NOV CA203AC, CA210AA, CA206AA, CA202AA, CA202AB Installation, Operation And Maintenance Instructions

English

Instructions

Installation, Operation
and Maintenance Instructions

Original

Series A Muncher - Mono

OMMP/061/01

Rev 2, October 2018

Index

Revisions 3

Spares & Service Contacts 4

Tools 5

ATEX Warning Statements 6

Introduction 7

EC Declaration 8

Installation, Operation & Maintenance Instructions 9

Recommended Lifting Points 15

Wiring Diagram 16

Weights 17

Part Number Reference 19

Coupling Options 20

Torque Tightening Figures 21

Muncher Coding Sheet 22

Dismantling & Assembly 23

Exploded Views 48

Sectional Arrangement 51

Adaptor Stool Coding 52

General Arrangement Drawings 54

2

Revisions

Rev.

1 24/01/2017

2 09/10/2018

3

4

5

Date

dd/mm/yy

Reason for Issue

Re-numbered from WD001. Updated EC Declaration &
added Authorised Distributors List

Updated adaptor stool part numbers on page 54. Removed
Distributor pages & added link to website for current
distributors on Spares and Service Contacts page.

Prepared ByChecked ByApproved

By

M. Bailey M. Davies A. Morris

M. Bailey M. Bailey M. Bailey

3

Spares and Service Contacts

UK

Spares [phone] (direct line 8.15 am – 5.00 pm)
E-mail [email protected]
Service [phone] (direct line 8.15 am – 5.00 pm)
E-mail [email protected]
Service [phone] (24 hrs)

France

Spares & Service [phone]
E-mail [email protected]

Australia

Melbourne [phone]
Sydney [phone]
Brisbane [phone]
Adelaide [phone]
Perth [phone]
Darwin [phone]
E-mail [email protected]

New Zealand

Spares & Service [phone]
E-mail [email protected]

USA

Houston Spares & Service [phone]
Ohio Spares & Service [phone]
E-mail [email protected]

China

Beijing [phone]
Shanghai [phone]
E-mail [email protected]

Distributors

For local distribution, please refer to our website:
www.mono-pumps.com/en-uk/sales_network

4

Tools

For servicing and maintenance work on the Muncher the following tools are recommended.

SB Muncher;

Metric Hexagon Keys - Range 6mm-8mm (0.24” - 0.31”)
Metric Spanners - Range 10mm-36mm (0.39” - 1.42”)
Torque Wrench

Series A Muncher;

Metric Hexagon Keys - Range 6mm-8mm (0.24” - 0.31”)
Metric Spanners - Range 10mm-36mm (0.39” - 1.42”)
Torque Wrench

Series F Muncher;

Metric Hexagon Keys - Range 6mm-8mm (0.24” - 0.31”)
Metric Spanners - Range 10mm-36mm (0.39” - 1.42”)
Torque Wrench
NOV Locknut Key - Item No.s MQ F06A 9750, CF F06A 9755 and MM F06A 9760

TR Muncher;

Metric Hexagon Keys - Range 6mm-14mm (0.24” - 0.55”)
Metric Spanners - Range 10mm-36mm (0.39” - 1.42”)
Torque Wrench

Series R Muncher;

Metric Hexagon Keys - Range 5mm-14mm (0.20” - 0.55”)
Metric Spanners - Range 10mm-36mm (0.39” - 1.42”)
Torque Wrench

All equipment should be in good working condition with no signs of excessive wear.

5

GRINDERS

Due to the nature and design of grinding and macerating
equipment it is possible that certain objects may enter the
cutters, from the process stream, with the potential to cause
sparking or jamming of the cutter assembly.

Where a grinder unit is to be installed in a potentially explosive

atmosphere ensure that this has been specifi ed at the time

of purchase and that the equipment has been supplied
accordingly and displays an ATEX nameplate or is supplied

with a certifi cate of conformity. If there is any doubt as to the

suitability of the equipment please contact your Supplier before
commencing with installation and commissioning.

Process liquids or fl uids should be kept within specifi ed

temperature limits otherwise the surface of grinder or
system components may become an ignition source due to
temperature rises. Where the process liquid temperature is
less that 90ºC (194ºF) the maximum surface temperature will
not exceed 90ºC (194ºF) provided the grinder is installed,
operated and maintained in accordance with this manual.

Where the process fl uid temperature exceeds 90ºC (194ºF)

the maximum surface temperature will be equal to the

maximum process fl uid temperature.

Cavities that could allow the accumulation of explosive gases,
such as under guards, should where possible, be designed out
of the system. Where this is not possible they should be fully
purged before any work is carried out on the grinder or system.

Electrical installation and maintenance work should only be

carried out by suitably qualifi ed and competent persons and

must be in accordance with relevant electrical regulations.

All electrical equipment, including control and safety devices,
should be suitably rated for the environment in to which they
are installed.

Where there may be a risk of an accumulation of explosive
gases or dust non-sparking tools should be used for
installation and maintenance.

To minimise the risk of sparking or temperature rises due to
mechanical or electrical overload the following control and

safety devices should be fi tted. A control system that will shut

the grinder down if the motor current or temperature exceed

specifi ed limits or a jam of the cutter stack occurs. This

may include a system that reverses the machine in order to
clear any such jam. An isolator switch that will disconnect all
electrical supply to the motor and ancillary electrical equipment

and be capable of being locked in the off position. All control
and safety devices should be fi tted, operated and maintained

in accordance with the manufacturer’s instructions.

It is important that the grinder rotates in the correct direction
to give an effi cient grinding operation. This must be checked

on installation and commissioning and after any maintenance
has been carried out. Failure to observe this may lead to
mechanical or electrical overload.

When fi tting drives, couplings, and guards to a grinder unit it is
essential that these are correctly fi tted, aligned and adjusted

in accordance with the O&M instructions. Failure to do so may
result in sparking due to unintended mechanical contact or
temperature rises due to mechanical or electrical overload.

Mechanical seals should be suitably rated for the environment.

The seal and any associated equipment, such as a fl ushing

system, must be installed, operated and maintained in
accordance with the manufacturer’s instructions.

Where a packed gland seal is fi tted this must be correctly fi tted

and adjusted. This type of seal relies on the process liquid to
cool the shaft and packing rings so a constant drip of liquid
from the gland section is required. Where this is undesirable

an alternative seal type should be fi tted.

Failure to operate or maintain the grinder and ancillary
equipment in line with the manufacturer’s instructions may lead
to premature and potentially dangerous failure of components.
Regular inspection, and where necessary replacement,
of bearings, seals, other wearing parts and lubrication is
essential.

The grinder and its components have been designed to ensure
safe operation within the guidelines covered by legislation.
Accordingly your Supplier has declared the machine safe

to use for the duty specifi ed as defi ned by the Declaration
of Incorporation or Conformity that is issued with this

instruction manual. The use of replacement parts that are not

manufactured by or approved by your Supplier may aff ect the

safe operation of the grinder and it may therefore become a

safety hazard to both operators and other equipment. In these

circumstances the Declaration provided will become invalid.
The guarantee referenced on the Terms and Conditions of
Sale will also be invalidated.

6

Inroduction

This information and all the information contained herein,
are the exclusive property of your Supplier, and contain
information of a proprietary nature. It is provided for the sole
purpose of transmitting the information contained to the
designated recipient.

This information is to be used only as specied in the

instrument of transmittal. It is not to be reproduced, copied
in whole, or in part, nor is information it contains to be
disclosed in any manner without the written consent of your

Supplier. Its use for any other reason than the specied

shall be a violation of the agreement with the recipient
concerning the legal rights of your Supplier.

Your Supplier reserves the right to make changes, which
may obsolete certain parts of this manual.

The manual gives a guide to the operation and maintenance
of the Muncher given that all Health and Safety and good
engineering practices are observed.

7

EC Declaration as defi ned by Machinery Directive 2006/42/EC.

EC Declaration

The following harmonised standards are applicable: BS EN ISO 12100: 2010

EC Declaration of Incorporation

This declaration is only valid when partly completed machinery
has been supplied.

In this case, the machinery meets the requirements of the said

directive and is intended for incorporation into other machinery
or for assembly with other machinery in order to constitute

relevant machinery as defi ned by the said directive including

any amendments, which are valid at the time of supply.

IMPORTANT

This machinery must not be put into service until the relevant
machinery into which it is to be incorporated has been
declared in conformity to the said directive.

This declaration is only valid when the machinery has been
installed, operated and maintained in accordance with these
instructions and safety guidelines contained within as well
as instructions supplied for equipment assembled with or
intended for use with this equipment.

EC Declaration of Conformity

This declaration is not valid for partly completed machinery
that has been supplied.

In this case the machinery meets the requirements of the said

directive including any amendments which are valid at the time
of supply.

We further declare that, where applicable, said machinery also
meets the requirements of:

The EMC Directive 2014/30/EU
The Low Voltage Directive 2014/35/EU
The Pressure Equipment Directive 2014/68/EU

IMPORTANT

This declaration is only valid when the machinery has been
installed, operated and maintained in accordance with these
instructions and safety guidelines contained within as well
as instructions supplied for equipment assembled with or
intended for use with this equipment.

Mr A. Morris - Director of Pump Technology for
NOV PFT UK Ltd., Greengate Way, Middleton,
Manchester, England, M24 1SA.

8

Lift

Correctly

Intallation, Operation & Maintenance

1.0 INSTALLATION

1.1 INSTALLATION & SAFETY RECOMMENDATIONS

In common with other items of process plant a Muncher

must be installed correctly to ensure satisfactory and
safe operation. The Muncher must also be maintained to
a suitable standard. Following these recommendations
will ensure that the safety of personnel and satisfactory
operation of the Muncher is achieved.

1.1.1 OPERATING PRINCIPLE

The Muncher is a slow speed, high torque grinder
designed to operate in the water, waste and biowaste
industries. All Munchers have two shafts operating at

diff erential speeds. Each shaft is fi tted with identical

interleaving cutters and spacers.

1.2 GENERAL

When handling harmful or objectionable materials,
adequate ventilation must be provided in order to

disperse dangerous concentrations of vapours. It is

recommended that wherever possible, your Supplier’s
Munchers should be installed with provision for adequate

lighting, thus ensuring that eff ective maintenance can be

carried out in satisfactory conditions. With certain product
materials, a hosing down facility with adequate draining
will simplify maintenance and prolong the life of the
Muncher components.

1.3 SYSTEM DESIGN AND INSTALLATION

At the system design stage, consideration must be given

to the provision of fi ller plugs, and the installation of non-

return and/or isolating valves where applicable.

Series ‘F’ AND ‘H’ Munchers are horizontal dry waste

machines and must be fi xed rigidly and horizontally either

to the ground, or to a rigid system.

TR Pipeline models are designed for horizontal
installation only.

Series ‘A’, SB and ‘R’ open channel models do not require

fi xing to the ground and can be supported either by

the concrete channel or by steel supports bolted to the
concrete channel walls.

Series ‘A’, SB and ‘R’ pipeline models can be installed at
any altitude.

Pipework to and from the unit should be independently
supported and not rely on the Muncher as a means of
support. Wherever possible when installed in a vertical
pipe system the Muncher unit should be independently
supported.

1.4 HANDLING

During installation and maintenance, attention must be
paid to the safe handling of all items. Where a Muncher

or its components weigh in excess of 20kg (45Ib) it is

recommended that suitable lifting tackle should be used
to ensure that personal injury or damage to components
does not occur.

Lifting illustrations are contained in this document on
page 13.

A weight table is included on pages 17 and 18.

NOTE
DO NOT ATTEMPT TO LIFT MUNCHER USING ONLY
ONE LIFTING LUG. EXTREME CAUTION SHOULD
BE OBSERVED FOR PERSONNEL SAFETY WHEN
LIFTING HEAVY OBJECTS.

BY DESIGN THE CUTTERS HAVE SHARP EDGES.

GREAT CARE MUST BE TAKEN WHEN HANDLING.
THE USE OF PROTECTIVE GLOVES IS
RECOMMENDED.

1.5 STORAGE

Munchers are dispatched from our factory with the cutter
chamber sprayed with a moisture repellent coating and
ready for immediate installation and operation.

Should the machine be stored or left stationary for any
length of time it is recommended that the cutter bank is
re-sprayed with anti-rust lubricant and that the shafts are
rotated monthly.

Removing the motor cowl and turning the fan by hand is
the easiest way to rotate the shafts.

Failure to do this may result in a higher frequency of
reversals and in extreme cases the machine to seize due
to the tight running clearances of the individual cutting
elements during commissioning and initial start-up.

The starter panel if supplied should be stored in a
controlled dry environment to prevent moisture build­up causing corrosion of contactors and other metallic
components.

See manufacturer instructions for motor/gearbox/drive
and panel storage procedures.

NOTE:

The Muncher must be protected by a PLC control unit
set up to the correct operating philosophy. Only PLC’s
supplied or approved by your Supplier should be used.
Failure to observe this requirement may cause premature

9

machine failure and could invalidate the warranty of the

machine. It is also important that the PLC be correctly

wired into the panel.

Please refer to Wiring Diagram on page 16.

GUARDS

In the interests of safety, and in accordance with relevant

legislation, all guards must be replaced after necessary
adjustments have been made.

IMMEDIATELY PRIOR TO INSTALLATION AND STARTING

Before installing the Muncher please ensure that all plugs
and inspection plates are replaced.

For TR Munchers please see section 1.9.1 prior to

starting for instructions on how to fi t constant level oilers.

1.6 ELECTRICAL

Electrical connection should only be made using
equipment suitable for both rating and environment.
Where any doubts exist regarding the suitability of
equipment, your Supplier should be consulted before
proceeding.

Earthing points will be provided on electric drives (if
supplied) and it is essential that these are correctly
connected. The electrical installation should include
appropriate isolating equipment to ensure that the unit is
safe to work on.

1.7 GENERAL SAFETY

GREAT CARE MUST BE TAKEN TO PROTECT ALL
ELECTRICAL EQUIPMENT FROM SPLASHING WHEN

must be used

SUPPLIED A BASIC MUNCHER THE ONUS IS ON THE

HOSING DOWN. WHERE YOUR SUPPLIER HAS

Guards

USER TO FIT ADEQUATE GUARDS IN COMPLIANCE
WITH THE REQUIREMENTS OF THE RELEVANT
REGULATIONS.

All nuts and bolts, securing fl anges and base mounting
fi xtures must be checked for tightness before operation.

When commissioning the plant, all joints in the system
must be checked thoroughly for leakage.

If, when starting, the Muncher does not appear to operate

correctly, the plant must be shut down immediately
and the cause of the malfunction established before
operations are recommenced.

May contain substances from the ECHA SVHC
Candidates List (REACH - Regulation (EC) No.
1907/2006)

NOTE:
NEVER inspect or work on or near the cutter chamber

without fi rst isolating and locking the machine.

It is strongly recommended that a Series ‘F’ or ‘H’ ONLY

horizontal dry Muncher system should incorporate: -

Guards

must be used

a) A steel (or similar) feed hopper with a minimum base to

top height of 1.0 metre (3.3 feet) or a minimum height

of 1.5 metres (4.9 feet) from fl oor level.

b) A steel (or similar) lower delivery chute, which is

inaccessible without tools.

c) A protective grid mounted over the Muncher and

conveyor system, especially where overhead walkways
are present.

d) Emergency stop buttons positioned within easy reach

of all operating staff .

The recommended extent of enclosure is illustrated in this

document on page 52 onwards (Series F or H ONLY).

1.7.1 WARNING /CONTROL DEVICE

Prior to operating the Muncher, if any warning or control

devices are fi tted these must be set in accordance with
their specifi c instructions.

1.7.2 NOISE LEVELS

The noise sound pressure level will not exceed 70dB at
one metre distance from the Muncher. This is based on

must be used

noise from other sources or any contribution from building

a typical installation and does not necessarily include

Guards

reverberation.

1.8 EXPLOSIVE PRODUCTS/ HAZARDOUS
ATMOSPHERES

In certain instances the product being treated may well be

of a hazardous nature.

In these installations consideration must be given to

provide suitable protection and appropriate warnings to
safeguard personnel and plant.

1.9 LUBRICATION

The gearmotor(s) is supplied with the correct type and
quantity of lubricant in the gearbox but should be checked
before use. For further data see separate information
supplied by manufacturer.

Series ‘F’ and ‘H’ bearings and rotary shaft seals are
lubricated via greasing points on each bearing housing.
The correct quantity of grease is reached when excess

10

can be seen around the outer lipseal. Other models have
sealed for life bearings that do not require maintenance.

long as there is oil visible in the oiler then the seals will be
quenched with oil

Gears should be inspected periodically to see if grease
replenishment is necessary, and if so, grease should be
added via the grease nipple until the housing is two thirds
full.

Only use recommended lubricant shown below for
Muncher shaft gears, bearings and rotary seals.

BP Energrease LC2 (-30°C to 180°C) (-22°F to 356°F).

At the following intervals, bearings, gears and seal
assembly inspection should take place along with
lubricant replenishment;
Series ‘F’, ‘H’, ‘R’ - 7,500 hrs
Series ‘A’, SB, TR - 10,000 hrs

PIPELINE MUNCHERS SHOULD BE ISOLATED BY
CLOSING LINE VALVES PRIOR TO SERVICING.

Under tropical or other arduous conditions, however,

more frequent lubrication may be necessary. It is

therefore advisable to establish a suitable maintenance
schedule or periodic inspection to match service
conditions.

2.0 START-UP PROCEDURE

By the nature of the equipment and its operating
environment the Muncher can be an extremely dangerous

machine. It is vital that operators are conversant with
these Operation and Maintenance Instructions prior to

working with the machine.

Where applicable:

1) Check the foundation bolts are secure once the

machine is installed in its correct operating position.

2) Check the gearbox lubricant, remove the plug and fi t

the air vent to prevent gearbox pressurisation. Not
applicable to submersible drive units.

3) Check all electrical connections for continuity and

earthing and that installation is in accordance with
relevant regulations and circuit diagrams.

4) If a feed hopper is fi tted, check that it is secure and

installed correctly, and that no personnel can gain
access to the moving parts of the machine.

1.9.1 All CT203 & CT205 TR Munchers require 2 constant
level

oilers to be fi tted to the bearing housing in order

to prevent the mechanical seals dry-running. The oilers
will be supplied loose with the Muncher to avoid damage
during transit, so upon receipt of the equipment they will

need to be installed prior to operation. Instructions for
fi tting the oilers are as follows:

● Completely fi ll the two mechanical seal cavities through

the upper ¼” BSP ports on the bearing housing as per
lubrication schedule so that no air is left surrounding
the mechanical seals. The two cavities are connected

however it may be necessary to fi ll with oil through

both ports due to the intricate path between the two
mechanical seal cavities.

● Before attaching the oilers to the bearing housing,

ensure the ¼” male nipple is fi tted to each oiler and
proceed to completely fi ll the oilers as per lubrication

schedule

● Attach the oilers to the ¼” BSP ports and tighten until

no oil leaks from the connection.

● Note the level of oil in the oiler and regularly check the

oilers to ensure they have not emptied.

Because mechanical seals do have an expected leak rate

the oilers will need to be re-fi lled with oil periodically. The

precise level of oil in the oilers is not critical because as

Guards

must be used

5) Always ensure that machine is guarded in accordance
with PD5304: 2000 Safety of Machinery requirements
before any attempt is made to operate.

6) Prior to start up ensure all CT203 & CT205 TR

Munchers have constant level oilers fi tted as per

section 1.9.1.

7) On start-up check the direction of rotation of the
cutters. The cutters should rotate towards the centre
when viewed from the inlet side.

NOTE:

If it is necessary to remove any inspection cover to

observe the action – EXTREME CARE should be
observed when carrying out this procedure.

8) Check that the Muncher stops when “STOP” button(s)
are activated.

9) Check for reverse rotation of cutters when “REVERSE”
button is activated.

10) Start up the machine. On initial start-up, allow

machine to run for approximately 45 minutes.

11) Start the feed system to the machine. Care should

be taken not to overburden the machine. Adjust feed
to maintain only the smallest practical reservoir of
material in cutter banks.

11

12) After a further 10 minutes of running, stop the

machine, switch off and lock the main isolator. Check

the tightness of all securing bolts. Recheck every 500
hours of operating time.

13) Check the tightness of all cables and connections.
Re-check every 500 hours of operating time.

14) Observe manufacturers guidelines with regard to
gearbox lubricant initial renewal and subsequent
intervals.

15) In the event of machine overload (jam), the controller

is programmed to activate the following procedure:-

i) Momentarily reverse rotation to clear the condition,

then return to normal operation

ii) If overload re-occurs within 60 seconds, reverse

rotation to clear the condition, then return to normal
operation.

iii) If a third overload occurs within 60 seconds of

the fi rst, machine shutdown in reverse mode and

energise alarm circuit.

16) After machine shutdown, isolate and lock off . Inspect

machine, removing any obstruction and press the
“RESET” button.

3.0 DISMANTLING AND ASSEMBLY

Section 3 contains the steps to dismantle and reassemble
the Muncher. All fastenings must be tightened securely

and where identifi ed the appropriate torque fi gures should

be used.

3.1 USE OF ITEMS NOT APPROVED OR
MANUFACTURED BY YOUR SUPPLIER

The Muncher and its components have been designed
to ensure that the machine will operate safely within the
guidelines covered by the legislation.

As a consequence your Supplier has declared the

machine safe to use for the duty specifi ed as defi ned
by the Declaration of Incorporation or Conformity that is
issued with this Instruction Manual.

The use of replacement items that are not approved by

or manufactured by your Supplier may aff ect the safe

operation of the machine and it may therefore become a

safety hazard to both operators and other equipment. In

these instances the Declaration provided will therefore
become invalid. The guarantee referenced in the
Terms and Conditions of Sale will also be invalidated if
replacement items are used that are not approved or
manufactured by your Supplier.

17) The machine can now be re-started as 10) above.

NEVER inspect or work on or near the cutter chamber

without fi rst isolating and locking the machine.

3.2 DISMANTLING ADVICE

(Refer to specifi ed drawings).

CAUTION: When servicing the Muncher, be certain

that the mains isolator is off and padlocked. Serious

injury could result from accidental start-up.

1) Disconnect wiring at motor(s) terminal box(es) and tag

leads for identifi cation.

2) Pipeline models - Isolate the Muncher pipeline by

closing line valves before and after the machine.

3) If necessary, the Muncher may be completely removed

from installation using the recommended lifting
equipment.

4) Pipeline models - Replace the pull back assembly with

the maintenance period screen (MPS) if required.

5) When dismantling cutters and spacers, take careful

note of the position and orientation of each component.

3.3 CLEANING / INSPECTION

TR MUNCHERS ONLY

It is important to periodically inspect (timeframe
dependant on usage) the trash trap for any grit build
up. If grit is present in the trash trap the grit should

12

be removed and cleaned to ensure optimal care and
working performance. See page 14 for more details.

ALL MUNCHERS

1) Steam clean and disinfect all parts of the Muncher
excluding motor, seal assemblies, gear drive unit and
bearings.

2) Remove any gasket material from joint faces.

3) Housings should be cleaned thoroughly.

4) Inspect all parts for excessive wear and replace if

necessary.

5) Sealed bearings cannot be re-greased, replace if
necessary.

6) Check and if necessary replace the internal ‘O’rings,
lipseals and mechanical seals.

7) Inspect gears for wear and damage and replace if

necessary.

8) All cutters and spacers must be clean and free from
cracks or excessive wear.

The unique internal trash trap built into the main body of
the machine (patent pending), has access covers placed
on either side for easy clean out.

Access cover plates drilled to suit standard NP16 50mm
diameter flange to allow hosetail or similar to be fitted for
flushing exercise when required.

25°

9) Shafts should be clean and any burrs fi led off for
easier stacking. Inspect shafts for excessive wear of

hexagonal portion. Replace if necessary.

3.4 REASSEMBLY ADVICE

1) Lubricate all bores, shafts and seals on reassembly.

2) Lubricate gears on re-assembly with the specifi ed

lubricant.

3) Reconnect wiring at motor(s) terminal box(es) using

tag leads for identifi cation.

4) Re-open system isolation valves.

5) On completion of assembly, run through the ‘initial
start-up’ procedure on page 11.

TR MUNCHERS ONLY

25° CUTTER STACK AND TRASH TRAP (CT201,CT206
& CT205 ONLY)

The cutter stack is inclined at 25° from the vertical
axis to allow any unbreakable solids to drop clear of
the cutters into the trash trap on reversal side of the
cutter stacks. the solids can then be manually removed
once the machine has been isolated (mechanically and
electrically).

CT201

25°

TRASH
TRAP

CT203 & CT205

13

CLEAN OUT FACILITY (TR MUNCHER ONLY)

Using the two clean out access ports, fl anged hoses
and valves can be fi tted to give an automatic fl ushing

sequence at sites where grit/solids are known to cause
problems.

H2O

S

14

Recommended Lifting

15

Wiring Diagram

16

Weights

Muncher Type

CA202AA
CA203AA
CA205AA
CA206AA
CA210AA
CA215AA

CA202AB
CA203AB

Series A

Series F

CA205AB
CA206AB
CA210AB
CA215AB

CA202AC
CA203AC
CA205AC
CA206AC
CA210AC
CA215AC

CF306RJS7B2

CF310RMS7B2

Gear Unit /

Class

IP55 2

IP55 2

IP55 4

Nord IP55

M/C Size (kW)

11

7.5 & 11

Weight

(kg)

241
251
276
286
351
400

254
264
284
294
369
439

265
275
295
305
380
450

780

1180

Series H

SB

TR

CH06
CH09
CH12

Pipeline CB201

Channel CB201A

CT203C IP55

CT203D IP55

CT203E IP55

Nord IP55

IP55

IP55

IP55

IP67 & IP68

11 & 15
15 & 22

1.1

1.5

2.2

1.1

1.5

2.2

1.1

1.5

2.2

1.1

1.5

2.2

1.5

2.2 / 4.0

1.5

2.2 / 4.0

1.5

2.2 / 4.0

1800
2300
2800

205
207
244

208
244
248

155
190
195

200
225
260

290
340

290
340

290
340

CT205F IP55

CT205G IP55

R CR145A IP55 8 800

1.5

2.2 / 4.0

1.5

2.2 / 4.0

345
390

345
390

17

Muncher Type Gear Unit / Class M/C Size (HP) Weight (lb)

Series A

Series F

Series H

CA202AA
CA203AA
CA205AA
CA206AA
CA210AA
CA215AA

CA202AB
CA203AB
CA205AB
CA206AB
CA210AB
CA215AB

CA202AC
CA203AC
CA205AC
CA206AC
CA210AC
CA215AC

CF306RJS7B2

CF310RMS7B2

CH06
CH09
CH12

TEFC 2

TEFC 3

TEFC 5

TEFC

TEFC

10 & 15

15 & 20 /

20 & 30

15

531
553
608
630
773
881

559
582
626
648
813
967

584
606
650
672
837
992

1719
2601

3968
5070
6172

SB

TR

Pipeline CB201

SUBMERSIBLE

Channel CB201A

SUBMERSIBLE

CT203P TEFC

CT203Q TEFC

CT203R TEFC

CT203S TEFC

CT203T TEFC

TEFC

TEFC

1.5
2
3

1.5
2
3

1.5
2
3

1.5
2
3

2

3 / 5

15

10 & 15

15

10 & 15

15

10 & 15

15

10 & 15

451
456
537

458
537
546

341
418
429

440
496
573

639
749

639
749

639
749

760
859

760
859

R CR145A TEFC 10 1763

18

Part Numbers

DESCRIPTION

Bearing Housing

Mid Housing

Nameplate

Warning Nameplate 0650 06B 3504

Bottom Cover Plate 1100 11A Spacer (Mid Bearing) 3556² 35C

Top Cover Plate

Adapter Stool

Cover Plate Gasket 2000 20A 2695¹

Side Rail Gasket 2010 20B 2696¹

Mid Bearing Housing Gasket 2020 20C 2697¹

Mounting Flange Gasket 2021 20D 2698¹

Side Rail

Cutter

Drive Shaft

¹ - Machines prior to 21/09/2015

² - Machines after 21/09/2015

For more information contact your Supplier

NOV
PART NO.

0100

0101 3255

0112 3256²

0113 3500

0175

0176 3502

0177 3506

0600

0630

1150

1152 Retaining Washer 4702 47A

1701

1708 Drive Gear 7800 78A

1720 Driven Gear 7850 78B

1721 Lifting Lug 9700 97A

1722

1723 Coupling Variations

1724

1725 2691¹

1726 2692¹

2100

2101

2105 2601 26B

2106

2110

2111

2120

2121

2123 80B06893²

2511

2513

2515 M040127G-T¹

2516 M040127G-NORTH¹

3200¹

3201 M040227G²

3205 M040227G-T²

3206² M040227G-NORTH²

3251 M040229G²

DRG.
REF

01A Driven Shaft

01B

06A

11B

17A

21A

25A

32A

DESCRIPTION NOV PART NO.

Spacer

Shim Spacer

Sleeve (Mid Bearing) 3557² 35D

Lock Washer 4701 47B

1 Piece Coupling

2 Piece Coupling

Pin & Buffer Coupling

Seal Variations

Mechanical Seal

DRG.
REF

3250¹

32B

3501

35A

3551

3503

2690¹

2699¹

2600 26A

80B06891²

M040127G¹

M040129G¹

35B

26C

P2092122 80B06892²

P305

19

Coupling Options

BEFORE

BEFORE

24/09/2015

24/09/2015

Serial Number 801481

CA202 - CA215 CA202 - CA206 CA210 - CA215

CA202 - CA215 CA202 - CA206 CA210 - CA215

AFTER

AFTER

24/09/2015

24/09/2015

20

Torque Settings

DESCRIPTION

THREAD

SIZE

PART NO.

MAX. TIGHTENING

TORQUE

Nm

Lbf.ft.

SLOTTED HEX NUT M24 x 3 P106 230

SOCKET CAP SCREW M10 x 1.5 P107 56

SOCKET CAP SCREW M8 x 1.25 P108 29

HEX HEAD SCREW M8 x 1.25 P109 29

SOCKET CAP SCREW M10 x 1.5 P114 56

HEX HEAD BOLT M12 x 1.75 P201 101

HEX HEAD BOLT M12 x 1.75 P202 101

HEX HEAD SCREW M10 x 1.5 P207 56

HEX HEAD SCREW M8 x 1.25 P400 29

HEX HEAD BOLT M8 x 1.25 P401 29

170

41

22

22

41

76

76

41

22

22

Torque tolerances are +/- 5% of stated values.

21

Muncher Coding Sheet

Features Description

Body Material

Product Series A Muncher A

Mark No. 2014 2

Throat Size

Machine Type and

Flange Bore

(Metric Flanges Drilled to BS4504

PN16 and Imperial Flanges

Drilled to ANSI B16.5 Class 150)

Build Option Refer to NOV *

Cutter

No. of Teeth

Thickness

Material (Cutters)

Oblique /

Field Variation V A R

Typical Code C A 3 0 2 B * T 7 B 2 / 1 2 3

Basic Code Variation

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Cast Iron C

Stainless Steel ** S

Gun Metal ** G

200mm (8”) 0 2

300mm (12”) 0 3

500mm (20”) 0 5

600mm (24”) 0 6

1000mm (40”) 1 0

1500mm (60”) 1 5

Basic (Channel Type) A

Pipeline 80 N.B. to BS4504 B

Pipeline 100 N.B. to BS4504 C

Pipeline 150 N.B. to BS4504 D

Pipeline 200 N.B. to BS4504 E

Pipeline 250 N.B. to BS4504 F

Pipeline 300 N.B. to BS4504 G

Upow 80 N.B. to BS4504 H

Upow 100 N.B. to BS4504 J

Upow 150 N.B. to BS4504 K

Upow 200 N.B. to BS4504 L

Pipeline 3” N.B. ANSI N

Pipeline 4” N.B. ANSI P

Pipeline 6” N.B. ANSI Q

Pipeline 8” N.B. ANSI R

Pipeline 10” N.B. ANSI S

Pipeline 12” N.B. ANSI T

Upow 3” N.B. ANSI U

Upow 4” N.B. ANSI V

Upow 6” N.B. ANSI W

Upow 8” N.B. ANSI Y

CAM T

ETOS W

5 (ETOS Only) 5

7 (CAM Or ETOS) 7

5.5mm (0.2165”) A

8.0mm (0.3150”) B

Stainless Steel (ETOS Only) 1

Chromium Molybdenum Steel
(CAM Only)

2

** Stainless Steel construction available with high ow side rails only
Note: “X” in any column denotes a special variation.

22

Dismantling Drawings

23

24 25 26 27 28 29 30 31 32 33 34 35

Assembly Drawings

36

37 38 39 40 41 42 43 44 45 46 47

Exploded Views

P207

P208

P209

P102

P108

P101

P117

P119P118

P109

P107

48

P109

P108

P30

3

5

3200

3250

017

49

P405

P406

P402

59A

20E

24A

20D

P403

P401

P407

P400

50

P117

P305

Sectional Arrrangement

2

QTY

BODY PARTS

DESCRIPTION

01A BEARING HOUSING

ITEM

1

1

4

1

1

2

4

8

NAMEPLATE (MUNCHER)

NAMEPLATE (WARNING)

MECHANICAL SEAL (INCL O-RINGS)

COVER PLATE (BOTTOM)

COVER PLATE (TOP)

COVER PLATE GASKET

SIDERAIL GASKET

WASHER

06A

06B

P305

11A

11B

20A

P115

20B

47A

06B

2

1

1

2

LOCK WASHER

DRIVE GEAR

DRIVEN GEAR

DOWEL PIN

47B

78B

78A

P101

1

2

8

2

20

ROTARY SHAFT LIPSEAL

SPLIT COTTER PIN

SGL COIL SPR WASHER

P102

P103

P104

8

ST STL SPR WASHER

ST STL HEX SOC CAPSCREW

P105

P106 SLOTTED HEX NUT

P107

8

4

4

8

2

2

20

ST STL HEX SOC CAPSCREW

HEX HD SCREW

ST STL SPR WASHER

ST STL HEX SOC CAPSCREW

DRIVESCREW

P108

P109

P113

P114

P115

2

HEX CSK PLUG

ABUTMENT RING

LOCK NUT

P116

P117

P118

2

1

2

LOCK WASHER

RECT PAR KEY

RECT PAR KEY

P119

P301

P306

*

2

1

1

ROTATING PARTS

SIDERAIL

CUTTER

DRIVE SHAFT

DRIVEN SHAFT

25A

32A

32B

21A

*

*

CUTTER SPACER

SHIM SPACER

35B

35A

P108 P104

P306

11B

P109

47A

P301 P102

P101

20A

78B

06A

P118

P115

P119

01A

21A

35B

P107 P105

32B

01A

47B

P108 P104

47A

P109

P103

P106

11A

78A

20B

21A

25A

51

35A

32A

Adaptor Stool Coding

P.C.D.

FLANGE/

GEARBOX

SHAFT

GEARBOX

DIAMETER

SIZE

ONE PIECE

CA215

CA210,-

PART NO.

GEARBOX COUPLING

PART NO.

MUNCHER COUPLING

STOOL

ADAPTOR

SIZE CA202,CA203,CA205,CA206

PART NO.

ADAPTOR

CODE

STOOL

J CD A02A 1723 MS A02A 2601 MS A02B 2660 80B06893 45 250/215

H CD A02A 1724 MS A02A 2601 MS A02A 2655 80B06892 40 250/215

G CD A02A 1725 MS A02G 2626 MS A02G 2626 80B06891 35 250/215

52

L CD A02C 1701 MS A02A 2601 MS A02C 2627 48 260/230

K CD A02A 1701 MS A02A 2600 MS A02A 2627 38 210/180

M CD A02B 1701 MS A02A 2601 MS A02B 2627 58 340/310

General Arrangements

MODEL kW

CA202AA 1.5 1059 515 175 155 215 305 350 145 178 260 159

CA203AA 1.5 1173 629 290 155 215 305 350 145 178 260 169

CA205AA 1.5 1323 779 440 155 215 305 350 145 178 260 189

CA206AA 1.5 1468 924 585 155 215 305 350 145 178 260 199

CA210AA 1.5 1883 1339 1000 155 215 305 350 145 178 260 274

CA202AB 2.2 1119 515 175 155 215 305 350 154 178 260 170

CA203AB 2.2 1233 629 290 155 215 305 350 154 178 260 180

CA205AB 2.2 1383 779 440 155 215 305 350 154 178 260 200

CA206AB 2.2 1528 924 585 155 215 305 350 154 178 260 210

CA210AB 2.2 1943 1339 1000 155 215 305 350 154 178 260 285

CA215AB 2.2 2453 1849 1510 155 215 305 350 154 178 260 355

CA202AC 4.0 1244 515 175 155 215 305 350 179 178 260 196

CA203AC 4.0 1358 629 290 155 215 305 350 179 178 260 206

CA205AC 4.0 1508 779 440 155 215 305 350 179 178 260 226

CA206AC 4.0 1653 924 585 155 215 305 350 179 178 260 236

CA210AC 4.0 2068 1339 1000 155 215 305 350 179 178 260 311

DIM A mmDIM B mmDIM C mmDIM D mmDIM E mmDIM F

mm

DIM G

(MAX)

mm

DIM H

mm

(MAX)

DIM J mmDIM K

mm

MASS

kg

(MAX)

CONDUIT

ENTRY

mm

21

53

MODEL

CA202AA 2.0 41.7 20.3 6.9 6.1 8.5 12.0 13.8 5.7 7.0 10.2 351

CA203AA 2.0 46.2 24.8 11.4 6.1 8.5 12.0 13.8 5.7 7.0 10.2 373

CA205AA 2.0 52.1 30.7 17.3 6.1 8.5 12.0 13.8 5.7 7.0 10.2 417

CA206AA 2.0 57.8 36.4 23.0 6.1 8.5 12.0 13.8 5.7 7.0 10.2 439

CA210AA 2.0 74.1 52.7 39.4 6.1 8.5 12.0 13.8 5.7 7.0 10.2 605

CA202AB 3.0 44.1 20.3 6.9 6.1 8.5 12.0 13.8 6.1 7.0 10.2 375

CA203AB 3.0 48.5 24.8 11.4 6.1 8.5 12.0 13.8 6.1 7.0 10.2 397

MOTOR HPDIM A

inches

DIM B
inches

DIM C

inches

DIM D

inches

DIM E
inches

DIM F

inches

DIM G
inches
(MAX)

DIM H
inches
(MAX)

DIM J

inches

DIM K

inches

MASS

lb

(MAX)

CONDUIT

ENTRY

inches

CA205AB 3.0 54.4 30.7 17.3 6.1 8.5 12.0 13.8 6.1 7.0 10.2 441

CA206AB 3.0 60.2 36.4 23.0 6.1 8.5 12.0 13.8 6.1 7.0 10.2 463

CA210AB 3.0 76.5 52.7 39.4 6.1 8.5 12.0 13.8 6.1 7.0 10.2 629

CA215AB 3.0 96.6 72.8 59.4 6.1 8.5 12.0 13.8 6.1 7.0 10.2 783

CA202AC 5.4 49.0 20.3 6.9 6.1 8.5 12.0 13.8 7.0 7.0 10.2 432

CA203AC 5.4 53.5 24.8 11.4 6.1 8.5 12.0 13.8 7.0 7.0 10.2 455

CA205AC 5.4 59.4 30.7 17.3 6.1 8.5 12.0 13.8 7.0 7.0 10.2 499

CA206AC 5.4 65.1 36.4 23.0 6.1 8.5 12.0 13.8 7.0 7.0 10.2 521

CA210AC 5.4 81.4 52.7 39.4 6.1 8.5 12.0 13.8 7.0 7.0 10.2 686

54

0.8

A
1

J

A

C

D
G

B

MOTOR kWDIM A

MODEL

CA202AA 1.5

CA203AA 1.5 748 629 290 155 215 305 178 260 131

CA205AA 1.5 898 779 440 155 215 305 178 260 151

CA206AA 1.5 1043 924 585 155 215 305 178 260 161

CA210AA 1.5 1458 1339 1000 155 215 305 178 260 236

CA202AB 2.2

CA203AB 2.2 757 629 290 155 215 305 178 260 131

CA205AB 2.2 907 779 440 155 215 305 178 260 151

CA206AB 2.2 1052 924 585 155 215 305 178 260 161

CA210AB 2.2 1467 1339 1000 155 215 305 178 260 236

CA215AB 2.2 1977 1849 1510 155 215 305 178 260 306

CA202AC 4.0

CA203AC 4.0 769 629 290 155 215 305 178 300 132

CA205AC 4.0 918 779 440 155 215 305 178 300 152

CA206AC 4.0 1063 924 585 155 215 305 178 300 162

CA210AC 4.0 1478 1339 1000 155 215 305 178 300 237

DIM

DIM B mmDIM C mmDIM D mmDIM E mmDIM F

A1

mm

mm

634 515 175 155 215 305

SEE DRIVE

UNIT SPEC

643 515 175 155 215 305

SEE DRIVE

UNIT SPEC

654 515 175 155 215 305

SEE DRIVE

UNIT SPEC

mm

DIM G

mm

(MAX)

SEE DRIVE

UNIT SPEC

SEE DRIVE

UNIT SPEC

SEE DRIVE

UNIT SPEC

DIM H

mm

(MAX)

SEE DRIVE

UNIT SPEC

SEE DRIVE

UNIT SPEC

SEE DRIVE

UNIT SPEC

mm

MASS

(MAX)

DIM J mmDIM K

178 260 121

178 260 121

178 300 122

kg

MOTOR HPDIM A

MODEL

CA202AA 2.0

CA203AA 2.0 29.4 24.8 11.4 6.1 8.5 12.0 7.0 10.2 289

CA205AA 2.0 35.4 30.7 17.3 6.1 8.5 12.0 7.0 10.2 333

CA206AA 2.0 41.1 36.4 23.0 6.1 8.5 12.0 7.0 10.2 355

CA210AA 2.0 57.4 52.7 39.4 6.1 8.5 12.0 7.0 10.2 521

CA202AB 3.0

CA203AB 3.0 29.8 24.8 11.4 6.1 8.5 12.0 7.0 10.2 289

CA205AB 3.0 35.7 30.7 17.3 6.1 8.5 12.0 7.0 10.2 333

CA206AB 3.0 41.4 36.4 23.0 6.1 8.5 12.0 7.0 10.2 355

CA210AB 3.0 57.8 52.7 39.4 6.1 8.5 12.0 7.0 10.2 521

CA215AB 3.0 77.8 72.8 59.4 6.1 8.5 12.0 7.0 10.2 675

CA202AC 5.4

CA203AC 5.4 30.3 24.8 11.4 6.1 8.5 12.0 7.0 11.8 291

CA205AC 5.4 36.1 30.7 17.3 6.1 8.5 12.0 7.0 11.8 335

CA206AC 5.4 41.9 36.4 23.0 6.1 8.5 12.0 7.0 11.8 357

CA210AC 5.4 58.2 52.7 39.4 6.1 8.5 12.0 7.0 11.8 523

DIM

DIM B

DIM C

A1

inches

UNIT SPEC

UNIT SPEC

UNIT SPEC

inches

inches

25.0 20.3 6.9 6.1 8.5 12.0

SEE DRIVE

25.3 20.3 6.9 6.1 8.5 12.0

SEE DRIVE

25.7 20.3 6.9 6.1 8.5 12.0

SEE DRIVE

inches

DIM D
inches

DIM E

inches

DIM F

inches

DIM G
inches
(MAX)

SEE DRIVE

UNIT SPEC

SEE DRIVE

UNIT SPEC

SEE DRIVE

UNIT SPEC

DIM H
inches
(MAX)

SEE DRIVE

UNIT SPEC

SEE DRIVE

UNIT SPEC

SEE DRIVE

UNIT SPEC

DIM J

DIM K

inches

inches

7.0 10.2 267

7.0 10.2 267

7.0 11.8 269

MASS

lb

(MAX)

55

J

C

A

B

B.S.4504 PN16

K

MODEL

CA202BA 2

CA202CA 2 634 515 205 24 100 305 178 544 150

CA202DA 2 634 515 205 24 150 305 178 544 152

CA203DA 2 748 629 230 24 150 305 178 544 167

CA203EA 2 748 629 255 24 200 305 178 584 179

CA205FA 2 898 779 280 24 250 305 178 684 224

CA206GA 2 1043 924 305 24 300 305 178 784 268

CA202BB 2

CA202CB 2 643 515 205 24 100 305 178 544 150

CA202DB 2 643 515 205 24 150 305 178 544 152

CA203DB 2 757 629 230 24 150 305 178 544 167

CA203EB 2 757 629 255 24 200 305 178 584 179

CA205FB 2 907 779 280 24 250 305 178 684 224

CA206GB 2 1052 924 305 24 300 305 178 784 268

CA202BC 4

CA202CC 4 654 515 205 24 100 305 178 544 151

CA202DC 4 654 515 205 24 150 305 178 544 153

CA203DC 4 768 629 230 24 150 305 178 544 168

CA203EC 4 768 629 255 24 200 305 178 584 180

CA205FC 4 918 779 280 24 250 305 178 684 225

CA206GC 4 1063 924 305 24 300 305 178 784 269

MODEL

CA202BA 2

CA202CA 2 25 20 8 1 4 12 7 21 331

CA202DA 2 25 20 8 1 6 12 7 21 335

CA203DA 2 29 25 9 1 6 12 7 21 368

CA203EA 2 29 25 10 1 8 12 7 23 395

CA205FA 2 35 31 11 1 10 12 7 27 494

CA206GA 2 41 36 12 1 12 12 7 31 591

CA202BB 3

CA202CB 3 25 20 8 1 4 12 7 21 331

CA202DB 3 25 20 8 1 6 12 7 21 335

CA203DB 3 30 25 9 1 6 12 7 21 368

CA203EB 3 30 25 10 1 8 12 7 23 395

CA205FB 3 36 31 11 1 10 12 7 27 494

CA206GB 3 41 36 12 1 12 12 7 31 591

CA202BC 5

CA202CC 5 26 20 8 1 4 12 7 21 333

CA202DC 5 26 20 8 1 6 12 7 21 338

CA203DC 5 30 25 9 1 6 12 7 21 371

CA203EC 5 30 25 10 1 8 12 7 23 397

CA205FC 5 36 31 11 1 10 12 7 27 496

CA206GC 5 42 36 12 1 12 12 7 31 594

MOTOR kWDIM A

MOTOR HPDIM A

inches

DIM

DIM B mmDIM C mmDIM D mmDIM E mmDIM F

A1

mm

mm

634 515 205 24 80 305

UNIT SPEC

SEE DRIVE

643 515 205 24 80 305

UNIT SPEC

SEE DRIVE

654 515 205 24 80 305

UNIT SPEC

SEE DRIVE

DIM

DIM B

DIM C

A1

inches

inches

25 20 8 1 3 12

UNIT SPEC

SEE DRIVE

25 20 8 1 3 12

UNIT SPEC

SEE DRIVE

26 20 8 1 3 12

UNIT SPEC

SEE DRIVE

inches

DIM D

inches

DIM E

inches

mm

DIM F

inches

DIM G

mm

(MAX)

SEE DRIVE

SEE DRIVE

SEE DRIVE

DIM G

inches

(MAX)

SEE DRIVE

SEE DRIVE

SEE DRIVE

DIM H

mm

(MAX)

UNIT SPEC

UNIT SPEC

SEE DRIVE

UNIT SPEC

UNIT SPEC

SEE DRIVE

UNIT SPEC

UNIT SPEC

SEE DRIVE

DIM H

inches

(MAX)

UNIT SPEC

UNIT SPEC

SEE DRIVE

UNIT SPEC

UNIT SPEC

SEE DRIVE

UNIT SPEC

UNIT SPEC

SEE DRIVE

DIM J mmDIM K

mm

178 544 149

178 544 149

178 544 150

DIM J

DIM K

inches

inches

7 21 329

7 21 329

7 21 331

MASS

kg

(MAX)

MASS

lb

(MAX)

56

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