SPX Votator II Instruction Manual

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Page 1

FPO

INSTRUCTION MANUAL

Votator® II

SCRAPED SURFACE HEAT EXCHANGER

FORM NO.: 95-03057 REVISION: 11/2012

READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.

Page 2

SPX Flow Technology

611 Sugar Creek Road

Delavan, WI 53115 USA

Tel: (800) 252-5200 or (262) 728-1900

Fax: (800) 252-5012 or (262) 728-4904

E-mail: wcb@spx.com

Web site: www.spx.com

Information contained in this manual is subject to change without notice and does not represent a commitment on the part of SPX Corporation. No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose, without the express written permission of SPX Corporation.

Revision Date: 11/2012

Publication: 95-03057

Page 3

Waukesha Cherry-Burrell Table of Contents

Warranty ......................................................................................................4

Shipping Damage or Loss ...........................................................................4

Warranty Claim ............................................................................................4

Safety ..........................................................................................................5

Care of Stainless Steel ..............................................................................6

Stainless Steel Corrosion ............................................................................6

Elastomer Seal Replacement Followin

Introduction ................................................................................................7

Models and Specifications ...........................................................................7

Cylinder Assembly .......................................................................................7

Product Side Pressure Rating .....................................................................7

Jacket Pressure Rating ...............................................................................7

Machine Serial Number ...............................................................................7

Votator II Media Configurations ...................................................................8

Special Considerations for Vertical Votator I

Installation ..................................................................................................9

Site Selection Considerations .....................................................................9

Foundation & Drainage .......... ... ... ... .... ... ... ....... ... ... ... ... .... ... ... ... .... ... ... ... ... .9

Clearances ..................................................................................................9

Leveling the Unit ..........................................................................................9

Electrical Power Connections ......................................................................9

Mutator Rotation Check ...............................................................................10

Mechanical Seals .......................................................................................10

Single Mechanical Seal .............................................................................10

Double Mechanical Seal ............................................................................10

2005 Mechanical Seal Design ...................................................................11

2012 Mechanical Seal Design ...................................................................11

Flush Fluid Requirements ......................

Piping ..........................................................................................................12

Guidelines for Piping ..................................................................................12

Suggested Media Piping for Steam .............................................................12

Suggested Media Piping for Water or Liquid ...............................................13

Refrigeration Piping Installation ...................................................................14

Liquid Line Installation ...............................................................................14

Suction Line Installation ......... ... ... ... .......

Hot Gas Line (if required) ..........................................................................14

Pressure Relief Line ....................... .... ... ... ....................................... ... ... ... .14

Refrigeration Valves ....................................................................................15

Liquid Feed Solenoid Valve ................... ... ... .... ... ...... ... .... ... ... ... .... ... ... ... ... .15

Dual Pressure Regulating Valve ................................................................15

Sporlan Level Master Control (LMC) or Level Swit Refrigerant Return Valve ...

Flow Control Valves ...................................................................................15

Hot Gas Pressure Regulating Valve ......

Pressure Relief Valve ............................................... ... ..............................16

Suggested Media Piping for Liquid Over Feed Refrigeration ......................16

Suggested Media Piping for Gravity Refrigeration ......................................17

Electrical Equipment ....................................................................................19

Refrigeration Wiring Schematics .........

Freeze Protection Components ............. ... ... .... ... ...... ... .... ... ... ... .... ... ... ... ... .20

Gravity Refrigeration with Level Master Cont

Gravity Refrigeration with Level Switch .....................................................22

Liquid Overfeed Refrigeration System .......................................................23

Media System Check ..................................................................................24

g Passivation ..................................6

I ..............................................8

....................................................12

....................................................14

ch ................................15

........................................................................15

....................................................16

........................................................20

rol (LMC) .............................21

11/2012 95-03057 Page 1

Page 4

Table of Contents Waukesha Cherry-Burrell

Special Considerations for Vertical Votator II ..............................................24

Minimum Height - Vertical Votator II ...........................................................24

Mounting Pole - Vertical Votator II ..............................................................24

Mounting Scrape Cylinders - Vertical Votator II ..........................................25

Hydraulic System - Vertical Votator II .........................................................25

Check and Adjust Hydraulic Cylinder ........................................................ 25

Fill Hydraulic Reservoir ............................................................................. 25

Check Balance and Pressure S

Gravity Refrigeration System - Vertical Votator II .......................................27

Typical Dimensional Data and Hydraulic Lift System ..................................28

Votator II General Assembly ..................................................................... 28

Horizontal Refrigeration Assembly ............................................................ 29

Vertical Refrigeration System .................... ... ... ... .... ... ... ...... .... ... ... ... .... ... ... 30

Horizontal Frame Options ......................................................................... 31

Vertical Mounting Pole/Hydraulics ........ .... ... ... ... .... ... ...... ... .... ... ... ... .... ... ... 32

Vertical Hydraulic Schematic ....... ... ... ... .... ... ... ... .... ... ... ...... .... ... ... ... .... ... ... 33

Operation ....................................................................................................34

Pre-Startup Check .......................................................................................34

For Refrigeration Units Only ...................................................................... 34

Pre-production Run Setup ...........................................................................34

Startup Procedure .......................................................................................35

Heating/Liquid Cooling Applications .......................................................... 35

Refrigeration Applications - Pumped and Grav

Shutdown Procedure ...................................................................................36

Preventing Tube Scoring .............................................................................36

Maintenance ............................................................................................... 37

Routine Maintenance Checklist - Vertical Votator II ....................................37

Routine Maintenance Checklist - Horizontal Votator II ................................38

Scheduled Maintenance ..............................................................................40

Preventive Maintenance ..............................................................................41

Mutator Shaft Bearing .................................................................................41

Extra Heavy Duty Votator II Shaft Bearing ................ ................................ 41

Shafts ..........................................................................................................42

Gear Drive ...................................................................................................42

Blades .........................................................................................................42

Mechanical Seals ........................................................................................42

Tubes ..........................................................................................................42

Care of Heat Exchanger Tube ....................................................................43

Product Side ................................................................................................44

Inspection of Chrome Plated Nickel or Stainless Steel Tubes ....................44

Inspection of Stainless Steel Tubes ............................................................44

Jacket Side ..................................................................................................45

For Units Using Steam, Water, Or Liquid ........................ .......................... 45

For Units Using Refrigerant ....................................................................... 45

Cleaning the Flanges ..................................................................................45

Leak Testing ................................................................................................45

Scraper Blade Maintenance ........................................................................45

Blade Inspection ........................................................................................ 45

Scraper Blade Removal & Replacement ................................................... 46

Scraper Blade Wear .................................................................................. 46

Blade Sharpening ...................................................................................... 46

Maintenance of Horizontal Votator II ...........................................................47

Shaft Removal - Horizontal Unit ................................................................ 47

Shaft Installation - Horizontal Unit ...

ettings ...................................................... 26

ity Systems ...... ... ... .... ... ... 35

.......................................................... 48

Page 2 95-03057 11/2012

Page 5

Waukesha Cherry-Burrell Table of Contents

Heat Exchanger Tube Removal - Horizontal Unit ......................................50

Heat Exchanger Tube Installation - Horizontal Unit ...................................51

Maintenance of Vertical Votator II ...............................................................51

Shaft Removal - Vertical Unit .....................................................................51

Shaft Installation - Vertical Unit ................................. .................................52

Heat Exchanger Tube Removal -Vertical Unit .

Mechanical Seal Maintenance ....................................................................56

Single Mechanical Seal ...............................................................................56

Seal Head Insert Removal and Installation ...................... ...... ....... ...... ...... .56

Seal Body Insert (Rotating Seal Face) Used Before 2012 ........................56

Single Mechanical Seal Installation ...........................................................57

One-Piece and Double Mechanical Seals ...................................................57

Primary/Secondary Seal Head Insert Removal and Installation ................57

2012 Primary/Secondary Seal Head Insert Removal and Installation .......58

One-Piece Primary Seal Body (Rotating Seal Face)

Removable Seal Body Insert (Rotating Seal Face) ...................................59

Assembly of Removable Primary Seal Body ... Assembly of 2012 Primary Seal Body ... Assembly of Secondary Seal Body (For Double Mechanical Seal Seal Assembly Installation on Shaf Servicing Mechanical Seals - Vertical Votator II

t ..........................................................60

Parts Lists ...................................................................................................63

Latch ............................................................................................................63

Product Heads .............................................................................................63

Cylinder Assembly .......................................................................................64

Cylinder Assembly - Shaft ...........................................................................66

Cylinder Assembly - Removable Tube ........................................................67

2012 Single and Double Mechanical Seal ...................................................69

One Pie

ce Single & Double Mechanical Seal .............................................71

Single Mechanical Seal ...............................................................................73

Vertical Refrigeration Piping ........................................................................74

Vertical Frame/Hydraulics ...........................................................................76

Heater (Optional) ...............................................................................77

Shaft

Votator II Blades ..........................................................................................78

Labels ..........................................................................................................78

Troubleshooting .........................................................................................79

Unthawing A Frozen System .......................................................................82

Water and Air in Refrigeration System ........................................................82

...................................... ....53

.................................59

..........................................59

....................................................59

Only) ...60

.................................... ....61

11/2012 95-03057 Page 3

Page 6

Warranty Waukesha Cherry-Burrell

Warranty

Seller warrants its products to be free from defect in materials and workmanship for a period of one (1) year from the date of shipment. This warranty shall not apply to products which require repair or replacement due to normal wear and tear or to products which are subjected to accident, misuse or improper maintenance. This warranty extends only to the original Buyer. Products

nufactured by others but furnished by Seller are exempted

ma from this warranty and are lim ited to the original manufacturer’s warranty.

Seller’s sole obligation under this wa replace any products that Seller determines, in its discretion, to be defective. Seller reserves the right either to inspect the products in the field or to request their prepaid return to Seller. Seller

ll not be responsible for any transportation charges, duty,

sha taxes, freight, labor or other costs. The cost of removing and/or installing products which have been repaired or replaced shall be at Buyer’s expense.

Seller expressly disclaims all other warranties, express or implied, inc ity of fitness for a particular purpose. The foregoing sets forth Seller’s entire and sole remedy, for any claim of damages in connection with the sale of products. In no event shall Seller be liable for any special consequential incidental or indirect damages (including without limitation attorney’s fees and expenses), nor shall Seller be liable for any loss of profit or material arising out of or relating to the sale or operation of the products based on contract, tort (including negligence), strict liability or

luding without limitation any warranty of merchantabil-

exclusive liability, and Buyer’s exclusive and

rranty shall be to repair or

otherwise.

Shipping Damage or Loss If equipment is damaged or lost in transit, file a claim at once with

the delivering carrier. The carrier has signed the Bill of Lading acknowledging that the shipment has been received from the seller in good condition. Seller is not responsible for the collection of claims or replacement of materials due to transit shortages or damages.

Warranty Claim Warranty claims must have a Returned Goods Authorization

(RGA) from the Seller before returns will be accepted.

Claims for shortages or other errors, exclusive ages or damages, must be made in writing to Seller within ten

10) days after delivery. Failure to give such notice shall consti-

( tute acceptance and waiver of all such claims by Buyer.

Page 4 95-03057 11/2012

of transit short-

Page 7

Waukesha Cherry-Burrell Safety

Safety

READ AND UNDERSTAND THIS MANUAL

PRIOR TO INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT

SPX recommends users of our equipment and designs follow the latest Industrial Safety Standards. At a minimum, these should include the industrial safety requ

irements established by:

1. Occupational Safety and Health Administration (OSHA), Section 1910.212- General Requirements for all Machines

2. National Fire Protection Association, ANSI/NFPA 79 ANSI/NFPA 79- Electrical Standards for

3. National Electrical Code, ANSI/NFPA 70 ANSI/NFPA 70- National Electrical Code ANSI/NFPA 70E- Electrical Safety Require

4. American National Standards Institute, Se

Attention: Servicing electrical shock, burn, or unintend ed actuation of controlled equipment. Recommended practice is to disconnect and lockout industrial equipment from power sources, and National Fire Protection Association Standard No. NFPA70E, Part II and (as applicable) OSHA rules for Control of Hazardous Energy Sources (Lockout-Tagout) and OSHA Elec including procedural requirements for:

• Lockout-tagout

• Personnel qualifications and tr

• When it is not feasible to de-energize and lockout-tagou on or near exposed circuit parts

Locking and Interlocking Devices: These d bility of performing their intended functions. parts or kits. Adjust or repair in accordance with the manufacturer’s instructions.

energized industrial equipment can be hazardous. Severe injury or de ath can res ult fr om

aining requirements

Industrial Machinery

ment for Employee Workplaces

ction B11

evices should be checked for proper working condition and ca pa-

Make replacements only with the original manufacturer’s renewal

Title 29 of the CFR

release stored energy, if present. Refer to the

trical Safety Related Work Practices,

t electrical circuits and equipment before working

Periodic Inspection: Industr based on environmental and operating conditions and adjusted as indicated by experience. At a minimum, an initial inspection within 3 to 4 months after installation is recommended. Inspection of the electrical control systems should meet the recommendations as specified in the Nation (NEMA) Standard No. ICS 1.3, Preventative Maintenance of Industrial Co ntrol and Systems Eq uipment, for th e general guidelines for setting-up a periodic maintenance program.

Replacement Equipment: Use on maintain the integrity of the equipment. Make sure the parts are properly matched to the equipment series, model, serial number, and revision level of the equipment.

Warnings and cautions are provided in this manual to help avoid serious injury and/or possible damage to

ment:

equip

DANGER:

Immediate hazards which WILL result in severe pe rs on al inju ry or death.

WARNING:

Hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION:

Hazards or unsafe practices which COULD result in minor personal injury or product or property damage.

marked with a stop sign.

marked with a warning triangle.

ial equipment should be inspected periodically. Inspection intervals should be

al Electrical M

ly replacement parts and devices recommended by the manufacturer to

anufacturers Association

11/2012 95-03057 Page 5

Page 8

Care of Stainless Steel Waukesha Cherry-Burrell

Care of Stainless Steel

Stainless Steel Corrosion

Corrosion resistance is greatest when a layer of oxide film is formed on the surface of stainless steel. If film is disturbed or destroyed, stainless steel becomes much less resistant to corrosion and may rust, pit or crack.

Corrosion pitting, rusting and stress cracks may occur due to

mical attack. Use only cleaning chemicals specified by a

che reputable chemical manufacturer for use with 300 series stainless steel. Do not use excessive concentrations, temperatures or exposure times. Avoid contact with highly corrosive acids such as hydrofluoric, hydrochloric or sulfuric. Also avoid prolonged contact with chloride-containing chemicals, especially in presence of acid. If chlorine-based sanitizers are used, such as sodium hypochlorite (bleach), do not exceed concentrations of 150 ppm available chlorine, do not exceed contact time of 20 minutes, and do not exceed temperatures of 104°F (40°C).

Corrosion discoloration, deposits or pitting may occur under

oduct deposits or under gaskets. Keep surfaces clean,

pr including those under gaskets or in grooves or tight corners. Clean immediately after use. Do no t allow equipment to set idle, exposed to air with accumulated foreign material on the surface.

Corrosion pitting may occur when stra in contact with moist stainless steel. Ensure all electrical devices connected to the equipment are correctly grounded.

y electrical currents come

Elastomer Seal Replacement Following Passivation

Passivation chemicals can damage product contact areas of WCB equipment. Elastomers (rubber components) are most likely to be affected. Always inspect all elastomer seals after passivation is completed. Replace any seals showing signs of chemical attack. Indications may include sw elling, cracks, loss of elasticity or any other noticeable changes when compared with new components.

Page 6 95-03057 11/2012

Page 9

Waukesha Cherry-Burrell Introduction

HE100-003a

SERIAL NO.

MODEL

www.spx.com

Votator

Introduction

Models and Specifications

Cylinder Assembly

The Votator II can be furnished for horizontal or vertical installation, available in the following models:

Model Heat Transfer Area Jacket Type

6 x 84 6 x 72 6 x 48 6 x 36 6 x 24

11 ft 9 ft 6 ft

4.2 ft

3.0 ft

(1.0 m2 )

(0.84 m2 )

(0.56 m2 )

(0.39 m2 )

(0.28 m2 )

This manual covers the Horizontal and Ve

Steam/Liquid Refrigeration Steam/Liquid Refrigeration Steam/Liquid Refrigeration Steam/Liquid Refrigeration Steam/Liquid Refrigeration

rtical Votator II, Concentric and Eccentric Designs, and the Extra Heavy Duty Votator II. Every attempt has been made to note where special considerations are needed for each model. Th ese differences are primarily in the installation and maintenance of the units.

The cylinder assembly consists of a rotating shaft inside of two tubes. The outer tube is called the jacket, and contains working fluid to heat or cool the contents of the inner, product tube. The product tube provides a heat exchange surface for the product.

Standard product tubes are one of the following:

Product Side Pressure Rating

Jacket Pressure Rating

Machine Serial Number

• Pure nickel with a hard chrome plated interior surface.

• Stainless steel with a

• Stainless steel with no

hard chrome plated interior surface.

plating.

• 400 psi (28 bar) @ 400°F (204°C) - Oval Tube

• 600 psi (42 bar) @ 400°F (204°C) - Std. Votator II

• 800 psi (56 bar) @ 400°F (204°C) - U Stamp Votator II

• 250 psi (17.5 bar) @ 400°F (204°C)

• 150 psi (10.5 bar) @ 400°F (204°C) (oval and high efficiency

tubes)

Check the data plate attached to the Votator cylinder for exact

ifications of the unit.

spe

The machine serial number is stamped on a serial number nameplate located on the machine side as shown in F igure 1. On vertical units (not shown), the nameplate is on the cylinder. Include th

e machine model and serial number with each parts

order.

Figure 1 - Machine Serial Number

Location

11/2012 95-03057 Page 7

Page 10

Introduction Waukesha Cherry-Burrell

Votator II Media Configurations

Special Considerations for Vertical Votator II

The Votator II is available in the following configurations:

• BWS-BRINE/WATER/STEAM For liquid and steam heating an

d cooling applications.

• LIQUID For water or glycol.

• VAPOR For steam or refrigeration.

The Vertical Votator II cylinder assembly is shipped for on-site installation on the mounting pole. When receiving the shipment, check for the following or multiples of (depending on the order) shipped separately in their own crate or crates:

• Scraped Surface Heat Exchanger.

• Frame poles (including attached hydraulic cylinder) with

raulic pump & reservoir assembly(s).

hyd

• Accumulators, Refrigeration Valves and Piping, if furnished.

• Mount plates, nuts & bolts, and interconnecting product

ing.

pip

Page 8 95-03057 11/2012

Page 11

Waukesha Cherry-Burrell Installation

Installation

Site Selection Considerations

Clearances

Foundation & Drainage

The Votator II should be located on a firm foundation, angled to allow liquids to drain away from the unit.

•The rear and sides of the unit, or unit cluster, should have

adequate clearance to provide easy access for maintenance.

•The

front of the Horizontal unit should have the following minimum clearances to allow for removal of the mutator shaft:

6 x 84 Votator II - 102 in (259 cm) 6 x 72 Votator II - 90 in (230 cm) 6 x 48 Votator II - 71 in (180 cm) 6 x 36 Votator II - 59 in (150 cm) 6 x 24 Votator II - 40 in (102 cm)

bottom of the Vertical unit should have the following minimum clearances to allow for removal of the mutator shaft:

6 x 84 Votator II - 96 in (244 cm) 6 x 72 Votator II - 84 in (214 cm) 6 x 48 Votator II - 66 in (168 cm) 6 x 36 Votator II - 54 in (137 cm) 6 x 24 Votator II - 48 in (122 cm)

Leveling the Unit

Electrical Power Connections

DANGER: The Votator with high voltage. Electrical work should be performed by a Licensed Electrician in accordance with local regulations.

II operates

The Horizontal Votator II should be leveled lengthwise (along the length of the cylinder) and crosswise by adjusting the feet on the legs.

For units that will perform CIP, s

0.3 degrees (1/16 inch per foot). If CIP is not required, set the level to w

drainage for the cylinder.

The following electrical components for the Votator II require connection in accordance with the electrical schematics in this manual, tagged vendor specifications, and local regulations:

• Drive Motor

Each cylinder is furnished with a motor with a horsepower rating per the application: Std. Votator II accepts 7-1/2 HP (5.5 kW), 10 HP (7.5 kW), 15

(11kw) or 20 HP (15 kW); Extra Heavy Duty Votator II

HP accepts 25 HP (18.8 kW), 30 HP (22.5 kW) or 40 HP (30 kW). Motor is fixed speed and suitable for use with a variable frequency controller.

• Hydraulic Pump Motor (Ver A 3/4 (0.5 kW) horsepower, fixed speed motor . A variab le fr e-

quency controller s

hould not be used for this motor.

et the level for a forward pitch of

hat will give the best

3-phase, multi-voltage gear

tical units only)

11/2012 95-03057 Page 9

Page 12

Installation Waukesha Cherry-Burrell

• Refrigeration Valves: liquid feed solenoid valve dual pressure regulating valve level switch hot gas pressure regulating valve hot gas solenoid valve

• Fre

eze Protection Components (if furnished):

current sensing instrument current transformer digital current indicator

relay

Mutator Rotation Check

Mechanical Seals

Figure 2 - Single Mechanical Seal

Correct mutator shaft rotation is counterclockwise when looking down the unit from the drive end (indicated by a sticker located near the motor). To check for correct rotation, momentarily start the drive motor and observe the rotation of the shaft in the back of the unit.

If rotation of the shaft is incorr incorrectly. Have a Licensed Electrician change the wiring so the rotation of the shaft is correct.

The Votator II is furnished with either a single or double mechanical seal on both ends of the mutator shaft. Units furnished before 2005 were installed with either a single or double mechanical seal configuration. See “2005 Mechanical Seal Design” on page 11 for units furnished between 2005 and

2012. See “2012 Mechanical Seal Design” on page 11 for

standard units finished from 2012 to the present. Certain

its have also been supplied with a special "Ball-lock

Votator Mechanical Seal" or a "Packing Gland" instead. Consult your order documentation to verify the specific seal configuration for each Votator II unit.

II un

ect, the dr

ive motor is wired

Single Mechanical Seal

The single mechanical seal is normally not flushed but it can be. It is shipped with a lip seal (See Figure 2) designed to contain water or a liquid flush. The spring in the seal must be removed and the seal reinst This will minimize any damage to the contact surface on the stub end of the shaft.

alled with the lip in the relief position to allow flushing.

When the single mechanical seal is product or water flow to provide cooling to the rotating surfaces to avoid permanent damage to the seal assembly.

If the seal is flushed, the fluid flow shou 10 gallons per hour and not exceed 5 psig. Piping to seals should be in the bottom of head and out the top and with parallel flow, never in series.

Figure 3 - Double Mechanical Seal

Page 10 95-03057 11/2012

Double Mechanical Seal

The double mechanical seal is furnished with a primary seal for product and a secondary seal to contain a steam or water flush.

rotating,

there must be

ld be in the range of 5 to

Page 13

Waukesha Cherry-Burrell Installation

HE100-118

HE100-117

2005 Mechanical Seal Design

Units furnished between 2005 and 2012 have a one-piece chrome-oxide coated rotating body running against a stationary ceramic head insert. It can easily be converted to a double mechanical seal by adding secondary components to contain a steam or water flush.

Figure 4 - Single Mechanical Seal

Figure 6 - 2012 Single Mechanical

Seal

Figure 5 - Double Mechanical Seal

2012 Mechanical Seal Design

Standard units furnished starting in 2012 have removable rotary seal faces in solid carbon, silicon carbide, tungsten carbide, and narrow-face tungsten carbide materials. The stationary seal faces are made of solid ceramic or silicon carbide. Like the 2005 design, the 2012 single mechanical seal can be converted to a double mechanical seal by adding secondary components to contain a water or steam flush.

Figure 7 - 2012 Double Mechanical Seal (shown with Narrow-

Face Rotary)

11/2012 95-03057 Page 11

Page 14

Installation Waukesha Cherry-Burrell

Flush Fluid Requirements

The double mechanical seal must be flushed, using the threaded flush ports, anytime the mutator shaft is rotated. Failure to do this will result in rapid seal failure due to excessive contaminate and heat buildup.

The fluid flow should be in the range of 5 to 10 gallons per hour, at a typ composition and temperature should be selected to dissolve or suspend any product leakage and cool the mechanical seal faces, and should also be compatible with the sealing o-ring material. Piping to seal cavities for horizontal units should be in the bottom of head and out the top, piped with parallel flo w, never with multiple seal cavities in series flow.

ical temperature of 80°F - 120°F (25°C - 49°C). Fluid

Piping

CAUTION: The safety valve should be installed on the discharge side of product pump for safety and equipment protection.

DANGER: Do not install any positive shutoff valves downstream of the Votator II unit.

WARNING: Do not allow a volume of liquid to become isolated in the jacket without relief protection. Thermal expansion created as liquid warms can generate enough force to crush tube, causing damage to internal components and drive system.

Suggested Media Piping for Steam

Guidelines for Piping

Refer to the general assembly drawings in this manual for jacket connection sizes and locations, and suggested media piping drawings.

• Support ALL piping independently.

• Provide for line expansion and contraction.

• Install a safety valve to protect jacket.

• Provide temperature indicators on both sides of Votator II

it.

• Provide pressure gauge on discharge side of pump.

• When using liquid coolant, provide a method to introduce

ating media into jacket to thaw overcooled product.

• Provide liquid coolant system bypass line around unit to allow

lant system to be brought down to operating temperature

coo without circulating coolant through jacket.

The steam solenoid is opened, which lets pressure controlled steam from the boiler into the jacket. A temperature sensor monitors the temperature of the product and regulates the steam flow to achieve the required temperature. Heating of the product takes place when the steam condenses into water from the transfer of heat through the jacket.

Page 12 95-03057 11/2012

Page 15

PITCTYTEPI

HE100-056

Waukesha Cherry-Burrell Installation

HE100-057

Table 1: Call Outs For Figure 8

1. Steam IN

2. Strainer

3. By-Pass Line

4. Steam Pressure Regulator

5. Steam Solenoid

6. Temperature Regulator

7. I/P

8. Temperature Control

9. Product OUT

10. Product IN

11. Drain Valve

12. Condensate Trap

Figure 8- Suggested Media Piping, Steam

Suggested Media Piping for Water or Liquid

The media piping should flow counter-current to the product flow, and should be circulating at a rate of 50 gpm. The suggested arrangement automates the source flow to the actual heat exchange requirements to provide maximum control of the process.

Table 2: Call Outs For Figure 9

1. Media IN

2. Product OUT

3. Product IN

4. Temperature Regulator

5. Media OUT

6. I/P

7. Temperature Control

Figure 9 - Suggested Media Piping, Water or Liquid

11/2012 95-03057 Page 13

Page 16

Installation Waukesha Cherry-Burrell

Refrigeration Piping Installation

WARNING: Ammon lines should be installed by fully trained and qualified Refrigeration Piping Specialists.

CAUTION: A auxiliary receiver should be installed in the line to prevent carry-over back to compressor.

ia or Freon

suction trap or

Analyze plant refrigeration load capacity thoroughly. The system must be sized to adequately support the additional capacity of this cylinder. All pipes must be clean and free of oil, chips and sealant residue. Excessive residue in plant piping can foul and clog cylinder refrigeration valves and components, causing costly delays in start-up. Refer to appropriate piping schematic in this manual for Liquid Overfeed (LOF) or Gravity Refrigeration System.

Liquid Line Installation

The liquid line should be installed to provide a constant and steady flow of liquid. Check with system requirements and plant capacities to ensure that refrigeration piping is sized properly.

Suction Line Installation

All Votator II refrigeration units operate best when provided with constant suction pressure. To ensure constant pressure do the following:

• Size suction header for at least 50% above rated capacity of

inder.

cyl

• Do not connect to a header already in use by other

uipment with widely varying loads.

• Insulate any suction line that passes through a cold room to

prevent condensate formation. Install a trap or auxiliary receiver in the line.

• Keep suction pressure at compressor as low as possible.

ower pressure allows greater cooling capacit y.)

DANGER: Never ins valve on this line. Never vent or connect relief line back to suction line.

CAUTION: The factory set for appropriate pressure and never needs adjusting.

tall a shut-off

relief valve is

Hot Gas Line (if required)

Review the following guidelines when connecting a hot gas line to the system:

• Connection of a hot gas line should be from compressor high

sid

e of line past oil trap or separator to minimize drawing in

oil.

• DO NOT run line through a cold room or beside a cold

suction line.

• Slope line away from equipment at 1/8 inch per foot (1 mm

r 100 mm) minimum.

• Install a strainer or filter in add

valves and pressure gauge.

ition to recommended shut-off

Pressure Relief Line

The pressure relief line MUST be exhausted to the outside of the building.

Never cap relief line or tie back to suction line.

Page 14 95-03057 11/2012

Page 17

Waukesha Cherry-Burrell Installation

Refrigeration Valves

Liquid Feed Solenoid V alve

Liquid Feed Solenoid Valve is for on/off control of liquid refrigerant flow. Valve is closed when de-energized.

Dual Pressure Regulating Valve

Dual Pressure Regulating Valve is shipped loose for installation in vapor line on discharge side of refrigeration piping. Valve regulates high-pressure for internal relief and low-pressure with on/off solenoid valve for process control. It can be furnished for manual regulating, pneumatic control with clean, dry, and oil free air from 0-60 psig, or with a 115 volt motor mounted on the regulating pilot that responds to a 4-20 milliamp electrical signal. When using air, a decrease in pressure will lower the inlet pressure producing a lower temperature.

Sporlan Level Master Control (LMC) or Level Switch

Gravity Systems with Accumulator are furnished with a Sporlan Level Master Control (LMC) or a Level Switch.

The LMC is a thermostatic expansion valve with a 15-watt heater ele

ment. As the level in the accumulator drops, the electrically added heat increases the pressure within the thermostatic element and opens the valve. As the liquid level rises, the electrical input is balanced by the heat transfer from the bulb to the liquid refrigerant and modulates or shuts off the liquid flow. Minor adjustments in the level response can be made by adjusting the spring tension of the expansion valve seat.

If a refrigerant level float switch is p depending upon specifications, it is used to control the accumulator level by opening or closing a solenoid operated refrigeration valve. These systems contain that valve and an expansion valve with a flow indicating scale.

rovided, single or double

Refrigerant Return Valve

Some Horizontal Votators have a solenoid operated Refrigerant Return Valve that is in the closed position when the solenoid is de-energized. This valve is used to stop the cooling process and is closed if hot gas is applied.

High capacity freon systems have two hot gas to activate the return valve, the other to bleed th e ga s to the suction line.

solenoid valves: one for

Flow Control Valves

Liquid Overfeed (LOF) or Pumped Refrigeration Systems have a manually adjusted Flow Control Valve with setting scale for refrigerant flow to each Votator cylinder. This valve maintains a constant flow of liquid to the Votator and can serve as a check valve to prevent back flow of liquid during hot gas.

The indicator scale on the valve corresponds to the refrigeration

nage. The regulator is set by multiplying the tonnage load by

ton the desired re-circulation rate. For example, if the refrigeration load is 10 tons and 200% (3:1) overfeed is desired, the valve should be set at 30 on the scale reading.

11/2012 95-03057 Page 15

Page 18

Installation Waukesha Cherry-Burrell

SSS

HE100-053a

Hot Gas Pressure Regulating Valve

Systems with hot gas include a solenoid-operated Pressure Regulating Valve for introducing and maintaining constant downstream pressure for hot gas inlet.

Pumped Refrigeration Systems include a solenoid operated Hot

Purge Valve for each Votator hot gas discharge line.

Gas

Pressure Relief Valve

DANGER: Never install a shutoff valve in a relief line.

Suggested Media Piping for Liquid Over Feed Refrigeration

This valve is located on the accumulator and should be exhausted to outside the building. The valve is factory set to relieve at the design pressure of the accumulator.

The liquid feed solenoid valve, when opened, allows liquid refrigerant to flow into the jacket of the heat exchanger. The flow is regulated by a manually set flow control valve. Cooling is achieved when the pressure control valve is opened, causing the pressure in the jacket to be reduced. This causes the liquid refrigerant to change phase, absorbing heat from the heat exchanger tube and product. The cooling rate is controlled by the back pressure on the system and stops when the valve is closed. Hot gas is used to push all of the remaining liquid from the system into the ammonia low pressure receiver and quickly warm the system. The low pressure receiver in the compressor room is designed to separate the liquid from the vapor before recompressing.

Figure 10- Suggested Media Piping, Liquid Over Feed or Pumped Refrigeration

Page 16 95-03057 11/2012

Page 19

Waukesha Cherry-Burrell Installation

562

151617

HE100-061a

Level Switch Control

Level Master Control

Table 3: Call Outs For Figure 10 (on page 16)

1. Safety Relief Valve 10. Dual Pressure Regulating Valve (includes Items 4, 8 and 9)

2. Product IN 11. To Refrigerant Low Pressure Receiver

3. Product OUT 12. Hot Gas Purge Valve

4. Low Pressure Solenoid Valve, see Item 10 13. Flow Control Valve

5. Hot Gas 14. Liquid Feed Solenoid Valve 6/7. Electric Control Signal or

Regulated to 60 PSI

8. Low Pressure Regulating Valve, see Item 10 17. Hot Gas Solenoid Valve

9. High Pressure Regulating Valve, see Item 10 18. Hot Gas Pressure Regulating Valve

Instrument Air

15. Liquid Refrigerant from Low Pressure Receiver

16. Hot Gas Reducing Valve

Suggested Media Piping for Gravity Refrigeration

Liquid refrigerant from the receiver is stored in a surge drum located above the Votator II. The level in the surge drum is automatically controlled by the level system provided with the equipment. Gravity forces the refrigerant into the cooling jacket where it comes into contact with the heat transfer tube. The warm product causes a portion of the liquid refrigerant to change phase, causing the heat transfer tube an d th e pr od uc t t o be cooled. The cooling rate is controlled by the refrigerant back pressure, and hot gas can be used to push the liquid refrigerant from the Votator cylinder and rapidly warm the system.

NOTE: Set

tlet pressure of hot gas pressure reducing valve and lowe r than

high pressure regulating valv e 5 t o 10 psi highe r th an

the relief setting.

Figure 11 - Suggested Media Piping, Gravity Refrigeration - HORIZONTAL

11/2012 95-03057 Page 17

Page 20

HE100-060a

Level Switch Control

Level Master Control

Installation Waukesha Cherry-Burrell

1. Safety Relief Valve (Dual) 12. Liquid Refrigerant from Low Pressure Receiver

2. Low Pressure Solenoid Valve, see Item 14 13. Level Control and Liquid Feed Expansion Valve or Level Switch

3. High Pressure Regulating Valve, see Item 14 14. Dual Pressure Regulating Valve (includes Items 2, 3, and 20)

4. To Low Pressure Receiver 15. Hot Gas Reducing Valve 5/6. Electric Control Signal or Instrument Air

Regu

lated

7. Level Control Heater 18. Drain Valve

8. Normal Operating Liquid Level 19. Product IN

9. Product OUT 20. Low Pressure Regulating Valve, see Item 14

10. Liquid Feed Solenoid Valve 21. Refrigerant Return Solenoid Valve (Horizontal only)

11. Block Valve 22. 1/4" Needle Valve with Regulating Stem (Horizontal only)

Figure 12- Suggested Media Piping, Gravity Refrigeration - VERTICAL

Table 4: Call Outs for Figure 11 (page 17) and Figure 12

to 60 PSI

16. Hot Gas Solenoid Valve

17. Hot Gas

Page 18 95-03057 11/2012

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Waukesha Cherry-Burrell Installation

Electrical Equipment

ITEM #

NO. OF

CYLIND

1 1

3 3 1 1

3 1 1 1

3 3 1 1

3 1 1 1

3 1

QTY DESCRIPTION

ERS

Cylinder Drive Motor(s) X2 2

Motor Starters: Customer responsible for correct sizing of starter, overload protection based on motor nameplate voltage, frequency, FLA’s, service factor, and horsepower.

Current sensing relay and plug-in base set at motor nameplate FLA’s (R-K Electronics CJD-120A-5 or equal) (Plug-in base = A-B 700-HN 125 or equal)

Cylinder Start/Stop push buttons (Start = A-B 800H-AR1A or equal) (Stop = A-B 800H-BR6D2 or equal)

3-Position selector switch Labeled: "REFRIGERANT SYSTEM MODE" "DEFROST OFF ON" Red, push to test, pilot light Labeled: "REFRIGERANT CONTROLS ON" (A-B 800

2-Position selector switch Labeled: "VOTATOR REFRIGERATION" "OFF ON" Red, push to test, pilot light Labeled "VOTATOR REFRIGERATION ON" (A-B 800

Digital current indicator (1/8 DIN) 1.77" x 3.62" Panel Cutout Labeled: "PERCENT FULL LOAD CURRENT" (Red Lion APL-ID-400 or equal)

Instrument transformer (Ohio Semitronics CTD-050A or equal)

The electrical components, if furnished by Waukesha CherryBurrell, are loose and require installation by customer.The list below is keyed to the suggested wiring diagrams on the following pages and describe typical components used in analog control panels.

If a Votator PLC Control Panel was purchased for the Votator II unit, Ite

m 3 below is furnished loose for inclusion in Buyer’s high voltage panel and Items 7 and 8 are not needed. The PLC panel for Votator II refrigeration units duplicates the control operation shown on the following pages; it serves as the operator station for the Votator II line. See the pertinent manual pages for operating instructions for the PLC panel.

FURNISHED BY

SPX Others

il, and thermal

X2 1

H-JR2A/800H-PRTH16R or equal)

H-HR2A/80

0H-PRTH16R or equal)

X2 1

X2 2

X2 1

1 1

3 1

Red, push to test, pilot light Labeled: "DEFROST ON" (A-B 800H-HR2A/800H-PRTH16R or equal)

X2 1

11/2012 95-03057 Page 19

Page 22

Installation Waukesha Cherry-Burrell

CURRENT

SENSE

RELAY

CURRENT METER

II-XX

1 2 34567 98

TRIP CURRENT = ADJUST SLIGHTLY

BELOW MAXIMUM OR FULL LOAD

FINE TUNING TO BE DONE AT SYSTEM STARTUP.

SEE PRODUCT INFO FOR FURTHER INSTRUCTIONS.

IF CURRENT LEVEL IS TOO LOW, MULTIPLE PASSES

THRU CT RAISES EFFECTIVE CURRENT LEVEL.

1 PASS - 1A=1A

2 PASS - 1A=2A

3 PASS - 1A=3A

HE100-100

Refrigeration Wiring Schematics

Freeze Protection Components

Figure 13- Suggested Electrical Schematic - Freeze Protection Components

Page 20 95-03057 11/2012

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Waukesha Cherry-Burrell Installation

HE100-101a

Gravity Refrigeration with Level Master Control (LMC)

Figure 14- Suggested Electrical Schematic - Gravity Refrigeration with Level Master Control (LMC)

11/2012 95-03057 Page 21

Page 24

Installation Waukesha Cherry-Burrell

HE100-108

Gravity Refrigeration with Level Switch

Figure 15- Suggested Electrical Schematic - Gravity Refrigeration with Level Switch

Page 22 95-03057 11/2012

Page 25

Waukesha Cherry-Burrell Installation

HE100-102

Liquid Overfeed Refrigeration System

Figure 16- Suggested Electrical Schematic - Liquid Overfeed Refrigeration System

11/2012 95-03057 Page 23

Page 26

Installation Waukesha Cherry-Burrell

Media System Check

DANGER: Refrigeration controls should be operated and serviced only by trained and qualified personnel.

Each cylinder is tested for leaks at the factory. vibrations and handling during shipping can loosen piping connections. Before starting a new unit, the system should be checked for media leaks at the Votator II cylinder, the media connections, and the piping to the cylinder using the following procedures:

On units jacketed for steam or liquids, follow steps 1 through 6,

d then

an On units jacketed for refrigeration, follow steps 1 through 6, and

then

1. If a media pressure gauge is not inst

2. Close off media return line from unit.

3. Open media inlet valve and let pressure increase to 5 psig,

4. Check front, back, and all piping connections for leaks.

5. If leaks are not detected, open inlet valve and let

drain condensate from cylinder.

pump down to remove refrigerant.

one at the media inlet of cylinder before processing.

then

close valve.

pressurize to 40 to 50 psig, then close valve.

However,

alled in system, install

system

Special Considerations for Vertical Votator II

Minimum Height - Vertical Votator II

Mounting Pole - Vertical Votator II

6. Check again for leaks at front, back, and all piping connections.

The customer is responsible for securing the top and bottom of the pole and scrape assembly. See "Votator II Vertical Mounting Suggestions" in Addendum Section.

The mounting pole with hydraulic components is assembled at the factory to provide the proper height from the floor when installed. Therefore, never trim the pole from the bottom. Check to be sure the cylinders will be positioned with minimum clearance to insure shaft can be removed correctly. See “Clearances” on page 9.

Attach post mount to floor. (Stainless steel disk which serves as base for pole.) There is a 13/16" diameter hole thro ugh the center of the disk for mounting it to the floor. Make sure post mount is level after installation.

Prepare site for attaching top of pole. Top of pole can be trimmed if needed.

NOTE: When installing pole, make sure toward same side scrape cylinders will be mounte d on.

Put bottom of pole over post mount and raise.

hydraulic cylinder faces

Attach top of pole to top mounting.

NOTE: Po

Figure 17 - Mounting Disk

Page 24 95-03057 11/2012

le MUST be vertical and plumb.

Page 27

Waukesha Cherry-Burrell Installation

Mounting Scrape Cylinders -

Vertical

Votator II

Hydraulic System - Vertical Votator II

Using a crane or other lift device, lift cylinder from pedestal (drive) end. Lifting in any other manner may damage cylinder.

Secure scrape cylinders in place with four (4) stainless steel 5/8inch bo between protective cap and floor. See “Clearances” on page 9.

The Vertical Votator II is furnished with a hydraulic cylinder, pump, motor, and fluid reservoir for removing and installing the mutator shaft and heat transfer tube.

Check all fittings and adjustments prior to use; vibrations during shipmen

lts and lock washers provided. Maintain minimum distance

t may cause them to loosen.

Check and Adjust Hydraulic Cylinder

After heat exchanger cylinders are mounted to the pole, check to ensure the proper distance is maintained between the bottom of the hydraulic cylinder and the floor. See "Vertical Mounting Pole/ Hydraulics" on page 32.

Fill Hydraulic Reservoir

The system is pre-piped, but requires approximately two (2) gallons of Dexron II ATF (ISO VG 32/68) to be added before use. Please consult the factory if it is necessary to substitute fluids.

CAUTION:

Mixing fluids will damage equipment.

Do not mix fluid types.

Figure 18- Removal of Reservoir

Remove reservoir from pump assembly and fill return line. Reservoir is sealed with an O-ring and secured by a clamp ring (See Figure 18, Item A). Pump return line (Figure 18,

the

item B) must be removed to access

reservoir.

to opening for

11/2012 95-03057 Page 25

Page 28

Installation Waukesha Cherry-Burrell

‘

Figure 19 - Direction Valve

Check Balance and Pressure Settings

Balance and pressure settings should be checked prior to startup as follows:

1. Start hydraulic pump.

NOTE: T device. Pump rotation is clockwise when viewed above motor.

2. Make sure Direction Valve (See Figure 19 - located on front

3. Make sure the Balance Valve (See Figure 20 - located on the

4. Check hydraulic pump pressure by moving hydraulic lift foot

he hydraulic pump must be wired to an on/off switch

of unit just above bottom product outlet) is functioning

operly. It is spring loaded and is moved up for up travel of

pr hydraulic cylinder and down for down travel.

front of the unit, just above the Direction Valve) is set in closed place with a 9/16" jam nut and adjusted with a 5/32" Allen Head set screw. It maintains pressure on hydraulic cylinder when hydraulic pump is off or in neutral position.

a dead head position. At this point, it should be adjusted for a gauge reading of 300 to 400 psig at the pump.

position, which is fully clockwise. Valve is locked in

way from Votator II unit and running cylinder in the full up,

Figure 20 - Balance Valve

Figure 21 - Pressure Adjustment

Screw

5. The pump pressure control (See Figure 21 , Item A) should be set to approximately 4-1/2 turns open in the counterclockwise

ection from the closed position. This adjustment controls

dir the system pressure and is at maximum when the setscrew is in the closed or full clockwise position. It is adjusted by a 3/ 16" Allen Head set screw and locked by a 9/16" jam nut.

Page 26 95-03057 11/2012

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Waukesha Cherry-Burrell Installation

Gravity Refrigeration System -

Vertical Votator II

The Gravity Refrigeration System includes the following items that must be installed:

• Accumulator

• Media piping

• Valves The accumulator, refrigeration piping, and valves are shipped

se for field installation, as shown in the drawing titled Vertical

loo Refrigeration System located in the addendum section and Votator II Vertical Refrigeration System drawing on page 18 showing the Process Flow Diagram of the Vertical Refrigeration

tem. It is necessary for on-site installation of these

Sys components to insure that the refrigeration system will mate properly with the Votator II cylinders.

A crane, or other lift device, is nee mounting bracket in place for installation. Lift the mounting bracket in place with a sling. Bolt the accumulator to the pole.

To simplify installation, piping is pr

• the accumulator to the lower manifold

• the lower manifold to the cylinder flange

• the upper manifold to the accumulator Also included are an elbow for the top of the accumulator and

ing legs for connecting the modules.

pip

ded to lift the accumulator

ovided in three modules:

The refrigeration valves and level control are packed and shippe d sep

arately. These components and the piping sections should be installed in accordance with the referenced drawings. A leak test MUST be performed after all welding is complete.

After a leak test has been successfully completed, the system

ing should be coated with a paint formulated for corrosion

pip resistance.

11/2012 95-03057 Page 27

Page 30

Installation Waukesha Cherry-Burrell

Votator II General Assembly

95 REQ'D FOR SHAFT REMOVAL

7-3/16”

(183mm)

7-1/4”

(181mm)

21-5/16”

DIM "C

DIM "B"

9”

DIM "A" (APPROX.)

DIM "D"

DIM "F"

DIM "H"

DIM "D"

3" 3"

30°

6-3/4"

SHAFT

ROTATION

PRODUCT

CONN. "E"

PRODUCT

CONN. "E"

GEAR HEAD MOTOR

SEE PROPOSAL FOR

VOLT., HP, & RPM

MEDIA CONN. "J"

MEDIA CONN. "G"

OIL DRAIN VALVE

(RFG CYL. ONLY)

5/8" - 11

THREADS

SHAFT HEATER OPTION

(SEE SEPARATE DWG)

MEDIA CONN. "E"

LOCATION FOR VERT.

APPLICATION ONLY

6 x 36

CYLINDER

DIM "A" DIM "B" DIM "C"

6 x 48

6 x 72

119-9/16"

(3037mm)

59-7/8"

(1521mm)

61-1/2"

(1562mm)

95-9/16"

(2427mm)

35-7/8"

(911mm)

37-1/2"

(952mm)

83-9/16"

(2122mm)

23-7/8"

(606mm)

25-1/2"

(648mm)

CYLINDE

DIM "F"CONN. "G"D

IM "H"RFGLIQUIDST

EAM

0-1/2

"(2

mm)

7-5/16"(186mm)1-1/2

" RFG1-1/2" FPT

8-1/4"(210mm)

CONN. "J"

1-1

FPT2-1/2

FG1-1/2" FPT1-1

FLANG

CONN. "E"

PRODUCT CONN.

DIM "D"

3" I-LINE

7-11/16"

(195mm)

MEDIA CONN.

"J"

LOCATION FOR VER

APPLICATION ON

(76mm)

(171mm)

(229mm)

(541mm)

10-1/

(267m

)

7-5/16"

(186mm)

8-1/4"(210m

)

E10

6 x 24

67-3/8"

(1710mm)

13-1/8"

(330mm)

22-3/16"

(560mm)

6 x 84

131-9/16"

(3342mm)

71-7/8"

(1826mm)

73-1/2"

(1867mm)

FLANGED 8-1/4"(210mm

)

*Dimensions will vary slightly depending on type of motor horsepower.

Typical Dimensional Data and Hydraulic Lift System

Votator II General Assembly

Page 28 95-03057 11/2012

Page 31

Waukesha Cherry-Burrell Installation

DIM "G

DIM

"H"

MULATORS BEAR

.S.M.E. S

TAMP FOR COMPLIANCE

WITH

SYSTEMS FOR L

EAK

S WITH AMMONIA

GAS

AT 75

PSI (

5.2 BAR).

. BOILER AND PRESSURE VES

L CODE.

3" S

UCTIO

OIL

DRAIN

4" FPT

ELEC

. CO

NN.

1/2

" FPT

) HOL

(

)

104"

(264

2mm)

(

)

(

)

(

)

(

)

UMB

ER OF

(

)

(10

2mm)

(

)

DIM

12"

(30

5mm)

M "G"

(

)

16"

(40

6mm)

(

)

26"

(66

0mm)

(

)

(

)

IM "J"

(

)

(

)

(

)

(229m

)

2 CU

(57

. RFG

ARGE

(

)

(

)

(

)

(

)

orizontal Ref

geration As

sem

HE100-048

Horizontal Refrigeration Assembly

11/2012 95-03057 Page 29

Page 32

Installation Waukesha Cherry-Burrell

”

(

)

”

)

”

(

)

(

)

(

)

(

)

(

)

HOLD

(

)

EF(

127mm)4-5

/16

" REF(109mm)1

'-6" RE

(

57mm)

" R

F(229mm

)

”

(

)

”

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

HE100-046

Vertical Refrigeration System

Page 30 95-03057 11/2012

Page 33

Waukesha Cherry-Burrell Installation

10”

DIM "A"

DIM "B"

DIM "D"

DIM "E"

DIM "F"

DIM "G"

DJU

T. LE

G 5" - 6"(1

27-

152mm

)DIM "K

DIM "C"

DIM "J"

DIM "H"

1 CYL

CONFIGURATION

(BETWEEN CENTERS)

DIM "B" DIM "C"

NA 20"

(508mm)

22"

(559mm)

CYLINDE

6 x 246 x 486 x 72 63-1/2"(1613mm) 3-1/2"(89mm) 18-3

/4"

(476m

)

DIM "

F" 32"(813mm) 39-1/2"(9

78mm)DIM "G" 67-1/2"(1715mm) 36"(

914mm

) 43-1/2

"(110

)DIM "H

FRAME

(SINGLE ROW)

2 CYL

38"

(965mm)

18"

(457mm)

40"

(1016mm)

(1 OVER 1)

2 CYL

54"

(1372mm)

36"

(914mm)

DIM "D"

30"

(762mm)

40-3/4"

(1035mm)

22-3/4"

(578mm)

DIM "K"

DIM "A" DIM "E"

(BETWEEN CENTERS)

(2 OVER 2)

3 OR 4 CYL

/2"(9

52mm) 61-1/2

"(1562mm)

M "J"

25-1/2"(648mm

)

LENGT

Votator II Horizontal Frame Optio

(254mm)

18"

(457mm)

20"

(508mm)

38"

(965mm)

22"

(559mm)

40"

(1016mm)

36"

(914mm)

54"

(1372mm)

30"

(762mm)

22-3/4"

(578mm)

40-3/4"

(1035mm)

HE1

0-0

49 18-

3/4"(476mm)6 x 36 14-1/4"(362mm) 32"(813mm) 36"(

914mm) 25-1/2"(648mm)6 x 84 75-1/2"(1918mm) 79-1/2"(2019mm

) 73-1/2

"(1867mm) 24-3/4"(629mm)

Horizontal Frame Options

11/2012 95-03057 Page 31

Page 34

Installation Waukesha Cherry-Burrell

Votator II Vertical Mounting Pole/Hydraulics

DIM "A"

3-15/16”

(100mm)

12-5/8”

(321mm)

FRONT

VIEW

SIDE VIEW

1. TOP OF THE POLE TO BE ATTACHED/SUPPORTED BY

THE CUSTOMER. 2. CUSTOMER MAY CUT OFF TOP OF POLE TO COMPLY

WITH CONSTRUCTION NEEDS. 3. THE CUSTOMER IS RESPONSIBLE FOR MOUNTING THE

SCRAPE UNITS. 4. FOR SUGGESTED MOUNTING SCHEMES FOR THIS SYSTEM

SEE INCLUDED DRAWING. 5. SHAFT STOP CLAMP SHIPPED LOOSE WITH UNIT .

6. SEE VII HYDRAULIC SCHEMATIC.

BOTTOM OF THE POLE

TO BE SECURED TO

THE FLOOR WITH A 3/4

INCH LAG BOLT OR 3/4

STUD WITH A NUT ON IT.

RESERVOIR NOT SHIPPED

WITH HYDRAULIC OIL.

CUSTOMER WILL NEED TO

FILL RESERVOIR PRIOR TO USE.

TO INSTALL PUSH-PULL ROD

YOU WILL FIRST HAVE TO

UNSCREW THE ACTUAT OR HANDLE

FROM THE SHEAR VALVE.

THEN INSERT THE THREADED END

OF THE HANDLE THROUGH THE

EYELET OF THE PUSH-PULL ROD.

SCREW THE HANDLE BACK

INTO THE SHEAR VALVE.

APPROX

SHIP LOOSE

APPROX

CYLINDER

6 x 24

6 x 48

6 x 72

91-7/16"

(2323mm)

43-7/16"

(1103mm)

67-7/16"

(1713mm)

DIM "A"

LENGTH

SHAFT STOP CLAMP

(SEE NOTE #5)

HE100-047

6 x 36

55-7/16"

(1408mm)

6 x 84

103-7/16"

(2627mm)

Vertical Mounting Pole/Hydraulics

Page 32 95-03057 11/2012

Page 35

Waukesha Cherry-Burrell Installation

YLINDER

DIRECTIONAL

VALVE

POWER

UNIT

COUNTER BALANC

VALVE

HE100-051

Vertical Hydraulic Schematic

11/2012 95-03057 Page 33

Page 36

Operation Waukesha Cherry-Burrell

Operation

Pre-Startup Check

These instructions are general and should be used only as a guide. It may be necessary to modify them to conform to actual in-plant requirements. Changes should be documented by plant personnel.

Before starting Votator

WARNING: Do no equipment without guards and interlocks properly installed.

II, perform the following system checks:

t operate

• Check that Votator II is properly assembled. All product connections, and heating/cooling media connections should be assembled and tight.

• If steam or water flush is required for mechanical seals, ope n

ply valve and set pressure and flow rate.

sup

• Momentarily start motor (1-3 seconds) to determine if shaft is rotating. determine why shaft will not turn.

• Check heating/cooling media to determine if temperature and pr supply of heating/cooling media.

• Check to determine if product is available and pressures ar e at re

If shaft is not rotating, turn off power to motor and

essure are at required values and there is an adequate

quired values.

For Refrigeration Units Only

• Check that main suction line is fully open.

• Check for proper compressor back pressure.

• Open liquid refrigerant supply valve, turn system refrigerant on and

verify that accumulator is full to float level.

Pre-production Run Setup

CAUTION: The Votator II has not been passivated as part of the manufacturing process. If the heat transfer tube is chrome plated nickel, DO NOT expose to acid

or acid cleaners.

NOTE: The following steps are not applicable to asep tic unit s,

which require special sterilization procedures.

The interior of the Votator II heat e heads, and product piping leading to the unit should be sterilized before running product.

Use sanitizing solution compatible wit Votator II. If a chlorine solution is used, it must not exceed 50 ppm at 75°F (24°C) and surface contact must be limited to 10 minutes.

xchanger tube, mutator shaft,

h the materials of the

Page 34 95-03057 11/2012

Page 37

Waukesha Cherry-Burrell Operation

Startup Procedure

STARTUP SUMMARY

QUID/STEAM

Establish seal flush flow (if required). Check media availability. Start product or water flow. Start mutator shaft. Establish operating pressure (if

required). Admit steam/coolant flow. Switch to product flow (if necessary). Adjust media for desired product

temperature. Redirect product flow (if necessary).

Heating/Liquid Cooling Applications

1. Start product pump using product or compatible liquid, such

as water.

2. After product flow is established,

motor. Do not run Votator II without product flow.

3. Establish operating pressure.

NOTE: Main product characteristics. In heating applications, operating pressure should be at a minimum of 15 pounds above jacket steam pressure. This will eliminate internal boiling and fouling of product side of heat transfer cylinder.

4. Gradually admit dry, saturated steam or coolant to reach

system o valve and immediately open bypass valve at trap to drain condensate. Close bypass valve after all condensate is drained.

5. If running material other than product, switch to product and

6. When operating conditions have been reached, redirect

tain an operating pressure that will result in desired

perating temperature. For steam units, open steam

just to desired processing rate.

oduct to desired out-flow point.

start Votator II mutator shaft

STARTUP SUMMARY

REFRIGERATION

Establish seal flush flow (if required). Turn refrigerant "ON". Start product or water flow. Start mutator shaft. Establish operating pressure (if

required). Turn cylinder refrigeration "ON". Adjust refrigeration PSIG. Adjust media for desired product

temperature. Redirect product flow (if necessary).

Refrigeration Applications - Pumped and Gravity Systems

1. Start product pump using product or compatible liquid, such

as water.

2. After product flow is established,

motor. Do not run Votator II without product flow.

3. Turn cylinder refrigeration "on".

4. Adjust back pressure control valve on accumulator to

proximately 20 psig above normal operating pressure.

5. Gradually reduce setting on back pressure control valve to

tain proper product temperature.

6. If running material other than product, switch to product and

just to desired processing rate.

7. When operating conditions have been reached, redirect

oduct to desired out-flow point.

start Votator II mutator shaft

11/2012 95-03057 Page 35

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Operation Waukesha Cherry-Burrell

Shutdown Procedure

CAUTION: The steam or refrigeration supply valves must be shut off BEFORE stopping product flow. Failure to do this could result in product burn-on or freezing in heat exchanger cylinders.

Preventing Tube Scoring

These instructions are general and should be used only as a guide. It may be necessary to modify them to conform to actual in-plant requirements. Changes should be documented by plant personnel. Emergency Shut-Down procedures should be documented by plant personnel after assessing system-wide requirements.

Where product characteristics permit, the media flow and the pump. Otherwise, it may be necessary to heat or cool the product to ambient temperature to avoid burn -on or freeze-up.

In instances where product provide a surge tank or a recirculation line.

With continuous operations, a product line can enable steam to soften and remove product in the tube at shut down.

The final option is to have hot water chase product from the tube at the en

Scoring of the heat exchanger tube can have many causes. The most common are temperature extremes, material problems in the heat exchanger tube, or units operated without product or CIP flow.

d of the run.

goes to a filler, it may be necessary to

steam line connected to the

shut off the mutator shaft,

The following suggestions will help prevent tube

• Do not pump cold product cleaning (this can cause temporary bowing of the tube). Wait until the tube has cooled before running cold product.

• Do not leave sterilizing water or solution in the tube after sterilization is sterilizing water or solution. Fill the tube with product prior to starting.

• Make sure that condensate is drained completely in BWS

inders. The steam trap must be large enough to carry

cyl away all condensate.

complete. Drain the tube completely of

into a unit that is still hot from

scoring:

Page 36 95-03057 11/2012

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Waukesha Cherry-Burrell Maintenance

Maintenance

Routine Maintenance Checklist - Vertical Votator

1. Tools required:

• Rubber or plastic mallet

•

Large adjustable wrench (2-3/8 inch) or WCB model 79-2 Sanitary Wrench for removing the shaft locknut

• Two adjustable or open-end wrenches (15/16 inch) for removing the bearing clamp on the non-driven head

• One 3/8 inch nut driver and one common screwdriver for removing the shaft guard on the drive end

• One small common screwdriver for removing the keeper o-ring on the seal

2. Lock out power.

3. Drain product piping and disconnect.

4. Position hydraulic lift foot under bottom product head.

5. Loosen latch on bayonet lock and disengage hea d by rotating clockw

6. Lower mutator shaft to floor with hydraulic cylinder.

7. Check conditions of scraper blades and replace if necessary. Se

installed with flat side out.

8. If lower mechanical seal needs servicing, remove shaft from lift cra mutator shaft and raise mutator shaft so that the center of one set of blade pins is positioned in the middle of the bayonet ring.

ise.

rvice top mechanical seal, if required. Blades are

dle, or remove two scraper blades from mid section of

9. Install shaft lock clamp and secure with locking latch.

10. Lower hydraulic cylinder so that the clamp supports the

tator.

11. Remove the hinge clamp and bearing cap.

12. Remove shaft lock nut (lef supporting the product head and carefully removing it from the mutator shaft.

13. The mechanical seals are the same on to p and bottom, and if

icing is required:

serv

• Remove the keeper o-ring and all seal components, seal

dy with seal ring, backing ring, u-cup and wavy spring. If it is a double mechanical seal, the secondary seal and spring must be removed before disassembling the primary seal.

• Inspect o-rings and seal fac es for scratches or cra cks. If the seal parts require replacement, refer to pages 56 and 72 or pages 57 and 70.

• When assembling the single mechanical seal, place the wave spring on the shaft, followed by the seal backing ring and the u-cup with the opening of the cup facing the body of the shaft. Position the seal body and install the keeper o-ring.

t hand threads) while firmly

11/2012 95-03057 Page 37

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Maintenance Waukesha Cherry-Burrell

HE100-116

• When assembling the double mechanical seal, place the wave spring on the shaft and then the seal body with o-ring. Position the seal body and install the keeper oring, followed by the secondary seal and wave spring.

• Check all seal assemblies to verify that they are locked in position by the drive pins and that they can be easily compressed.

14. To remove the top product head, remove the sha ft guard held in place by four bolts, and rotate the head counter-clockwise to disengage. Check condition of the o-ring in the head before reinstalling.

15. Check the condition of the o-ring in the product head, lubricate it on the mutator shaft. The grease ring on the bearing

should be facing the product side of the head.

16. Seat bearing in head using a plastic mallet, if required, and install shaft lock

17. Apply anti-seize compound to the drive end splines and the ne

xt 3 inches of stub shaft length. Place the shaft and head

back into the lift cradle if necessary.

lightly, and carefully place the head with bearing

nut and bearing cap.

WARNING: To avoid same person should operate the hydraulic controls and guide the mutator shaft.

injury, the

Routine Maintenance Checklist - Horizontal Votator II

Figure 22 - Head Removal Tool

18. When installing the mutator the blades in the cylinder while the mutator is raised. It may be necessary to turn the mutator shaft slightly to align the spline in the motor drive.

19. Rotate the product head counter-clockwise to engage the bayonet lock, and close the locking hatch.

20. Grease bearing. (Not required for Extra He av y Duty Votator I

1. Tools required:

• Rubber or plastic mallet

•

• Two adjustable or open-end wrenches (15/16 inch) for

• One 3/8 inch nut driver and one common screwdriver for

• One small common screwdriver for removing the keeper

• Head Removal Tool (HRT), part number LL121191. (See

2. Lock out power.

I.)

Large adjustable wrench (2-3/8 inch) or WCB model 79-2 Sanitary Wrench for removing the shaft locknut

removing the bearing clamp on the non-driven head

removing the shaft guard on the drive end

o-ring on the seal

Figure 22.)

shaft in the unit, carefully guide

3. Drain product piping and disconnect.

4. Loosen latch on bayonet lock and disengage hea d by rotating

ise.

clockw

5. Lift head and pull assembly out about 1 inch, and rest the sha

ft on the heat transfer tube.

6. Remove the hinged clamp and bearing cap.

7. Remove shaft locknut (le

Page 38 95-03057 11/2012

ft hand threads).

Page 41

Waukesha Cherry-Burrell Maintenance

CAUTION: Failing to use the Head Removal tool can result in damage to the seal face. Use of the HRT prevents chipping the stationary seal face on the end of the shaft during removal or replacement of the head.

8. Insert the Head Removal Tool (HRT) through the b earing and

into the threaded end of the shaft, then slide the head ove r the tool so that the seal face is past the end of the shaft. Grasp the end of the tool and the head and carry it to a table or other stable work surface for further maintenance if needed.

9. Insert plastic shaft skid in unit, install on top

so skid is under shaft. Remove both shaft and skid from unit. Place on a table or cradle.

10. Remove product head on drive end (if required) by removing

shaft guard held in place by four bolts. Rotate the head

the counter-clockwise to disengage. Check the condition of the oring in the head before reinstalling.

11. The mechanical seals are the same on to p and bottom, and if

icing is required:

serv

• Remove the keeper o-ring and all seal components, seal bo

dy with seal ring, backing ring, u-cup and wavy spring. If it is a double mechanical seal, the secondary seal and spring must be removed before disassembling the primary seal.

• Inspect o-rings and seal fac es for scratches or cra cks. If the seal parts require replacement, refer to pages 56 and 72 or pages 57 and 70.

• Check all seal assemblies to verify that they are locked in position by the drive pins and that they can be easily compressed.

12. Inspect the condition of the scr necessary. Install the new blades while the shaft is on the cradle or table, attaching two rows of scraper blades on the top of the mutator, and place the shaft skid over the blades. Turn the mutator and shaft skid over so that the sk id is on bottom of the table or cradle, and install the other two rows of blades on top. Blades are always installed with the flat

side up.

aper blades and replace if

and rotate shaft

13. Apply anti-seize compound to the drive end splines and the

xt 3 inches of stub shaft length.

14. Use the shaft skid to slide the mutator in the heat exchanger cyli

nder and lift up the mutator slightly to remove the shaft

skid.

15. Check the condition of the O-ring in the product head and lubricate it necessary. The grease ring on the bearing should be facing the product side of the head. Insert the HRT into the

11/2012 95-03057 Page 39

lightly. Replace the bearing in the product head if

Page 42

Maintenance Waukesha Cherry-Burrell

end of the shaft. Slide the bearing race over the tool and onto the shaft to protect the stationary seal face during assembly.

16. Seat the bearing in the head, using a plastic mallet, if requ

ired.

17. Install shaft locknut and bearing cap, over bayonet ring and turn counter-clockwise. Close locking latch.

18. Grease bearing. (Not required for Extra He av y Duty Votator II.)

Scheduled Maintenance

The following table is provided only as a guideline. It may be necessary to modify the schedule to conform to actual in-plant requirements. All changes should be documented by

t personnel.

plan

Table 5: Table of Scheduled Maintenance

Frequency Component Suggested Service Weekly Mutator Shaft

Bearing

Shaft Assembly

Product Tube Inspect the tube’s inner chrome surface to be sure it is smooth and bright.

Lubricate each fitting with a handgun, approximately three shots. Use a suitable NLGI Grade-2 bearing grease. (Not required for Extra Heavy D

Remove shaft assembly at least once a week. Always use the removal trough Replace the mechanical seal shell O-rings.

If roug correct the cause. Replace the tube, if necessary.

uty Votator II.)

skid to avoid bottom blades scoring the heat transfer tube.

h areas, marks or chrome plating deterioration exist, locate and

position product head

Scraper Blades

Jacket/ Accumulator

Monthly Inlet and

Outlet Fitt Gear motor Check oil level and add as required.

SemiAnnually

gerant Inspect for oil and/or contaminants.

Refri

Flange O-rings Replace O-rings at least every 12-18 months.

ings

Examin amount of wear, establish service frequency.

Maintain blades in good condition for longest machine life and best prod replacement. Worn or rough blades reduce heat transfer and can dam age the heat transfer tube.

Purge gathered oil from accumulator s ammonia charge is dumped from accumulator daily, oil is carried back with it.

Replace O-rings on inlet and outlet fittings monthly, or more frequently as needed.

e scraper blades weekly, or after 40 operating hours. Based on

uction rates. Reserve a complete set of spare blades for routine

ction of accumulator jacket. If

Page 40 95-03057 11/2012

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Waukesha Cherry-Burrell Maintenance

Preventive Maintenance

Mutator Shaft Bearing

• Correct problems as soon as they are dis covered.

• Inspect equipment frequently following changes in product

ulation, processing conditions or CIP regimen.

form

• Always note and report any abnormal or unusual conditions.

• Follow a regular preventive maintenance schedule. Many

factors de servicing. The severity of the application and the time between scheduled shutdowns are two of the most significant.

When new units are first put into service, they should be

ssem

disa obvious wear patterns. These initial inspections will establish a process history, as well as provide a basis for establishing a preventive maintenance schedule. Inspections should focus primarily on tube, shaft, blade and seal components. During normal production runs, any abnormal conditions such as unusual noise, leakage or vibration should be noted and corrective action taken.

The Votator II has only one serviceable ball bearing assembly, located in the Opposite Drive End Head of the unit. Lubrication of this bearing while in service is done through the use of the grease fitting located on the Opposite Drive End Head.

rmine the interval required for scheduled

bled after each production run and inspected for any

Figure 23 - Lubrication Ring

Orientation

Install bearing with lubrication ring Use a suitable NLGI grade-2 bearing grease for the shaft bearing.

Do not over-lubricate. Excessively packed bearings will over heat and fail prematurely.

Frequency of lubrication is dependant o it is in contact with water or steam, otherwise weekly lubrication usually is sufficient.

WARNING:

Bearing in cleaning solution or subject to steam. Clean bearing with a dry cloth and lubricate.

Inspection of bearing should be ongoing. If looseness is detected , rep

lace bearing immediately. Worn out bear ings ca use shaft misalignment that will cause mechanical seals and gearbox to wear out prematurely.

Never immerse the Front Mutator Shaft

in line with grease fitting.

n the environment; daily if

Extra Heavy Duty Votator II Shaft Bearing

The shaft bearing on the Extra Heavy Duty Votator II located in the opposite drive end head is a sealed bearing and does not require lubrication.

11/2012 95-03057 Page 41

Page 44

Maintenance Waukesha Cherry-Burrell

Shafts

Gear Drive

Table 6: Lubrication Quantities

NORD

gearb

SK 4282

SK 5282

Orientation Quantity

Horizontal 4.97 qt.

Vertical 5.71 qt.

Horizontal 7.93 qt.

Vertical 9.30 qt.

All shaft surfaces, especially in seal and bearing areas, should be kept smooth and clean. Special care should be taken while cleaning and maintaining seals and bearings to assure that these areas of the shaft are not scratched or damaged.

Shaft porosity can be detected by making an adaptor for the threaded end of the sh be detected as air bubbles by submersing the shaft in a water bath. Leaky shafts can be repaired at WCB.

Bent or imbalanced shafts will cause premature bearing, seal and

de wear and may damage tube walls. Shafts should be

bla checked for straightness and balance annually.

Manufacturer recommendations should be followed for gear oil

cement. When draining oil, examine closely for foreign

repla matter or debris, flushing or gear replacement may be required.

NOTE: Consult the sticker on the NORD gearbox to verify the correct lubricant.

The current standard lubricant for the NORD gearbox is Mobil SHC Cibus™ 220.

For quantities (fill capacity for an empty gearbox The gearbox (SK 4282 or SK 5282) is indicated on the

tification plate.

iden

aft and pressurizing it with air. Pinholes will

For alternates, see NORD document U11000.

), see Table 6.

Blades

Mechanical Seals

Tubes

Blades that have developed a heel greater than WCB specifications should be sharpened per instructions in this manual. Blades worn beyond the minimum sharpening dimensions should be replaced. Worn blades reduce heat transfer, result in poor performance and may damage product tubes. See “Scraper Blade Maintenance” on page 45.

Votator II heat exchangers are equipped with single or double mechanical seals at each end of the mutator shaf t.

NOTE: Double mechanical seals MUST BE flushed to prevent se

al faces from over heating.

Mechanical seal faces with nicks, bliste abnormality on the seal face, must be replaced. Elastomers that are brittle, deformed, cut, or have any abnormality must be replaced. It is an excellent practice to replace all elastomers and gaskets whenever maintenance is performed.

A frequent cause of tube wall damage is careless handling when removing or installing the mutator shaft. The shaft trough skid should always be used when removing or installing the mutator shaft in the Horizontal Votator II (or the Vertical unit if in a horizontal position) to prevent the blade mounting pins from scoring and damaging the tube wall.

rs, grooves, or any

A common way to damage tube ends is to bang or dr op the sh aft

nals when removing or inserting the shaft.

jou Tubes should be examined for wear anytime the shaft is removed

or at

least once every 3 months. Chrome plated tubes should be

Page 42 95-03057 11/2012

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Waukesha Cherry-Burrell Maintenance

inspected for flaking of the chrome. Normally, tubes will develop phonographic patterns from blade contact and rotation; this phonographic pattern is generally visible to the eye but is not significant unless detectable by touch. Scoring is significant when the base metal has been damaged; roughness of the tube wall is obvious both visually and by touch. A badly scored tube will make cleaning more difficult, reduce heat transfer, result in poor performance and increase blade wear.

Re-conditioning the tube is the only way to restore performance.

there is suspicion that scoring has penetrated the tub e wall, the

If unit can be pressure tested by turning on the jacket media and observing the inside of the tube for leaks.

Tubes should be removed every 12 to 18 months for cleaning

bris from the media side. Jacket side O-rings should be

de replaced when tubes are reinstalled.

Care of Heat Exchanger Tube

NOTE: Rep by a shop with ASME certified welders. The heat exchanger tubes are ASME coded parts. Failure to get repairs done by an ASME coded machine shop with certified welders will void the warranty and possibly void insurance. SPX has all required certifications necessary for repair of ASME coded parts.

air work must be performed

You probably recognize that your Votator® and Thermutator® Heat Exchangers are valuable elements of your production facility. Day in and day out, they continuously and efficiently heat and cool products that often cannot be handled in any other equipment. You may not be aware that these units are considered pressure vessels under the ASME Code, and that SPX is the only facility authorized to make OEM repairs to the removable tubes that maintain their ASME Code certification. This certification is your assurance that the equipment meets its original design pressure rating.

The removable tubes are wear parts, and must be r eplaced when they lose too much metal. Their inner surface is scraped by rotating blades and is potentially exposed to corrosive or abrasive products or cleaners. In some cases chrome plating is applied to resist mechanical wear, but it eventually wears away or the tubes become damaged or scored and lose performance. SPX can inspect the tubes against the original drawings and determine whether they can be honed to restore a smooth inne r su rfa ce , while keeping enough tube wall thickness to satisfy the ASME Code design calculations. Removable tubes that are worn beyond repair are condemned by our facility for your protection.

A breach in the removable tube that occurs during operation

ld be an extremely costly and hazardous event. In a recent

cou incident, a removable tube was honed by an unauthorized machine shop that removed too much metal. The extremely thin tube wall flexed under the pressure of the product and the scraping blade edge, until one blade penetrated and tore a hole in the tube. Consequences of this kind of failure can include: contamination of product - with a damaging recall; circulation of product throughout a media system like a refrigeration compressor installation; and/or release of a hazardous substance like ammonia refrigerant inside your facility! Even if these are not high risks in your application, your production line will be down or operating at reduced capacity for some time until a replacement tube can be obtained.

Having your tubes professionally repaired sense, but there are other potential benefits as well. Maintaining ASME certification keeps you in compliance with state and local

11/2012 95-03057 Page 43

by SPX just makes

Page 46

Maintenance Waukesha Cherry-Burrell

regulations, depending on the location of your facility. It is also a requirement of most business insurance carriers, so you are helping to protect your company against potential fines and uninsured losses. With stakes this high, tube repair by SPX is the smart bet.

Product Side

The heat exchanger tube is designed to last a long time with little maintenance.

If tubes wear out prematurely, one or more of the following may be th

e cause:

• Failure to use shaft trough wh cause scratching or gouging of tube wall.

• Careless assembly and installation of blades.

• Rotating shaft without product or product flow.

• Use of the wrong detergent or incorrect use of a detergent.

• Starting shafts against stiffened or solidified product in tubes.

• Starting the flow of jacket med Water, etc.) before establishing full product flow under operating pressures.

• Failure to clear tubes of product after every use.

• Starting operation before dissolving particles such as salt,

r, detergents, etc.

sug

• Using dull blades or blades that have been sharpened below minimum width spec

• Using blades other than those furnished by Waukesha Cherry-Burrell.

ifications.

en removing mutator shaft will

a (Ammonia, Freon, Steam,

Inspection of Chrome Plated Nickel or Stainless Steel Tubes

Inspection of Stainless Steel Tubes

Worn mutator shaft bearings.

•

During each inspection of the scraper blades, inspect the inside surface of the tube for scoring, gouging, and roughness. When the surface of the plating is damaged or worn through, it may be rechromed to original specifications by Waukesha Cherry-Burrell. WCB has the equipment and product knowled ge to re pa ir th e tube back to factory specifications and determine if the tube will comply with ASME specifications.

CAUTION:

chrome plated nickel heat transfer tubes. Cleaners should be

compatible with the elastomers in the heat exchanger.

During each inspection of the scraper blades, inspect the inside surface of the tube for scoring, gouging, and roughness. Shallow score marks, shallow gouges, and roughness can be ta ken out by honing the tube followed by polishing. Depending on the damage to the tube, Waukesha Cherry-Burrell may be able to rehone the tube to comply with ASME code specifications.

Acid cleaners are not recommended for

Page 44 95-03057 11/2012

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Waukesha Cherry-Burrell Maintenance

Jacket Side

Cleaning the Flanges

For Units Using Steam, Water, Or Liquid

The jacket side of the heat transfer tube has a sealed cover that allows the media flow to circulate around the tube. If it becomes coated with foreign matter and heat transfer is reduced, it can be cleaned by pumping a detergent solution compatible with the carbon steel jacket at a rate of about 100 gpm. The frequency of this cleaning process will vary greatly from one installation to another.

For Units Using Refrigerant

The jacket side of the heat transfer tube will become fouled with oil and sludge over time and prevent efficient heat transfer. This tube does not have a sealed flow spiral and can be cleaned by removing it from the jacket. It should be removed for cleaning every 12 to 18 months.

u plan

NOTE: If yo materials and methods mentioned previously, please contact Customer Service.

Remove the O-rings and clean the grooves thoroughly of all residue and buildup. Care must be taken in cleaning the flanges, as they are part of the seal mechanism of the unit.

Install new O-rings any time the unit is disassembled.

to clean the tube with anything other than the

Leak Testing

Scraper Blade Maintenance

NOTE: Replace the O-rings every 12-18 months.

bricate the O-rings.

Each cylinder is thoroughly tested for leaks at the factory. It is necessary to check for leaks in the refrigeration system any time the piping is opened to the atmosphere for maintenance or repa ir.

WARNING:

electrical system checkout is completed. Personnel must wear safety goggles and protective clothing.

Do not open valves or check for leaks until the

Blade Inspection

The blades should be inspected for wear and signs of fatigue or cracking at the pin location and should be replaced if damage has occurred. Failure to replace damaged bla de s ma y re su lt in breakage, which can damage other blades or the heat transfer tube, and result in blade particles in the product.

CAUTION:

be avoided if plastic scraper blades are used. Cleaners

ld be compatible with the elastomers in the heat

shou exchanger.

High concentrations of acid or caustic should

11/2012 95-03057 Page 45

Page 48

Maintenance Waukesha Cherry-Burrell

Scraper Blade Removal & Replacement

1. Remove scraper blades by lifting up and pulling them from the pins. PEEK Blades have a locking groove.

Figure 24 - Scraper Blade Removal

Figure 25 - Blade Wear and

Sharpening

2. After lifting, push to the right before pulling pins.

NOTE: Blad shaft throughout life of blade. Make sure blades are removed an d reinstalled in the same location on the shaft.

Reverse this procedure for installation. Make sure beveled edge is

installed toward shaft.

es should be kept in the same position on mutator

them from the

Scraper Blade Wear

Worn blades reduce heat transfer efficiency and can cause excessive wear on the product tube wall.

As the scraper blades scrape across the interior of the heat exchanger tube, they wear into the contour of the tube. A flat surface called the heel and a burr or feathered edge develops at the contact area on the side of the blade that is against the tube wall. See Figure 25.

The blades must be maintained to achieve maximum

rformance. When the heel of the blade reaches a maximum of

pe 1/16" (1.6 mm) on metal blades or 1/8" (3.2 mm) on plastic blades, they must be replaced or re-sharpened.

Blade Sharpening

Scraper blades can be sharpened by several methods, depending on the blade material.

The best method utilizes a high speed keeps the backside of the blade perpendicular to the cutting edge. The cutting edge of the blade should be parallel to th e back surface of the blade within 1/64".

A new universal blade is 2 inches wide by 6 inches long. For mutator shafts that are 4-1/2 inche

blade should not be sharpened to a blade width of less than 1-3/8 inches.

For mutator shafts that are 4 inches in diameter, the blade should not be sharpened to a blade width of less than 1-1/2 inches.

Stainless steel blades for the 5-1/4 in x 23-29/32. The minimum width after sharpening is 1-3/8 inches and the sharpening edge is at a 15-degree angle.

45° cutter and fixture that

s in diameter or larger, the

ch mutator shafts are 1-9/16

Page 46 95-03057 11/2012

Page 49

Waukesha Cherry-Burrell Maintenance

HRT

Mutator Shaft

Maintenance of Horizontal Votator II

Figure 26 - Removal of Hinged Clamp

DANGER: Before doing any maintenance work on the

Votator II, lock out and tag out equipment.

Shaft Removal - Horizontal Unit

1. Check to make sure all supply lines to unit are closed, locked

out and tagged out.

2. Disconnect product piping and

3. Rotate head in OFF direction until you feel head disengage.

4. Pull head and shaft assembly out approximately one (1) inch.

5. Remove hinged clamp that holds shaft nut gua

See Figure 26.

6. Remove shaft locknut. (Locknut is left hand threaded). See

Figure 27.

7. Insert HRT as shown in Figure 28 and slide the head and

bearing off the shaft to protect the stationary seal face dur ing disassem

bly.

seal flush lines.

Small end of tool engages shaft thread (shown out of position)

in place.

Figure 27 - Removal of Shaft Locknut

Figure 29 - Shaft Removal

Figure 30 - Removal of Shaft Drive

End

Figure 28 - Use of Head Removal Tool (HRT)

8. Lift shaft so that shaft removal skid can be inserted between

shaft and tube.

NOTE: NEVER remove mutator shaft without using shaft removal sk

id. Failure to do so will result in permanent damage to heat

transfer tube.

9. Slide shaft removal skid into tube.

10. Pull shaft and shaft removal skid from tube as a unit. This will

ensure

that tube will not be scored when shaft is removed.

11/2012 95-03057 Page 47

Page 50

Maintenance Waukesha Cherry-Burrell

11. Remove scraper blades and service as necessary. See “Scraper Blade Maintenance” on page 45

Figure 31 - Scraper Blade Removal

Figure 32 - Drive End Head O-ring

NOTE: B

mutator shaft throughout the life of blade. Make sure blades are removed and reinstalled in the same location on the shaft.

lades should be kept in the same position on the

Shaft Installation - Horizontal Unit

1. If the drive end head has been removed, make sure the Oring (See Figure 32, Item A) is installed in opposite drive end head. Lubricate lightly.

2. Install drive end head (if necessary).

3. Install mechanical seal on drive end of shaft as shown in Figure 33. see “Mechanical Seal Maintenance” on page 56.

4. Install all scraper blades on mutator shaft.

Figure 33 - Mechanical Seal

Installation

NOTE: Blad

shaft throughout life of blade. Make sure blades are removed an d reinstalled in the same location on the shaft.

5. Place shaft in shaft removal skid.

6. Apply anti-seize compound to the drive end splines and the ne

7. Push shaft and shaft removal sk ensure that tube will not be scored when shaft is replaced.

8. Push spline of shaft partially into gear reducer. Shaft may ne See Figure 34.

9. Lift shaft slightly to remove shaft removal skid.

es should be kept in the same position on mutator

xt 3 inches of stub shaft length

id into tube as a unit. This will

ed to be rotated slightly for splines to seat in gear re ducer.

Figure 34 - Align Shaft Splines with

Gear Reducer

Page 48 95-03057 11/2012

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Waukesha Cherry-Burrell Maintenance

Figure 35 - Opposite Drive End Head

O-ring

10. Make sure O-ring (See Figure 35, Item A) is installed in the

opposite drive end head. Lubricate lightly

11. Install opposite drive end head by reversing procedure for

removal of head.

Figure 36 - Install Head Shaft Bearing

12. Install shaft bearing in head. Install

HRT into the end of the shaft and slide head and bearing onto the shaft. Remove HRT.

13. Push on bearing retainer and secure with clamp.

14. Install shaft nut onto shaft (

nut is left hand threaded) and

tighten nut against bearing’s inner race

15. Lift the shaft and head, place over the tube ring and position bayonet closure. Close locking latch and secure by tightening latch retainer nut.

Figure 37 - Installation of Shaft

Locknut

16. Install all product connections and seal flush piping.

17. Inspect unit for correct assembly.

18. Remove tag-out and lock-out. Prepare unit for operation.

Figure 38 - Installation of Hinged

Clamp

11/2012 95-03057 Page 49

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Maintenance Waukesha Cherry-Burrell

Heat Exchanger Tube Removal - Horizontal Unit

DANGER: Before doing any maintenance work on the Votator II, lock out and tag out equipment.

DANGER: Be heat exchanger tube from the jacket, all refrigerant must be evacuated from the jacket assembly.

fore removing the

1. Check to insure all supply lines to unit are closed and locked and tagged out.

2. Make sure that entire unit is purged of fluids (product, coo

lant, refrigerant, etc.)

3. Remove mutator shaft and drive end head as described in t

his section.

4. Remove locking latch and associated hardware that holds front cover in place.

5. Remove the eight (8) 3/8-inch bolts that hold removable tube to jacket. See Figure 39.

6. Take four (4) bolts and thread them into the “B” holes. The “B

” holes are located at the 12, 3, 6, and 9 o’clock locations.

DO NOT TIGHTEN!

7. Using an X pattern, gradually tighten bolts to withdraw tube

om jacket. Considerable effort may be needed to overcome

fr any stickiness.

If tube does not start to pull away tightened, stop and do the following:

from jacket as bolts are

Figure 39 - Removal of Tube to Jacket

Bolts

Figure 40 - Tube Removal

• Ma

• Place a block of wood across drive end of tube and apply

• When tube is loose, use bolts to complete removal.

• If tube cannot be budged, contact SPX.

8. Pull tube out of jacket. Care should be taken to avoid marring jacket and jacket so that tube can be reinstalled in same jacket. See Figure 40. On BWS or liquid units, install a new packing ring.

ke sure product head on drive end is removed.

pressure to force tube opposite the drive end.

cylinder during heat transfer tube removal. Mark tube

Page 50 95-03057 11/2012

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Waukesha Cherry-Burrell Maintenance

Heat Exchanger Tube Installation - Horizontal Unit

1. Inspect jacket cylinder interior and wipe out all dirt and

impurities.

2. Lubricate sealing surfaces inside jacket cylinder and install

new

O-rings in the tube.

Figure 41- Install Tube to Jacket Bolts

Maintenance of Vertical Votator II

3. Carefully insert tube into jacket cy

exchanger tube should be at 5 o’clock and 7 o’clock positions during insertion.

4. Push tube into cylinder as far as

5. Thread the eight (8) 3/8-inch bolts through the flange of heat

exchanger tube into jacket cylinder.

6. Tighten bolts in a crossing pattern until tube is snugged down

to jacket cylinder.

Torque bolts to 240 in-lbs (20 ft-lbs).

8. Install front cover.

9. Install latch hardware.

10. Install drive end head.

11. Install shaft (with mechanical seals).

12. Install opposite drive end head.

DANGER: Before doing any maintenance work on the Votator II, lock out and tag out equipment.

linder. Support pins of heat

it will go.

Shaft Removal - Vertical Unit

Figure 42- Location Of Hydraulic Arm

For Removal

1. Purge all product from unit.

2. Disconnect product piping from opposite drive end head.

3. Lower arm of hydraulic lift so that arm

under opposite drive end head. (See Figure 42, Item A).

4. Raise arm of hydraulic lift to just below opposite drive end

head

(See Figure 42, Item B) and position lift pin (See Figure

42, Item C) to go into shaft nut.

5. Raise arm so that lift pin is engaged in head and just barely

pushing

against shaft nut.

WARNING:

position without hydraulic foot in place beneat h he ad .

Do not move latch or loosen n ut from locked

can be positioned

11/2012 95-03057 Page 51

Page 54

Maintenance Waukesha Cherry-Burrell

6. Unlatch locking latch.

7. The head has an ON-OFF engraving on the rim, located just above

product outlet. Rotate head in OFF direction until head

disengages.

8. Lower head until hydraulic rod is fully extended. See Figure

44.

9. Once shaft is in down position, blade s may be removed from shaft.

Figure 43 - Disengaging Locking

Latch

NOTE: Blades sh

shaft throughout life of blade. Make sure blades are removed an d reinstalled in the same location on shaft.

10. If shaft is to be removed from unit, lift head and shaft off lift pin and move head away from unit while a second person guides spline end of shaft out of unit.

11. Place shaft and head assembly on a table or suitable frame

rvicing.

for se

12. Scraper blades can be removed and serviced at this time.

ould be kept in the same position on mutator

Shaft Installation - Vertical Unit

1. Check the condition of the O-ring in the head and lubricate lightly. Assemble head to shaft if necessary, following procedures under “Shaft Installation - Horizontal Unit” on page 48.

2. Assemble head to shaft.

3. Apply anti-seize compound to the drive end splines and the next 3 inche

4. Slide splined end of shaft into unit.

5. Lift head onto lift pin.

s of stub shaft length.

Figure 44- Shaft Fully Extended

6. Install scraper blades.

NOTE: Blades sh shaft throughout life of blade. Make sure blades are removed an d reinstalled in the same location on shaft.

Page 52 95-03057 11/2012

Figure 45 - Head Installed on Pin

ould be kept in the same position on mutator

Page 55

Waukesha Cherry-Burrell Maintenance

7. If optional blade aligning tool is used, install it on the bayon et

ring of heat transfer tube. Place each half of the ring on the bayonet and rotate it as one piece.

8. Raise shaft slowly, tucking blades into shaft while shaft and

e assembly is being inserted into tube.

blad

Figure 46 - Align One Half of Blade

Alignment Tool

Figure 47 - Blade Alignment Tool

Installed

NOTE: If lift bind

that blades have not swung fully out and are not binding on the edge of alignment tool. If this happens, check blades and replace as necessary. Restart lift, taking care to guide blades into alignment tool.

9. If blade aligning tool is not used, the ind

hydraulic lift should use one hand to guide each pair of blades into tube.

10. As shaft is raised into gear reducer, it may be necessary to

rotate shaft slightly to assure

11. Continue to raise shaft until head is a bout six ( 6) inch es from

being

engaged.

12. Once the last set of blades has been started in tube, remove

alignme

13. Continue to raise head slowly, aligning teeth of head with

spac

es of tube. Raise and turn head so teeth are engage d

and product port is facing forward.

14. Close locking latch. See Figure 48.

15. Install product piping and electrical connections.

s, STOP and back off hydraulic pressure. Check

ividual controlling

splines are meshed correctly.

nt tool, if used.

Figure 48 - Close Locking Latch

Heat Exchanger Tube Removal -Vertical Unit

The hydraulic lift on the vertical unit can be used to remove the heat transfer tube from the jacket of the unit.

DANGER:

the jacket, all refrigerant must be evacuated from the jacket assembly.

Remove mutator shaft from unit as described in this section.

2. Remove shaft and head from hydraulic lift.

3. Place assembly on a table or maintenance frame.

4. Remove the driven end product head.

Before removing the heat exchanger tube from

11/2012 95-03057 Page 53

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Maintenance Waukesha Cherry-Burrell

Figure 49 - Remove Front Jacket

Cover Bolts

5. Remove the three (3) bolts holding front jacket cover in p lace.

6. Remove the non-driven product head from mutator shaft.

7. Reattach head to tube. See Figure 50. Reattach shaft nut cover and clamp, and use lift to

position non-driven end head.

8. Loosen bolts on jacket flange.

Figure 50 - Head Reinstalled

9. Lower head slightly with hydraulic c

ylinder to allow tube to

move down.

NOTE: Tub

e may slide out easily or it may need coaxing out.

10. Lower lift arm slightly to allow tube to move down. At the 12, 6, 3, and 9 o’clock positions, tube flange is threaded for jack screws. Thread two (2) bolts into either the 12 & 6 or 3 & 9 o’clock positions.

11. Tighten bolts about 1/2 turn alternately on each side until

ge loosens from jacket. It may be necessary to lower foot

flan on hydraulic cylinder slightly while removing tube from jacket.

Figure 51 - Insert Jack Screws

Page 54 95-03057 11/2012

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Waukesha Cherry-Burrell Maintenance

12. Lower head and tube assembly and service as required.

13. Lubricate and install new O-rings on both ends of tube.

14. Install new packing ring (on steam or liquid tubes).

15. To reinstall tube, reverse the procedure.

16. Torque bolts to 240 in-lbs (20 ft-lbs).

Figure 52 - Lower Tube and Service

NOTE: Take car

the holes in the jacket.

e to orient the tube flange holes to line up with

11/2012 95-03057 Page 55

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Maintenance Waukesha Cherry-Burrell

Mechanical Seal Maintenance

Single Mechanical Seal

Figure 53 - Seal Head Insert Removal

The mechanical seals on the Votator II are the same on both the non-driven and driven ends of the unit. The O-rings and seal materials have been selected for the product specifications. Various options are shown in the Parts Lists starting on page 63.

Units furnished before 2005 were installed with either a single or double mechanical seal configuration. For detailed parts drawing breakdown see “Single Mechanical Seal” on page 72.

Seal Head Insert Removal and Installation

The Seal Head Insert located in the product head is removed by tapping the back of the seal with a plastic block or rod. Make sure to hold the insert or use a soft cloth to catch it to prevent it from dropping when removed.

NOTE: To face down on any surface during maintenance.

If the mechanical seal is going to be seal should be removed to protect the stub ends on the mutator shaft. Install the seal in the relief position as shown in Figure 54.

To install a new insert, lubricate the o-rings and the inside bore. Insert in the head with an even distribution of force on the face. The face must be protected with plastic to avoid damage.

prevent damage to the seal face do not place the seal

flushed, the springs in the lip

Figure 54 - Lip Seal Orientation

Seal Body Insert (Rotating Seal Face) Used Before 2012

The rotating seal face is referred to as the Seal Body Insert. This part is designed to wear at a greater frequency than the seal head insert. An O-ring holds the insert stationary in the seal b ody.

NOTE: Do because the insert must remain stationary with respect to the body. If necessary, water can be used as a lubricant.

The seal insert is symmetrical an becomes scratched.

The seal body is held in place o drive pins. Each one should be 3/32 inches (+/-0.015) above the stub shaft surface. It is extremely important that thes e pin s ar e not rounded on the edges and this dimension is maintained. If the pins are higher than 3/32", the seal will jam; if the pins are too low, the body will rotate. See Figure 57.

Install the Seal Body Insert in the Seal Body as follows:

1. Place O-ring in Seal Body.

2. Push Seal Body Insert down evenly with both hands until it b

not use a lubricant on the Seal Body Insert O-ring

d can be reversed if one side

n the mutator shaft by two seal

ottoms out. See Figure 55.

Figure 55 - Press Insert Down Evenly

with Both Hands

Page 56 95-03057 11/2012

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Waukesha Cherry-Burrell Maintenance

Single Mechanical Seal Installation

After the head insert and the body insert are installed, the remaining components are installed as follows:

1. Place wavy washer spring (See Figure 56, Item A) on shaft.

2. Install seal back-up ring. (See Figure 56, Item B).

3. Install U cup seal with opening toward product side, as shown

in Figure 56, Item C.

4. Place seal body (See Figure 56, Item D) on shaft, aligning

slots with seal drive pins.

Figure 56 - Orientation of Seal

Components

5. Install "keeper" O-ring (See Figure 57, Item E) on shaft to

keep rotating parts assembled.

Figure 57 - Install Keeper O-ring

One-Piece and Double Mechanical Seals

6. Inspect seal to insure that it moves fre

drive pins keep it stationary with respect to mutator shaft.

For detailed parts drawing breakdown, see “Double Mechanical Seal” on page 70. Units furnished before 2005 had a removable seal body insert as described below. In 2005, all single and

uble mechanical seals were furnished with a one-piece primary

do seal body. Starting in 2012, a new seal body design with a removable wear face is furnished.

ely with spring and that

Primary/Secondary Seal Head Insert Removal and Installation

The primary seal head insert located in the product head is removed by tapping the back of the seal with a plastic block or rod. It contains the secondary seal head insert and the two parts can be removed as an assembly or separately, as the secondary ring is held in the primary by an O-ring. Make sure to hold the insert or use a soft cloth to catch it to prevent it from dropping when removed.

NOTE: To pr

Figure 58 - Seal Head Insert Removal

11/2012 95-03057 Page 57

face down on any surface during maintenance.

event damage to the seal face, do not place seal

Page 60

Maintenance Waukesha Cherry-Burrell

HE100-115

HE100-120

HE100-121

HE100-122

To install a new primary or secondary insert, lubricate o- rings and the inside bore. Insert in the head with an even distribution of force on face. Protect the face with plastic to avoid dam a ge .

2012 Primary/Secondary Seal Head Insert Removal and Installation

The primary seal head insert from 2012 onward has two parts, a gland and a seat, but is removed by pushing with the special Seal Installation/Removal tool, part number 130007+ (See Figure 60).

Figure 60 - Seal Installation/Removal Tool

Figure 59 - Gland and Seat Removal

The gland contains the secondary seal head insert, if present, which is held in the primary by an O-ring. Make sure to hold the insert or use a soft cloth to catch it to prevent it from dropping when removed.

Figure 61 - Gland Installation

NOTE: To preven

t damage to the seal face, do not place seal

face down on any surface during maintenance.

To install a new primary or secondary insert, lubricate a

ll o-rings. Use the fit of the o-ring at the top of the head bore to verify that the inserts are correctly aligned in the bore. Make sure to align the anti-rotation pin with the hole in the bottom of the hea d bor e.

Insert the stainless steel gland into the head, using the 130007+ Seal Ins

tallation/Removal Tool with an even distribution of force. Then install the secondary insert into the gland. Finally, align the lugs on the stationary seal face with the spaces between th e lugs on the gland, and insert until it meets the gland.

Figure 62 - Seal Installation

Page 58 95-03057 11/2012

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Waukesha Cherry-Burrell Maintenance

HE100-123

One-Piece Primary Seal Body (Rotating Seal Face)

See Figure 63.

Removable Seal Body Insert (Rotating Seal Face)

The rotating seal face is referred to as the Seal Body Insert. This part is designed to wear at a greater frequency than the seal head insert. An O-ring holds the insert station ary in the seal body.

Assembly of Removable Primary Seal Body

The Primary Seal Body has two O-rings, one on the outside diameter of the ring and the other on the inside diameter that

Figure 63 - One-Piece Seal Body

holds the ring stationary. The O-rings can be hand stretched slightly to fit snugly in the

grooves. Preferred assembly is with the O-ring dry. If necessary, water or soapy water can be used as a lubricant.

1. Install one O-ring (See Figure 64, Item B) on outside diameter of ring.

2. Install other O-ring (See Figure 64, Item A) on inside diameter of primary seal.

Figure 64 - O-ring Installation on

Primary Seal

Figure 65 - Press Insert Down Evenly

with Both Hands

3. Push insert down evenly with both hands until it the housing (Figure 65).

4. Vent trapped air by placing a small flat screwdriver blade be

tween seal ring and outside O-ring.

NOTE: Air can be become trapped behind Primary Seal Insert after assembly. This air must be vented by placing a small flat screwdriver blade between seal ring and outside O-ring to provide a vent for trapped air.

5. While the screwdriver is in place, push down firmly on ring .

6. Release screwdriver and check seal to insure that it firm and solid.

7. Place the inner O-ring in the seal bo this O-ring).

dy (apply lubrication to

bottoms in

Assembly of 2012 Primary Seal Body

The 2012 primary seal body has one O-ring and three antirotation pins that hold the insert stationary on the body.

To install the insert in the sea

1. Lubricate and place seal face O-ring in body.

2. Align anti-rotation pins with slots on seal face.

3. Push seal face down evenly with over the O-ring.

Figure 66 - 2012 Primary Seal Body

4. Place the inner O-ring in the seal bo this O-ring).

11/2012 95-03057 Page 59

l body:

both hands until it snaps

dy (apply lubrication to

Page 62

Maintenance Waukesha Cherry-Burrell

Assembly of Secondary Seal Body (For Double Mechanical Seal Only)

The secondary seal body has one O-ring that holds the insert stationary in the body.

Figure 67 - Install Wavy Spring

To install the insert in the sea

1. Place O-ring in body (no lubrication).

2. Push insert down evenly with both

3. Place O-ring in seal body (lubrication should be applied to this O

-ring).

l body:

hands until it bottoms out.

Seal Assembly Installation on Shaft

After the head insert and the body insert are installed, the remaining components are installed as follows:

1. The primary seal body is held in place on the mutator shaft by tw

o seal drive pins. Each one should be 5/32 inches (+/-

0.015") above the stub shaft surface. The secondary seal body is held in place by one seal drive pin. It should be 3/32 inch (+/-0.015") above the stub shaft surface. It is extremely important that these dimensions be maintained. If the pins are too high, the seal will jam; if they are too low, the body will rotate. See Figure 67 and Figure 70.

2. Place wavy washer spring (See Figure 67, Item A) on shaft.

3. Place seal body (Figure 68) or one piece seal on shaft, aligning slots with seal drive pins.

Figure 68 - Install Seal Body

4. Install "keeper" O-ring (See Figure 69, Item E) on shaft to keep rotating parts assembled.

5. Inspect seal to insure that it moves fre drive pins keep it stationary with respect to the mutator shaft.

6. Assemble Secondary Seal Wavy Washer on shaft, if require d (See Figure 70).

Figure 69 - Install Keeper O-ring

Page 60 95-03057 11/2012

ely with spring and that

Page 63

Waukesha Cherry-Burrell Maintenance

7. Slide seal body over seal body drive pin so that O-ring in

body seats in groove in mutator shaft.

Figure 70 - Double Mechanical Seal

Installed

Figure 71 - Exposing Top Mechanical

Seal

8. Check seal to insure that it will

move freely with spring and

that drive pins hold it stationary with respect to shaft.

Servicing Mechanical Seals - Vertical Votator II

The top mechanical seal can be serviced by lowering the shaft to the floor and removing the seals from the shaft while the spline end is in the heat transfer tube. See Figure 71. See “Mechanical Seal Maintenance” on page 56 for information regarding servicing the seal.

The bottom mechanical seal can be serviced with the mutator

ft in the unit by using the shaft clamp. See Figure 72.

sha

1. Lower shaft approximately two (2) feet or to a convenient

height.

Figure 72 - Shaft Clamp

Figure 73 - Installed Shaft Clamp

2. Remove top two (2) exposed scraper blades.

3. Position shaft so that blade pins are centered between the

yonet ring on the heat transfer tube.

4. Install shaft clamp around teeth of tube and shaft.

(See Figure 73, Item A)

5. Close locking latch. (See Figure 73, Item B)

6. Lower shaft until a pin from right or left side contacts shaft

clamp.

SHAFT MUST BE SUPPORTED BY A PIN AND

NOT BY A SCRAPER BLADE.

7. Lower hydraulic arm and rotate it out of the way.

11/2012 95-03057 Page 61

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Maintenance Waukesha Cherry-Burrell

8. Remove clamp on head. (See Figure 74, Item A) and shaft nut guard.

Figure 74 - Remove Head Clamp

9. While supporting head, remove shaft nut. (Nut

is left hand

threaded.)

10. Grasp head with both hands, remove it from shaft.

Figure 75 - Shaft With Head Removed

11. Seals can now be serviced. See “Mechanical Seal Maintenance” on page 56.

12. To install, reverse the procedure.

Page 62 95-03057 11/2012

Page 65

Waukesha Cherry-Burrell Parts Lists

Parts Lists

Latch

ITEM # PART DESCRIPTION QTY PART #

35 VII Locking Latch 1 LL923221 36 Washer Plain 3/8” 18-8 Narrow 8 43-30 37A Wing Nut 1 LL2200281 37B Acorn Nut 1 LL711155 38 Spacer 3 LL2200321 39 Stud 1 LL2200277 40 Hexagon Head Shoulder Screw 1 LL925499 52 Spacer Washer 1 LL931315

Product Heads

APPLICATION DESCRIPTION PART #

Opposite Drive End Concentric 3” I-Line LL923245

Concentric 3” Flanged LL118415 Concentric/XHD Bearing 3” Flanged LL120325 Concentric/XHD Bearing 3” I-Line LL119402 Eccentric 3” I-Line LL118337 Eccentric 3” Flanged LL118419 Eccentric/Oval/XHD Bearing 3” Flanged LL120326 Eccentric/Oval/XHD Bearing 3” I-Line LL118391 Eccentric/Oval Spider Head LL121314 Concentric Spider Head LL121359

Drive End Concentric 3” I-Line LL923255

Concentric 3” Flanged LL118414 Eccentric/Oval 3” I-Line LL118336 Eccentric/Oval 3” Flanged LL118418

CAUTION: Product heads comply with the ASME pressure vessel code and must not be changed between units of the same design. Also, a concentric he design.

ad is not interchangeable with an ecce nt ric/ ov al

11/2012 95-03057 Page 63

Page 66

Parts Lists Waukesha Cherry-Burrell

HE100-039b

16,36

Extra Heavy Duty Bearing Option-

HE100-124

Spider Head Option

obsolete after 2009

Extra Heavy Duty Bearing Option (Current Design)

Cylinder Assembly

Page 64 95-03057 11/2012

Page 67

Waukesha Cherry-Burrell Parts Lists

Cylinder Assembly

ITEM # PART DESCRIPTION QTY MODEL/MATERIAL PART #

12 Jacket O-ring (Drive End) 2 EPDM E70444

Neoprene (Rfg) R70444 Fluoroelastomer V75444

13 Blades AR PEEK LL118683

410 SS LL900127 Celcon LL900129 Brass LL918089 410 SS (5-1/4" dia. only) LL926752

14 Packing, Concentric and

Eccentric Packing, Oval 1 Liquid Jacket LL710296

15 Jacket O-ring (Opposite

Drive End)

16 Heavy Hex Head Bolt

3/8-16 x 1

19 Bearing Retainer 1 Votator II LL923214

19B Clamp Ring 1 Spider Head Only LL117678 20 Shaft Nut Guard 1 Horizontal LL923212

21 Shaft Locknut 1 Votator II LL119275A

21A Shaft Locknut Wrench 1 All 79-2 21B Hex Head Cap Screw 1 Spider Head Only LL718934 22 * Ball Bearing 1 Votator II LL923215

22B Sleeve Bearing 1 Spider Head Only LL117679F 23 Hinged Sanitary Clamp 1 Votator II 0346223+

24 * Bearing Sleeve 1 Extra Heavy Duty Votator II (obsolete after 2009) LL118394

24B Shaft Sleeve 1 Spider Head Only LL117680C 26 * Stator 1 Extra Heavy Duty Votator II (Current design) 128475+ * XHD Bearing Assembly 1 Extra Heavy Duty Votator II (Current design) 128472+

1 BWS only LL710015

2 EPDM E70446

Neoprene (Rfg) R70446 Fluoroelastomer V75446

8 ASME SA193-B8, Class 1 LL928781

Extra Heavy Duty Votator II (obsolete after 2009) LL118393 Extra Heavy Duty Votator II (Current design) 128476+

W/ Shaft Heater (horz or vert) Vertical

Extra Heavy Duty Votator II (obsolete after 2009) LL118395 Extra Heavy Duty Votator II (Current design) 128477+

Extra Heavy Duty Votator II (obsolete after 2009) LL118392 Extra Heavy Duty Votator II (Current design) 128473+

Extra Heavy Duty Votator II (both designs) 0348223+

Extra Heavy Duty Votator II (Current design) 128474+

LL929346

* For the Extra Heavy Duty Bearing Option (Current Design) only, XHD Bearing Assembl y (128472+) includes: item 22, Bearing (128473+); item 24, Bearing sleeve (128474+); and item 26, Stator (128475+). Order part numb er 128472+ to get these parts assembled at the factory.

11/2012 95-03057 Page 65

Page 68

Parts Lists Waukesha Cherry-Burrell

Cylinder Assembly - Shaft

SIZE SEAL TYPE

6 x 24 Single Mechanical 5-1/4" dia LL118919 Double Mechanical 4" dia LL122760

6 x 36 Single Mechanical 2-1/2" dia LL935989 Double Mechanical 2-1/2" dia NA

6 x 48 Single Mechanical 2-1/2" dia LL935987 Double Mechanical 2-1/2" dia NA

6 x 72 Single Mechanical 2-1/2" dia LL936763 Double Mechanical 2-1/2" dia LL935679

6 x 84 Single Mechanical 2-1/2" dia NA Double Mechanical 2-1/2" dia NA

SHAFT MODEL

4" dia LL930524 4" dia LL935518 4-1/2" dia LL936898 4-1/2" dia LL935563 5-1/4" dia NA 5-1/4" dia NA

4" dia LL936764 4" dia LL936743 4-1/2" dia LL936765 4-1/2" dia LL936786 5-1/4" dia LL935921 5-1/4" dia NA EHD 4" dia NA EHD 4" dia LL122335

4" dia LL929847 4" dia LL934809 4-1/2" dia LL935650 4-1/2" dia LL935423 5-1/4" dia LL929872 5-1/4" dia LL936147 ECC 4" dia LL936761 EHD 4" dia LL123534 EHD 4-1/2" dia LL123855 EHD 4-1/2" dia LL122585

4" dia NA 4" dia LL124774 4-1/2" dia LL122304 4-1/2" dia LL121858

PART # SEAL TYPE

SHAFT MODEL

4-1/2" dia LL936881

EHD 5-1/4” dia LL122617

EHD 2-1/2” dia 131148+ EHD 4” dia 131149+

PART #

DESCRIPTION SIZE PART #

Shaft Skid (horizontal Votator only) 6 x 24 LL934744

6 x 36 6 x 48 6 x 72 LL934394 6 x 84

Page 66 95-03057 11/2012

Page 69

Waukesha Cherry-Burrell Parts Lists

Cylinder Assembly - Removable Tube

SIZE APPLICATION CODE TYPE DESCRIPTION PART #

6 x 24 BWS

VAPOR UM 316 SS TW/W RINGS LL118829

6 x 36 BWS UM NI/CR LL930693

VAPOR UM NI/CR (600 PSI) LL936784

6 x 48 BWS UM NI/CR (600 PSI) LL935920

VAPOR UM NI/CR LL936583

6 X 72 BWS UM NI/CR (600 PSI) LL929756

VAPOR U NI/CR (600 PSI) LL929396

6 X 84 BWS UM 316 SS TW/WO RINGS LL122017

VAPOR UM 316 SS TW/WO RINGS LL122018

UM 316 SS TW/WO RINGS LL936879 UM 316 SS CR 130906+ UM NI/CR LL122763

UM NI/CR LL118909

UM 316 SS TW/WO RINGS LL930078 UM ECC NI/CR LL934767

U NI/CR (800 PSI) LL934076 UM 316 SS TW/W RINGS LL930077 UM 316 SS TW/CR/WO RINGS LL123554

UM 316 SS TW/WO RINGS LL934342 UM 316 SS CR/WO RINGS LL936802 UM ECC NI/CR LL936730

UM 316 SS TW/W RINGS LL930582 UM ECC NI/CR NA

UM 316 SS TW/WO RINGS LL929263 UM 316 SS TW/CR/WO RINGS LL930735 UM CS/CR LL121057 UM ECC NI/CR LL935827 UM ECC TW/CR/WO RINGS LL123513 UM OVAL NI/CR (400 PSI & 150 PSI) LL120327 UM OVAL NI/CR (400 PSI & 60 PSI) LL123535 U NI/CR (800 PSI) LL925501 U 316 SS (800 PSI) LL935644

UM 316 SS TW/W RINGS LL928761 UM CS/CR LL120274 UM ECC NI/CR (600 PSI) LL929917 U 316 SS TW/CR/W RINGS LL930351 UM OVAL NI/CR (400 PSI & 150 PSI) LL119565 U NI/CR (800 PSI) LL925507 U 316 SS (800 PSI) LL928641 U ECC 316 SS (800 PSI) LL929819 UM ECC 316 SS (600 PSI)

UM NI/CR 129916+ UM 316 SS TW/CR W/O RINGS LL125960 UM CS/CR LL121059

UM 316 SS TW/W RINGS LL122019 UM 316 SS TW/CR W/RINGS LL124775 UM CS/CR LL121058 UM NI/CR 131130+

LL119113

11/2012 95-03057 Page 67

Page 70

Parts Lists Waukesha Cherry-Burrell

11A

7A 9 10

HE100-113

HE100-116

HE100-115

ODE Head Installation/Removal Tool

LL121191

Seal Installation/Removal Tool

130007+

2012 Double Mechanical Seal

Page 68 95-03057 11/2012

Page 71

Waukesha Cherry-Burrell Parts Lists

2012 Single and Double Mechanical Seal

ITEM # DESCRIPTION

1 Spring-VII Product Seal (Wavy Washer) 1 Standard LL922313A 3 O-ring 1 Buna N75237

4* Seal ring 1 Chrome oxide LL934871 5* Seal Body-VII Secondary 1 LL932357 6 O-ring 2 Buna N70239

7 Gland-VII Pinned Seal Seat 1 316LSS 129426+ 7A Seat-Seal Head Insert 1 Ceramic 122986+

8 Seal Face-VII Rotary 1 Carbon 129059+

9 O-ring 1 Buna N70152

10 Seal Body-VII Positive Drive 1 Standard 128896+ 11* O-ring 1 Buna N70147

11A* O-ring 1 Buna N70146

32* Insert-Seal Body 1 LL934083 43* Spring-VII Outer Seal (Wavy Washer) 1 Standard LL932362 44* O-ring 1 Buna N70140

45 O-ring 1 Buna N70230

QTY PER SEAL

MATERIAL

EPDM E70237 FKM V70237-680

EPDM E70239 FKM V70239

Silicon Carbide 122987+

Silicon Carbide 129061+ Tungsten Carbide 129062+ Tungsten Carbide (narrow face) 129402+

EPDM E70152 FKM V70152

EPDM E70147 FKM V70147

EPDM E70146 FKM V70146

EPDM E70140 FKM V70140

EPDM E70230 FKM V70230

OPTION PART #

NOTE: Seal face material options (items 7A and 8): Permissible material combinations are: Carbon/Ceramic; Carbon/Silicon Carbide; Silicon Carbide/Silicon Carbide; and Tungsten Carbide/Silicon Carbide.

NOTE: Item NOTE: Use

s 4, 5, 11, 11A, 32, 43, and 44 are required when the seal must be flushed. ODE Head Installation Tool LL121191 to protect head insert when installing or removing the

opposite drive end product head. NOTE: Se

al installation tool 130007+ can be used for inserting and removing the gland and seal. The small end is used for secondary seal installation and removal and removal of the gland and seat. The large end is used for gland and seal seat installation.

* Used on Double Mechanical Seal only.

11/2012 95-03057 Page 69

Page 72

Parts Lists Waukesha Cherry-Burrell

11A

HE100-114

HE100-116

ODE Head Installation/Removal Tool

LL121191

Double Mechanical Seal

Page 70 95-03057 11/2012

Page 73

Waukesha Cherry-Burrell Parts Lists

One Piece Single & Double Mechanical Seal

ITEM # D ESCRIPTION

1 Wavy Washer (Primary) 1 Standard LL922313 3 Seal Body O-ring (Primary) 1 Buna N75237

4* Seal Ring (Se condary), if required 1 All LL934871 5* Seal Body (Secondary), if re quired 1 All LL932357 6 Seal Head Insert O-ring (Primary) 2 Buna N75044

7 Seal Head Insert (Pri mary) 1 Ceramic LL934873 10 One Piece Seal Body (Primary) 1 Chrome Oxide/316SS LL122411 11* Seal Ring/Body O-ring (Secondary) 1 Buna N70147

11A* Seal Ring/Body O-ring 1 Buna N70146

17 Product Head O-ring 2

32* Seal Body Insert (Secondary) 1 A ll LL934083 43* Wavy Washer (Secondary) 1 All LL932362 44* Seal Body O-ring (I.D. Secondary) 1 Buna N70140

45 Seal Keeper O-ring (Primary) 1 Buna N70230

QTY PER SEAL

per cyl

MATERIAL OPTION

Fluoroelastomer V70237-680 EPDM E70237

Fluoroelastomer V70044-680 EPDM E70044

EPDM E70147

EPDM E70146 Buna N70259 Fluoroelastomer V70259-680 EPDM E70259

EPDM E70140

EPDM E70230

PART #

NOTE: Use ODE Head Installation Tool LL121191 to protect head insert when installing or removing the opposite drive end product head.

11/2012 95-03057 Page 71

Page 74

Parts Lists Waukesha Cherry-Burrell

Single Mechanical Seal

Page 72 95-03057 11/2012

Page 75

Waukesha Cherry-Burrell Parts Lists

Single Mechanical Seal

ITEM # DESCRIPTION QTY PER SEAL MATERIAL OPTION PART #

1 Wavy Washer 1 Standard LL922313

Particulate Option LL19625A

2 Seal Body U-cup 1 Buna LL700014A05

Fluoroelastomer LL700014A08 EPDM LL700014A03

3 Seal Keeper O-ring 1 Buna N75226

Fluoroelastomer V70226-680

EPDM E70226 4 Flushing Lip Seal 1 All LL925472 5 Retaining Ring 1 All LL930685 6 Seal Head Insert O-ring 2 Buna N75044

Fluoroelastomer V70044-680

EPDM E70044 7 Seal Head Insert 1 Chrome Oxide/316 SS LL923210

Ceramic LL928508 8 Seal Body Insert 1 Carbon LL110892A4

Siliconized Graphite LL929270

Ceramic LL110892C1

Pin Option (Ceramic) LL934610 9 Seal Body Insert O-ring 1 Buna N75235

Fluoroelastomer V70235-680

EPDM E70235 10 Seal Body 1 Standard LL110893A

Pin Option LL927352 11 Seal Back Up Ring 1 Standard LL110203Cl 17 Product Head O-ring 2

per cyl

Buna N70259

Fluoroelastomer V70259-680

EPDM E70259

NOTE: Use ODE Head Installation Tool LL121191 to protect head insert when installing or removing the opposite drive end product head.

NOTE: Item

s 4, 5, 11, 11A, 32, 43, and 44 are required when the seal must be flushed.

* Used on Double Mechanical Seal only.

11/2012 95-03057 Page 73

Page 76

Parts Lists Waukesha Cherry-Burrell

Vertical Refrigeration Piping

Page 74 95-03057 11/2012

Page 77

Waukesha Cherry-Burrell Parts Lists

Vertical Refrigeration Piping

ITEM # DESCRIPTION QTY PER ACC NOTES PART #

1 Accumulator 1 16" Diameter LL929516 2 Refrigeration Piping 1 Upper Accumulator Piping LL930348 4 Refrigeration Piping 1 Lower Accumulator Piping LL930349 5 Weld Cap AR One Cylinder Only LL901386 6 Weld Cap AR One Cylinder Only LL901387 7 Refrigeration Piping 1 Upper Accumulator Piping LL930347 9 S W Refrigeration Flange AR 2-1/2 Male LL700017A62 10 Refrige ra ti on Flange Gasket AR 2-1/2 LL710260 11 Squa re Head Machine Bolt 4 per flg 3/4 - 10 x 3-1/2 Lg LL723931 12 Hex Nut 4 per flg 3/4 - 10 LL710112 13 S W Refrigeration Flange AR 1-1/2 Female LL919616 14 Refrige ra ti on Flange Gasket AR 1-1/2 LL917488 15 Squa re Head Machine Bolt 4 per flg 5/8 - 11 x 3 Lg LL301535 16 Hex Nut 4 per flg 5/8 - 11 LL710011 27 Carbo n Steel Pipe AR 2-1/2 Sch 40 LL006396 28 Carbo n Steel Pipe AR 1-1/2 Sch 80 LL003028 29 Carbo n Steel Pipe AR 2 Sch 40 LL001149 30 Hex Hea d Cap Screw 2 1/2 - 13 x 1 Lg LL712482 31 Flat Washer 2 1/2 LL710292 32 Spring Lockwasher 2 1/2 LL712553 33 Hex Nut 2 1/2 - 13 LL711662

11/2012 95-03057 Page 75

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Parts Lists Waukesha Cherry-Burrell

Vertical Frame/Hydraulics

ITEM # DESCRIPTION QTY PER POLE MODEL PART #

3 Hydraulic Valve 1 All LL928736 4 Push - Pull Handle 1 All LL929343 5 Hydraulic Power Assembly 1 3/4 HP CLR LL928737

Pump/Adapter Kit Only 1 LL928737-1

16 Shaft Stop Clamp 1 4” Shaft LL935529

4-1/2” Shaft LL931279 5-1/4” Shaft LL935191

22 Hydraulic Cylinder 1 6 x 24 Cylinder LL121897

6 x 36 Cylinder LL121898 6 x 48 Cylinder LL121899 6 x 72 Cylinder LL121884 6 x 84 Cylinder LL121900

32 Pivot Pin 1 All LL928742

Page 76 95-03057 11/2012

Page 79

Waukesha Cherry-Burrell Parts Lists

Shaft Heater (Optional)

ITEM # DESCRIPTION MODEL QTY PART #

20 Shaft Nut Guard All 1 LL929346 21 Shaft Locknut All 1 LL119275A 46 Gasket All 1 LL117720 47 O-ring All 1 N70222-674 48 Shaft Heater Pipe 6 x 24 Cylinder 1 LL123001

6 x 36 Cylinder 6 x 48 Cylinder 6 x 72 Cylinder 6 x 84 Cylinder

49 Heater Pipe Support 6 x 24 Cylinder 1 LL936930

6 x 36 Cylinder 1 LL934075 6 x 48 Cylinder 1 LL936598 6 x 72 Cylinder 1 LL929942 6 x 84 Cylinder 1 LL123553

50 Rotary Joint All 1 LL700043D61

1 LL112278E

11/2012 95-03057 Page 77

Page 80

6x84 6x72 6x48 6x36 6x24

410SS LL900127 CELCON LL900129 BRASS LL916284 17-7 SS LL900124 PEEK LL118683 410SS LL125801 BRASS LL918089 17-7 SS LL919100 CELCON LL900133 PEEK LL121856

128675+ N/A 8 4 N/A 2 128675M1 N/A 2 2 N/A N/A 128675M2 N/A 2 2 N/A N/A LL926752 N/A 8 4 N/A 2 LL926752M1 N/A 2 2 N/A N/A LL926752M2 N/A 2 2 N/A N/A

POLY

For 5-1/ 4” shaft onl y

LL3005185 N/A 12 8 N/A 2

HE100-004

QUANTITY

MAT ERI AL REMARKS PART NO.

DELRIN

16 12 8

For 5-1/ 4” shaft onl y

28 24

410SS

Open Style

with holes

Open Style

Parts Lists Waukesha Cherry-Burrell

Votator II Blades

PART NUMBER DESCRIPTION

Page 78 95-03057 11/2012

LL927603 Corrosion Prevention LL725499 Caution/Warning Shaft Guard LL119170 Danger - Contents Under Pressure LL125098 3-A Label LL119169 Safety Instructions LL930514 SPX/WCB Logo Horizontal LL930513 SPX/WCB Logo Vertical LL931360 Caution/Warning Product Head Locking Latch (Vertical) LL931407 Caution/Warning Product Head Locking Latch (Vertical)

Labels

Page 81

Waukesha Cherry-Burrell Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Freeze-up. Power failure. Check power supply.

Heat transfer not at expected level.

Product outlet temperature too low

Product flow rate too low. Adjust process to increase product

Product ran out of supply tank pr

Incorrect start-shutdown pr

Process not set correctly. Check current process to system

Product pressure lower than st

Oil in system. Check and drain oil regularly from

Steam on jacket super he

ematurely.

ocedure.

eam pressure in jacket.

ated.

Adjust process to raise product outlet temperature.

. Check that pump is matched to

flow process.

Adjust supply to prevent supply lines from running dry.

Refer to “Startup Procedure” on page 35.

at time of installation.

specs Utilize back valve to assure that

system pressure is at a minimum of 10 psi (0.7 bar) above the media pressure.

ccumulator and other oil separators,

a oil legs or pots in refrigeration system.

Use only dry and saturated steam.

Oil deposits on transfer tube. Remove heat transfer tube and clean

y deposits on tube. Add filter

an system to remove impurities from cooling agents.

Liquid flow rate on jacket too

low One or several system valves

floats not functioning

or properly.

Water and air in cooling

tem.

sys

Tube Scoring. Temperature extremes. Replace tube if scoring becomes

Lower back pressure required

o achieve desired refrigerant

t temperatures.

Increased compressor head

essure.

System operating at a high vacuum causing water in refrigeration system.

Air in refrigeration system. Refer to “Water and Air in

Use jacket recycle loop at a flow of 50 GPM.

Inspect and test system valves and floats as indicated in “Preventive Maintenance” on page 41. Replace as necessary.

See “Water and Air in Refrigeration System” on page 82.

. Refer to “Care of Heat

great Exchanger Tube” on page 43.

Refer to “Water and Air in Refrigeration System” on page 82.

Refrigeration System” on page 82.

11/2012 95-03057 Page 79

Page 82

Troubleshooting Waukesha Cherry-Burrell

PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Increased gas discharge

temperature. Seal head will not install

operly.

Leakage across seal body. O-ring twisted when installed. Lubricate before installing.

Air in refrigeration system. Refer to “Water and Air in

Refrigeration System” on page 82. Twisted when installed. Lubricate before installing. Installed wrong size, distorted

O-

ring, or cut O-ring.

Wrong O-ring compound (ring

different color than

is a normal).

Damaged seal head insert. Replace entire seal. Recess in head for seal head

rt damaged.

inse

Wrong O-ring compound (ring

different color than

is a normal).

Damaged seal body. Replace entire seal. Damaged seal backing ring. Replace seal backing ring. Damaged shaft at O-ring

aling surface.

Replace O-ring.

Replace with specified O-ring. If

unsure of correct O-ring, contact

WCB.

Contact WCB for repair instructions.

Replace with specified O-ring. If

unsure of correct O-ring contact WCB.

Contact WCB for repair instructions.

Seal ring rotating in seal

dy.

Assemble ring in body without

lubrication.

Page 80 95-03057 11/2012

Page 83

Waukesha Cherry-Burrell Troubleshooting

PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Product leaking:

• Between lapped or polished urfaces of seal head insert

s and seal body.

• Around O-rings of interface

head and seal head

of insert.

• Around interface of seal

dy and shaft.

Seal insert cocked when

alled.

inst Seal body and/or seal faces

n or damaged.

wor Seal insert cracked. Replace seal insert. Seal springs weak. Replace springs. Seal backing ring deformed. Replace backing ring. Seal body freedom

inished.

dim Seal drive pin worn or

missing. Seal retaining ring out of

ce.

pla Insufficient spring pressure to

ld body and insert together

ho after several hours of running.

Seal body and/or seal insert

maged by handling.

Remove and reinstall, making sure the o-ring is not twisted.

Replace entire seal.

Disassemble, clean, inspect, lubricate pieces and reassemble.

Replace with new seal drive pin.

Inspect retaining ring and lip seal. Replace as necessary.

Replace springs.

Always lay seal faces on clean cloth. Move mutator shaft into operating position carefully. Do not ram shaft into place. Inspect seal for damage, replace as necessary.

New or repaired seal body

alled against a worn or

inst damaged seal insert, a worn part, or a worn seal body.

Excessive wear of seal body insert.

Seal drive pins too high. Install per dimensions on page 56 or

Both need to be in good condition.

ce.

Repla

Do not operate shaft for more than a

w moments without product in

fe cylinder.

60 of manual.

11/2012 95-03057 Page 81

Page 84

Troubleshooting Waukesha Cherry-Burrell

Unthawing A Frozen System

Water and Air in Refrigeration System

To unthaw a system that has frozen-up, perform the following procedures. The cause of freeze-up MUST BE corrected before operation is restarted. See the Troubleshooting Chart starting on page 79 for cause and solution aids.

1. Turn refrigeration or coolant source OFF.

2. Heat mutator shaft with shaft heater attachment using hot water (if applic

3. Cautiously pump hot water or hot product through unit. Imme

diately shut down pump if excessive pressure is encountered. If hot gas defrost line is connected, thaw by blowing hot gas through the jacket

4. Continue pumping until shaft can be rotated by bumping the tor.

5. Severe freeze-ups may necessitate disassembly of

uipment to remove blockage.

6. Resume normal start-up procedure. The cause of freeze-up

MUST BE cor Troubleshooting Chart on page 79 for cause and solution aids.

Water and ammonia combine to form ammon ium hyd r oxid e , which combines with oil to form sludge. Sludge is extremely difficult to remove.

able).

rected before operation is restarted. See the

Water condenses at the accumulator’s pressure and temperature

d remains to dilute the liquid ammonia. Ammonia diluted with

an water has a higher boiling point that requires lower back pressure to achieve the desired refrigerant temperature.

Air in ammonia increases the compressor head pressure and

eases the gas discharge temperature. Higher head pressure

incr and temperature may carbonize or vaporize oil. Air also contains moisture that the ammonia refrigerant absorbs.

To avoid difficulties with water and air:

• Regularly purge refrigeration system of air and

ncombustible gases. An automatic air purger in the system

no is recommended.

• Grease all valve stems to keep packing soft. Soft packing

ws a better seal to prevent leakage of air past stems, if

allo the systems ever separate on a vacuum.

• Tighten up stuffing boxes to seal out air and moisture.

• Avoid operating system on a high vacuum.

Page 82 95-03057 11/2012

Page 85

Page 86

Votator® II

SCRAPED SURFACE HEAT EXCHANGER

SPX FLOW TECHNOLOGY

611 Sugar Creek Road Delavan, WI 53115 P: (262) 728-1900 or (800) 252-5200 F: (262) 728-4904 or (800) 252-5012 E: wcb@spx.com

SPX reserves the right to incorporate our latest design and material changes without notice or obligation.

Design features, materials of construction and dimensional data, as described in this bulletin, are provided for your information only and should not be relied upon unless confirmed in writing. Please contact your local sales representative for product availability in your region. For more information visit www.spx.com.

The green “>” is a trademark of SPX Corporation, Inc.