SPX Waukesha Cherry-Burrell Votator II Operation And Maintenance Manual Download Page 4

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Table of Contents

Page 4

95-03057

October 2005

Freeze Protection Components .................................................................. 22

Gravity Refrigeration with Level Master Control (LMC) ......................... 23

Gravity Refrigeration with Level Switch ................................................... 24

Liquid Overfeed Refrigeration System ...................................................... 25

Media System Check ....................................................................................26

Special Considerations for Vertical Votator II .............................................26

Minimum Height - Vertical Votator II .........................................................26

Mounting Pole - Vertical Votator II .............................................................26

Mounting Scrape Cylinders - Vertical Votator II .........................................26

Hydraulic System - Vertical Votator II .........................................................27

Check and Adjust Hydraulic Cylinder ....................................................... 27

Fill Hydraulic Reservoir ............................................................................ 27

Check Balance and Pressure Settings ........................................................ 27

Gravity Refrigeration System - Vertical Votator II ......................................28

Operation ...................................................................................................... 29

Pre-Startup Check .........................................................................................29

For Refrigeration Units Only ..................................................................... 29

Pre-production Run Setup .............................................................................29

Startup Procedure ..........................................................................................29

Heating/Liquid Cooling Applications ........................................................ 29

Refrigeration Applications - Pumped and Gravity Systems ...................... 30

PLC Maintenance Setup and Startup Procedures for Refrigeration .......... 30

Refrigeration Applications - Pumped and Gravity Systems - PLC Panel . 31

Refrigeration Sequence of Operation ...........................................................35

Liquid Overfeed System ............................................................................ 35

Gravity Systems ......................................................................................... 35

Refrigeration Sequence of Operation - PLC Control Panel ..........................36

Liquid Overfeed System ............................................................................ 36

Gravity Systems ......................................................................................... 36

Shutdown Procedure .....................................................................................37

Preventing Tube Scoring ..............................................................................37

Maintenance .................................................................................................. 38

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

Routine Maintenance Checklist - Horizontal Votator II ...............................39

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

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

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

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

Shafts ............................................................................................................41

Gear Drive .....................................................................................................41

Blades ............................................................................................................41

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

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

Care of Heat Exchanger Tube .......................................................................42

Product Side ..................................................................................................42

Inspection of Chrome Plated Nickel or Stainless Steel Tubes ......................43

Inspection of Stainless Steel Tubes ..............................................................43

Summary of Contents for Waukesha Cherry-Burrell Votator II

Page 1: ...Operation and Maintenance Manual Scraped Surface Heat Exchanger Read and understand this manual prior to installing operating or servicing this equipment...

Page 2: ...is subject to change without notice and does not represent a commitment on the part of Waukesha Cherry Burrell No part of this manual may be reproduced or transmitted in any form or by any means elect...

Page 3: ...1 Mutator Rotation Check 11 Mechanical Seals 12 Single Mechanical Seal 12 Double Mechanical Seal 12 2005 Mechanical Seal Design 12 Flush Water Requirements 13 Piping 13 Guidelines for Piping 13 Sugges...

Page 4: ...29 Heating Liquid Cooling Applications 29 Refrigeration Applications Pumped and Gravity Systems 30 PLC Maintenance Setup and Startup Procedures for Refrigeration 30 Refrigeration Applications Pumped a...

Page 5: ...52 Seal Head Insert Removal and Installation 52 Seal Body Insert Rotating Seal Face 52 Single Mechanical Seal Installation 53 One Piece and Double Mechanical Seals 53 Primary Secondary Seal Head Inser...

Page 6: ...tober 2005 Vertical Refrigeration System 75 Horizontal Frame Options 76 Vertical Mounting Pole Hydraulics 77 Vertical Hydraulic Schematic 78 Troubleshooting Chart 79 Unthawing A Frozen System 82 Water...

Page 7: ...lied including without limitation any warranty of merchantability of fitness for a particular purpose The foregoing sets forth Seller s entire and exclusive liability and Buyer s exclusive and sole re...

Page 8: ...ts and equipment before working on or near exposed circuit parts Locking and Interlocking Devices These devices should be checked for proper working condition and capability of performing their intend...

Page 9: ...leach 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 o...

Page 10: ...204 C oval and high efficiency tubes Check the data plate attached to the Votator cylinder for exact specifications of the unit Machine Serial Number The machine serial number is stamped on a serial n...

Page 11: ...gh voltage Electrical work should be performed by a Licensed Electrician in accordance with local regulations The following electrical components for the Votator II require connection in accordance wi...

Page 12: ...en the single mechanical seal is rotating there must be 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 flui...

Page 13: ...expansion and contraction Install a safety valve to protect jacket CAUTION The safety valve should be installed on the discharge side of product pump for safety and equipment protection DANGER Do not...

Page 14: ...ates 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 Table 1 Call Outs For Figure...

Page 15: ...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...

Page 16: ...ove rated capacity of cylinder Do not connect to a header already in use by other equipment with widely varying loads Insulate any suction line that passes through a cold room to prevent condensate fo...

Page 17: ...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 Refrigerant...

Page 18: ...m 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 re compressing...

Page 19: ...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 and the product to be cooled The cooling ra...

Page 20: ...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 A...

Page 21: ...onsible for correct sizing of starter coil and thermal overload protection based on motor nameplate voltage frequency FLA s service factor and horsepower X 2 2 3 3 3 1 1 Current sensing relay and plug...

Page 22: ...Installation Waukesha Cherry Burrell Page 22 95 03057 October 2005 Refrigeration Wiring Schematics Freeze Protection Components Figure 9 Suggested Electrical Schematic Freeze Protection Components...

Page 23: ...ha Cherry Burrell Installation October 2005 95 03057 Page 23 Gravity Refrigeration with Level Master Control LMC Figure 10 Suggested Electrical Schematic Gravity Refrigeration with Level Master Contro...

Page 24: ...Installation Waukesha Cherry Burrell Page 24 95 03057 October 2005 Gravity Refrigeration with Level Switch Figure 11 Suggested Electrical Schematic Gravity Refrigeration with Level Switch...

Page 25: ...Waukesha Cherry Burrell Installation October 2005 95 03057 Page 25 Liquid Overfeed Refrigeration System Figure 12 Suggested Electrical Schematic Liquid Overfeed Refrigeration System...

Page 26: ...esponsible for securing the top and bottom of the pole and scrape assembly See Votator II Vertical Mounting Suggestions in Addendum Section Minimum Height Vertical Votator II The mounting pole with hy...

Page 27: ...servoir from pump assembly and fill to opening for return line Reservoir is sealed with an O ring and secured by a clamp ring See Figure 14 Item A Pump return line See Figure 14 Item B must be removed...

Page 28: ...he addendum section and Votator II Vertical Refrigeration System drawing on page 20 showing the Process Flow Diagram of the Vertical Refrigeration System It is necessary for on site installation of th...

Page 29: ...o the unit should be sterilized before running product Use sanitizing solution compatible with the materials of the Votator II If a chlorine solution is used it must not exceed 50 ppm at 75 F 24 C and...

Page 30: ...adjust to desired processing rate 7 When operating conditions have been reached redirect product to desired out flow point PLC Maintenance Setup and Startup Procedures for Refrigeration If a Votator P...

Page 31: ...TRIP TO FUNCTION PROPERLY Enter a value for the HI HI Current Trip in an integer of motor amps THIS VALUE SHOULD BE ABOVE THE HI CURRENT TRIP IN ORDER TO FUNCTION PROPERLY Refrigeration Applications...

Page 32: ...tion Waukesha Cherry Burrell Page 32 95 03057 October 2005 2 After product flow is established start Votator II mutator shaft motor MOTOR Do not run Votator II without product flow 3 Turn Refrigeratio...

Page 33: ...er 2005 95 03057 Page 33 4 Select the TEMP PID pushbutton 5 Auto MODE Start Verify that the Auto Man Mode Selector is in AUTO See Below To Start up MANUALLY go to Step 6 Enter the desired product temp...

Page 34: ...t going to auto without a temperature setpoint Observe the PV Process temperature as it approaches your desired temperature When ready verify that the Local SP value is your desired process temperatur...

Page 35: ...system must be restarted following normal start up procedures 7 When shutting the system down the Votator II Refrigeration and the Refrigerant System Mode switches should be placed in the OFF positio...

Page 36: ...itches should be placed in OFF and product or flush flow should be maintained until warm up 8 Turn Votator II mutator drives OFF Gravity Systems 1 The Refrigerant System Mode switch is placed in the O...

Page 37: ...to provide a surge tank or a recirculation line With continuous operations a steam line connected to the product line can enable steam to soften and remove product in the tube at shut down The final...

Page 38: ...ng 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 faces for scratches or crac...

Page 39: ...re disassembling the primary seal Inspect o rings and seal faces for scratches or cracks If the seal parts require replacement refer to pages 52 and 64 or pages 53 and 66 When assembling the single me...

Page 40: ...rome surface to be sure it is smooth and bright If rough areas marks or chrome plating deterioration exist locate and correct the cause Replace the tube if necessary Scraper Blades Examine scraper bla...

Page 41: ...mmerse the Front Mutator Shaft 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 replace be...

Page 42: ...ce heat transfer result in poor performance and increase blade wear Re conditioning the tube is the only way to restore performance If there is suspicion that scoring has penetrated the tube wall the...

Page 43: ...ulate 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...

Page 44: ...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...

Page 45: ...removal skid can be inserted between shaft and tube NOTE NEVER remove mutator shaft without using shaft removal skid Failure to do so will result in permanent damage to heat transfer tube 9 Slide shaf...

Page 46: ...shaft and shaft removal skid into tube as a unit This will ensure that tube will not be scored when shaft is replaced 7 Push spline of shaft partially into gear reducer Shaft may need to be rotated s...

Page 47: ...ds front cover in place 5 Remove the eight 8 3 8 inch bolts that hold removable tube to jacket See Figure 33 6 Take four 4 bolts and thread them into the B holes The B holes are located at the 12 3 6...

Page 48: ...stall drive end head 11 Install shaft with mechanical seals 12 Install opposite drive end head Maintenance of Vertical Votator II DANGER Before doing any maintenance work on the Votator II lock out an...

Page 49: ...erson guides spline end of shaft out of unit 11 Place shaft and head assembly on a table or suitable frame for servicing 12 Scraper blades can be removed and serviced at this time Shaft Installation V...

Page 50: ...e Raise and turn head so teeth are engaged and product port is facing forward 12 Close locking latch See Figure 42 13 Install product piping and electrical connections Heat Exchanger Tube Removal Vert...

Page 51: ...il flange loosens from jacket It may be necessary to lower foot on hydraulic cylinder slightly while removing tube from jacket 12 Lower head and tube assembly and service as required 13 Lubricate and...

Page 52: ...o 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 Seal Body Ins...

Page 53: ...insert as described below In 2005 all single and double mechanical seals were furnished with a one piece primary seal body Primary Secondary Seal Head Insert Removal and Installation The primary seal...

Page 54: ...lat 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...

Page 55: ...in body seats in groove in mutator shaft 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 Vo...

Page 56: ...mp around teeth of tube and shaft See Figure 61 Item A 5 Close locking latch See Figure 61 Item B 6 Lower shaft until a pin from right or left side contacts shaft clamp SHAFT MUST BE SUPPORTED BY A PI...

Page 57: ...nance October 2005 95 03057 Page 57 10 Grasp head with both hands remove it from shaft 11 Seals can now be serviced See Mechanical Seal Maintenance on page 52 12 To install reverse the procedure s Fig...

Page 58: ...Cylinder Assembly 60 Latch 61 Product Heads 61 Cylinder Assembly Shaft 62 Cylinder Assembly Removable Tube 63 Single Mechanical Seal 64 Double Mechanical Seal 66 Vertical Refrigeration Piping 68 Vert...

Page 59: ...ION 927603 3A Authorization 925499 Caution Warning Shaft Guard 119169 Danger Contents Under Pressure 119170 Safety Instructions 930514 Votator II Logo Horizontal 930513 Votator II Logo Vertical 931360...

Page 60: ...ss 1 928781 19 Bearing Retainer 1 Votator II 923214 Extra Heavy Duty Votator II 118393 19B Clamp Ring 1 Spider Head Only LL117678 20 Shaft Nut Guard 1 Horizontal 923212 W Shaft Heater horz or vert 929...

Page 61: ...5 38 Spacer 3 2200321 39 Stud 1 2200277 40 Hexagon Head Shoulder Screw 1 925499 52 Spacer Washer 1 931315 APPLICATION DESCRIPTION PART Opposite Drive End Concentric 3 I Line 923245 Concentric 3 Flange...

Page 62: ...chanical 2 1 2 dia 935987 Double Mechanical 2 1 2 dia NA 4 dia NA 4 dia NA 4 1 2 dia 936476 4 1 2 dia 936786 5 1 4 dia 935921 5 1 4 dia NA ECC 4 dia 936764 ECC 4 dia 936743 EHD 4 dia NA EHD 4 dia 1223...

Page 63: ...2 316 SS CR WO RINGS 936802 ECC NI CR 936730 VAPOR UM NI CR 936583 316 SS TW W RINGS 930582 ECC NI CR NA 6 X 72 BWS U NI CR 600 PSI 929756 UM 316 SS TW WO RINGS 929263 UM 316 SS TW CR WO RINGS 930735...

Page 64: ...Parts Lists Waukesha Cherry Burrell Page 64 95 03057 October 2005 Single Mechanical Seal...

Page 65: ...ing 1 Buna N75226 Fluoroelastomer V70226 680 EPDM E70226 4 Flushing Lip Seal 1 All 925472 5 Retaining Ring 1 All 930685 6 Seal Head Insert O ring 2 Buna N75044 Fluoroelastomer V70044 680 EPDM E75044 7...

Page 66: ...Parts Lists Waukesha Cherry Burrell Page 66 95 03057 October 2005 Double Mechanical Seal...

Page 67: ...3 3 Seal Body 0 ring Primary 1 Buna N75237 Fluoroelastomer V70237 680 EPDM E70237 4 Seal Ring Secondary if required 1 All 934871 5 Seal Body Secondary if required 1 All 932357 6 Seal Head Insert 0 Rin...

Page 68: ...Parts Lists Waukesha Cherry Burrell Page 68 95 03057 October 2005 Vertical Refrigeration Piping...

Page 69: ...tion Flange AR 2 1 2 Male 700017A62 10 Refrigeration Flange Gasket AR 2 1 2 710260 11 Square Head Machine Bolt 4 per flg 3 4 10 x 3 1 2 Lg 723931 12 Hex Nut 4 per flg 3 4 10 710112 13 S W Refrigeratio...

Page 70: ...36 4 Push Pull Handle 1 All 929343 5 Hydraulic Power Assembly 1 3 4 HP CLR 928737 Pump Adapter Kit Only 1 928737 1 16 Shaft Stop Clamp 1 4 Shaft 935529 4 1 2 Shaft 931279 4 11 16 Shaft 5 1 4 Shaft NA...

Page 71: ...03057 Page 71 Shaft Heater Optional ITEM DESCRIPTION QTY PART 20 Shaft Nut Guard 1 929346 21 Shaft Locknut 1 119275A 46 Gasket 1 117720 47 0 ring 1 N70222 674 48 Shaft Heater Pipe 1 112278E 49 Heater...

Page 72: ...Head O ring 2 2 2 2 2 ONE PIECE AND DOUBLE MECHANICAL SEAL 6 x 84 QTY 6 x 72 QTY 6 x 48 QTY 6 x 36 QTY 6 x 24 QTY Blades 6 28 24 16 12 8 Jacket O ring Drive End 2 2 2 2 2 Jacket O ring Opposite Drive...

Page 73: ...Waukesha Cherry Burrell Addendum October 2005 95 03057 Page73 Addendum Votator II General Assembly...

Page 74: ...Addendum Waukesha Cherry Burrell Page 74 95 03057 October 2005 Horizontal Refrigeration Assembly...

Page 75: ...Waukesha Cherry Burrell Addendum October 2005 95 03057 Page75 Vertical Refrigeration System...

Page 76: ...Addendum Waukesha Cherry Burrell Page 76 95 03057 October 2005 Horizontal Frame Options...

Page 77: ...Waukesha Cherry Burrell Addendum October 2005 95 03057 Page77 Vertical Mounting Pole Hydraulics...

Page 78: ...Addendum Waukesha Cherry Burrell Page 78 95 03057 October 2005 Vertical Hydraulic Schematic...

Page 79: ...re lower than steam pressure in jacket Utilize back valve to assure that system pressure is at a minimum of 10 psi 0 7 bar above the media pressure Oil in system Check and drain oil regularly from acc...

Page 80: ...talled Lubricate before installing Installed wrong size distorted O ring or cut O ring Replace O ring Wrong O ring compound ring is a different color than normal Replace with specified O ring If unsur...

Page 81: ...pieces and reassemble Seal drive pin worn or missing Replace with new seal drive pin Seal retaining ring out of place Inspect retaining ring and lip seal Replace as necessary Insufficient spring press...

Page 82: ...Water and Air in Refrigeration System Water and ammonia combine to form ammonium hydroxide which combines with oil to form sludge Sludge is extremely difficult to remove Water condenses at the accumul...

Page 83: ......

Page 84: ...ugar Creek Road Delavan WI 53115 USA Tel 800 252 5200 or 262 728 1900 Fax 800 252 5012 or 262 728 4904 E mail info processequipment spx com Web site www spxprocessequipment com Issued October 2005 95...

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