CUMFLOW RP100XD HD ROTATING PAN MIXER PARTS & OPERATION MANUAL WINGET LIMITED PO BOX 41 EDGEFOLD INDUSTRIAL ESTATE PLODDER LANE BOLTON LANCS BL4 OLS Tel: ++44 (0)1204 854650 Fax: ++44 (0)1204 854663 crokersales@winget.co.uk parts@winget.co.uk service@winget.co.uk www.winget.co.
INDEX SECTION 1 GENERAL INFORMATION 1.1. 1.2. 1.3. 1.4 Company Details Important Notice Mixer Operational and Safety Requirements Installation Drawing SECTION 2 INSTALLATION AND OPERATING INSTRUCTIONS 2.1. 2.2. 2.3. Pre Installation Notes Installation Instructions Operating Instructions SECTION 3 TECHNICAL SPECIFICATION AND MAINTENANCE 3.1. 3.2. 3.3. 3.4. Technical Specification Shutdown Procedure and Maintenance Lubrication Gear Unit Maintenance SECTION 4 MIXER SPARE PARTS 4.1. 4.2. 4.3. 4.4.
SECTION 6 ELECTRICAL SYSTEM 6.1 6.2 Electrical Instructions Wiring Diagrams SECTION 7 MISCELLEANEOUS 7.1 Noise Details The contents of this handbook although correct at the time of publication, may be subject to alteration by the manufacturers without notice and Winget Limited can accept no responsibility for any errors or omissions contained within the following pages. Nor can we accept any liability whatsoever arising from the use of this manual howsoever caused.
OPERATING AND MAINTENANCE MANUAL SECTION 1 GENERAL INFORMATION RP100XD HD
COMPANY DETAILS AND GENERAL INFORMATION For any spares or service work, please contact:Winget Limited P.O. Box 41 Edgefold Industrial Estate Plodder Lane Bolton Lancs BL4 OLS Telephone No: Facsimile No: ‘E Mail’ ++ 44 (0) 1204 854650 ++ 44 (0) 1204 854663 crokersales@winget.co.uk parts@winget.co.uk service@winget.co.
IMPORTANT NOTICE The CUMFLOW RP100XD HD is a high performance mixer The following precautions are necessary to obtain the best results and to avoid damage to the MIXING STAR and PAN DRIVE AGGREGATES Strict control of graded aggregates must be maintained Maximum size 19mm Oversize lumps of aggregate or rogue materials must be prevented from entering the Pan MIXING STAR BLADES They are to a special shape and material to prolong wear life.
THE MANUFACTURERS ACCEPT NO RESPONSIBILITY FOR ANY MODIFICATIONS MADE AFTER THE MACHINE HAS LEFT THE FACTORY, UNLESS PREVIOUSLY AGREED IN WRITING. THE MANUFACTURERS WILL ACCEPT NO LIABILITY FOR DAMAGE TO PROPERTY, PERSONNEL OR THE MACHINE IF FAILURE IS BROUGHT ABOUT DUE TO SUCH MODIFICATIONS, OR THE FITMENT OF SPURIOUS PARTS.
RP100XD HD OPERATIONAL AND SAFETY REQUIREMENTS PRE-DELIVERY 1.1 Drive coupling alignments, pan and star meshing of pan rack and drive gear. 1.2 Operating clearances star blade to pan. Fixed blade to pan wall. 1.3 Correct oil level in gearboxes. All grease points charged. Gear teeth greased. 1.4 No load test. Correct rotations. PRE INSTALLATION 2.1 Check consignment. 2.2 Offload equipment using certified lifting gear of suitable capacity, by a competent person (see separate chart for nett weight).
OPERATION 5.1 5.2 Correct oil level in the gearboxes. Check the Mixing pan clear of loose nuts and bolts to prevent damage to fingers and blades. 5.3 Check correct rotation – mixing star – anti clockwise; mixing pan – anti clockwise. All when viewed from the top. 5.4 Blade operating clearances adjust in line with maintenance instructions. 5.5 Never exceed manufacturer’s maximum capacity as detailed in specification. SHUTDOWN 6.
8.2 Mixer star blades to be checked daily for damage. 8.3 Pan rim and base wearing plates must be replaced before excessive wear causes distortion. 8.4 Ensure mixing pan is rotating concentrically and pan base is rotating in horizontal plane. 8.5 Mixer must not be stopped and started when there is mix in the pan. 8.6 Refer to the Contract Drawing for scope of supply and the Site instruction notes outlining weights etc. 8.
INSTALLATION DRAWING
OPERATING AND MAINTENANCE MANUAL SECTION 2 INSTALLATION AND OPERATING INSTRUCTIONS
PRE-INSTALLATION On arrival of the equipment it is advisable to check that all packages listed on the consignment note have been received. The equipment must be offloaded using certified lifting gear of suitable capacity, by a competent person. An outline drawing and bolt hold plan is normally sent prior to the despatch of the machine and will enable preparations to be made for the installation.
INSTALLATION Please refer to the contract arrangement and site instructions as applicable. It is recommended that a concrete foundation (to take foundation bolts – not supplied) should be provided for the machine to be mounted on Before completing the installation, check that the main mixer frame is level with a spirit level. Packings should be inserted as required under the main frame. Check that the pan is seated and that the pan rack and drive gear are in mesh..
OPERATING THE MIXER Prior to start up, the following points should be checked:1) That there is oil in a) b) the pan drive gearbox the star drive gearbox 2) The mixing pan should be clear of loose nuts, bolts, spanners, etc as these will damage the fingers and blades. 3) Check that the blade clearances are correct and if necessary adjust, in line with the maintenance instructions.
OPERATING THE MIXER SAFETY NOTES Never operate the mixer unless you have read and fully understand the contents of the Operators Manual Never operate the mixer whilst wearing loose fitting clothing Never reach inside the Pan whilst it is rotating Never operate any equipment unless you have received adequate training Cement, certain other minerals and organic compounds can cause skin irritation leading to Dermatitis. Always use Personal Protective Equipment i.e.
Decals and Instruction Plates are attached to the equipment to warn against hazards and assist in the safe operation of the equipment, if they become damaged or defaced they must be replaced. OPERATING INSTRUCTIONS FOUR WHEEL PAN TROLLEY The Four-Wheel Pan Trolley is designed to allow the safe and speedy removal and transportation of the pan and mixed materials to wherever they may be required within the plant.
trolley can be braced as described above, the handle pulled backwards against the stops and the pan transported back to mixer where the pan can be easily and quickly positioned over the rack and lowered into place. 9) On no account must attempts be made to engage the trolley with the mixer mainframe/chassis unless the Star Drive is raised and the rack stationary.
OPERATING AND MAINTENANCE MANUAL SECTION 3 TECHNICAL SPECIFICATION AND MAINTENANCE
TECHNICAL SPECIFICATION OF CUMFLOW RP100XD HD Maximum Batch Capacity CAPACITIES: by Weight 200 kgs by Volume 140 litres Batch capacity and outputs will vary with material densities. FEED MATERIAL: Maximum Size MIXER FRAME: Strongly constructed from welded Steel Channel MIXING PAN: Steel Base Pan removed by hand or with the aid of a special trolley.
MAINTENANCE OF MIXER IMPORTANT NOTE: Ensure that all maintenance is carried out in accordance with the Parts and Operating Manual and Proprietary Manufacturer’s specific instruction. PROCEDURE 1 ISOLATE ELECTRICAL AND OTHER SERVICES TO THE MIXER (see separate section). 2 Service at recommended intervals. 3 Use Croker manufactured replacement parts available from WINGET LIMITED. 4 Ensure all safety guards and interlocks are reinstated prior to operating the mixer.
MAINTENANCE AND LUBRICATION NOTE: ALWAYS ENSURE APPARATUS IS ISOLATED FROM MAINS SUPPLY BEFORE COMMENCING MAINTENANCE. IF NECESSARY A ‘PERMIT TO WORK’ SHOULD BE OBTAINED DAILY: Charge the grease points using Total EP2 Grease (or equivalent) WEEKLY Lubricate Racks Pinions Apply Open Gear Lubricant (or equivalent) Apply Open Gear Lubricant ( or equivalent) Inspect and top-up if necessary. 1. 2. Star Gear Box Pan Drive Gear Box Use Total Carter EP460 3.5 litres cap Use Total Carter EP460 3.
MAINTENANCE FOR GEAR UNITS MAINTENANCE OF THE MOTORS The surface of the housing as well as the cover lattice of the fan bonnet should be kept clean in order not to endanger the cooling of the motor with dust and dirt.
LUBRICATION CHART
OPERATING AND MAINTENANCE MANUAL SECTION 4 MIXER SPARE PARTS
RP100XD HD MIXING PAN & DRIVE
RP100XD HD MIXING PAN & DRIVE 1 3 4 5 6 7 7A 7B 8 9 10 11 12 12A 13 13A 13B 13C 14 14A 15 16 16A 16B 16C 17 17A 17B 17C 18 19 20 20A 21 22 23 23A 23B 23C 24 26 26A 27 29 30 32 32A 32B 32C 32D CR549026 CR210136 CR520179 CR560006 CR150153 CR210137 333104020 176S01 CR210092 CR630047 11S06F CR530477 68S05C 17S05 8S06H 61S06 267S09 105S07 CR320021 CR320023 CR460022 CR150925 176S01 7S06 11S06P 8S05J 61S05 267S07 105S05 CR520177 CR329015 79S05F 253S05 CR230042 CR239018 8S05G 61S05 267S07 105S05 CR329049 CR229061
RP100XD HD MIXING PAN & DRIVE (2) 33 33A 33B CR640003 10S05 CR241587 EYE LIFTING WASHER FLAT 1/2" NUT 5/8" BSW NYLOC 4 4 4
RP100XD HD STAR DRIVE ASSEMBLY
RP100XD HD STAR DRIVE ASSEMBLY 1 1A 1B 3 3A 3B 3C 4 4A 4B 5 6 6A 6B 7 7A 7B 7C 7D 8 8A 8B 8C 8D 8E 9 9A 10 10A 10B 11 12 13 14 14A 15 16 17 21 23 23A 23B 23C 24 24A 24B 24C 25 25A 25B 25C 26 CR229062 555114904 V2005269 CR239019 CR239030 CR239028 CR230047 CR230044 57S05J1 CR329000 CR329046 CR520113 CR529015 57S05D2 CR159006 176S01 CR549006 11S06P 7S06 CR460024 57S05D2 555116600 11S04D 17S05 267S06 CR329046 CR329093 CR210139 333104020 176S01 CR529011 CR529012 CR529013 8S02C 17S03 CR150149 CR569008 CR569007 C
RP100XD HD MIXING STAR ASSEMBLY
RP100XD HD MIXING STAR ASSEMBLY 14 14A 14B 17 18 19 19 19A 19B 19C 19D 20 21 21A 22 22A 22B 22C 26 26A 28 28A 28B 29 31 32 33 33A 33B 34 34A 35 35A 35B 36 36A 36B 36C 37 37A 37B 38 CR529020 11S05B 17S06 CR210140 CR329053 CR757244 CR219009C CR219009P CR219009SS CR219009SP CR219009SC CR330061 11S05K 7S05 8S05J 267S07 17S06 7S05 CR260390 CR269149 CR210142 333104020 176S01 CR260415 CR539157 CR539158 CR639004 10S31 CR289002 8S04J 61S04 8S06L 17S08 267S08 52S05H 267S07 17S06 7S05 52S04K 17S05 7S04 CR330022 KEY
RP100XD HD MIXING STAR LIFTING ARRANGEMENT
RP100XD HD MIXING STAR LIFTING ARRANGEMENT 1 2 2A 2B 3 5 5A 6 7 8 9 10 10A 11 11A 12 12A 13 14 14A 15 16 17 18 18A 19 19A 19C 20 20A 20B 21 21A 21B 21C 22 CR520175 CR190017 333104020 176S01 CR549025 CR630383 CR249098 CR260394 CR549009 CR520176 CR190046 CR360007 57S05D2 CR639000 CR249000 CR349005 CR249000 CR329050 CR200131 134104002 CR200134 CR200072 CR329046 CR289003 176S01 8S06N 267S08 61S06 8S05E 267S07 61S05 52S05G 17S06 7S05 CR220505 CR329047 PIVOT SHAFT PIVOT SHAFT BEARING NIPPLE GREASE 1/4 BSP STRAI
RP100XD HD COVERS & GUARDS
RP100XD HD COVERS & GUARDS 1 1 1A 1B 1D 1E 1F 1G 1H 1J 1K 1L 1N 1P 2 2 2A 2B 2C 3 3A 3B 3C 4 4A 4B 4C 4D 5 5A 5B 5C 6A 6B 6C 6D 7 7A 9 9A 9B 9C 9D 10 10A 10B 10C 11 11A 12 13 13A CR53100636 CR53100805 11S05D 267S07 61S05 CR249505 11S01AA 11S01A 267S03 17S02 7S01 11S04B 267S06 61S04 CR540448 CR549188 11S04C 17S05 267S06 CR540441 11S05D 17S06 267S07 CR540447 11S04C 267S06 17S05 7S04 CR549027 267S06 17S05 7S04 11S02A 267S04 17S03 7S02 CR549027B CR549027A CR540442 11S04C 267S06 17S05 7S04 11S05D 267S07 17S06 7
RP100XD HD COVERS & GUARDS (2) 13B 13C 13D 15 15A 15B 15C 15D 267S06 17S05 11S02AA CR549146 11S03C 267S05 17S04 7S03 WASHER FLAT M10 WASHER SPRING M10 SCREW SET M6 X 12 GUARD PINION SHAFT (NOT ILLUS) UP TO S/No 6019 SCREW SET M8 X 25 UP TO S/No 6019 WASHER FLAT M8 UP TO S/No 6019 WASHER SPRING M8 UP TO S/No 6019 NUT PLAIN M8 UP TO S/No 6019 7 7 2 1 4 4 4 4
BLACK RED Check position of Terminal Box on Motor BEFORE CUTTING CONDUIT, if on top of Motor use 470mm x 2 to feed from motor to housing through coupling and down to R/H side upper entry point on Control Panel Top Motor (Star Drive) to entry point through housing:- CONDUIT 680MM LONG Sensor nearest to Control Panel to lower side entry in panel:- CONDUIT 540MM LONG Sensor furthest away from Control Panel to upper side entry in panel:- CONDUIT 730MM LONG CONDUIT LENGTHS ADJUST PROXIMITY SWITCHES SO GAP
RP100XD HD MICROSWITCH, CAM & PROXIMITY SENSOR 1 2 2A 2B 2C 3 4 4A 4B 6 7 8 8A 8B 8C 8D 9 10 CR220505 CR549009 11S02C 17S03 267S04 CR531793 11S02C 267S04 17S03 CR243129 CR241632 CR269146 52S05F 267S07 17S06 7S05 CR229098 CR229090 MICROSWITCH CAM SCREW SET M6 X 25 WASHER SPRING M6 WASHER FLAT M6 SUPPORT, MICROSWITCH SCREW SET M6 X 25 WASHER FLAT M6 WASHER SPRING M6 SCREW, CHEESE HEAD 4BA X 1.
RP100XD HD ELECTRICAL SWITCH GEAR 1 1A 1B 1C 1D 2 3 4 5 6 7 8 9 10 11 12 13 14 CR229063 11S03C 267S05 17S04 7S03 CR229109 CR229110 191902200 144799000 144700100 144798000 CR229103 CR229104 CR229105 191902200 CR229114 CR229115 CR229111 CONTROL PANEL ASSEMBLY C/W KEYS SCREW SET M8 X 30 WASHER FLAT M8 WASHER SPRING M8 NUT M8 SP20 CONDUIT SP20/M20/TYPE B FITTINGS TERMINAL RING 'CRIMP ON TYPE' CABLE 1.5MM SQ G/Y (6491X H07) CABLE 1.5MM SQ RED (6491X H07) CABLE 1.5MM SQ BLACK (6491X H07) CABLE 2.
RP100XD HD DECALS AND LOGOS 1 CROKER CUMFLOW RP100XD HD 9 2 10 4 5 11 6 12 7 13 8
RP100XD HD DECALS AND LOGOS 1 2 3 4 5 6 7 8 9 10 11 12 13 CR85100807 V2003037 101S05D V2003039 V2003665 V2003598 V2004307 V2004223 V2004229 V2004744 504694600 V2004130 V2003575 DECAL RP100XD HD PLATE SERIAL NUMBER RIVET POP DECAL 'WINGET' MEDIUM DECAL SLING POINT DECAL BRITISH MADE DECAL ELECTRICAL HAZARD DECAL 'CE' MARK DECAL OPERATORS HANDBOOK DECAL EYE PROTECTION DECAL SAFETY DECAL NOISE 80 LPA DECAL NOISE 105 LWA 2 1 4 2 4 2 2 1 2 2 1 1 1
OPERATING AND MAINTENANCE MANUAL SECTION 5 ANCILLARY EQUIPMENT SPARE PARTS
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RP100XD HD FOUR WHEEL PAN TROLLEY FROM MARCH 2001 ONWARDS 1 1A 2 3 4 4A 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 CR26100858 CR47100860 11S04G 7S04 CR26100857 CR47100861 CR26100850 59S11 267S09 CR53100849 59S11 267S09 CR53100852 11S03C 17S04 267S05 11S03B 17S04 CR53100846 8S03E 61S03 FRAME LOWER INSERT BLANKING 60 X 40 STOP SCREWS M10 X 45 NUT M10 FRAME UPPER INSERT BLANKING 50 X 25 PIVOT BAR FRONT NUT NYLOC M16 WASHER FLAT M16 PIVOT BAR REAR C/W HANDLE CARRIERS NUT NYLOC M16 WASHER FLAT M16 PLATE PICKUP, P
RP100XD HD ADDITIONAL PARTS REQUIREMENT MoD ADDITIONAL PARTS LISTED BELOW ARE NOT ILLUSTRATED 1 2 V2005120 101S05D PLATE - NOMENCLATURE/INSCRIPTION RIVET POP 1 4 3 4 5 6 7 V2005132 CR54100774 11S04B 17S05 7S04 TOOL KIT TOOL BOX SCREW SET M10 WASHER SPRING M10 NUT M10 1 1 2 2 2
OPERATING AND MAINTENANCE MANUAL SECTION 6 ELECTRICAL SYSTEM
CONTROL BOX WIRING LAYOUT
OPERATING AND MAINTENANCE MANUAL SECTION 7 MISCELLANEOUS
7.
