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CAPKOLD
TUMBLE CHILLER
MODEL CKTC-320
Instruction & Parts Manual
January 2007
CKTC-320 01-03-07.doc
MODEL # CKTC·320·1101
MACHINE SERIAL # 5846·07·01·102
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TABLE OF CONTENTS
Instruction & Parts Manual
CapKold Tumble Chiller
Model CKTC-320
Forward.......................................................................................................................................3
Chapter One...................................................................................................................................4
Introduction................................................................................................................................4
Safety...........................................................................................................................................4
Chapter Two...................................................................................................................................5
Installation..................................................................................................................................5
General....................................................................................................................................................5
Receiving and Setting..............................................................................................................................5
Utility Connections..................................................................................................................................6
Chapter Three................................................................................................................................7
Equipment Description..............................................................................................................7
General....................................................................................................................................................7
General Specifications.............................................................................................................................7
Standard Features and Component Details.............................................................................8
Optional Equipment...................................................................................................................9
Machine Specification Sheet....................................................................................................10
Chapter Four................................................................................................................................13
Operations.................................................................................................................................13
Safety Precautions and Instructions.......................................................................................................13
Preoperational Checks...........................................................................................................................14
Machine Controls..................................................................................................................................15
Chiller Operation...................................................................................................................................17
Manual Operation..................................................................................................................................24
Troubleshooting.....................................................................................................................................27
Chapter Five.................................................................................................................................28
Maintenance and Repair .........................................................................................................28
Scheduled Maintenance.........................................................................................................................28
Sensor Adjustment................................................................................................................................28
Water and Steam Valves.......................................................................................................................29
Door Seal...............................................................................................................................................32
Drive Assembly.....................................................................................................................................33
Chapter Six...................................................................................................................................34
Spare Parts List........................................................................................................................34
Chapter Seven..............................................................................................................................35
Diagrams...................................................................................................................................35
Pneumatic Diagram...............................................................................................................................35
Water Valve Diagram............................................................................................................................36
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Instruction & Parts Manual
Forward
The purpose of this manual is to provide information that will aid in the installation, operation,
maintenance and repair of a CapKold Tumble Chiller. This manual should be read completely
before installing and/or operating this machine. While every effort is made to provide accurate
and up-to-date information, CapKold reserves the right to change the specifications herein
without notice. CapKold also reserves the right to make changes and improve this product
without obligating itself to install any such changes or improvements in products previously
manufactured. The illustrations and descriptions herein are general in nature and may not include
all standard equipment or may include optional equipment.
The only applicable warranty is our standard written warranty, and there is no other warranty,
written or implied.
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Chapter One
Introduction
The information in this section will aid in the operation of the CapKold Tumble Chiller and must
be read completely before operating the unit.
The CapKold Model CKTC-320 front loading batch tumble chiller is designed to rapidly chill
food packaged in flexible plastic casings by gently agitating the casings in a water bath that
accelerates product chilling from 180 deg F to 40 deg F in less than 60 minutes. The touch screen
control provides easy operator interface and is also password protected to add or change formulas
to meet the customer’s product requirements. The chilled water source provided by the customer
is pumped through a heat exchanger which includes an automatic back flush to maintain optimal
heat transfer efficiency. A recycle tank is available to reuse chilled water after each cycle saving
water and energy.
Safety
The CapKold Tumble Chiller was designed with the safety of the operator and maintenance
personnel in mind, as well as the safe functioning of the machine. Continuous safety of the
operators and plant personnel can only be maintained through cautious and competent operation
as well as regular and complete maintenance.
Safety precautions and warnings are noted in this manual as their need occurs. Please make note
of them and pay special attention.
This tells the operator that extreme danger exists and explains the necessary and safe actions to
This tells the operator that equipment may be damaged unless certain actions are taken.
Calls attention to an important condition or event.
WARNING
protect himself and others.
CAUTION
NOTE
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Chapter Two
Installation
General
The following instructions will aid in a quick and correct installation of your new Tumble Chiller.
Receiving and Setting
Receiving: Immediately upon receipt, the unit should be inspected for any damage that may have
occurred during shipping. Any damage should be reported to the driver and the freight company
immediately.
Tools Required: Open end wrenches and flat blade screwdriver.
Lifting and Handling: The approximate weight of the tumble chiller is 2500 lbs. The machine
may be lifted by fork truck from the front of the machine.
Setting Machine: Choose a clean level area protected from weather conditions, moisture, heat,
and any foreign debris above or around the unit. Insure that adequate clearance exists between
machine and other machines and obstructions. A minimum of 3 feet should be maintained.
Final Machine Leveling: Machine must be level from front to back as well as side to side. If
not level, adjust leveling legs maintaining a minimum of 6 inch clearance from floor to bottom of
machine.
Optional Recycle Tank: The approximate weight of the recycle tank is 700 lbs. The tank may
be lifted by fork truck from the front of the machine. Align the 4 pins with the holes on the base
machine and lower in place. Connect hoses to base machine.
Panels: Install all panels using the truss screws provided.
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Utility Connections
Electrical: Installation and grounding must conform with local codes, or in absence of local
codes, with the National Electrical Code.
Branch Circuit Protection
Machine Voltage Wire Size * Breaker Size
208 VAC 12 15 AMP, 3 Pole
220 VAC 12 15 AMP, 3 Pole
460 VAC 12 15 AMP, 3 Pole
* Wire size based on THW or MTW wire. If run exceeds 300 ft, use next larger size.
Air: The air supply is connected to a 1/4” pipe at the rear left side of the machine. The air supply
must be 90-100 PSIG. A shut off valve should be provided at or near the connection.
Mains Water: The mains water supply is connected to a 1 1/2” pipe located at the rear right side
of the machine (see Figure 2). A shut off valve should be provided at or near the connection.
Chilled Water: The chilled water supply is connected to a 1 1/2” pipe located at the rear right
side of the machine (see Figure 2). The chilled water return is connected to a 1 1/2” pipe located
above the chilled water supply connection. A shut off valve should be provided at or near the
connections.
Steam: The steam supply is connected to a 1-1/4” pipe located at the rear right side of the
machine (see Figure 2). A shut off valve should be provided at or near the connection.
Waste Drain: The waste drain is connected to a 2” pipe located at the rear bottom right side of
the machine (see Figure 2).
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Chapter Three
Equipment Description
General
The CapKold Model CKTC-320 batch tumble chiller will chill up to 320 gallons of bagged
product. The machine is stainless steel construction throughout with a perforated stainless steel
basket. An inclined loading chute allows continuous loading of product while the basket is in
motion.
The touch screen control provides easy operator interface, with simple custom programming.
The drive system consists of a variable speed 1 HP motor and a selectable reversing function for
improved tumble action while chilling and a manual jog for distribution while unloading. Power
transmission to the cylinder is performed by a direct drive gear box to achieve smooth operation.
The door is locked and sealed pneumatically and may not be opened while the tumble chiller is
operating. This interlock also requires that the door be shut and sealed prior to starting.
General Specifications
Basket Size 58” Diameter x 46” Depth
Basket Volume 70.3 Cubic Ft.
Basket Material 14 Gauge 304 Stainless Steel
Basket Rib Size Four 4 1/4” High Triangular Ribs
Basket Angle 10 Degrees
Door Opening Size 30” Diameter
Door Chute Opening Size 12” Diameter
Drive Motor 1 HP
Centrifugal Pump Motor 1 1/2 HP
Basket RPM 2-8 RPM
Water Inlet Size 1 1/2”
Chilled Water Inlet Size 1-1/2”
Steam Inlet Size 1 1/4”
Drain Size 2”
Overflow/Vent Size 1 1/2”
Electrical Service 208VAC-16 Amps
Air Supply 1/4”, 90-100 PSI
Shipping Weight 2,500 LBS
Shipping Dimensions Tumble
Chiller
Shipping Dimensions Optional
Recycle Tank
64” Wide x 96” Deep x
80” High
64” Wide x 83” Deep x
24” High
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Standard Features and Component Details
Gear Motor Drive with Inverter: The machine includes a 1 HP single motor drive and AC
variable frequency inverter. This arrangement provides precise speed control of the inner basket
between 2 and 8 rpm’s through a gearbox motor mounted directly to the basket’s main shaft. The
basket rotation options include one way, oscillate and gentle. The energy efficient motor is rated
for continuous duty. The inverter is safely mounted in the electrical cabinet.
Front Door: The front door includes an inclined loading chute to allow continuous loading of
product while the basket is in motion. Pneumatics are used to seal/lock and unlock the door.
Heat Exchanger: The chilled water source is pumped through a high heat transfer coefficient
plate heat exchanger.
Leveling System: A leveling system consisting of four adjustable legs. No special foundation is
required other than a floor with the capacity to hold the static weight load of the machine, water,
and products contained within.
Bearing Design: A shaft mounted flange bearing design and integrated bearing/motor/gear box
supports the cantilevered load of the inner basket. The front and rear bearings are sealed ball
bearings and do not require grease.
Seal Housing: A housing containing a spring loaded ceramic seal keeps water and chemicals
contained in the machines shell from leaking out, while allowing the machine’s main basket shaft
to rotate freely. The ceramic seal is lubricated with water and the basket will not rotate without
the centrifugal pump turned on or without the mains fill open.
Mains Water Inlet Valve: The water inlet valve is pneumatically operated, 1 1/2” butterfly type,
and is closed by spring pressure.
Chilled Water Inlet Valve: The water inlet valve is pneumatically operated, 1 1/2” butterfly
type, and is closed by spring pressure.
Steam Inlet Valve: The steam inlet valve is pneumatically operated, 1-1/4” butterfly type, and is
closed by spring pressure. The standard machine is outfitted with one valve for direct steam
injection into the bottom of the shell through a diffuser nozzle. Steaming does not occur until the
water level has been satisfied. If no steam is available, hot water supply can be used and must be
programmed in the formula.
Drain Valve: A pneumatically operated, 2” butterfly type valve mounted below the outside shell
allows for rapid gravity draining of waste water.
Automatic Back Flush: An automatic back flush of the heat exchanger will back flush build up
of foreign matter which has entered the heat exchanger in order to maintain optimal heat transfer
between chilled water and product.
In-Line Filter: An easily accessible in-line filter provides protection for the pre piped centrifugal
pump in the event a plastic bag breaks open.
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Touch Screen Controller: A PLC-based, Operator Interface Terminal with a graphical touch
screen provides the formula control for the machine. It provides a storage capacity for up to 99
formulas, up to 99 events (steps) per formula, and 99 product codes. Functions include step time,
rotation intervals and speed, water addition and draining, temperature control, chemical and
steam injection, door operation and safety interlocks for the protection of the operator and
machine. The OIT connects to the machine’s PLC allowing multiple input/output capability,
while providing the operator and maintenance personnel with an easy to program control system.
Optional Equipment
Recycle Tank: An insulated recycle tank with high and low level sensors and 1” water valves to
direct water to the tank. The tank also includes a 1 1/2” drain valve which drains the water into
the shell.
Control Right Side/Left Hinged Door: A control mounted on the right side of the machine with
a left hinged door is available.
Prison Package: The prison package includes tamper proof hardware per the American
Correctional Food Service Association Guidelines.
Automatic Sanitizer Injection: The machine supports liquid supply injection with 1 standard
connection port. Automatic liquid injection can be controlled by the BTC-8 touch screen formula
control with outputs from the PLC terminal strip.
RS232 Port: A 9 pin RS232 port will be available for communication.
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Machine Specification Sheet
Front Elevation
Figure 1
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Rear Elevation
Figure 2
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Right Elevation
Figure 3
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Chapter Four
Operations
Safety Precautions and Instructions
The following instructions will aid in a quick and correct installation for your new CapKold
Tumble Chiller.
**To avoid serious bodily Injury or Equipment damage operate equipment in strict
accordance with manufacturer’s operating instructions**
DO NOT operate machine unless all original safeties are installed and in proper working order
including door interlocks, access panels and signal devices.
DO NOT exceed designed load capacity of machine (100 gallons to 320 gallons of bagged
product).
DO NOT process material containing flammable or volatile cleaning agents into machine.
DISCONNECT power to machine when not in use to limit risk of unauthorized operation.
IN CASE OF EMERGENCY: Push the red “EMERGENCY STOP” switch located on the
operator station, the control circuit will be disabled, turning off the machine.
ALWAYS DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE:
• Performing any type of maintenance, repair, or inspection.
• Entering the basket or area beneath the tub.
• Removing any safety covers, guards, or access panels.
NEVER REMOVE, DISCONNECT, OR ALTER MACHINE SAFETY FEATURES,
MECHANICAL INTERLOCKS, ELECTRICAL INTERLOCKS, OR SIGNAL DEVICES.
DO NOT OPERATE, REPAIR, MAINTAIN, OR ADJUST THIS EQUIPMENT:
• Without reading and understanding this manual.
• Unless these precautions are understood.
• If under the influence of drugs or alcohol.
• If taking medication which distorts judgment or causes drowsiness.
• If advised by doctor or other medical personnel not to operate heavy machinery.
• If, at any time, you doubt your own ability to safely operate this machinery.
IF THERE ARE ANY QUESTIONS CONCERNING SAFETY PRECAUTIONS OF
MACHINE OR ITS OPERATION, CONTACT CAPKOLD.
WARNING
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Preoperational Checks
• Verify air supply pressure is in accordance with nameplate data. Open air supply valve
slowly to prevent injury to personnel.
• Ensure the main air pressure regulator is set at 80 psi.
• Verify steam supply pressure is in accordance with nameplate data. Open supply valve
slowly to prevent shock to steam lines. If not using steam, check temperature of hot water.
• Ensure water supply pressure is in accordance with nameplate data. Check individual
pressures of mains and chilled water. Open all water supply valves slowly.
• Open the control panel and inspect for cleanliness – panel must be free of dirt and debris
before energizing. Clean panel interior with vacuum cleaner and a dry or slightly damp cloth
only. Inspect control panel door seal and replace if worn or damaged. Check electrical
connections for tightness.
• Close all electrical panel doors and ensure all latches are properly fastened.
• Verify that proper voltage and current are available at disconnect in accordance with
nameplate data. Use voltage meter to verify voltage.
• Centrifugal Pump - Do not run pump dry as permanent damage to the mechanical seal will
result.
• Important: Proper Rotation – Power supply should be applied momentarily to the pump at
first and the direction of rotation checked. When viewing the front of the pump, the motor
shaft (impeller) should be rotating counterclockwise. If it is not, disconnect power and recheck wiring to motor. To change rotation on three-phase models, interchange any two
incoming line (power) leads.
• Do not rotate basket without water connected as permanent damage to the mechanical seal
will result.
CAUTION
CAUTION
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Machine Controls
Panel Disconnect: An electrical disconnect is provided on the exterior of the rear electrical
panel. This switch shall be in the down or “OFF” position when the tumble chiller is not in use.
The disconnect has provisions for being locked in the “OFF” position. This feature must be used
during machine maintenance. The rear panel door is mechanically interlocked with the
disconnect switch in order to prevent the door from being opened while the disconnect is in the
up or “ON” position.
**To prevent electric shock ensure there is no voltage available to input lugs of panel
disconnect switch prior to service in panel.**
Control Panel: See Figure 5 for the control panel.
WARNING
Figure 5
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On/Off/Reset: The On/Off/Reset switch is located below the Emergency Stop switch and is of a
rocker type. The first two positions are maintained while the third (RESET) is momentary and
spring returns to center (ON).
Off: Power is removed from all control circuits. However, the two transformers remain
energized. This is the desired position when the tumble chiller is temporarily not in use.
This does not sufficiently remove power for maintenance purposes. Always use the
Panel Disconnect for this purpose.
On: Power is available to control circuits if the switch has been first placed in the
“RESET” position. The switch must momentarily be in this position for any machine
function to occur.
Reset: Energizes control circuits by creating a “latching” circuit. This circuit is
maintained through the Emergency Stop switches and the On/Off/Reset switch as long as
it is in the “ON” position. Anytime the tumble chiller loses power the control circuits
must be energized by momentarily placing the On/Off/Reset switch to “RESET”.
Emergency Stop: The Emergency Stop is located on the top center of the panel and is easily
identified by its large red mushroom shaped operator. Pushing the Emergency Stop push button
at any time will stop machine action. The PLC outputs for machine motion may be disabled more
completely by turning the On/Off/Reset switch to “Off”. The tumble chiller has been designed
to fail safe. This means that when power is lost (due to power outage, On/Off/Reset switch, etc.)
the door will remain sealed and locked.
The Emergency Stop switches are a push-pull type. To reset the Emergency Stop, it must be
pulled out. To restore machine function, simply push the Power switch to the “RESET” position
and SLOWLY release. The power switch will return to the “ON” position.
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Chiller Operation
**Ensure all preoperational checks of Chapter 4 have been satisfactorily completed prior to
performing startup**
• Press rocker switch to RESET position momentarily and then slowly release. The switch will
remain in the ON position
o Chiller powers up, PLC runs internal I/O and software check
**Push the red Emergency Stop switch if any unsafe or unexpected condition appears to
exist**
• Start of Chill Cycle
o Close door, LOCK DOOR button appears.
o Press LOCK DOOR.
o UNLOCK DOOR button appears and can be unlocked provided the basket is empty.
o Press “Cycle” area on screen, list of cycle formulas appear.
NOTE
CAUTION
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o Select the desired Chill cycle formula by highlighting and then pressing SELECT.
o Press START CYCLE.
o Drum will fill with water, the centrifugal pump and the basket will rotate when the low
water level is reached and the chilled water valve will open.
o Operator will be alerted “Ready to Load Bags” and the BAGS LOADED button will
appear.
o Operator will load bags and then press BAGS LOADED.
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o The chill cycle will run for the programmed time or when the temperature has been
maintained for 5 minutes and the timer has ran for 1/2 the programmed time, then the
operator will be alerted to “Check Bags”.
o Press PAUSE CYCLE to stop basket rotation and centrifugal pump to remove a bag
to sample the temperature.
o If the temperature of the product is below 40 deg F, then press END CYCLE. If the
temperature of the product is above 40 deg F, then press START and continue the
chill cycle. The chill cycle will continue until the operator is alerted to “Check Bags”
and the temperature verification process is repeated.
o After the temperature of the product is below 40 deg F and the END CYCLE button
is pressed, the basket will stop rotation, the chilled water valve will close, and the
centrifugal pump will stop.
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o Press the appropriate button DRAIN TO TANK or DRAIN TO WASTE.
o When the water has drained completely, the operator is alerted to “Remove Bags”.
o Press UNLOCK DOOR.
o Unload bags and press JOG button as required to redistribute the bags.
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• Start of Clean Cycle
o Close door, LOCK DOOR button appears.
o Press LOCK DOOR.
o UNLOCK DOOR button appears and can be unlocked provided the basket is empty.
o Press “Cycle” area on screen, list of cycle formulas appear.
o Select the desired Clean cycle formula by highlighting and then pressing SELECT.
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o Press START CYCLE.
o Drum will fill with water, the centrifugal pump and the basket will rotate when the low
water level is reached and the steam valve will open.
o The automatic sanitizer injection will start (option) or a sanitizer can be added manually
through the chute opening.
o The drum will continue filling to programmed temperature and level, then the timer will
start.
o When the timer reaches 00:00, the basket and the centrifugal pump will stop. The
transfer valves will open and the water will be transferred to the tank.
o When the tank is full, the timer will start.
o When the timer reaches 00:00, the tank will drain and the operator will be alerted to
“Clean Out In-Line Filter”.
o Press END CYCLE.
o Press UNLOCK DOOR
o Repeat with a Rinse Cycle if chemicals were used.
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• Start of Back Flush Cycle
o Close door, LOCK DOOR button appears.
o Press LOCK DOOR.
o UNLOCK DOOR button appears and can be unlocked provided the basket is empty.
o Press “Cycle” area on screen, list of cycle formulas appear.
o Select the desired Back flush cycle formula by highlighting and then pressing SELECT.
o Press START CYCLE. Valves will open to back flush heat exchanger and timer will
start.
o Press END CYCLE when the timer reaches 00:00.
o UNLOCK DOOR appears.
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Manual Operation
• To perform Manual Operation or to check Input/Output Screen
o Press MENU button.
o Press MACHINE INFO button.
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o Key in password and press ENTER.
o Press I/O SCREEN button or Press MANUAL OPERATION
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o Sample display of inputs. Press OUTPUT1 or OUTPUT2 button to display output
screens. The dark filled circle indicates the input/output is active.
o Sample display of manual operation. Press button and hold to manually activate
desired operation.
o Press PAGE 2 or PAGE 3 to view additional manual operation screens.
o Press MAIN SCREEN button to return to main screen.
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Troubleshooting
Fault Probable Cause
Door will not lock Check door close sensor
Check door lock sensor
Check air pressure
Shim door locks as required
Door will not unlock Check door lock sensor
Check air pressure
Shim door locks as required
Door will not seal Inspect and replace seal
Shim door hinge and door locks as required
Product will not chill properly Clean strainer
Perform automatic back flush cycle on heat exchanger
Check temperature probe
Check chilled water temperature and flow
Pump motor O.L. Clean strainer
Perform automatic back flush cycle on heat exchanger
Drive Motor Thermal O.L. Drum overloaded
Emergency Stop Switch Pressed After investigation, pull out on emergency stop switch
Water Level Too High Check float level
Formula Not Loaded No valid product/item selected
Water valves not opening Check air pressure
Check air lines for leaks
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Chapter Five
**To avoid personal injury disconnect all power before servicing.**
CAUTION
Maintenance and Repair
Scheduled Maintenance
Daily
• Empty pneumatic system water separator bowl.
• Check water and air lines for leakage.
• Check for abnormal noises.
• Check water leaking from seal housing (1/4 plastic drain line in seal housing).
• Empty inline filter (ensure the drum is empty).
Monthly
• Check and fill the oil level in the gear box to the fill plug. Lubrication type is
mineral oil per ISO VG220.
Sensor Adjustment
Door Open/Close Sensor
• Adjust door closed sensor so there is a 1/16 to 1/8 inch gap between the sensor and
the front panel when door is closed.
Door Lock/Seal Sensor
• Remove cover plates to access door lock sensor.
• Close door and press LOCK DOOR button.
• The red LED light should be illuminated with the door in the lock position.
• To adjust sensor, loosen clamp holding the sensor on the air cylinder and move the
sensor up/down until red LED light illuminates and tighten clamp.
• Check functionality by cycling UNLOCK DOOR and LOCK DOOR button and
readjust as required.
• Install covers.
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Water and Steam Valves
Removal of Actuator from Water Valve Body: Apply 80 psi air pressure to the valve actuator.
This will retract the valve plunger from the seat, relieving the pressure on the actuator. Loosen
the retaining nut and remove the actuator assembly from the body. There is a gasket located
under the nut. This gasket must be properly seated when reassembling the valve or leakage will
occur. The steam valve actuator does not require air to disassemble as its spring is much weaker.
Valve Assembly: See Figure 4
1. To insert spindle seals into actuator base
sequence elastomer-teflon-flexible elastomer-teflon with support ring (7), spring (6), guide
ring (5) and wiping ring (13) into the actuator base (25) and secure with circlip (3).
2. To assemble spindle
(19). Secure plug (15) onto spindle (2) with pin (16). Caution: Valve plug should be flexible
on spindle.
3. To insert spindle and fit piston
through the spindle seals located within the actuator base. Position the piston assembly (20),
which is complete with lip ring (21) and O-ring (22), over the spindle (22) and secure with
lock nut (11).
4. To assemble actuator
(20). Grease the sliding surface of the actuator housing (10), insert the O-ring (24) into the
groove on the face of the sleeve (10.02). Place the actuator housing (10.01) over the spring
(17)(18) and piston assembly in the inverted position. Mount on actuator base, use a press
and clamp the actuator housing (10) to the actuator base (25), ensuring that the O-ring (24) is
located within the groove, and secure with screw (23).
5. Valve fitting
actuator and pressurize the actuator. Secure the retaining nut (7) to the valve body (1).
6. Dismantling
**Dismantling of the actuator must be undertaken using a press, as the actuator is spring
loaded**
Fitting Instructions:
1. The valve can be mounted in any position.
2. An arrow indicates the flow direction which must be adhered to. See Figure 5.
3. Maximum permissible working pressure is indicated on the type label.
4. Minimum and maximum control pressures are indicated on the type label.
5. The valve is easy to clean and is achieved by loosening and removing the retaining nut and
actuator assembly from the body.
Reassembly of Actuator to Valve Body: Apply 80 psi air pressure to the actuator. This will
retract the plunger. Place the actuator into the valve body. Check that the air inlet is in the
correct location (the actuator may be assembled with air inlet pointing in any direction) so that the
machine air line may be attached. Ensure that the retaining nut gasket is in place in the valve
body. Tighten the nut. Remove air pressure from the actuator. Reconnect the machine’s air line.
: Insert gasket (4) into the valve body (1). Connect the control media to the
: Dismantling is done in the reverse sequence.
: Insert the seat seal (14) into the plug (15) and secure with retaining nut
: Slide the spindle assembly, with twisting movements,
: Place the spring(17) [also spring (18) where required] over the piston
: Insert ring (9), packing rings (8) and (33) in the
CAUTION
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Valve Diagram
Figure 4
1 Valve body 14 Seat seal, PTE
2 Spindle 15 Plug
3 Circlip 16 Pin
4 Gasket 17 Spring
5 Guide ring 18 Spring
6 Spring 19 Retaining nut
7 Support Ring 20 Piston assembly
8 Packing ring, PTFE 21 Lip ring
9 Ring 22 O-ring
10.01 Actuator housing 23 Socket head cap screw
10.02 Sleeve 24 O-ring
11 Lock nut 25 Actuator base
12 Cap 26 Lip ring
13 Wiping ring 33 Packing ring EPDM
Seal Kit (Items 4, 6, 7, 8, 9, 13, 14, 33)
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Valve Flow Direction
Figure 5
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Door Seal
Door Seal Removal
• To replace door seal, remove old door seal and clean off the residual silicone adhesive.
• Place a small bead of clear silicone adhesive/sealant 5005 or equivalent in the door
groove.
• Firmly press door seal in groove starting at the top of the door and cutting off the excess
at the end. Ensure seal is seated properly in groove all around.
• Remove excess silicone adhesive and allow to cure for 24 hours.
Door Lock/Seal Adjustment
• To adjust door lock/seals, add or remove shims beneath door hinges as required.
• Remove cover plates to access door locks.
**Disconnect and bleed off air supply prior to disconnecting air lines**
• Disconnect air line to access bolt for air cylinder bracket.
• Remove air cylinder bracket and add or remove shims beneath bracket as required.
• Reassemble in reverse order.
• Check functionality by cycling UNLOCK DOOR and LOCK DOOR button and readjust
as required.
• Install covers.
WARNING
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Drive Assembly
**To avoid personal injury, disconnect and lock out power to machine prior to performing
any work on drive assembly**
Drive Assembly Removal
• To remove gearbox motor, flange bearing and/or shaft seal , the basket needs to be
secured as described.
• Remove 3/4 plugs from bottom of shell and replace with 3/4-10 x 4 long hex bolt. Screw
bolts in until they touch basket.
• Secure basket from front to prevent the basket from sliding towards rear of machine.
• Place saddle underneath shaft between gearbox motor and flange bearing.
• Unbolt motor and remove shims between motor plate and motor.
• Remove key retainer and slide motor off shaft with minimal up/down and side/side
movement.
• Remove locking collar.
• Unbolt flange bearing and slide rearward to saddle. Place second saddle in front of
flange bearing and remove first saddle and flange bearing.
• Unbolt seal housing and remove drain line. Slide seal housing back carefully ensuring
the housing is perpendicular to the shaft to prevent damage to ceramic seat. Slide off
shaft using two saddles with one saddle always supporting shaft.
• Slide spring/seal assembly off shaft (lubricant may be required) using two saddles with
one saddle always supporting shaft.
• Reassemble in reverse order.
CAUTION
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Chapter Six
Spare Parts List
Mechanical/Electrical Spare Parts List
Item Part Number Description
1 1060035 1 HP Motor Gearbox
2 1220080 1 1/2 HP Centrifugal Pump
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
1450081
1300070
1210055
1220078
1210052
1210053
5846256
0316031
2000103
2000102
2000110
2000094
1220079
2160143
2020063
2160181
TBD
Flange Bearing
Ceramic Seal
Door Damper
Flow Control Valve
Air Cylinder
Switch Assembly NPN Sinking
Door Seal
1 NPT Water Valve
1 1/2 NPT Water Valve
2 NPT Water Valve
1 1/4 NPT Steam Valve
Valve 120/60, 3W
Liquid Level Control
RTD Probe
Sensor Assembly
Monochrome Touch Screen
Inverter, 1 HP, 208VAC
34
Page 35
Chapter Seven
Diagrams
Pneumatic Diagram
35
Page 36
Water Valve Diagram
36
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