160 Mixer Installation

8/13/2019 160 Mixer Installation

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MIXER160 CUBIC FOOT

World Headquarters801 Johnson St. • Alpena, Michigan, 49707 • U.S.A.

Phone (989) 354-4111

INSTALLATION MANUAL

466381F0201

APRIL 2003 • US$250



COMPANY NAME: ..............................................................

SERIAL NUMBER: ..............................................................

ASSEMBLY NUMBER: ..............................................................

WIRING DIAGRAM NUMBER: ..............................................................

INSTALLATION DRAWING NUMBER: ............................................................



160 Cubic Foot

i

Table of Contents

466381F0201US F1 24AP03

160 CUBIC FOOT MIXER

TABLE OF CONTENTS

LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

MIXER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

PRIMARY MIXER DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi

MIXER ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii

SAFETY BULLETIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x

SAFETY SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi

LIFTING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi

SECTION 1 MIXER OVERVIEW

1.1 INFORMATION ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 MIXER ASSEMBLY OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.4 MIXER INSTALLATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.5 REQUIRED PARTS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . .1-3

SECTION 2 POSITION MIXER

2.1 CHARGING SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 DISCHARGE SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

SECTION 3 PREPARE SITE

3.1 PREPARE THE SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.1.1 Installation At or Below Plant Grade . . . . . . . . . . . . . . . . . . . . . . .3-1

3.1.2 Position the I-Beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.1.3 Installation Below Floor Level . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3.1.4 Installation Above Floor Level . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3.2 ELECTRICAL, WATER AND AIR SUPPLY CONSIDERATIONS . . . . . . . .3-6

3.3 CHARGING CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3.3.1 Optimum Charging Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3.3.2 Recommended Charging Area . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3.4 GROUTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

SECTION 4 INSTALLATION GUIDELINES

4.1 LIFTING CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1



Table of Contents

160 Cubic Foot TABLE OF CONTENTS

ii 466381F0201US F1 24AP03

4.2 MIXER INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.2.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.2.2 Elevation and Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24.2.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.3 ELECTRICAL INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . . . .4-2

4.3.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.3.2 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.3.3 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.3.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.4 AIR SUPPLY INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . .4-3

4.5 WATER SUPPLY INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . .4-3



A Overall Mixer Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi

B Mixer Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv

C Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi

SECTION 1 MIXER OVERVIEW

1.1 Major Components of the Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

SECTION 2 POSITION MIXER

2.1 Typical Platform for Maintenance – Top View . . . . . . . . . . . . . . . . . . . . .2-2

2.2 Typical Platform for Maintenance – Front View . . . . . . . . . . . . . . . . . . . .2-3

2.3 Typical Platform for Maintenance – Side View . . . . . . . . . . . . . . . . . . . . .2-4

SECTION 3 PREPARE SITE

3.1 I-Beam Locations and Load Requirements . . . . . . . . . . . . . . . . . . . . . . .3-2

3.2 I-Beam Elevation Relative to Plant Grade Elevation . . . . . . . . . . . . . . . .3-3

3.3 Anchor Bolt Locations in the I-Beams . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3.4 Pit Dimensions for Below Floor Level Installation – Top View – . . . . . . . .3-4

3.5 Pit Dimensions for Below Floor Level Installation – Side View – . . . . . . .3-5

3.6 Typical Platform for Maintenance – Front View . . . . . . . . . . . . . . . . . . . .3-6

3.7 Typical Platform for Maintenance – Top View . . . . . . . . . . . . . . . . . . . . . .3-7

SECTION 4 INSTALLATION GUIDELINES

4.1 Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2 Electrical Wiring Block Diagram for aTypical Mixer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

160 CUBIC FOOT

LIST OF FIGURES

TABLE OF CONTENTS 160 Cubic Foot

iii

List of Figures

466381F0201US F1 24AP03



Notice


iv 466381F0201US F1 24AP03

NOTICE

Information in this manual is subject to change. Updates will be provided when safety issues arise, orwhen information becomes outdated. The Besser Company drawings and prints provided with your equip-

ment and machinery are current to the date of manufacture.Illustrations in this manual are provided to help you understand the instructions. The illustrations have

not been drawn to scale. Please read and understand this manual and the Operation/Maintenance Manualbefore operating this machinery. Observe all safety signs and OSHA-approved lockout and tagout proce-

dures. If you have questions about these safety procedures, please contact your Besser Sales andService Representative before start-up of the machine.




v

Specifications

466381F0201US F1 24AP03

160 CUBIC FOOT

SPECIFICATIONS

SHIPPING WEIGHT

(APPROXIMATE) 33,000 pounds [14,969 kg]

OVERALL DIMENSIONS W: 9 feet 6 1/4 inches [2902 mm]L: 17 feet 2 1/4 inches [5239 mm]

H: 7 feet 5 1/2 inches [2273 mm]

PRODUCTION CAPACITY

Maximum volume 160 cubic feet [4.5 m3]

Maximum weight 16,000 pounds [7258 kg]

MIXER ELECTRICAL

MOTOR RATING 2 @ 75 hp [56 kW]

BLADE SHAFT SPEED (RPM) 15.7

MIXER AIR REQUIREMENTS

Air inlet supply 76 inches above floor [1930 mm]

Discharge gate, each 2 1/2 cubic feet [0.071 m3]open/close cycle, (36.72 SCFM)at 120 psi [827.4 kPa]

MIXER WATER REQUIREMENTS

Water supply inlet 1 1/2 inches [38 mm] ID

Gallons [liters] per batch 116 gallons [440 L]

SENSOR AND CONTROL PANEL

OPERATING RANGES

Ambient operating temperature 32° to 131° F[0° to 55°C]

Humidity range 5 to 95 percent,noncondensing

Line voltage 85 to 132 VAC

OPERATING CONDITIONS Besser Company machinery and equipment is designed to comply

with the essential health and safety regulations (EHSR) that apply todirectives which are applicable to an industrial environment. Thebuyer shall utilize this equipment in a manner consistent with itsdesign, and only in an industrial environment.

NOTE:

SCFM means standard cubic feet per minute.



Primary Mixer Dimensions


vi 466381F0201US F1 24AP03

7 ft - 5.5 in[2273 mm]

9 ft - 6.25 in[2902 mm]

17 ft - 2.25 in[5239 mm]

Figure A Overall Mixer Dimensions




vii

Electrical Data

466381F0201US F1 24AP03

160 CUBIC FOOT

ELECTRICAL DATA

CAUTION:

To Comply with Articles 110-9 110-10 of the National Electrical Code:• The customer shall supply a branch circuit protective device to protect the control panel.

The protective device shall have a short circuit interrupting rating of no less than the avail-able short circuit current. Failure to do so could result in a rupture of the protective device

while personnel are attempting to clear a fault.• Besser Company recommends the use of protective devices with interrupting ratings of

no less than 200,000 amps RMS symmetrical.

The caution below applies to the 160 cubic foot mixer electrical data.



Electrical Data


viii 466381F0201US F1 24AP03

160 CUBIC FOOT

ELECTRICAL DATA

PLANT POWER

SUPPLY(VOLTS)

208V60 HZ

220V

50 HZ

230V60HZ

380V50 HZ

415V50 HZ

460V

60 HZ

575V60 HZ

400

400

400

200

200

200

200

350

300

300

200

175

150

125

2.5 IN64 MM

2.5 IN

64 MM

2 IN51 MM

1.5 IN38 MM

1.5 IN38 MM

1.25 IN

32 MM

1 IN25 MM

BRANCH

CIRCUITDISTRIBUTION

SWITCH(AMPS)

BRANCHCIRCUIT

FUSE FRS-R

(AMPS)

BRANCHCIRCUITFEEDER

THHN

BRANCHCIRCUITFEEDER

CONDUIT

AMPSPER

MOTOR

SHORT

CIRCUITINTERRUPTING

CAPACITY(AIC)

350KCMIL

350KCMIL

350KCMIL

3/0 AWG85 MM

2/0 AWG

67.5 MM

1 AWG42.4 MM

2 AWG33.6 MM

200,000

200,000

200,000

200,000

200,000

200,000

200,000

203.80

193

184

112

103

92

73.50

Table A 160 Cubic Foot Mixer Electrical Data for One Starter per Electric Motor

This information is the same for all 160 Cubic Foot Mixers.

TOTAL HORSEPOWER: 150

NUMBER OF MOTORS/HORSEPOWER: 2/75

TOTAL KILOWATTS: 111.86

NUMBER OF MOTORS/KILOWATTS: 2/55.93

CONTROL PANEL TRANSFORMER: 500 volt amps (if used)

NOTES:• Fuses and wire and conduit are sized for 125% of motor full load amperes.

• Full load amperes may vary from one motor to another.

• Table A data is representative of each motor’s specifications not a combination of both motors.These specifications are used when each electric motor has its own starter. However, BesserCompany recommends the use of a single soft starter, sized to start both motors at the same time.

When a single soft starter is used, refer to Table B.

Consult tables A and B to find the appropriate electrical data for your 160 cubic foot Mixer. First, find your

corresponding plant power supply in the left column. Then find the corresponding electrical data on thesame row as your power plant supply.



Electrical Data


ix466381F0201US F1 24AP03

Example: Your power plant supply is 460V at 60 Hz and you use a single soft starter to start both motorsat the same time. Using the tables and general information, you will get these values:

PLANT POWER SUPPLY: 460 volt – 3-phase – 60 hertz

MIXER MOTORSTotal Horsepower: 150Number of Motors/Horsepower: 2/75

Total Kilowatts: 111.86Number of Motors/Kilowatts: 2/55.93

BRANCH CIRCUIT TO STARTER (TABLE B)

Distribution Switch Recommended: 400 amp

Fuse Recommended [FRS–R]: 250 ampFeeder Recommended [THHN]: 250 KCMILFeeder Conduit Recommended: 2.0 in. [51 mm]Short Circuit Interrupting Capacity: 200,000 AIC

Total Ampere Load 207

EACH MIXER MOTOR

Horsepower: 75Kilowatts: 55.93

CIRCUIT TO MOTOR (TABLE A)Feeder Recommended [THHN]: No. 1 AWG (42.4 mm)Feeder Conduit Recommended: 1.25 in. [32 mm]Ampere/Motor: 92

CONTROL PANEL TRANSFORMER: 500 volt amps (if used)

ELECTRICAL DATA NOTESFor safety purposes, Besser Company requires that this equipment be connected to a lockable

electrical disconnect. Due to the high current required, use of 230 VAC or less is not recommended.

PLANT POWERSUPPLY(VOLTS)

220V50 HZ

230V60HZ

380V

50 HZ

415V50 HZ

440V50 HZ

460V60 HZ

575V

60 HZ

600

600

400

400

400

400

200

500

500

350

300

250

250

200

2.5 IN*64 MM

2.5 IN*64 MM

2.5 IN

64 MM

2.5 IN64 MM

2.0 IN51 MM

2.0 IN51 MM

1.5 IN

38 MM

BRANCHCIRCUIT

DISTRIBUTIONSWITCH

(AMPS)

BRANCHCIRCUIT

FUSE FRS-R(AMPS)

BRANCHCIRCUIT

FEEDERTHHN

BRANCHCIRCUIT

FEEDERCONDUIT

AMPSPER

MOTOR

CALCULATEDTOTAL

AMPS

SHORTCIRCUIT

INTERRUPTINGCAPACITY

(AIC)

350*

KCMIL

350*KCMIL

350KCMIL

350KCMIL

250

KCMIL

250

KCMIL

3/0 AWG85 MM

200,000

200,000

200,000

200,000

200,000

200,000

200,000

193

184

112

103

100

92

73.5

434

414

252

232

225

207

165

NOTE: * 2 Sets of Wires / * 2 Runs of Conduit

Table B 160 Cubic Foot Mixer Electrical Data for One Starter for Both Motors



Safety Bulletin


x 466381F0201US F1 24AP03

SAFETY BULLETINThis notice is issued to advise you that some previously accepted shop practices may not be keeping upwith changing Federal and State Safety and Health Standards. Your current shop practices may notemphasize the need for proper precautions to insure safe operation and use of machines, tools, automatic

loaders and allied equipment and/or warn against the use of certain solvents or other cleaning substancesthat are now considered unsafe or prohibited by law. Since many of your shop practices may not reflectcurrent safety practices and procedures, particularly with regard to the safe operation of equipment, it isimportant that you review your practices to ensure compliance with Federal and State Safety and Health

Standards.

IMPORTANTThe operation of any machine or power-operated device can be extremely hazardous unless

proper safety precautions are strictly observed. Observe the following safety precautions:

Always be sure proper guarding is in place for all pinch, catch, shear, crush and nip points.

Always make sure that all personnel are clear of the equipment before starting it.Always be sure the equipment is properly grounded.

Always turn the main electrical panel off and lock it out in accordance with published lockout/tag-out procedures prior to making adjustments, repairs, and maintenance.

Always wear appropriate protective equipment like safety glasses, safety shoes, hearingprotection and hard hats.

Always keep chemical and flammable material away from electrical or operating equipment.

Always maintain a safe work area that is free from slipping and tripping hazards.

Always be sure appropriate safety devices are used when providing maintenance and repairs to allequipment.

Never exceed the rated capacity of a machine or tool.

Never modify machinery in any way without prior written approval of the Besser EngineeringDepartment.

Never operate equipment unless proper maintenance has been regularly performed.

Never operate any equipment if unusual or excessive noise or vibration occurs.

Never operate any equipment while any part of the body is in the proximity of potentially haz-ardous areas.

Never use any toxic flammable substance as a solvent cleaner.

Never allow the operation or repair of equipment by untrained personnel.

Never climb or stand on equipment when it is operational.

It is important that you review Federal and State Safety and Health Standards on a continual basis. Allshop supervisors, maintenance personnel, machine operators, tool operators, and any other person

involved in the setup, operation, maintenance, repair or adjustment of Besser-built equipment should readand understand this bulletin and Federal and State Safety and Health Standards on which this bulletin isbased.




xi

Safety Signs

466381F0201US F1 24AP03

SAFETY SIGNSSign Description Required1 All Panels ............................................................................................................1

2 Mixer ...................................................................................................................4

3 Concrete Products Machine................................................................................1

Depalleter............................................................................................................2

4 Mixer ...................................................................................................................2

5 Skiploader ...........................................................................................................4

6 Skiploader/Mixer Platforms .................................................................................8

7 Skiploader/Mixer Platforms .................................................................................8

8 Vertical: Pallet Transport System ........................................................................2

Horizontal: LSC-40A/LSC-100 ............................................................................6

Pallet Transport System ......................................................................................4

9 Besser-Matic .......................................................................................................410 Besser-Matic .......................................................................................................4

11 Skiploader ...........................................................................................................4

12 All Panels ............................................................................................................1

13 Overhead Block Transfer.....................................................................................4

14 Block Pusher.......................................................................................................2

Pallet Transfer System ........................................................................................4

15 Concrete Products Machine................................................................................2

16 Conveyors .........................................................................................................12

17 Cuber ..................................................................................................................8

18 Cuber ..................................................................................................................3Block Turnovers...................................................................................................2

Slat Conveyors....................................................................................................2

To order safety decals, contact your local Besser representativeor the Besser Central Order Department.

Thank you!



Safety Signs


xii 466381F0201US F1 24AP03

D NGER

PELIGRO

Mixer blade hazard.Close front paneland stay clearduring operation.Follow lockoutprocedure before

servicing.

113237F0410 Mixer Blade Hazard

Width 4 1/2 inch Height 10 1/4 inch

DANGERNGER

PELIGRO

High voltage.Follow lockoutprocedure beforeservicing panel

or machine.

Large: 113236F0409 High Voltage


Small: 113236F0204 High Voltage Width 2 inch

Height 4 1/8 inch

D NGER

PELIGRO

Crush hazards.Stay clear ofmachine.Follow lockoutprocedure

before servicing.

Vertical: 113240F0307 Crush Hazard


Horizontal: 113239F0604 Crush Hazard

Width 6 5/8 inch

Height 4 inch

D NGER

PELIGRO

Crush hazard.Stay clear.Follow lockoutprocedure beforeservicing.

114688F0906 Crush Hazard


D NGER

PELIGRO

Nip points.Stay clear. Followlockout procedurebefore servicing.

114692F1006 Nip Points


W RNING

MU HO

UID DO

Fall hazard.Stay clear.

114689F0804 Fall Hazard


1 2 3

4 5 6




xiii

Safety Signs

466381F0201US F1 24AP03

Crush hazard.Stay clear of carand crawler.Follow lockout

procedure beforeservicing.

D NGER

PELIGRO

Vertical: 113244F0410 Crush Hazard

Width 4 1/2 inch Height 10 inch

Horizontal: 113245F1005 Crush Hazard Width 10 inch

Height 5 3/4 inch

W RNING

MU HO

UID DO

Falling objects.Hard hat area.

114690F0805 Falling Objects


D NGER

PELIGRO

Crush hazard.Stay clear oftransfer area.Follow lockoutprocedure before

servicing.

113242F0409 Crush Hazard


D NGER

PELIGRO

Shear hazard.Fall hazard.Stay clear. Followlockout procedurebefore servicing.

114691F1006 Shear and Fall Hazards


SUGGESTEDLOCKOUTPROCEDURE

1. Announce lockout to other employees.

2. Turn power off at main panel.

3. Lockout power in off position.

4. Put key in pocket.

5. Clear machine of

all personnel.

6. Test lockout by hitting run button.

7. Block, chain or release stored energy sources.

8. Clear machine of personnel before restarting machine.

113249F0410 Safety Instructions Decal –

Suggested Lock-out Procedure Width 4 inch

Height 10 inch

Falling objects.Stay clear oftransfer area.Follow lockoutprocedure beforeservicing.

D NGER

PELIGRO

113243F0410 Falling Objects


7 9

11

8

10 12



Safety Signs


xiv 466381F0201US F1 24AP03

D NGER

PELIGRO

Crush hazard.Stay clear ofmachine. Followlockout procedurebefore servicing.

Crush hazard. Stay

lockout procedurearea. Follow

before servicing.

clear of transfer

D NGER

PELIGRO

113238F1005

Crush Hazard Width 10 inch

Height 5 3/4 inch

113248F1006


Height 6 inch

D NGER

PELIGRO

Crush and pinchpoints. Stay clearof machine. Followlockout procedurebefore servicing.

Nip hazard.

lockout procedureconveyor. Follow

before servicing.

stay clear of

W RNING

MU HO

UID DO

113241F0605 Crush and Pinch Points

Width 6 5/8 inch

Height 4 inch

113246F0704 Nip Hazard

Width 7 inch

Height 4 1/2 inch

Crush hazard.

secure elevatorprocedure and

before servicing.

Follow lockout

D NGER

PELIGRO

D NGER

PELIGROCrush and pinch-points. Stay offconveyor. Followlockout procedurebefore servicing.

113247F1006


Height 6 inch

113250F1006

Crush and Pinch Hazard Width 10 inch

Height 6 inch

13

15

14

17

16

18




xv

Lifting Points

466381F0201US F1 24AP03

LIFTING POINTSBesser Company recommends that the cus-

tomer use a professional rigging crew to hoist theheavy Mixer components The method used to

hoist this equipment may vary, depending uponavailable rigging equipment and the plant layout.

LiftingPoints

Figure B Mixer Lifting Points

To ensure the safety of plant personnel during

Mixer installation, the rigging system must have alifting capacity that meets or exceeds the shipping

weight of the Mixer as listed in MixerSpecifications at the front of this manual.



Decals


xvi 466381F0201US F1 24AP03

Decal322271

Decal

299892

Decal112880F0418

Decal112880F0418

Decal113236F0204

Decal113236F0204

Decal113241F0605

Decal

113241F0605

Decal113463F1205

Decal113463F1205

Decal113241F0605

Decal113237F0410

and113249F0410

Decal113237F0410

and113249F0410

Decal313700 and

313761

Decal313700 and

313761

Decal313700 and

313761

Decal313700 and

313761

Figure C Decals



1-1466381F0201US F1 24AP03

1.2 SAFETY INFORMATION

Review the Safety Bulletin at the front of thismanual before installing or working on the Mixer.

During Mixer installation, be sure to observe allapplicable Federal, State and local safety regula-tions, as well as Cautions and Warnings that are

in this manual.

1.3 MIXER ASSEMBLY OVERVIEW

Figure 1.1 shows the major components

of the Mixer. For complete parts description,identification and illustration, refer to theOperation/Maintenance Manual and the Mixer

Parts Catalog.

1.1 INFORMATION ABOUT THIS MANUAL

The manual will help you install the Mixersafely and correctly.

Refer to Mixer Specifications and Mixer

Electrical Data at the front of this manual to iden-tify certain requirements of your Mixer. The Mixermodel number is on the name and lubricationplate on the Mixer. For installation details that

might not be in this manual, refer to BesserCompany drawings and information provided withyour equipment.

SECTION 1

MIXER OVERVIEW

IMPORTANT:

This manual contains instructions and guide-lines for the correct handling, placement andinstallation of the Besser Mixer. Installing the

Mixer without fully understanding and followingthe material in this manual may result in seriousinjury to personnel or damage to machinery. If

you have questions about any instructions,procedures or guidelines, contact your

Besser Sales and Service Representative forassistance.

INSTALLATION 160 Cubic Foot

SECTION 1



SECTION 1

160 Cubic Foot INSTALLATION

1-2 466381F0201US F1 24AP03

Pulley Sleeve BearingLube System

PulleyAssembly

Blade ShaftAssembly

ElectricMotor

Front PanelAssembly

Mixer Head

Mixer Head

Head Liners

Dust Hub

Mixer Drum

Discharge GateAssemblyDischarge

Chute

PulleyGuard

Assembly

GearcaseAssembly

Head Scrapers

ShroudAssembly

Water PipeAssembly

Cleaning Rings

Figure 1.1 Major Components of the Mixer



1-3466381F0201US F1 24AP03


SECTION 1

1.4 MIXER INSTALLATION OVERVIEW

Much of the work involved in installing theMixer is that which goes into preparing the site

and constructing the foundation on which the

Mixer will be mounted. The following primarysteps must be done to install the Mixer. Refer tothe other sections for detailed procedures and

information.1. Determine the required orientation of the

Mixer at the site. Identify each side andfunction of the Mixer, taking into consider-

ation the function of each side and itsspace requirements for operation andmaintenance.

2. Determine the Mixer site and at whatgrade the Mixer will be installed – below

plant grade, at plant grade, or above plantgrade. The site must be able to safely

support the Mixer and its operating loads.3. Collect the material required for site

preparation and Mixer installation.4. Prepare the site.

5. Install the Mixer and any associatedequipment. Associated equipment mustcharge Mixer properly. Refer to Section

4.6 and Besser Company InstallationDrawings for charging information.

6. Connect the Mixer to the electrical, pneu-matic and water sources. Refer to the

front of this manual and to BesserCompany drawings, for specifications,electrical data and supply requirements.

7. Install ladders, platforms, guarding, and

other materials that will be needed foroperation and maintenance for your plantlayout. Be sure your installation meets all

applicable Federal, State, and local safetycode requirements.

1.5 REQUIRED PARTS AND EQUIPMENT

The following materials and components areneeded for installing the Mixer. These are usuallynot provided by Besser Company.

• Four steel I-beams, 6 inches [152 mm] x 121/2 pound [6 kg], and 6 feet [1829 mm] long• Anchor bolts and nuts

• Conduit to the Mixer for control wiring• Conduit and wire from the Mixer motor

starter to the motor• Incoming power feed, with fuse box, circuit

breaker, and lockable electrical disconnect• Water and air supply lines to the Mixer• Controls for the Mixer, if not supplied as a

Mixer option• Motor starter, if not supplied as a Mixer

option• Ladders, platforms, guarding, and other

materials that will be needed for Mixer oper-ation and maintenance for your plant layout.

Refer to the front of this manual and to BesserCompany drawings, for specifications, electrical

data, and supply requirements.



SECTION 1


1-4 466381F0201US F1 24AP03






SECTION 2

2-2 466381F0201US F1 24AP03

Figure 2.1 Typical Platform for Maintenance – Top View

Interlocked hinged guardfor mixer gate safety stop

shuts down mixer when open.

FOR REFERENCE ONLYCheck your Installation

Drawings for exact dimensions.

NOTE:

The customer is required to purchase ladder,walkways and guarding from Besser Company or

another supplier. If the customer purchases lad-der, walkway and guarding from a source otherthan the Besser Company, the customer assumes

all responsibility for meeting all safety code

requirements.



2-3466381F0201US F1 24AP03


SECTION 2

Front PanelFOR REFERENCE ONLYCheck your Installation


Figure 2.2 Typical Platform for Maintenance – Front View



2-4 466381F0201US F1 24AP03

Height PerDesign



Figure 2.3 Typical Platform Maintenance – Charging Side View


SECTION 2




SECTION 3

3-1466381F0201US F1 24AP03

3.1 PREPARE THE SITE

3.1.1 Installation At or Below Plant GradeMixer installation at or below plant grade

requires a concrete foundation.The concretefoundation must have four steel I-beams set with-

in non-shrink grout and located as shown onFigure 3.1 and Mixer installation drawings.

3.1.2 Position the I-Beams

1. Use four 6 inch [152 mm] x 12 1/2 lb[6 Kg] I-beams, 6 feet [1829 mm] long.

2. The top of each steel beam is 1/8 inch[3 mm] above the Mixer elevation. SeeFigure 3.2. If the Mixer elevation isunknown, the height of the steel beams

can be determined from the plant layout.For example, if the Mixer’s plant layoutgrade is at elevation 100 feet [30480 mm],the tops of the beams need to be 1/8 inch

[3 mm] above this elevation, or at 100 feet[30480 mm] plus 1/8 inch [3 mm].

A primary consideration when selecting aMixer site is the grade level needed for the Mixerto function in the overall plant operation. Three

common grade levels are:• below plant grade• at plant grade, or floor level• above floor level

Each type of installation requires a foundationcorrectly designed for the static and operating

loads of the Mixer. Load requirements are shownon Figure 3.1 and on Besser Company installa-tion drawings for your Mixer. Trained professionalsat Besser Company can assist in determining thebest site and design for your facility. Be sure the

plant meets all applicable Federal, State and localsafety code requirements. Be sure to obtain orfabricate ladders, platforms, guarding and othermaterial that will be needed for operation and

maintenance.

SECTION 3

PREPARE SITE






SECTION 3

3-3466381F0201US F1 24AP03

= ANCHOR BOLTS 1.125 in. [29 mm] Diameter Anchor Bolt Hole (8 Places)

CL

86.625 in.[2200 mm]

54.625 in.[1387 mm]

MIXER

54.625 in.[1387 mm]

86.625 in.[2200 mm]

Figure 3.3 Anchor Bolt Locations in the I-Beams

When installing the I-beams, set them intheir correct locations and level them to within1/16 inch [2 mm] of the required height, using atransit. Pour non-shrink grout between the beams

to secure their locations. When the Mixer isinstalled and after the non-shrink grout has ade-quately set, secure the Mixer either by welding it

to the I-beams, or bolting it to the beams usinganchor bolts. If bolts will be used, locate them asshown in Figure 3.3 before setting the beams.

NOTE:When securing Mixer fill voids between Mixerbase and four I-beams with shims to avoid distort-

ing Mixer base when tightening anchor bolts.

0.125 in.[3.175 mm]

Plant Grade Elevation

Poured ConcreteNon-ShrinkGrout

I-Beam

Figure 3.2 I-Beam Elevation Relative to Plant Grade Elevation




SECTION 3

3-4 466381F0201US F1 24AP03

3.1.3 Installation Below Floor LevelFigure 3.4 and 3.5 shows recommended mini-

mum pit dimensions for installing the Mixer belowfloor level of the plant. When planning a below

grade installation, be sure the plant meets allapplicable Federal, State and local safety coderequirements. Be sure to obtain or fabricate lad-

ders, platforms, guarding, and other material thatwill be needed for operation and maintenance.

Figure 3.4 Pit Dimensions for Below Floor Level Installation – Top View

24 in.[610 mm]

36 in.[914 mm]

CHARGINGAREA

36 in.[914 mm]

Gearcase

Motor

Pulley Guard




SECTION 3

3-5466381F0201US F1 24AP03

Pulley Guard

Arc OfFront Panel

GATE ORDISCHARGE

SIDE

CHARGINGSIDE

30 in.[762 mm]

89.500 in.[2273 mm]

To Top OfEnd Plate

32.500 in.[826 mm]

2 7 .7 5 0 i n . [ 7 0 5 m m ]

32.500 in.[826 mm]

34 in.[863 mm]

Anchor Holes?

Head Plate

34 in.[863 mm]

46.500 in.

[1181 mm]

46.500 in.

[1181 mm]

117.250 in.[2902 mm]

Figure 3.5 Pit Dimensions for Below Floor Level Installation – Side View




SECTION 3

3-6 466381F0201US F1 24AP03

3.3 CHARGING CONSIDERATIONCentralized introduction of cement will

improve mixing efficiency and reduce mixing time.

3.3.1 Optimum Charging Location

The center of the aggregate and cementcharging area is located on the center of the

Mixer drum and 12 inches [305 mm] in front ofthe Mixer shaft on the down stroke of the Mixerblade. See Figure 3.4 showing the charging area.

3.3.2 Recommended Charging AreaIntroduce aggregate and cement within

36 inches [914 mm] to either side of the center of

the Mixer drum and within 24 inches [610 mm] infront of the Mixer shaft on the down stroke of theMixer blade. See Figure 3.4 showing the charging

area.

NOTE:

For charging location different than above consultBesser Company Engineering Department.

3.1.4 Installation Above Floor LevelFor an above grade installation, see Figure 3.1.

It is crucial to design the support structure to sup-port the Mixer static and operating loads.The sup-

port structure should also be large enough to pro-vide adequate platform area for personnel to safelyoperate and maintain the Mixer. See Figure 3.6 and3.7. Locations of required anchor bolts are shown in

Figure 3.3 and the Mixer installation drawing.When planning an above floor level installa-

tion be sure the plant meets all applicable

Federal, State, and local safety code require-ments. Be sure to obtain or fabricate ladders, plat-forms, guarding, and other material that will beneeded for operation and maintenance.

3.2 ELECTRICAL, WATER AND AIR SUPPLYCONSIDERATIONS

The site must have adequate and correctlyconfigured electrical, water and air supplies.Refer to the front of this manual, BesserCompany installation drawings and Figure 3.1

(Electric Motor Conduit Location) for specifica-tions, electrical data and supply requirements.

Front PanelFOR REFERENCE ONLY

Check your Installation


Figure 3.6 Typical Platform for Maintenance – Front View



3-7466381F0201US F1 24AP03


SECTION 3

Interlocked hinged guardfor mixer gate safety stop

shuts down mixer when open.



Figure 3.7 Typical Platform for Maintenance – Top View



3-8 466381F0201US F1 24AP03


SECTION 3

3.4 GROUTING PROCEDUREThe first batch for a Mixer with blade wear lin-

ers, is referred to as a “grouting batch.” The“grouting batch” fills the void between the backup

blade and blade liners providing support to bladeliners. Often, a Besser Sales and ServiceRepresentative runs the grouting batch. For moreinformation about the grouting procedure, refer to

Besser Company print number 360464.To prepare your new Besser Mixer blades for

operation, follow this grouting procedure for agood seating of Ni-hard liners to the Mixer blade:

1. Run a throw-away first batch a day or twobefore the start of actual production.

2. Use a fine grout mix made of:• 4,000 lbs very fine sand

• 1,000 lbs cement• Water to make 7 – 9 inch slump.

3. Add cement and water at same time to

make cement slurry.4. Slowly add fine sand to make grout.5. When mix is consistent, stop one blade in

submerged position. Allow enough time

for grout to hold in all spaces betweenbackup blade and Ni-hard blade liners.

6. Submerge opposite blade.7. Perform lockout. See Section 2.1 of

Maintenance/Operation Manual.8. Clean Mixer by hand to allow grout inblades to harden before start of produc-

tion operation.




SECTION 4

4-1466381F0201US F1 24AP03

Besser Company recommends the use a pro-fessional rigging crew to hoist the Mixer into posi-

tion. The method used to hoist this equipmentmay vary, depending upon available riggingequipment and the plant layout. To ensure thesafety of plant personnel during Mixer installation,

the rigging system must have a lifting capacitythat meets or exceeds the shipping weight of theMixer as listed in Mixer Specifications at the front

of this manual. See Figure 4.1.

4.1 LIFTING CONSIDERATIONS

SECTION 4

INSTALLATION GUIDELINES

WARNING:

Failure to use a professional riggingcrew and equipment may result inserious personal injury or propertydamage.

LiftingPoints

Figure 4.1 Lifting Points




SECTION 4

4-2 466381F0201US F1 24AP03

4.2 MIXER INSTALLATION GUIDELINESOnce the site has been prepared, non-shrink

grout is cured and as applicable, the I-beamsfirmly set, the site is ready for Mixer installation.

4.2.1 Safety InformationDuring Mixer installation, be sure to observe

all applicable Federal, State and local safety regu-lations.

4.2.2 Elevation and Leveling

Use a transit to check the I-beams again, tomake sure they are still at the required elevationand are level after any settling. If necessary, place

shims to maintain I-beam top surface level within1/16 inch.

4.2.3 InstallationOnce the elevation and leveling checks have

been completed, hoist the Mixer into position. Ifanchor bolts are used to secure the Mixer, align

the Mixer and anchor bolt holes during position-ing. When the Mixer is in position, secure it bywelding or bolting to the I-beams.

NOTE:When securing Mixer with anchor bolts, fill voidsbetween Mixer base and three I-beams with

shims to avoid distorting Mixer base whentightening anchor bolts.

4.3 ELECTRICAL INSTALLATIONGUIDELINES

4.3.1 Safety Information

Besser Company requires its customers to

adhere to the following:1. When installing the Mixer, observe the

requirements and specifications on

Besser Company electrical drawings anddiagrams.

2. Use a batching control system or equiva-lent alternative controls.

3. Use lockable electrical disconnects onelectric motors. The wiring to the motorfrom the lockable disconnect can be run

through conduit placed in the floor, or

from overhead. See Figure 3.1. Refer toMixer Electrical Data at the front of thismanual, and Besser Company installation

drawings. Run conduit, as necessary, fromthe batching control panel to the Mixer forthe control wiring.




SECTION 4

4-3466381F0201US F1 24AP03

Mixer ControlStation (if used)

Mixer ControlPanel

(if used)

Mixer StarterPanel

BatchingControls

Gearcase

Motor

PulleyGuard

Figure 4.2 Electrical Wiring Block Diagram for a Typical Mixer Configuration

4.4 AIR SUPPLY INSTALLATIONGUIDELINES

Install compressed air supply lines to theMixer according to applicable federal, state and

local codes. The supply source and lines must becapable of providing a continuous 120 psi[827.4 kPa] air supply, regulated as given in MixerSpecifications at the front of this manual, and onBesser Company installation drawings.

4.5 WATER SUPPLY INSTALLATIONGUIDELINES

Refer to Besser Company installation draw-

ings and front of this manual for water supplyconnection points and gallons per batch to sizeand install the water supply.

4.3.2 ControlsIf ordered as part of the Mixer, the Mixer

includes an electric motor and starter, and manu-al electrical gate and clutch controls. Besser

Company recommends using a soft starter toenable slow starting of the Mixer motor for energyconservation. Automatic controls are usually part

of a batching control panel.

4.3.3 Electrical WiringAn electrical wiring block diagram of a typical

installation is shown on Figure 4.2. Refer toBesser Company electrical drawings and dia-grams for specific wiring information regarding

gate open/close, Mixer disconnect interlock andunderspeed relay.

4.3.4 InstallationIf not provided with the Mixer, install the Mixer

controls. Install any needed conduit and wiringfrom the power source to the control panel and

motor.




SECTION 4

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