Professional Documents
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WAUKESHA CHERRY-BURRELL
COLLOID MILL
95-03028
SAFETY
Warnings, cautions and notes are contained in this manual. To avoid serious injury and/or possible damage to equipment, pay attention to these messages. WARNING Hazards or unsafe practices which COULD result in severe personal injury or death and how to avoid it. Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. Important information pertaining directly to the subject. (Information to be aware of when completing the task.)
CAUTION
NOTE
CAUTION
MILL PARTS HAVE SHARP EDGES. TO AVOID CUTTING INJURY, WEAR GLOVES AND HANDLE PARTS CAREFULLY.
WARNING To avoid electrocution, ALL electrical should be done by a registered Electrician, following Industry Safety Standards. All power must be OFF and LOCKED OUT during installation.
WARNING
TO AVOID POSSIBLE SERIOUS INJURY, SHUT OFF AND DRAIN PRODUCT FROM MILL PRIOR TO DISCONNECTING PIPING.
WARNING
TO AVOID SERIOUS INJURY, DO NOT INSTALL OR SERVICE MILL UNLESS ALL POWER IS OFF AND LOCKED OUT.
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GENERAL INFORMATION
SHIPPING DAMAGE Inspect your shipment immediately. If damage is found, note it on the drivers copy (packing slip) and request the driver to ask the Inspector to call. You are responsible for initiating shipping damage claims.
HIDDEN DAMAGE OR WARRANTY CLAIM If during installation, you discover damage, contact the Shipper immediately and ask for an Inspector to call. Notify your Distributor of the problem. In warranty claims you must have a returned goods authorization from the manufacturer before any returns will be accepted. Your Distributor will help you with a warranty problem. (See WARRANTY.)
ORDERING /RETURNING PARTS See page 21 for complete information on ordering and returning parts. MANUAL FORMAT This manual is laid out in sections. Each section addresses a specific subject. Familiarize yourself with the subjects by scanning through the manual. Whether installing, operating, troubleshooting, maintaining or ordering parts, read through that section and follow instructions.
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LIST OF CONTENTS
SAFETY ............................................................. 3 WARRANTY ...................................................... 4 GENERAL INFORMATION Shipping Damage ....................................... Warranty Claims ......................................... Ordering Parts ............................................. Returning Parts ...........................................
MILL SERVICE B. Partial disassembly ................................ 11 C. Complete Disassembly .......................... 12-13 Adjustment and Calibration ........................ Flush Water Seal Replacement ................. Sanitary Seal Replacement Multiple Spring ............................................ Seal Parts list ....................................... 13 14 15 15
4 4 21 21
INTRODUCTION ............................................... 6 Specifications .............................................. 6 INSTALLATION AND STARTUP Dimensions, Colloid mill ............................. Dimensions, Motor Base Assembly ........... 1. Variation of Oulet Port ............................ 2. Overhead Equipment .............................. 3. Wiring ...................................................... 4. Rotation Direction ................................ 5. Seal Flush ............................................... 6. Lubrication ............................................ 7. Method of Feeding and Capacity ...........
Single Spring to Multiple Spring Kit .......... 16 Seal Kit Parts list .................................. 16
6 7 8 8 8 8 9 9 9
GEAR CASE SERVICE .................................... Tools Required ............................................ Service Preparation .................................... Front Seal Replacement ............................. Rear Seal Replacement ............................. Bearing Replacement .................................
17 17 17 17 17 17
PARTS LISTS COLLOID MILL ........................................... 18-19 GEAR CASE ............................................... 20 NOTES .............................................................. 21 PARTS ORDERING .......................................... 22
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INTRODUCTION/SPECIFICATIONS
The Waukesha Cherry-Burrell Colloid Mill produces controlled, highly sheared, uniform dispersions and stable emulsions made up of uniform globules of moderate fineness. A serrated conical stator and a serrated rotating cone make up the emulsifying head. Operating clearance can be adjusted in .001-inch increments between .010 and .240 inches. Capacities range from 6.6 to 33.3 GPM Viscosity range is limited only by the maximum 150 psi feed pressure.
t,
SPECIFICATIONS NOMINAL CAPACITY TO 6.6 TO 33.3 GPM (25 TO 126 L/M NOMINAL TEMPERATURE RANGE TO 200 (93 C)
INSTALLATION
UNIT DIMENSIONS
Figure 1
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INSTALLATION
NOTE: 1. For 10 HP units motor is shimmed to J height. 2. For 15 HP and 20 HP uniits, pump is shimmed to J height.
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Figure 3
1. VARIATION OF INLET PORT The mill is shipped from the factory with the inlet port as shown in Position 1. For convenience, the inlet port can be relocated to any of the other three positions. (See Disassembly Procedure ) If Position 4 is used the calibrations at the pointer will be upside down. We suggest the use of a mirror.
2. OVERHEAD EQUIPMENT Follow accepted engineering practice when connecting inlet and outlet with overhead equipment, piping or tubing. Use hangers to eliminate any weight, stress or strain on the mill. Remember, if direct connection is made with any overhead tank, expansion joints should be installed in the line. This will prevent mechanical loads on the mill which would damage it, or affect its operation.
3. WIRING 3 Phase 60 Cycle 230-460 Volts. Follow wiring directions on motor. Check direction of rotation.
4. ROTATION Counter-clockwise when facing outlet port. If run clockwise the rotor retaining nut may back off resulting in damage to the mill.
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Figure 4
GLAND
6. LUBRICATION The mill is shipped with oil in the bearing case. The level should be checked at the oil level hole and if necessary, oil should be added through the oil fill hole. Use Mobil oil DTE BB ISO Grade 220 R & O (Rust inhibited) gear oil. (Part No. 000 140 001). If DTEBB is not available use S.A.E. 40 non-detergent mineral oil. The mill is shipped with a solid cap screw in the oil fill hole. This should be removed and replaced with the breather cap which is wired to the mill. Frequency of lubrication is dependent upon temperature and moisture conditions. If room temperature is normal, 70 to 80 F. and water does not contact the bearing case, change oil every 240 operating hours. When temperature varies from hot to cold or mill is flushed out with water, condensation will occur in the bearing case necessitating more frequent oil changes. Normal operating temperature of the bearing case is 170 F. to 190 F.
BREATHER CAP
OIL LEVEL
INLET
7. METHOD OF FEEDING AND CAPACITY The inlet and outlet ports are 2 inch sanitary male threads. The inlet port is located in the bodyits position can be changed. (See variation of inlet port diagram; page 8). The outlet port is located in the cover of the mill. The mill must be fed with a pump. A WAUKESHA positive displacement type pump is recommended. The capacity of the mill is 400 to 2000 gallons per hour. (6.6 TO 33.3 gallons per minute) Figure 6
OUTLET
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PROBLEM
Seals leaking .
LIKELY CAUSE
1.Exceeding 150 PSI pressure limitation of pump 2. Seal flush water improperly plumbed
SOLUTION/S
1.Open up gap reduce pressure 2. Connect flush water to IN/OUT ports as stamped on gland 3. Adjust to 1/2-one quart per minute 3. Re-align seals to proper fit.
Tighten nut to 75 ft lbs. Check mill rotation (Counterclockwise facing outlet port) Set gap and tighten knurled screw in hole. Tighten bolt and nut on oposite side. Replace worn parts
10
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T-HANDLE B. PARTIAL DISASSEMBLY: Caution: Handle all parts carefully to avoid nicks and scratches which will be detrimental to operation of the mill.
3. Pull the cover/stator assembly outward. Some resistance to stator movement will be encountered which is due to friction from the O-ring. KNURLED LOCK SCREW ADJUSTING RING O-RING
As soon as O-ring is free, the cover and stator assembly can be easily removed. It is not necessary to remove adjusting ring. Disassembly to this point allows complete drainage. NOTE: To prevent wearing of the faces between adjusting ring and stator, it is recommended that these surfaces be lubricated occasionally with an approved silicone type lubricant.
Figure 7
Figure 8 95-03028
11
MAINTENANCE
C. COMPLETE DISASSEMBLY: 1. Follow 3 steps outlined in B. O-RING
2. Remove cover capscrews and pull off cover, then COVER remove the O-ring. 3. Pull stator off studs and remove O-ring.
STATOR
O-RING
4. O-RING 5. Slide rotor off shaft, handle with care to avoid damage to rotor or seal seat which is contained in rotor. 6. Gently pull seal seat from back of rotor and remove O-ring.
5.
SEAL SEAT
O-RING Figure 10 6.
8. Remove four 1/2-13 hex nuts which secure body to bearing case and slide body off. 9. Remove four capscrews from gland on back side of body and disassemble gland. There are six loose springs in the gland. The gland lip seal can be pressed out if replacement is required. 10. Remove O-ring from inside body. Use O-ring tool if necessary. NOTE: Clean and inspect all parts thoroughly. DO NOT reuse seal or seal seat if scratched, chipped or worn.
7.
8.
8. SPRINGS
9. LIP SEAL
12
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MAINTENANCE
D. ASSEMBLY:
1. Apply a suitable lubricant to all O-rings and insert them in their respective grooves. NOTE: Seal seat O-ring should be placed over seal seat and then seat inserted into rotor. 2. Follow disassembly procedure in reverse order to complete assembly.(Torque rotor nut to approximately 75 ft. lbs.) 3. Seal water to mill must be connected to gland connection marked IN. Inlet of gland contains the smaller hole. Outlet contains the larger hole. (See Figure 12) CAUTION: Flushing backwards can cause seal leakage and flush media will enter product zone. Figure 12 WATER FLUSH SYSTEM IN SMALL HOLE (IN)
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MAINTENANCE
FLUSH WATER SEAL REPLACEMENT
1. Disassemble as described in Daily Maintenance paragraph C complete sanitary disassembly. 2. Remove four nuts. (Figure 16)
Figure 17
REMOVE BODY
4. Pull seal out with hook tool. Insert new water lip seal with lip facing in. (See Item 8, Figure 19) 5. Re-assemble in reverse order.
Figure 18
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MAINTENANCE
SANITARY SEAL REPLACEMENT
NOTE: Use care at all times to avoid chipping or scratching seal or seat . Keep seal face areas clean and dry. 1. Install lip seal (8) into rear of gland plate (3). 2. Apply a small amount of sealant (7) to one end of each spring (4)and place in gland spring holes (3). 3. Apply gasket (7) to the sealing face of the gland plate (3). 4. Attach gland plate (3) to mill body using existing capscrews. 5. Install one O-ring (6) into groove in mill body. 6. Attach body to bearing case (4 nuts) . 7. Lubricate O-ring (6) and small O.D. of seal (1) with a compatible lubricant and install seal into mill, aligning notches on the seal with pins in gland plate. Avoid grease type lubricants which can harden and bind the seal; use food grade lubricant when processing food products. 8. Lubricate remaining O-ring (6) with compatible lubricant and install on small O.D. of seat (2). 9. Install seat (2) (with pins and O-ring) into rear of rotor, aligning pins with holes in rotor. 10. Install rotor onto shaft, being careful to avoid damage to the seat (2) or seal (1). Tighten rotor nut to 75 ft.lbs. 11. Complete mill assembly.
Figure 19
ITEM DESCRIPTION 1 SEAL, ONE-PIECE STATIONARY CARBON 2 *SEAT, ROTATING 3 GLAND PLATE 316 S.S 4 SPRING, COMPRESSION 316 S.S. 5 HEX HEAD CAP SCREW 6 O-RING Fluoroelastomer 7 GLAND GASKET 8 LIP SEAL BUNA *SILICONIZED GRAPHITE
PART NUMBER OMS 306 003 OMS 014 002 OMS 058 200 OMS 304 200 30-98 OMS 302 V00 OMS 042 G00 OMS 030 200
QTY 1 1 1 6 4 2 1 1
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MAINTENANCE
KIT # 35379 Convert single spring seal to multiple spring seal
7. Lubricate O-ring (6) and small O.D. of seal (1) with a compatible lubricant and install seal into mill, aligning notches on the seal with pins in gland plate. Avoid grease type lubricants which can harden and bind the seal; use food grade lubricant when processing food products. 8. Apply a small amount of silicone sealant to one end of each drive pin (5) and insert into holes in seat (2). 9. Lubricate remaining O-ring (6) with compatible lubricant and install on small O.D. of seat (2). 10. Install seat (2) (with pins and O-ring) into rear of rotor, aligning pins with holes in rotor. 10. Install rotor onto shaft, being careful to avoid damage to the seat (2) or seal (1). Torque rotor nut to approximately 75 ft. lbs. 11. Complete mill assembly.
NOTE:: Use care at all times to avoid chipping or scratching seal or seat . Keep seal face areas clean and dry. 1. Install lip seal (8) into rear of gland plate (3). 2. Apply a small amount of silicone sealant (7) to one end of each spring (4)and place in gland spring holes (3). 3. Place gasket (7) onto gland plate, aligning bolt holes in gasket with holes in gland plate. 4. Attach gland plate (3) to mill body using existing capscrews. 5. Install one O-ring (6) into groove in mill body. 6. Attach body to bearing case (4 nuts) per standard instructions.
Figure 20
ITEM DESCRIPTION 1 SEAL, ONE-PIECE STATIONARY CARBON 2 *SEAT, ROTATING 3 GLAND PLATE 316 S.S 4 SPRING, COMPRESSION 316 S.S. 5 DRIVE PIN 6 O-RING Fluoroelastomer 7 GLAND GASKET 8 LIP SEAL BUNA *SILICONIZED GRAPHITE PART NUMBER OMS 306 003 OMS 014 002 OMS 058 200 OMS 304 200 OMS 126 000 OMS 302 V00 OMS 042 G00 OMS 030 200 QTY 1 1 1 6 3 2 1 1
16
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MAINTENANCE
Tools required for seal and/or bearing replacement: Assorted hand tools including soft hammer. Bearing puller or press. Hook tool for seal removal. Spanner wrench for bearing retainer nut removal Wrench GD0019000 for rotor nut.. Anti-seize and seal lubricating grease. 2 quarts DTE BB Mobil oil or equivalent.
CAUTION
Mill parts have sharp edges. To avoid cutting injury, wear gloves and handle parts carefully. Service Preparation 1. Shut OFF and lock out all power. 2. Remove all product and flushing from mill. 3. Disconnect all piping to mill. 4. Remove pump anchor screws and slide gearcase off motor coupling. 5. Place mill on sturdy work surface. 6. Disassemble wet end of mill completely. (See Page 11 for Disassembly) 7. Drain oil from gear case. (Figure 21) Front Seal Replacement (Figure 22) 1. Remove slinger. (Pull off) 2. Remove bearing retainer assembly(front seal inside) (Held in place with four (4) capscrews). 4. Note seal lip position and knock out old seal, place lubrication around new seal and press into bearing retainer. Replace gasket, if necessary. Lubricate seal lip and install bearing retainer and slinger. Rear Seal Replacement (Figure 123) 1. Pull rear oil seal off drive shaft with hooked tool. 2. Place tape over shaft keyway and install new seal. (Lubricate seal lip before sliding onto shaft). Bearing Replacement 1. Remove rear seal. Remove rear bearing retaining ring. Press drive shaft out through front of gear case (through rear bearing). (Figure 23) 2. Remove bearing locknut from shaft (counterclockwise)and press front bearing off. (Figure 22) 3. Press the rear bearing out of the front of gear case. (Figure 23) Clean and lubricate all parts thoroughly before reassembling. Do not unwrap new bearings until ready to install. 4. Lubricate inner races and press new bearings onto shaft. Tighten locknut on front bearing to 40 ft. lbs. (Figure 24) 5. Lubricate outer races and press shaft assembly into case. Replace retaining ring and rear seal. (Figure 18) 6. Replace mill assemblies. Torque rotor nut to 75 ft. lbs. Refill crankcase with 2 quarts Mobil DTE BB oil. Figure 21 OIL LEVEL OIL DRAIN
SLINGER
REAR SEAL
LOCKNUT Figure 24
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PARTS LIST
Figure 25
18
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ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
PART NUMBER DESCRIPTION OMS 001 000 Body OMS 002 000 Cover OMS 003 000 Adjusting ring OMS 004 000 Stator 001 061 002 Name plate 33-62 Caution label OM S 010000 Rotor OMS 011 000 Stud for body OMS 011 100 Stud for handle shaft 36-70 Hex nut 1/2-13 30-151 Hex head cap screw 36-55 Hex nut 3/8-16 30-86 Hex head cap screw, 2.5 OMS 052 000 Rotor retaining nut OMS 054000 Adjusting handle OMS 056 100 Indicator bracket
QTY 1 1 1 1 1 1 1 4 4 4 4 1 1 1 2 1
ITEM 17 18 19 20 21 22 23 24 25 26 27 28 29
PART NUMBER DESCRIPTION 30-299 Rd. Hd. machine screw 43-21 #10 Lockwasher OMS 099 000 Handle shaft OMS 100 000 Pin for handle shaft OMS 454 000 Sacer V70253 O-ring cover gasket V70263 O-ring stator gasket BD0 128 000 Oil level & drain plug OMS 129 000 Knurled lock screw V70222 O-ring for rotor nut 000 373 003 Key OM S018 000 1/4" pipe nipple (flush) CD0 019 000 Rotor wrench (not shown)
QTY 2 2 4 4 2 1 1 2 1 1 1 2 1
PARTS LIST
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PARTS LIST
14
11
13
12
6 16
15 1
10
Figure 26
ITEM PART NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 BD0 087 R00 OMS 008 000 STD 046 001 78-148 0MS 005 000 0MS 030 000 0MS 030 100 0MS 036 N00 0MS 036 000 0MS 036 300 0MS 080 000 30-274 0MS 045 000 0MS 042 B00 001 061 002 33-62
DESCRIPTION
QTY 1 1 1 2 1 1 1 1 1 1 1 4 1 1 1 1
Ring, TRUARC Drive Shaft Filter Breather Pipe Plug, SQ 1/2-14 Gear Case Seal 1.500 I.D. X .562 Seal 2.375 I.D. X .375-.438 Locknut Bearing, No. 5308, Dble Row Bearing, Roller Bushing, Bearing Retainer SHCS, 5/16-18 x 2.0" Stl 2 Slinger, Zinc Plated Retainer Gasket Nameplate Label, Caution
20
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NOTES
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PARTS ORDERING
Any correspondence concerning colloid mills will require the following information be documented: PRODUCT NAME/MODEL:___________________________________________________________ PRODUCT SERIAL NUMBER:_________________________________________________________ DATE OF PURCHASE:_____________________________________ INVOICE NUMBER:________________________________________ INVOICE DATE:___________________________________________ HOW TO ORDER PARTS By Phone Telephone your repair parts or fittings order to your Distributor. To speed your order and avoid delays, please have your equipment model and serial number and the part numbers from the parts list before you call your Distributor. If you do not know your Distributors number, call Waukesha Cherry-Burrell Customer Service at: Phone: 800-252-5200 or 262-728-4900 Fax: 800-252-5045 or 262-728-4904 Your call will be directed to a specialist who can provide you with Distributor information for your area. 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 your Distributor. Please give the following information: Invoice number and date Quantity Part Number (from parts list) Exact reason for return
Your Distributor will provide a Return Goods Authorization. (Returns will not be accepted without advance authorization.) DISTRIBUTOR: ______________________________________________________________________ ADDRESS: __________________________________________________________________________ CITY: __________________________________________________ STATE:____ ZIP:_________ CONTACT: ______________________________________________ PHONE: ________________________________________________ FAX: _________________________________________________
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611 SUGAR CREEK ROAD DELAVAN, Wl 53115 U.S.A. CUSTOMER SERVICE TELEPHONE 1-800-252-5200 OR 262-728-4900 TOLL FREE TELEFAX 1-800-252-5045 OR 262-728-4904
95-03028 Effective Date: September 30, 1997