s.fco Oro Manual 4vte100 Oc 184559,l30

5/19/2018 s.fco Oro Manual 4vte100 Oc 184559,l30

1/33

08/20/2012CONDUMEX, INC.2590 114TH STREETSUITE 200GRAND PRAIRIE, TX 75050USA

Purchase Order #: 1845Sales Order #: 0001Line Item: 0000

Please note this documentation has been submitted for informational purposes only, and the has been released to production in accordance with the design as detailed per the encloseddocumentation.

Submitted Date: 08/20/2012

Print Quantity: 01

Document Name

Safety Check List

Installation Drawing

Machine Assembly Drawing

General Instructions

Recommended Bolting Torques

Flange and Gasket Proportions

Operation & Maintenance Instruction

R510 Impeller Assembly Drawing

Motor Maintenance Instructions

Sales Offices

DocumentRevision

G

D

P

DocumentNumber

IT-2144

1532628000030-A

1532628010-B

R281754-F

IT-850

DS-E-571

R281754-E

1532628010-C

IT-1488

IT-3839

Thank You.

For Questions please call: Manuel Nagano

SPX Process Equipment Mexico

Phone #: 55-5243-4218

Email: [email protected]


2/33

MIXER MANUAL - INSTRUCTIONS

INSTALLATION

OPERATION

MAINTENANCE

Ship To: CONDUMEX, INC.Customer: CONDUMEX, INC.PO Number: 184559Model: Lightnin Mixer Model 4VTE100Order Number: 0001532628Line Number: 000030

http://www.lightninmixers.com


3/33

MIXER MANUAL - INSTRUCTIONS

LIGHTNIN SALES ORDER 0001532628

LIGHTNIN LINE ITEM 000030

Safety Check ListInstallation DrawingMachine Assembly DrawingGeneral InstructionsRecommended Bolting TorquesFlange and Gasket ProportionsOperation & Maintenance InstructionR510 Impeller Assembly DrawingMotor Maintenance InstructionsSales Offices

IT-21441532628000030-A1532628010-BR281754-FIT-850DS-E-571R281754-E1532628010-CIT-1488IT-3839

DOCUMENT NO.TITLE

Table of Contents


4/33

CAUTION -

WARNING -

DANGER -

Revision Date: 5/9/1986

H Revised: 9/9/2011

Signals unsafe practices or hazards which couldcause severepersonal injury or death.

Signals immediate hazards which willprobably cause severepersonal injury or death.

This mixer should be equipped with safety or instructional labels similar to those shown below. If any of the labels are

missing, damaged or otherwise illegible, DO NOTinstall, service or operate the mixer. Contact your LIGHTNIN

representative immediately for instructions.

INST. No. IT-2144

COPYRIGHT 2011 SPX CORPORATION Page 1 OF 4

EXAMPLES:

Signals unsafe practices or hazards which couldcause minorpersonal injury or property damage.

IMPORTANT: READ THIS SECTION THOROUGHLY

SAFETY INSTRUCTIONS / CHECKLIST

IF YOU DO NOT UNDERSTAND ANY PORTION OF THESE INSTRUCTIONS DO NOTATTEMPT TO INSTALL OR

OPERATE THIS MIXER! CONTACT YOUR LIGHTNIN REPRESENTATIVE FOR ANY QUESTIONS YOU MAY

HAVE CONCERNING SAFETY OR THESE INSTRUCTIONS.

Your LIGHTNIN mixer is equipped with safety labels which contain specific instructions pertaining to the safe

handling and operation of the mixer. For your protection, you must understand that failure to follow the safety

instructions imprinted on the safety labels or failure to follow the safety instructions printed in this instruction manual

may result in serious personal injury or death. In addition, failure to adhere to safety instructions may cause damage to

property or equipment.

In this publication, and on the mixer safety labels, the words DANGER, WARNING and CAUTION may be used to

signify special instructions to be observed by the installer or user. These instructions warn of potential hazards

concerning service, installation or operation if the instructions are performed incorrectly, carelessly or are ignored.

Safety instructions alone cannot eliminate the hazards they signal. Strict compliance with these special instructions,along with safe work habits and simple "common sense" are major accident prevention measures.


5/33

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Date: 5/9/1986

Revised: 9/9/2011

SAFETY CHECK LIST

WARNING: When moving, installing or lifting this mixer, always use equipment which is rated to carry the full load

of the mixer. Use only the lifting device, if provided, on your unit to install the mixer. Failure to follow these

instructions could cause severe injury, death or damage to property. Consult the appropriate section of this manual

for lifting and installation instructions.

WARNING: DO NOT connect the motor to the power source until all components are assembled, the mixer is

installed, and all hardware is tightened to the proper torque which is specified in the operation and maintenance

manuals supplied by LIGHTNIN.

DO NOT operate shaft sealing devices at temperatures higher than those specified in the manual or on the

nameplates.

DO NOT service the mixer until you have followed your "Control of Hazardous Energy Sources" (lockout, tagout

procedure) as required by OSHA.

IMPORTANT WARNINGS

WARNING: DO NOT attempt to connect a power source to this mixer unless you are licensed or certified to do so.

Failure to follow this instruction could cause severe injury, death or damage to property.

All LIGHTNINMixers and Aerators are provided with properly designed lifting devices and safety covers to avoid potential

injury and/or equipment damage. The following SAFETY CHECK LIST should be THOROUGHLY REVIEWED AND ADHERED

TO before installing, operating or performing maintenance on the mixer. FAILURE TO FOLLOW THESE INSTRUCTIONS

COULD RESULT IN SERIOUS INJURY. Ensure the use of qualified, quality trained and safety conscious personnel.

Revision

H

WARNING: Never attempt to move or adjust a mixer while it is running.

WARNING: Never touch a mixer, which has an electric motor, or any part of an electrical service line cord or

conduit, while your hands or feet are wet or if you are standing on a wet or damp surface. Failure to follow this

instruction may result in severe electrical shock or death.

DANGER: Never touch any rotating part of a mixer with bare hands, gloved hands or any other part of your body,

or with any hand held object. Rotating parts include, but are not limited to, the mixer shaft, impeller(s), set screws,

hardware, couplings, mechanical seals and motor fans.

COPYRIGHT 2011 SPX CORPORATION

INST. No. IT-2144

Page 2 OF 4

WARNING: DO NOT touch any part of mixer that has the potential of having a hot surface including the motor,

gear drive housing, seal, shafting and flange. When a mixer is running, the motor temperature rises. This is a

normal occurrence, but the motor temperature may be high enough to cause burns to the hands or any other part of

the body. DO NOT touch a mixer motor until it cools for at least one hour. Failure to follow these instructions may

result in severe personal injury.

WARNING: DO NOT operate mixer for service other than its intended use, that being fluid mixing with the mixer

attached to a rigid structure and connected to a power source appropriate to operate the mixer drive motor.


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11.

12.

13.

14.

15.

16.

17.

Date: 5/9/1986

Revised: 9/9/2011H COPYRIGHT 2011 SPX CORPORATION Page 3 OF 4

WARNING: Eye protection must be worn at all times while servicing this mixer. Failure to follow this instructions

may result in severe injury or death.

WARNING: Never attempt to clean or service the mixer, or any part of it, while the mixer is running, or while it is

connected to a power source. Always turn the mixer off and disconnect the power before cleaning or servicing.

CAUTION: When repairing the mixer, or replacing parts, use factory authorized parts and procedures. Failure to

do so may result in damage to the mixer or injury to the user.

DO NOT enter the mixing vessel UNLESS:

A. The mixer power supply is locked out (follow item number 5).

B. The mixer shaft is firmly attached to the mixer drive or the shaft is supported securely from below.

C. You have followed applicable confined space regulations.

Revision INST. No. IT-2144

DO NOT operate mixer until you have checked the following items:

A. Make sure the mixer is properly grounded.

B. Ensure all protective guards and covers are installed.

Guarding of the mixer shaft below the mixer mounting surface is the responsibility of the customer.

C. Ensure all detachable components are securely coupled to the mixer.

D. Thoroughly REVIEW and ADHERE TO the mixer operating instructions supplied by LIGHTNIN.

E. Ensure the mixer output shaft rotates freely by hand.

F. Ensure all personnel and equipment are clear of rotating parts.

G. Ensure all external connections(electrical, hydraulic, pneumatic, etc.) have been completed in accordance

with all applicable codes and regulations.

DO NOT make any field changes or modifications (horsepower, seal material components, output speed, shaft

lengths, impellers, etc.) without reviewing the changes with your LIGHTNINSales Representative or the

LIGHTNINCustomer Service Department.

DO NOT install an aftermarket Variable Frequency Drive without first consulting your LIGHTNINSales

Representative or the LIGHTNINCustomer Service Department to determine the compatibility of the existing

motor with the Variable Frequency Drive.

SAFETY CHECK LIST, cont'd.

IMPORTANT WARNINGS, cont'd.


7/33

5152606 5501523 6517233 6860474 7168848 7387431 7550120

5152934 5511881 6517246 6877750 7168849 7407322 7572112

5203630 5568975 6742923 6986507 7278799 7473025 7726946

5344235 5779359 6746147 7001063 7328809 7481573 7753215

5368390 5925293 6789314 7056095 7329065 7488137 7874719

5470152 5988604 6796707 7114844 7331704 7507028

5480228 6158722 6796770 7168641 7384551 7547135

Revision Date: 5/9/1986

H Revised: 9/9/2011

CAUTION: When applicable specific markings required by Pressure Equipment Directive 97/23/EC (PED) and/or

Equipment for Use in Potential Explosive Atmospheres Directive 94/9/EC (ATEX) will be indicated on supporting

nameplates. If there is any doubt relating to the intended use of this equipment please contact LIGHTNINbefore

installation and operation.

PATENTS

ENVIRONMENTAL NOTICE

Dispose of equipment responsibly at the end of its service, in accordance with

local laws and directives. Correct disposal is the responsibility of the end

user. If in doubt, consult with local environmental agencies for advice on the

best method of disposal.

CE COMPLIANCE

COPYRIGHT 2011 SPX CORPORATION Page 4 OF 4

If the mixer nameplate has a CE marking on it, then the equipment furnished conforms to the following directives:

Machinery Directive: 2006/42/EC

Electro-Magnetic Compatibility: 2004/108/EC

Low Voltage Directive: 2006/95/EC

Any CE marking and/or associated documentation applies to the mixer only. This has been supplied on the basis

that the mixer is a unique system. When the mixer is installed, it becomes an integral part of a larger system which

is not within the scope of supply and CE marking is the responsibility of others.

INST. No. IT-2144

Heavy Series: S10, 70/80, 500/600 - maximum 85 dBA @ 1 meter.

THIS PRODUCT MAY BE COVERED BY ONE OR MORE OF THE FOLLOWING U.S. PATENTS:

NOISE LEVELS

SOUND PRESSURE LEVELSPortable Series: ECL, EV - maximum 80 dBA @ 1 meter.

Noise: 2000/14/EC


8/33


9/33


10/33

REVISION

2005

DATE 11--1--05

REVISED PAGE 1 OF 7

INST. NO. R281754--F LIGHTNINLIGHTNIN

MIXERS AND AERATORS

GENERAL INSTRUCTIONS FOR MODEL VTEThis LIGHTNIN Agitator is a piece of precision machinery of the highest quality. It is designed to operatesatisfactorily under all the conditions normally encountered.

With proper care, this LIGHTNIN Agitator will give years of trouble free service. If you should have any questionsregarding its operation, that are not answered in this manual, contact your authorized LIGHTNIN Mixer

Representative.WARNING: Before attempting anymaintenance or service on this machine, it is essential thatappropriate safetyprecautions betaken, includingbutnotlimitedtolockingoutthepowersourceandrestrainingbothinputand outputshafts of the unitfromunexpected rotation. Even with the power source locked out, it is possible for a mixer shaft(andthus allconnectedmachinery) tobe causedtorotate bytheactions ofthe media beingmixed,orotherexternalfactors. Thus, it is necessary to ensure that the shafts are restrained from rotation or other movement while theunitis beingserviced.In additiontorestrainingtheshaftfromunexpectedrotation,itis also essentialthatanylockedin torque loading (or other sources of stored energy) in the system be released or positively restrained beforeattempting any service.

FAILURE TOBOTHLOCKOUT ANDRESTRAINTHE MACHINE FROMUNEXPECTED MOVEMENTBEFORESERVICE OR MAINTENANCE ACTIONS CAN RESULT INSERIOUS INJ URY OR DEATH.

WARNING: EYE PROTECTION MUST BE WORN AT ALL TIMES WHILE SERVICING THIS AGITATOR.

SECTION 1 -- INITIAL INSPECTION, SHIPPING ARRANGEMENTS

1.1 As soon as the unitis uncrated, check for possible shipping damage. Reportany damage immediatelyto thecarrier and our factory. DO NOT proceed with the servicing or installation of any unit with shipping damageunless so directed by the factory.

1.2 Theagitatoris shippedas a completeunit, wheneverpossible, readyto installafterunboltingfromthe shippingskid. Any grease lubricated bearings in the unit have been serviced at the factory.

Various small components, such as impeller hardware, plugs, etc. are often packaged separately to avoiddamage during assembly or to insure thatthe unitremains sealed andproperly preserved during shipment.

These components should be identified and assembled to the unit.

If shipping restrictions limit overall size, drives and/or motors may be shipped disassembled.

Factory installed V--belt drives are accurately aligned and adjusted, but should be rechecked in casemisalignment occured during shipping and handling. Refer to Section 2 of the Operating Instructions forcomplete information and alignment of V--belts.

1.3 SHIPP ING PROTECTIONAll units are treated withcorrosion inhibitors for protection during shipment andpossible short termstorage.

a . External Steel Surfaces -- All external steel surfaces not protected with permanentcoatings are coveredwith a rust preventative that is easily removed with kerosene or a similar solvent. All preservatives mustberemoved before checkingshaft alignments. Do not remove any wrappings or rotate the shafts until theunit is ready for operation.

b . Protection Period -- Factoryappliedinhibitors will protectunits frominternalcorrosion for periods up to (1)year if stored indoors in clean, temperature controlled, dry surroundings. ReviewSection 4 of this manualcarefully if the unit is to be stored in conditions other than those described above prior to installation.

c . Storage -- This equipmentis protectedwith corrosioninhibitors andpreventatives beforeshipping and maybestoredindoors for a period ofONE YEAR afterthe time itleaves thefactory. For longer storageperiods,or if the protective treatments have been disturbed in any way, see Section 4 of these instructions formethods of reapplying the preservative treatments.

In the eventthat outdoor storageis necessary, the unitmustbe protected fromthe elements andextremetemperature fluctuations. Constant temperature and dry ambient conditions will afford the best storageresults. Contactthe factoryif extended outdoor storage is required. Unprotected outdoor storage is NOTPERMITTED.


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REVISION

2005

DATE 11--1--05

REVISED PAGE 2 OF 7


MIXERS AND AERATORS

SECTION 2 -- INSTALLATION

2.1 Refer to the Installation Drawing for:

a . Proper agitator location and off bottomdistance.

b . Design loads, mounting details.

c . A minimumclearance of 3is required around totallyenclosed fan cooledmotors toinsureadequatemotor

ventilation. The motor must be wired for the rotation as indicated by the rotation arrow.2.2 The ImpellerInstructions listthe minimumopeningrequiredtopass the impellerintothe tank.The impellertype

and diameter is listed on the installation drawing.

2.3 The unit must be installed by accomplishing each of the following actions in the order prescribed:

CAUTION: NEVER use the motor eyebolts to lift or supportthe assembled agitator. DO NOT hoist, handleor rest the unit on any shaft extension.

a . Remove safety coverplates (320 & 322).

b . Support the mixer through openings in the fixed (120) bearingmember andsling between the motor feetand motor bracket (108) and mount the unit on the mouting flange (see Figure 1).

CAUTION: When takingup slackon lifting cables, avoid suddenimpact loading on the liftingdevices.

Figure 1

SLINGSLING

c . Install safety coverplates (320 & 322).

d . Assemble the impellerto the mixer shaft. Referto the impellerassemblydrawingR281754--C. Make surethe impellerhardwareis tightenedto the specific torques inthe impellerinstructions. A torquewrenchmustbeusedto tighten allbolts to theirspecified torque values. Tighten all otherhardware to the values shownin IT--850. All bolts should be retightened 12 hours after assembly, and at each scheduled shut downthereafter.

e . Motor Power Connections:

In order to insure proper functioning of the unit, it is essential that the motor maintenance instructions inthis manual and the nameplate be reviewed before connecting to power source.

2.4 It is the customers responsibility to touch up any paint damage incurred during installation and/or storage.

SECTION 3 -- ROLLER BEARING LUBRICATION

3.1 REGREASABLE BEARINGS

Open type bearings are initially lubricated at our factory. Housings are provided with grease fittings andautomatic relieffittings or relief plugs when required. Lithiumbased NLGI #2 consistency grease is usedtolubricate all open bearings.


12/33

REVISION

2005

DATE 11--1--05

REVISED PAGE 3 OF 7


MIXERS AND AERATORS

Lithiumbase grease is a multi--purpose grease mostideallysuited to coveringthe broadrange of operatingconditions bearings are subjected to. It offers good resistance to water and remains stable through a widerange of varying mechanical, oxidation and temperature conditions.

With the exception of polyurea greases, as noted below, only lithium greases must be used. Without takingthe bearingapartand throughlycleaning it, itis virtually impossible to remove all of the lithiumgreasewhichwas installed at the factory, and thus, undesirable cross contamination is unavoidable. Many greases arenotcompatible with one another and cross contamination can, therefore, create serious problems. Since it

is not practical to present a complete compatability chart in this manual, it is best not to mix grease.

Greases made with polyurea complex thickeners are compatible with most greases, including lithiumthickened greases. Polyurea greases are generallyhigher in load capacity and may be used where an EPgrease is required.

3.2 REGREASING PROCEDURE

a . Installed bearings:

Before regreasing besure tocleanall grease fittings andpurgeports thoroughly topreventcontaminationof the coupling during the regreasing operation. Make sure the recommended type of grease has beenloaded into the grease gun and that itis clean and free of contamination. Refer to the Assembly Drawingfor location of the grease and purge ports.

Use only one of the approved greases listed herein, NLGI Grade 2, when regreasing the couplings. Therequired regreasing interval is dependant upon operating temperature of the coupling. At each

regreasing, the coupling should be checked for signs of leakage. Such leakage will greatly shorten therequired lubrication interval and thus the coupling seals must be maintained to prevent leakage.

Grease should be added to the coupling until fresh, clean grease is observed to flowfromthe purge port.Do notstoppumping greaseatthefirst sign ofgreasein the purge port. It is importantthatthe newgreasereplace as much of the old, worn grease as possible in order to insure that maximum coupling life isattained. Be sure to wipeawayany excess grease and replaceand safety guards and covers whichmayhave been removed after completion of the regreasing operation.

b . Uninstalled bearings:

If a bearingis removedfromthe shaftassembly, itshouldbecleanedthoroughlywith kerosene ora similarsolventuntilall oldgreaseandforeign matteris removed. Allowto airdry. DO NOT SP IN DRY BEARINGS.Dip bearing in a light lubricating oil for protection if it is not to be regreased immediately.

Regrease the bearing by forcing grease between the rolling elements and the inner and outer races.Thoroughly work the grease in fromboth sides of the bearing to insure that it is fully packed.

Before reinstalling the bearing, thoroughly clean the housing and coat it with fresh bearing grease. Inaddition, packthe cavitybelowthebearingwith freshbearinggrease ofthesame type. Replace allcoversandadd lubricantthrough the fitting to purge the housing of air pockets andinsure that the channels arefull.


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REVISION

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DATE 11--1--05

REVISED PAGE 4 OF 7


MIXERS AND AERATORS

3.3 APPROVED GREASES

Greases of various types may be used inLIGHTNINunits, depending on the specific operating conditionsto which the units are being subjected. Only greases selected from those identified in this manual asApproved Greasesmay be usedinLIGHTNIN units. All products listedin Tables 1 &2 are compatible withthe original grease used at the factory.

a . Standard LithiumGreases

The greases listedin Table 1 are standard duty products and maybe usedfor all couplings and bearingsin these units. Units shippedfromthe factorycontaina standardlithiumgrease unless otherwisespecifiedbythepurchaser, thus the factory fill is compatiblewith anygrease listedin Table 1.In general, a standardlithium grease is adequate for most applications.

b . Medium Duty LithiumEP Greases

For a small cost premium, the greases listed in Table 2 will provide generally longer bearing life andimproved systemreliability. They may be used on any unit. Since these greases are lithiumbased, theyare also compatible with the products listed in Table 1 and with the original factory grease fill.

c . Heavy Duty EP Greases

For a slightly higher cost premium than the medium duty greases defined above, the heavy duty EPgreases listedin Table 3 canbeusedin allsevereapplications toyieldlonger bearinglife andsignificantlyimproved systemreliability. They may be used in any unit.

It should be noted that these greases are not fully compatible with some lithium greases and thus anybearing or coupling in which these products are to be used mustbe fullypurged to eliminate as much ofthe lithium product as possible before the unit is placed in service. On special request, units can bedelivered fromthe factory filled with a heavy duty EP grease.

TABLE 1APPROVED STANDARD LITHIUM GREASES

MANUFACTURER

AMERICAN INDUSTRIAL RESEARCHCORP. -- EAS T RUTHERFORD, NJ

SHELL OIL CO.HOUSTON, TX

TEXACO LUBRICANTS CO.HOUSTON, TX

WITCO CORP. -- LUBRIMATIC DIV.OLATHE, KS

PRODUCT

REXLUBE

TERMALENE

CASTROL EP GREASE

PREMIUM LITHIUM EP

DURA--LITH

LITHIUM E P

1200

PQ 400 SERIES

EP LITHIUM

PENNLITH EP

ALVANIA

REGAL

HI--TEMP LC

MANUFACTURER

AMOCOCHICAGO, IL

BP OIL CO.CLEVELAND, OH

CATO OIL & GREASE CO.OKLAHOMA CITY, OK

CONOCO, INC.HOUSTON, TX

COOKS INDUSTRIAL LUBRICANTSLINDEN, NJ

EXXON CO., U.S.A.HOUSTON, TX

GULF OIL CO.HOUSTON, TX

MOBIL OIL CORP.EDISON, NJ

PENNWALT CORP., KEY STONE LUBESKING OF PRUSSIA, PA

PHILLIPS 66 CO.

BARTLESVILLE, OKSUN OIL CO.PHILADELPHIA, PA

UNION OIL CO.

ZURN CO.PHILADELPHIA, PA

PRODUCT

AMOLITH

ENERGREASE LS

MYSTIK J T

SUPE R--STA GREASE

UNIVERSAL GREASE

LIDOK EP

GULFCROWN GREASE

MOBILITH AW

81 EP

PHILUBE EP

PRESTIGE

UNAX RX

ZURN GREASE EP

BEL--RAY CO., INC.FARMINGDALE, NY

CASTROL INDUSTRIAL, INC.CHICAGO, IL

CITGO PETROLEUM CORP.TULSA, OK

CHEVRON U.S.A., INC.SAN FRANCISCO, CA

DRYDEN OIL CO., INC.BALTIMORE, MD

FISK BROTHERS REFINING CO.LUBRIPLATE DIV. -- NEWARK, NJ

HULS AMERICAN, INC.PIS CATAWAY, NJ

NIAGRA LUBRICANT CO.BUFFALO, NY

PENNZOIL PRODUCTS CO.

HOUSTON, TX


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REVISION

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DATE 11--1--05

REVISED PAGE 5 OF 7


MIXERS AND AERATORS

TABLE 2APPROVED MEDIUM DUTY EP LITHIUM GREASES

MANUFACTURER

MOBIL OIL CORP.

EDISON, NJ

TEXACO LUBRICANTS CO.

HOUSTON, TX

CHEVRON U.S.A., INC.

SAN FRANCISCO, CA

PRODUCT

AMOLITH EP

MOBILUX E P

MULTIFAK EP

DURA--LITH EP

FALK CORP.

MILWAUKEE, WI LTG

TIMKEN OK LOAD

40

40

40

40

50

AMOCO

CHICAGO, IL

GULF OIL CO.

HOUSTON, TX GULFCROWN EP40

TABLE 3

APPROVED HEAVY DUTY EP GREASES

MANUFACTURER

SHELL OIL CO.

HOUSTON, TX

PRODUCT

POLYUREAEP

ALVANIA EP

KEYSTONE EP

TIMKEN OK LOAD

60

60

75

CHEVRON U.S.A., INC.

SAN FRANCISCO, CA

PENNWALT CORP., KEY STONE LUBES

KING OF PRUSSIA, PA

3.4 REGRE ASING INTERVALS

Open type bearings require fresh lubricantat regular intervals. The frequency of relubrication depends on:

a . Presence of excessive moisture.b . Extent of atmospheric contamination.

c . Variations in ambient temperature.

d . Bearing operating temperatures.

TABLE 4GREASED COMPONENT RELUBRICATION SCHEDULE

TYP E OFGREASE

BEARING OPE RATING TEMPE RATURE

UNDER160 F

160--185 F 186--200 F

STANDARDNLGI #2

NLGI #2 (EP)EXTREME

PRESSURE

NLGI -- NATIONAL LUBRICATING GRE ASE INSTITUTE

6 MOS. 5 MOS. 4 MOS.

3 MOS. 2 MOS. 1 MO.

For mostapplications, the regreasingintervals specifiedin Table 4 are adequate. Bearings operatingathightemperatures and/or bearings lubricated with extreme pressure (EP ) grease require fresh grease at morefrequent intervals.


15/33

REVISION

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DATE 11--1--05

REVISED PAGE 6 OF 7


MIXERS AND AERATORS

Periodic temperature checks should be made to establish lubrication intervals and to detect potentialproblems thatcanresultfromoverheating. Bearingoperatingtemperatures canbedeterminedwitha surfacepyrometerorthermometerplacedonthe bearinghousingwall adjacenttothe bearing. Add10F to theactualreading to compensate for heat transfer loss.

SECTION4 -- STORAGE

LIGHTNINAgitators, like all precision equipment, must be protected against corrosion during prolonged periodsofinactivity. The primarycause ofcorrosionis condensationduetofluctuatingtemperatures,high humidity, orboth.Properly treated and located in clean, dry surroundings, inactive equipment can be successfully stored withoutdamage due to corrosive attack. REVIEW and FOLLOW all instructions in this section.

FAILURE TO PROPERLY STORE AND PROTECT EQUIPMENT AS OUTLINEDMAY VOIDANY WARRANTY,EXPRESSED OR IMPLIED.

4.1 STORAGE C ONSIDERATIONS

LIGHTNIN Agitators, like all precision equipment, must be protected against corrosion during prolongedperiods of inactivity. The primary cause of corrosion is condensation due to fluctuating temperatures, highhumidity, or both. Properly treated and located in clean, dry surroundings, inactive equipment can besuccessfully stored for up to one year without damage fromcorrosive attack.

Electric motors or otherprime movers are notprepared for indoorstorage beyond the periods shown belowby LIGHTNIN. Outdoor storage of electric motors is not recommended by any motor manufacturer. Forstorage periods beyond those shown below, refer to motor maintenance instructions furnished with this

manual for further details.

4.2 STORAGE OF NEW UNITS

LIGHTNIN Agitators are factory treated with high quality corrosion inhibitors and rust preventatives. Withreasonable care at the site, the products will effectivelyprotectnew, uninstalled units fromcorrosion due towater andwatervapor, for upto oneyear, dependingon howthe unitis stored.Outdoor, unprotectedstorageis not permitted under any circumstances unless the unit has been specifically prepared for such storageat the factory prior to shipment.

a . Uninstalled, Protected Storage

Installed, Inoperative Units

Installed, Operative Units

Depending on the conditions under which a new unit which has not been installed is stored, the initialfactory applied corrosion protection treatmentwill last up to one year. Actual preservation periods, as a

function of storage conditions are defined in Table 5.

TABLE 5

CORROSION PROTECTION PERIODS

STORAGE CONDITIONSPROTECTION PERIOD, MONTHS

INITIAL PERIODIC INSPECTION

INDOORS IN A DRY AMBIENTATMOSPHERE WITH CONTROLLED

TEMPERATURES

INDOORS IN A DRY AMBIENTATMOSPHERE WITHOUT TEMPERATURECONTROL

OUTDOORS AS CRATED WITH SUITABLEPROTECTION FROM THE ELEMENTS.COVERINGS MUST BE WATERP ROOF, BUTHAVE PROVISIONS FOR FREE CIRCULATIONOF AIR TO AVOID BUILDUPS OF CONDENSATION.EQUIPMENT MUST BE ELEVATED AT LEAST12 INCHES ABOVE GROUND LEVEL TO REDUCEMOISTURE PICKUP.

12 12

6 6

4 4


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DATE 11--1--05

REVISED PAGE 7 OF 7


MIXERS AND AERATORS

b . Periodic Inspection

All protective coatings and wrappings must be maintained in good condition. Stored units should bevisually inspected periodically to insure that the factory wrappings and coatings are intact. If factorywrappings and coatings are accidentally removed or damaged, reapply them over the exposed areas.

c . Refer to electric motor maintenance instructions furnished with this manual for further details onrepreservation of the electric motor.

4.3 STORAGE OF DEACTIVATED UNITSUnder normal circumstances, units that have been in service, but will be idle less than 3 months, must berun for at least 15 minutes every week, to redistribute grease, and receive regular maintenance. If thisprocedure is followed carefully, such units do not require represervation.

a . Cover units stored outdoors with waterproof covering, allowing for free air circulation.

b . Periodic Inspection

All protective coatings and wrappings must be maintained in good condition. Stored units should bevisually inspected periodically to insure that the factory wrappings and coatings are intact. If factorywrappings and coatings are accidentally removed or damaged, reapply them over the exposed areas.

c . Refer to electric motor maintenance instructions furnished with this manual for further details onrepreservation of the electric motor.

4.4 START--UP PREPARATION

When a unit is removed from storage, performthe following steps before placing the unit in service:

a . Remove all wrappings and coverings.

b . Service the unit with lubricants as defined in Section 3.

c . Check shafts for free rotation.

d . Install all safety guards.


17/33

LIGHTNIN

REVISION DATE 2-1-85 LIGHTNIN LIGHTNIN INST. NO. IT-850H REVISED 12-08-11 MIXERS AND AERATORS 2008 PAGE 1 OF 1

BOLT TIGHTENING TORQUE RECOMMENDATIONSInadequately or improperly tightened hardware can loosen due to vibration or the load reactions imposed by fluid forces. This can result in reducedequipment service life or damage and failure.

Recommended torques for tightening ANSI bolts and screws on LIGHTNINMixers and Aerators and their mounting structures are listed below for yourgeneral reference. These average torque values should be considered only as guides and not as absolute values.

The amount of torque required to maintain a tight connection can vary considerably for bolts of the same size under different operating conditions.Variations such as basic joint design, compression factors, type and strength of base and hardware material, surface finish of mating parts andlubrication are only some of the factors that influence the tightness of bolted connections for given bolt torques.

UNLESS SPECIFICALLY LISTED ELSEWHERE IN THE DETAILED INSTRUCTIONS, TIGHTEN THE MIXER AND MOUNTING HARDWARE TOTHE RECOMMENDED VALUES SHOWN. A torque wrench must be used to ensure compliance with these torque requirements.

Certain assembly connections may require special torques that are not listed in the table. These torques can be found in the detailed assembly anddisassembly sections of your manual. REVIEW YOUR MANUAL CAREFULLY TO DETERMINE WHERE SPECIAL TORQUES ARE REQUIRED.

For severe duty service, torques higher than listed, to tighten a bolt to maximum capacity, can often be used. However, due to the many variablespreviously mentioned, the only absolute method to determine optimum torque is to deliberately yield a bolt under actual conditions. If a bolt does yield oshear, 75% of the torque applied in yielding the bolt can be used to obtain a tight connection that is satisfactory.

ALL BOLTS SHOULD BE RETIGHTENED 12 HOURS AFTER ASSEMBLY, AND AT EACH SCHEDULED SHUT DOWN THEREAFTER.

RECOMMENDED TIGHTENING TORQUES FOR COMMERCIAL

GRADE STEEL, GR5, 304 AND 316 STAINLESS STEEL (1) (2)

BOLTTHREAD

SIZE

TIGHTENING TORQUES(FT-LBS) (4)

GRADE 2, 3 OR304/316 SS BOLTS

LUBRICATED

TIGHTENING TORQUES(FT-LBS) (4)

GRADE 5BOLTS

LUBRICATED

MARKING

GRADE

STEEL SAE GRADEMARKING REFERENCE

GUIDE

(2)1/4

_20 4.6 7.2

NO MARK

SAE GRADES0, 1 AND 2

5/16

_18 9.6 15

3/8

_16 17 26

7/16

_14 27 42

SAE GRADE 31/2

_13 41 64

9/16

_12 60 92

5/8

_11 83 128

SAE GRADE 53/4

_10 120 (3) 226

7/8

_9 142 (3) 365

1_8 212 547

ALL SOCKETHEAD CAP SCREWS

SAE GRADE 5

11/8

_7 301 675 (3)

11/4

_7 425 952

13/8

_6 557 1249

11/2

_6 739 1657

13/4

_5 754 (3) 1600 (3)

2_4

1/2 1134 2406

21/4

_4

1/2 1659 3519

21/2

_4 2269 4813

(1) ALL BOLTS SHOULD BE COATED WITH OIL, GREASE OR AN ANTI-SEIZE COMPOUND WHENEVER POSSIBLE. THE THREADS ANDBEARING FACE OF BOLT HEADS AND/OR NUTS SHOULD BE LUBRICATED.

(2) TORQUE VALUES SHOWN SUPERSEDE PREVIOUS TABLES THAT MAY HAVE ALLOWED LOWER VALUES. IT IS RECOMMENDED THAT

ONLY FASTENERS BE USED THAT ARE PROPERLY MARKED, INCLUDING MANUFACTURERS TRADE MARKING. ONLY FASTENERSMARKED AS SHOWN ARE GUARANTEED TO MEET SPECIFICATION AND PERFORMANCE REQUIREMENTS.

(3) ALLOWABLE BOLT STRESS VALUES CHANGE AT THESE LOCATIONS AND IS REFLECTED IN THE SUGGESTED TORQUE VALUES.

(4) CONVERSION FACTORS:

FRICTION LOCKING DEVICES MULTIPLY LUBRICATED VALUE BY 1.15. THESE TORQUES PERTAIN TO BOLTS OR NUTS WITH FRICTIONLOCKING DEVICES SUCH AS NYLON PELLETS OR PATCHES, FIBER INSERTS OR UPSET THREADS.

DRY VALUES MULTIPLY LUBRICATED VALUE BY 1.33.

METRIC VALUES IN N-m 1FT-LB = 1.3558 N-m


18/33

LIGHTNINSALES DATA BOOK DATE 520

ALL EQUIPMENT DESIGN AND APPLICATION DATA SHHEREIN AND RELATED KNOW-HOW ISCONFIDENTIALTHE PROPERTY OF THE LIGHTNIN GROUP OF COMPANO USE OR DISCLOSURE THEREOF MAY BE MADE WIOUR WRITTEN PERMISSION.

MIXERS AND AERATORS

DRAWING NO. DSE5

GASKET I.D.

RAISED FACE DIA.

GASKET O.D.

BOLT CIRCLE DIA.

FLANGE O.D.

STEEL

CONSTRUCTION

ALLOY

CONSTRUCTION

1/16 RAISED

FLANGE GASKETNOT FURNISHEDBY LIGHTNIN

NOMINAL 3/16RAISED FACE

FLANGE IS STEEL.FACING & PARTS EXPOSED

TO TANK CONTENTS AREALLOY SPECIFIED

SEE NOTE 1

NOTES:

1. GASKETS MUST BE SEATED BETWEEN THE RAISED FACES OF THEMIXER AND TANK FLANGE TO EFFECTIVELY SEAL AGAINST PRESSURE,VAPOR LEAKS AND/OR PRODUCT CONTAMINATION. DIMENSION CIS THE MINIMUM GASKET CONTACT AREA FOR 150 LB. RAISED FACES.

2. THE STANDARD RING GASKET OUTSIDE DIAMETER EXTENDS TO THEINNER EGDES OF THE FLANGE BOLTS, WHICH ACT AS CENTERINGDEVICES.

3. FULL FACE ANSI GASKETS ARE GASKETS WHICH EXTEND TO THE O.D.OF THE FLANGE. FLANGE BOLT CLEARANCE HOLES MUST BE DRILLEDIN THIS FULL FACE TYPE GASKET. SEE TABLE FOR HOLE SIZE AND BOLT CIRCLE.

4. GASKETS CAN ALSO BE MADE EQUAL TO THE RAISED FACE (R.F.) DIAMETERWITH THE SAME I.D. AS SHOWN IN THE TABLE (DIM. B)

5. GASKET MATERIAL AND THICKNESS ARE THE RESPONSIBILITY OF THEUSER. THEY MUST BE PRODUCT COMPATIBLE AND SUITABLE FOR ALLSERVICE CONDITIONS.

6. GASKET STYLES OTHER THAN FLAT FACE RING GASKETS ARE AVAILABLE,BUT ARE USUALLY MORE EXPENSIVE. GASKETS FOR FLANGES WITHRATINGS IN EXCESS OF 150 LBS. ARE NOT SHOWN DUE TO VARIABLE DESIGNCONDITIONS ENCOUNTERED. SPECIFICATIONS FOR OTHER THAN RINGGASKETS AND HIGHER PRESSURE DESIGNS CAN BE FOUND IN ASMEUNFIRED PRESSURE VESSEL CODES OR ANSI STANDARDS.

150 LB. ANSI STANDARDFLANGE & GASKET

PROPORTIONS

OUTLINE DIMENSIONS IN INCHES

B

R.F.

A

B.C.

O.D.

Certified By Date

NOM.SIZE

O.D. R.F. HOLEQUAN.

C

A(O.D.)

10.0 7.31

B.C.

8.50

HOLEDIA.

7.750

B(I.D.)

5.562

WIDTH

1.094

CMIN.

.885 8 .88

FLANGE BOLTHOLE SIZE &

QUANTITY

11.0 8.50 9.50 8.750 6.625 1.062 .946 8 .88

13.5 10.62 11.75 11.000 8.625 1.188 1.008 8 .88

16.0 12.75 14.25 13.375 10.750 1.312 1.0010 12 1.00

19.0 15.00 17.00 16.125 12.750 1.688 1.1212 12 1.00

21.0 16.25 18.75 17.750 14.000 1.875 1.1214 12 1.13

23.5 18.50 21.25 20.250 16.000 2.125 1.2516 16 1.13

25.0 21.00 22.75 21.625 18.000 1.812 1.5018 16 1.25

27.5 23.00 25.00 23.875 20.000 1.937 1.5020 20 1.25

32.0 27.25 29.50 28.250 24.000 2.125 1.6224 20 1.38

ANSI 150 LB. FLANGE DATA ANSI RING GASKET DATA

2

SEC. 14 PAGE 3.00

LIG

198

C

ISO 9

CERTI


19/33

REVISION

2005

DATE 11--1--05

REVISED PAGE 1 OF 7

INST. NO. R281754--E LIGHTNINLIGHTNIN

MIXERS AND AERATORS

OPERATING AND MAINTENANCE INSTRUCTIONSFOR MODEL VTE

This LIGHTNIN Agitator is a piece of precision machinery of the highest quality. It is designed to operatesatisfactorily under all the conditions normally encountered.

With proper care, thisLIGHTNIN

Agitator will give years of trouble free service. If you should have any questionsregarding its operation, that are not answered in this manual, contact your authorized LIGHTNIN MixerRepresentative.

WARNING: Before attempting anymaintenance or service on this machine, it is essential thatappropriate safetyprecautions betaken, includingbutnotlimitedtolockingoutthepowersourceandrestrainingbothinputand outputshafts of the unitfromunexpected rotation. Even with the power source locked out, it is possible for a mixer shaft(andthus allconnectedmachinery) tobe causedtorotate bytheactions ofthe media beingmixed,orotherexternalfactors. Thus, it is necessary to ensure that the shafts are restrained from rotation or other movement while theunitis beingserviced.In additiontorestrainingtheshaftfromunexpectedrotation,itis also essentialthatanylockedin torque loading (or other sources of stored energy) in the system be released or positively restrained beforeattempting any service.

FAILURE TOBOTHLOCKOUT ANDRESTRAINTHE MACHINE FROMUNEXPECTED MOVEMENTBEFORESERVICE OR MAINTENANCE ACTIONS CAN RESULT INSERIOUS INJ URY OR DEATH.

WARNING: EYE PROTECTION MUST BE WORNAT ALL TIMES WHILE SERVICING THIS MIXER.

SECTION 1 -- OPERATING THE MIXER

1.1 LIGHTNINAgitators are designed to operate continuously under all standard conditions, in air, at low liquidlevels, andatnormal levels. It is notgood practice, however, tooperate continuouslywhen extreme vortexingor surging occurs. Before operating the unit, check all bolts and other fasteners to make sure that they aretight.

At the end of the mixing cycle, it is good practice to turn off the mixer before the tank has been drained toa level which will result in excessive splashing.

Check all fasteners and mounting hardware for tightness 12 hours after assembly, and at each scheduledshutdownthereafter. Carefullyexaminethe gear driveandassociatedcomponents foranysigns ofleakage.Stopthegeardrive, allowallrotationto cease, and rechecktheoillevel.Reservicethe geardrive as required.If excessive leakageis observed, the cause mustbeestablishedandcorrectedbeforecontinuingto operatethe unit.

Dirton themotorcase acts as aninsulatorandwillpreventpropercooling.Alwayskeepthemotorclean.R eferto Motor Maintenance Instructions furnished with this manual for further details.

SECTION 2 -- VEE BELT ALIGNMENT AND MAINTENANCE

2.1 If the drive was not completely assembled at the factory, proceed as follows:

a . Install the motor and/or belt guard (with cover removed) if not previously assembled.

b . Make sure the motor shaft is parallel with the agitator shaft.

NOTE: Use U--shaped shims under the motor feet to correct anymotor shaft to agitator shaft parallelismso as to provide proper support to the motor feet.

c . Install thesheaves. If thedrive ordriven sheave is furnishedwith a taperbushing, refer to thetagfurnishedwith the unit, and install the flanged side of the bushing facing in the direction indicated.

d . Lineupthesheaves so thatthe correspondingbeltgrooves in each sheaveare in alignment. Use a straight

edge to help obtain proper alignment.

e . Do notforce belts overthesheaves, lowerthe motorbybackingoffthenutsontheadjustable motorsupportarm(110).

2.2 StandardLIGHTNINunits are equipped with V--belts having one of the cross sections shown in Table 1. Toensure that the V--belts are properly tensioned, determine the type V--belt supplied and refer to theappropriate deflection force table. V--belt identifiers are located on the V--belt component.


20/33

REVISION

2005

DATE 11--1--05

REVISED PAGE 2 OF 7


MIXERS AND AERATORS

REVISION

2005

DATE 11--1--05

REVISED PAGE 2 OF 7


MIXERS AND AERATORS

TABLE 1 -- V--BELT CROSS SECTION

A B C

AX BX CX

3V 5V 8V

3VX 5VX ----

a . Seatthe belts in thesheave grooves and take uptheslackbyraising themotorsupportwith theadjustable

motorsupportarm(110)until a SLIGHT BOW appears onthe slacksideofthedrivewhilethe unitis runningunder full load.

b . Stop the drive and apply the proper tension to the belts following the steps outlined. Refer to Figure 1.

c . Measure the belt span.

d . Using a spring scale or weight, apply a force to any ONE of the belts in the center of the span. The forceshould be perpendicular to the span and toward the center of the drive. Measure the force required todeflect any one of the belts 1/64 inch for every inch of span length. For example, the deflection for a 32inch span would be 1/64 inch multiplied by 32, or 1/2 inch.

e . Tension new drives atthe maximumdeflection force recommended (see Table 2 or 3). Check the tensionatleasttwo times during the first days operationas there will normallybe a rapiddecrease in belttensionuntil the belts have run in.

DEFLECTION

FORCE

BELT SPAN

FIGURE 1

TABLE 2

SMALLSHEAVE

DIA.

BELTCROSS

SECTION

DEFLECTIONFORCE -- LBS.

MIN. MAX.

BELTCROSS

SECTION


MIN. MAX.

3 4--1/43.0 -- 3.6 3--7/8 5--1/2

3--1/2 53.8 -- 4.8 A AX 4--1/2 6--1/4

4 5--1/25.0 -- 7.0 5 6--7/8

4 5--1/23.4 -- 4.2 5--3/4 8

5--1/8 7--1/84.4 -- 5.6 B BX 6--1/2 9--1/8

6--3/8 8--3/45.8 -- 8.6 7--3/8 10--1/8

11--1/4 14--3/87.0 -- 9.4CX

13--3/4 17--7/8

14--1/8 18--1/29.6 -- 16.0 C 15--1/4 20--1/4

TABLE 3

SMALLSHEAVE

DIA.

BELTCROSS

SECTION


MIN. MAX.

BELTCROSS

SECTION


MIN. MAX.

3--1/2 52.65 -- 3.65 3--7/8 5--1/2

4--3/4 6--7/84.12 -- 6.90 3V 3VX

5--1/4 7--7/8

-- --4.40 -- 6.70 10 15

10--1/2 15--3/47.1 -- 10.9 5V 5VX 12--7/8 18--3/4

13 19--1/211.8 -- 16.0 15 22

27 40--1/212.5 -- 17.0--

-- --

30 4518.0 -- 22.4 8V -- --

2.3 Check the tension periodically after the first days operation and keep tension in recommended area. Thecorrectoperatingtensionfora V--beltdriveis the lowesttensionatwhich the belts will notslip under peakload

conditions.2.4 Do not use belt dressing if belts are slipping, clean with warm, soapy water and readjust tension.

2.5 When it becomes necessary to replace belts, install a complete newmatched set. Newunstretched belts willbe shorter in length than the old belts and will, therefore, carry a greater portion of the load.

SECTION 3 -- REMOVING BEARINGS

3.1 Shaft bearings and components can be removed and replaced without lowering the liquid level in the chestby tightly compressing the packing during the replacement procedure.


21/33

REVISION

2005

DATE 11--1--05

REVISED PAGE 3 OF 7


MIXERS AND AERATORS

3.2 PR EPARATION

a . Remove the following components from the agitator:

1 . Belt guard (184) and V--belts (183).

2 . Remove the driven sheave (182).

3.3 INBOARD BEARING REMOVAL (REFER TO FIGURE 3)

a . If both inboard and outboard bearings are to be replaced, the inboard bearing is to be removed from itshousing firstto allow the shaft to be supported by the slinger collar (280).

b . To free the bearing fromthe tapered adapter sleeve:

1 . Remove three (3)jacking screws (281) fromtheir storage position andinstall in the slinger collar (280)so that they are 1/4 inch fromthe locknut (226).

2 . Mark a line along the inboard face of the slinger collar (280) for repositioning reference.

3 . Slide the collar (280) against the packing gland adjusting nuts (137).

4 . With a brass bar and mallet, tap the locknut until the tapered adapter sleeve (224) breaks free of thebearing taper.

c . Re--position the slinger collar (280) at the scribed line and tighten the set screws (282).

d . Remove the 4jackingscrews (285) fromstorage positionandinsertthroughthe outersetof clearanceholesin the slinger collar (280) flange.

e . Remove the plugscrews (283) and gaskets (284)and thread the jackingscrews (285) into the plugscrewholes.

f . To remove the bearing fromthe bearing housing:

1 . Unbolt the inboard oil seal retainer (133) and slide outboard on the shaft.

2 . Tighten the inner jacking screws (281) as far as they will go to partially push the bearing from thehousing.

3 . Back off the inner jacking screws (281).

4 . Remove the slinger collar set screws (282).

5 . Tighten the outer jacking screws (285) until they contact the bearing (123).

6 . Readjust the inner jacking screws (281) until they seat against the locknut (226).

7 . Tighten the outer jacking screws (285) evenly to simultaneously push the bearing out of the housingand seat the slinger collar (280) in the housing bore.

CAUTION: The collarmustseat in the housing bore before the bearing is completelyfree of the housing.


22/33

REVISION

2005

DATE 11--1--05

REVISED PAGE 4 OF 7


MIXERS AND AERATORS

FIGURE 3 -- INBOARD BEARING ASSEMBLY DETAIL

BEARING REMOVAL POSITION

OPERATING POSITION

OUTBOARD INBOARD

216

285

281

117

226

225

280301

283

284122

STORAGE 120

123

133

224

115

POSITION281 & 285

282

3.4 OUTBOARD BEARING REMOVAL (REFER TO FIGURE 4)

a . To loosen the outboard bearing:

1 . Wrap the outboard shaft extension with tape and coat the tape with grease to protect the oil seal lipsduring removal.

2 . Remove the outboard oil seal retainer (114).

3 . Remove the outboard retaining ring (119).

4 . Back off the locknut (126) 1/4 inch.

5 . Tap the loosened locknut to break the taper fit.

6 . Remove the locknut (126) and slide the tapered adapter sleeve off the shaft.

b . Unbolt the bearing housing (121) fromthe fixed bearing member (120) byremoving the (8) housing bolts(305).

c . The bearinghousing (121)complete with bearings (123) canberemovedfromtheshaft, washedcleanandthe bearing replaced if necessary.

3.5 REP LACING BEARINGS

a . Model VTE with agitatorshafts 2.5inchdiameterand smallerare furnishedwithballbearings whichrequirestandard tightening procedures for tapered adapter sleeve mounting.

b . ModelVTE withagitatorshafts3 inch diameterand larger are furnishedwith sphericalrollerbearings whicharemanufactured with aninternal clearancegreaterthanrequiredin actualservice.Precisemeasurementand tightening is required to expand the inner race and obtain the proper operating internal clearance.

c . Prior to installing spherical roller bearings:

1 . Measure the unmounted radial clearance bystandingthe bearinguprighton its outer race. Rotate theinner race to uniformly seat the rollers in the raceways.

2 . Measure the clearance between the outer race and the uppermost set of rollers by insertingprogressively thicker feelerblades. Slide the feelerblades straight in over the length of the rollers, DONOT roll the blade across the rollers. Select the thickness that most closely approaches line to linecontact without excessive drag. Check opposite set of rollers.

3 . Repeat the measurements at two or three other locations with other sets of rollers. Record thepredominant blade thickness. This is the unmounted radial clearance that must be reduced to thevalues in Table 1 during tightening.


23/33

REVISION

2005

DATE 11--1--05

REVISED PAGE 5 OF 7


MIXERS AND AERATORS

d . Slide the inboard bearing components on the shaft in the following order:

1 . Locknutand washer (226), solid adapter sleeve (225) and oil seal (301).

2 . Inboard bearings (123), taperedadapter sleeve (224), retainergasket(134) andoil seal retainer (133)with oil seal (115).

e . Slide the outboard bearing locknut and washer (126) and solid adapter sleeve (125) onto shaft. (seeFigure 4)

f . If removed, install the Spirolox retaining ring (300) in the groove on the shaft (117) inboard of the bearingadapter sleeve.

g . Press the oil seal (127) and outboard bearing into the outboard bearing housing (121). Use the oil sealretainer (114) to firmly bottom the bearing against the housing shoulder, then remove.

h . Mount and secure the outboard bearing housing (121) to the bearing member (122).

i . Slide the tapered adapter sleeve (124) through the bearing and seat it against the split thrustcollar (323).

j . Install the outer retaining ring (119).

k . Insertthe solidadapter sleeve (125) through theoil seal(127) andthreadthelocknut (126) andtheadaptersleeve (124) hand tight.

l . Loosen the packing gland adjusting nuts (137) and readjust finger tight.

m . Rotate the shaft by hand and firmly tap the end of the shaft to help seatthe adapter sleeve and squeeze

excess grease frombetween the rollers and bearing races.

FIGURE 4 -- OUTBOARD BEARING DETAIL

LOCKNUTWASHER

TANG

124

300

126

125

127

116114115

119

123

121

FEELERBLADES

n . For spherical roller bearings, tighten the locknut (126) with a hammer and drift. Periodically measure theinternal clearance during tightening. Continue tightening until the required reduction and final clearancelisted in Table 4 is obtained.


24/33

REVISION

2005

DATE 11--1--05

REVISED PAGE 6 OF 7


MIXERS AND AERATORS

TABLE 4

SPHERICAL ROLLER BEARING RADIALINTERNAL CLEARANCE VALUES

SHAFTDIA.

UNMOUNTEDMIN. / MAX.

REDUCTION REQD.MIN. / MAX.

FINALCLEARANCE

3.03.5 .0032 / .0044 .0018 / .0025 .0014

4.0 .0039 / .0053 .0020 / .0028 .0020

4.55.0 .0047 / .0063 .0025 / .0035 .0022

5.5 .0051 / .0071 .0030 / .0040 .0022

6.06.5 .0055 / .0079 .0030 / .0045 .0024

7.07.5 .0063 / .0088 .0035 / .0050 .0028

7.07.5 .0079 / .0102 .0030 / .0045 .0049

INBOARD

OUTBOARD

o . For ball bearings, simply tighten the locknut securely.

p . Setthe locknut washer tang in theclosestslot. ALWAYS TIGHTEN.DO NOT LOOSEN ifnecessarytolineup with slot.

q . Install the inboard bearing (See Figure 5):

1 . Remove the (4) outer jacking screws (285) from the housing and slinger collar (280) and reinstall inthe tapped jacking screw holes in the collar flange.

2 . Tighten the jacking screws (285) until the collar is free of the housing.

3 . Remove both sets of jacking screws (281 and 285) and slide the slinger collar inboard as far as itwillgo.

4 . Installthe (4) outerjackingscrews (285) intheirstorage positionintheoutboardbearingmember(120).

5 . Install the oil seal (301). Use a piece of split pipe and tap in carefully. Use care to avoid damaging themetal case on the seal.

6 . Install the bearing (123). Tap evenly to start the bearing into the housing bore.7 . Push the tapered adapter sleeve (224) into the bearing bore.

8 . Installthegasket(216) and theoilseal retainer (133). Use theoilseal retainer to press the bearing intothe bore.

9 . Insert the solid adapter sleeve (225) through the oil seal (301) and thread the locknut (226) on theadapter sleeve hand tight.


25/33

REVISION

2005

DATE 11--1--05

REVISED PAGE 7 OF 7


MIXERS AND AERATORS

FIGURE 5 -- INBOARD BEARING ASSEMBLY DETAIL

OUTBOARDINBOARD

216

280

285

117

226225

280

301

283

284122

STORAGE 120

123133

224115

POSITION281 & 285

282

3/16SCRIBED REF.LINE

3/16 FLOAT

r . Set the inboard bearing:

It is important that the inboard bearing is located midway in the housing to allow positive float axially ineither direction.

1 . Force the entire bearing assembly inboard by applying and axial force against the top of the locknutwith a pry bar.

2 . Tighten the locknut (226) hand tight.

3 . Mark a reference line on the shaft locating the inboard face of the tapered adapter sleeve (224).

4 . Tap the bearing assembly outboard 3/16 of an inch beyond the reference line. Scribe a secondreference line for sleeve location.

s . Tighten the locknut (226):

1 . Tighten ball bearings by tightening the locknut securely.

2 . Tighten sphericalrollerbearings using the feelerblademeasurementand internalclearancereductionprocedure outlined in 4.5.n and values in Table 4.

3 . While tightening floating bearings, use short, sharp blows with the drift and do not allowthe sleeve tomove more than1/16 of an inch fromthe scribed reference line.

4 . Bendthelocknutwashertanginto theclosestslot. ALWAYS TIGHTEN. DO NOT LOOSEN ifnecessaryto line up with slot.

t . Install the oil seal retainer (133) and gasket (216).

u . Reposition the slinger collar (280) on the shaft in its original location and tighten the set screws (282).

v . Install the (3) jacking screws (281) in their storage position in the outboard bearing member (120).

w . Install the sheaves and V--belts. Align and adjust the V--belts as outlined in Section 2 of the OperatingInstructions.

x . Install the outboard supports or secure to the mounting support using the shims originally installed.y . Lubricatethe inboard andoutboard bearingassemblies as outlinedin the bearinglubricationsectionofthe

General Instructions. Add lubricant until clean grease appears at the relief fitting.

z . Starttheunitandadjustthepackinggland(131)until there is a slightleakageofwaterbeyondtheoutboardring of packing.

aa . Replace all safety covers and guards.

3.6 Refer to General Instructions for lubrication information.


26/33

REVISION

1978

DATE 3--1--78

REVISED 04--26--06 PAGE 1 OF 4

INST. NO. IT--1488

DLIGHTNIN

MIXERS AND AERATORS

LIGHTNIN

MOTOR MAINTENANCE INSTRUCTIONSFOR C--FACE AND FOOT MOUNTED

MOTORS FURNISHED BYLIGHTNIN

SECTION 1 -- INITIAL INSPECTION, SHIPPING ARRANGEMENTS

1.1 Careis takenatthe factorytoassure thatthemotorarrives atits destinationinfirstclass condition. If thereis evidence of rough handlingor damage in shipment, file a claimatonce with the carrier and notify ourfactory.

Examinethe outside of the motor carefullyfordamage, with particularattentionto the conduitbox, fansand covers. Check nameplate for correct speed, horsepower, voltage, hertz and phase forconformance withpower supply. Turn the shaftbyhandto besureitrotates freely. If themotor has beenmishandled sufficiently to break external parts, the end shield should also be removed to check forinternal damageunless the motor is explosion--proof. See warningbelowon explosion--proof motors.

1.2 ! WARNING

EXPLOSION--PROOF MOTORS -- These motors are constructed to comply with the U.L. LabelService Procedure manual. Whenrepairingand reassemblinga motor thathas anUnderwriters Label,it is imperative that the unit be reinspected and;

a . All original fits and tolerances must be maintained

b . All plugs and hardware to be securely fastened

c . Any part replacements, including hardware, be accurate duplicates of the originals

REPAIR WORK ON EXPLOSION--PROOF MOTORS CAN ONLY BE DONE BY THE ORIGINALMANUFACTURER OR U.L. CERTIFIED SERVICE SHOPS. VIOLATIONS OF ANY OF THE ABOVEITEMS WILL INVALIDATE THE SIGNIFICANCE OF THE U.L. LABEL.

SECTION 2 -- START--UP

2.1 After unpacking and inspection to see that all parts are in good condition, turn the shaft by hand to besure there are no obstructions to free rotation. Equipment which has been in storage should be testedprior to being put into service.

a . It is bestto check the insulation resistance of the stator winding with a megohmeter. If resis-tance is lower than one megaohm, the windings should be dried thoroughly before operating.Do not exceed a temperature of 80C (185F) in drying.

b . Motors are shipped fromthe factory with the bearings properly packed with grease and readyto operate. Where the unit has been subjected to extended storage (6 months or more), thebearings should be relubricated prior to starting.

2.2 WIRING -- Examine the nameplate data to see that it agrees with the power circuit to which the motoris to be connected. The motor is guaranteed to operate successfully with frequency not more than 5%and voltage not more than 10% above or below the nameplate data, or combined variation of voltageand frequency of not more than 10% above or belownameplate data. Efficiency, power factor and cur-rent may vary from nameplate data.

2.3 Temporarilyconnectthe motor leads to a power source thatmatches the line voltage and wiring diagramspecified on the motor nameplate.

2.4 Check impeller shaft rotation by jogging the motor until it is determined that rotation is correct.


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REVISION

1978

DATE 3--1--78


INST. NO. IT--1488

DLIGHTNIN

MIXERS AND AERATORS

LIGHTNIN

2.5 ! CAUTION

Repeated trial starts can overheat the motor (particularly for across-the-line starting). If repeated trialstarts aremade, allowsufficienttime betweentrials to permitheatto dissipate fromthewindings orrotorto prevent overheating. Startingcurrents are several times runningcurrents, and heatingvaries as thesquare of the current.

When checks are satisfactory, make permanent connections.

2.6 ! WARNING

The frames and other metal exteriors of motors shouldbe groundedto limittheir potential to ground inthe event of accidental connection or contact between live electrical parts and the metal exteriors.Explosion-proof motors should be grounded through the conduitbox.

2.7 ! WARNING

Beforestarting motor, remove all unusedshaftkeys andloose rotatingparts to preventthemfromflyingoff.

2.8 Startmotor and operate atminimumload priorto filling the tank or basin. Look for any unusual condition.

The motor shouldrun smoothlywith little noise. If the motor shouldfail to start and produces a decidedhum, it may be that the load is too great for the motor or that it has been connected improperly. Shutdown immediately and investigate for trouble.

If motor is totally enclosed fan--cooled or non--ventilated, it is recommended that condensation drainplugs beremoved.These arelocatedinthe lower portions of theendshields or frame. Explosion--proofmotors do nothave any plugs to remove.

SECTION 3 -- MOTOR MAINTENANCE AND STORAGE

3.1 Toinsurecontinuedreliable operationofelectricmotors, thefollowing basic rule applies:KEEP THE MO-TOR CLEAN, DRY AND PROPERLY LUBRICATED. Motors should be inspected at regular intervalswith frequency depending upon the type of motor and the service.

Windings should be cleaned byblowing or vacuumingdust fromthem. Ventilating openings must be keptclear. Ifdust and dirtis to be removed with a vacuumcleaner, nozzles should be of the non--metallic type. Deposits of dirt

andgrease mayberemovedbyusinga commerciallyavailable lowvolatile solvent.DO NOTUSE GASOLINE OROTHER FLAMMABLE SOLVENTS.

3.2 Terminal connections and assembly hardware may loosen from vibration during service and should betightened.

3.3 Insulation resistance should be checked atoperative temperature and humidity conditions to determinepossible deterioration of insulation due to excessive moisture or extremes in operating environment. Ifwide variations are detected, motors should be reconditioned.

3.4 LUBRICATION - Priorto shipment, motorbearings are greasedwiththeproperamountandgrade oflubri-cantby the motor vendor. Motors equippedwithsealedbearings require noadditionallubrication.Motorsequipped with open or shielded bearings require lubrication periodically. It is recommended that thebearing lubricant be inspected at the end of two or three months to determine the necessity to addgrease. Frequency of re--lubrication will varywith particularapplicationandcan bedeterminedwith peri-

odic inspection. The followingtable offers suggestedre--lubricationfrequencybased on general operat-ing conditions.


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REVISION

1978

DATE 3--1--78


INST. NO. IT--1488

DLIGHTNIN

MIXERS AND AERATORS

LIGHTNIN

Type of HP Re--Lubrication

Service General Conditions Range Frequency

Standard E ight hours per day, normal or light 11/2 -- 71/2 3 years

loading, clean, 100F Maximum Ambient 10 -- 40 1 year

50 -- 150 6 months

200 -- 350 3 months

Severe Twenty--four hours per day operation or 11/2 -- 71/2 1

1/2 years

shock loading, vibration or in dirt or 10 -- 40 6 months

dust @ 40 -- 50C (100 -- 120 F) 50 -- 150 3 months

Ambient 200 -- 350 1 1/2 months

Very Severe Heavy shock or vibration, dirt or dust, 11/2 -- 71/2 6 months

high ambient temperature 10 -- 40 3 months

50 -- 150 2 months

200 -- 350 1 month

All motors over 1800 RPM should be checked for re--lubrication at three month intervals.

! CAUTION:The greatest cause of bearing failure is over--greasing rather than under--greasing.

3.5 TYPE OF LUBRICANT

a . Check the motor nameplate to determine whether a specific grease has been recommendedby the motor manufacturer. Use that grease, if possible.

b . Lacking a specific grease recommendation, refer to the following.For best results, grease should be compounded froma lithiumsoap base and a good gradeof petroleumoil. It should be of No. 2 consistency and stabilized against oxidation. Most lead-ing oil companies have special bearing greases that are satisfactory.

3.6 LUBRICATION PROCEDURE

a . Motors equipped with grease fittings or plugs:

1 . Motor should be warm and disconnected frompower source.

2 . Clean the exterior of the motor.

3 . Remove all pipe plugs and relief plugs.

(For some TEFC motors, itmay be necessary to remove caps on fan cover and hexagonal rodthrough fan cover to gain access to grease plugs and relief plugs)

4 . Using a lowpressure, handoperatedgrease gun, pump in cleangrease until itappears attherelief hole or along motor shaft.

5 . Run the motor with the plugs removed for approximately two (2) hours.

6 . Stop the motor and wipe away excess grease atrelief or along shaft and replace plugs.

b . Motors not having pipe plugs or grease fittings in bearing housings can be re--lubricated byremoving end shields from motor, cleaning grease cavities and refilling cavities to capacitywith new grease.

! CAUTION: Bearings and grease mustbe keptfree of dirt.c . Oil lubricated motors -- (sleeve bearing equipped) Oil should be added annually after 3 years

of normal or 1 year of heavy duty service. Electric motor or SAE 20 oil should be used.

For more specific maintenance and lubrication instructions, contact your local motormanufacturer representative.


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REVISION

1978

DATE 3--1--78


INST. NO. IT--1488

DLIGHTNIN

MIXERS AND AERATORS

LIGHTNIN

REVISION

1978

DATE 3--1--78


INST. NO. IT--1488

DLIGHTNIN

MIXERS AND AERATORS

LIGHTNIN

SECTION4 -- STORAGE

Electricmotors and other prime movers are notprepared byLIGHTNINforindoor storage beyond 12monthsina dryambientatmosphere withcontrolledtemperatures or6months ina dryambientatmosphere withouttemperature control. OUTDOOR STORAGE OF ELECTRIC MOTORS IS NOTRECOMMENDED BY ANYMOTOR MANUFACTURER. For information on storage periods beyond those shown, consult the motormanufacturer.

4.1 STORAGEREQUIREMENTSFORMOTORS --These extendedstoragerequirements mustbefollowedto allow the submission of a valid warranty claim.

a . The motors, if not mounted, are to be stored in the original containers in a clean, dry, pro-tected warehouse.

b . The storage area is to be free fromany vibration and fromextremes in temperature.

c . Bearings

1 . Ball & Roller (anti--friction) -- The bearings are to be fully greased at the time of going intoextended storage. Motor shafts are to be rotated manually every month at least 10 to 15revolutions, and every 6 months, additional grease added purging some of that in the cavity.Grease in the bearings is to be purged atthe time of removal fromstorage, making sure that

an ample supply of fresh grease is in each grease cavity.2 . Sleeve (oil lube) -- The bearings are tested using an oil containing a rust inhibitor. If motor is

stored for more than one month, the oil reservoirs must be refilled to the indicated level withthe specified lubricant. The shaft should be rotated by hand every month at least 10 to 15revolutions to assure that an oil filmis on the shaftand bearing surfaces.

d . All drains to be fully operable while in storage, and/or the drain plugs removed. The motorsmust be stored so that the drain is at the lowest point. All breathers and automatic T drainsmust be operable to allow breathing at points other than through the bearing fits.

e . All units equipped with heaters are to have the heaters connected if storage conditions in anyway simulate or approach atmospheric conditions experienced in operation.

f . Windings to be megged atthe time equipment is putinto storage. At the time of removal fromstorage, the resistance reading mustnot have dropped more than 50% fromthe initial read-ing. Any drop below this point necessitates electrical or mechanical drying. Where a largequantity of motors is stored, an inspection or sampling should be made by removing the endbrackets and visually inspecting for the presence of water in the grease, or rust on the bear-ing. If present, replace the bearings and relubricate.

g . All external parts and motors subjected to corrosion should be protected by a corrosive resis-tant coating.

h . Where motors are not stored in the original containers, the mounting mustbe such that thedrains and breathers are fully operable. In this respect, the drains mustbe keptat the lowestpoint in the motor and/or the drain plugs removed so that all condensation can automaticallydrain out.

i . All other storage conditions apply, including rotation of motor shafts. Where such conditions

cannot be met, then the equipment must be treated the same as if it were mounted in its nor-mal position, and all protective devices such as heaters, breathers and drains fully operable.


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LIGHTNIN____________________________________________________________________

REVISION DATE 12/28/05 LIGHTNIN INST. NO. IT-383P REVISED 01/05/06 MIXERS AND AERATORS LIGHTNIN 2005 PAGE 1 OF 1

FOR AN UP TO DATE REPRESENTATIVE LIST

PLEASE GO TO: www.lightnin-mixers.com

-OR-

CALL: 1-888-649-2378

1-888-MIX-BEST


31/33


32/33

Notes

LIMITED WARRANTYUnless otherwise noted on the face hereof, SPX goods, auxiliaries and parts thereof are warranted to the original purchaser

defective workmanship and material for a period of twelve (12) months from date of installation or (18) months from date ofshipment from factory, whichever expires first. If the goods or services do not conform to the warranty stated above, then assole remedy, SPX shall, at SPX s option, either repair or replace the defective goods or re-perform defective services. Thirdgoods furnished by SPX will be repaired or replaced as Buyer s sole remedy, but only to the extent provided in and honoredoriginal manufacturer s warranty. Unless otherwise agreed to in writing, SPX shall not be liable for breach of warranty or othin any manner whatsoever for: (i) normal wear and tear; (ii) corrosion, abrasion or erosion; (iii) any good or services which, fdelivery or performance by SPX, has been subjected to accident, abuse, misapplication, improper repair, alteration, impropeinstallation or maintenance, neglect, or excessive operating conditions; (iv) defects resulting from Buyer s specifications or dor those of Buyer s contractors or subcontractors other than SPX; or (v) defects resulting from the manufacture, distribution,promotion or sale of Buyer s products.THE WARRANTIES CONTAINED HEREIN ARE THE SOLE AND EXCLUSIVE WARRANTIES AVAILABLE TO BUYER ANHEREBY DISCLAIMS ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMWARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE FOREGOING REPAIR,REPLACEMENT AND REPERFORMANCE OBLIGATIONS STATE SPX S ENTIRE AND EXCLUSIVE LIABILITY AND BUYEXCLUSIVE REMEDY FOR ANY CLAIM IN CONNECTION WITH THE SALE AND FURNISHING OF SERVICES, GOODS

PARTS, THEIR DESIGN, SUITABILITY FOR USE, INSTALLATION OR OPERATIONS.


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LIGHTNIN Aftermarket ServicesThe fastest route to uptime.

Expertise: Service technicians are the backbone of our dedicated serviceorganization. They are uniquely qualified to keep your LIGHTNIN mixers runningright.

Lightnin Certified Technicians: All service technicians are certified via train-ing courses to ensure that the work they do meets the highest standards forconsistency and reliability.

Genuine LIGHTNIN Parts: All LTN repairs follow original design specs anduse only factory-authorized replacement parts.

Full LIGHTNIN Factory Warranty: We're so confident we'll do the job rightthat all LTN repair and service work is covered by a full factory warranty. Whatwe repair, we guarantee - 100%.

Repair Services: LIGHTNIN provides quick, reliable repair services - usingonly certified technicians and factory-authorized replacement parts - on gear-boxes, mechanical seals (seal cartridge and seal assembly), steady bearings,machine assemblies, impellers, shafts and all portable units. This service canbe provided either at your site or at a LIGHTNIN Service Center location. Allwork is backed by LIGHTNIN's full warranty on all parts and service.

Exchange Services: By eliminating repair time, LIGHTNIN Exchange Ser-vices offer the fastest way to get up and running when a breakdown occurs.LTN keeps selected speed reducers, portable units and mixer subassembliesin stock - and available for immediate exchange - at regional service centers.Simply call and we will configure the appropriate assembly and ship it to youwithin 24 hours. Then send the damaged assembly back to us within 30 days -to ensure you receive a discounted price.

Equipment Upgrade Services: Preventive maintenance is your best defenseagainst costly unplanned downtime and repairs associated with old or obsoleteequipment. The full range of LTN upgrade services give you a convenient andcost-efficient way to address problems before they happen by converting olderequipment to the latest, most reliable LIGHTNIN designs.

Additional LTN Services: In addition to minimizing downtime and repaircosts when equipment failure occurs, LTN offers a comprehensive range ofservices for maximizing productivity through every stage of the equipment lifecycle.

Installation and Startup

LIGHTNINAftermarket ServicesWhen repairs to your LIGHTNIN mixer isneeded, we guarantee the result for one year. This exclusive warranty covers all pand labor. Talk to your LIGHTNIN salesrepresentative for more information.

CALL:The LIGHTNIN ExpertsWhen your need is urgent and after

normal business hours call our 24-h

BEST (U.S. and Canada). Your reque

will be promptly processed and dire

to your nearest LTN team member. F

more information visit our website:

www.spxft.com

Factory ServiceCenter LocationsDelavan, Wisconsin California FloridaRochester, New YorkHouston, TexasWytheville, Virginia

Authorized ServiceCenter LocationsBaton Rouge, LouisianaConcord, Ontario, CanadaEast Hanover, New Jersey

Georgia

LIGHTNIN, An SPX Brand135 Mt. Read Blvd., Rochester, NY 14611Phone: (888) MIX-BEST or (888) 649-2378, Fax: (585) 436-5589E-mail: [email protected]

For more information about our worldwide locations, approvals, certifications, and local representatives, please visit www.lightninmixers.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 shouldnot be relied upon unless confirmed in writing. Certified drawings are available upon request.

Issued: 03/2010

REPAIR & SERVICEGUIDE

s.fco Oro Manual 4vte100 Oc 184559,l30

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