MIXER MANUAL
INSTRUCTIONS INSTALLATION OPERATION MAINTENANCE
Customer Name: PO Number: Model: Order Number: Project Number: Tag:
KINEFLOW CORP K2814 X6P50 875318 447693 Ref PO 004461
INSTRUCTION MANUAL LIGHTNIN SALES ORDER 875318 LIGHTNIN PROJECT 447693 TABLE OF CONTENTS
TITLE
DOCUMENT NO.
General Arrangement Drawing Safety Check List Assembly Drawing X5P & X6P Operating & Maintenance Instr. A310 (1 piece) Impeller Assembly Bolt Tightening Torques Bolt Tightening Torques 1 Wiring Diagram Spare Parts X5P & X6P US Sales Offices
R447693-A IT-2144 L-17918 IT-5098 L-16701 IT-850 IT-3940 IT-2081 IT-5105 IT-3839
IMPORTANT: READ THIS SECTION THOROUGHLY SAFETY INSTRUCTIONS / CHECKLIST IF YOU DO NOT UNDERSTAND ANY PORTION OF THESE INSTRUCTIONS DO NOT ATTEMPT TO INSTALL OR OPERATE THIS MIXER! CONTACT YOUR LIGHTNIN ® REPRESENTATIVE FOR ANY QUESTIONS YOU MAY HAVE CONCERNING SAFETY OR THESE INSTRUCTIONS. Your LIGHTNIN ® mixer is equipped with safety labels which contain specific instructions pertaining to the safe handling and operation of the mixer. For your protection, you must understand that failure to follow the safety instructions imprinted on the safety labels or failure to follow the safety instructions printed in this instruction manual may result in serious personal injury or death. In addition, failure to adhere to safety instructions may cause damage to property or equipment. In this publication, and on the mixer safety labels, the words DANGER, WARNING and CAUTION may be used to signify special instructions to be observed by the installer or user. These instructions warn of potential hazards concerning service, installation or operation if the instructions are performed incorrectly, carelessly or are ignored. Safety instructions alone cannot eliminate the hazards they signal. Strict compliance with these special instructions, along with safe work habits and simple "common sense" are major accident prevention measures. CAUTION - Signals unsafe practices or hazards which could cause minor personal injury or property damage. WARNING - Signals unsafe practices or hazards which could cause severe personal injury or death. DANGER - Signals immediate hazards which will probably cause severe personal injury or death. This mixer should be equipped with safety or instructional labels similar to those shown below. If any of the labels are missing, damaged or otherwise illegible, DO NOT install, service or operate the mixer. Contact your LIGHTNIN ® representative immediately for instructions.
EXAMPLES:
Revision H
Date:
5/9/1986
Revised:
9/9/2011
INST. No. IT-2144 COPYRIGHT © 2011 SPX CORPORATION
Page 1 OF 4
SAFETY CHECK LIST IMPORTANT WARNINGS All LIGHTNIN ® Mixers and Aerators are provided with properly designed lifting devices and safety covers to avoid potential injury and/or equipment damage. The following SAFETY CHECK LIST should be THOROUGHLY REVIEWED AND ADHERED TO before installing, operating or performing maintenance on the mixer. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS INJURY. Ensure the use of qualified, quality trained and safety conscious personnel. 1.
WARNING: When moving, installing or lifting this mixer, always use equipment which is rated to carry the full load of the mixer. Use only the lifting device, if provided, on your unit to install the mixer. Failure to follow these instructions could cause severe injury, death or damage to property. Consult the appropriate section of this manual for lifting and installation instructions.
2.
WARNING: DO NOT attempt to connect a power source to this mixer unless you are licensed or certified to do so. Failure to follow this instruction could cause severe injury, death or damage to property.
3.
WARNING: DO NOT connect the motor to the power source until all components are assembled, the mixer is installed, and all hardware is tightened to the proper torque which is specified in the operation and maintenance manuals supplied by LIGHTNIN ®.
4.
DO NOT operate shaft sealing devices at temperatures higher than those specified in the manual or on the nameplates.
5.
DO NOT service the mixer until you have followed your "Control of Hazardous Energy Sources" (lockout, tagout procedure) as required by OSHA.
6.
WARNING: Never touch a mixer, which has an electric motor, or any part of an electrical service line cord or conduit, while your hands or feet are wet or if you are standing on a wet or damp surface. Failure to follow this instruction may result in severe electrical shock or death.
7.
WARNING: DO NOT touch any part of mixer that has the potential of having a hot surface including the motor, gear drive housing, seal, shafting and flange. When a mixer is running, the motor temperature rises. This is a normal occurrence, but the motor temperature may be high enough to cause burns to the hands or any other part of the body. DO NOT touch a mixer motor until it cools for at least one hour. Failure to follow these instructions may result in severe personal injury.
8.
DANGER: Never touch any rotating part of a mixer with bare hands, gloved hands or any other part of your body, or with any hand held object. Rotating parts include, but are not limited to, the mixer shaft, impeller(s), set screws, hardware, couplings, mechanical seals and motor fans.
9.
WARNING: DO NOT operate mixer for service other than its intended use, that being fluid mixing with the mixer attached to a rigid structure and connected to a power source appropriate to operate the mixer drive motor.
10.
WARNING: Never attempt to move or adjust a mixer while it is running.
Revision H
Date:
5/9/1986
Revised:
9/9/2011
INST. No. IT-2144 COPYRIGHT © 2011 SPX CORPORATION
Page 2 OF 4
SAFETY CHECK LIST, cont'd. IMPORTANT WARNINGS, cont'd. 11.
DO NOT make any field changes or modifications (horsepower, seal material components, output speed, shaft lengths, impellers, etc.) without reviewing the changes with your LIGHTNIN ® Sales Representative or the LIGHTNIN ® Customer Service Department.
12.
DO NOT install an aftermarket Variable Frequency Drive without first consulting your LIGHTNIN ® Sales Representative or the LIGHTNIN ® Customer Service Department to determine the compatibility of the existing motor with the Variable Frequency Drive.
13.
DO NOT operate mixer until you have checked the following items: A. Make sure the mixer is properly grounded. B. Ensure all protective guards and covers are installed. Guarding of the mixer shaft below the mixer mounting surface is the responsibility of the customer. C. Ensure all detachable components are securely coupled to the mixer. D. Thoroughly REVIEW and ADHERE TO the mixer operating instructions supplied by LIGHTNIN ®. E. Ensure the mixer output shaft rotates freely by hand. F. Ensure all personnel and equipment are clear of rotating parts. G. Ensure all external connections(electrical, hydraulic, pneumatic, etc.) have been completed in accordance with all applicable codes and regulations.
14.
DO NOT enter the mixing vessel UNLESS: A. The mixer power supply is locked out (follow item number 5). B. The mixer shaft is firmly attached to the mixer drive or the shaft is supported securely from below. C. You have followed applicable confined space regulations.
15.
WARNING: Eye protection must be worn at all times while servicing this mixer. Failure to follow this instructions may result in severe injury or death.
16.
WARNING: Never attempt to clean or service the mixer, or any part of it, while the mixer is running, or while it is connected to a power source. Always turn the mixer off and disconnect the power before cleaning or servicing.
17.
CAUTION: When repairing the mixer, or replacing parts, use factory authorized parts and procedures. Failure to do so may result in damage to the mixer or injury to the user.
Revision H
Date:
5/9/1986
Revised:
9/9/2011
INST. No. IT-2144 COPYRIGHT © 2011 SPX CORPORATION
Page 3 OF 4
CE COMPLIANCE If the mixer nameplate has a CE marking on it, then the equipment furnished conforms to the following directives: Machinery Directive: 2006/42/EC Electro-Magnetic Compatibility: 2004/108/EC Low Voltage Directive: 2006/95/EC Noise: 2000/14/EC
CAUTION: When applicable specific markings required by Pressure Equipment Directive 97/23/EC (PED) and/or Equipment for Use in Potential Explosive Atmospheres Directive 94/9/EC (ATEX) will be indicated on supporting nameplates. If there is any doubt relating to the intended use of this equipment please contact LIGHTNIN® before installation and operation.
Any CE marking and/or associated documentation applies to the mixer only. This has been supplied on the basis that the mixer is a unique system. When the mixer is installed, it becomes an integral part of a larger system which is not within the scope of supply and CE marking is the responsibility of others.
NOISE LEVELS SOUND PRESSURE LEVELS Portable Series: ECL, EV - maximum 80 dBA @ 1 meter. Heavy Series: S10, 70/80, 500/600 - maximum 85 dBA @ 1 meter.
PATENTS THIS PRODUCT MAY BE COVERED BY ONE OR MORE OF THE FOLLOWING U.S. PATENTS: 5152606 5152934 5203630 5344235 5368390 5470152 5480228
5501523 5511881 5568975 5779359 5925293 5988604 6158722
6517233 6517246 6742923 6746147 6789314 6796707 6796770
6860474 6877750 6986507 7001063 7056095 7114844 7168641
7168848 7168849 7278799 7328809 7329065 7331704 7384551
7387431 7407322 7473025 7481573 7488137 7507028 7547135
7550120 7572112 7726946 7753215 7874719
ENVIRONMENTAL NOTICE Dispose of equipment responsibly at the end of its service, in accordance with local laws and directives. Correct disposal is the responsibility of the end user. If in doubt, consult with local environmental agencies for advice on the best method of disposal.
Revision H
Date:
5/9/1986
Revised:
9/9/2011
INST. No. IT-2144 COPYRIGHT © 2011 SPX CORPORATION
Page 4 OF 4
SALES DATA BOOK
SEC.: 0.42
PAGE: 1.10
DATE: 05-28-03
53 MOTOR HANDLE
OPTIONAL CUP PLATE ASSEMBLY (REPLACES ITEMS 115, 116, 118, 119 & 125)
101 51
13
14
15
24
34
108 9
36
60
110
2
1
56
1 DRIVE FLAT
DETAIL "A"
35
52
38
114
1
7
5
11 GEAR CARRIER ASSEMBLY AND RING GEAR
8
37
121
98
52 59
17
51
41 98 59 4 40
38
97
3 SEE DETAIL "A"
116
125
WHEN ORDERING PARTS, SPECIFY: DRAWING NO., PART NAME, ITEM NO., AND MIXER SERIAL NUMBER. 1 2 3 4 5 7 8 9 11 12 13 14 15 17 24 34 35 36 37 38 40 41 42 ITEM
GEAR CARRIER ASSEMBLY RING GEAR HEX HEAD CAP SCREW RETAINING WASHER RING GEAR RETAINING PIN RETAINING RING CHUCK SCREW SUN GEAR PLANET GEAR THRUST WASHER (NOT SHOWN) NEEDLE BEARING COIN CARRIER BODY CLAMP PAD PLANET DOWEL PIN CHUCK GRIP LIMIT PIN HOUSING BALL BEARING OIL SEAL (2) VIBRATION PAD BALL BEARING IMPELLER SHAFT PART NAME
119
118
97 115
42
42 44 45
50 44 45 50 51 52 53 56 59 60 67 68 97 98 101 108 110 114 115 116 118 119 121 125 ITEM
67 68
IMPELLER SET SCREW CLAMP ASSEMBLY DRIVE SHAFT RETAINING RING (2) CUP PLATE RETAINING RING RETAINING RING (2) SOCKET HEAD CAP SCREW HEX HEAD CAP SCREW LOCK WASHER SHAFT GUARD WORM GEAR CLAMP MOTOR GASKET DRIVE COUPLING ASSEMBLY HEX NUT CLAMP CLAMP SCREW TRAVELER PLATE RETAINING RING PLAIN WASHER PLAIN WASHER PART NAME
OPTIONAL COUPLING CONSTRUCTION (ITEMS 8, 34 & 35 NOT FURNISHED)
NOTE: 1
GEAR KIT CONSISTS OF ITEMS 2, 5, 7, 108, 110 AND GEAR CARRIER ASSEMBLY ITEMS 9, 11, 12,13,14,15, & 24. KIT IS SOLD AS A SET. INDIVIDUAL ITEMS ARE NOT AVAILABLE. ALL EQUIPMENT DESIGN AND APPLICATION DATA SHOWN HEREIN AND RELATED KNOW-HOW IS CONFIDENTIAL AND THE PROPERTY OF THE LIGHTNIN GROUP OF COMPANIES. NO USE OR DISCLOSURE THEREOF MAY BE MADE WITHOUT OUR WRITTEN PERMISSION. R
MIXERS AND AERATORS
ASSEMBLY DRAWING ISO 9001
CERTIFIED C
LIGHTNIN 2001
X5P25, X5P33 & X5P50 X6P25, X6P33 & X6P50 GEAR DRIVE ECL WITH ELECTRIC MOTOR DRAWING NO. L-17918E
OPERATING AND MAINTENANCE INSTRUCTIONS FOR LIGHTNINR X1P, X5P & X6P SERIES PORTABLE MIXERS SECTION 1 – INITIAL INSPECTION, SHIPPING ARRANGEMENTS AND STORAGE 1.1 Check the shipping crates and your LIGHTNIN equipment for possible shipping damage. Report any damage immediately to the carrier and our factory. 1.2 The mixer and impellers are packed together. The impeller shaft, if over 48 inches (1200mm) long, is packed in a separate container. 1.3 Do not remove any protective coatings or wrappings until the mixer is ready to be put into service. If the mixer is to be stored, store only in an indoor, clean, dry location with controlled temperatures of 59° F to 104° F (15° C to 40° C). When gear drive models have been stored for more than one year, the gear lubricant should be replaced (see lubrication instructions). Motor shafts are to be rotated manually every month, at least 10 to 15 revolutions. 1.4 For units with electronic tachometer, refer to tachometer instructions.
SECTION 2 – MIXER INSTALLATION AND POSITIONING WARNING: EYE PROTECTION MUST BE WORN AT ALL TIMES WHILE SERVICING THIS MIXER. 2.1 Refer to Installation Drawing for: a . Proper mixer mounting and location. b . Proper minimum impeller off–bottom and relative spacing for dual impeller applications. 2.2 All mixers are furnished with shaft guard (97) safety covers to eliminate contact with mixer shaft. WARNING: DO NOT OPERATE THE MIXER UNLESS THE GUARD IS IN PLACE. 2.3 Lift the mixer from its crate using the motor handle provided (refer to Figure 1). DO NOT LIFT THE UNIT BY THE SHAFT GUARD. Loosen the clamp screw (116) sufficiently so that the clamp base will engage the tank lip or rim when the mixer is mounted. Set the clamp (115) squarely on the mounting surface so that the clamp rests on the lip of the tank if a lip is present. Tighten the clamp screw (116), making sure the traveller plate (118) is parallel to the tank lip when it contacts the tank wall. Using an M8 socket or box wrench, or a 5/16 hex wrench, tighten the clamp screw to 40–50 ft–lbs (54–61 N⋅m) so that the mixer is held securely to the tank. DO NOT IMPACT THE WRENCH OR USE AN EXTENSION. DO NOT LIFT MIXER BY USING SHAFT GUARD (97)
MOTOR HANDLE
TRAVELER PLATE (118) CLAMP (115)
POTENTIAL PINCH POINT
CLAMP SCREW (116)
FIGURE 1 2.4 Impeller rotation must be according to the arrow on the mixer nameplate. a . Single phase totally enclosed motors are wired at our factory for correct rotation. b . All three phase and explosion proof motors must be field wired for proper rotation. If rotation does not agree with nameplate, reverse any two line leads. c . Dual voltage motors can be wired for the desired voltage. Refer to the connection diagrams provided on the motor nameplate and inside the conduit box cover.
REVISION F
DATE 12–30–00 REVISED 4–23–08
LIGHTNIN MIXERS AND AERATORS
®
© LIGHTNIN 2002
INST. NO. IT–5098 PAGE 1 OF 13
2.5 The positioning device of the mixer combines a vertical index on the ball of the housing, and a horizontal index on the rim of the clamp socket. Mixing positions are established by referencing one index against the other. Figure 2 shows the indexes in D–5 position, a typical setting. To change the mixing position, loosen the hex nut (114), adjust the mixer by its motor handle, and tighten the hex nut.
HOUSING BALL INDEX
HEX NUT (114)
CLAMP PAD (17) CLAMP RIM INDEX
FIGURE 2 – POSITIONING INDEXES
2.6 The correct position for the mixer will vary in individual cases. Use Table 1 to position the mixer in relation to the tank diameter and height for normal applications. In operation, some adjustment of position may be desirable for best results. MIXING PATTERN
BATCH HEIGHT (Z)
NORMAL MIXING Off–center position Top to bottom turnover No swirling VORTEXING On–center position SWIRLING Off–center position Usually vortexing
CLAMP RIM INDEX (HORIZONTAL ANGLE)
HOUSING BALL INDEX (VERTICAL ANGLE)
Z/T less than 1 Z/T greater than 1
D D
5 6
Z/T less than 1 Z/T greater than 1
E E
5 6
Z/T less than 1 Z/T greater than 1
F F
6 7
TANK DIAMETER (T)
Swirling and vortexing positions may be useful for surface introduction of solids, liquids or gases.
TABLE 1 – MIXER POSITIONING
SECTION 3 – MOTOR CONNECTIONS 3.1 LIGHTNIN Portables are equipped with ball bearing chemical plant motors specifically designed for mixer service in totally enclosed or explosion proof construction. a . Constant speed mixers are furnished with LIGHTNIN mixer motors unless otherwise specified. b . For variable speed mixers with electronic or air driven motors, refer to supplementary instructions for motor control data and connection requirements.
REVISION F
DATE 12–30–00 REVISED 4–23–08
LIGHTNIN MIXERS AND AERATORS
®
© LIGHTNIN 2002
INST. NO. IT–5098 PAGE 2 OF 13
3.2 Single Phase Motors or motors nameplated 1/4 thru 3/4 horsepower: a . Totally enclosed motors may be furnished with power cords fitted with UL approved three prong grounded plugs suitable for the correct voltage. b . Explosion proof motors are furnished with a pipe tap connection and suitable leads. A conduit box with internal switch is available for explosion proof service. c . All LIGHTNIN single phase motors are equipped with an internal over–temperature device with manual reset. If the thermal trips, wait fifteen (15) minutes and depress the reset button on the motor body. A click indicates reset. 3.3 Three Phase Motors: a . All totally enclosed motors are equipped with a conduit box and suitable leads. b . All explosion proof motors are furnished with a pipe tap connection and suitable leads.
SECTION 4 – MIXER IMPELLER AND SHAFT INSTALLATION WARNING: EYE PROTECTION MUST BE WORN AT ALL TIMES WHILE SERVICING THIS MIXER. 4.1 Position the impeller(s) on the impeller shaft. Refer to the specification sheet for recommended dual impeller spacing. a . A100 impeller – “Motor End” is cast on the upper side of the impeller. Figure 3 shows how to determine the upper face of the impeller in the event the printing becomes illegible. Tighten impeller set screws securely. For unusually severe conditions, the shaft should be spotted for the set screws. b . A310 impeller – The larger wedge shaped portion of the hub body must face up towards the mixer. The bottom of the hub is stamped “Down”. Refer to Figure 3 for general orientation reference. Tighten impeller set screws securely. For unusually severe conditions, the shaft should be spotted for the set screws. ROTATION
LARGE WEDGE SHAPED PORTION OF HUB MUST FACE UP.
CAST LETTERING ”MOTOR END” MUST FACE UP.
LEADING EDGE
LEADING EDGE SWEPT BACK
CONVEX SURFACE
A100
A310
”DOWN” STAMPED ON LOWER FACE
FIGURE 3 – IMPELLER ORIENTATION
4.2 To install the mixer shaft, back off the chuck screw (8) (refer to Figure 4) as far as the limit pin (35) will allow. DO NOT FORCE. Loosely place the shaft guard (97) and worm gear clamp (98) on the impeller shaft (42). NOTE: The shaft guard hinge must face the impeller end of the shaft. Make sure the shaft is clean, with no burrs. Insert the impeller shaft into the chuck bore as far as it will go. Draw up the chuck screw, rotating the shaft slightly back and forth to make sure the chuck grip (34) seats against the flat of the shaft. Tighten the chuck screw, not exceeding the values listed in Table 2. DO NOT IMPACT THE WRENCH OR USE AN EXTENSION
REVISION F
DATE 12–30–00 REVISED 4–23–08
LIGHTNIN MIXERS AND AERATORS
®
© LIGHTNIN 2002
INST. NO. IT–5098 PAGE 3 OF 13
NOTE: A safety feature is provided by a slight taper in the flat on the impeller shaft. The shaft cannot drop out unless the grip is intentionally released.
CHUCK GRIP (34) DRIVE SHAFT (51) CHUCK
CHUCK SCREW (8)
LIMIT PIN (35)
FIGURE 4 – CHUCK DETAILS
Housing Size 1
2 3
Lower Shaft Diameter
Torque Values ft. lbs. / (Nm)
1/2”, 5/8”, 16mm
10 / 14
3/4”, 20mm
19 / 26
5/8”
10 / 14
3/4”, 20mm
19 / 26
1”, 25mm
34 / 46
7/8”, 1”
34 / 46
TABLE 2 – CHUCK SCREW TORQUE VALUES 4.3 ALTERNATE PROCEDURE FOR UNITS EQUIPPED WITH COUPLING: Connect the impeller shaft to the drive shaft by bolting the coupling halves together. Use care to prevent damage to the rabbets. Make sure the mating faces are flush and free of debris before torquing the hardware. 4.4 Slide the worm gear clamp and shaft guard onto the housing and tighten the clamp securely. DO NOT OPERATE THE MIXER UNLESS THE GUARD IS IN PLACE.
SECTION 5 – MIXER OPERATION 5.1 This LIGHTNIN mixer is designed for continuous operation, and normally needs no additional maintenance. 5.2 Variable speed units have specified critical speed ranges where the unit should not be operated during draw off condition or operated in air. CAUTION: THESE CONDITIONS MUST BE AVOIDED WHEN THE UNIT IS BEING OPERATED WITH A VARIABLE SPEED DRIVE. IT IS ALSO NOT RECOMMENDED TO OPERATE THE MIXER WITH EXTREME VORTEXING OR SURGING OF THE LIQUID BEING MIXED. 5.3 All bolts should be retightened 12 hours after assembly, and at each scheduled shut down thereafter. 5.4 Turn on the mixer. Allow time for the mixing pattern to be established, then make any required adjustments of position as outlined in Section 2 of these instructions.
SECTION 6 – LUBRICATION 6.1 Your LIGHTNIN mixer has been lubricated at the factory with the correct type and amount of high quality lubricants. Lubricant cleanliness is protected by properly designed closures.
REVISION F
DATE 12–30–00 REVISED 4–23–08
LIGHTNIN MIXERS AND AERATORS
®
© LIGHTNIN 2002
INST. NO. IT–5098 PAGE 4 OF 13
6.2 All mixer bearings are sealed type and are pre–packed with lubricant. Relubrication of these bearings is not necessary. 6.3 The gear chamber in LIGHTNIN X5P & X6P Series mixers has been factory filled with a grease suitable for ambient temperature ranges of –4° F to +122° F (–20° C to +50° C). Under normal operating conditions, this lubricant need not be changed until the unit has been dismantled for some reason. Refer to Table 3 for lubricant specifications. 6.4 Under adverse operating conditions, periodic changes of lubricant may be necessary. Adverse conditions are defined as operating in very humid, dust laden, chemical atmospheres, or where wide variations in ambient temperatures occurs. Such adverse conditions can lead to deterioration of lubricant compounds and additives, and it is recommended that the condition of the grease be checked within six months of start–up. Refer to Section 9 for instructions on disassembling the gear drive. NOTE: THE GEAR CHAMBER SHOULD BE FILLED TO 1.0 INCHES (25.4mm) FROM THE TOP OF THE GEAR CHAMBER. ALL O–RINGS SHOULD BE CHECKED FOR INTEGRITY AND REPLACED IF THEY ARE DEFORMED, CUT OR DETERIORATED. RECOMMENDED GREASE
MODEL
STANDARD
X5P & X6P33–50 X5P & X6P75–300
LIGHTNIN SHC 0
GEAR HOUSING CAPACITY
FOOD GRADE
LBS.
BEL–RAY NO–TOX HD 0
2.2
kg 1
3.75
1.7
LIGHTNIN STANDARD GREASE (PART NUMBER 293101PSP – 2 LB. CONTAINER) AND FOOD GRADE GREASE (PART NUMBER 275255PSP – 14 OZ. TUBE) ARE AVAILABLE.
1.0” (25.4mm)
TABLE 3 – LUBRICANT RECOMMENDATION & CAPACITY
6.5 CHANGING GEAR LUBRICANT Standard Grease: Gear sets are initially lubricated at the factory with LIGHTNIN SHC 0 grease. This is the optimum lubricant. It will give the best performance, and is available from LIGHTNIN. An alternate grease, Mobilith SHC 007 can be used, but assembly and disassembly will be more difficult due to the fluid nature of this grease. Greater care must be taken during assembly and disassembly to ensure the grease remains in the gear chamber. Food Grade Grease: Gear sets are initially lubricated at the factory with Bell–Ray No–Tox HD 0 grease. This is the optimum lubricant. NO OTHER FOOD GRADE GREASE IS ALLOWED. It will give the best performance, with no derate necessary, and is available from LIGHTNIN. a . Make sure the gear housing is vertical to prevent spillage. b . Remove all old grease from the gear chamber and wipe the gear chamber clean. c . Pack the gear chamber with fresh grease (see Table 3). Paddle the grease to fill voids and remove air pockets, rotating the shaft and shaking the housing while paddling. d . Check for free movement of all components by rotating the drive shaft. If satisfactory, refer to Section 9 and complete assembly.
SECTION 7 – PREPARATION FOR DISASSEMBLY AND ASSEMBLY
REVISION F
DATE 12–30–00 REVISED 4–23–08
LIGHTNIN MIXERS AND AERATORS
®
© LIGHTNIN 2002
INST. NO. IT–5098 PAGE 5 OF 13
WARNING: DISCONNECT MOTOR LEADS OR OTHERWISE LOCK–OUT POWER SUPPLY BEFORE SERVICING THIS MIXER. EYE PROTECTION MUST BE WORN. NOTE: FOR UNITS WITH ELECTRONIC TACHOMETER, REFER TO TACHOMETER INSTRUCTIONS FOR REMOVAL INFORMATION. 7.1 GENERAL – LIGHTNIN mixers are precision manufactured and assembled to provide long, trouble free service when properly maintained. If it becomes necessary to disassemble the unit, careful, precise reassembly is necessary. Refer to the assembly drawing for location of parts. Equipment that will be required to service the mixer, in addition to standard mechanics tools, is a rubber mallet, retaining ring pliers, arbor press and torque wrench. When disassembling the mixer, clean adjacent external surfaces to prevent dirt from entering the housings. It is recommended that oil seals, O–rings and non–metallic gaskets be replaced when the mixer is disassembled. 7.2 SEAL REPLACEMENT New oil seals, O–rings and gaskets should always be used. Drive out all old oil seals and remove accumulations of sealing compound. When replacing seals: a . Coat the lips of seals with bearing grease. b . Install oil seals with the lip facing in the direction indicated on the assembly drawing. c . Coat the section of the shaft sealing surface with oil. If the oil seal must pass over a keyway, wrap the shaft with thin paper or tape, coat with grease, and pass the seal over. 7.3 BEARING REPLACEMENT Inspect the bearings carefully and replace if necessary. a . Old bearings can be removed with a puller or an arbor press. b . New bearings can be pressed onto the shafts. Be careful to apply load only to the inner race. c . Make sure the bearings are tightly seated against the shaft or housing shoulder with no clearance.
SECTION 8 – DISASSEMBLY AND ASSEMBLY OF DIRECT DRIVE UNITS NOTE: FOR UNITS WITH ELECTRONIC TACHOMETER, REFER TO TACHOMETER INSTRUCTIONS FOR REMOVAL INFORMATION. DISASSEMBLY – X1P SERIES: 8.1 MOTOR REMOVAL a . Remove the mixer from the tank. b . Loosen the worm gear clamp (98) and slide the shaft guard (97) down the impeller shaft (42). c . Remove the impeller shaft (42) from the drive shaft (51), back off the chuck screw (8) as far as the limit pin (35) will allow. The impeller shaft is now free from the chuck and can be withdrawn. FOR MODELS EQUIPPED WITH COUPLING: Remove the coupling bolts (67), then remove the impeller shaft. d . Remove the mixer hardware (3, 114 & 121), clamp assembly (50), vibration pad (40) and clamp pad from the housing (36). e . Set the mixer upright on a workbench. f . X1P33 – 50 electric motor: Remove the four cap screws (60) holding the motor (101) to the housing (36). X1P 75 – 300 electric motor: Remove the four cap screws (155) and washers (62) holding the adapter (103) and electric motor (101) to the housing (36). g . X1P75 – 300 electric motor:
REVISION F
DATE 12–30–00 REVISED 4–23–08
LIGHTNIN MIXERS AND AERATORS
®
© LIGHTNIN 2002
INST. NO. IT–5098 PAGE 6 OF 13
Remove the four flat head screws (60) holding the adapter (103) to the electric motor. Remove the O–ring (109). h . Lift the motor (101), motor coupling half and motor gasket (108) off the housing. i . Loosen the set screw, and remove the motor coupling half and key (106). j . Loosen the set screw, and remove the drive shaft coupling half, coupling insert and key (Item 117 – Models X1P75 thru 300 only). 8.2 DRIVE SHAFT & HOUSING DISASSEMBLY a . Place the housing (36) upright on a workbench and remove the retaining rings (52 & 56). b . Place the housing upright in a press, and press out the drive shaft (51), bearing (41) and oil seal (38). c . Remove the upper retaining ring (59) and press or pull the lower bearing (41) off the shaft. Remove the lower retaining ring (59) and oil seal (38). d . Turn the housing over and press out the upper bearing (37). Models X1P33 – 50: Remove the lower retaining ring (52) from the housing (36). e . Inspect the bearings (37 & 41). Replace if there is excessive wear. 8.3 CHUCK DISASSEMBLY a . Place a flat blade screwdriver between the limit pin (35) and chuck screw (8), and drive the pin down sufficiently to allow removal with pliers. b . Remove the chuck screw (8) and chuck grip (34). ASSEMBLY – X1P SERIES: 8.4 PREPARING FOR ASSEMBLY a . Clean all parts thoroughly. b . Inspect for the following defects: 1 . Cracks or damage of the housing. 2 . Dents, gouges or scoring of the drive shaft, housing bore, and particularly the mating faces of the motor and housing. c . Repair or replace defective parts. It is good practice to replace an oil seal which has been removed from the housing. Apply a small quantity of bearing grease to the housing bore, and around the oil seal lip to provide lubrication and make the seal more effective. d . Replace the bearings if they show indications of wear. 8.5 DRIVE SHAFT ASSEMBLY a . Press the lower oil seal (38) down the drive shaft (51) as far as possible, with the seal cavity facing the retaining ring grooves as shown in Figure 5. Make sure the oil seal has the internal spring removed. This is a non–lubricated seal, and will run hot and have a shortened life if the spring is not removed. HOUSING (36)
BEARING (41)
OIL SEAL (38) SHOWN WITH SPRING REMOVED DRIVE SHAFT (51)
FIGURE 5 – OIL SEAL INSTALLATION
b . Install the lower retaining ring (59).
REVISION F
DATE 12–30–00 REVISED 4–23–08
LIGHTNIN MIXERS AND AERATORS
®
© LIGHTNIN 2002
INST. NO. IT–5098 PAGE 7 OF 13
c . Press the lower bearing (41) onto the drive shaft (51). The bearing must seat against the retaining ring with no visible gap. d . Install the upper retaining ring (59). e . For mixers with chuck type drive shaft: 1 . Assemble the chuck grip (34) on the chuck screw (8). 2 . Thread the chuck screw into the chuck (51). 3 . Insert the limit pin (35) so that it is flush with the drive shaft (51) face. 8.6 DRIVE SHAFT AND HOUSING ASSEMBLY a . Models X1P33 – 50: Install the lower retaining ring (52) in the housing (36). b . Mount the housing (36) in an arbor press, large end up. c . Press the bearing (37) on its outer race to the retaining ring (Models X1P33 – 50) or the shoulder of the housing bore (Models X1P75 – 300). d . Install the upper retaining ring (52). e . Support the housing, large end down, by resting the inner race of the bearing on a suitable sleeve. f . Press the drive shaft (38) into the bearing until the shoulder of the shaft registers against the inner race of the bearing. g . Install the upper retaining ring (56) in the shaft groove. h . Turn the housing large end down, and adjust the lower oil seal until it is flush with the end of the housing. 8.7 MOTOR COUPLING ASSEMBLY a . Position the motor coupling hub as shown in Figure 6. b . Tighten the set screws. c . Place the drive coupling half and key (Item 117, Models X1P75 – 300 only) onto the drive shaft until it bottoms on the shaft shoulder. Tighten the set screw. d . Install the coupling insert into the drive shaft coupling half.
HUB MUST SIT FLUSH WITH END OF MOTOR SHAFT
MOTOR COUPLING HUB
MOTOR (101)
FIGURE 6 – MOTOR COUPLING PLACEMENT
8.8 MOTOR ASSEMBLY a . X1P75 – 300 electric motor: Install the O–ring (109) in the adapter plate (103) and place them on the motor (101). Secure with the flat head screws (60). b . Install the motor gasket (108) on the motor (101) (Models X1P33 – 50) or the adapter plate (103) (Models X1P75 – 300). A small amount of grease on the motor/adapter mounting face, to hold the gasket in place, and oil on the gasket rabbet will ease motor/adapter to housing assembly. NOTE: X1P33 – 50 Align the slots in the motor gasket with the motor mounting holes to ensure a leak tight seal. X1P75 – 300 Align the slots in the motor gasket as shown in Figure 6A to ensure a leak tight seal.
REVISION F
DATE 12–30–00 REVISED 4–23–08
LIGHTNIN MIXERS AND AERATORS
®
© LIGHTNIN 2002
INST. NO. IT–5098 PAGE 8 OF 13
c . Align the motor and the housing so that the switch conduit box (or junction box) of the motor, and the ball of the housing are on the same side. d . X1P33 – 50: Align the screw holes, install the housing cap screws (60) and tighten evenly. e . X1P75 – 300: Align the screw holes, install the housing cap screws (155) and washers (62) and tighten evenly.
MOTOR / ADAPTER MOUNTING HOLE
GASKET SLOT
FIGURE 6A – MOTOR / ADAPTER & GASKET
8.9 CLAMP ASSEMBLY a . Thread the clamp screw (116) through the outer arm of the clamp (115). Slide the plain washer (125) over the end of the clamp screw. Install the traveler plate (118) so that the four raised surfaces are facing away from the clamp screw. Slide the retaining ring (119) onto the clamp screw. Position the retaining ring to allow free movement of the traveler plate (118). b . Set the clamp pad (17) in place in the ball of the housing. c . Install the hex head cap screw (3) in the clamp (115). To keep the cap screw in position, slide the retaining washer (4) in place on the cap screw. d . Install the vibration pad (40) in the clamp (115). e . Pass the hex head cap screw through the slot in the ball of the housing, install the plain washer (121), and loosely thread the hex nut (114) onto the clamp pad. f . Tighten the hex head cap screw until the clamp can just be moved in the housing ball. 8.10 SAFETY GUARD AND IMPELLER SHAFT ASSEMBLY a . Loosely place the safety guard (97) and worm gear clamp (98) on the impeller shaft (42). b . Install the impeller shaft as outlined in Section 4 of these instructions.
REVISION F
DATE 12–30–00 REVISED 4–23–08
LIGHTNIN MIXERS AND AERATORS
®
© LIGHTNIN 2002
INST. NO. IT–5098 PAGE 9 OF 13
SECTION 9 – DISASSEMBLY AND ASSEMBLY OF GEAR DRIVE UNITS NOTE: FOR UNITS WITH ELECTRONIC TACHOMETER, REFER TO TACHOMETER INSTRUCTIONS FOR REMOVAL INFORMATION. DISASSEMBLY – X5P & X6P SERIES: 9.1 MOTOR REMOVAL a . Remove the mixer from the tank. b . Loosen the worm gear clamp (98) and slide the shaft guard (97) down the impeller shaft (42). c . Remove the impeller shaft (42) from the drive shaft (51), back off the chuck screw (8) as far as the limit pin (35) will allow. The impeller shaft is now free from the chuck and can be withdrawn. FOR MODELS EQUIPPED WITH COUPLING: Remove the coupling bolts (67), then remove the impeller shaft. d . Remove the mixer hardware (3, 114 & 121), clamp assembly (50), vibration pad (40) and clamp pad from the housing (36). e . Set the mixer upright on a workbench. f . X5P, X6P33 – 50 electric motor: Remove the four cap screws (60) holding the electric or air motor (101) to the housing (36). X5P, X6P75 – 300 electric motor: Remove the four cap screws (155) holding the adapter (103) and electric motor (101) to the housing (36). g . X5P, X6P75 – 300 electric motor: Remove the four flat head screws (60) holding the adapter (103) to the electric motor. Remove the O–ring (109). h . Lift the motor (101), motor coupling assembly (102), sun gear (9) and motor gasket (108) off the housing. i . Remove the sun gear (9) and motor coupling assembly (102). j . Remove the retaining ring (7), gear carrier assembly (1), ring gear (2), key (Item 27 – Models X5P & X6P200 thru 300 only), and any remaining old lubricant. 9.2 DRIVE SHAFT & HOUSING DISASSEMBLY a . Place the housing (36) upright on a workbench and remove the retaining rings (52 & 56). b . Place the housing upright in a press, and press out the drive shaft (51), bearing (41) and oil seal (38). c . Remove the upper retaining ring (59) and press or pull the lower bearing (41) off the shaft. Remove the lower retaining ring (59) and oil seal (38). d . Turn the housing over and press out the upper bearing (37). e . Remove the oil seal (38) from the housing (36). f . Inspect the bearings (37 & 41). Replace if there is excessive wear. 9.3 CHUCK DISASSEMBLY a . Place a flat blade screwdriver between the limit pin (35) and chuck screw (8), and drive the pin down sufficiently to allow removal with pliers. b . Remove the chuck screw (8) and chuck grip (34).
REVISION F
DATE 12–30–00 REVISED 4–23–08
LIGHTNIN MIXERS AND AERATORS
®
© LIGHTNIN 2002
INST. NO. IT–5098 PAGE 10 OF 13
ASSEMBLY – X5P & X6P SERIES: 9.4 PREPARING FOR ASSEMBLY a . Clean all parts thoroughly. b . Inspect for the following defects: 1 . Cracks or damage of the housing. 2 . Dents, gouges or scoring of the drive shaft, housing bore, and particularly the mating faces of the motor and housing. c . Repair or replace defective parts. It is good practice to replace an oil seal which has been removed from the housing. Apply a small quantity of bearing grease to the housing bore, and around the oil seal lip to provide lubrication and make the seal more effective. d . Replace the bearings if they show indications of wear. 9.5 DRIVE SHAFT ASSEMBLY a . Press the lower oil seal (38) down the drive shaft (51) as far as possible, with the seal cavity facing the retaining ring grooves as shown in Figure 7. Make sure the oil seal has the internal spring removed. This is a non–lubricated seal, and will run hot and have a shortened life if the spring is not removed. HOUSING (36)
BEARING (41)
OIL SEAL (38) SHOWN WITH SPRING REMOVED DRIVE SHAFT (51)
FIGURE 7 – OIL SEAL INSTALLATION
b . Install the lower retaining ring (59). c . Press the lower bearing (41) onto the drive shaft (51). The bearing must seat against the retaining ring with no visible gap. d . Install the upper retaining ring (59). e . For mixers with chuck type drive shaft: 1 . Assemble the chuck grip (34) on the chuck screw (8). 2 . Thread the chuck screw into the chuck (51). 3 . Insert the limit pin (35) so that it is flush with the drive shaft (51) face. 9.6 DRIVE SHAFT AND HOUSING ASSEMBLY a . Models X5P, X6P33 – 50: Install the lower retaining ring (52) in the housing (36). b . Mount the housing (36) in an arbor press, large end up. c . Press the oil upper seal (38) into the housing (36) with the seal cavity facing the large end of the housing. d . Press the bearing (37) on its outer race to the shoulder of the housing bore. e . Install the upper retaining ring (52). f . Support the housing, large end down, by resting the inner race of the bearing on a suitable sleeve. g . Press the drive shaft (38) into the bearing until the shoulder of the shaft registers against the inner race of the bearing. h . Install the upper retaining ring (56) in the shaft groove. i . Turn the housing large end down, and adjust the lower oil seal until it is flush with the end of the housing.
REVISION F
DATE 12–30–00 REVISED 4–23–08
LIGHTNIN MIXERS AND AERATORS
®
© LIGHTNIN 2002
INST. NO. IT–5098 PAGE 11 OF 13
9.7 GEAR ASSEMBLY a . If removed, install the ring gear retaining pins (5). b . Install the ring gear (2) in the gear housing (21). c . Install the retaining ring (7) in the groove above the ring gear. d . PACK THE GEAR CARRIER (1) WITH GREASE and rotate the gears several times to distribute the grease to the needle bearings (13). Refer to Section 6 of these instructions for lubricant recommendations. e . X5P & X6P75 thru 150: Align the flats on the inside of the gear carrier (1) with the flats on the drive shaft (51). f . X5P & X6P200 thru 300: Install the key (27) in the drive shaft (51). Align the keyway in the gear carrier (1) with the keyway on the drive shaft (51). g . Place the gear carrier assembly onto the drive shaft. 9.8 MOTOR COUPLING ASSEMBLY a . Assemble the sun gear (9), the drive coupling (110) and key (Item 107 – Models X5P100 thru 300 and X6P100 thru 300 only) until the sun gear shoulders against the drive coupling. Tighten the set screws. b . Set the elevation of the sun gear to the dimension shown in Figure 8, and tighten the remaining set screws. SUN GEAR (9) 3.98–4.00” (101.2–101.5mm) 3.87–3.89” (98.43–98.73mm) DRIVE COUPLING (110)
ADAPTER (108) MOTOR (101) 1 SIZE
2 & 3 SIZE
FIGURE 8 – SUN GEAR PLACEMENT
c . Fill the gear housing with lubricant to approximately 1 inch (25mm) from the top. Refer to Section 6 of these instructions for lubricant recommendations. 9.9 MOTOR ASSEMBLY a . X5P, X6P75 – 300 electric motor: Install the O–ring (109) in the adapter plate (103) and place them on the motor (101). Secure with the flat head screws (60). b . Install the motor gasket (108) on the motor (101) (Models X5, X6P33 – 50) or the adapter plate (103) (Models X5, X6P75 – 300). A small amount of grease on the motor/adapter mounting face, to hold the gasket in place, and oil on the gasket rabbet will ease motor/adapter to housing assembly. NOTE: X5, X6P33 – 50 Align the slots in the motor gasket with the motor mounting holes to ensure a leak tight seal. X5, X6P75 – 300 Align the slots in the motor gasket as shown in Figure 6A to ensure a leak tight seal. c . Align the motor and the housing so that the switch conduit box (or junction box) of the motor, and the ball of the housing are on the same side. d . X5P, X6P33 – 50: Align the screw holes, install the housing cap screws (60) and tighten evenly. e . X5P, X6P75 – 300: Align the screw holes, install the housing cap screws (155) and washers (62) and tighten evenly.
REVISION F
DATE 12–30–00 REVISED 4–23–08
LIGHTNIN MIXERS AND AERATORS
®
© LIGHTNIN 2002
INST. NO. IT–5098 PAGE 12 OF 13
9.10 CLAMP ASSEMBLY a . Thread the clamp screw (116) through the outer arm of the clamp (115). Slide the plain washer (125) over the end of the clamp screw. Install the traveler plate (118) so that the four raised surfaces are facing away from the clamp screw. Slide the retaining ring (119) onto the clamp screw. Position the retaining ring to allow free movement of the traveler plate (118). b . Set the clamp pad (17) in place in the ball of the housing. c . Install the hex head cap screw (3) in the clamp (115). To keep the cap screw in position, slide the retaining washer (4) in place on the cap screw. d . Assemble the clamp, vibration pad (40) and hex head cap screw (3). e . Pass the hex head cap screw through the slot in the ball of the housing, install the plain washer (121), and loosely thread the hex nut (114) onto the clamp pad. f . Tighten the hex head cap screw until the clamp can just be moved in the housing ball. 9.11 SAFETY GUARD AND IMPELLER SHAFT ASSEMBLY a . Loosely place the safety guard (97) and worm gear clamp (98) on the impeller shaft (42). b . Install the impeller shaft as outlined in Section 4 of these instructions.
REVISION F
DATE 12–30–00 REVISED 4–23–08
LIGHTNIN MIXERS AND AERATORS
®
© LIGHTNIN 2002
INST. NO. IT–5098 PAGE 13 OF 13
LIGHTNIN BOLT TIGHTENING TORQUE RECOMMENDATIONS Inadequately or improperly tightened hardware can loosen due to vibration or the load reactions imposed by fluid forces. This can result in reduced equipment service life or damage and failure. Recommended torques for tightening ANSI bolts and screws on LIGHTNIN Mixers and Aerators and their mounting structures are listed below for your general reference. These average torque values should be considered only as guides and not as absolute values. The amount of torque required to maintain a tight connection can vary considerably for bolts of the same size under different operating conditions. Variations such as basic joint design, compression factors, type and strength of base and hardware material, surface finish of mating parts and lubrication are only some of the factors that influence the tightness of bolted connections for given bolt torques. UNLESS SPECIFICALLY LISTED ELSEWHERE IN THE DETAILED INSTRUCTIONS, TIGHTEN THE MIXER AND MOUNTING HARDWARE TO THE RECOMMENDED VALUES SHOWN. A torque wrench must be used to ensure compliance with these torque requirements. Certain assembly connections may require special torques that are not listed in the table. These torques can be found in the detailed assembly and disassembly sections of your manual. REVIEW YOUR MANUAL CAREFULLY TO DETERMINE WHERE SPECIAL TORQUES ARE REQUIRED. For severe duty service, torques higher than listed, to tighten a bolt to maximum capacity, can often be used. However, due to the many variables previously mentioned, the only absolute method to determine optimum torque is to deliberately yield a bolt under actual conditions. If a bolt does yield or shear, 75% of the torque applied in yielding the bolt can be used to obtain a tight connection that is satisfactory. ALL BOLTS SHOULD BE RETIGHTENED 12 HOURS AFTER ASSEMBLY, AND AT EACH SCHEDULED SHUT DOWN THEREAFTER.
RECOMMENDED TIGHTENING TORQUES FOR COMMERCIAL GRADE STEEL, GR5, 304 AND 316 STAINLESS STEEL (1) (2) TIGHTENING TORQUES (FT-LBS) (4) GRADE 2, 3 OR 304/316 SS BOLTS LUBRICATED
TIGHTENING TORQUES (FT-LBS) (4) GRADE 5 BOLTS LUBRICATED
/4 20
4.6
7.2
/16 18
_
9.6
15
3
/8 16
_
17
26
7
_
27
42
/2 13
41
64
/16 12
_
60
92
5
_
83
128
3
_
/4 10
120 (3)
226
7
/8 9
142 (3)
365
1 8
_
212
547
1
_
301
675 (3)
1
_
425
952
3
_
557
1249
1
_
739
1657
3
_
754 (3)
1600 (3)
2 4 /2
1134
2406
1
1
1659
3519
2 /2 4
2269
4813
BOLT THREAD SIZE 1
_
5
/16 14
1
_
9
/8 11
_
1 /8 7 1 /4 7 1 /8 6 1 /2 6 1 /4 5 _
1
_
2 /4 4 /2 1
_
MARKING GRADE
STEEL SAE GRADE MARKING REFERENCE GUIDE (2) SAE GRADES 0, 1 AND 2
NO MARK
SAE GRADE 3
SAE GRADE 5
ALL SOCKET HEAD CAP SCREWS SAE GRADE 5
(1) ALL BOLTS SHOULD BE COATED WITH OIL, GREASE OR AN ANTI-SEIZE COMPOUND WHENEVER POSSIBLE. THE THREADS AND BEARING FACE OF BOLT HEADS AND/OR NUTS SHOULD BE LUBRICATED. (2) TORQUE VALUES SHOWN SUPERSEDE PREVIOUS TABLES THAT MAY HAVE ALLOWED LOWER VALUES. IT IS RECOMMENDED THAT ONLY FASTENERS BE USED THAT ARE PROPERLY MARKED, INCLUDING MANUFACTURER’S TRADE MARKING. ONLY FASTENERS MARKED AS SHOWN ARE GUARANTEED TO MEET SPECIFICATION AND PERFORMANCE REQUIREMENTS. (3) ALLOWABLE BOLT STRESS VALUES CHANGE AT THESE LOCATIONS AND IS REFLECTED IN THE SUGGESTED TORQUE VALUES. (4) CONVERSION FACTORS: FRICTION LOCKING DEVICES MULTIPLY LUBRICATED VALUE BY 1.15. THESE TORQUES PERTAIN TO BOLTS OR NUTS WITH FRICTION LOCKING DEVICES SUCH AS NYLON PELLETS OR PATCHES, FIBER INSERTS OR UPSET THREADS. DRY VALUES MULTIPLY LUBRICATED VALUE BY 1.33. METRIC VALUES IN N-m 1FT-LB = 1.3558 N-m
REVISION H
DATE 2-1-85 REVISED 12-08-11
LIGHTNIN£ MIXERS AND AERATORS
¤
LIGHTNIN 2008
INST. NO. IT-850 PAGE 1 OF 1
LIGHTNIN BOLT TIGHTENING TORQUE RECOMMENDATIONS Inadequately or improperly tightened hardware can loosen due to vibration or the load reactions imposed by fluid forces. This can result in reduced equipment service life or damage and failure. Recommended torques for tightening metric bolts and screws on LIGHTNIN Mixers and Aerators and their mounting structures are listed below for your general reference. These average torque values should be considered only as guides and not as absolute values. The amount of torque required to maintain a tight connection can vary considerably for bolts of the same size under different operating conditions. Variations such as basic joint design, compression factors, type and strength of base and hardware material, surface finish of mating parts and lubrication are only some of the factors that influence the tightness of bolted connections for given bolt torques. UNLESS SPECIFICALLY LISTED ELSEWHERE IN THE DETAILED INSTRUCTIONS, TIGHTEN THE MIXER AND MOUNTING HARDWARE TO THE RECOMMENDED VALUES SHOWN IN. A torque wrench must be used to ensure compliance with these torque requirements. Certain assembly connections may require special torques that are not listed in the table. These torques can be found in the detailed assembly and disassembly sections of your manual. REVIEW YOUR MANUAL CAREFULLY TO DETERMINE WHERE SPECIAL TORQUES ARE REQUIRED. For severe duty service, torques higher than listed, to tighten a bolt to maximum capacity, can often be used. However, due to the many variables previously mentioned, the only absolute method to determine optimum torque is to deliberately yield a bolt under actual conditions. If a bolt does yield or shear, 75% of the torque applied in yielding the bolt can be used to obtain a tight connection that is satisfactory. ALL BOLTS SHOULD BE RETIGHTENED 12 HOURS AFTER ASSEMBLY, AND AT EACH SCHEDULED SHUT DOWN THEREAFTER.
RECOMMENDED TIGHTENING TORQUES FOR COMMERCIAL GRADE STEEL, GR5, 304 AND 316 STAINLESS STEEL (1) (2) BOLT THREAD SIZE
TIGHTENING TORQUES (FT-LBS) (3) GRADE 5.6 OR 304/316 SS BOLTS LUBRICATED
TIGHTENING TORQUES (FT-LBS) (3) GRADE 8.8 BOLTS LUBRICATED
M5
1.7
4.1
M6
3.0
7.0
M7
5.0
12
M8
7.0
17
M10
14
34
M12
25
59
M14
39
93
M16
62
146
M18
85
200
M20
120
284
M22
163
386
M24
207
491
M27
303
718
M30
412
975
M33
561
1327
M36
720
1704
M39
932
2205
M42
1153
2727
ISO MARKING REFERENCE GUIDE (2) HEX HEAD CAP SSREWS
HEX NUT
SOCKET HEAD CAP SSREWS
(1) ALL BOLTS SHOULD BE COATED WITH OIL, GREASE OR AN ANTI-SEIZE COMPOUND WHENEVER POSSIBLE. THE THREADS AND BEARING FACE OF BOLT HEADS AND/OR NUTS SHOULD BE LUBRICATED. (2) TORQUE VALUES SHOWN SUPERSEDE PREVIOUS TABLES THAT MAY HAVE ALLOWED LOWER VALUES. IT IS RECOMMENDED THAT ONLY FASTENERS BE USED THAT ARE PROPERLY MARKED, INCLUDING MANUFACTURER’S TRADE MARKING. ONLY FASTENERS MARKED AS SHOWN ARE GUARANTEED TO MEET SPECIFICATION AND PERFORMANCE REQUIREMENTS. (3) CONVERSION FACTORS: FRICTION LOCKING DEVICES MULTIPLY LUBRICATED VALUE BY 1.15. THESE TORQUES PERTAIN TO BOLTS OR NUTS WITH FRICTION LOCKING DEVICES SUCH AS NYLON PELLETS OR PATCHES, FIBER INSERTS OR UPSET THREADS. DRY VALUES MULTIPLY LUBRICATED VALUE BY 1.33. METRIC VALUES IN N-m 1FT-LB = 1.3558 N-m
REVISION F
DATE 6-1-96 REVISED 08-09-11
LIGHTNIN£ MIXERS AND AERATORS
¤
LIGHTNIN 2008
INST. NO. IT-3940 PAGE 1 OF 1
CONNECTION DIAGRAM SINGLE PHASE MOTORS FIGURE 1 – CONNECTION DIAGRAM 6 LEADS WITHOUT THERMAL PROTECTOR LOW VOLTAGE
7 LEADS WITH THERMAL PROTECTOR
HIGH VOLTAGE
LOW VOLTAGE
HIGH VOLTAGE
4 1
1
2
3
3
J
1
3 5
5 LINE
5
8 LINE
LINE
2
2
1
8
8
5
4
4
3
LINE
2 J 8 4
VERIFY PROPER MIXER ROTATION TO REVERSE ROTATION, INTERCHANGE LEADS 5 AND 8
CONNECTION DIAGRAM THREE PHASE MOTORS FIGURE 2 – CONNECTION DIAGRAM 9 LEADS WITH OPTIONAL THERMAL PROTECTOR 1 J THERMOSTATS CAN BE LOCATED IN ANY COMBINATION OF PHASES
4 J
7
LOW VOLTAGE
J
THERMOSTAT LEADS
J 1
L1
7 2
L2
8 6
9
8
3
5
L3
9 3
2
TYPICAL THERMAL CONNECTION IN FULL VOLTAGE STARTERS START STOP CR
L1
J
J
HIGH VOLTAGE
J J 1
L1
2
L2
3
L3
4 7 5
4
8
5
6
6
9
L2
CR
THERMOSTAT LEADS
VERIFY PROPER MIXER ROTATION TO REVERSE ROTATION, INTERCHANGE ANY TWO LINE LEADS
ALL XP MOTORS HAVE THERMAL PROTECTION (J)
REVISION C
DATE 9–30–83
LIGHTNIN
REVISED 12–15–05
MIXERS AND AERATORS
®
© LIGHTNIN 1999
INST. NO. IT–2081 PAGE 1 OF 2
CONNECTION DIAGRAM 3 PHASE SINGLE VOLTAGE FIGURE 3 – CONNECTION DIAGRAM 3 LEADS WITH OPTIONAL THERMAL PROTECTION 1
THERMAL PROTECTOR
1
L1
2
L2
3
L3
1 4 3
2 6
5
2
3
VERIFY PROPER MIXER ROTATION TO REVERSE ROTATION, INTERCHANGE ANY TWO LINE LEADS
WARNING: MOTORS THAT HAVE AUTOMATIC THERMAL RESETS CAN START AUTOMATICALLY ONCE THE MOTOR HAS COOLED. TO AVOID POSSIBLE INJURY, DISCONNECT THE POWER, ALLOW THE MOTOR TO COOL, THEN RECONNECT THE POWER.
REVISION C
DATE 9–30–83
LIGHTNIN
REVISED 12–15–05
MIXERS AND AERATORS
®
© LIGHTNIN 1999
INST. NO. IT–2081 PAGE 2 OF 2
PARTS PRICING BOOK
MIXER PARTS
SECTION: 4
UNIT SIZE:
PAGE: 5.00
DATE: 7--31--06
X5P25, X5P33, X5P50 X6P25, X6P33, X6P50
ECL PORTABLE GEAR DRIVE ELECTRIC MOTOR
For service and repair, call 1--888--MIX BEST (1--888--649--2378) ITEM NO.
IDENT. CODE
DESCRIPTION
QTY.
PART NO.
PRICE SHIPMENT (EACH) (WEEKS)
NOTE: See mixer nameplate or spec. sheet for unit size & ratio. See Assembly Drawing for item no. identifier REFER TO DRAWING L--17918 53
P
101
1
Contact LIGHTNIN Representative
872264PSP
GASKET
1
272671PSP
L
CLAMP
1
872261PSP
C
DRIVE SHAFT KIT -- COMPLETE CHUCK -- 3/4” DIA. LOWER SHAFT
1
872315PSP
108 115
CUP PLATE MOTOR
CONSISTS OF THE FOLLOWING PARTS: 8
C
CHUCK SCREW
1
272243174
34
C
CHUCK GRIP
1
272240316
35
C
LIMIT PIN
1
272668420
51
C
DRIVE SHAFT
1
272286PD4
R
DRIVE SHAFT KIT -- COMPLETE RIGID COUPLING -- 3/4” DIA. LOWER SHAFT
1
872316PSP
51
R
DRIVE SHAFT
1
272296PD4
67
R
HEX HEAD CAP SCREW
4
290225316
68
R
LOCKWASHER
4
290210316
R
DRIVE SHAFT KIT -- COMPLETE RIGID COUPLING -- 1” DIA. LOWER SHAFT
1
872317PSP
CONSISTS OF THE FOLLOWING PARTS:
CONSISTS OF THE FOLLOWING PARTS: 51
R
DRIVE SHAFT
1
272297PD4
67
R
HEX HEAD CAP SCREW
4
290225316
68
R
LOCKWASHER
4
290210316
IDENTITY CODE: C = Use With Chuck Drive Shaft L = Use With Clamp
P = Use With Cup Plate R = Use With Rigid Coupling Drive Shaft
5 = 350 RPM 6 = 280 RPM
Blank code denotes common parts
* Recommended spare parts REVISION F
IT--5105 PAGE 1 OF 4
PARTS PRICING BOOK
MIXER PARTS
SECTION: 4
UNIT SIZE:
PAGE: 5.10
DATE: 11--01--04
X5P25, X5P33, X5P50 X6P25, X6P33, X6P50
ECL PORTABLE GEAR DRIVE ELECTRIC MOTOR
For service and repair, call 1--888--MIX BEST (1--888--649--2378) ITEM NO.
IDENT. CODE
*
DESCRIPTION
BEARING & SEAL KIT -- COMPLETE
QTY.
PART NO.
STANDARD
1
872250PSP
FOOD GRADE
1
872521PSP
PRICE SHIPMENT (EACH) (WEEKS)
CONSISTS OF THE FOLLOWING PARTS: 37
BALL BEARING
1
290151PSP
38
OIL SEAL
2
272230PSP
41
BALL BEARING
1
290152PSP
52
RETAINING RING
2
114240PSP
56
RETAINING RING
1
291592PSP
59
RETAINING RING
2
114275PSP
108
GASKET
1
272671PSP
STANDARD -- 2 LB CAN
2
293101PSP
FOOD GRADE -- 14 OZ TUBE
3
275255PSP
1
872284PSP
LUBRICANT
HIGH SPEED COUPLING KIT -- COMPLETE CONSISTS OF THE FOLLOWING PARTS: 108
GASKET
1
272671PSP
110
HIGH SPEED COUPLING
1
292246PSP
C
DRIVE SHAFT HARDWARE KIT -- COMPLETE
1
872241PSP
8
C
CHUCK SCREW
1
272243174
34
C
CHUCK GRIP
1
272240316
35
C
LIMIT PIN
1
272668420
CONSISTS OF THE FOLLOWING PARTS:
RIGID COUPLING CONSTRUCTION HARDWARE: 67
R
HEX HEAD CAP SCREW
4
290225316
68
R
LOCKWASHER
4
290210316
C
CHUCK SHAFT GUARD KIT -- COMPLETE
1
872244PSP
CONSISTS OF THE FOLLOWING PARTS: 97
C
SHAFT GUARD
1
272333PSP
98
C
WORM GEAR CLAMP
1
272669PSP
IDENTITY CODE: C = Use With Chuck Drive Shaft L = Use With Clamp
P = Use With Cup Plate R = Use With Rigid Coupling Drive Shaft
5 = 350 RPM 6 = 280 RPM
Blank code denotes common parts
* Recommended spare parts REVISION F
IT--5105 PAGE 2 OF 4
PARTS PRICING BOOK
MIXER PARTS
SECTION: 4
UNIT SIZE:
PAGE: 5.20
DATE: 7--31--06
X5P25, X5P33, X5P50 X6P25, X6P33, X6P50
ECL PORTABLE GEAR DRIVE ELECTRIC MOTOR
For service and repair, call 1--888--MIX BEST (1--888--649--2378) ITEM NO.
IDENT. CODE
R
DESCRIPTION
RIGID COUPLING CONSTRUCTION SHAFT GUARD KIT -- COMPLETE
QTY.
PART NO.
1
872246PSP
PRICE SHIPMENT (EACH) (WEEKS)
CONSISTS OF THE FOLLOWING PARTS: 97
R
SHAFT GUARD
1
272334PSP
98
R
WORM GEAR CLAMP
1
272669PSP
MOUNTING COMPONENTS KIT -- COMPLETE
1
872267PSP 273101PSP
CONSISTS OF THE FOLLOWING PARTS: 3
HEX HEAD CAP SCREW
1
4
RETAINING WASHER
1
274932PSP
17
CLAMP PAD
1
274656GPC 150332DUK
40
VIBRATION PAD
1
114
HEX NUT
1
290228PSP
121
PLAIN WASHER
1
290249PSP
L
CLAMP SCREW KIT -- COMPLETE
1
872270PSP
116
L
CLAMP SCREW
1
272673ZPS
118
L
TRAVELER PLATE
1
274743316
119
L
RETAINING RING
1
274635PSP
125
L
FLAT WASHER
1
290241PSP
CONSISTS OF THE FOLLOWING PARTS:
IDENTITY CODE: C = Use With Chuck Drive Shaft L = Use With Clamp
P = Use With Cup Plate R = Use With Rigid Coupling Drive Shaft
5 = 350 RPM 6 = 280 RPM
Blank code denotes common parts
* Recommended spare parts REVISION F
IT--5105 PAGE 3 OF 4
PARTS PRICING BOOK
MIXER PARTS
SECTION: 4
UNIT SIZE:
PAGE: 5.30
DATE: 7--31--06
X5P25, X5P33, X5P50 X6P25, X6P33, X6P50
ECL PORTABLE GEAR DRIVE ELECTRIC MOTOR
For service and repair, call 1--888--MIX BEST (1--888--649--2378) ITEM NO.
IDENT. CODE
*
5
DESCRIPTION
GEAR KIT -- COMPLETE
QTY.
PART NO.
STANDARD
1
872273PSP
FOOD GRADE
1
872524PSP
PRICE SHIPMENT (EACH) (WEEKS)
CONSISTS OF THE FOLLOWING PARTS: 2
5
RING GEAR
1
290901PSP
5
5
DOWEL PIN
4
272234PSP
7
5
RETAINING RING
1
272232PSP
9
5
SUN GEAR
1
290902PSP
11
5
PLANET GEAR
3
272032PSP
12
5
THRUST WASHER
3
291551PSP
13
5
NEEEDLE BEARING
3
290154PSP
14
5
1 SIZE COIN
1
291568PSP
15
5
GEAR CARRIER
1
290926FRP
24
5
DOWEL PIN
3
291552PSP
108
5
RING GASKET
1
272671PSP
110
5
HIGH SPEED COUPLING
*
5
LUBRICANT
6
GEAR KIT -- COMPLETE
1
292246PSP
STANDARD -- 2 LB CAN
2
293101PSP
FOOD GRADE -- 14 OZ TUBE
3
275255PSP
STANDARD
1
872275PSP
FOOD GRADE
1
872525PSP
CONSISTS OF THE FOLLOWING PARTS: 2
6
RING GEAR
1
290901PSP
5
6
DOWEL PIN
4
272234PSP
7
6
RETAINING RING
1
272232PSP
9
6
SUN GEAR
1
290904PSP
11
6
PLANET GEAR
3
272033PSP
12
6
THRUST WASHER
3
291551PSP
13
6
NEEEDLE BEARING
3
290154PSP
14
6
1 SIZE COIN
1
291568PSP
15
6
GEAR CARRIER
1
290927FRP
24
6
DOWEL PIN
3
291552PSP
108
6
RING GASKET
1
272671PSP
110
6
HIGH SPEED COUPLING
1
292246PSP
6
LUBRICANT
STANDARD -- 2 LB CAN
2
293101PSP
FOOD GRADE -- 14 OZ TUBE
3
275255PSP
IDENTITY CODE: C = Use With Chuck Drive Shaft L = Use With Clamp
P = Use With Cup Plate R = Use With Rigid Coupling Drive Shaft
5 = 350 RPM 6 = 280 RPM
Blank code denotes common parts
* Recommended spare parts REVISION F
IT--5105 PAGE 4 OF 4
LIGHTNIN _____________________________________________________________________
FOR AN UP TO DATE REPRESENTATIVE LIST PLEASE GO TO: www.lightnin-mixers.com
-OR-
CALL: 1-888-649-2378 1-888-MIX-BEST
REVISION P
DATE 12/28/05 REVISED 01/05/06
LIGHTNIN£ MIXERS AND AERATORS
¤
LIGHTNIN 2005
INST. NO. IT-3839 PAGE 1 OF 1
Notes
LIGHTNIN Process Equipment Services Warranty REPAIR & SERVICE GUIDE LIGHTNIN Process Equipment Services (LPES): The fastest route to uptime. Expertise: LPES technicians are the backbone of our dedicated service organization.They’re uniquely qualified to keep your LIGHTNIN mixers running right. Lightnin Certified Technicians: All LPES technicians are certified via training courses to ensure that the work they do meets the highest standards for consistency and reliability. Genuine LIGHTNIN Parts: All LPES repairs follow original design specs and use only factory-authorized replacement parts. Full LIGHTNIN Factory Warranty: We’re so confident we’ll do the job right that all LPES repair and service work is covered by a full factory warranty.What we repair, we guarantee – 100%.
When repairs to your LIGHTNIN mixer are needed, we guarantee the results for one full year.This exclusive warranty covers all parts and labor.Talk to your LIGHTNIN sales representative for more information.
Call: The LIGHTNIN Experts When your need is urgent and after normal business hours call our 24-hour response team hotline at 1-888-MIX-BEST (U.S. and Canada).Your request will be promptly processed and directed to your nearest LPES team member. For more information visit our website at: www.lightninmixers.com.
Repair Services:
LIGHTNIN provides quick, reliable repair services – using only certified technicians and factory-authorized replacement parts – on gearboxes, mechanical seals (seal cartridge and seal assembly), steady bearings, machine assemblies, impellers, shafts and all portable units.This service can be provided either at your site or at a LIGHTNIN Service Center location. All work is backed by LIGHTNIN’s full warranty on all parts and service.
Exchange Services:
By eliminating repair time, LIGHTNIN Exchange Services offer the fastest way to get up and running when a breakdown occurs. LPES keeps selected speed reducers, portable units and mixer subassemblies in stock – and available for immediate exchange – at regional service centers. Simply call and we will configure the appropriate assembly and ship it to you within 24 hours.Then send the damaged assembly back to us within 30 days – to ensure you receive a discounted price.
Equipment Upgrade Services:
Preventive maintenance is your best defense against costly unplanned downtime and repairs associated with old or obsolete equipment.The full range of LPES upgrade services give you a convenient and cost-efficient way to address problems before they happen by converting older equipment to the latest, most reliable LIGHTNIN designs.
Additional LPES Services:
In addition to minimizing downtime and repair costs when equipment failure occurs, LPES offers a comprehensive range of services for maximizing productivity through every stage of the equipment life cycle. • Installation and Start-up • Maintenance and Repair • Asset Management
Factory Service Center Locations Chicago, Illinois Houston, Texas Mulberry, Florida Reading, Pennsylvania Rochester, New York San Francisco, California Wytheville, Virginia
Authorized Service Center Locations Baton Rouge, Louisiana Concord, Ontario, Canada East Hanover, New Jersey Macon, Pooler, Roswell, Georgia
