding conductor must be connected to the grounding terminal provided in the terminal housing. This grounding terminal is either a ground screw, ground lug, or a tapped hole to be used with a separately provided ground screw. The internal grounding feature is accessible inside the terminal housing and must be used as the primary grounding connection. Secondary "External" Ground: Some motors are provided with a supplemental grounding terminal located on the external surface of the motor frame or feet. This external terminal is for supplemental bonding connections where local codes permit or require such connection
3.4.5
START UP: WARNING:
ELECTRICAL SHOCK HAZARD: Be certain that all connections are secure and the conduit box cover is fastened in place before electrical power is connected. Failure to follow these instructions could result in serious personal injury, death, and/or property damage.
WARNING: LOOSE & ROTATING PARTS HAZARD Before proceeding read Section 1-2 on Mechanical Safety. Failure to follow the instructions in Section 1-2 could result in serious personal injury, death and/or property damage WARNING: EXCESSIVE SURFACE TEMPERATURE HAZARD Motors with the temperature code stated on the nameplate are designed to operate within this limit. Improper application or operation can cause the maximum surface temperature to be exceeded. A motor operated in a Hazardous Location that exceeds this surface temperature limit increases the potential of igniting hazardous materials. Therefore, motor selection, installation, operation, and maintenance must be carefully considered to ensure against the following conditions: (1) Motor load exceeds service factor value, (2) Ambient temperature above nameplate value, (3) Voltages outside of limits (3.4.1.3), (4) Loss of proper ventilation, (5) VFD operation exceeding motor nameplate rating, (6) Altitude above 3300 feet /1000 meters, (7) Severe duty cycles, (8) Repeated starts, (9) Motor stall, (10) Motor reversing, and (10) Single phase operation. Failure to follow these instructions could result in serious personal injury, death and/or property damage.
Do not start more than twice in succession under full load. Repeated starts and/or jogs of induction motors can cause overheating and immediate failure. Contact the motor manufacturer if it is necessary to repeatedly start or jog the motor.
4.0 MAINTENANCE:
Hazardous Locations Motor Repair HAZARD: Division 1 Hazardous Locations motors can only be modified or repaired by the manufacturer or a facility that is Listed under UL's category "Motors and Generators, Rebuilt for use in Hazardous Locations". Failure to follow these instructions could result in serious personal injury, death and/or property damage. WARNING: ELECTRICAL SHOCK HAZARD Electrical connections are to be made by qualified electrical personnel in accordance with all applicable codes, ordinances and sound practices. Failure to follow these instructions could result in serious personal injury, death and/or property damage. Only qualified personnel who are familiar with the applicable national codes, local codes and sound practices should install or repair electric motors and their accessories.
A WARNING:
WARNING: ELECTRICAL LIVE CIRCUIT HAZARD Do not touch electrically live parts. Disconnect, lockout and tag input power supply before installing or servicing motor (includes accessory devices).
CAUTION: HOT SURFACE Normal motor surface temperatures may exceed 90 C (194 F). Touching the motor frame may cause discomfort or injury. Surface temperatures should only be measured with suitable instruments and not estimated by hand touch.
4.1
GENERAL
INSPECTION
Inspect the motor approximately every 500 hours of operation or every three months, whichever occurs first. Keep the motor clean and the ventilation and fin openings clear. The following steps should be performed at each inspection:
3.4.5.1
1.
Start
Up - No Load
Procedure
2.
Check Instructions: Before startup carefully read and fully understand these instructions including all warnings, cautions, and safety notice statements. Motor out of storage after more than three months: Check winding insulation integrity with a Megger. If winding resistance to ground is less than 1.5 Meg-ohms consult the local authorized service shop before energizing the motor. Check Installation: Mechanical - Check tightness of all bolts and nuts. Manually rotate the motor shaft to ensure motor shaft rotates freely. Note: Shaft & bearing seals will add drag. Electrical - Inspect all electrical connections for proper terminations, clearance, mechanical tightness and electrical continuity. Be sure to verify connections are made per the nameplate connection diagram or separate connection plate. Replace all panels and covers that were removed during installation before energizing the motor. Energize Motor: Check Rotation If practical check motor rotation before coupling to the load. Unlock the electrical system. Momentarily provide power to motor to verify direction of rotation. If opposite rotation is required, lock out power before reconnecting motor. If motor has a rotational arrow only operate the motor in the rotation identified. Reapply power to ensure proper operation. Record No Load Amps, Watts & Voltage: Recommend - To establish a baseline value check and record the no load amps, watts, and voltage. Start Up - Load Connected Procedure
4.1.1
VENTILATION: Check that the ventilation openings and/or exterior of the motor is free of dirt, oil, grease, water, etc, which can accumulate and block motor ventilation. If the motor is not properly ventilated, overheating can occur and cause early motor failure.
3.
INSULATION: Use a "Megger" the integrity of the winding insulation has the Megger readings. If winding resistance Meg-ohms consult the local authorized energizing the motor.
4.1.2
~
periodically to ensure that been maintained. Record to ground is less than 1.5 service shop before re-
4.1.3 4.2
ELECTRICAL CONNECTIONS: connectors to be sure that they are tight. LUBRICATION
Check
all
electrical
&
BEARINGS:
4.
The lubricating ability of 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 operating conditions. Longer bearing life can be obtained if the listed recommendations are followed: NOTE: If lubrication instructions are provided on the motor nameplate, the nameplate instructions will supersede these instructions. Motors marked "Permanently Lubricated" do not require additional service. CAUTION: BEARING / MOTOR DAMAGE WARNING Lubricant should be added at a steady moderate pressure. If added under heavy pressure bearing shield(s) may collapse. Over greasing bearinqs greatly increases bearing friction and can cause premature bearing and/or motor failure.
5.
3.4.5.2
1.
2.
3.
Check Instructions: Before startup carefully read and fully understand these instructions including all warnings, cautions, & safety notice statements. Coupling Installation: Check that the connected equipment is properly aligned and not binding. Check that all guards and protective devices are properly installed. Energize Motor: When all personnel are clear of the machine, apply power and verify that the load is not transmitting excessive vibration back to the motor though the shaft or the foundation. Verify that motor amps are within nameplate rating. For repeated starts see 3.4.5.3. The equipment can now be fully loaded and operated within specified limits as stated on the nameplate. Jogging and/or Repeated Starts
4.2.1
GREASE TYPE (unless nameplate states otherwise): Nameplate Ambient Temperature between -30C (-22F) to 65C (150F) inclusive: Recommended grease for standard service conditions is Mobil Polyrex EM. Equivalent and compatible greases include: Texaco Polystar RB, Rykon Premium #2, Pennzoil Pen 2 Lube, Chevron SRI & Mobil SHC 100. ~
Nameplate Ambient Temperature below -30C (-22F): Special low temperature grease is recommended, such as Aeroshell 7 or Beacon 325 for ball bearings and Mobil SHC 100 for roller bearings.
3.4.5.3
Nameplate Ambient Temperature above 65C (150F): Dow Corning DC44 or equivalent, a special high temperature grease is required. Note that Dow Corning DC44 grease does not mix with other grease types.
For RTD settings see Table 3-7.
4.2.2 BEARING OPERATING TEMPERATURE:

CAUTION: HOT SURFACE The external surface temperature of the end shield (bracket) bearing hub may reach 100 C (212 F) during normal operation. Touching this surface may cause discomfort or injury. Surface temperatures should only be measured with suitable instruments and not estimated by hand touch.
4.2.3 LUBRICATION INTERVALS: (For motors with regreasing provisions)

Eq.4.2 Table Lubrication Interval
[(Table 4-1) hrs] x [Interval Multiplier (Table 4-2)] x [Construction Multiplier (Table 4-3)] (Hours) These values are based on average use. Operating Speed - RPM (See Table 3.4 for Maximum
4-1 Lubrication
Intervals
Operating
Speed)
NEMA I [IEC] Frame Size

56-180 210-250 280 320 360 400-440 >440 Seasonal Service: [80-110] [130-160] [180] [200] [225] [250 - 280] [>280]
<7200
2500 Hrs.
<5400
4000 Hrs 2500 Hrs 2000 Hrs
<4500
5000 Hrs 4000 Hrs 3000 Hrs 2000 Hrs 1500 Hrs
<3600
6000 Hrs. 5000 Hrs. 4000 Hrs. 3000 Hrs. 2000 Hrs. 1500 Hrs. 1000 Hrs.
<1800
<1200
If motor remains idle for more than six months, Lubricate at the beginning of the season, then follow lubrication interval. safe operating speed Table 3-4 without manufacturer's approval
Do not exceed maximum
Table 4-2 Service Conditions Use hiqhest level Multiplier: Maximum Ambient Temperature Severity of Maximum Ambient Service Temperature
Standard Severe Extreme Less than 40 C (104 F) Above 40 C (104 F) to 50 C Greater than 50 C Class H Insulation or
and Contamination
are independent
factors
Atmospheric
Contamination
Multiplier
1.0 0.5 0.2
Clean, Slight Corrosion, indoors, less than 16 hrs per day Moderate dirt or Corrosion or outdoors or more than 16 hrs per day Severe dirt or Abrasive dust or Corrosion
Table
43 u - C ons t ruc f Ion Mu Ifrpner

Construction
Angular Contact or Roller Bearing Vertical Motor All others
Table Multiplier
0.5 0.5 1.0
4-4 Relubrication
Frame Size
NEMA 48-56 143-145 182-184 213-215 254-256 284-286 324-326 364-365 404-405 444-449 >449 IEC 80 90 110 130 160 180 200 225 250 280 >280
Amounts Volume
Cu. In. 0.25 0.25 0.50 0.75 1.00 1.50 2.00 3.00 3.80 4.10 4.50 Fluid oz 0.14 0.14 0.28 0.42 0.55 0.83 1.11 1.66 2.11 2.27 2.50 ml 4.0 4.0 8.0 12.5 16.0 25.0 33.0 50.0 62.0 67.0 74.0
For regreasing
while operating
multiply volume by 125%.
_I
1. 2.
4.2.4 LUBRICATION PROCEDURE: (For Motors with Regreasing Provisions) CAUTION: BEARING DAMAGE WARNING Added grease must be compatible with the original equipment's grease. If a grease other than those stated in 4.2.1 is to be utilized contact the motor manufacturer. Nameplate information supersedes section 4.2.1 (GREASE TYPE). New grease must be free of dirt. Failure to follow these instructions and procedure below may result in bearing and/or motor damage.
For an extremely dirty environment, manufacturer for additional information. LUBRICATION PROCEDURE: Remove grease drain plug and clear outlet hole contact the motor
3. 4.
Table 4-1 list 10,000 hours for standard conditions. Table 4-2 classifies severity of service as "Severe" with a multiplier of 0.5. Table 4-3 lists a multiplier value of 0.5 for "Vertical" (Eq.4.2) Interval 10,000 hrs x 0.5 x 0.5 2500 hrs
Table 4-4 shows that 1.5 in of grease is to be added.

3
Relubricate every 2,500 recommended grease.
hrs
of
service
with
1.5
in
of
4.3 TROUBLE-SHOOTING WARNING: READ INSTRUCTIONS: Before trouble-shooting a motor, carefully read and fully understand the warnings, cautions, & safety notice statements in this manual.
1.. Clean
the grease inlet plug or zerk fittings prior to regreasing.
2.
(If present) blockage.
WARNING: Hazardous Locations Motor Repair: Motors nameplated for use in Division 1 Hazardous Locations can only be disassembled, modified or repaired by the plant of manufacturer or a facility that is Listed under UL's category "Motors and Generators, Rebuilt for use in Hazardous Locations". Failure to follow these instructions could result in serious personal injury, death and/or property damage CAUTION:
CAUTION: GREASE DRAIN PLUGGED: Old grease may completely block the drain opening and must be mechanically removed prior to regreasing. Forcing a blocked drain open by increased greasing pressure may collapse bearing shields and / or force excess grease through the bearings and into the motor.
DISASSEMBLY APPROVAL REQUIRED: Motor disassembly must be performed by a party approved by the motor manufacturer. To disassemble the motor without approval voids the warranty.
4.3.1 GENERAL TROUBLE-SHOOTING WARNINGS

1. 2. 3. 4. 5. DISCONNECT POWER TO THE MOTOR BEFORE PERFORMING SERVICE OR MAINTENANCE. Discharge all capacitors before servicing motor. Always keep hands and clothing away from moving parts. Be sure required safety guards are in place before starting equipment. If the problem persists contact the manufacturer.
3. 4.
Add grease per Table 4-4 Re-install grease inlet and drain plugs (if removed).
EXPLOSION HAZARD Do NOT energize a Hazardous Locations motor without all grease fittings properly installed.
WARNING:
4.2.5 EXAMPLE: LUBRICATION

Assume - NEMA 286T (IEC 180),1750 RPM Vertical motor driving an exhaust fan in an ambient temperature of 43 C and the atmosphere is moderately corrosive.
t" 432 . . Mot or T rou ble-s hoOlng C ause IC orrec t"rve At" cion - T a bl e 45 Issue: Likely Cause: Motor fails to start upon initial installation:
A.) B.) C.) D.) E.) F.) G.) H.)
Supply voltage is too low or is severely unbalanced phase is low or missing). Motor leads are miswired at conduit box. Driven load exceeds motor capacity Load is jammed. Fan guard is bent and making contact with fan VFD with power factor capacitors installed (one (1) Check power supply fuses (2) Match motor lead wiring to nameplate connection diagram and supply voltage (3) Ensure that steady state supply voltage at motor terminals is within limits (see section 3.4.1.3). Correct as needed (4) Obtain correc motor to match actual supply voltage. (1) Verify that motor & load turn freely (2) Disconnect motor from load & ensure motor turns freely. Note: Roller bearings make noise when motor is uncoupled and shaft is rotated (3) Verify that motor starts when disconnected from load (4) Remove excessive / bindinq load if present. Replace fan guard & fan (if blades are damaged) Remove power factor correction capacitors if equipped Ensure that motor neutral lead is ungrounded (1) Repeat checks listed above (2) Verify that VFD current limit and starting boost are set correctly (5) Double-check motor and feedback parameter settings and VFD permissives (6) Repeat autotune (for vector drives) procedure (7) Consult VFD supplier.
Corrective Action:
VFD with motor neutral lead grounded
VFD programmed
incorrectly
Motor has been running, then slow down, stalls, or fails to restart:
Supply voltage unbalanced has drooped or has become (1) Replace fuse or reset circuit breaker. Allow motor to cool down before resetting manual protector on motor. Warnings - See section 1.1 for automatic and manual severely reset protector warnings (2) Verify that rated and balanced supply voltage has been restored before restarting motor. Measure voltage during restart. Ensure that steady state supply voltage at motor terminals is within limits (see section 3.4.1.3). (1) Verify that motor & load turn freely. Repair binding components as needed (2) Reduce driven load to match motor capacity or increase motor size to match load requirements. (1) Check fault codes on VFD and follow VFD troubleshooting procedures (2) Verify that VFD input voltage is balanced and within limits (3) Remove excessive mechanical load if present. Warning: Potential Shock Hazard: Contact service shop to check capacitor.
A.)
B.) C.) D.)
Motor is overloaded Motor bearings are seized Load Is jammed. VFD will not restart motor after tripping Capacitor failure on single phase motor (if equipped)
r:
E.) F.)
Motor takes too long to accelerate:

A.) B.) C.) D.) E.)
Motor leads are not connected Supply voltage unbalanced. has correctly or become severely Match motor lead wiring to nameplate diagram. (1) Ensure that steady state supply voltage at motor terminals is within limits (see section 3.4.1.3). Correct as needed (2) Obtain correct motor to match actual supply voltaqe. Determine correct replacement motor. motor size and contact motor representative to obtain
drooped
Load exceeds motor capability
Faulty start capacitor (Single Phase)
Motor may be too small for load. Record acceleration fail if acceleration time exceeds 3 seconds.
time. Start capacitors
may
Mechanical Failure
(1) Check to make sure motor & load turn freely (2) Disconnect ensure motor turns freely
motor from load &
Motor rotates in the wrong direction:

A.)
Incorrect wiring connection at motor [Single Phase] Reconnect motor according to wiring schematic Some motors are non-reversible [Three Phase] Interchange any two power supply (phase) leads. provided. Note:
Motor overheats or overload protector repeatedly trips

A.)
Driven Load is excessive (1) If motor current exceeds nameplate value, ensure that driven load has no increased. Correct as needed. (2) If new motor is a replacement, verify that the rating is the same as the old motor. If previous motor was a special design, a general purpose motor may not have the correct performance. Most motors are designed to operate in an ambient up to 40C. Hot Surface Caution) Remove foreign materials fins (TEFC motors) - clear vent openings, (See section 4.2.2
r:
B.) C.) D.)
Ambient temperature
too high
Motor cooling fins and/or vent openings blocked
fan guard air inlets and frame
Insufficient Air Flow
TEAO (Totally Enclosed Air Over) motors: Measure airflow next to motor surface and obtain minimum requirements from motor manufacturer.
E.) F.)
Motor is started too frequently
See section 3.4.5.3 (1) Ensure that steady state supply voltage at motor terminals is within limits (see section 3.4.1.3) Correct as needed (2) Reconnect motor per input voltage (3) Obtain correct motor to match power supply.
Supply voltage too low, too high, or unbalanced
Motor Vibrates
A.) B.)
Motor misaligned to load. Realign load (1) Ensure that load is dynamically balanced: (2) Remove motor from load and inspect motor by itself. Verify that motor shaft is not bent. Rule of thumb is 0.002" runout for shafts extension lengths up to 3.00". Add 0.0005" per every additional inch of shaft lenoth bevond 3.00". Mixing new with used belts. of matched belts. Replace multiple belt applications with a complete set
Load out of balance (Direct drive application)
C.)
Uneven tension on multiple belts
D.)
Driven load frequency.
operating
at
resonant
point
(1) De-energize motor and record vibration as load coasts from 100% speed to 0 RPM. If vibration drops immediately, vibration source is electrical. If levels do no natural drop immediately, source is mechanical (2) Redesign system to operate below the resonant point (3) On VFD-driven loads, program skip frequencies to bypass resonant points (4) Increase carrier frequency to obtain <3% THD current (5) On variable torque loads reduce volts/hertz below base speed. (1) Adjust VFD to obtain <3% THD current @ rated motor current (2) Adjust VFD stability for smooth operation. Vector drives may be unstable at light load. Match motor lead wiring to nameplate connection diagram. Shim, strengthen or tighten where required.
E.) F.) G.)
VFD torque pulsations Motor miswired at terminal box Uneven, weak or loose mounting support.
H.)
Motor bearings defective
Test motor by itself. If bearings are bad, you will hear noise or feel roughness. Roller bearings are normally noisy when operated without load. If sleeve bearing, add oil per nameplate instructions. For motors with regreasing provisions, add If noise persists contac grease per relubricating instructions (see section 4.2.3). warrantv service. Disconnect from load. Set motor on rubber pads on solid floor. Secure a Y, height key in shaft keyway and energize from balanced power supply @ rated voltage. If excessive Record vibration levels and compare with appropriate standards. vibration persists contact motor manufacturer.
I.)
Motor out of balance
Bearings repeatedly fail.

A.) B.) C.) D.)
Load to motor may be excessive or unbalanced (1) If belt drive check system per section 3.3.4. (2) Other than belting, check loading on motor shaft. An unbalanced load will also cause the bearings to fail. (3) Check runouts of mating components, such as a C-face and pump flange. Motor enclosure construction See section 4.2.1 not suitable for environment. Replace with correct enclosure
Bearings contaminated. Incorrect grease or bearings for ambient extremes. VFD bearing damage
Ground brush, common mode filter, or insulated bearings must be added. Contac motor manufacturer.
Motor, at start up, makes a loud rubbing, grinding, or squealing noise.

A.)
Contact between rotating and stationary components Belt squeal during across the line starting is normal: (1) Verify that supply voltage is within limits (see section 3.4.1.3). (2) Ensure that motor lead wiring matches nameplate connection diagram: (3) Isolate motor from load. (4) To locate point 0 contact turn motor shaft by hand. (5) If point of contact is not located contact motor service shop.
Start capacitors repeatedly fail.

A.) B.) C.) D.)
The motor acceleration time is too long Motor may be too small for load. Record acceleration fail if acceleration time exceeds 3 seconds. time. Start capacitors may i 3
Motor is being started too frequently Motor voltage low Defective start switch inside motor
Excessive starting will damage motor capacitors. Contact motor manufacturer motor is started more than 20 times/hour or if acceleration time exceeds seconds. Verify that voltage at the motor terminals is within limits (see section 3.4.1.3). Motor internal switch failure overheats motor manufacturer. start capacitor. Contact
service shop or
Run capacitor fails.

A.)
High ambient temperature Verify that the ambient does not exceed motor's nameplate value
----~----~~ ..----------_n-------------------------------
P.O. Box 8003 VVausau, VVI 54401-8003 PH:(715) 675-3311
Certification Data Sheet

(DA TA IS BASED ON 460 VOL TS)
Model #:256TTFNA4001 Winding: K2562124 NP HP: 20 NP VOLTS: NP AMPS: NP RPM: NP EFF: 460 23.5 3530 90.2% DESIGN: FREQ: LR CODE: 95% PF Corr: Sound@
Outline
Drawing:
B-SS2030 15-1225 A-EE7308 Frame: Max Load Inertia: Approx Mtr Wgt: 256T 58 (Ib ft2) 334 1 (Ib ft2) 2 (NEMA VVK2) 20 See F CONTINUOUS
Connection B 60 HZ G 5
Diagram:
Rotor Inertia: Starts/Hour: Stall Time: Insulation: Duty:

--,--
1M: 78 dBA 40 C 1.15
NP PF: 87.5% GTD EFF: Thermal Protection: 88.5% NONE EQUIVALENT R1 0.26838
Ambient Service Factor:
WYE CKT. PARAMETERS R2 X1 1.09198
(OHMS PER PHASE) X2 0.923 XM 38.624
0.2201
RM 88.8
ZREF 14.2
XR 5.2
TO 0.02
TOO 0.477
________
-+~_AM~~ 7 13
RPM I-~ --KW ----.3600

T
TQ(lb-ft)
- ---
I
I
I
EFF(%)
. - -!
--_.
PF(%) 9.5
RlR(C) 0 0 0 55 75 PF(%) 36.5 70

, i
I
I
NoLO N/A N/A 1.0L~J 1.15 LD
18 24
i i
i .-
8.5
-- --
3570
010
--or--
12.5 16.5
3550 3530
.,
r-1
-.
f
-.
--1 22.2 i
- y---...
30
14.8
90.2 91 90.2 90.2
78.5 85 87.5 88
T~"--'"
1_'
27
- --
19
---
3520
-
-.--.--34.5
r
II j 1
!,
i
---- - -NEMA TQ
J'
MTRAMPS L.R. B.D. Mechanical 145 90 Information Shaft Material: Enclosure: Frame: Frame Material: Shaft: Grease: Hazardous Location:
NEMAAMPS 617 383
MTRTQ 173 % 290 %
I r
I
577 %
-
967%
STANDARD TEFC 256T CAST IRON T STANDARD NONE Conduit
Mounting: Electrical Type:
RIGID STANDARD NONE HORIZONTAL F1
Spaceheaters: Orientation: Assembly:
Bearings Bearings
DE: 309 ODE: 210
HIGH VOLTAGE T1 T2 T3 T4 T7 T5 TB T6 T9
DUAL L1 L2 L3
THREE AHASE VOLTA~E MOTOR
EE7308
> > >

LOW VOLTAGE
T1 T4 T9 T7 TB T6 T5 T2 T3 L1 L2 VIEW OF TER~INAL END REF. WINDING DIAGRAM L3 OPTIONAL CORD CONNECTION L1 L2

WHITE
T1 T7 T2 TB T3 T9 T4 T5 T6
---->------y----___ 7
----~-<,
TBY, T2Y, T28L, T48X, T2EC, T2G ( T68Z, T28, T68L, T4AV, T68, T4B
RED
L3~LACK
DRAWN
RIll .
11/20/18110 11/21/18110
.x
I .1
APPD
$AS
04-/24,
1-1
~+~~= __ ~~~~~
2 ADDED THE OPllONAl. COftO CONNECllON
I REDRAYitl
REVISION
-IMU48318
I
~-4;';;';"'~;;':';;'_-4TITlE
RDH 04/24fJ/m
IRM 11/20/1990I
BY & DATE
CONNECTION DIAGRAt-4 3. - IbUAL VOLTAGE t-40TOR

IMAn IFINISH ICAD FilE
SCALE
1
No,l
I.xxxxi
RFP
015T ~
OOD5
REF
THIS DRAWING IN DESIGN AND DErAil IS OUR PROPERTY AND MUST NOT BE USED EXCEPT IN CONNECTION WITH OUR WORK ALL RIGHTS OF DESIGN AND INVENTION ARE RESERVED
THIS IS AN ELECTRONICALLY ~ENERATED DOCUMENT 00 NOl SCALE THIS PRINT
I CHK I ANG I 7'30"
f'--
FMF S~E IDRAWING ~E7;~~E
PREY OF
~I

Manual de Usuario Granalladora PDF

Enviado por

Dados do documento

Descrição original:

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Manual de Usuario Granalladora PDF

Enviado por

Direitos autorais:

Formatos disponíveis

LLheelabrator

T: 905-319-7930 T: 800-845-8508 F: 905-319-7561 F: 800-571-5637 vmw.wheelabratorgroup.com

Wheelabrator Group 1219 Corporate Drive Burlington, Ontario L7L 5V5

Operation & Maintenance Manual

Gunderson GIMSA S. de R.L. de C.V.

Mar. 17/08 Mexico

4 Wheel Plate Descaling Machine J3463

Dust Collector: Dust Collector

5D15L Dust Collector

Created: March 28, 2008 Revision:

Operation & Maintenance Manual

lit.. ...... "...... .....

1ft truetteA GAd Wambtg Syfftbols.. .. ...... .. .. . . ..1.2

1.2.1 1.2.2 1.2.3 1.2.4 1.2.5

1.3.1 1.3.2 1.3.3 1.3.4 1.3.5

,fety - W mings & Preca

ions................. ...................... ............ 19

Highly Explosive Dust. Aluminum Media & Parts Adding Limestone

20 20 Dry Type Collectors

3.2.2.1 3.2.2.2 3.2.2.3

Dust Collector Hopper(s) Ductwork Velocity - Aluminum Applications

Created: March 28, 2008

Operation & Maintenance Manual

3.4.1 3.4.2 3.4.3 3.4.4

Installation Lift points Tipping Hazard Equipment Placement

3.5.1.1 3.5.1.2 3.5.1.3 3.5.2

Items to be checked and completed before start-up ctft.iCClI ~Oft

Mechanical Do's & Don'ts Items:

March 28, 2008

Operation & Maintenance Manual

5.1.1.1 5.1.1.2 5.1.1.3

5.2.1 5.2.2 5.2.3

Elevator Head Section Elevator Boot Section Elevator Belt Assembly

5.4.1.3.1 Primary LP Magnetic Separators 5.4.1.3.2 Secondary LP Magnetic Separators

Mounting and locating dribble valve AI"~u:f8e

Operation & Maintenance Manual

6.2.1.1 6.2.1.1.1 6.2.1.1.2 6.2.1.1.3 6.2.1.1.4 6.2.1.1.5 6.2.1.1.6 6.2.2

6.2.3.1 6.2.3.1.1 6.2.3.1.2 6.2.3.1.3 6.2.3.1.4 6.2.3.1.5 6.2.3.1.6 6.2.3.1.7 6.2.3.1.8

March 28, 2008

Operation & Maintenance Manual

used Oft PulseBag Cartridge

".. " "

Created: March 28, 2008

Blast Wheel Media Handling System

~.~~~~.~~~~~~~~~~~ " ,.""' " "' ,.""'."', ,........ ~

tio~ ReJKdrlReplacelMftt of Palts & CofltlM)fteftts .............. 113

117 117 119

:UO!S!A;}lI 8t110 6 ;}~~d

...................................... ~~~II~ ~: .. .. .. . . .. .. . .' . ._ v. ~ lUJ81~_.taefd'a

v..t~J, .- '" lUJDJ-_ ~O'J' D .............. .. ~ ~ ~1t.lI I~~ 1"1

.... ... ..... ... -

t-tt ~,,~ ~~~~~~~ . ~~ ~ . ~~~~~~~~ . ~~~~~ . ~~~~n . ~n~~~~~~~~~~~~~~S1J.d &.leas puewWOO&~~~"UOll~

' ' '." ~

lenuew a:ueuaJu!ew " uO!JeJado

Operation & Maintenance Manual

March 28, 2008

Operation & Maintenance Manual

Yellow background with black text

Orange background with black text

Operation & Maintenance Manual

1.3.2 Understanding the Equipment

1.3.3 Equipment Operators & Maintenance Personnel Qualifications

~..~~~~~~~ " ,.""' " "' ,.""'."', ,........ ~

t-tt ~,,~ ~~~~~ . ~ . ~~~~~~ . ~ . ~~n . ~n~~~~~~~~~~~~S1J.d &.leas puewWOO&~"UOll~

=..:":":~.~-.:::fiit~~~~~- .. --.-:~- . -~-""=-"""~~~=: ..

~_ m.mm __ m._...ef!....f!...rJ.{RP~),;..+ 40 RPfvt1 .. m m_._..