Operations Manual - United Food & Beverage

Operations Manual

Serial Number: E-0935-10

Tanks – Processors – Silos – Pharmaceutical Vessels

Made Especially for:

STATCO ENGINEERING

HUNTINGTON BEACH, CA

Integral HorsepowerAC Induction Motors

Installation & Operating Manual

2/09 MN400

Any trademarks used in this manual are the property of their respective owners.

Table of Contents

Table of Contents iMN400

Section 1General Information 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limited Warranty 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Notice 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiving 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal From Storage 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2Installation & Operation 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alignment 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Doweling & Bolting 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guarding 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Connection 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conduit Box 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Power 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotation 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

First Time Start Up 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coupled Start Up 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jogging and Repeated Starts 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3Maintenance & Troubleshooting 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Inspection 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relubrication & Bearings 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type of Grease 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relubrication Intervals 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relubrication Procedure 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Chart 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suggested bearing and winding RTD setting guidelines 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1General Information

ii Table of Contents MN400


General Information 1-1MN400

Overview This manual contains general procedures that apply to Baldor Motor products. Be sure to read andunderstand the Safety Notice statements in this manual. For your protection, do not install, operate orattempt to perform maintenance procedures until you understand the Warning and Caution statements. A Warning statement indicates a possible unsafe condition that can cause harm to personnel. A Caution statement indicates a condition that can cause damage to equipment.

Important: This instruction manual is not intended to include a comprehensive listing of all details for allprocedures required for installation, operation and maintenance. This manual describes generalguidelines that apply to most of the motor products shipped by Baldor. If you have a questionabout a procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldordistributor for more information or clarification.Before you install, operate or perform maintenance, become familiar with the 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

Limited Warranty

www.baldor.com/support/warranty_standard.asp

Safety Notice: This equipment contains high voltage! Electrical shock can cause serious or fatal injury. Only qualifiedpersonnel 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 andguide for selection, installation and use of electric motors and generators, the National Electrical Code andlocal 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 theinstallation, operation and maintenance of this equipment.

WARNING: Disconnect all electrical power from the motor windings and accessory devices beforedisassembly of the motor. Electrical shock can cause serious or fatal injury.

WARNING: Be sure the system is properly grounded before applying power. Do not apply AC power beforeyou ensure that all grounding instructions have been followed. Electrical shock can causeserious or fatal injury. National Electrical Code and Local codes must be carefully followed.

WARNING: Avoid extended exposure to machinery with high noise levels. Be sure to wear ear protectivedevices to reduce harmful effects to your hearing.

WARNING: Surface temperatures of motor enclosures may reach temperatures which can cause discomfortor injury to personnel accidentally coming into contact with hot surfaces. When installing,protection should be provided by the user to protect against accidental contact with hot surfaces.Failure to observe this precaution could result in bodily injury.

WARNING: This equipment may be connected to other machinery that has rotating parts or parts that aredriven by this equipment. Improper use can cause serious or fatal injury. Only qualifiedpersonnel should attempt to install operate or maintain this equipment.

WARNING: Do not by-pass or disable protective devices or safety guards. Safety features are designed toprevent damage to personnel or equipment. These devices can only provide protection if theyremain operative.

WARNING: Avoid the use of automatic reset devices if the automatic restarting of equipment can behazardous to personnel or equipment.

WARNING: Be sure the load is properly coupled to the motor shaft before applying power. The shaft keymust be fully captive by the load device. Improper coupling can cause harm to personnel orequipment if the load decouples from the shaft during operation.

WARNING: Use proper care and procedures that are safe during handling, lifting, installing, operating andmaintaining operations. Improper methods may cause muscle strain or other harm.

WARNING: Thermostat contacts automatically reset when the motor has slightly cooled down. To preventinjury or damage, the control circuit should be designed so that automatic starting of the motor isnot possible when the thermostat resets.


1-2 General Information MN400

Safety Notice ContinuedWARNING: UL Listed motors must only be serviced by UL Approved Authorized Baldor Service Centers if

these motors are to be returned to a hazardous and/or explosive atmosphere.WARNING: Pacemaker danger − Magnetic and electromagnetic fields in the vicinity of current carrying

carrying conductors and permanent magnet motors can result result in a serious health hazard topersons with cardiac pacemakers, metal implants, and hearing aids. To avoid risk, stay way fromthe area surrounding a permanent magnet motor.

WARNING: Before performing any motor maintenance procedure, be sure that the equipment connected tothe motor shaft cannot cause shaft rotation. If the load can cause shaft rotation, disconnect theload from the motor shaft before maintenance is performed. Unexpected mechanical rotation ofthe motor parts can cause injury or motor damage.

WARNING: Use only UL/CSA listed explosion proof motors in the presence of flammable or combustiblevapors or dust.

WARNING: Motors that are to be used in flammable and/or explosive atmospheres must display the UL labelon the nameplate along with CSA listed logo. Specific service conditions for these motors aredefined in NFPA 70 (NEC) Article 500.

WARNING: Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unusedshaft extensions, should be permanently guarded to prevent accidental contact by personnel.Accidental contact with body parts or clothing can cause serious or fatal injury.

Caution: To prevent premature equipment failure or damage, only qualified maintenance personnel shouldperform maintenance.

Caution: Do not over−lubricate motor as this may cause premature bearing failure.Caution: Do not over tension belts. Excess tension may damage the motor or driven equipment.Caution: 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 (gears, pumps, compressors, or otherdriven equipment) from the motor shaft before lifting the motor.

Caution: If eye bolts are used for lifting a motor, be sure they are securely tightened. The lifting directionshould not exceed a 20° angle from the shank of the eye bolt or lifting lug. Excessive liftingangles can cause damage.

Caution: To prevent equipment damage, be sure that the electrical service is not capable of delivering morethan the maximum motor rated amps listed on the rating plate.

Caution: If a HI POT test (High Potential Insulation test) must be performed, follow the precautions andprocedure in NEMA MG1 and MG2 standards to avoid equipment damage.If you have any questions or are uncertain about any statement or procedure, or if you require additionalinformation please contact your Baldor distributor or an Authorized Baldor Service Center.

Receiving Each Baldor Electric Motor is thoroughly tested at the factory and carefully packaged for shipment. Whenyou receive your motor, there are several things you should do immediately.1. Observe the condition of the shipping container and report any damage immediately to the

commercial carrier that delivered your motor.2. Verify that the part number of the motor you received is the same as the part number listed on your

purchase order.Handling The motor should be lifted using the lifting lugs or eye bolts provided.Caution: 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 (gears, pumps, compressors, or otherdriven equipment) from the motor shaft before lifting the motor.1. Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the motor and additional

equipment connected to the motor by this method. The lugs or eye bolts provided are designed to liftonly the motor. Never lift the motor by the motor shaft or the hood of a WPII motor.

2. To avoid condensation inside the motor, do not unpack until the motor has reached room temperature.(Room temperature is the temperature of the room in which it will be installed). The packing provides insulation from temperature changes during transportation.

3. When lifting a WPII (Weather Proof Type 2) motor, do not lift the motor by inserting lifting lugs intoholes on top of the cooling hood. These lugs are to be used for hood removal only. A spreader bar should be used to lift the motor by the cast lifting lugs located on the motor frame.

General Information 1-3MN400

4. If the motor must be mounted to a plate with the driven equipment such as pump, compressor etc., it may not be possible to lift the motor alone. For this case, the assembly should be lifted by a slingaround the mounting base. The entire assembly can be lifted as an assembly for installation.Do not lift the assembly using the motor lugs or eye bolts provided. Lugs or eye bolts are designed tolift motor only. If the load is unbalanced (as with couplings or additional attachments) additional slingsor other means must be used to prevent tipping. In any event, the load must be secure before lifting.If the load is unbalanced (as with couplings or additional attachments) additional slings or othermeans must be used to prevent tipping. In any event, the load must be secure before lifting.

Storage Storage requirements for motors and generators that will not be placed in service for at least six monthsfrom date of shipment.Improper motor storage will result in seriously reduced reliability and failure. An electric motor that doesnot experience regular usage while being exposed to normally humid atmospheric conditions is likely todevelop rust in the bearings or rust particles from surrounding surfaces may contaminate the bearings. The electrical insulation may absorb an excessive amount of moisture leading to the motor windingfailure.A wooden crate “shell” should be constructed to secure the motor during storage. This is similar to anexport box but the sides & top must be secured to the wooden base with lag bolts (not nailed as exportboxes are) to allow opening and reclosing many times without damage to the “shell”.Minimum resistance of motor winding insulation is 5 Meg ohms or the calculated minimum, which ever isgreater. Minimum resistance is calculated as follows: Rm = kV + 1

where: (Rm is minimum resistance to ground in Meg−Ohms and kV is rated nameplate voltage defined as Kilo−Volts.)

Example: For a 480VAC rated motor Rm =1.48 meg−ohms (use 5 MΩ). For a 4160VAC rated motor Rm = 5.16 meg−ohms.

Preparation for Storage

1. Some motors have a shipping brace attached to the shaft to prevent damage during transportation.The shipping brace, if provided, must be removed and stored for future use. The brace must bereinstalled to hold the shaft firmly in place against the bearing before the motor is moved.

2. Store in a clean, dry, protected warehouse where control is maintained as follows:a. Shock or vibration must not exceed 2 mils maximum at 60 hertz, to prevent the bearings from

brinelling. If shock or vibration exceeds this limit vibration isolation pads must be used.b. Storage temperatures of 10°C (50°F) to 49°C (120°F) must be maintained.c. Relative humidity must not exceed 60%.d. Motor space heaters (when present) are to be connected and energized whenever there is a

possibility that the storage ambient conditions will reach the dew point. Space heaters are optional.Note: Remove motor from containers when heaters are energized, reprotect if necessary.

3. Measure and record the resistance of the winding insulation (dielectric withstand) every 30 days ofstorage.a. If motor insulation resistance decreases below the minimum resistance, contact your Baldor

District office.b. Place new desiccant inside the vapor bag and re−seal by taping it closed.c. If a zipper−closing type bag is used instead of the heat−sealed type bag, zip the bag closed

instead of taping it. Be sure to place new desiccant inside bag after each monthly inspection.d. Place the shell over the motor and secure with lag bolts.

4. Where motors are mounted to machinery, the mounting must be such that the drains and breathersare fully operable and are at the lowest point of the motor. Vertical motors must be stored in thevertical position. Storage environment must be maintained as stated in step 2.

1-4 General Information MN400

5. Motors with anti−friction bearings are to be greased at the time of going into extended storage withperiodic service as follows:a. Motors marked “Do Not Lubricate” on the nameplate do not need to be greased before or during

storage.b. Ball and roller bearing (anti−friction) motor shafts are to be rotated manually every 3 months and

greased every 6 months in accordance with the Maintenance section of this manual.c. Sleeve bearing (oil lube) motors are drained of oil prior to shipment.

The oil reservoirs must be refilled to the indicated level with the specified lubricant, (seeMaintenance). The shaft should be rotated monthly by hand at least 10 to 15 revolutions todistribute oil to bearing surfaces.

d. “Provisions for oil mist lubrication” – These motors are packed with grease. Storage proceduresare the same as paragraph 5b.

e. “Oil Mist Lubricated” – These bearings are protected for temporary storage by a corrosioninhibitor. If stored for greater than 3 months or outdoor storage is anticipated, connected to the oilmist system while in storage. If this is not possible, add the amount of grease indicated under“Standard Condition” in Section 3, then rotate the shaft 15 times by hand.

6. All breather drains are to be fully operable while in storage (drain plugs removed). The motors mustbe stored so that the drain is at the lowest point. All breathers and automatic “T” drains must beoperable to allow breathing and draining at points other than through the bearings around the shaft. Vertical motors should be stored in a safe stable vertical position.

7. Coat all external machined surfaces with a rust preventing material. An acceptable product for this purpose is Exxon Rust Ban # 392.

Non−Regreaseable MotorsNon−regreasable motors with “Do Not Lubricate” on the nameplate should have the motor shaft rotated15 times to redistribute the grease within the bearing every 3 months or more often.All Other Motor TypesBefore storage, the following procedure must be performed.1. Remove the grease drain plug, if supplied, (opposite the grease fitting) on the bottom of each bracket

prior to lubricating the motor.2. The motor with regreasable bearing must be greased as instructed in Section 3 of this manual.3. Replace the grease drain plug after greasing.4. The motor shaft must be rotated a minimum of 15 times after greasing.5. Motor Shafts are to be rotated at least 15 revolutions manually every 3 months and additional grease

added every nine months (see Section 3) to each bearing.6. Bearings are to be greased at the time of removal from storage.

Removal From Storage

1. Remove all packing material.2. Measure and record the electrical resistance of the winding insulation resistance meter at the time of

removal from storage. The insulation resistance must not be less than 50% from the initial readingrecorded when the motor was placed into storage. A decrease in resistance indicates moisture in thewindings and necessitates electrical or mechanical drying before the motor can be placed intoservice. If resistance is low, contact your Baldor District office.

3. Regrease the bearings as instructed in Section 3 of this manual.4. Reinstall the original shipping brace if motor is to be moved. This will hold the shaft firmly against the

bearing and prevent damage during movement.

Section 2Installation & Operation

Installation & Operation 2-1MN400

Overview Installation should conform to the National Electrical Code as well as local codes and practices. Whenother devices are coupled to the motor shaft, be sure to install protective devices to prevent futureaccidents. Some protective devices include, coupling, belt guard, chain guard, shaft covers etc. Theseprotect against accidental contact with moving parts. Machinery that is accessible to personnel shouldprovide further protection in the form of guard rails, screening, warning signs etc.

Location It is important that motors be installed in locations that are compatible with motor enclosure and ambientconditions. Improper selection of the motor enclosure and ambient conditions can lead to reducedoperating life of the motor.Proper ventilation for the motor must be provided. Obstructed airflow can lead to reduction of motor life.1. Open Drip−Proof/WPI motors are intended for use indoors where atmosphere is relatively clean, dry,

well ventilated and non−corrosive.2. Totally Enclosed and WPII motors may be installed where dirt, moisture or dust are present and in

outdoor locations.Severe Duty, IEEE 841 and Washdown Duty enclosed motors are designed for installations with highcorrosion or excessive moisture conditions. These motors should not be placed into an environmentwhere there is the presence of flammable or combustible vapors, dust or any combustible material, unlessspecifically designed for this type of service.Hazardous Locations are those where there is a risk of ignition or explosion due to the presence ofcombustible gases, vapors, dust, fibers, or flyings. Facilities requiring special equipment for hazardouslocations are typically classified in accordance with local requirements. In the US market, guidance isprovided by the National Electric Code.

Caution: Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardwareis adequate for lifting only the motor. Disconnect the load (gears, pumps, compressors, or otherdriven equipment) from the motor shaft before lifting the motor.

Mounting The motor must be securely installed to a rigid foundation or mounting surface to minimize vibration andmaintain alignment between the motor and shaft load. Failure to provide a proper mounting surface maycause vibration, misalignment and bearing damage.Foundation caps and sole plates are designed to act as spacers for the equipment they support. If thesedevices 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 baseshould be grouted to the foundation to maintain this alignment.The standard motor base is designed for horizontal or vertical mounting. Adjustable or sliding rails aredesigned for horizontal mounting only. Consult your Baldor distributor or authorized Baldor Service Centerfor further information.

Alignment Accurate alignment of the motor with the driven equipment is extremely important. The pulley, sprocket,or gear used in the drive should be located on the shaft as close to the shaft shoulder as possible. It is recommended to heat the pulley, sprocket, or gear before installing on the motor shaft. Forcibly driving a unit on the motor shaft will damage the bearings.1. Direct Coupling

For direct drive, use flexible couplings if possible. Consult the drive or equipment manufacturer formore 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 asrecommended by the coupling manufacturer.

2. End-Play AdjustmentThe axial position of the motor frame with respect to its load is also extremely important. The motorbearings are not designed for excessive external axial thrust loads. Improper adjustment will causefailure.

3. Pulley RatioThe pulley ratio should not exceed 8:1.

Caution: Do not over tension belts. Excess tension may damage the motor or driven equipment.4. Belt Drive

Align sheaves carefully to minimize belt wear and axial bearing loads (see End-Play Adjustment). Belttension should be sufficient to prevent belt slippage at rated speed and load. However, belt slippagemay occur during starting.

5. Sleeve bearing motors are only suitable for coupled loads.


2-2 Installation & Operation MN400

Doweling & Bolting After proper alignment is verified, dowel pins should be inserted through the motor feet into thefoundation. This will maintain the correct motor position should motor removal be required. (Baldor motors are designed for doweling.)1. Drill dowel holes in diagonally opposite motor feet in the locations provided.2. Drill corresponding holes in the foundation.3. Ream all holes.4. Install proper fitting dowels.5. Mounting bolts must be carefully tightened to prevent changes in alignment. Use a flat washer and

lock washer under each nut or bolt head to hold the motor feet secure. Flanged nuts or bolts may beused as an alternative to washers.

WARNING: Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unusedshaft extensions, should be permanently guarded to prevent accidental contact by personnel.Accidental contact with body parts or clothing can cause serious or fatal injury.

Guarding Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused shaftextensions. This is particularly important where the parts have surface irregularities such as keys, keyways or set screws. Some satisfactory methods of guarding are:1. Covering the machine and associated rotating parts with structural or decorative parts of the driven

equipment.2. Providing covers for the rotating parts. Covers should be sufficiently rigid to maintain adequate

guarding during normal service.Power Connection Motor and control wiring, overload protection, disconnects, accessories and grounding should

conform to the National Electrical Code and local codes and practices. Flying leads must be insulated withtwo full wraps of electrical grade insulating tape or heat shrink tubing.

Conduit Box For ease of making connections, an oversize conduit box is provided. The box can be rotated 360° in 90° increments. Auxiliary conduit boxes are provided on some motors for accessories such as space heaters, RTD’s etc.

AC Power Connect the motor leads as shown on the connection diagram located on the name plate or inside thecover on the conduit box. Be sure the following guidelines are met:

1. AC power is within ±10% of rated voltage with rated frequency. (See motor name plate for ratings). OR

2. AC power is within ±5% of rated frequency with rated voltage. OR

3. A combined variation in voltage and frequency of ±10% (sum of absolute values) of rated values,provided the frequency variation does not exceed ±5% of rated frequency.

Performance within these voltage and frequency variations are shown in Figure 2-2.Figure 2-1 Accessory Connections

One heater is installed in each end of motor. Leads for each heater are labeled H1 & H2. (Like numbers should be tied together).

Three thermistors are installed in windings and tied in series.Leads are labeled T1 & T2.

Winding RTDs are installed in windings (2) per phase. Each set of leads is labeled W1, W2, W3, W4, W5, & W6.

* One bearing RTD is installed in Drive endplate (PUEP), leads are labeled RTDDE.

* One bearing RTD is installed in Opposite Drive endplate (FREP), leads are labeled RTDODE.

* Note RTD may have 2−Red/1−White leads; or 2−White/1−Red Lead.


Installation & Operation 2-3MN400

Figure 2-2 Typical Motor Performance VS Voltage Variations+20

+15

+10

+5

0

−5

−10

−15

−20−15 −10 −5 0 +5 +10 +15

Voltage Variations (%)

Ch

ang

es in

Mo

tor

Per

form

ance

(%

)Full -LoadCurrent

Full -LoadCurrentPower

Factor

PowerFactor

Efficiency Efficiency

MaximumTorque

MaximumTorque

Rotation All three phase motors are reversible. To reverse the direction of rotation, disconnect and lock out powerand interchange any two of the three line leads for three phase motors. For single phase motors, checkthe connection diagram to determine if the motor is reversible and follow the connection instructions forlead numbers to be interchanged. Not all single phase motors are reversible.Adjustable Frequency Power Inverters used to supply adjustable frequency power to induction motorsproduce wave forms with lower order harmonics with voltage spikes superimposed. Turn−to−turn,phase−to−phase, and ground insulation of stator windings are subject to the resulting dielectric stresses.Suitable precautions should be taken in the design of these drive systems to minimize the magnitude ofthese voltage spikes. Consult the drive instructions for maximum acceptable motor lead lengths, andproper grounding.


2-4 Installation & Operation MN400

First Time Start Up Be sure that all power to motor and accessories is off. Be sure the motor shaft is disconnected fromthe load and will not cause mechanical rotation of the motor shaft.1. Make sure that the mechanical installation is secure. All bolts and nuts are tightened etc.2. If motor has been in storage or idle for some time, check winding insulation integrity.3. Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical

continuity.4. Be sure all shipping materials and braces (if used) are removed from motor shaft.5. Manually rotate the motor shaft to ensure that it rotates freely.6. Replace all panels and covers that were removed during installation.7. Momentarily apply power and check the direction of rotation of the motor shaft.8. If motor rotation is wrong, be sure power is off and change the motor lead connections.

Verify rotation direction before you continue.9. Start the motor and ensure operation is smooth without excessive vibration or noise.

If so, run the motor for 1 hour with no load connected.10. After 1 hour of operation, disconnect power and connect the load to the motor shaft. Verify all

coupling guards and protective devices are installed. Ensure motor is properly ventilated.Coupled Start Up This procedure assumes a coupled start up. Also, that the first time start up procedure was

successful.1. Check the coupling and ensure that all guards and protective devices are installed.2. Check that the coupling is properly aligned and not binding.3. The first coupled start up should be with no load. Apply power and verify that the load is not

transmitting excessive vibration back to the motor though the coupling or the foundation. Vibrationshould be at an acceptable level.

4. Run for approximately 1 hour with the driven equipment in an unloaded condition.The equipment can now be loaded and operated within specified limits. Do not exceed the name plateratings for amperes for steady continuous loads.

Jogging and Repeated Starts Repeated starts and/or jogs of induction motors generally reduce the life of the motorwinding insulation. A much greater amount of heat is produced by each acceleration or jog than by thesame motor under full load. If it is necessary to repeatedly start or jog the motor, it is advisable to checkthe 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 BaldorDistrict Office or Baldor Service Center.

Section 3Maintenance & Troubleshooting

Maintenance & Troubleshooting 3-1MN400

WARNING: UL Listed motors must only be serviced by UL Approved Authorized Baldor Service Centers ifthese motors are to be returned to a hazardous and/or explosive atmosphere.

General Inspection Inspect the motor at regular intervals, approximately every 500 hours of operation or every 3months, whichever occurs first. Keep the motor clean and the ventilation openings clear. The followingsteps 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 theinstallation, 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 motorventilation. If the motor is not properly ventilated, overheating can occur and cause early motorfailure.

2. Use a “Megger” periodically to ensure that the integrity of the winding insulation has beenmaintained. Record the Megger readings. Immediately investigate any significant drop in insulationresistance.

3. Check all electrical connectors to be sure that they are tight.Relubrication & 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 speedat which the bearing operates and the severity of the operating conditions. Good results can be obtainedif the following recommendations are used in your maintenance program.

Type of Grease A high grade ball or roller bearing grease should be used. Recommended grease for standardservice conditions is Polyrex EM (Mobil). Do not mix greases unless compatibility has beenchecked and verified.

Equivalent and compatible greases include:Texaco Polystar, Rykon Premium #2, Pennzoil Pen 2 Lube and Chevron SRI.

Relubrication Intervals Recommended relubrication intervals are shown in Table 3-1. It is important to realize thatthe recommended intervals of Table 3-1 are based on average use.

Refer to additional information contained in Tables 3-2, 3-3 and 3-4.

Table 3-1 Relubrication Intervals *

NEMA / (IEC) Frame SizeRated Speed - RPM

10000 6000 3600 1800 1200 900Up to 210 incl. (132) ** 2700 Hrs. 5500 Hrs. 12000 Hrs. 18000 Hrs. 22000 Hrs.Over 210 to 280 incl. (180) ** 3600 Hrs. 9500 Hrs. 15000 Hrs. 18000 Hrs.Over 280 to 360 incl. (225) ** * 2200 Hrs. 7400 Hrs. 12000 Hrs. 15000 Hrs.Over 360 to 5800 incl. (300) ** *2200 Hrs. 3500 Hrs. 7400 Hrs. 10500 Hrs.

* Relubrication intervals are for ball bearings. For vertically mounted motors and roller bearings, divide the relubrication interval by 2.

** For motors operating at speeds greater than 3600 RPM, contact Baldor for relubrication recommendations.

3-2 Maintenance & Troubleshooting MN400

Table 3-2 Service Conditions

Severity of Service Hours per dayof Operation

Ambient TemperatureMaximum

AtmosphericContamination

Standard 8 40° C Clean, Little CorrosionSevere 16 Plus 50° C Moderate dirt, CorrosionExtreme 16 Plus >50° C* or

Class H InsulationSevere dirt, Abrasive dust, Corrosion, Heavy

Shock or VibrationLow Temperature <−29° C **

* Special high temperature grease is recommended (Dow Corning DC44). Note that Dow Corning DC44 grease doesnot mix with other grease types. Thoroughly clean bearing & cavity before adding grease.

** Special low temperature grease is recommended (Aeroshell 7).

Table 3-3 Relubrication Interval Multiplier

Severity of Service MultiplierStandard 1.0Severe 0.5Extreme 0.1

Low Temperature 1.0

Some motor designs use different bearings on each motor end. This is normally indicated on the motor nameplate. In this case, the larger bearing is installed on the motor Drive endplate. For best relubrication results, only use theappropriate amount of grease for each bearing size (not the same for both).

Table 3-4 Bearings Sizes and Types

Frame SizeNEMA (IEC)

Bearing Description(These are the “Large” bearings (Shaft End) in each frame size)

BearingWeight of Grease to

add *oz (Grams)

Volume of greaseto be added

in3 teaspoon56 to 140 (90) 6203 0.08 (2.4) 0.15 0.5

140 (90) 6205 0.15 (3.9) 0.2 0.8180 (100−112) 6206 0.19 (5.0) 0.3 1.0

210 (132) 6307 0.30 (8.4) 0.6 2.0250 (160) 6309 0.47 (12.5) 0.7 2.5280 (180) 6311 0.61 (17) 1.2 3.9320 (200) 6312 0.76 (20.1) 1.2 4.0360 (225) 6313 0.81 (23) 1.5 5.2400 (250) 6316 1.25 (33) 2.0 6.6440 (280) 6319 2.12 (60) 4.1 13.4

5000 to 5800 (315−450) 6328 4.70 (130) 9.2 30.05000 to 5800 (315−450) NU328 4.70 (130) 9.2 30.0360 to 449 (225−280) NU319 2.12 (60) 4.1 13.4

AC Induction Servo76 Frame 180 (112) 6207 0.22 (6.1) 0.44 1.477 Frame 210 (132) 6210 0.32 (9.0) 0.64 2.180 Frame 250(160) 6213 0.49 (14.0) 0.99 3.3

* Weight in grams = .005 DBof grease to be added

Note: Not all bearing sizes are listed. For intermediate bearing sizes, use the grease volume for the nextlarger size bearing.


Caution: To avoid damage to motor bearings, grease must be kept free of dirt. For an extremely dirtyenvironment, contact your Baldor distributor or an authorized Baldor Service Center foradditional information.

Relubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease alreadyin the motor. Consult your Baldor distributor or an authorized service center if a grease other than therecommended type is to be used.

Caution: Do not over−lubricate motor as this may cause premature bearing failure.With Grease Outlet Plug1. With the motor stopped, clean all grease fittings with a clean cloth.2. Remove grease outlet plug.

Caution: Over−lubricating can cause excessive bearing temperatures, premature lubrication breakdownand bearing failure.3. Add the recommended amount of grease.4. Operate the motor for 15 minutes with grease plug removed.

This allows excess grease to purge.5. Re-install grease outlet plug.Without Grease ProvisionsNote: Only a Baldor authorized and UL or CSA certified service center can disassemble a UL/CSA

listed explosion proof motor to maintain it’s UL/CSA listing.1. Disassemble the motor.2. Add recommended amount of grease to bearing and bearing cavity. (Bearing should be about 1/3

full of grease and outboard bearing cavity should be about 1/2 full of grease.)3. Assemble the motor.

Sample Relubrication Determination

Assume - NEMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an ambient temperature of43° C and the atmosphere is moderately corrosive.1. Table 3-1 list 9500 hours for standard conditions.2. Table 3-2 classifies severity of service as “Severe”.3. Table 3-4 shows that 1.2 in3 or 3.9 teaspoon of grease is to be added.Note: Smaller bearings in size category may require reduced amounts of grease.



Table 3-5 Troubleshooting Chart

Symptom Possible Causes Possible SolutionsMotor will not start Usually caused by line trouble, such

as, single phasing at the starter.Check source of power. Check overloads, fuses,controls, etc.

Excessive humming High Voltage. Check input line connections.Eccentric air gap. Have motor serviced at local Baldor service center.

Motor Over Heating Overload. Compare actual amps(measured) with nameplate rating.

Locate and remove source of excessive friction inmotor or load.Reduce load or replace with motor of greater capacity.

Single Phasing. Check current at all phases (should be approximatelyequal) to isolate and correct the problem.

Improper ventilation. Check external cooling fan to be sure air is movingproperly across cooling fins.Excessive dirt build-up on motor. Clean motor.

Unbalanced voltage. Check voltage at all phases (should be approximatelyequal) to isolate and correct the problem.

Rotor rubbing on stator. Check air gap clearance and bearings.Tighten “Thru Bolts”.

Over voltage or under voltage. Check input voltage at each phase to motor.Open stator winding. Check stator resistance at all three phases for

balance.Grounded winding. Perform dielectric test and repair as required.Improper connections. Inspect all electrical connections for proper

termination, clearance, mechanical strength andelectrical continuity. Refer to motor lead connectiondiagram.

Bearing Over Heating Misalignment. Check and align motor and driven equipment.Excessive belt tension. Reduce belt tension to proper point for load.Excessive end thrust. Reduce the end thrust from driven machine.Excessive grease in bearing. Remove grease until cavity is approximately 3/4 filled.Insufficient grease in bearing. Add grease until cavity is approximately 3/4 filled.Dirt in bearing. Clean bearing cavity and bearing. Repack with correct

grease until cavity is approximately 3/4 filled.Vibration Misalignment. Check and align motor and driven equipment.

Rubbing between rotating parts andstationary parts.

Isolate and eliminate cause of rubbing.

Rotor out of balance. Have rotor balance checked are repaired at yourBaldor Service Center.

Resonance. Tune system or contact your Baldor Service Centerfor assistance.

Noise Foreign material in air gap orventilation openings.

Remove rotor and foreign material. Reinstall rotor.Check insulation integrity. Clean ventilation openings.

Growling or whining Bad bearing. Replace bearing. Clean all grease from cavity andnew bearing. Repack with correct grease until cavityis approximately 3/4 filled.


Suggested bearing and winding RTD setting guidelinesMost large frame AC Baldor motors with a 1.15 service factor are designed to operate below a Class B(80°C) temperature rise at rated load and are built with a Class H winding insulation system. Based onthis low temperature rise, RTD (Resistance Temperature Detectors) settings for Class B rise should beused 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 windingRTD alarm and trip settings should be selected based on these tables unless otherwise specified forspecific 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 asspecified by NEMA. Bearing RTDs should be installed so they are in contact with the outer race on ballor roller bearings or in direct contact with the sleeve bearing shell.

Winding RTDs − Temperature Limit In �C (40�C Maximum Ambient)

Motor LoadClass B Temp Rise � 80°C

(Typical Design) Class F Temp Rise � 105°C Class H Temp Rise � 125°C

Alarm Trip Alarm Trip Alarm Trip� Rated Load 130 140 155 165 175 185Rated Load to 1.15 S.F.

140 150 160 165 180 185

Note: � Winding RTDs are factory production installed, not from Mod−Express.� When Class H temperatures are used, consider bearing temperatures and relubrication requirements.

Bearing RTDs − Temperature Limit In �C (40�C Maximum Ambient)

Bearing TypeOil or Grease

Anti−Friction SleeveAlarm Trip Alarm Trip

Standard* 95 100 85 95High Temperature** 110 115 105 110

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.

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− Mobilith SHC−100 − Pennzoil Pennzlube EM−2 − Chevron Black Pearl− Darmex 707 − Darmex 711 − Petro−Canada Peerless LLG

See the motor nameplate for replacement grease or oil recommendation. Contact Baldor application engineering for special lubricants or further clarifications.


Baldor District Offices

© 2009 Baldor Electric CompanyMN400

All rights reserved. Printed in USA2/09

BALDOR ELECTRIC COMPANYWorld Headquarters

P.O. Box 2400 Fort Smith, AR 72901−2400(479) 646−4711 Fax (479) 648−5792

www.baldor.com

Preparation

Determine if the pump is in goodcondition.

A. Check the shaft or sleeve.

1. Remove all burrs and sharp corners, especially in areas where the O-ring has to slide. Cover threads and keyway slots with a thin tape to prevent cutting the O-ring. The distance from the face of the stuffing box to the center of the O-ring grooveis approximately 1.12" (28,5 mm).

2. The shaft finish should be no rougherthan 32 microinches (0,8 microns)AA. It should feel smooth if you runyour fingernail along the shaft in theaxial direction.

3. Make sure the shaft or sleevediameter is within tolerance (nomore than +/- .002" [0,05 mm]from nominal).

Example: 1.750" shaft should not belarger than 1.752" or smaller than1.748".

4. Use a dial indicator to measure theshaft runout in the area where theseal is to be installed. Readingsshould not exceed .001" TIR perinch (0,001 mm TIR per millimeter)of shaft diameter.

5. Place the dial indicator on the end ofthe shaft and alternately push andpull the shaft in the axial direction tomeasure end play. If the bearings arein a good condition, end play shouldnot exceed .005" (0,13 mm) TIR.

6. Protect the sleeve O-ring by lubricating the shaft with a clean silicone based lubricant. A sufficient quantity is provided with the seal.

B. Check the stuffing box face.

1. The stuffing box face must besmooth enough for a gasket to seal;maximum 125 microinches (3,2 microns) AA.

2. Split case pumps will sometimes cause a step (misalignment) to occur on the stuffing box face. This step must be machined flat.

3. Make sure the stuffing box is clean and clear along its entire length.

4. If possible, attach the base of a dial indicator to shaft and rotate shaft and indicator slowly while reading the runout of the stuffing box face. Misalignment of the stuffing box relative to the shaft should not exceed .005" TIR per inch (0,005 mm TIR per millimeter) of shaft diameter. Though the 255 can accommodate upto 0.025" (0,64 mm) of misalignment, minimizing the misalignment will maximize seal life.

Installation

1. Check the chemical listing to determine if the Fluorocarbon O-rings installed in this seal are compatible with the fluid being sealed. If it is necessary to change the O-ring material, disassemble the seal as shown in the instructions and replace it with suitable O-rings. A spare set of Ethylene Propylene O-rings is supplied with the seal.

2. The 1/4 dog point set screws go into smaller holes in the sleeve. Do not disengage the 1/4 dog point screws from the sleeve when positioning the seal. The three (six for sizes above 2.50" and 60 mm) cup point set screws go through the larger holes in the sleeve. Make sure all six screws (nine screws for sizes above 2.50" and 60 mm) are engaged into the sleeve but do not protrude into the ID bore. Additionally, when re-positioning or removing the seal makesure the three centering clips and socket head cap screws are engaged.

3. The centering clips have been preset at the factory. If for any reason you loosen or remove the centering clipcap screws, re-tighten as follows prior to installing seal on your equipment: Tighten the cap screw finger tight, then using the Allen wrench, tighten the capscrew an additional 1/8 of a turn. This will approximate the 30 lbs-in (3,4 Nm)of torque set at the factory. Make sure that the lip on the end of the centering clips is inside the groove in the gland.

4. CAUTION: If the 255 seal is operating at a stuffing box pressure of over 300 psig (20 Bar)or if the shaft is case hardened, replace the three (six for sizes above 2.50" and 60 mm) 316 stainless steel set screws that go through the larger holes on the sleeve with the hardened steel set screws supplied with the seal.

5. Slide the seal onto the shaft, makingsure the 1/4 dog point set screws areengaged through the seal sleeve.

255™

CARTRIDGE DUAL SEAL

SEAL INSTALLATION

MECHANICAL SEALINSTALLATION INSTRUCTIONS

2

6. Reassemble the pump and makenecessary shaft alignments andimpeller adjustments. The impeller can be reset at any time, as long as the centering clips are in place and the seal set screws are loosened while the shaft is being moved.

7. Orient the barrier fluid connections to the location required. The ports are plugged prior to shipping. Removal of the plugs will require 25 lbs-ft. (34 Nm) of torque.

8. Piping connections should not be made prior to tightening the gland bolts.

9. Tighten the gland nuts evenly. Important: the gland nuts must be tightened before tightening set screws onto the shaft.

10.Evenly tighten all six set screws (three cup point set screws and three 1/4 dog point set screws) with the hexkey provided. After they have been tightened with the hex key, tighten them again with a torque wrench to 50-60 lbs-in. (5,7- 6,8 Nm). Note: For sizes above 2.50" and 60 mm there is a total of nine set screws (six cup point set screws and three 1/4 dog point set screws).

11.Remove centering clips and socket head cap screws, retain for later use.

12.Check the spring gap, between the rotary and lock ring, to check if it is aneven 1/16" (approximately) all around. An equal 1/16" (1,6 mm) spring gap is indicative of squareness of the stuffing box to the shaft.

CAUTIONS

These instructions are general in nature. It is assumed that the installer is familiar with sealsand certainly with the requirements of their plant for successful use of mechanical seals. If indoubt, get assistance from someone in the plant who is familiar with the seals or delay theinstallation until a seal representative is available. All necessary auxiliary arrangements forsuccessful operation (heating, cooling, flushing) as well as safety devices must be employed.These decisions are to be made by the user. The chemical listing is intended as a generalreference for this seal only. The decision to use this seal or any other Chesterton seal in aparticular service is the customer’s responsibility.

SEAL INSTALLATION

13. IMPORTANT: It is important to make sure that the gland is properly centered over the sleeve. To do this, turn the shaft by hand to make sure the seal turns freely. If you hear metal to metal contact within the seal, it was improperly centered. Replace the centering clips finger tight, loosen gland bolts, tighten clips, re-tighten gland bolts, and then remove clips. If metal to metal contact still existscheck the centering of the stuffingbox.

14.Piping connections should not be made until the gland nuts are tightened.

15.BARRIER FLUID CONNECTIONS:The barrier fluid port connections are:

• 1/4" NPT for 1.00" through -1.50"and 25 mm through 38 mm.

• 3/8" NPT for 1.625" through -2.50" and 40 mm through 60 mm.

• 1/2" NPT for 2.625" through -3.750" and 65 mm through 120 mm.

This seal is equipped with a pumping device to circulate the barrier fluid. The Piping Connections are Dependent on Shaft Rotation.When looking at the lock ring end of the seal: CONVECTION (when ports are positioned at 12:00).

A. CLOCKWISE shaft rotation

• The cool fluid enters through the right port.

• The hot fluid exits the seal through the left port and goes to the top of the convection tank.

B. COUNTER-CLOCKWISE shaftrotation

• The cool fluid from the bottom of the convection tank enters throughthe left port.

• The hot fluid exits the seal through the right port and goes to the top of the convection tank.

• Add fluid, typically 50/50 ethylene glycol and water or Chesterton®

610 Synthetic Lubricating Oil, to the convection tank.

FORCED CIRCULATION(when ports are positioned at 12:00)

A. CLOCKWISE shaft rotation

• The cool fluid enters through theright port.

• The hot fluid exits the seal throughthe left port.

B. COUNTER-CLOCKWISE shaftrotation

• The cool fluid enters through theleft port.

• The hot fluid exits the seal throughthe right port.

For a double sealing arrangement,the barrier fluid is typically pressurized at approximately15-20 psig (1-1,5Bar) above the stuffing box pressure.For a tandem sealing arrangement,the barrier fluid is typicallypressurized between 15 psig (1 Bar)and half of the stuffing boxpressure. Take all necessaryprecautions and follow normalsafety procedures before startingequipment.

3

DISASSEMBLY (1-10)

You will need the hex keys provided with the seal, and an O-ring extractor or paper clip to disassemble the seal.

1

Place the seal, lock ring side up, on a flat surface. Remove the centering clips.

2

While pressing down on the lock ring, back off all the set screws so they disengage from the sleeve.

3

Carefully lift the lock ring and rotary assembly out holding the rotary seal ring as well as the lock ring. This will keep the rotary seal ring from falling off. Place the lock ring assembly with the rotary seal ring side up.

4

Separate the rotary seal ring and the lock ring.

5

Refer to the chemical listing to determine the chemical compatibility of the elastomers with the fluid being sealed. The 255 is supplied with Flourocarbon O-rings installed.If necessary, replace the Flourocarbon with the Ethylene Propylene provided. If Flourocarbon and Ethylene Propylene are not compatible, you may obtain Buna-N, Neoprene, Chesterton 76, Chemraz** or Kalrez* elastomers from your Chesterton distributor.

* Registered Trademark of DuPont ** Registered Trademark of Green, Tweed, & Co.

4

Remove the two stationary seal rings out of the gland and remove the O-rings.

9

Remove the flow channel out of the gland and remove the drive lug. The flow channel can only be removed in one direction.

10

DISASSEMBLY (1-10)

Remove the springs and the O-rings from the lock ring.

6

Rest the gland on its edge and slide the sleeve and inboard rotary assembly out.

7

Remove the rotary seal ring and the two O-rings from the sleeve.

8

5

Place the gland with the outboard side facing up (gasket side down). Slide one of the stationery seal rings into the outboard end of the gland, pushing gently past the O-ring, until it engages with the drive clips on the flow channel. Make sure the drive clips are lined up with the stationary seal ring slots.

15

ASSEMBLY (11-21)

Turn the gland assembly over. Push the other stationary into the inboard end of the gland, pushing gently past the O-ring, until it engages with the drive clips on the flow channel. Make sure the drive clips are lined up with the stationary slots. This assembly should be able to move (axially) easily.

16

The O-ring placement by increasing size is:Smallest size O-ring (1) Sleeve IDNext larger size O-ring (1) Lock Ring IDNext larger size O-rings (2) Rotary Seal RingsLargest size O-rings (2) Gland

11

Lubricate the sleeve ID O-ring with the silicone grease provided and install it in the sleeve ID O-ring groove. Lubricate the sleeve rotary O-ring and install it in the sleeve OD O-ring groove. Slide the rotary seal ring onto the sleeve, lining up the sleeve drive tabs with rotary seal ring slots, until it bottoms out.

12

If the two drive clips are not already attached, install the two drive clips in the slots in the flow channel. Note: There are four drive clips for sizes above 2.50" and 60 mm.

13

Lubricate one gland O-ring with the silicone grease provided and install it in one of the gland O-ring grooves. Place rectangular side of drive lug into the gland horizontally. The square shaped side of the drive lug should be facing up. Place the gland on its edge and slide the channel into the gland past the other O-ring groove, lining up the drive lug with the slot in the flow channel. Lubricate the other gland O-ring with the silicone grease provided and install it in the other gland O-ring groove.

14

Arrange O-ring by size.

6

ASSEMBLY (11-21)

Press down on the lock ring and tighten the 1/4 dog point set screws and the cup point set screws. Check to ensure that the sleeve is not deformed while tightening the set screws. Make sure the screws do not protrude into the sleeve ID bore. Install and re-tighten the centering clips as follows: Tighten the cap screw finger tight, then using the Allen wrench, tighten the capscrew an additional 1/8 of a turn. Make sure that the lip on the end of the centering clips is inside the groove in the gland. The assembly is now complete.

21

Carefully pick up the lock ring and rotary assembly holding the rotary seal ring as well as the lock ring. This will keep the rotary from falling off. Make sure the drive tabs are still aligned with the rotary seal ring slots. Turn the lock ring assembly over and slide it over the sleeve, aligning the 1/4 point set screws with the smaller holes and the cup point set screws with the larger holes. Hold the rotary seal ring with your fingers while gently pushing down on the lock ring till the rotary makes contact with the stationary seal ring.

20

Place the sleeve assembly with the lock ring side facing up. Lift the gland assembly and slide it onto the sleeve, making sure that the outboard side of the gland faces up towards the lock ring end of the sleeve.

19

Slide the outboard rotary seal ring over the lock ring until it is over the O-ring, aligning the drive tabs with the rotary slots. Press on the rotary seal ring to compress the springs to make sure that the rotary seal ring can move freely. Wipe the stationary and rotary seal ring faces clean with a lint free cloth.

1817

Lubricate the lock ring O-rings and place them in the lock ring O-ring grooves. Make sure the proper screws are in the lock ring. There should be three cup point set screws and three hybrid dog/cup point set screws placed alternately in the bigger holes on the lock ring. (For sizes above 2.50" and 60 mm there are six cup point set screws). Place a spring in each hole in the lock ring. Apply a small amount of silicone grease to the bottom of each spring. This will help the springs stay in the holes.

7

DIMENSIONAL DATA (DRAWINGS) – SMALL

DC

E MIN F

A

XW Y Y X Z

B MAX

G MIN H

DASH A B C C D E F G MINNO. MAX MIN MAX MAX MIN MAX 3/8" 1/2" 5/8" H W X Y Z

8 1.000 4.12 1.75 1.81 1.73 1.36 2.16 2.81 2.94 0.57 120 124 126 121

9 1.125 4.12 1.88 1.94 1.85 1.36 2.16 2.95 3.08 0.57 122 126 128 124

10 1.250 4.12 2.00 2.06 1.98 1.36 2.16 3.08 3.21 0.57 124 128 130 126

11 1.375 4.37 2.13 2.31 2.10 1.36 2.16 3.21 3.34 0.57 126 130 132 128

12 1.500 4.50 2.25 2.44 2.23 1.36 2.16 3.33 3.46 0.57 128 132 134 130

13 1.625 5.00 2.38 2.56 2.35 1.36 2.16 3.45 3.58 0.56 130 134 136 132

14 1.750 5.50 2.50 2.81 2.48 1.36 2.16 3.66 3.79 0.56 132 136 138 134

15 1.875 5.50 2.63 2.94 2.60 1.36 2.16 3.78 3.91 0.56 134 138 140 136

16 2.000 5.50 2.75 3.19 2.73 1.36 2.16 4.03 4.16 0.56 136 140 142 138

17 2.125 6.01 2.88 3.44 2.85 1.36 2.16 4.29 4.42 4.54 0.68 138 142 144 140

18 2.250 6.01 3.00 3.56 2.98 1.36 2.16 4.41 4.54 4.66 0.68 140 144 146 142

19 2.375 6.01 3.13 3.59 3.10 1.36 2.16 4.44 4.57 4.69 0.68 142 146 148 144

20 2.500 6.51 3.25 3.81 3.23 1.36 2.16 4.66 4.79 4.91 0.68 144 148 150 146

A B C C D E F G MINMAX MIN MAX MAX MIN MAX 8 mm 10 mm 12 mm H W X Y Z

25 105 44 46 43 35 55 70 72 74 14 120 124 126 121

28 105 47 49 46 35 55 73 75 77 14 121 126 128 123

30 105 49 51 48 35 55 76 78 80 14 123 127 129 125

32 105 51 52 50 35 55 77 79 81 14 124 128 131 126

33 114 54 58 53 35 55 78 80 82 14 125 129 131 127

35 111 54 59 53 35 55 80 82 84 14 126 130 132 128

38 114 57 62 57 35 55 83 85 87 14 128 132 134 130

40 127 59 61 58 35 55 86 88 90 14 129 134 136 131

43 127 64 69 63 35 55 89 91 93 14 131 135 137 133

45 140 64 66 63 35 55 93 95 97 14 132 137 139 134

48 140 69 74 68 35 55 94 96 98 14 134 139 141 136

50 140 69 71 68 35 55 98 100 102 14 136 140 142 137

55 153 74 76 73 35 55 103 105 17 139 143 145 140

60 153 79 85 79 35 55 113 115 17 142 146 148 144

KEY (drawings & charts)A – Shaft SizeB – Maximum Gland DiameterC – Stuffing Box Inside DiameterD – Seal Diameter in Stuffing BoxE – Minimum Stuffing Box DepthF – Outboard Seal LengthG– Minimum Bolt Circle by Bolt SizeH – Slot WidthW– Shaft O-RingX – Rotary Seal O-Ring (2)Y – Stationary Seal O-Ring (2)Z – Sleeve O-Ring

8

255 DIMENSIONAL DATA (INCH) – SMALL

255 DIMENSIONAL DATA (METRIC) – SMALL

9

DIMENSIONAL DATA (DRAWINGS) – LARGE

DC

E MIN F

A

XW Y Y X Z

B MAX

G MINH

DASH A B C C D E F G MIN

NO. MAX MIN MAX MAX MIN MAX 1/2" 5/8" 3/4" H W X Y Z

21 2.625 6.45 3.63 3.69 3.60 1.64 2.52 5.02 5.15 0.68 231 234 236 233

22 2.750 7.71 3.75 4.19 3.72 1.64 2.52 5.42 5.55 0.68 232 235 237 234

23 2.875 7.83 3.88 4.32 3.85 1.64 2.52 5.50 5.63 0.68 233 236 238 235

24 3.000 7.94 4.00 4.44 3.97 1.64 2.52 5.65 5.78 0.68 234 237 239 236

25 3.125 7.99 4.13 4.57 4.10 1.64 2.52 5.80 5.93 0.68 235 238 240 237

26 3.250 8.19 4.25 4.69 4.22 1.64 2.52 5.93 6.06 0.68 236 239 241 238

27 3.375 8.31 4.38 4.82 4.35 1.64 2.52 6.00 6.13 6.26 0.81 237 240 242 239

28 3.500 8.44 4.50 4.94 4.47 1.64 2.52 6.16 6.29 6.42 0.81 238 241 243 240

29 3.625 8.49 4.63 5.07 4.60 1.64 2.52 6.29 6.42 6.55 0.81 239 242 244 241

30 3.750 8.72 4.75 5.19 4.72 1.64 2.52 6.36 6.49 6.62 0.81 240 243 245 242

31 3.875 8.84 4.88 5.32 4.85 1.64 2.52 6.50 6.63 6.76 0.81 241 244 246 243

32 4.000 8.96 5.00 5.44 4.97 1.64 2.52 6.64 6.77 6.90 0.81 242 245 247 244

33 4.125 8.99 5.13 5.57 5.10 1.64 2.52 6.76 6.89 7.02 0.81 243 246 248 245

34 4.250 8.99 5.25 5.69 5.22 1.64 2.52 6.89 7.02 7.15 0.81 244 247 249 246

35 4.375 9.34 5.38 5.82 5.35 1.64 2.52 7.01 7.14 7.27 0.81 245 248 250 247

36 4.500 9.49 5.50 5.94 5.47 1.64 2.52 7.16 7.29 7.42 0.81 246 249 251 248

37 4.625 9.49 5.63 6.07 5.60 1.64 2.52 7.26 7.39 7.52 0.81 247 250 252 249

38 4.750 10.49 5.75 6.19 5.72 1.64 2.52 7.38 7.51 7.64 0.81 248 251 253 250

A B C C D E F G MINMAX MIN MAX MAX MIN MAX 12 mm 16 mm 20 mm H W X Y Z

65 164 92 93 91 42 64 127 131 17 231 234 236 232

70 196 95 105 95 42 64 137 141 17 232 235 237 234

75 202 102 112 101 42 64 143 147 17 234 237 239 235

80 203 105 115 104 42 64 147 151 17 235 238 240 237

85 211 111 121 110 42 64 152 156 160 21 237 240 242 238

90 214 114 124 114 42 64 156 160 164 21 238 241 243 240

95 221 121 131 120 42 64 161 165 169 21 240 243 245 241

100 228 127 137 126 42 64 168 172 176 21 242 245 247 243

110 237 137 147 136 42 64 177 181 185 21 245 248 250 246

120 266 146 156 145 42 64 187 191 195 21 248 251 253 249

255 DIMENSIONAL DATA (INCH) – LARGE

10

255 DIMENSIONAL DATA (METRIC) – LARGE

KEY (drawings & charts)A – Shaft SizeB – Maximum Gland DiameterC – Stuffing Box Inside DiameterD – Seal Diameter in Stuffing BoxE – Minimum Stuffing Box DepthF – Outboard Seal LengthG– Minimum Bolt Circle by Bolt SizeH – Slot WidthW– Shaft O-RingX – Rotary Seal O-Ring (2)Y – Stationary Seal O-Ring (2)Z – Sleeve O-Ring


NO. MAX MIN MAX MAX MIN MAX 3/8" 1/2" 5/8" H V W X Y Z

8 1.000 4.12 1.75 1.81 1.73 1.18 2.35 2.81 2.94 0.57 133 120 124 126 121

9 1.125 4.12 1.88 1.94 1.85 1.18 2.35 2.95 3.08 0.57 135 122 126 128 124

10 1.250 4.12 2.00 2.06 1.98 1.18 2.35 3.08 3.21 0.57 137 124 128 130 126

11 1.375 4.37 2.13 2.31 2.10 1.18 2.35 3.21 3.34 0.57 139 126 130 132 128

12 1.500 4.50 2.25 2.44 2.23 1.18 2.35 3.33 3.46 0.57 141 128 132 134 130

13 1.625 5.00 2.38 2.56 2.35 1.18 2.35 3.45 3.58 0.56 143 130 134 136 132

14 1.750 5.50 2.50 2.81 2.48 1.18 2.35 3.66 3.79 0.56 145 132 136 138 134

15 1.875 5.50 2.63 2.94 2.60 1.18 2.35 3.78 3.91 0.56 147 134 138 140 136

16 2.000 5.50 2.75 3.19 2.73 1.18 2.35 4.03 4.16 0.56 149 136 140 142 138

17 2.125 6.01 2.88 3.44 2.85 1.18 2.35 4.29 4.42 4.55 0.68 150 138 142 144 140

18 2.250 6.01 3.00 3.56 2.98 1.18 2.35 4.41 4.54 4.67 0.68 151 140 144 146 142

19 2.375 6.01 3.13 3.59 3.10 1.18 2.35 4.44 4.57 4.70 0.68 151 142 146 148 144

20 2.500 6.51 3.25 3.81 3.23 1.18 2.35 4.66 4.79 4.92 0.68 152 144 148 150 146


NO. MAX MIN MAX MAX MIN MAX 3/8" 1/2" 5/8" H W X Y Z

-9 1.125 4.49 2.63 2.94 2.62 1.48 1.98 3.77 0.44 122 126 128 124

11 1.375 5.40 2.82 2.99 2.80 1.48 1.98 4.02 0.44 126 130 132 128

14 1.750 6.64 3.51 3.74 3.48 1.30 2.16 5.21 5.34 5.46 0.75 132 136 138 134

15 1.875 5.99 3.57 3.80 3.54 1.30 2.16 4.94 0.63 134 138 140 136

17 2.125 6.99 3.89 4.24 3.87 1.30 2.16 5.89 0.75 138 142 144 140

20 2.500 7.77 4.51 4.74 4.49 1.30 2.16 6.70 0.75 144 148 150 146

11

255 DIMENSIONAL DATA (OVERSIZE)

255 DIMENSIONAL DATA (ADAPTER VERSION)

255 is a trademark of A.W. Chesterton Company.

PARTS IDENTIFICATION

KEY 1 – Gasket2 – Drive Lug3 – Stationary Seal Ring4 – Rotary Seal Ring5 – Sleeve6 – O-Rings7 – Drive Clip8 – Flow Channel

9 – Cap plug10 – Gland (Cast gland shown)11 – Lock Ring12 – Spring13 – 1/4 Dog Pt Set Screw14 – Cup Point Set Screw15 – Centering Clip16 – Socket Head Screw

1

2

3

4

9

10

3

4

12

11

13

14

15

6

16

6

5

6

6

7

8

FORM NO. 071958 REV. 4 PRINTED IN USA 8/06

860 Salem StreetGroveland, MA 01834 USATelephone: 781-438-7000 Fax: 978-469-6528www.chesterton.com

© A.W.Chesterton Company, 2006. All rights reserved.® Registered trademark owned and licensed by

A.W.Chesterton Company in USA and other countries.

ISO Certifications available at www.chesterton.com/corporate/iso

This equipment cannot be entered without

a Confined Space Permit

per your facility requirements.

Prior to entry, ALL equipment

must follow the appropriate

Lock-Out Tag-Out procedures

per your facility requirements.

FELDMEIEREQUIPMENT, INC.

575 EAST MILL STREET • LITTLE FALLS, NEW YORK 13365•TEL: (315) 823-2000 • FAX: (315) 823-5012

Manufacturing Facilities

Syracuse, New York � Little Falls, New York � Montgomery, Alabama � Fernley, Nevada � Shell Rock, Iowa

CARE OF STAINLESS STEEL

The stainless steel components in Feldmeier equipment are machined, welded, and assembled by skilled craftsmen using manufacturing methods that preserve the corrosion-resistant quality of the stainless steel.

Retention of corrosion-resistant qualities under processing conditions requires regular attention to the precautions listed below. (Note: Corrosion-resistance is greatest when a layer of oxide film is formed on the surface of the stainless steel; should this film be disturbed or destroyed, stainless steel becomes active and much less resistant to corrosion)

1.) Regularly check all electrical devices connected to the equipment for stray currents caused by improper grounding, damaged insulation or other defects.

Corrosion: “Pitting” often occurs when stray currents come in contact with moist stainless steel.

2.) Never leave rubber mats, fittings, wrenches, etc. in contact with stainless steel.

Corrosion: Pitting or galvanic action. Objects retard complete drying, preventing air from reforming the protective oxide film. Galvanic Corrosion occurs when two dissimilar metals touch when wet.

3.) Use water conditioner when the water supply contains foreign matter, which may cause discoloration or deposits.

Corrosion: Pitting, deposits, discoloration. Deposits counteract the best cleaning practices and cause corrosion of the best quality stainless steel.

4.) Immediately rinse equipment after use with warm water until the rinse water is clean. Clean the equipment (manual or CIP) as soon as possible after rinsing.

Corrosion: Discoloration, deposits, pitting. Product deposits often cause pitting beneath the particles.

5.) Use only recommended cleaning compounds. Purchase chemicals from reputable and responsible chemical manufacturers familiar with stainless steel processing equipment. They continuously check the effects of their products on stainless steel.

6.) Use cleaning chemicals exactly as specified by the manufacturer. Do not use excessive concentrations, temperatures, or exposure times.

Corrosion: Pitting, discoloration, stress cracks. Permanent damage often occurs from excessive chemical concentrations, temperatures, or exposure times.





CARE OF STAINLESS STEEL – Cont.

7.) For manual cleaning, use only soft non-metallic brushes, sponges, or pads. Brush with the grain on polished surfaces; avoid scratching the surface.

Corrosion: Pitting, scratches. Metal brushes or sponges will scratch the surface and promote corrosion over a period of time. Metal particles allowed to remain on a stainless steel surface will cause pitting.

8.) Use chemical bactericides exactly as prescribed by the chemical manufacturer in concurrence with local health authority. Use the lowest permissible concentration, temperature and exposure time possible. Flush immediately after bacterial treatment. In no case should the solution be in contact with stainless steel more than 20 minutes.

Corrosion: Protective film destroyed. Chlorine and other halogen bactericides can destroy the protective film. A few degrees increase in temperature greatly increases chemical activity and accelerates corrosion.

9.) Regularly inspect equipment for surface corrosion. If deposit or color corrosion is detected, remove it immediately using mild scouring powder. Rinse thoroughly and allow to air dry. Review production and cleaning procedures to determine the cause.

Note: If corrosion is not removed, the protective film cannot be restored and corrosion will continue at an accelerated rate.





INSTALLATIONInspection on ArrivalThis equipment has received a careful final inspection. It has been crated securely to ensure delivery without damage or loss of any parts. At the time of delivery, please inspect the equipment for any visual damage or shortage. If damage or shortage has occurred, record on freight bill accordingly and have the driver sign.Unpack the equipment as soon as possible, and if you find concealed damage, hold all packaging material and call delivering carrier for inspection and to fill out inspection report (furnished by the transportation company).Then file a claim with the transportation company. They are responsible for any damage that may have occurred in shipment. For our records, we will appreciate your advising us of any damage or loss claims you file so we may assist you in every way.

Setting and LevelingMake certain the floor is strong enough to support the tank when fully loaded. Skid the tank to the selected location.

Lifting lugs around the upper seam provide a means for handling. Level as accurately as possible by holding a plumb line near the sides and establishing the vertical accuracy at several points between the top and bottom. Adjust the screw type legs to engagement as 11/2 inches.

If outlet height is important, it should be established before leveling and rechecked after leveling.

Electrical ConnectionA qualified electrician should make the motor power connections. The power characteristics must agree with those on the motor data plate. Machines are normally shipped without motor starting switches.

Direction of Agitator RotationRotation of the drive-motor shaft must be in the direction shown by the arrow on the tank. On 3-phase motors, reverse any two of the three wires if motor is turning in the wrong direction.

Water TestAfter installation of the tank and all accessories, a static test with water should be performed to ensure that there are no leaks.





MAINTENANCEDaily Cleaning of Exposed SurfacesCleaning all the surfaces, both inside and outside of the equipment is very important in order to maintain good sanitation as well as to preserve the stainless steel finish. Food products and foreign materials, which are allowed to adhere to the surface for any length of time, can cause a change in the finish surface of stainless steel. These surfaces must have free access to the air. Ordinarily, normal air exposure that occurs between one day’s processing and the next will be sufficient.

Do not use plain wool to brighten surfaces as the plain steel particles may adhere to the surface and show up as rust spots on the stainless steel. If you must use a steel wool, be sure it us made of stainless steel.

SANITIZINGHot Water Hot water sanitizing (above 1800 F) should be preceded by a warm tempering spray rinse.

SteamIf steam sanitizing is preformed just prior to product run, never direct steam flow against any metal surface. Severe metal stress will result.

Important facts to Remember

1. Venting is necessary if sudden internal air temperature changes occur.

2. Sudden changes in temperature (thermo-shock) which will create excessive stain in the lining should be avoided.

a. While spray cleaning is on the heating phase of any cycle, build up the liquid temperature for the first 10 minutes to act as a tempered rinse. Continue to circulate for 15 minutes at the final solution temperature for the wash cycle and 5 minutes for the sanitation cycle.

b. On cooling rinse cycles, bring the temperature down by letting some of the hot solution go to waste while fresh tap water is introduced to the supply tank.

c. A good rule to follow is to provide a 100 change per minute in the spray. Where burn-on or precipitation of minerals is a problem, special consideration must be given to greater rates of change.

3. Processors not designed for vacuum must never be operated under vacuum and all procedures that can create this condition must be eliminated. CIP systems with centrally controlled timer operation should be set to avoid sudden temperature drops which would create a vacuum.

4. CIP cleaning is not always capable of 100% cleaning. Some agitator components may have to be disassembled and hand cleaned prior to sanitizing. Whenever possible, vessel should be filled to top of agitator with CIP solution and agitator should be running during cleaning cycle.





REQUIRED VENTING FOR VACUUM CONDITIONS IN VESSELS

In order to protect processing and storage tanks against implosion that can occur adequate venting must be provided. Conditions, which can cause implosion (or a vessel to be sucked in), are:

� When too much vacuum is pulled during liquid product withdrawal � During cooling cycle following hot water or steam cleaning of tanks � During an overflow condition

When product is discharged the venting must allow for an equivalent volume of air to enter the vessel. Per the 3-A sanitary standards a 2” vent is adequate for 175 gpm discharge, a 3” vent handles 400 gpm and a 4” vent is adequate for 700 gpm. Table A-1 from the 3-A standards is shown below. When a silo is imploded during discharge it is generally due to an obstructed vent or vent line.

Flash cooling following CIP is the most often overlooked condition causing a vessel to implode. The vacuum created when cool water is sprayed into a hot vessel can cause the volume of air to shrink by 10% in one second. The manway must be open to accommodate this condition. Below is a caption from the 3-A standards describing this condition.

Overflow may also cause a vessel to be exposed to vacuum. In most silos for example designated lines are provided for venting and overflow conditions. During discharge both serve as a vent. During an overflow condition air is drawn from the top head with the liquid. The vent is designed for this. If the product is allowed to continue to overflow and fills the vent line the top head can implode.

TABLE A-1From 3-A standard #22-08

Min. Free Vent Opening Size Max. Filling or Emptying RateArea I.D.

2.5 in.2 (16 cm2) 1-3/4 in. (44.5 mm) 175 gpm (662 Lpm) 4.0 in.2 (26 cm2) 2-1/4 in. (57.2 mm) 300 gpm (1136 Lpm) 6.0 in.2 (39 cm2) 2-3/4 in. (69.9 mm) 400 gpm (1514 Lpm) 11.0in.2 (71 cm2) 3-3/4 in. (95.2 mm) 700 gpm (2650 Lpm)

26.0in.2 (168 cm2) 5-3/4 in. (146.0 mm) 1500 gpm (5678 Lpm) 47.2in.2 (304 cm2) 7-3/4 in. (196.8 mm) 2750 gpm (10410 Lpm)

From 3-A standard #22-08For example, when a 6,000 gal. Tank (with 800 ft. sq. of 135 deg. F hot air after cleaning) is suddenly flash cooled by 50 deg. F water sprayed at 100 gpm the following takes place: Within on second, the 800 ft sq. of hot air shrinks approximately 51 ft. sq. in volume. This is the equivalent in occupied space of approximately 382 gal of product. The shrinkage creates a vacuum sufficient to collapse the tank unless the vent, manhole, or other openings allow the air to enter the tank at approximately the same rate as it shrinks. It is obvious, therefore, that a very large air vent such as the manhole opening is required to accommodate this airflow.





TROUBLESHOOTING

Difficulty Cause RemedySlow Heating 1.) Steam supply line too

small or too long. Check for tap-off to other equipment. Increase size of line for low pressure steam.

2.) Boiler overloaded. Measure the pressure at the vat while it is operating.Increase the boiler capacity or rearrange the plant operating schedule.

3.) Temperature regulator defective.

Test by removing bulb and check for operation in can of water of known temperature, then see "Spare Parts" page attached.

4.) Heating zones waterlogged (steam heating).

Steam trap is not discharging water. Repair of replace, see "Spare Parts" page attached.

5.) Condensate return line to boiler plugged or valve closed.

Open or replace line.

6.) Heating zones air bound (hot water heating).

Discharge air through "air vent" valve.

7.) Failure to use steam bypass on automatic regulator during early heating.

Open bypass until product reaches 1000F

8.) Steam strainer clogged. Remove plug and blow out. 9.) Channels and headers plugged with water scale or rust.

Flush with cleaner

10.) Defective pump (hot water heating).

Check for air leaks in suction side, binding or shaft, leaky packing, worn impeller, impeller clogged by excelsior, foreign material, or impeller running in wrong direction.

11.) Pump impeller running in wrong direction (hot water heating).

Reverse two leads in starter box.

12.) Plugged lines feeding headers.

Replace lines (or clean), see "Spare Parts" page attached.

13.) Valve following steam trap closed.

Open when cooling is completed.

14.) Insufficient agitation. Adjust baffle for greater agitation or use higher agitation speed if available.

15.) Agitator blades pitched too low.

Have serviceman adjust. See "Spare parts" page attached.





Difficulty Cause Remedy

Excessive burn-on 1.) Steam in zones above product level.

Open zone valves beneath product level, one by one, as level rises. (Note that the vat is designed to permit some steam to bleed into the shut-off zones to preheat them and limit distortion of vat linings.)

2.) Insufficient agitation. Increase pitch of adjustable baffle or increase speed of the agitator (is so equipped).

3.) Agitator running in wrong direction.

Reverse any two leads of three phase connections at starter.

4.) Excessive agitation throws product on side walls.

Change baffle position or lower speed of agitator.

5.) Temperature regulator faulty.

Consult supplier.

Slow Cooling 1.) Insufficient water supply. Check requirements. 2.) Burn-on during heating. See remedies under "Burn-on". 4.) Cooling water bypassing through pump (hot water heating).

Keep union valve "I" closed while cooling.

5.) Zones above product level turned on.

Turn off to avoid wasting water through ineffective zones.

6.) Circulating pump clogged by foreign material.

Clean out pump and lines before installing.

7.) Temperature of cooling water is too high.

Check temperature.

8.) Air space heater may have been left on.

Shut off when cooling.

9.) Low voltage condition affecting pump and agitator.

Check plant wiring for overload.

Agitation Wobbles 1.) Mount is out of alignment Have service man align per factory instructions. 2.) Shaft is bent Have service man align per factory instructions. 3.) Bottom bushing problem Inspect / replace bottom bushing

Slow Mixing 1.) Adjustable baffle incorrectly set.

Move baffle at right angles to flow of product.

2.) Agitator running wrong direction.

Reverse any pair of 3 phase wires to starting relay.

3.) Agitation running slow. Increase speed if equipped with VFD.

Motor Troubles. 1.) Agitator motor running hot.

a. Overload- Motor may be unsuited for product more viscous than originally planned. Check motor amp draw.Compare with motor nameplate.

b. Motor improperly connected. c. Motor and agitator out of alignment. Have serviceman

check. d. Motor or reduction unit requires lubrication. See

"Lubrication" information attached.





For Spare Parts Contact:

Richard J. Bailey Repair Parts Coordinator

575 East Mill Street Little Falls, NY 13365

Phone: (800) 258-0118 or (315) 823-2000

Fax: (315) 823-0234

PART # DESCRIPTION QTY. LIST PRICE EACH

4030448 ALIGNMENT TOOL-DOUBLE SEAL RM 1 $140.00

1550069 BALDOR 40HP 1800RPM C FACE 1 $3,840.00

S1040500 GASKET 40MPU BUNA-N 4.0" 1 $3.25

1590694S GASKET-24"-WHITE SILICONE 1 $240.00

1032595 GASKET-IMPELLER-RADIPMIXER 1 $26.50

1554418 MECH SEAL CHESTRTN 255 MODIF 1 $2,550.00

Z04214 O-RING #214 VITON (FDA) 1 $7.00

1554520 O-RING 244 VITON 1 $10.50

1034539 SLINGER-LOWER BEARING RM 1 $21.00

FELDMEIER EQUIPMENT - SPARE PARTS LIST FELDMEIER SERIAL NO.: E-0935-10

12/27/2010 PRICING VALID FOR (30) DAYS

Contact: Rich Bailey (p) 800-258-0118(f) 315-823-0234

[email protected]





PARTS LIST

HOW TO ORDER PARTS

800-258-0118 THIS IS THE TOLL FREE NUMBER TO CALL WHEN YOU NEED REPAIR PARTS. YOU WILL BE CONNECTED WITH A SPECIALIST ON YOUR EQUIPMENT WHO CAN ASSIST IN DETERMINING THE PARTS YOU REQUIRE.

IF YOU NEED INFORMATION ABOUT SHIPPING DATES, ROUTING, AND DELIVERY INFORMATION THE SPECIALIST WHO EXPEDITES YOUR ORDER WILL HAVE IT AVAILABLE. SHOULD YOU CHOOSE TO SEND YOUR ORDERS FOR PARTS BY MAIL, PLEASE DIRECT THEM TO:

FELDMEIER EQUIPMENT REPAIR PARTS 575 EAST MILL ST. LITTLE FALLS, NY 13365

HOW TO RETURN PARTS

PARTS MAY BE RETURNED FOR CREDIT SUBJECT TO THE CONDITIONS OF OUR RETURN GOODS POLICY. TO OBTAIN AUTHORIZATION TO RETURN A PART, CONTACT THE SPECIALIST BY PHONE OR LETTER AT THE SAME ADDRESS AS ABOVE OR BY CALLING OUR TOLL FREE NUMBER AND PLEASE GIVE THE FOLLOWING INFORMATION:

� INVOICE NUMBER AND DATE

� QUANTITY

� PART NUMBER

� IF A DEFECT IS CLAIMED, THE MODEL AND SERIAL NUMBER OF THE MACHINE MUST BE STATED

RETURNS ARE SUBJECT TO RESTOCKING CHARGES





EQUIPMENT WARRANTY

We warrant to the original purchaser that all equipment or parts thereof manufactured by us will be free from defects in material and workmanship only, under normal use and service, for a period of one year from the date of original shipment.

This warranty will not apply to any equipment or parts thereof which have been subjected to accident, alteration, abuse, or misuse. This warranty is in lieu of all other warranties, expressed or implied and of all other obligations or liabilities on our part, and we will neither assume nor authorize any other person to assume for us any other obligation or liability in connection with this equipment.

Components not manufactured by us but furnished as part of our equipment (for example: motors, starters, thermometers, controls, etc.) will be warranted by use only to the extent of the components manufacturer’s warranty.

In the event that equipment or parts thereof manufactured by us can be returned to our factory, our obligation will be limited to repairing or replacing parts which upon our examination are found to our satisfaction to be defective in either material or workmanship.

All repairs or replacements of equipment of our manufacture are F.O.B. Syracuse, New York.

When a customer plans to install our equipment in a manner that will make it impractical to return it for in-warranty repairs, he is encouraged to visit our plant before shipment to inspect and, when possible, witness testing of the equipment. Should an in-warranty failure occur after installation, and it is in our judgment impractical to return the item for repairs, we will arrange for the repairs to be made by our personnel or, when practical, sublet to a nearby approved company. The customer will be expected to cooperate by making the equipment available and accessible when the work is scheduled and is expected to provide the necessary utilities. If local labor conditions prohibit such work being done by our personnel, our obligation shall be limited to the supervision of the work and the replacement of defective parts with labor being the responsibility of the customer.

Equipment installed outside the continental United States will not be covered by this warranty.

Date post:	01-Oct-2021
Category:	Documents
Upload:	others
View:	1 times
Download:	0 times

Operations Manual - United Food & Beverage

Documents