Bp30 - Operation - Maintenance - Final Manual 1-12-07

Concrete Batching Plant
Operating Instructions &

Maintenance Manual
Catalogue Number Issued On

DC 000184 A 1.12.2007
INDEX
S.NO CONTENTS PAGE
1.00 GENERAL 02
2.00 SAFETY INSTRUCTIONS 03-04
3.00 TECHINICAL DATA 05
4.00 OPERATING INSTRUCTIONS 06
4.01 INTRODUCTION
4.02 SYSTEM DESCRIPTION 06-07
5.00 EQUIPMENT DESCRIPTION 07
5.01 LOAD CELLS 07-08
5.02 LOAD INDICARTOR 08-13
5.03 CONTROL DESK 13-14
6.00 TB DETAILS 15-17
7.00 OPERATION PROCEDURE 17-18
8.00 ELECTRICAL SCHEME 19-35
9.00 DRAWINGS 36-38
10.00 COMPUTER SCREEN 39-46
11.00 MAINTANANCE 47-52
ACCESSORIES 53-140
NOTES
Greaves Cotton Limited 1

1.00 GENERAL
Using this manual will
• Help you to become acquainted with the Plant
• Avoid malfunctions caused by unprofessional operation
Observing the maintenance instruction will
• Increase the reliability of the Plant

• Prolong the lifetime of the Plant
• Reduce repair costs and downtime
• Greaves will NOT assume liability for the correct function
of the machine
• If the operation does NOT comply with the usual modes of use
• If the machine is used for purpose other than the ones mentioned
• in this manual
1.01 No warranty claims can be lodged for damages resulting from:
• Operating errors
• Insufficient / Incorrect maintenance and
• Usage of wrong lubricants.
1.02 Please Note!
• This manual is made for the operator and service mechanic of the plant.
• Always keep this manual close at hand, e.g. in the operator cabin of the plant .
• The operating and maintenance instructions are the part of the plant.
• Operate the plant after thorough inspection and by following this manual.
• We wish you success with your Concrete Batching Plant - Greaves Perfect Mix 500
1.03 Important!
• You are now the custodian of one of the most reliable products manufactured by GREAVES.
• It is important to follow the correct operation and maintenance procedures, as laid down in this
manual, for making effective use of these Concrete Batching Plant.
• You have to pay attention to the emphasize points in instruction leaf lets. General guidelines are
provided here under. A few of these may not be relevant to this specific plant.
• It is important that operator should be aware of all the aspects of plant operation as laid in the
manual.

2.00 SAFETY INSTRUCTION
• All electrical woks and connections to be handled by an Electrical Expert.

• Any work on the plant may be performed only when the plant is switched - OFF.
• In case the Plant is completely switched OFF for Maintenance and Repair works, it
must be safeguarded against unexpected Switching – ON.
• Hence to ensure safety, Lock up Main Switching Equipment, Press Emergency Stop
and draw off the key.
• Incase of irregular in Electric Supply (i.e.) Unbalanced Voltage, Single Phasing and
Over/Under Voltage, please switch - OFF the plant immediately. And DO NOT
START. Ensure that the problem is sorted out before restarting the plant.
• Use Voltage Insulated tools only, when working in electrical areas.
2.01 Electrical Installation
• The incoming Aluminum power cable (4 Core 35 Sq. mm) is in customer scope.
• Since earthing plays very important role for accuracy of the plant, we request the
customer to provide proper earth to the structure and control panel of the plant.
2.02 Diesel Generator ( DG ) Requirement
• The minimum capacity of the D.G provided by the customer should be 75KVA and
should have 150% overload capacity.
2.03 Power Failure
• In the event of power failure, during the mixing cycle, the pan mixer can be started
in direct ON-LINE mode for which direct starting of mixer is provided.
• However this must NOT be frequently operated.
• Greaves does not take any responsibility under any circumstances, if the above
facility is misused.
2.04 Welding in Plant
• If it is necessary to do welding in the batching plant, kindly switch OFF the control
panel power and isolate the load cell from the weigher by tightening the transportation
lock.
2.05 Protective and Safety Devices
• All protective and safety devices are to be kept operative and must be repaired /
replaced immediately, in the event of failure.
• Bypassing the safety devices may result in heavy injuries or even loss of life.
• No claim can be made in the event of by - passing of any protective / safety devices in
the control system.
• Greaves does not take any responsibility in such cases and will not accept any warranty
claims.
• We recommend stocking minimum spare parts available at all times. Refer the
recommended spare part list available in the manual.
• All protection breakers for motors are provided for the specified motor rating only.
2.06 Replacement of Electrical Items
• The life of the electrical power and control contactors are 0.5 million operations at a
constant ambient temperature of 40°C. De-rating is applicable when operating at
higher temperature.
• However considering the dusty atmosphere and to get the best result, we recommend
replacing the Contactors every 1,05,000 m3 or 4800 working hours, whichever is
earlier and do not replace just the Contacts.

3.00 Technical Data
Motor Details
Compressor motor:……………………………………….. 1.5 KW / 2 HP

Sand vibrator motor:……………………………………… 0.18KW /0.24 HP
Screw conveyor motor-1:………………………………… 7.5 KW / 10 HP
Fly ash Screw conveyor: (Optional)…………………….. 7.5 KW / 10 HP
Mixer motor:……………………………………………….. 22 KW / 30 HP
Skip motor:….Slow speed/High speed ……………….. 2 * 1.3 KW / 4 KW
Admixture dosing motor: ………………………………… 0.37KW / 0.5HP
Water pump: (Customer Scope) ……………………….. 3.7 KW / 5 HP
Scraper motor: …………………………………………… 7.5 KW / 10 HP
Scraper swing motor: ……………………………………. 0.37 KW / 0.5 HP
Note:
All the above motors are 3 phase 415 V AC ± 10%, 50 HZ, unless, otherwise, specified in the
drawings.
All Contactor coil Voltage - 220 V AC
All Relay Coil Voltage - 24 V DC
All Solenoid Coil Voltage - 24 V DC
Skip Motor Brake Rectifier Input Voltage - 230 V AC
Scraper swing motor brake rectifier input voltage - 230V AC
All the Motor Protection Circuit Breakers and the Multi Core Cables are provided along with
the Batching Plant and are designed for Constant Ambient temperature of 45° C. De-rating is
applicable when operating at higher temperature.
Load Cell Details:
Input Resistance : 350 Ohms ± 2 Ω

Output Resistance : 350 Ohms ± 2 Ω
Excitation Voltage : 10 V DC
Non – Linearity : < ± 0.025 %
Full Scale Output : 2 mV /V
Load Cell Wiring Details:

Red : Excitation(+ 10VDC)
Black : Excitation( 0 V DC)
White : - Signal
Green : +Signal
Brake Rectifier Details

Input Voltage : 230 V AC Between terminal No. 2 and 3.
Brake Coil : 12.7 V DC Between terminal No.1 and 3 .
: 90 V DC Between terminal No.3 and 5.
: 77 V DC Between terminal No.1 and 5.
Rectifier Resistance : 0.5KΩ between terminal No. 1 and 5.
Reverse Direction : OPEN Circuit
Rectifier Resistance : OPEN Between terminal No.2 and 5.
Reverse Direction : OPEN Circuit

4.00 OPERATING INSTRUCTIONS
4.01 INTRODUCTION
The AUTOMATION OF READY MIX CONCREATE PLANT provides a fast and reliable way for
batching and mixing of ready mix concrete. The system is designed to produce 30 cum. Per hour of ready
mix. The system facilitates the complete control and interlocks for operating the system in manual and
auto mode. It improves the productivity of the plant to a great extent and provides a foolproof method of
producing the right mix. It can be operated by even a semi-skilled operator, and at the same time, avoids
any chance of wrong doings by interlocks. The Programmable Logic Controller (PLC) does the
supervision of operations. And the control, operator interface and report generation is done by the
computer.
The batch control unit of the system ensures only the exact set quantity of the ingredients are fed into the
process, first time and each time. The PLC control logic assures the quality of the mix and at the same
time avoids the wastage of the raw materials.
The instantaneous weight in the weigh hoppers are displayed on the batch controllers and the
annunciations on the computer gives working condition of each equipment at any given point of time.
Any malfunction or fault in the operation can be identified from the custom engineered computer screen,
which makes the rectification quick and easy. The equipments in the field are operated and controlled by
the PLC. The various sensors and limit switches provides the necessary feedback signal to the PLC. The
PLC is again connected to the computer and the SCADA software controls the functioning. The SCADA
package makes the PLC very flexible and user friendly. The annunciations like operating conditions; fault
indications etc. can be very easily displayed on the computer screen with the help of SCADA. The
software makes the data storage and printout very flexible and easy. The live weights of the ingredient
weigh hoppers are continuously upgraded on the computer along with the operating status of equipments.
The recipes can be entered from the computer. The history of all the batches is available on the computer,
and is available for printout .the batch data are stored as trip report, monthly report and yearly report and
these data will be available for printout at the click of a button.
Greaves does not take any responsibility in the event of misuse of materials (i.e.) taking Cement
instead of Fly ash / additional consumption of materials if batching done in manual mode and no
claim can be made. Please note that customer must record material consumption in manual
mode.
4.02 SYSTEM DESCRIPTION
The AUTOMATION OF READY MIX CONCRETE PLANT comprises of the load cells, batch
controllers, PLC with SCADA package & software, control desk. The main function of this equipment is
to produce the right grade mix in the fastest possible time. The RMC plant comprises of storage bunker
for various raw materials, aggregate weigh hopper, skip hoist, cement weigh hopper, storage silos and
feeding screw conveyors, weigh tanks and storage tanks for water and admix along with feeding and
discharge devices, mixer etc. The raw materials like aggregate, sand dust, cement, water and admix are
initially loaded into the storage hoppers. The materials from storage bunkers for the aggregate, sand and
dust are extracted through sector gates. The extracted material is collected at a weigh hopper below as per
the preset recipe, before discharging to the skip hoist. The skip hoist delivers material to the mixer. From
the storage silo the cement is extracted to the cement weigh hopper through the screw conveyor
depending on the recipe value. Similar way the required quantity of water and admix also are collected
separately at the weigh hoppers. These weighed raw materials are then discharged into the mixer per the
preset sequence. The operations like the mixing time and sequence of operations are controlled by the
PLC.
The quantity of material to be fed from each hopper is set prior to the operation. The setting can be done
as recipe on the computer. The required recipe for the mix can be selected from the memory or new
values can be entered in the blank recipe format. The load indicator units on the control desk sends the
weight data continuously to the PLC in the form of 4-20mA and the PLC controls the feeding gates and
screw conveyor at the bottom of the storage hoppers. Once the correct weight quantity is achieved, the
weigh hoppers discharge sequentially into the mixer. The mixer is run for a certain preset period of time
& then empties the material into the truck.
The Batching system electronics comprises of load cells, load indicators, PLC and the software. The PLC
is in turn connected to a computer (through communication port 1). The load cells are mounted on
support frame, which in turn is bolted to the weigh hoppers. There are 4 weigh hoppers in the system.
One each for aggregates, cement, water and admix. The aggregate weigh hopper is mounted on 2 load
cells, where as the cement and water weigh hoppers are supported on 3 load cells and admix on single
load cell. These Load cells are having parallel termination onto a junction box. From each junction box a
single 4 Core shielded cable connects to the corresponding load indicator on the control panel. There are
4 load indicators in the control panel corresponding to 4 weigh hoppers. The load cells gives mill volt
signal corresponding to the load applied. These signals are amplified at the load indicator converted to
digital, processed & then displayed as weight data. The weight data is transferred to the PLC and as per
the recipe settings the relays are energised. These control relays in turn operate the field devices Viz:
pneumatically operated sector gates, screw conveyor and ball valves. Limit switch inputs are used for
various inter locks to make the system fool proof. Additional controls & data regarding Batch time, date,
Individual raw material weight etc., is provided at the computer. Adequate software to this effect is
provided.
5.00 EQUIPMENT DESCRIPTION
5.01 LOAD CELL
The load cell is strain gauge based transducer that converts load applied into mill volts signal. The load
applied on the weigh hopper will be transferred to the load cell and the load cell gives corresponding
millivolt output to the digital readout where the signal is processed and is displayed.
The load applied creates a bending movement in the load cell, which in turn causes compressive and
tensile strains in the strain gauges. When strain is created resistance of strain gauge varies. The strain
gauges are connected to form a whetstone’s bridge and an excitation voltage is supplied to it from the
processing unit, a small voltage variation in terms of millivolts is created when the load is applied on the
load cell.
The signal from the load cells in the form of millivolts is fed to the load indicator unit on the control
panel. The weight values are displayed on the front panel.
The load cells used are of single ended Shear Beam Type / S-Type. The aggregate weigh hopper is
supported on load cells of 1250 kg. Capacity each. Where as cement and water weigh hoppers are
supported on 250 kg. Load cells each. The admix weigh hopper is supported on 22.5 kg. Capacity load
cell.
SPECIFICATIONS
Type Single ended Shear Beam Type / S -Type

Make Sensortronics
Capacity of load cell 1250 kgs. - 2 nos.
250 kgs. - 6 nos.
22.5 kgs. - 1 no.
Safe overload 150%
Ultimate 0/l 300%
Excitation 14 volts dc Max
Insulation resistance >1000 mΩ @ 50v dc
Operating temperature -20ºc to +70ºc
Output at nominal load 3 mv/v
Input resistance 350 ohms
Combined error (+/- 0.025% of full scale)
CREEP (30 minutes) (+/- 0.020% of full scale)
Protection class IP 67
For mounting details of load cells refer the enclosed load cell mounting drawing.
5.02 LOAD INDICATOR
The Load indicators are DPM type and are mounted in the control desk with the help of clamps.
This accepts 0-3mV/V from the load cells and amplifies and displays true weight data present in the
weigh hopper after eliminating all noise, introduced error like offset and common mode signal. This
indicator generates 4-20mA isolated current output which is used for long distance transmission. This
signal is fed to the PLC for further data processing and control.
The Load indicator is designed to work from an AC power source of 230V AC drawing a current
of 0.1Amps (nominal).
SPECIFICATION
Type : Micro-controller Based
Model : IA-PT-420
Power Input : 230V +/- 10V AC 50Hz +/- 2Hz
(0.5A maximum)
Signal Input : 0-42mV from Load cell corresponding to
0-100% Load
Load cell Excitation : 14V DC Max
Signal Output : 4-20mA isolated current output corresponds
To net weight (No load to Full load)
Display : Six-digit red LED display with 0.25-inch
Character height to display weight data and
Other functions.
Load indicator is micro-controller based, which displays the live load at the weigh hopper and
communicates with the PLC. Feeding and discharging of material is controlled by the PLC. The Load cell
m. V signal, which represents true weight, is fed to the load indicator from load cells. As Explained
above, 4 cores shielded cable from junction box is wired to the terminal block of the indicator. The

system accepts this signal amplifies and displays the same as a stable load/weight data. Using internal
Trim pot does span error adjustments/Calibration. It also provides digital/keyboard calibration.
MICRO CONTROLLER BASED ADC (IA-PT-420-01A):

This is a 89C52 based, which uses DUAL SLOPE Analog to Digital Converter, converts the amplified
load cell signal to a Digital signal and presents it to the micro controller for further data processing.
The amplifier itself is a High-precision, low-drift Instrumentation amplifier, which amplifies the low milli
volt load cell signal and presents it to the ADC for conversion.
The 7135 ADC accepts amplified signal from INSTRUMENTATION AMPLIFIER & converts the same
into BCD signal, this is fed to the micro controller for further processing.
A common adjustment for SPAN is provided for trimming the linearity error. Resistors Rg is the GAIN
resistor of the AMPLIFIER. Generally this is factory set, but if any change is done in load cell capacity at
a later date, then this resistor will have to be changed. Analog 16 Bit, High Resolution Isolated Outputs (4-
20mA) are available on the terminal blocks Backside of the Indicator corresponding to No Load to Full
Load.
CPU, ADC & POWER SUPPLIES
The CPU is powered with a +5 volt digital supply. The ADC is powered with a separate twin power
supply of + 5 volts – 5 volts (ANALOG).
The current Transmitter with a twin power supply of +15v & +5volts. All the above-mentioned POWER
SUPPLIES are mounted on IA-PT-420-01P. Voltage switching regulator 4576 is used for digital
supply.7805 & 7905 for Analog and 7815,7805 are used in current transmitter section.
TRANSFORMER GX234-58 is used for generating secondary AC voltages for all the above-mentioned
DC POWER SUPPLIERS.
Step-down TRANSFORMER GX762–59 is used to generate various secondary AC voltages from primary
AC source of 230 volts. The secondary AC voltages are fully rectified and fed to LINEAR regulators for
generating the various DC voltages.
Following are the DC voltages:
a.V1: +5 v at 1.5 amps (from 10 V AC, 1.5 A) for the Micro controller
and its peripherals.
b. V2 : + 7 v ( 12 V AC, 0.2 A) &

V3 : - 7 v ( 12 V AC, 0.2 A) For the instrumentation amplifier.
c. V+ : +15V (18V AC, 0.2A)

VCC2 : +5V For Current Transmitter Section

PARAMETER SETTINGS

5.03 CONTROL DESK
The control desk houses the load indicators, push buttons, selector switches, and the relays for the logic
circuit. Refer enclosed drawing for the dimension details of the control desk.
The desk is of sheet steel construction with structural steel frame. It has a vertical panel housing the PLC,
Contactors and Relays, then the door housing indicators and the pushbuttons and selector switches. The
panel have the provisions to run the plant in auto mode as well as in manual mode. Inside the control desk
it contains the PLC modules, SMPS and relays.
The power supply is connected through an isolation transformer to avoid spikes and smoothen the power
supply. A 2-phase 440-v Ac supply is connected to the isolation transformer and a 230V ac supply is
drawn from it.

The inputs and outputs for various motors, feeding and discharging devices are routed through relays and
contactors of adequate capacity.
Refer enclosed drawing for the detailed component layout.
TROUBLE SHOOTING
For load indicator/ signal conditioner in case of erratic display
Check the ac mains power supply for “low voltage”. System may behave erratically if AC mains are
less than 150 volts.
- Check whether all load cell connections and cables are firmly secured and in the right place.
- Now physically check the individual load cell, which is showing abnormal or excess ‘load’ value.
Load cell can be physically checked for its correctness by just measuring the impedance across the
opposite terminals after isolating the connections from the load indicator.
Resistance should be as follows:

When measured across red & black or green & white the resistance shown should be 350 ohms or almost
equal to it.
When measured across each arm resistance should be around 350 ohms.
if any abnormality is noticed in the above then it can be concluded that load cell is faulty
No load test
- Connect back the connector of the load cell, which was removed, but isolate only the load cell output
wires green and white from the connector. Connect a milli volt multi meter across the above two
wires make sure that no load is acting on the load cell & load cell should be absolutely free. if
required load cell can be taken out from the weigh hopper. Under the above conditions the milli volt
measured on the multi meter should not exceed 1.5-milli volt. if any abnormality is noticed in the
above reading then it can be safely implied that load cell is faulty.
- If load cells are found to be ok from the above tests, after switching off the power to the system look
for any connectors plugged out or loosely connected and secure them properly.
- Next switch on the power and measure all the dc voltages present in the system. All voltages should
be within tolerance limits if any abnormality is noticed get the defective power supply replaced or
replace the power supply card with a spare one.
- If all above are ok then replace the main ADC+CPU card with a spare one.

6.00 TB DETAILS
Sl.No Fr.No Description Remarks

01 103
02 104 EMG
03 ------- SPARE -----
04 ------- SPARE ----
05 105 +24V
06 160 SKIP BOTTOM LEVEL SENSOR
07 161 SKIP BOTTOM SPEED SENSOR
08 162 SKIP WALK SENSOR
09 163 SKIP TOP LEVEL SENSOR
10 164 WATER GATE CLOSE
11 165 CEMENT GATE CLOSE
12 166 MIXER GATE CLOSE
13 167 MIXER GATE OPEN INPUT FROM SENSOR
14 168 MIXER DOOR L.S
15 169 AGG GATE CLOSE LS
16 170 SLAG ROPE
17 171 THERMAL SENSOR SKIP M1,M2
18 199 GND
19 501 MIXER GATE OPEN
20 502 MIXER GATE CLOSE
21 503 WATER FILLING
22 504 WATER DISCHARGE
23 505 AGG1 OPEN
24 506 AGG2 OPEN
25 507 AGG3 OPEN
26 508 AGG4 OPEN OUT PUT TO
SOLONIED COIL
27 509 CEMENT DISCHARGE
28 510 ADMIX DISCHARGE
29 511 ADMIX FILL VALVE
30 512 CYCLE OVER ALARM
31 ---- SPARE -----
32 ---- RED
33 ----- BLACK
34 ---- WHITE AGG L.C
35 ---- GREEN
36 ----- SPARE
37 ---- RED
38 ---- BLACK
39 ----- WHITE CEMENT L.C
40 ---- GREEN
41 ---- SPARE
42 ----- RED
43 ---- BLACK WATER L.C
44 ---- WHITE

45 ----- GREEN
46 ---- SPARE
47 ---- RED
48 ----- BLACK
49 ---- WHITE ADMIX L.C
50 ---- GREEN
51 ----- SPARE
52 ----- 325 COMPRESSOR
53 326 PRESSURE SWITCH
54 ---- SPARE --------
Sl.No Fr.No Description Remarks

01 004 NEUTRL
02 ----- SPARE ---
03 073 L1
04 074 L2
BOOM SCRAPER
05 075 L3
06 ----- SPARE ------
07 011 L1
08 012 L2 MIXER STAR
09 013 L3
10 014 L1
11 015 L2
MIXER DELTA
12 016 L3
13 ----- SPARE ----
14 023 L1
15 024 L2
SKIP SLOW
16 025 L3
17 ---- SPARE
18 026 L1
19 027 L2
SKIP FAST
20 028 L3
21 ---- SPARE
22 71 LINE
23 72 NEUTRAL SKIP BREAK
24 SPARE
25 032 L1
26 033 L2
COMPRESSOR
27 034 L3
28 ----- SPARE
29 038 L1
30 039 L2
CEMENT 1
31 040 L3
32 ---- SPARE
33 044 L1

34 045 L2 CEMENT2
35 046 L3
36 ---- SPARE -----
37 050 L1
38 051 L2
39 052 L3 SAND VIBRATOR
40 ---- SPARE
41 056 L1
42 057 L2
ADMIX PUMP
43 058 L3
44 ----- SPARE -----
45 062 L1
46 063 L2
WATER PUMP
47 064 L3
48 ---- SPARE -----
49 005 LINE1 TRANSFORMER
50 007 LINE2 INPUT
51 410 LINE TRANSFORMER
52 411 NEUTRAL OUTPUT
7.00 OPERATION PROCEDURE
• Switch on the PLC through SW1 provided at the rear side of the panel
• Switch ON the Control supply through SW2 provided adjacent to SW1
• Switch ON all the Signal Conditioner Unit with MCB 2
• Now Switch ON the computer through Mains Supply.
• The MIMIC screen appears on the PC Monitor.
• All the signals available are displayed as green colour on the mimic screen of computer.
• Signals unavailable are shown as red colour on the computer screen.
• Before auto start mode check whether all the starting sequence are displayed in
green colour viz.
WATER PUMP ON
COMPRESSOR ON
MIXER ON
AUTO MODE SELECTED
• In case of recipe error, the same is indicated in red by flashing.
• Correct the recipe value in the main screen.

• Now check the weight display value this should be zero/minimum, in case the value is higher
discharge the material in the weigh hopper through manual operation/ by adjusting the tare POT
provided on the backside of the DPM.
• Now give the batch start signal, by clicking the mouse on “Batch Start” Icon, and then the system
starts batching as per the recipe selected.
• On completion of the batching the system checks for mixer gate open and close condition,
operator can give the vehicle in command through the switch provided at the front side of the
panel.
• On confirmation of the above conditions the aggregate weigh hopper discharges to the skip.
• Now the skip moves up and discharges to the mixer. Here we are having 4 Limit switches, namely
a) Skip bottom, b) Skip Top, c) Speed Change Over and d) Skip wait.
• Once the skip in bottom position then aggregate starts filling when the start button given.
• Once all the four materials filling (aggregate) is over then the skip will move automatically,
slowly up to speed change over limit switch, once it reaches speed change over limit switch then it
will move fast up to it reaches skip wait limit switch. Here the skip will wait for Cement, Admix
and water filling. Once those three materials get filled the skip will go up (skip Top Limit switch
sense that the skip is available at the top and ready to discharge the material) and deliver the
material in to the Mixer. By that time the Cement, Admix and Water will get discharge (receives
discharge signal) and starts next batch. Mean time the Skip will come down slowly up to skip wait
limit switch and the it start to come down very fast up to speed change over limit switch then it
will come to bottom. Once the skip is in bottom then it starts filling for Next Batch.
• If any emergency press “Batch Stop” Push Button to stop the Batch
• On completion of discharging, the mixer timer starts.
• On achieving the preset mixing time the mixer gate open (It also ensures the vehicle IN command)
for discharging the material (with settable discharge time).
• The Batch counter will be updated on completion of the batch.
• This cycle repeats till achieving the target tonnage value/cubic meter.

8.0 ELECTRICAL SCHEME.

9.00 DRAWINGS

10.00 COMPUTER SCREEN DETAILS
SCREEN 1
This is the main screen of the RMC batching system. This screen contains Graphical display of
Aggregates, water, and cement and admixes. It shows status of the operation mode, Mixer ON, Auto
Mode ON and Compressor ON. If you want to run the system in Auto mode you will have to satisfy all
these three condition. If any one of the conditions is not satisfied then the system will not run in Auto
mode. After satisfying all three conditions operator has to give batch start signal by simply clicking
“BATCH START” button and can be stopped by simply clicking “BATCH STOP” button. Here operator
can set the water correction values, Total cubic meter and batch numbers and can be viewed different
status like Mixer ON time, Recipe No etc.,
Once the batch is Start aggregates, water, Admix and cement will get fill and this will be indicated by
green lines and the set values of all the materials and filled values of all the materials also displayed in the
corresponding hopper. Mixer ON time and Material discharge time are settable. After batch starting
Aggregates will get fill first and then water, cement and admix will get filled at a time, then skip will
move to up and discharges the material in to Mixer, after some small delay water, admix and cement will
get discharge fully and mixer time start for mixing (will be indicated in the main screen) after that mixer
gate will get open and discharges the material (discharge time also settable and will be indicated in the
screen). From the main screen user can access for Recipe selection, In-flight selection screen and
Password protection screens. The vehicle can come in by simply selecting the vehicle in input (Graphical
display will be indicated).

Once the skip in bottom position then aggregate starts filling when the start button given. Once all the
four materials filling (aggregate) is over then the skip will move automatically, slowly up to speed change
over limit switch, once it reaches speed change over limit switch then it will move fast up to it reaches
skip wait limit switch. Here the skip will wait for Cement, Admix and water filling. Once those three
materials get filled the skip will go up (skip Top Limit switch sense that the skip is available at the top
and ready to discharge the material) and deliver the material in to the Mixer. By that time the Cement,
Admix and Water will get discharge (receives discharge signal) and starts next batch. Mean time the Skip
will come down slowly up to skip wait limit switch and the it start to come down very fast up to speed
change over limit switch then it will come to bottom. Once the skip is in bottom then it starts filling for
Next Batch.
If any emergency press “Batch Stop” Push Button to stop the Batch
On completion of discharging, the mixer timer starts

On achieving the preset mixing time the mixer gate open (It also ensures the vehicle IN command) for
discharging the material (with settable discharge time)
The Batch counter will be updated on completion of the batch
This cycle repeats till achieving the target tonnage value/cubic meter.
SCREEN 2
This screen is used to enter in to recipe build screen. Operator can view the RECIPE BUILD SCREEN by
simply clicking “RECIPE BUILD” button or close this screen by simply clicking “CLOSE” button.

SCREEN 3:
This screen is used to set the In-flight and Zero margin values of Aggregates, Cement, Water and Admix.
After entering the values please click “SAVE” to save/click “DELETE” to delete/click “EDIT” to Edit/
click “EXIT” to exit from this screen.
SCREEN 4:
This screen is used to set the recipe values, Mix design category, and Mixing time, Discharge time, and
skip up time. After entering please click “SAVE” to save the values or click “EXIT” from this screen.

SCREEN 5:
If you press the “RECIPE SELECTION” in the screen 1, immediately this screen will appear and it will
shows you the current/ running Recipe number, material grades, Mix design category, Mixer ON and
Discharge Time and set values of all the four materials.

SCREEN 6
This screen will appear when you click Report button in the first screen (Main screen).
In this you will have the printing format options i.e) Batch Report Date wise and Trip sheet wise
(Summary and in Detail).
Select the date from which you want print out then select the option whether you want in summary format
or in detail description format. You can select the customer, vehicle, place and Mix design by clicking
the particular point and you can view the particular option (selected one) by clicking “SHOW” button.
Press Enter after selecting all the parameter to get print out or click “EXIT” Button to escape from this
screen.

SCREEN 7:
This window will appear when you select the format in summary form and clicking “VIEW”. From this
you can confirm the value stored in the data sheet after confirming when you close the window the
following command will appear, click “End now” then the window will get close.

SCREEN 8:
This window will appear when you select the format in Detail description format and clicking “VIEW”.
From this you can confirm the value stored in the data sheet after confirming when you close the window
the following command will appear, click “End now” then the window will get close.
After confirming click “PRINT” button and you

will get printout.

SCREEN 9:
This window will appear when you select the format in Trip slip number wise, Enter the trip slip number
from which you want print output and click “PRINT” button to get printout click “VIEW” button to view
the Trip sheet number wise Report. By clicking “VIEW” button you can confirm the value stored in the
data sheet after confirming when you close the window the following command will appear, click “End
now” then the window will get close.
The trip number wise Report will appear as given below

11.00 MAINTENANCE
• Do not leave maintenance tools on the plant where by vibration may move them into moving
parts.
• Only qualified personnel must examine electrical equipments.
• Never leave material in storage hoppers when plant in not working.
• Clean compressor air filter and check the oil level regularly.
• Avoid careless use of mechanical shovels that may damage the unit.
• Ensure proper tightening of all fasteners
• Check pneumatic lines for any leakages
• Check and drain water from FRL unit regularly
• Check lubricant level in FRL unit regularly
SKIP STRUCTURE:
• Check and ensure the correctness of skip weighing frame and load cells alignment at regular
intervals.
• Check and ensure proper lubrication and clearance of skip bucket rollers
• Check and lubricate skip tracks regularly
• Check and lubricate skip ropes regularly
CEMENT & WATER WEIGHING HOPPERS:
• Check and ensure the correctness of hopper weighing frame and load cells alignment at
regular intervals
ADMIX WEIGHING:
• Check and ensure the correctness of admix weighing frame and load cell alignment at
regular intervals
PAN MIXER:
• For any repair work inside pan mixer, isolate the mixer motor from mains power and
ensure the emergency switch is in OFF position. Take all necessary precautions to
ensure that mixer not to be operated while work in progress.
• Inspect new plant after a few hours of operation and regularly thereof.
• Check all fasteners for tightness.
• Check all shaft for its position and lubricate regularly.
• Check all blades and scrapers for its position and tightness.
• At days end of production clean the mixer with water to avoid mix material from
getting deposited. If this not done regularly it may result in reduced capacity.

HYDRAULIC HAND PUMP UNIT FOR SECTOR GATE

WINDING OF SKIP ROPES
1. Put skip bucket into filling position

2. Switch off control system of the plant and
secure against switching on.
3. Dismount old ropes.
4. Lay down new ropes on the place of mounting
onto a wooden pallet (Do not lay rope onto
sandy underground!)
5. Positioning of rope:
LEFT-HAND rope onto the right rope
pulley.
RIGHT HAND rope onto the left rope
pulley
6. Screw-on rope fittings, counter nuts and screw
into the right and left turnbuckle on the skip.
7. Lift the loose ends on a lowered hemp rope,
loop via the slack rope pulley 2.5 times
over the rope pulley on the motor side. Lead
the rope end into the wedge
sparing.
8. Tighten each rope by hand evenly. Indroduce
the wedge and clamp the rope strongly with the
two hexagon socket screws.
9. Switch on the plant’s control system and have
the skip run out of the weighing frame into the
vertical skip track, approx.1.5m above ground
in manual mode.
10. Check the horizontal position of the skip by
means of a bubble level. Readjust via the
turnbuckle on the skip, if required . Tighten
counter nuts on both sides strongly.

COBRA RAU GEARBOX
Oil quality Castrol Deusol Super 20W/40 or equivalent.
Oil level Fill in oil to the max. mark. Run mixer for a few minutes. Check oil
level. Top up if required.
Oil change In the case of a new or reconditioned gearbox the oil change should be
after 100 operating hours.
Additional changes after every 1500 operating hours but at least once a
Check oil level once a month
Oil filling procedure

Filter change First filter after 500 hours. Additional filter changes after every 1500
hours but at least once a year.
IMPORTANT Filter cartridge must not be cleaned, but must be replaced

INFORMATION Check all fittings regularly for any leakage.
Filling quantity 16 ltr.

MAINTENANCE SHEDULE
Maintenance schedule-Plant Time intervals W
Does not replace operating every …. Da Mon Quarte Half- Year
ee Rem
instructions. replace operating Service hours ily thly rly Yearly ly
kly arks.
instructions. 9 200 500 1000 2000
50
Maintenance works to be carried out
0.1.0 Plant in general.
1 Clean the area below the feeder skip X
2 Check the skip rope for wear. X
Check the skip track and wheel
3 X
adjustment.
Check the clearance of the skip roller in
4 X
the weigher.
Check the slack rope sagging and the
5 X
function of the slack rope switches.
Check the weighers. The weigher must be
suspended freely. Use control weight to
6. X
check the taring and the control indication
at the weigher head.
Check and lubricate skip rope with
7. X
cardium compound.
Check the adjustment of the skip
8. X
discharge position.
Check the batching gates and compressed
9. X
air cylinders.
Clean and grease pillow blocks of the
10. X
batching gates
Grease the track rollers, support rollers,
11. rope pulleys and flanged bearings of the X
skip.
Check all limits switches function if
12. X
necessary clean and adjust.
Check the function of the emergency limit
13. X
switch.
Clean the dirt trap in the water line, if
14. X
necessary replace the sleve.
Check the fastening screws of the skip
15. X
drive and retighten them, if necessary
16. When required clean the verification hose
from the mixer to the cement weighing X
hopper
When required, remove cement cakings,
17. in the gate of the aggregate charging X
hopper
When required, remove cement cakings
18. from the gate of the aggregate charging X
hopper

MAINTENANCE SCHEDULE
Maintenance schedule-Plant Time intervals W

Does not replace operating every …. Da Mon Quarte Half- Year
ee Rem
instructions. Replace Service hours ily thly rly Yearly ly
kly arks.
operating instructions. 9 200 500 1000 1500
50
Maintenance works to be carried out
0.1.0 Plant in general.
Check the additive and water nozzles and
19. X
clean them when required
20. PANMIXER
Clean the complete inside of the mixer
1 X
cover
Spray the complete mixer cover with
2 X
crude oil or concrete removing agent
Check all rubber parts & nylon for wear
3 X
and replace them, if necessary.
Check and grease all the spring holder
4 X
spring assly tighting screws if required.
Check the discharge door movement clean
5 X
if necessary.
Check the tightening of the blade and
6 X
scrapers.
7 Check the function of hand pump unit. X
21. BOOM SCRAPER
1 Check and grease slew bearing X
2 Check and grease clutch assembly X
3 Check the scraper ropes for wear X

Check and lubricate the ropes with
4 X
cardium compound.
Check and grease all the pulley and
5 X
rollers.
22. GEAR BOX
1. Filter X X
2. Gear Box Oil change (20w/40) X X
23. PNUMATIC PANEL
1. Check and remove water control in FRL X
2. Check oil level in FRL X

1. TECHNICAL DATA
1.1 COMPRESSOR
Model : TCH200 TCH300

Type : Reciprocating, air cooled & oil splash lubricated.
Free air delivery : 9.18 m3/hr 14.54m3/hr
Working pressure : 12kg/cm2 12kg/cm2
No.of cylinder : 2 2
No.of stages : 2 2
Cylinder bore and stroke length : LP 70X85 mm LP70X85mm
: HP 50X85mm HP50X85 mm
Type of valve (suction and delivery) : Stainless steel finger type
Belt type quantity : A68 -2.Nos A72 –2Nos
Speed : 600 rpm 950 rpm
Pressure switch cuts off pressure : 12 kg/ cm2 12 kg/ cm2
Pressure switch cuts in pressure : 9 kg/ cm2 9 kg/ cm2
Safety valve on the after cooler
Opening pressure : 16kg/cm2 16 kg /cm2
Safety valve on the air receiver
opening pressure : 16kg/cm2 16kg/cm2
Safety valve on the intercooler
opening pressure : 5kg/cm2 5kg/cm2
Crankcase oil capacity Min. : 40 ml
Max : 580ml.
Net weight Tank mounted :
Base mounted :
Overall dimensions (LxWxH) :
Tank mounted : 1260+/-10x 600+/-10 x970+/-10

1.2 MOTOR
Make : SUGUNA
Type :
Voltage/ Phase/ Frequency : 415Volts / 3Phase /50 Hz
Power : 2HP 3HP
No. of poles :
Class of insulation :
1.3 AIR RECEIVER

Make : SUGUNA PNEUMATICS
Capacity : 160 Liters
Working pressure : 12 Kg/cm2
Hydraulically tested pressure : 22.5 Kg /cm2
1.4 PISTON AND PISTON RINGS
Size Normal Max. Clearance

Component mm clearance in permissible in
Cylinder mm cylinder mm
_____________________________________________________________________________________
LOW PRESSURE PISTON & PISTON RINGS
1. Piston diameter at skirt 69.90 to 0.08 to

69.92 0.11 0.20
2. Piston ring butt clearance 0.08 to

0.18 0.40
3. Piston ring side play in groove 0.04 to

0.08 0.12
HIGH PRESSURE PISTON & PISTON RINGS
1. Piston diameter at skirt 49. 92to 0.06 to

49.94 0.08 0.20
2. Piston ring butt clearance 0.08 to
0.18 0.40
3. Piston ring side play in groove 0.03 to

0.07 0.10
4. Clearance between piston crown 1.4 to

And cylinder top (value flat) 1.6
3. INSTRALLATION AND OPERATIONS

3.1 ELECTRICAL CONNECTION
Connect the electric power supply as shown in the wiring diagram given in the manual. After
connecting the power line start the unit momentarily and observe the direction of rotation of the
compressor. The direction of rotation should be antic lock wise when viewed from the front side (oil level
indicator side). If the direction of rotation is not correct change the direction by interchange .any of the
two phases in the starter. The compressor must be electrically earthed by connecting a copper wire to the
body of the compressor and earth..
3.2 ADJUSTING BELT TENSION

The Belt tension between the motor and compressor pulleys must be suitably adjusted. When correctly
adjusted the belt will have a play of 10mm about their mean position.
3.3 STARTING PROCEDURE
Check whether the following things are ok before starting the unit.
9 Check the crankcase oil level on the oil level indicator. If it is below the minimum level mark, add
fresh oil of the correct grade
9 Make sure that the belt tension between the compressor and motor is correct to avoid whipping.
Too much tension will put an excessive load on the motor and compressor bearings.
9 Check that compressor rotates freely by hand that there are no mechanical obstructions.
9 Check that the drain on the air receiver is shut.
9 Momentarily switch on the compressor and see that it rotates in the right direction.
3.4 CHECKS DURING COMPRESSION OPERATION
9 Check whether the compressor is running smoothly and that the running sound is normal.
9 Feel the compressor suction parts, crankcase and air receiver to ensure their temperatures are with
in limits. (Note that the delivery parts of the compressor will be very hot and do not touch them.
Touching may case burns).
9 Observe for air leaks at the joints of the pipes and if noticed stop the compressor and rectify the
defects.
If all above checks are satisfactory, continue to run the compressor and note the pressure at which
the compressor cuts off automatically. Then let out air from the receiver and note the pressure at
which the unit cuts in.
3.5 PRESSURE SWITCH ADJUSTMENTS

The pressure switch operating pressures are adjusted at the factory and will not normally required
readjustment. However, if it is necessary to alter the factory settings, the pressure may be increased or
reduced with in the limits indicted in the technical data. The upper limits should never be exceeded.
PRESSURE ADJUSTMENT
While operating the compressor it may be necessary to vary the delivery pressure. The pressure
adjustment is quite easily done by the following simple procedure.
1. Remove the cover on the pressure switch.

2. Unlock and turn the control screw clockwise for increasing the cut off pressure.
3. Turn the control screw anti-clockwise for reducing the cut off pressure.
DIFFERENTIAL ADJUSTMENT
Depress the screw against the spring and turn clockwise for decreasing the differential i.e., to
increase the cut in pressure and anti-clock wise to increase the different pressure i.e., to decrease the cut
in pressure.
NOTE
It is necessary to keep the compressor pressure switch correctly
adjusted as it is uneconomical to run the compressor at higher
pressure, if the air pressure required id lower.
4. MAINTENANCE SCHEDULE
4.1 For Every 24 Hours of Operation.
1. The compressor should be cleaned thoroughly.

2. Check the oil level in the crankcase and replenish with the correct grade if required.
3. The compressor belt tension must be checked.
4. Water from the air receiver must be drained.
4.2 FOR EVERY 125 HOURS OF OPERATION
Dismantle the drain valve from the air receiver and clean. Run the compressor for some time
without the drain valve to blow out all the moisture and dirt from the receiver.
Reassemble the drain valve.

NOTE:
On installing a new compressor, the first oil change
should be carried out after 150 hours of operation. The
subsequence oil changes should be done after 500 hours
of operation.
1. Check the compressor for satisfactory operation which include:

Operational noise and vibration.
Tightness of mounting bolts and other fasteners.
Air leaks at the pressure, line inter cooler, safety valves, drain valve, etc.
Cut off and cut in pressures.
1. Suction filter: Dismantle the suction filter and clean it with compressed air. After through cleaning
reassemble on the compressor.
4.4 FOR EVERY 500 HOURS OF OPERATION.
1. Breather : The breather valve should be dismantled, Cleaned and

Checked for perfect seating of the valve.
2. Lubricating oil : Drain the oil and renew.
4.5 FOR EVERY 1000 HOURS OF OPERATION.
1. The cylinder heads should be removed and inspect and valve plates. The worn out parts should
parts should be replaced with spares.
2. Check all the pipe liners for leaks at joints and if necessary renew the packing.
3. Dismantle the non-return valve and then examine the spring for stiffness and check its valve seat
if required.
4. The after- cooler and the inter –cooler pipe should be decarbonizes.
General overhaul: The compressor should be completely stripped by an experienced staff. All parts have
to be thoroughly cleaned, examined and repaired in a clean surrounding.
Renew suction air filter element.

4.7 FOR EVER EVERY 2 YEARS
Clean the inside of the air receiver chemically.
Examine the hand hole packing and renew if required.
Hydraulically test receiver to the specified pressure in the technical data.
NOTE:
User are advised to adhere to the requirements of
inspections/pressure test of government, safety
agencies in respect of air receivers as applicable
6. FAULT DIAGNOUS CHART

Over heating of the Due to dirty oil. Change oil.
component Due to oil level low. Fill correct grade oil up to maximum
level in the oil level indicator.
Blow with compressed air or clean

Due to dirty cylinder and inter manually.
cooler fins. Open, clean and refit after checking.
Due to breather not working. Inter change any of the two phases in
Due to wrong direction of the starter.
rotation.
Open and clean.
Due to blocked un loader Open the pressure switch cover and
Compressor does not tubes. adjust the nylock nut.
unload. Due to defective in loader.
Clean or renew the air filter element.
Due to chocked air filter. Drain to correct level.
Oil carry over in Change to recommended grade.
compressed air. Due to high oil level. Open clean and refit after checking.
Due to low oil level. Loose the piston rings. If broken
Due to breather not working. change the rings as a set. Check all
Due to piston rings struck in related parts for wear before fitting.
grooves or broken. Check and change as required.
Excessive piston to cylinder Check and replace the breather valve,

clearance. if necessary.
Due to faulty breather.

Increase frequency of cleaning.
Water or rust Increase frequency with more
formation in periodic check of oil.

crankcase. Due to inadequate air filter Change to correct grade as given in
maintenance. recommended lubricants chart.
Unusual wear of Due to insufficient oil change
cylinder ,piston and frequency. Open clean and refit the breather.
rings. Due to incorrect grade of oil. Loose the piston rings. If broken
change the rings as set.
Due to breather not working. Check all related parts to wear before
Due to piston rings struck in fitting.
grooves or broken. Check and change as required.
Oil leak through
breather.
Due to excessive piston to Remove fan pulley and examine key-
cylinder clearance. way for wear.
Overhaul compressor unit and replace
Due to loose compressor fan the related components.
pulley.
Due to won out piston,
cylinder crankshaft and Adjust or replace, if elongated.
Compressor connecting rod bearings. Open and re-tighten with Teflon tape
knocking or jute and shellac.
Due to loose belts. Open, clean and refit after careful
Due to leaky joints in pressure check.
lines. Replace after checking the related
Due to defective seating of components.
Pressure built up inlet and delivery valve
time excessive. plates.
Due to worn out piston rings. Check and adjust using a straight
edge or string across the diameter of
Due to incorrect motor and both the pulleys.
compressor pulley alignment. Check belt adjustments frequently.
Due to incorrect belt tension.
Excessive belt wear.

PRESSURE SWITCH
During compressor Due to dirt between the cone Clean the cone seat and resemble.
operation air leaks seat and valve seat. Replace the valve seat by a new one.
through the cross hole Due to defective valve seat.
of unloaded valve.
Readjust.
Faulty working Due to this may be due to
pressure different from over adjusting. New contact assemblies should be
those of seating. Due to melted contact points. fitted.
Sparking of controls.
Punched diaphragm. Due to very frequent Replace the diaphragm and reset the
operations (hunting for a very pressure with more differentials.
long time due to very low Replace diaphragm.
differentials).
Due to very hot air.
Un loader bottom level may be
Unload valve leakly. Due to dirty valve seat or torn pressing the un loader pin. Adjust the
valve seat. nut or replace the valve seat.
8. RECONNENDED LUBRICANTS.
LUBRICANT MANUFACTURES
I.S.O. BHARAT HINDUSTAN INDIAN CASTROL

AMBIET
V.G.NO PETROLEUM PETROLEUM OIL
TEMPº C
I.S.O 32 Bharat Enklo 32 Servo Perfecto 32
-30 to –15 Hydrol 32 Press 32 Perfecto T-32
-15 to +10 Hydrol 68 Press 68 Perfecto T-68
10 to 25 Hydrol 100 Press 100 Perfecto T-100
I.S.O 150 Bharat Enklo 150 Servo Hyspin VG 150
25 to 80 Hydrol 150 Press 150 Hyspin 175
MOTOR BEARING GREASE
BhratUnives Wheel Servo Castrol Ball

‘A’ Bearing Grease Bearing Grease
Grease MP AP 0- 3

NOTE:
To fill the lubricating oil in to the crankcase remove the
breather assembly.
To drain the lubricating oil from the crankcase unscrew
the drain plug.
The electric motor bearings should be lubricated by using a
special grease gun or by removing the end covers.
9. WIRING DIAGRAM
FOR DIRECT ON LINE STARTER.

.
Switches and contacts are shown in De- Energized and pressure free condition.
For correct Motor protection set the over load calibration lever to the actual motor current.
TCH 200 – 2 H.P.
TCH 300 – 3 H.P.
10. OIL BATH FILTER (Optional)

GENDRAL ARRENGENMENT
This is a special type of air filter designed for use in the suction ports of the compressor in dusty
atmospheric conditions like that of foundries and textiles mills. Dry type filters can filter dust particles
above 10microns size only. Fine dust below 10 microns size will escape the filter and enter the cylinder
resulting in fast wearing of cylinder and piston rings. Too mush dust collection on the filter element often
results in chocking and filter damaging. So oil bath filters are recommended to be used in these places.
In this filter, first suction air suction air passes through the oil bath and then the wire mesh. While
the air passing through the oil bath all dust particles init will be absorbed by oil and few oil particles may
mix with the air. During its passage through wire mesh, the oil particles will be separated from the air, So
the suction air will be dust free.
Maintenance:
For every 250 hours of operation dismantle the air filter unscrewing the wing nut. Pour the oil
from the filter to some other vessel. Rinse and clean all the parts in petrol or kerosene. After through
cleaning and drying with dry pressurized air, reassemble the filter. If the oil is contaminated too much,
Chance the oil. Pour oil up to the maximum level marked on the filter.
COMPRESSOR FILTER OIL CAPACIT RECOMMENDED OIL
TCS 300/TCS 500
TCH 200/TCH 300 TYPE ’A’ 150ml As pet the recommended

lubricat chart of the
TCS750 / TCS1000 compressor.
TCH500 / TCH600 TYPE ‘B’ 250ml

DON’TS
DOS
1.The manual should be read in detail Neglect the routine attention.
and the instructions should be followed
carefully
2. The Compressor should be cleaned Allow any leakage in the system.
regularly.
3. Air Filter must be kept clean. Keep any tools or loose items on
the compressor.
4. Only company spares must be used. Meddle with any adjustments or
settings.
5. Maintain correct belt tension. Run compressor without the belt
guard.
6. Maintain correct oil level in the Use cleaning agents, when changing
crankcase. oil.
7.Only clean recommended lubricants Do any repair work while the unit is
should be used. running.
8. Proper should be used. Overload the compressor for a long
period, even though it is of
continuous rating as we recommend
intermittent use only.
9. The condensate should be drained by
Opening the drain valve daily.
10. Anything unusual with compressor
must be attended to immediately.

INSTRUCTION MANUAL
WARINING
Keep the power supply away from any contact with the water.
Use a circuit breaker unit for safety.
The pump unit must properly be earthed. In case of difficulty consult a qualified electrician or your pump
distributor.
If the pump stops during use, Always switch off the power supply before inspection.
Three-phase motor is not equipped with a current overload protector (Starter).
It is to be provided by the user.
CAUTION
Be careful not to exceed the given specifications in the use of your products. Check the nameplate for
your pump’s head (LIFT) discharge volume (CAPACITY), speed (RPM) and arrow mark to check
direction of rotation.
INTRODUCTION
Check the following points upon receipt of your pump.

1) Is the pump exactly what you ordered? Check the nameplate..
2) Has any damage occurred during transit? Are any bolts or nuts loose?
3) Have all necessary accessories been supplied?
INSTALLATION
WARNING
Before insulation resistance measurement, always disconnect the power first. All electric work should be
performed by qualified electrician and all national and local electrical codes must be observed.
1) LOCATION
a) Install where inspections and maintenance can be easily performed.
b) Provide suitable enclosure to prevent entry of un-authorized persons.
c) Install pump as close to liquid source as possible. Suction height (height from surface of liquid to
center of pump) should be as low as possible, and suction piping should be short.
d) Suction head should be less the 4 meters. In certain cases, such as with hot liquid, section head
must be lower. To minimize suction piping loss, excessive use of elbows and valves should be
avoided.
2) PIPING (FIG 1)
a) Use adequate support for suction and discharge piping to prevent pump and motor from becoming
misaligned.
b) A Check valve must be installed between the pump and the discharge valve in the following cases:
When delivery piping is long; when head is high; when is automatic; when water is being pumped
to pressure tank; and when two or more pumps are in parallel operation.
c) Install an air-release valve in piping to prevent the formation of air pockets due to construction.
Note however, that an air-release valve must not be installed where pressure may drop below
atmospheric pressure since the valve may suck in air instead of expelling it.
d) To reduce effect of water hammer install a quick-closing check valve.
e) Suction system:
i) The end of the suction piping should be submerged to a depth of at least twice the diameter (D) of
the piping and should be at a distance between 1 to 1.5 times the diameter of the piping from the
bottom of the pit.
ii) Install suction strainer at the end of the suction piping to block entrance of foreign matter.
Suction piping should be inclined upward (over 1/100) in relation to the pump to prevent formation of
air pockets. Pipe joints must be tight so that there will be no possibility of air suction.
iii) Keep suction piping as short and straight as possible. Do not attach a sluice valve.
3) CENTERING: (FOR EXTENDED SHAFT TYPE)
Through the pump and driver have been centered in the factory, the bed nay be distorted when the
foundation bolts are tightened during installation. Adjust by placing tapered liners underneath the bed,
and center so that the shaft coupling is within the range indicated in fig 2.
To center a pump, which has been purchased without, a driver and which is to be directly driven,
inserts liners under the drive, and center so that the shaft coupling is within the range indicated in fir 2.
The coupling guard must be removed to make centering adjustments. Be sure to replace before beginning
operation.

4. ELECTRICAL WIRING
a) Refer to motor manual for correct wiring. It is important that the wiring is correct and that the
motor is properly grounded.
b) Check the following points before switching on,
1) Is the fuse the right type?
2) Is the wiring correct?
3) Has motor been grounded?
4) With three- phase motor, Check connections are fully tightened. Operating on only two
terminals will result in phase omission, causing motor burn out.
c) Terminal voltage in motor may be with in +/- 5% of the rated voltage. Exceeding this range will
lead to breakdown.
d) Overloading the motor beyond the prescribed limit will reduce its efficiency. It is not economical
and will eventually lead to motor malfunction. We recommend that a protective motor relay be
installed to prevent burnout caused by over loading.
OPERATION:
1) BEFORE STARTING
To rotate by hand, remove the motor end cap and turn slot on shaft end with a screwdriver.
a) Turn pump by hand to check for smooth rotation. If movement is sluggish or uneven, components
inside the pump may be in contact.
For extended shaft type disengage the coupling and check the direction of rotation as indicated on the
pump.
b) Turn operation switch on and off two or three times to check operating condition.
C) Prime the pump. Operating the pump with out priming will cause breakdown: dry run would
instantaneously damage Mechanical seal.
Open air-release valve and prime pump. When the piping is full of water and the pump is printed, open
the suction and discharge valves, and air release valve to check if the pump is fully primed.
2) TEST OPERATION:
CAUTION
Check rotation
Pump will be started with gate-valve closed and then open the valve gradually.
a) Close the air- release valve and discharge valve after priming has been completed. Ensure the
suction valve is fully open.
b) Turn operation switch on and off two or there times to check operating condition. Attach shaft-
coupling guard after operating check has been completed.
c) Begin continuous and gradual opening of discharge valve.
d) Check the pressure, current; vibration and noise (refer to maintenance) are at normal levels.
Both the pressure gauge and compound gauge cocks should be kept closed except at specified
times. Leaving them open may lead to malfunction.
e) If there is no check valve on the discharge piping, close the discharge sluice valve slowly when
stopping pump operation. Turn off operation switch after the sluice valve has been completely
closed.
f) Subsequent operation can proceed with out checks, if all conditions are normal.
MAINTENANCE:
WARNING
Disconnect power cable from power source before servicing unit. Normal maintenance should be
done by qualified personnel.
1 ) DAILY INSPECTION:
a) Pressure or current variations, abnormal vibration or noise are signs of malfunction. Refer to Trouble –
Shooting and make necessary repairs as soon as possible. We recommend, that you keep a record of daily
operating conditions so that you will be able to detect early signs of trouble.
b) There should be no leakage if shaft sealing mechanical seal is normal. Replace entire seal if there is
leakage.
c) Fig 3. Indicates the normal level of vibration when installation and piping are correct. Excessive
vibration may be due of defective piping or loose foundation bolts. Inspect carefully.
2. Observe the following points :

A) Operating the pump for an extended period of time with the discharge valve closed will cause pump
damaged.
B) Too frequency starting and stopping of the pump will cause damage. Keep pump-starting frequency to
a minimum.
C) Be sure to turn off operation switch in the event of power failure. It is dangerous to leave the switch
on, as the pump will suddenly start when power is restored.
TROUBLE POSSIBLE POSSIBLE CAUSE TROUBLE SHOOTING

Motor does not start 1, Motor malfunctions 1, Repair motor
2, Power source 2, Inspect, repair, or consult
malfunctions power company
3, Rotating parts in contact 3, Manually rotate,
rusted, burn out: reassemble & have it
4, Foreign matter clogging repaired in specialist shop
contacting parts 4, Remove foreign matter
Pump is operating but there 1, pump not primed 1, Prime
is no water discharge. Does 2. valve closed / 2, open valve
not obtain specified insufficiently open.
discharge volume 3, Excessive piping loss . 3, Re-examine original plan
4, Suction height too high 4, Re – examine original
for pump. plan
5, Cavitations 5, Consult specialist
6, Rotation direction 6, correct rotation direction
reversed. 7, Check with tachometer
7, Rotation speed low- -check nameplate and
wrong number of poles in change
motor. - check the name plate and
-60 Hz pump being used in change
50 Hz area - check the power source
-voltage drop and remedy
8. Impeller clogged 8. Remove foreign matter
9. Piping clogged 9. Remove foreign matter
10, Air suction 10. Inspect, repair suction
11, Foot valve or Suction piping, Shaft sealing
piping end not submerged 11, Extend suction piping
sufficiently and submerge end to
12. Discharge piping sufficient depth
leakage 12. Inspect. Repair
13. Impeller corroded 13. Check quality of liquid
14, Casing impeller worn and consult specialist.
15. Casing ring worn 14. Replace impeller
16, Liquid temperature too 15. Replace casing ring
high. Volatile liquid 16. Re- examine original
plan
Water discharges but soon 1, Insufficient priming 1,Prime sufficiently
stops 2, Air Suction 2. Inspect. Repair Suction
3, Air pockets in suction piping shaft sealing.
piping 3. Reinstall piping
4, Suction height too high 4.Re-exemine original plan
for pump
Over load s 1, Head low. Excessive 1, Partially close discharge
(over current) volume flow valve.
2, Rotation speed low 2, Check with tachometer
- wrong number of poles in - Check number plate and
motor change
- 50 Hz pump being used - Check number plate and
in 60 Hz area change
3, Rotation parts in contact, 3, Have repaired in
shaft bent specialist shop
4, Liquid density , viscosity 4, Re-examine original
too high plan.
5, Excessive pipe load on 5, Adjust pipe load.
pump
Pump vibrates, Excessive 1, Piping vibration 1, Reinforce piping support

noise 2, Rotation direction 2, Check with arrow and
reversed rewire
3, Coupling rubber worn. 3, Replace coupling rubber
4, Rotating parts in contact, 4, Have repaired in
shaft bent specialist shop.
5, Cavitations 5, Consult specialist
6, Excessive discharge 6, Partially close discharge
volume valve
7, Insufficient discharge 7, Operate at specified flow
volume level
8, Excessive pump 8, Open sufficiency.
operation with discharge
valve insufficiently open
Excessive leakage from 1, Damaged mechanical 1, Replace mechanical seal

shaft seal seal 2, Re-examine original plan
2, Excessive influx pressure 3, Reinstall
of packing 4, Replace packing
3, Incorrect installation of 5, Replace with new parts
packing 6, Have repaired in
4, Damaged packing specialist shop
5, Shaft on sleeve worn 7, Adjust to appropriate
6, Shaft bent pressure
7, Excessive Water flushing
pressure.
Bearing Overheats 1, Bearing damaged 1, Bearing damaged

2, Excessive pump 2, Excessive pump
operation with discharge operation with discharge
valve insufficiently opened. valve insufficiently opened.

ES
(ES, ESL, ESV)
E) INSTALLATION
E1) PREPARATION
Remove packing from gear motor. If feeder has flanged pipe sections remove screw blocking brackets,
plugs from splined bushes and protection from splined shafts.
Before lifting the entirely preassembled screw feeder from the ground, once again tighten all nuts and
bolts.
During installation or maintenance use only approved hoists!
During each phase of the installation always handle screw feeder using appropriate hoisting
equipment fixed on the welded lifting eyes on each feeder pipe section.
E2) ELECTRICALCONNECTIONS
The connections with the mains must be carried out by a electrician or other qualified
personnel.
BEFORE ANY ACTION DISCONNECT FROM MAINS SUPPLY!
Before connection ensure that plate and voltage supply match. Pay attention to safety regulations.
E3) GENERAL PRECAUTIONS

Never put your hands into a running screw feeder!
Never open the inspection hatches before having disconnected the feeder from mains supply.
F) COMMISSIONING PROCEDURE
Check foreign substances or water have entered the conveyor housing. lf so, remove the access plates
and clean . Afterwards, replace access plates and seal.
If the screw feeder is supplied without inlet and/or outlet spout and if inlet and/or outlet spout are fitted

by the customer ensure end flanges are perpendicular. If they are not shim before starting operation.
Avoid deflection of the screw conveyor by ensuring perfect alignment between inlet and outlet.
Otherwise the screw may scrape against the casing and stop. Check the direction of rotation
(anti-clock wise if seen from inlet). If wrong, then reverse the polarity of the electric motor.
Make sure that gear reduction unit is filled with oil and that hanger bearings are lubricated. Before
feeding in material, start the empty screw conveyor and check if running is smooth: if so, feed in the
material and proceed with normal operation.
ATTENTION!
AT THE BOTTOM OF THE DRIVE HEAD WITH INCORPORATED END BEARING ASSEM-
BLY THE OUTFLOW OF A VISCOUS AND STICKY SUBSTANCE MAY BE NOTICED.
THIS IS NO LUBRICANT LEAKAGE FROM A FAULTY REDUCER OR BEARING ASSEMBLY
BUT THE SURPLUS OF A SPECIAL LIQUID USED FOR THE IMPREGNATION OF THE
SHAFT SEALING RINGS OF THE STUFFING BOX. THE IMPREGNATION GUARANTEES A
MUCH LONGER LIFE OF THE SEALS. HOWEVER, IT HAS TO BE ACCEPTED THAT DURING
THE COMMISSIONING PROCEDURE AND EVEN THROUGHOUT A PERIOD OF VARIOUS
HOURS OF OPERATION EXCESS LIQUID MAY BE EXPELLED UNTIL IT EVENTUALLY
STOPS. THE FUNCTIONING OF THE SCREW FEEDER OR CONVEYOR IS NOT DISTURBED
BY THIS PHENOMENON.
G) OPERATION
According to the type of plant, operation is controlled either by a remote control panel in
the main control room or by a local starter. Screw feeders having two or more inlets must
be fed from only one inlet at a time. If screw feeders feed to each other the receiving feeder
must be sized for a higher throughput rate than the in feeding unit.
The life of the screw feeder will be increased by closing the inlet valve and by emptying the screw
feeder at the end of each working day. This is particularly important if the material conveyed tends
to harden or become more viscous or sticky if allowed to stand for a period of time.
H) ASSEMBLY - DISMANTLING
H 1) FASTENING
The fastening of inlets and outlets can be carried out in different ways.
- Screw feeders beneath silos or hoppers: if a butterfly valve is fitted to the silo connect feeder inlet
with valve bottom flange.
- Screw feeders with two or more inlets: important to keep the unused inlet closed in order to
prevent the penetration of rainwater.
- Screw feeders have to be supported firmly and symmetrically in minimum two points per section,
either by base support or tube clamp.
If the screw feeder is equipped with a universal inlet and or outlet, after fitting of the feeder, the gap
between the upper and the lower hemisphere of the spout must be sealed with appropriate material.
Screw feeders, which are longer than, & certain inlet-outlet length (see catalogue) are divided by
flanges so that they may be transported or shipped by normal means.
Avoid any kind of vibration.
For screw feeders with one or more inspection hatches it is necessary:
1) To equip those with locking bolts and nuts or

2) To provide for an EN1088-standard device that stops the screw conveyor in case of opening or removal
of the inspection hatch.
N.B.:
The optional grille beneath the standard inspection hatch cover cannot be considered as a “safety
component”. It only avoids that foreign bodies can penetrate through the open inspection hatch
the screw feeder.
Before assembly, ensure serial numbers on each tube section match.
Prior to assembly of the pipe sections fit flange gaskets.
H2) FASTENING OF CABLEGUIDING TUBES

If you want to use STP4-type tube supports please proceed as shown below

H3) DISMANTLING
Prior to dismantling of the gear reducer or the end bearing from the screw feeder, the
screw must be secured against sliding out of the tubular housing, the screw being simply slid
onto the end shaft of either gear reducer or end bearing. First remove lid and gasket from
inspection hatch beneath the inlet spout. introduce a wooden plank into the inlet the opening
and restrain.
Only now gear reducer or end bearing may be taken off.
ATTENTION!
BEFORE OPENING THE INSPECTION HATCH ENSURES MAINS SUPPLY TO ELECTRIC
MOTOR IS DISCONNECTED.
I) MAINTANANCE
Failure to follow the maintenance instructions may cause problems and could invalidate the guarantee.
Every day, after finishing operation, empty the screw feeder.
Once a week, check to see if outlet and hanger bearing are free of crusts. if not, clean in order to avoid
blockages.
Once every two years, it is advisable to replace the following parts: seals and hanger bearing (if worm
out).
Lubrication and parts substitution timing depends on service of screw feeder and on type of product.
However, even with difference types of seals or bearings operations to be performed are the same.
BEFORE ANY ACTION, DISCONNECT MAINS SUPPLY!
Referring to Fig: 1 carryout the following steps:

1) Close silo valve.
2) Empty screw feeder.
3) Disconnect electric motor from mains.
4) Open inspections hatches.
5) Prevent the inlet screw (D) from sliding out by introducing a plank (A) into the inlet hatch ensuring
plank firmly locks in.
6) Ensure eyebolt (F) of electric motor is tightly screwed on.
7) Fix the lifting device to the eyebolt (F).
8) Remove reducer flange bolts and remove gear motor (B).
9) Replace seals (C) with new ones.
10) Reassembling parts proceeding in the opposite way as described.
The same operations apply also if drive unit is at outlet end.
And if the sealing of the end bearing has to be substituted.
I2) REPLACEMENT OF HANGER BEARING
With reference to Fig. 2 carry out the following steps:

1) Open inspection hatch beneath the bearing to be replaced.
2) Remove bolts that fasten the two bearing halves.
3) Lower bearing half is now free. Remove external hanger bolts and turn upper hanger half until
it can be extracted through the hatch.
I3) REPLACEMENT OF HANGER BEARING (INCLUDING SHAFT)

In addition to fig.1, as well as to instructions under I2 proceed as follows:
4) Carefully loosen plank (A)
5) Gently lower inlet spiral (D)
Until shaft (E) is free.
6) Replace shaft (E).
For reassembly proceed the opposite way.
If only the slide bushes must be replaced the above-mentioned steps do not have to be carried out.
The half bush may be simply replaced without carrying out the above steps.
I4) LUBRICATION
OUTLET END BEARING (with drive at inlet)
- Supplied with along life grease filling the bearing does not require any further lubrication.
INLET END BEARING (with drive at outlet)
Grease approx. every 200 working hours (depends on handled material). Substitute lubricant
approx. every 7500 working hours.
HANGER BEARING

For most materials handled is not lubrication required. For those materials that require
lubrication, grease every 10 working hour’s approx.
The trademarks of the lubricants are in alphabetical order, which does not refer to the quality of the
product. The list does not cover all available lubricants. Other quality makes can equally be used.
TABLE OF LUBRIFICANTS
DIN K2K GREASE TRADE MARK
GR-MU2 AGIP
ARALUP HL2 ARAL
BP-ENGERGREASEL 2 BP
CALYPSOLH 433 CALYPSOL
ANDOK B ESSO
MOBILU X2 MOBIL OIL
MOBIPLEX 47
ALVANIA 2 SHELL
GLISSANDO FL 20 TEXACO
MULTIFAX 2
GEAR REDUCER
M19 and M17 gear reduction units are supplied with long life oil filling. They are only equipped with a
filling plug and the oil does not need to be topped up changed.
M12, M11 and M15 gear reduction units are supplied with a first oil filling and are equipped with oil level,
outlet and breather plugs.
First oil replacement after 1000 operating hours, then every 2500 operating hours approximately.
OIL TRADE MARK

BLASIA AGIP
DEGOL BG220 ARAL
ENERGOL GR – XP 220 BP
NL GEAR COMPOUND 220 CHEVRON
MOBILGEAR 630 MOBIL OIL
OMALA 220 SHELL
MEROPA 220 TEXACO
SPARTAN EP 220 ESSO
OIL QUANTITY FOR ONE FILLING

TYPE MOTOR SIZE A=O° A = 45°
M12 100-112 0.75 1
M12 132 1 1.50
M12 160 1.40 /
M11 132 1 1.50
M11 160 1.50 2.75
M15 160-180 4 6.50
The trademarks of the lubricants are in alphabetical order which dos not refer to the quality of the product.
The list does not cover all available lubricants. Other quality makes can equally be used.
Table data refer to operation temperature between 0°C and 35°C. For temperatures higher than 35°C
higher viscosity oils must be used, for temperatures lower than 0°C less viscous oils must be used.
J) NOISE
Noise level depends on several factors, among which screw dimensions, type of material handled and
box load
The noise level, however, is never higher than 80 dB (A). This value was measured from one meter
distance in the most favorable position.
N.B: with special materials (e.g. big grain size) contact our sales office.
K) DISMANTLING AND DISPOSAL OF SCREW FEEDERS

K1) STORAGE FOR LONGER PERIODS
Fill gear reducer up to the top with oil.
Clean feeder thoroughly especially inside.
Provide the inlets and outlets with covers as to avoid penetration of water and/or foreign bodies.
K2) DEMOLITION OF THE SCREW FEEDER
Recover reducer oil and proceed to disposal at special collection centers.
Recover plastic materials (e.g. rotary shaft seals, coatings, lining etc,) and deliver them to special
collection centers.
Deliver all remaining parts, which are made from steel and cast iron, to specific scrap yards.
L) FAULT FINDING
Minor problems can be solved without consulting a specialist. Below is a list of the more
common problems with their possible causes and remedies.
PROBLEM
Motor does not start
POSSIBLE REASONS
1) No correct wiring
2) Motor failure or failure in the wiring supply
ACTION
1) Check fuses; if faulty, replace
2) Repair or replace part concerned
PROBLEM
The motor starts but then stops
POSSIBLE REASONS
1) Incorrect rotation
2) Screw obstruction
3) Output rate too high
4) Motor burnt out
5) Defective bearing or gear reducer
6) Outlet blocked
ACTION
1) Reverse pales
2) Change hanger bearings; if necessary clean whole screw feeder
3) Check ammeter reading and output rate; if both are too high contact our Sales Office.
4) Discover reason and only then replace motor
5) Discover reason (see 2 ) Could be normal wear - replace part concerned
6) Free outlet
PROBLEM
Motor starts, but screw does not convey
POSSIBLE REASONS
1) Gear pinion or drive shaft sheared
2) Incorrect rotation
3) Bad outflow of material from silo due to faulty fluidization
ACTION
1) Discover reason, replace part concerned
2) Reverse pales
3) Improve outflow of material
M) CHECK LIST IN CASE OF SCREW FEEDER TROUBLE

1) General questions Fault description
a) Ask plant operator when and under which circumstances feeder stops. Does feeder start with out
problems after long resting periods?.
b) Do weather conditions negatively influence feeder operation?
c) If valve is fitted to feeder outlet check the center line of the valve shaft is parallel with the center
line of the feeder, as would be fitted in normal circumstances.
Check valve fully opens.
Make sure feeder outlet valve is open when feeder starts and it only closes when feeder has already
stopped.
If necessary disconnect valve actuator in open position.
2) Silo check
a) Is the silo equipped with a deflecting or bridge cone?
b) Does silo include a fluidization system? If so how does it operate? Automatically at intervals
while feeder is turned on? Manually for emergency in case of bridging?
c) Is silo cone equipped with a vibrator or knocker? How does it work?
3) Electric equipments check

a) Is a droop in voltage possible through the contemporary starting of various machines?
b) Is the plant equipped with a generato?
c) Check mains supply of the motor.
d) Check the electric motor is correctly wired and make sure wires are tightly fastened.
f) Check sense of motor rotation is correct .
g) Read amperage with feeder running on empty, then with filled up feeder starting as well as with
full feeder running.
h) Check cross section of mains cables are suitable for the installed drive power.

4) Mechanical parts check
a) Is breather plug of gear reducer working well okay?
b) Check outlet is free of crusts. Describe outlet (e.g. Vertical or angular).
c) Check weigh hopper vent is functioning correctly and check correct dimensioning of same.
5) Feeder check
a) Are feeder parts correctly assembled? Do all inspection hatches point downloads?
b) Does feeder bend?. Stretch a string . If necessary additional support must be fitted ( every 3 to 5
meters).
c) Shut silo outlet valve. Empty feeder.
d) Open inspections hatches check intermediate bearing are okay and correctly mounted.
e) Turn feeder by hand using a spanner on the outlet end bearing shaft. If you don’t feel any
resistance and don’t hear any grinding noise it is most certain that feeder is mechanically sound.
f) Shut inspection hatches. Start feeder .Read amperage, voltage, cycles and screw r.p.m. with
empty feeder running. Compare ammeter reading with motor plate data.
h) Repeat starting procedure with feeder at full load and read amperage. Voltage and cycles.
6) Material check
a) Material description?
b) Bulk density? ( kg/dm3)
c) Partial size? (µm/mm)
d) Humidity ? (%)
e) Flowabillty? (make material slide down a metal plate by varying the angle from low to steep)
f) Compressive material? (Can you make a “snowball”?)
g) Abrasive material? (Does is thurt when rubbing it between your fingers? )
h)
H) ASSEMBLY/ DISMANTLING
H1) FIXING
Put the valve in position and bolt it on carefully using nuts, bolts and stud bolts respectively.
Ensure the valve is mounted the right way round.
Carry out pneumatic and electrical connections in the correct manner.
IMPORTANT
For accident prevention it is essential to keep the valve out of reach of personal during operation.
With this aim in mind the customer devices such as grilles, as well as protective inlet and outlet joints
(either robust flexible socks or rigid pipe unlons).
When using movable safety devices provide protection limit switches which stop the valve
instantaneously if the protection is opened or removed. Restarting of the valve operation is only
possible when the protection is effective again.
H2) DISMANTLING
Prior to dismantling ensure mains supply is disconnected.
1) Failure to follow the maintenance instructions could cause problems and might invalidate the
warranty.
Once a week, check material flows freely and no material deposits spoil the function of the valve.
If necessary clean contact parts thoroughly.

PRIOR TO EVERY MAINTENANCE JOB, DISCONNECT VALVE FROM MAIN SUPPLY!
CM - TYPE MANUAL ACTUATORS ASSEMBLY
The supply includes:

B) 1 lever setting mask
C) 2 countersunk hexagonal socket screws
D) 1 lever
E) 1 knob fixing bolt
F) 1 washer
G) 1 lever fixing knob
The valve disc has been preassembled on the body at the factory.
Put the valve on a level surface.For the version with coated discs, wiring on the lower disc side must point
upwards. For castiron versions, flat lower disc side must point upwards.
Remove protection from disc shaft. Assemble lever setting mask (B) Using the two socket screws
(C) With the large side pointing upwards as shown in (fig. 1) Mount lever (D)- with bent part pointing
towards the mask on to the splined disc shaft ensuring the lever is placed in the "closed" position (fig.3).
Fasten the lever using knob fixing bolt (E), washer (F) and lever fixing knob (G) as shown in (fig.2).
CMP 2 - TYPE MANUAL ACTUATOR ASSEMBLY

A ) Splined shaft
B) 1 lever setting mask
C) 2 countersunk hexagonal socket screws
D) 1 lever
E) 1 knob-fixing bolt
F) 1 washer
G) 1 lever-fixing knob

The valve disc has been preassembled on the body at the factory.
Put the valve on a level surface.For the version with coated discs, wiring on the lower disc side must
point upwards. For castiron versions, flat lower disc side must point upwards.
Remove protection from disc shaft.
- Fit the shaft with relative bushing (A) into extension (F).
- Lock extension (F)to the valve body using the grower screws
- Fit setting mask (B) on extension (F) using the screw plus 2 washers and a self-locking nut (E)
.- Fit lever (D) on the splined shaft and fix it using screw plus washer (G).
CP - TYPE ELECTROPNEUMATIC ACTUATORS

ASSEMBLY
B)1 electro pneumatic actuator
C) 2 hexagonal bolts
Put the valve (A) on a level horizontal surface. For the version with coated discs, wiring on the lower disc
side must point downwards.. For castiron versions, flat lower disc side must point downwards. Remove
protection from the disc shaft .- Before fitting the actuator, ensure the piston is fully retracted by
turning the shaft with the aid of a spanner either to the left or the right as far as it well go. Mount the
actuator (B), which has been preassembled complete with its accessories, as per the instructions in
the actuator manual, onto the splined disc shaft keeping it in a horizontal position with the axis (Y)
pointing to the east (Fig. 2).
- Insert the two bolts (C) into the holes of the support flange and screw on firmly. Carry out test
operation.
If the valve does not completely close, although the piston is fully retracted, proceed as shown in
Fig.2
1) Disconnect compressed air supply
2) Loosen the large nut (E) and socket screw (D) at the opposite end of the actuator
3) Push down the valve disc until it is fully closed
4) Turn socket screw (D) clockwise until you feel some resistance and fasten nut (E) in order to lock
the socket screw.
11) REPLACEMENT OF WEAR PARTS
The disc seal as the only wear part in the VFS-valves must be replaced occasionally.
Procedure:
(see fig. 1 and 2)
- Ensure the container below which the valve is fitted is empty.
- Disconnect mains and compressed air supply from the actuator.
- Remove actuator
- Remove valve.

-Loosen bolts (6) and (10) and remove them. Do not lose nuts (9).
-Separate semi-bodies (item (3) and (8) with V1IFS, twice item (3) with V2FS).
-Separate valve disc along with seal and hexagonal bushes from the valve body.
-Remove hexagonal bushes (7) from disc shaft.
-Remove disc seal (1) from the two shaft ends.
-Fit new seal on the two shaft ends. Ensure seal does not get damaged.
-Slide the two hexagonal bushes (7) over the shaft ends.
-Introduce drive shaft into the bore of the actuator support bracket. Ensure correct fit of the two hexagonal bushes

(see fig. 2).
- Fit upper valve semi-body. For the correct assembly of the disk seal the spigots in the semi-bodies must
be precisely on top of each other.
- Fix semi-bodies with bolts (10) and nuts (9) and tighten evenly. Screw on bolts (6) and tighten firmly.
I2) LUBRICATION
No lubrication required.
J) NOISE
Noise level depends on handled material and on actuator type.
L) DISMANTLING AND DISPOSAL
Storage of equipment for longer Periods
Clean the equipment thoroughly.
Store the equipment in a container.
Scrapping
Recycle plastic materials (e.g. seals, coatings etc.) and dispose according to regulations.
Dispose of metal parts at the scrap yard.
M) FAULT FINDING
Minor problems can be resolved without consulting a specialist.
1. FAULT
Valve either does not open or stays open.
POSSIBLE REASON
1.1 Lumps formed in material.
1.2 Bulk density too high.
1.3 Actuator air pressure too low.
1.4 Drive power too low.
ACTION
1.1 Strip down valve, clean thoroughly and reinstall.
1.2 Provide weight relief inside bin cone.
1.3 Check for leakages in compressed air main and repair.
1.4 Check electric motor and main supply. Then eliminate fault.
2. FAULT
Valve leaks.
POSSIBLE REASON
2.1 Valve does not close completely.
2.2 Disc seal worn out.
ACTION
2.1 See item 1.
2.2 Replace disc seal.

SILO VENTING FILTERS
INSTRALATION, OPERATION AND MAINTENANCE
GENERAL STANDARDS
This “USE AND MAINTENANCE” booklet constitutes an integral part of the equipment, and must
available at hand for personnel involved in machine operation and maintenance. The user, the operator,
and maintenance personnel must be familiar with the contents of this booklet. The descriptions and
illustrations in this publication are not to be considered as binding. With the basic features of the
machines as described, the Manufacturer reserves every right to make modifications to parts,
details and accessories considered to be necessary for improving the product for design or commercial
reasons, at any time without any obligation to update the publication immediately.
DECLARATION OF CONFORMITY
The equipment is accompanied by a declaration of conformity to existing regulations, but, since

it is a component to be integrated into a system or plant, its safety is connected to compliance with all the
directives applicable in final assembly of the machine. Improper use of the filter without following the
instructions in this manual frees the Manufacturer of all responsibility for poor working of the filter.
Unless otherwise specified, all the dimensions are given in millimeters.
OPERATING CONDITIONS
The SILOTOP® R01 filters operate under the following conditions :
1) Maximum acceptable air flow temperature:
POSITIVE: .
80°C continuous
100°C peak
NEGATIVE:
-20°C
2) Maximum acceptable static pressure of filter body:
POSITIVE:
750mm H2O
(0.075 bar - 7.5 k Pa)
NEGATIVE:
- 500mm H2O
- (-0.05 bar - 6 k Pa)
- The equipment is not designed for operating in hazardous conditions or with dangerous materials;
therefore, when the equipment is to be used in these conditions, it is necessary to advise the
manufacturer.
- Materials considered as hazardous are: explosive, toxic, flammable, harmful and/or similar
materials.
WARNINGS
The manufacturer shall be relieved of all responsibility concerning the safety of persons and
objects and operations if the truck loading and unloading operations, transport, positioning at the worksite,
use, repairs, maintenance are not carried out in conformity with the instructions in this manual.
Similarly the manufacturer shall not be responsible if the filter is used:
- improperly;
- by unauthorized and/or unskilled personnel;
- with modifications to the original configuration;
- with spare parts that are not original;
- in a manner non conforming to existing standards and legislation;
- non conforming to the recommendations in this manual or on the warning and hazard notices
on the machine.
The user is obliged to carefully check that the work area is clear of obstacles, persons, and machines
with potential risk, before carrying out any operation.
Lifting, transport, installation at the worksite, set-up, checking stability and operations, routine and
extraordinary maintenance, etc. must be carried out by qualified authorized personnel ac-cording to the
instructions in this manual and in compliance with the existing safety regulations. When positioning the
filter at the worksite, the filter must be earthed.
It is forbidden to carry out maintenance, repairs or modifications with the machine in operation.
For every operation, it is compulsory to disconnect all the electric power supplies to the machine.
It is forbidden to remove the guards and safeties present on the machine.
Before startup, make sure all the guards are installed correctly.
SILOTOP® R01 is a flanged round dust filter with compressed air cleaning designed for de dusting
cement silos.
Thanks to its features, it can also be used with other materials having features similar to cement.
It is made entirely of AISI, except for the iron seal plate.
The filter elements cleaning sys-tem is an innovative blowing system involving the use of “full

immersion” solenoid valves and cleaning tubes connected directly to the tank.
This system is completely embedded in the cover to reduce the dimensions and maintenance time as
far as possible.
Unless otherwise specified, all the dimensions are in millimeters.
WAM® S.p.A. provides a 1 2 -month warranty on their products. This period starts from the date of
the consignment note. The warranty is not applicable for break age and /or defects caused by
incorrect installation or use, or incorrect maintenance, or modifications not authorized by the
Manufacturer. The warranty does not extend to parts that wear out following normal use and
electrical components. The warranty elapses if the filter:
- has been tampered with or modified,
- has not been used correctly,
- has been used without respecting the limits indicated in this manual and/or has been
subjected to excessive mechanical stress,
- has not been subjected to the necessary maintenance or these operations have been carried out
partly and/or incorrectly,
- has been damaged due to carelessness during transport, installation and use,
- has been fitted with spare parts that are not original.
On receiving the product, the user must check these for defects deriving from transport
and/or incomplete supply. Defects, damage or incompleteness of the supply must be immediately
communicated to the Manufacturer in writing and countersigned by the haulage transporter.
LIFTING OF FILTER
The filters should only be handled and lifted using the handling eyebolts provided. Use lifting
machinery suitable for the weight and dimensions of the filter and for the lifting distances in
question. Hook up the filters to the lifting machinery using shackle and safety hooks; do not use
clamps, rings, open hooks or any other system that does not guarantee the same degree of safety as
shackles and safety hooks
LIFTING MACHINERY

POSITIONING OF FILTER FLANGE

INSTRALATION OF FILTER FLANGE ON TOP OF THIS SILO
The filter is supplied completed of perimeter gasket, to be inserted between filter and bottom ring.
GASKET
GASKET POSITIONING

LEVEL INDICATOR
LEVEL INDICATOR
INTRODUCTION, RULES AND GENERAL PROHIBITIONS

GENERAL DIAGRAM
ORDER CODES
OTHER VERSIONS OF THE ILT AND ACCESSORIES
DIMENSION
SAFETY NOCITES
CONNECTIONS
OPTIONS
COMMISIONING – TESTING
COMMISIONING - TESTING-MOUNTING
MAINTENANCE
SAFETY ITEMS
DEMOLITION
INTRODUCTION, PRESCRIPTIONS ET CONSIGNES GENERALES

SCHEMA GENERAL
CODES DE SELECTION
AUTRE VERSIONNES ILT ET ACCESSOIRES
DIMENSIONS
INDICATIONS DE SÉCURITÉ...
RACCORDEMENTS
OPTIONS
MISE EN SERVICE ET ESSAI DE RECEPTION
MISE EN SERVICE ET ESSAI DE RECEPTION-INSTALLATION
ENTRETIEN
CONSIGNES DE SÉCURITÉ
DEMONTAGE
This "OPERATING AND MAINTENANCE MANUAL" is an essential and integral part of the machine
and must bereadily available to operating and servicing personnel.
The owner, operator and maintenance. Manager must be familiar with the contents of this Manual. The
description and illustrations used in Thus Manual are not binding on Manufacturer.
While the basic characteristics of the machine remain unchanged as described, Manufacturer
reserves the right to make any modifications to assemblies, parts and accessories it deems necessary for
product improvement on for fabrication or marketing needs and this without prior notice and without being
obliged to update this Manual at the time of modifications.
GENERAL PROHIBITIONS AND REGULATIONS

This machine must not be used even partially by unauthorized personnel.
The shop foreman or Department Manager is responsible for Machine operator training and for
checking training level achieved.
The machine must not be used for purposes other than those is was designed for.
Read carefully the warning notices attached to the machine.
Do not remove the warning notices attached to the machine,
When the machine is running, do not service, repair, regulate the machine or carry out any other
operation not strictly required by the work cycle. Before any of the above listed operations, always
disconnect the machine for all electric power supply sources.
DO not remove the guards and the safety devices on the machine
DO not start to work with protections opened or do not open them during the work,
Always wear safety gloves when working on the machine.
At the end of the work shift, disconnect the machine from the electric and hydraulic supply.
Any repair, service or maintenance work, whether electrical or otherwise, must be in compliance with
CEI standards 64,8 462.2 463.1573.3.
CARACTERISIQUES MECANIQUES
ENVELOPPE IP 66
Filet age De Record G 11/2” et G2 ½”
Matiere du filet age de raccord Plastique
Matiere de I arbre et de la palettle Acier inoxydable
Commande d” embrayage Protection des engranages de I” impact de la
palette.
Retard de signal 1.3 s. environ
Sensibillite Reglable par le rappel du resort dans trios
positions
Vitesse de la palette 1 tour / min

CARACTERISTIQUES ELECTRIQUES
Tension de secteur 24v/48v 50-60Hz-110/20v 50/60 Hz 24v cc
(toutes les tensions + 10% / -15%
Charge installee 3VA (3w)
Borme 1x1.5 mm2 max.
Serre-cable visse 1xPG 13.5”
(1x bouchon PG 13.5) en platique.
Single de sortie Microrupter flottant CA 250V max, 2A,
500W (cos=1) CC 300V max,60W
Diagramme de connection Version CA : sur circuit imprime
Version CC: a I’interieur du couvercle
Classe de protection I
CONDITIONS DE SERVICE
Surpression Conteneur MAX 0.8 bar
Temperature -20°C ., +80°C
Temperature -20°.. +70°C
GENERAL DIAGRAM
Item pos. Description Quantity

A Cover 1
B Frame 1
C Shaft
1
support
D Paddle 1
E Shaft 1

DIMENSIONS
ELECTRICAL CONNECTIONS
Take note of the power supply indicated on the ledgend plate.

Always observe safety regulation (See safety instructions.IEC….)

View electronic board only Switching logic.
The unit must be mounted with the thread at the container. Mounting may be vertical, oblique or
horizontal. During mounting, turn the housing in the right direction. This is possible with a suitable
sealing material, which fix and seal the unit (to counter the plastic screw part with the container is only
by hand not by tools allowed).
water enters into the housing through the screwed cable gland. It is not possible to turn the housing after
fixing the head. The electrical connections are made in accordant with the connection diagram. Make
sure, that the cable in the screwed cable gland is seated tightly without fail. Adjusting the unit at site is
not required.

CUSTOMER SAFETY INSTRUCTIONS &
INSTALLATION CHECK LIST
CAUTION :
All operations must be carried out by appropriately trained personal. For full installation and
maintenance instructions refer this book thoroughly or consult the supplier, if in doubt.
LIFITING:
1) Use all lifting facilities provided – Both lifting points if fitted or single lifting point if fitted. Do not use
any other part of the motor for lifting.
Note: Maximum hand lift is 20 kg below shoulder, but above ground level.
2) Vertical lifting – prevent uncontrolled rotation of the motor.
3) Do not lift other equipments with motor lifting points only.
Maximum weights: (Unpacked)
Weights in 3000
250 500 1000 1500 2000
KG
FRAME
SIZE 200 250
160 180 315 355
225 280
INSPECTION ON RECEIPT:
1) Make sure the right motor is received.

2) Check for transit damage.
3) If necessary, please open packing case in presence of an authorised insurance agent.
4) Please report damages to us giving complete nameplate detail.
STORAGE :
1. Ensure motors are stored in a place with an ambient range of-20º to 45ºC.
2. Store motors under shade and not in open.
3. Ensure that the stored motor does not revive and harmful vibration.
4. Ensure no water drips ion motor and no water logging under the motor
5. Energise heaters if fitted.
6. Ensure all plugs originally provided are in place (e.g. cable entry hole plugs &
fan cover greasing hole plug of TEFC motors.)
Every 1st week Rotate shaft

PERIODIC Check insulation
REQUIRMENTS Every 3 months resistance, If less than
10M, Ohm, Dry out.

PRE – INSTRALLATION CHECKS:
Ensure TICK WHEN CHECKED
1. Motor not corroded excessively. ⁫
2. Fan cover not damaged or touching fan ⁫
3. Foot not broken or cracked. ⁫
4. Shaft not damages / bend. ⁫
5. All fasteners are tight. ⁫
6. Check all the name plate details. ⁫
7. Check free running by band. ⁫
8. Check grease condition if motor is idle for more. ⁫
Than 6 months. If bad (Ref,; IS900) replace with fresh grease,
9. Add lubricating oil seal (IF Provided) ⁫
INTALLATION-MECHANICAL:
1. Level mounting surface, clean mounting ⁫
foot / flange & shaft of the motor.
2. Check mounting plane .Add shims if necessary ⁫
(Max Change of indicator reading –0.075MM with
mounting bolts loose & tight –while checking mounting ⁫
surface w,r,t motor foot/flange.
3. Check for any misalignment in motor &drive shaft. ⁫
(APPROX, TIR-0.050 m).
4. While mounting use appropriate fasteners
&tightening torques. ⁫
5. Check all the gasket, sealants & guards are
correctly fitted. ⁫
6. Verify belt tension. ⁫
INSTALLATION-ELECTRICAL:
1. Ensure power supply system is grounded. ⁫
2. Ensure proper ear thing. ⁫
3. Check insulation resistance of all windings
With 500V dc megger .if< 10 Mohm, dry
out as per procedure given in is:900. ⁫
4. Ensure the equipment is fused and
interior of terminal box is fused and
isolated correctly. ⁫
5. Ensure all the covers are fitted and
interior of terminal box is clean &free of cable
residues. ⁫
6. Seal unused cable entries ⁫
CONNECTION:
1. Check connection diagram and ensure correct terminal arrangement. ⁫

2. Ensure all the connections are tight and clean. ⁫

3. Ensure air clearance between live & live to earth>10mm. ⁫
4. Check driven equipment is free. ⁫
5. Check rotation, uncoupled. ⁫
6. Ensure rating of fuse, setting of protecting device are correct recommended
protection over load ,single phasing, under voltage ,earth fault. ⁫
7. Ensure space heater (if provided) is off while starting the motor. ⁫
OPERATION:
FREE RUNNING BEFORE COUPLING TO LOAD:
1. Ensure supply voltage as per nameplate & balanced in all three phase. (max. allowable
is 1%)for more unbalance, reduce the output by derating factor from the graph ⁫
2. Check three phase currents at no load (free shaft) & tally with the test certificate at the
back cover of this book at the back cover of this book. ⁫
Note: The current will be more if the voltage is less. The increase &decrease will not be
in linear proportion with voltage. ⁫
3. No abnormal noise,(use a screwdriver as a medium to hear.) ⁫
4. Bearing not heating up abnormally. ⁫
5. Check direction of rotation, if specific,(frame 280&above 2 pole motors may be fitted
with unidirectional fan. ⁫
6. Check vibration.(vibration level on the mounting structure immediately below the motor
should be within 30% of horizontal vibration level at the bearing housing) ⁫
RUNNING ON LOAD
1. Ensure rated voltage at the motor terminal during start up and check starting time ⁫
with in designed limit, (Any normal application, the time required will not be more
than 5 sec,. at DOL, For high inertia load the starting time is longer but special design
is required to cater this. for star / delta & reduced voltage starter the time will be longer
than in DOL). Refer to Crompton Greaves in case of doubt.
2. Ensure full load currents are balance in all phases (Maxm.unbalance 8% corresponding ⁫
to 1% unbalance of voltage) and the valve is with in name plate Data. In case of
pulsating load we recommend the maximum current to be within nameplate value.
3. No abnormal vibration. (If change in vibration level is observed, check alignment ⁫
again preferably in not condition)
4. No abnormal noise. ⁫
5. Check maxim. air inlet temperature = Ambient temperature mentioned on Nameplate. ⁫

6. No abnormal heating up. ⁫
Total permissible temperature including ambient for class B rated motors are
approximately as follows:
by temperature : At Eyebolt : 90ºC
At Bearing Cover: 80ºC
On Slip ring surface: 90ºC
Check the temperature after 4-5 hours of operation, when it is stabilised.
7. Check no sparking is appearing on the slip ring in case of slip ring motor. ⁫
PROBLEMS:
Noisy
Vibrating
Tripping Refer to supplier with machine no.
Overheating
Not starting
MAINTANANCE :
While carrying out maintenance
1. Ensure that the motor is isolated
2. Refer to supplier, if in doubt.
SPARE PARTS:
While ordering spare Parts, always quote Machine Number and Reference number, which will be found
on the Nameplate.
Please use only genuine spares.
HAZARDOUS AREAS: !
If motor is marked with “Ex” Symbol, special conditions apply, Refer appropriate installation manual and
relevant standards.
All operations are to be carried out by appropriately trained personal.
OPERATING & MAINTENANCE TIPS:
(ALSO REFER IS: 900 – 1992)
CROMPTION GREAVES Motors have been designed, manufactured and tested to a high standard of
excellence. Motors conform to relevant Indian standards as given on the nameplate.
These motors are sound in design and robust in construction and will give satisfactory service with
correct installation and normal routine maintenance.

SITE
- Check for proper ventilation. TEFC Motors should be provided with at least 2” gap between
fan cover and nearest barrier.
- Check for ambient conditions, if special treatment on motor is provided for adverse ambient.
- Ensure passages in between ribs in TEFC motors are properly cleaned.
FOUNDATION
The foundation of the motor should be preferably of concert, or structural steel, and must be sufficiently
rigid to minimize vibrations and to maintain alignment between the motor and the load. Normally a
mixture of four parts of stone and two parts of sand and one part of cement by volume is suitable.
PINIONS, PULLEYS AND COUPLINGS
- Use flexible coupling. For rigid couplings refer to CROMPTION GREAVES.
- Use dynamically balanced (with half key) Pulley / couplings/pinions (Motor Rotors are
balanced with half key)
- For belt drive mount belt nearest to motor bearings. Belts should not be too tight.
- Use pulley diameter and coupling/ pulley bore as follows:
PULLEY DIMENSIONS (mm)

TOLARANCE ON BORE DIA – OF
PULEY &COUPLING (H-7)
FRAME MIN MAX FACE NORMAL TOLERANCE

DIA WIDTH
160 150 177 30 t0 50 +0.0
180 180 203 +0.025
200 187 280 50 to 80 +0.0
225 197 330 +0.030
250 228 380 80 to 120 +0.0
280 375 380 +0.035
315 400 380
355 500 400

STARTING
Squirrel cage motors are suitable for DOL, star/delta or Auto Transformer starting.
Slip ring motors should be started by stator / rotor starter with suitable external resistance in rotor circuit
which should be cut off gradually when motor picks up speed.
- In case of star / delta starter, put to ‘Delta’ when the motor picks up fully in ‘STAR’ position.
- While operating on load & the motor is hot, the motor is suitable for 3 starts in one hour,
unless it is designed for higher number of starts.
- In case of slip ring starters, ensure the current and voltage of the starter are same as specified
on the motor nameplate (RV &R)
PREVENTIVE MAINTANANCE:
Motor should be kept clean and free from oil, dust and moisture; care should be taken to see that
ventilation passages are not blocked. The earthling conductor should be regularly inspected and checked
for continuity. The insulation resistance of stator and rotor winding should check regularly between
respective terminals and the frame.
In case of spring motors, carbon dust should be blown out regularly from slip rings and bushes. The
pressure on bushes and wear out should be checked.
BEARING:
Grease lubricated roller and ball bearing are already changed with right quantity of grease.
For republication and replenishing of grease use the following rules:
1. Check republication interval on nameplate. The re greasing interval should be shortened for high
ambient temperature, presence of corrosive vapours or extreme level of contamination.
2, For replenishing fresh grease in the bearing:
- Quantity of Grease to be filled in bearing (in gms) = Bearing bore dia.
- Fill 1/ 3rd of the bearing cover cavities with grease.
Recommended grease is Servo gem 2 of M/s IOCL, or MP2 of M/s Bharat petroleum or AP2 of
CASTROL, MIXING OF DIFFERENT GREASE SHOULD BE AVOIDED.
While removing bearing from the shaft, use properly designed draw–off tackle or puller to hold the
bearing preferably at inner race. While pulling out the bearing, rotate the bearing to avoid damages if
the bearing is intended to be used again.
Bearing should be re–fitted on shaft after hearing up to approximately 90ºC and by slip ring on the
shaft.
SLIP RING / BRUSHGEAR

Size of brushes on the slip ring motors are as below-
FRAME a x t x r (Dimensions are in mm)
160-180 12.5 x 16 x 20/24
200-250 16 x 20 x 30
280-315 20 x 40 x 28
here,
t – thickness
a – Axial width
r – Radial width.*
(*Radial width should not be allowed to wear below 15mm length).
- If slip ring surface is not smooth, smoothen, with fine glass paper (DO NOT USE EMERY
CLOTH).
- Brushes should be free in holder, recommended brush pressure is 0.2KG/SQ.CM. (t x a)
- Ensure that slip ring and bushes are free from oil and dust. Below out carbon dust from slip
ring and bushes periodically.
- Use brush grade M15E of Assam Carbon or BE22 of Electro Carbonium.
- For new brushes proper brading is to be done with sand paper, so that curvatures of bushes and
slip ring are perfectly matched.
Note:
In case of the Non – Standard motors, wherever necessary, special instructions will be provided.
SECTION 1- Description and main features

1.0 PRESENTATION
This manual states the information, and all considered necessary for the understanding, installation,
correct use and maintenance of the MVSI, M3/65 Series, ITV-VR, ITV-VF Vibrators manufactured by
Italvibras Giogrio Silingardi S.p.a. of Sassuolo (Modena) Italy. All stated does not make up a complete
description of the various elements or a detailed description of their functioning. The user will however
find all information normally useful for correct installation, correct, safe use and for good preservation of
the vibrator. Normal functioning, duration and operating costs of the vibrator depend on compliance with
the afore-mentioned prescriptions. Lack of compliance with the regulations described in this booklet,
negligence and an incorrect and inadequate use of the vibrator may cause ITALVIBRAS to void the
warranty it gives to the vibrator.
On receipt of the vibrator check that:
- Packaging, if envisioned, has not deteriorated to the point of having damaged the vibrator;
- The supply corresponds to order specification (see the transport document);
- There is no external damage to the vibrator.
If the supply does not correspond to the order or the vibrator is externally damaged, inform both the
forwarding agent and ITALVIBRAS or its local representative, immediately.
ITALVIBRAS, is however at complete disposal to ensure quick and accurate technical assistance and for
all that may be necessary for improved functioning and to obtain maximum performance from the
vibrator.
1.1 WARRANTY
The Manufacturer, as well as that stated in the supply contract, guarantees its products for a period of 12
(twelve) months from the date of purchase. This warranty is only applied in the free repair or
replacement of those parts which, after careful examination by the Manufacturer’s technical office, result
faulty (excluding electrical parts). The warranty, with exclusion of all liability for direct or indirect
damage, is limited to defects in materials and ceases to have effect whenever the returned parts are
disassembled, tampered with or repaired outside of the factory.
Damage deriving form negligence, carelessness, incorrect and improper use of the vibrator, incorrect
manoeuvres by the operator and incorrect installation are also excluded form the warranty. Removal of
the vibrator’s safety devices, will automatically cause the warranty to be forfeited along with liability of
the Manufacturer. The warranty is also forfeited whenever non-original spare parts are used.
The returned material, even if under warranty must be delivered with carriage paid.
1.2 IDENTIFICATION
The vibrator’s serial number is embossed on the identification plate (6 Fig.1, page2). This plate, as well
as other various data, states:
A) Vibrator type;
B) Vibrator series;
C) Serial number.

This information must always be stated when requesting spare parts or a technical intervention
1.3 IDENTIFICATION
The vibrator has been built in compliance with that envisioned by the regulations in force prescribed by
the European Community, and in particular with:
- Insulation class F;
- Tropicalised winding;
- IP66 mechanical protection (EN 60529), IK08 shock-resistance level (EN 50102);
- Admitted environmental temperature to ensure the indicated performance – 30o C ÷+ 40 o C;
- Electrical construction according to Regulation EN 60034-1;
- Airborne noise measured in free field < 70 dB (A) sec. IEC.
Description Fig. 1 (page 2):

1 Cable-gland for electrical power supply cable entry;
2 Vibrator body;
3 Weight cover;
4 Support and fixing feet;
5 Coupling bracket for lifting and safety;
6 Identification plate.
1.4 USE OF THE VIBRATOR

The vibrators listed in this booklet have been designed and built for specific needs and relative to use on
vibrating machines. This vibrator, cannot be commissioned before the machine into which it will be
incorporated has been declared in compliance with the dispositions in the 98/37/EC Directive (art.4,
par.2) and successive amendments. Its use for jobs different from those envisioned and non/conform to
that described in this booklet, as well as being considered improper and prohibited, releases the
Manufacturer from any direct and/or indirect liability.
1.5 TECHNICAL FEATURES

See the specific tables starting from page 66 for the << Technical Features >> of the individual vibrators.
SECTION 2 – Safety regulations

2.0 SAFETY

Careful reading of this manual is highly recommended, the safety regulations in particular.
Pay great attention to dangerous operations.
The Manufacturer declines all liability for non-compliance to safety regulations and to accident-
prevention prescriptions described below. It also declines any responsibility for damage caused by
improper use of the vibrator or by unauthorized modifications.
Pay attention to the danger signal present in this manual; it precedes the signal for a potential danger.
2.1 GENERAL SAFETY REGULATINS

When using electrical equipment, it is necessary to adopt opportune safety precautions to reduce the risk
of fire, electric shock and injury to persons. Therefore, before using the vibrator, carefully read and
memories the following safety regulations. After reading, preserve this manual with care.
- It is prohibited to use the vibrator in saturated environments with danger of explosion.

- Maintain the work area clean and in order. Untidy areas and environments favor accidents.
- Before starting work, check the perfect integrity of the vibrator and the machine to which it is applied.
Check normal functioning and that no elements are damaged or broken. The damaged or broke parts
must be repaired or replaced by authorized, trained staff.
- Repair, or have repaired by unauthorized staff, means, operating with unsafe and potentially
dangerous equipment as well as loosing the warranty.
- Do not touch the vibrator when functioning.
- Any type of check, control, cleaning, maintenance, change and piece replacement, must be carried out
with the vibrator and machine switched off with the plug disconnected from the socket
- It is prohibited for children, unauthorized persons, unskilled persons and persons who are not in good
health to touch or use the vibrator.
- Check that the plant power supply is in compliance with the regulations.
- On installation, check that the power supply cable is very flexible and ensure that the earth is
connected (Fig.3, page2).
- Check that the plug socket is suitable and in compliance and has an automatic protection switch
incorporated.
- Any extension of the electric cable must have plugs/sockets and cable with earth circuit as envisioned
by the regulation.
- Never stop the vibrator by removing the plug from the socket and do not pull the cable to remove the
plug from the socket.
- Periodically check integrity of the cable. Replace it if not integral. This operation must only be
carried out by authorized, trained staff.
- Only use admitted and marked extension cables.

- Protect the cable from high temperatures, lubricants and sharp corners. Prevent coiling and knotting
of the cable.
- Do not allow children and unauthorized persons to touch the cable with the plug inserted.
- If the insertion of a vibrator onto a machine causes the sound level, established by the regulations in
force in the country in which it is to be used, to be exceeded, operators must use adequate protection to
protect their hearing e.g. earphones.
- Even if vibrators are planned to work at low temperatures, in particularly hot environments the
temperature of the vibrators may reach very high values which are induced by the environment itself.
Wait for the vibrator to cool before intervening.
Only authorized tools that are described in the instructions or shown in the Manufacturers catalogue
can be used. Ignoring this advice means operating unsafe and potentially dangerous equipment.
Repairs must only be carried out by staff authorized by the Manufacturer. The Manufacturer
is however at complete disposal to ensure immediate and accurate technical assistance and all that
is necessary for good functioning and maximum performance of the vibrator.
For vibrators without weight covers the user must prevent persons or foreign bodies from coming
into contact with the eccentric weights during functioning.
SECTION 3 – Handling and installation

The vibrator may be supplied without packaging or palletised according to its type and size.
To handle the unit, if palletised, use a forklift truck or transpallet with forks. If it is not Packed
exclusively use the rods or hoisting eye-bolts
If the vibrator must be stored for a long period of time (up to a max. of two years), the storage
environment must have an environmental temperature that is not less than + 5o C and with relative
humidity not exceeding 60%.
After two years storage of vibrators with roller bearings re-greasing must take place according to the
quantity of re-lubrication indicated in the table
After three years storage of vibrators with ball bearings the bearings must be completely replaced; for
vibrators with roller bearings the old grease must be entirely removed and replaced completely with new
grease.
When handling the unit avoid blows or vibrations to prevent damage to the rolling bearings.

3.0 BEFORE INSTALLATION
If the vibrator has been stored for a long period of time (more than 2 years), before installation remove
one of the weight covers and check that the shaft turns freely
The electrical insulation of every individual phase to earth, and between phases, is necessary and
indispensable.
To control electrical insulation only use the Megger Insulation Tester at the test voltage of 2.2Kv ac and
for a time that does not exceed 5 seconds between phases and 10 seconds between phase and earth
If anomalies result from the control, the vibrator must be sent to an ITAVIBRAS Assistance Center or to
ITALVIBRAS itself, for restoration of efficiency.
3.1 INSTALLATION
ITALVIBRAS vibrators can be installed in any position.
ATTETION: MVSI series special vibrators with 600 – 720 rpm. may only be used in a vertical
position with maximum angle of incidence (a max) as shown in the table.
The vibrator must however be fixed to be perfectly flat surface using bolts (quality 8.8 – DIN 931-933)
and nuts (quality 8.8 – DIN 934). Use a dynamometric wrench adjusted according to that stated in the
”Coupling torque” table. The diameter of the bolt, on the basis of the type of vibrator to install, must
correspond to that indicated in the table
It is also indispensable to control that the bolts are tightened fully home. This control is particularly
necessary during the initial functioning period.
Remember that most damage and faults are due to irregular fixing or badly performed tightening.
Re-control tightening after a brief functioning period.
It is advised to fix the installed vibrator to a steel safety cable, with opportune diameter and a length that
will support the vibrator in the case of its accidental detachment.
Max, fall of 15 cm (6”).
Attention: Do not carry out welding to the structure with the vibrator mounted and connected. Welding
could cause damage to windings and bearings.

3.2 ELECTRICAL CONNECTION
The wires making up the power supply cable used to connect the vibrator to the network must have an
adequate section so that the current density, in each wire does not exceed 4 a/mm2. One of these is used
exclusively for the connection of the vibrator to earth. The section of the wires must also be adequate for
the length of the cable used so that a drop voltage along the cable is not caused that exceeds the values
prescribed by the regulation on this subject. It is also recommended to use flexible cables that have an
external diameter that corresponds to that stated in the << Technical features>> table. This guarantees the
perfect hold of the terminal board box cable-holder on the power supply cable.
3.3 TERMINAL BOARD WIRING DIAGRAMS
ATTENTION: A tropicalised screw, indicated with the earth symbol, is situated in the terminal box. The
yellow-green (only green for USA) wire of the power supply cable must be connected to this screw that
acts as the earth connection of the vibrator.
The sheet of wiring diagrams is found inside the terminal board compartment. Use the diagram that has
the reference that corresponds to that indicated on the identification plate.
ATTENTION: For ITV-VR vibrators electric connection and adjustment of the weights are linked to the
pre-selected frequency variation range.
DIAGRAM 2A
A) Lower voltage ∆ Delta
B) Higher voltage Y star
C) Power supply network
DIAGRAM 2A
A) Lower voltage YY double star
DIAGRAM 2D
DIAGRAM 5A

A) Lower voltage ∆ Delta
D) Themistor
E) Control equipment
DIAGRAM 5B
A) Lower voltage YY double star
D) Themistor
E) Control equipment
DIAGRAM 1A
F) To invert the direction of rotation
For the SINGLE-PHASE connection.
DIAGRAM 1B
F) To invert the direction of rotation
DIAGRAM 1E
D) To invert the direction of rotation
NOTE: The single-phase vibrators are supplied without capacitor, which the user must insert in an area
protected from vibrations. The capacitor value to be used is indicated on the identification plate (CAP.
F), for example 10 means that a 10 F condenser must be used, while the indication of 32/12 means that
for start-up 32 F are necessary and for normal running 12 F are necessary.

3.4 FIXING OF THE POWER SUPPLY CABLE TO THE VIBRATOR TERMINAL BOARD
Follow the sequence of operations as indicated below.
Insert the power supply cable through the cable-gland inside the terminal box
Always use eyelet terminal for connections
Prevent progressive disintegration that could cause interruption of short circuits Remember to place the
relevant washers before the nuts (B Fig, 23, pag.4). This prevents loosening with consequent uncertain do
not overlay the individual cable wires.
Carry out the connection according to the diagrams shown and tighten the cable-holder fully home
Position the foam rubber block ensuring that all wires are held and assemble the cover paying attention
not to damage the seals
3.5 FIXING OF THE POWER SUPPLY CABLE TO THE NETWORK
Fixing of the power supply cable to the network must be carried out by a qualified installer according to
the safety regulations in force.
Connection of the vibrator to earth, through the yellow-green wire (green for the USA) of the power
supply cable, is obligatory.
Always check that the network voltage and frequency correspond to that indicated on the vibrator’s
identification plate before supplying power.
All vibrators must be connected to an adequate external overloading protection according to the
regulations in force.
When vibrators are installed in pairs it is important that each one has its own eternal overloading
protection and that these protections are interlocked together. This is because if a vibrator accidentally
shuts down, the power supply is interrupted to both vibrators at the same time, so as not to damage the
equipment to which they are applied. See diagrams A and B as examples of power and control circuits in
the case of vibrators with thermistor (supplied starting from and including the gr.70).
All vibrators starting from and including gr.70 are equipped with a PTC 130oCthemistor (DIN 44081-
44082). This themistor is accessible in the terminal box and can be connected to an adequate control
equipment for protection of the vibrator.
Important!: For the choice of start-up/shutdown and overloading protection electrical appliances refer to
the technical data, electrical features, nominal current and start-up current. Also always choose delayed
magnetic-circuit breakers, to prevent release during start-up time, which may be longer in low
environmental temperatures.
3.6 POWER SUPPLY WITH FREQUENCY VARIATOR

All of the vibrators can be powered with a 20Hz frequency variator (inverter) up to plate frequency, with
constant torque functioning (rather with linear course of the Volt-Hertz curve) using a PWM (Pulse Width
Modulation) variator.
The ITV-VR high variable frequency vibrators are designed to be powered by frequency variators up to
100Hz.
The ITVAF high fixed frequency vibrators are designed to be powered with fixed frequency according to
the technical specifications of each type.
SECTION 4 – Use of the vibrator
4.0 PRELIMINARY CHECKS
ATTENTION: Controls must be carried out by specialised staff. During disassembly and re-assembly of
protective parts (terminal box cover and weight cover), remove the power supply from the vibrator.
Check current draw.

- Remove the cover from the terminal board compartment.
- Power the vibrator.
- Use ammeter pliers to verify, on each phase, that the absorbed current does not exceed the value
indicated on the identification plate.
ATTENTION:
Avoid touching or allowing anyone to touch live parts such as the terminal board.
If the current draw exceeds that stated on the plate:
- Check that the flexible system and the vibrating machine framework are in compliance with the
regulations for correct application.
- Reduce force (Centrifugal force) by adjusting the weights. Reduce them until the value of
absorbed current corresponds to that stated on the identification plate.
Remember to allow the vibrators to function for brief periods of time during set-up. This prevents
damage to the vibrator and structure in the case of anomalies.
Once the indicated controls have been carried out close the cover definitively.
MVSI-MP special series models with 600 – 720 rpm are equipped with permanent magnet device to
ensure shutdown of the vibrators with weight always in phase.
Check direction of rotation:

In applications where direction of rotation must be ascertained.
- Remove a weight cover;
- Wear protective glasses;
- Power the vibrator for a brief period of time;
ATTENTION: in this phase ensure that no one can touch or be struck by the rotating masses.
- If the direction of rotation must be inverted, act on terminal board connections, after having
removed the power supply from the vibrator.
- Reposition the covers, ensuring that the seals (OR) are correctly positioned and tighten the screw
fastener.

4.1 VIBRATION FORCE ADJUSTMENT
AT T E N T I O N : T H I S O P E R AT I O N M U S T B E C A R R I E D O U T E X C L U S I V E LY B Y B Y S P E C I A L I S E D
S TA F F W I T H T H E PO W E R S U P P LY D I S C O N N E C T E D .
- To adjust vibration intensity it is necessary to remove the weight covers.

- It is usually necessary to adjust the weights in the same direction in the two ends. To
allow exact adjustment of the weights, the vibrators are equipped with a patented system
that prevents the adjustable weight to turn in the wrong direction
- Unscrew the mobile weight screw fastener or nut. The adjustable weights positioned at the two ends
of the shaft must be positioned in a way to read the same value on the reference percentage scale. The
weights positioned at the two sides of the vibrator can only be adjusted on two different values for
particular machines and for special uses.
- For the MVSI-TS and MNSL-ACC series adjustments must be carried out as for the corresponding
MVSI series motors.
- Once the eccentric weight has been taken to the desired value tighten the screw fastener or nut using the
dynamometric wrench and repeat the same operation on the opposite weight
ATTENTION:
For every ITV-V adjustment of the weight (number NF of fixed weights per side, number NR of a
adjustable weights per side and maximum adjustment percentage PMax% of the adjustable
weights) and connection to the terminal board (star Y or U Delta) are linked to the desired power
supply frequency variation field (HZ) – page 80 (refer to terminal board connection diagram sheet).
Contact Italvibras technical staff for different adjustments.
- Once the operation on the two sides has been carried out, remount the covers on the screws and washers
paying attention that the seals are correctly positioned in their houses.
4.2 START-UP AND SHOUTDOWN OF THE VIBRATOR DURING USE.
Start-up takes place by always and only acting on the power supply switch by positioning it in the ON
position (insertion of the power supply network).
The Vibrator works.
Stop the vibrator by always and only acting on the power supply switch by positioning it in the OFF
position (disconnection of the power supply network).
Section 5 – Maintenance of the Vibrator
ITAL VIBRAS vibrators have no particular need for maintenance.
Only authorised technicians can intervene on the parts that make up the vibrator.
Before carrying out maintenance on the vibrator wait until the temperature of the vibrator case is not
above 40OC and ensure that the electrical power supply has been disconnected.
If parts must be replaces, only ITAL VIBRAS original spare parts must be used.
5.0 BEARING REPLACEMENT

5.0.1 Bearing replacement gr.00-01-01-AF10-20
These vibrators have ball and shielded bearings and bearings that are pre-lubricated for life.
Remove the power supply from the vibrators, disassemble the eccentric weights.
Disassemble the 2 (two) Seeger rings mounted on the flanges near to the bearings. For these vibrators the
flanges form a unique motor group unit with the casing and cannot be disassemble.
Push the shaft from one side using an adequate force until it exits from the opposite side. The shaft will
drag at least one bearing while one remains in its flange. By exercising axial one bearing while one
remains in its flange. By exercising axial pressure, remove the bearing from the shaft and the one
remaining in the flange. Check the baring seat in the flange. If it is worn the entire motor unit must be
replaces. The flanges are fixed tightly to the casing and cannot be replaces. Mount the first bearing in a
flange paying attention that it remains just beyond the seat of the Seeger ring, then mount the Seeger
ring. Pressure-mount the second bearing onto the shaft from the side where the bearing is blocked
(ATTENTION : the shaft is not symmetrical, from one side the bearing is blocked in a radial manner,
from the other side the bearing is free). Insert the shaft into the motor unit from the correct side and press
until the shaft enters its final position, mount the second Seeger ring. Re-mount the masse, seals and
weight covers. Control the state of the seals during this operation and replace them if necessary. Turn the
shaft manually to ensure that it turns freely without axial play.
5.0.2 Bearing replacement gr.30-AF30-AF33-35...up to gr.110

These vibrators have roller bearings, already lubricated in the factory by ITALVIBRAS.
Remove the power supply from the vibrator, disassemble it from the machine, remove the weights.
Remove the flanges from the casing using the threaded extraction holes. Remove the shaft and the second
flange. Remove the bearing cover and slide the bearing out through the extraction holes. Using the
necessary equipment on the bench, replace the bearings and the specific hold rings.
Check the bearing seat in the flange. If worn replace the flange. On re-mounting the bearings pay
attention that they rest correctly on the stroke of their seat. Half fill the chamber between the sealing ring
and the bearing with grease.
Apply the new grease in the quantity prescribed in the <<Technical Features>> table (page 81-92)
spreading deeply inside the bearing applying pressure to allow penetration of the grease into the rolling
parts.
Once the operation has been carried out, re-mount by preforming the operations in the opposite order
taking care to maintain perfect orthogonality of the flange with respect to the casing Pay attention that the
seals are correctly positioned in their seats. Control the state of the seals during this operation and replace
them if necessary.
Turn the shaft manually and ensure that it has axial play between 0.5 and 1.5 mm.
ATTENTION:
Every time the afore-mentioned maintenance operations are carried out it is recommended that all
disassembled screws and spring washers are replaced and that the screws are tightened using a
dynamometric wrench.
5.1 LUBRICATION
All bearings are correctly lubricated on mounting the vibrator.
All ITAL VIBRAS vibrators are realized to use the “FOR LIFE” lubrication system and therefore do not
require periodical lubrication.
Only for heavy work, as for example 24 hours service with high environmental temperatures, staring from
gr. AF33 and 35 periodical re-lubrication of the bearings is recommended, using the two external greases
with the following type of grease:
- speed of 3000 rpm or higher : KLUEBER ISOFTEX NBU 15;
- speed of 1800 rpm or lower: KLUEBER STABURAGS NBU 8 EP;
- MVSI special series 600-720 rpm; KLUEBER ISOFLEX NBU 15.
Approximately, on average, the frequency of re-lubrication can be included between 1000 and 5000 hours
and depends on the operative conditions and the type of vibrator, therefore it can be lower or higher than
the indicated values. The quantity of grease to be introduced on periodical lubrication is indicated in the
table on page 81. It is advised to contact ITALVIBRAS for particular uses, which is at complete disposal
to advise the client on the best lubrication possible for the specific use.
Never mix greases even if they have similar feature. Excessive quantity of grease causes increases heating
of the bearings and consequent anomalous current absorption.
Respect the ecological laws in force in the country in which the equipment is used, relative to use and
disposal of products used for cleaning and maintenance of the vibrator. Always comply with
recommendations of the manufacturer of these products. If the machine must be demolished, comply
with the anti-pollution regulations envisioned in the country to use.
Remember that the Manufacturer is always available for any type of assistance and spare parts.
5.2. SPARE PARTS
On requesting spare parts always state:

- Type of vibrator (TYPE detectable from the identification plate).
- Vibrator series (SERIES detectable from the identification plate).
- Serial number (SERIEL NO. detectable from the identification plate).
- Power supply voltage and frequency (VOLT and HZ detectable from the identification plate).
- Spare part number (detectable from the spare part table starting from page 93).and desired quantity.
- Exact destination address of the goods and means of deliver. ITALVIBRAS, declines any liability
for incorrect forwarding due to incomplete or confused requests.
Inspection/Maintenance
Inspection/maintenance for BMGO5-8, BM 15-62 brakes
BM (g)05-08 brakes
Key
1. Motor with brake bearing and shield
2. Carrier
3. Circlip
4. Niro dist (BMG only)
5. Rubber sealing collar
6. Annular spring
7. Brake disk
8. Pressure plate
9. Damping plate (BMG only)
10a Stud (3 pcs.)
10b Counter spring
10c Pressure ring
10e Hex nut
10. Brake spring
11. Brake coil body
12. In BMG, Gasket in BM: V-ring
13. Dowel pin
14. Release lover with hand lever
15. Stud (2pcs.)
16. Conical coil spring
17. Setting nut
18. Fan
19. Circlip
20. Fan guard
21. Housing Screw.
BM 15-62 BRAKE
Key
1. Motor with brake bearing and shield
2. Carrier
3. Circlip
4. Niro disk (BMG only)
5. Rubber sealing collar
6. Annular spring
7. Brake disk
7b Only BM 32,62
Brake stationary disk annular spring, Brake disk.
8. Pressure plate
9. Damping plate (BMG only)
10a Stud (3 pcs.)
10b Pressure ring
10c Hex nut
10. Brake spring
11. Brake coil body
13. In BMG Gasket, In BM V-ring
14. Dowel pin
15. Release lever with hand lever
16. Stud (2 pcs.)
17. Conical coil spring
18. Setting nut
19. Fan
20. Circlip
21. Fan guard
22. Housing screw
BMG05-8, BM15-62 brakes, set the working air gap
1. Isolate the motor and brake from the supply, safeguarding them against unintentional power-up.
2. Remove the following:
- If installed, forced cooling fan, tacho/encoder (→Sec. “Preliminary work for motor and
brake maintenance”)
- Flange cover or fan guard [21]
3. Push the rubber sealing collar aside [5]
- Release the clip to do this, if necessary
- Extract the abraded matter.
4. Measure the brake disc[7],[7b]:

If the brake disk is
- < 9 mm on brake motors up to size 100
- < 10 mm on brake motors up to size 112
Install a new brake disk (→Sec. “Changing the brake disk BMG 05-8, BM 15-62”),
otherwise
5. With BM30-62:
Loosen the setting sleeve [10d] by turning it towards the bearing end shield
6. Measure the working air gap A (→ following figure)
(use a feeler guage and measure at three points offset by 120o)
- In BM, between the pressure plate [8] and the brake coil body [12]
- In BMG, between the pressure plate [8] and the damping plate [9]
7. Tighten the hexagon nuts [10e]
- Until the working air gap is set correctly (→ Sec. “Technical Date”)
- In BM 30-62, until the working air gap is initially 0.25 mm
8. With BM30-62:
Tighten the setting sleeves
- Against the brake coil body
- Untill the working air gap is set correctly (→Sec.”Technical Data”)
9. Install the rubber sealing collar back in place and re-install the dismantled
parts.
Changing the BMG05-8, BM15-62 brake discs
When fitting a new brake disk (in BMG05-4 < 9mm; in BMG62 < 10mm) inspect the other
removed parts as well and install new ones if necessary.
1. Isolate the motor and brake from the supply, safeguarding them against unintentional power-up!
- If installed, forced cooling fan, tacho/encoder (→ Sec. “Preliminary work for motor and
brake maintenance”)
- Flange or fan guard [21], circlip [20] and fan [19].
3. Remove the rubber sealing collar [5] and the manual brake release:
- Setting nuts [18], conical coil springs [17], studs [16], release lever[15], dowel pin [14}
4. Unscrew hexagon nuts [10e], carefully pull off the coil body [12] (brake cable!) and take out the
brake springs [11].
5. Remove the damping cable [9], pressure plate [8] and brake disc [7], [7b], clean the crake
components
6. Install a new brake disk
7. Re-install the brake components
- Except for the rubber sealing collar, fan and fan guard, set the working air gap (→ Sec.
“Inspecting brake B<G 05-8, BM 30-62, setting the working air gap”, points 5 to 8)
8. With manual brake release: Use setting nuts to set the floating clearance “s” between the conical
coil springs (pressed flat) and the setting nuts (→ following figure)

Brake Floating clearances (mm)
BMG05-1 1.5
BMG2-8 2
BM15-62 2
Important : The floating clearance “s” is necessary so that the pressure plate can move up as the brake
lining wears. Otherwise, reliable braking is not guaranteed.
9. Install the rubber sealing collar back in place and re-install the dismantled parts.
- The lockable manual brake release (type HF) is already released if resistance is
encountered when operating the grub screw.
- The self – reengaging manual brake release (type HR) can be operated with normal hand
pressure.
Important: In brake motors with self – reengaging manual brake release, the manual brake release
lever must be removed after startup/maintenance! A bracket is provided for storing the lever on the
outside of the motor.
Change braking torque of BMG05-8, BM15-62

The braking torque can be changed in steps (→Sec. “Technical Data”)
• by installing different brake springs
• by changing the number of brake springs
• by changing the brake coil body:
- BMG05: If the maximum braking torque is not sufficient for the specific application,
install the brake coil body [12] of brake, BMG1 of the same design to ensure safe braking.
- BMG2: If the maximum braking torque is not sufficient for the specific application, Install
the brake coil body [12] of brake BMG4 of the same design to ensure safe braking.
1. Isolate the motor and brake from the supply, safeguarding them against unintentional power-
up
- If installed, forced cooling fan, tacho/encoder (→ Sec. “Preliminary work for motor and
brake maintenance)
- Flange or fan guard [21], circlip [20] and fan [19].
3. Remove the rubber sealing collar [5] and the manual brake release:
- Setting nuts[18], conical coil springs[17], studs [16], release lever[15], dowel pin [14]
4. Unscrew hex nuts [10e] pull off the coil body [12]
- by approx. 50mm (watch the brake cable)
5. Change or add brake spring[11]
- Position the brake spring symmetrically
6. Re-install the brake components
- Except for the rubber sealing collar, fan and fan guard, set the jworking air gap (→ Sec.
“Inspecting brake BMG 05-8, BM 15-62”,points 5to8)
7. With manual brake release: Use setting nuts to set the floating clearance “s” between the conical
coil springs (pressed flat) and the setting nuts (→following figure)
Brake Floating clearances (mm)

BMG05-1 1.5
BMG2-8 2
BM15-62 2
Important : The floating clearance “s” is necessary so that the pressure plate can move up as the brake
lining wears. Otherwise reliable braking is not guaranteed.
8. Install the rubber sealing collar back in place and re-install the dismantled parts. Install new
setting nuts [18] and hexagon nuts [10e] if the removal procedure is repeated!
9.3 Work done, working air gap, braking torques of BMG 05-8, BR03, BC, Bd
Braking torque settings

Work done
For Working air Type and no,
Brake until Braking Order number or
motor gap [mm] or brake
type maintenanc torque brake springs
size springs
e [106 J] 1)
min max. [Nm] standard red standard red
-
3.2 6
2
2.4 4
BR03 63 200 - 0.8 - 185 815 7 1858734
1.6 3
6
0.8 -
5.0 3 -
4.0 2 2
71
BMG052) 60 0.25 0.6 2.5 - 6 135,017X 135 018.8
80
1.6 - 4
1.2 - 3
10 6 -
BMG1 80 60 0.25 0.6 7.5 4 2 135,017X 135 018 8
6.0 3 3
20 3 -
16 2 2
90
BMG23) 130 0.25 0.6 10 - 6 135 150 8 135151 6
100
6.6 - 4
5.0 - 3
BMG4 100 130 0.25 0.6 10 6 - 135 150 8 135 151 6
30 4 2
24 3 3
75 6 -
55 4 2
45 3 3
112M 37 3 -
BMG8 300 0.3 0.9 184 845 3 135 570 8
132S 30 2 2
19 - 6
12.6 - 4
9.5 - 3

Safety Instructions

Compressed Air Safety
Followed Safety instructions should be strictly followed. Failure to do so may result in accidents,
equipment malfunctioning, serious personal injury and /or loss of life.
Compressed air is a source of considerable energy. When handling products dealing with compressed air,
the following precautions must be taken to prevent accidents.
1. Human hands or any parts of a human body should not block compressed air, Compressed air should
not be allowed to impinge on any portion of the human body.
2. Before connecting any pneumatic equipment to the compressed air supply, all mounted fittings, piping
assemblies and electrical connections should be checked for security. All plastic plugs in the equipment
used for protection during shipping should be removed.
3. No piping alterations, removal of fittings, repairing of equipment etc., should be attempted with air
supplies connected. Air and electrical supplies must be disconnected before beginning any adjustment,
maintenance or dismantling of equipment.
4. The maximum allowable operating pressures, temperature, flows etc., must be strictly observed.
Failure to do so might result in catastrophic failure of equipment, and result in serious personal injury
and /or death. Refer to individual catalogs for this information, and any other operating or application
limitations.
Compressed Air Safety for Pneumatic Equipment :
Warning
1. Compatibility of pneumatic equipment
Ensuring the compatibility of the procured FRL equipment is the responsibility of the person who designs
the pneumatic system and/or System specifications. This should be based on specifications or after
analysis and /or tests to meet specific requirements.
2. Repair & Maintenance

Assembly, handling, or repair of pneumatic systems should be performed by only trained and experienced
operators.
3. Safety First
Do not service machinery/equipment or attempt to remove any component until safety is confirmed.
¾ Inspection and maintenance of machinery/equipment should only be performed after confirmation that
both compressed air and electrical supply have been positively disconnected and all residual
compressed air in the system has been completely exhausted to the atmosphere.
Product Selection
Warning
Standard Filters, Regulators, Lubricators and Filter – Regulator Combination units should be used in
accordance with the specifications mentioned in the catalogs/specifications sheets. While installing and
using this equipment, please also follow the respective specification & instruction manual available for
each product.
Wherever this symbol is shown, it indicates Caution! and/or Warning!
It indicates that operator error can lead to damage and malfunctioning of the pneumatic equipment and
can lead to serious personal injury or loss of life.
1. Air Filter and Lubricator
Standard Filters and Lubricators incorporate polycarbonate bowls and/or observation windows. Do not
use filters & lubricators in an environment that will expose the above components to synthetic fluids,
organic solvents, corrosive chemicals cutting lubricants, thread sealant or similar materials.
Make sure that the condensate in periodically drained when using manual drain valves on Filters.
1. Air Filter and Lubricator
Standard Filters and Lubricators incorporate polycarbonate bowls and/or observation secondary side will
be minimized in the event of a malfunction.
b. In a standard regulator, when the supply pressure is removed or disconnected, either of the following
may happen:
1. The residual pressure will remain on the secondary side or the regulator.
2. The pressure on the secondary side of the regulator will exhaust.
The designer should add components to the circuit to compensate for any of the above conditions.
c. Regulator operation may be affected when used in Balanced on Secondary sealed circuits. Please
consult Janatics regarding these applications.
3. Lubricators
Ensure proper function of the Lubricator. Minimum airflow rate should be ensured for effective
lubrication.
4. Automatic Drains – Normally Open
Ensure minimum working pressure for proper functioning of the Auto drain. The Filter unit must be
periodically checked for condensate that would not be drained in case of any drain malfunction.
Safety Instructions for the use, transportation, installation, commissioning and maintenance of
electric motors, MOVIMOT® geared motors, (variable speed) geared motors and gear units
1. General
During and after operation, electric motors, MOVIMOT® geared motors, (variable speed) geared motors
and gear units live voltage and moving components and may have hot surfaces.
All transportation, storage, assembly/installation, connection, commissioning, maintenance and repair

work must be carried out only by qualified, skilled personnel) taking the following in to account:
the relevant detailed operating instructions and circuit diagrams
all warning and information signs on the motor/gear unit geared motor concerned
regulations and requirements pertaining to the equipment concerned
as well as national and regional safety and accident prevention regulations.
Detailed documentation must be obtained from the manufacturer if necessary.
Serious personal injury and property damage can occur through
¾ inappropriate use
¾ incorrect installation or operation
¾ unauthorized removal of the protective cover or the housing.
2. Proper Use.
These electronic motors, MOVIMOT® geared motors, (variable speed) geared motors and gear units are
intended per use in commercial equipment. They comply with the applicable standards and regulations
and full fill the low voltage Directive 73/23/EEC.
You can find technical data and information’s on permissible conditions in the place of use on the name
plate and in the documentation.
All stipulations must be adhered to in all cases.
Permissible ambient temperatures

00 C + 400 C for (Variable speed), geared motors and gear units.
-150 C + 400 C for motors with back stop, DC motors and MOVIMOT®
-200 C + 400 C for explosion protected motors.
-250 C + 400 C for all others motors.
If not expressly designed for other temperatures.

Maximum permissible installation altitude: 1000m above sea level.
The following are prohibited :
Use outdoors (enclosures < IP 23)

Use in hazardous areas (unless expressly designed for such use).
Use in the vicinity of oils, acids, gases, vapours, dusts, radiation,etc.,
Ambient conditions must be comply with the data on the name plate. Electric motors, MOVIMOT®
geared motors,(variable speed) geared motors and gear units are components intended for installation in
machinery. Commissioning (starting operation in accordance with the inteded use) is prohibited untill
such time as the machine’s conformity with EMC directive 89/336/EEC and the end product’s conformity
with machinery directive 89/392/EEC has been established (not EN 60204).
3. Transportation, Storage
Notified the carries immediately of any damage discovered after delivery; where applicable, the
equipment should not be commissioned.
Tighten any ring bolts that have been screwed in. These are intened to bear the weight of the motors,
(variable speed), gaered motor or gear unit only. no additional loads should be applied.
Where necessary, use suitable adequately dimensioned transportation equipment (e.g. rope guides).
Removes any transportation safety devices before commissioning.
Motors, MOVIMOT® geared motors, (variable speed) geared motors and gear units may only be stored
at temperatures from between -200 C + 850C in a dry, dust-free, low-vibration environment (Vett < 0.2
mm/s) in order to avoid damage to bearings while stationary.
If the equipment is to be in store for 12 months or more, the grease service life of the bearings will be
reduced.
4. Assembly/Installation
When assembling or installing the equipment, not the following points:
¾ Ensure that the equipment is installed evenly on a level, low vibration, torsionally, rigid
substructure
¾ Our put elements (belt pulleys couplings etc.,
must be balanced without the key (SEW motors with full spline balancing)
may only be installed with suitable mounting jigs and pull-off devices (pre heat output
elements if necessary)
must be covered to protect against accidental contact.
¾ Ensure correct belt tension (not manufacturer’s specification).
¾ Ensure secure foot flante and shaft mounting.
¾ Ensure proper alignment in the case of direct couplings.
¾ Prevent distortion in the case of combined foot/flange, flange/shaft or foot/shaft mounting.
¾ Allow unhindered motor ventilation, hot air from other assemblies must be prevented from being
drawn directly in to the equipment.
¾ Ensure that the direction of rotation is correct by checking it in and uncoupled state (see point 5)
and note any unusual grinding sounds as it turns,
¾ Verticals mountings positions :
- Cover motors with downward shaft ends with of protective cover if necessary.
- Prevent foreign bodies or water from entering motors with upward shaft ends by suitable means if
necessary.
- Ensure that the filling with lubricant is correct.

5. Electrical connection:
All work must be carried out only when:
The electrical supply is switched off and prevented from being switched on accidentally.
You have double-checked that the equipment is de-energized.
The electric motor or (variable speed) geared motor, MOVIMOT® gear motor, is at rest.
When connecting the equipment to the power supply, ensure that:
The valid harmonized standards and regulations are maintained.

The connected valued do not exceed the standard tolerances ( Voltage + 5%, frequency + 2%,
characteristic pattern, symmetry e.g. of frequency inverter supply) to avoid overheating.
The power connection is lastingly secured (no ends of wires sticking out etc.,) following the
terminal assignment specified.
The protective earth wire connection (PE) is secure., the specified clearances between individual
bare live components and between these components and the earth are adherd to.
The terminal / connection box is free from foreign bodies and is dirt and damp proof.
Any screw-type conduct fitting not needed and the terminal/connection box are sealed so that they
are dust proof and water proof.
EMC- Compliant installation(e.g. Shielding, earthing, arrangement of filters and laying of
conductors) and adherence to the limites specified by statuory EMC regulations are the
responsibility of the manufacturer of the plant or machinery (consult documentation for plants
with inverters, DC converters etc.,)
The insulation resistance of electric motors, (variable speed) geared motors or MOVIMOT®
geared motors is measured be for commissioning (normal >1k per volt operating voltage) and that
the function of the brakes on brake motors is checked. if resistance is too low or the brakes are not
functioning properly, consult the installation operating instructions for assistance.
6. Operation:
Secure the key before the trial run without the output elements. Do not disable monitoring and protective
features during the trial run.
Operating DC shunt-wound motors without excitation or allowing series-wound motors to idle can result
in dangerous over speeds and must be prevented by locking.
Vibrations Vett < 3.5mm/s (PN.> 15 KW in coupled operation are insignificant.
In the event of changes in the operating state (e.g. highertemperature, noises, vibrations), switch off the
electric motor MOVIMOT® geared motors or (variable speed) geared motor incase of doubt. Establish the
cause, connect SEW if necessary (refer to the diagnostic instruction in the documentation)
After power is removed from MOVIMOT® geared motors, voltage carrying part should not be
touched, because of capacitive loading, for at least 10 minutes after disconnection from the supply
net work.
7. Inspection/maintenance:
It is essential that all inspection and maintenance intervals and work specified in the installation and
operating instructions be adhered to.
1) Qualified skilled personnel are persons who have a relevant vocational qualification and have proper
knowledge of the execution of the above mentioned work.
6. Design and Operating Notes
6.1 Lubricants
General information : Unless a special arrangement is made, SEW-EURODRIVE supplies the drives
with a lubricant fill adapted for the specific gear unit and mounting position. The decisive factor is the
mounting position (M1...M6, ´ Sec. “Mounting Positions and Important Order Information”) specified
when ordering the drive. You must adapt the lubricant fill in case of any subsequent changes made to the
mounting position (´ Lubricant fill quantities).
Lubricant table : The lubricant table on the following page shows the permitted lubricants
for SEW-EU-RODRIVE gear units. Please note the following key to the lubricant table.
Key to the lubricant Abbreviations used, meaning of shading and notes:
table CLP = Mineral oil

CLPPG = Polyglycol (W gear units, conforms to USDA – H1)
CLPHC = Synthetic hydrocarbons
E = Ester oil (water pollution danger category WGK 1)
HCE =Synthetic hydrocabons + easter oil (USDA – H1 certification)
HLP = Hydraulic oil
=Sunthetic lubricant (= synthetic anti-friction bearing grease)
=Mineral lubricant (= mineral-based anti-friction bearing grese)
1. Helical-worm gear units with PG oil: Please contact SEW-EURODRIVE

2. Special lubricant for Spiroplan® gear units only
3. Recommendation: Select SEW fB > 1.2
4. Pay attention to critical starting behavior at low temperatuers!
5. Low-viscosity grease
6. Ambient temperature
Lubricant for the food industry (fod grade oil)

Biodegradable oil (lubricant for use in agriculture, forestry and water resources)
Anti-friction bearing greases : The anti-friction bearings in gear units and motors are given a
factory-fill with the greases listed below. SEW-EURODRIVE recommends that you regrease anti-
friction bearings with a grease fill at the same time as changing the oil.
Ambient Manufacturer Type

temperature
Anti-friction -20oC... +60oC Mobil Mobilux EP2
bearing in gear unit -40oC... +80oC Mobil MobiltempSHC 100
Anti-friction -20oC... +80oC Esso Unirex EQ3
bearing in gear unit -20oC... +60oC Shell Alvania RL3

+80oC... +100oC Kluber Barrierta L55/2
o o
-45 C... +25 C Shell Aero Shell Grease
161
Special greases for anti-friction bearings in gear units:
-30oC... +40oC Aral Aero Eural Grease
161
-20oC... +40oC Aral Aero Aralube BAB
EP2
1 Recommended for continuous operation at ambient temperatures below 00 C, for example in a

cold storage.
The following grease quantities are required:
For fast-running bearing (motor and gear unit input end); Fill the cavities between the rolling
elements on third full with grease.
For slow-running bearing (in gear units and at gear unit output end): Fill the cavities between the
rolling elements two thirds full with grease.
Lubricant fill quantities : The specified fill quantities are recommended values. The precise values
vary depending on the jumper of stages and gear ratio. When filling, it is essential to check the oil level
plug since it indicates the precise oil capacity.
The following tables show guide values for lubricant fill quantities in relation to the mounting position
M1 ...M6.
Helical (R-) gear units RX
Gear M1 M2 M3 M4 M5 M6
unit
RX57 0.60 0.80 1.30 1.30 0.90 0.90
RX67 0.80 0.80 1.70 1.90 1.10 1.10
RX77 1.10 1.50 2.60 2.70 1.60 1.60
RX87 1.70 2.50 4.80 4.80 2.90 2.90
RX97 2.10 3.40 7.4 7.0 4.80 4.80
RX107 3.90 5.6 11.6 11.9 7.7 7.7

RXF..
unit
RX57 0.50 0.80 1.10 1.10 0.70 0.70
RX67 0.70 0.80 1.40 1.40 1.00 1.00
RX77 0.90 1.30 2.40 2.00 1.60 1.60
RX87 1.60 1.95 4.90 3.95 2.90 2.90
RX97 2.10 3.70 7.1 6.3 4.80 4.80
RX107 3.10 5.7 11.2 9.3 7.2 7.2
R..,R..F
unit
R07 0.12 0.20 0.20 0.20 0.20 0.20
R17 0.25 0.55 0.35 0.55 0.35 0.35
R27 0.25/0.40 0.70 0.50 0.70 0.50 0.50
R37 0.30/0.95 0.85 0.95 1.05 0.95 0.95
R47 0.70/1.50 1.60 1.50 1.65 1.50 1.50
R57 0.80/1.70 1.90 1.70 2.10 1.70 1.70
R67 1.10/2.30 2.60/3.50 2.80 3.20 1.80 2.00
R77 1.20/3.00 3.80/4.10 3.60 4.10 2.50 3.40
R87 2.30/6.0 6.7/8.2 7.2 7.7 6.3 6.5
R97 4.60/9.8 11.7/14.0 11.7 13.4 11.3 11.7
R107 6.0/13.7 16.3 16.9 19.2 13.2 15.9
R137 10.0/25.0 28.0 29.5 31.5 25.0 25.0
R147 15.4/40.0 46.5 48.0 52.0 39.5 41.0
R167 27.0/70.0 82.0 78.0 88.0 66.0 69.0
1 The larger gear unit of multi-stage gear units must be filed with the lager oil volume.
unit
RF07 0.12 0.20 0.20 0.20 0.20 0.20
RF17 0.25 0.55 0.35 0.55 0.35 0.35
RF27 0.25/0.40 0.70 0.50 0.70 0.50 0.50
RF37 0.35/0.95 0.90 0.95 1.05 0.75 0.95

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Bp30 - Operation - Maintenance - Final Manual 1-12-07

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Concrete Batching Plant

Operating Instructions &

Catalogue Number Issued On

S.NO CONTENTS PAGE

2.00 SAFETY INSTRUCTIONS 03-04

3.00 TECHINICAL DATA 05

4.00 OPERATING INSTRUCTIONS 06

4.02 SYSTEM DESCRIPTION 06-07

5.00 EQUIPMENT DESCRIPTION 07

5.01 LOAD CELLS 07-08

5.02 LOAD INDICARTOR 08-13

5.03 CONTROL DESK 13-14

6.00 TB DETAILS 15-17

7.00 OPERATION PROCEDURE 17-18

8.00 ELECTRICAL SCHEME 19-35

9.00 DRAWINGS 36-38

10.00 COMPUTER SCREEN 39-46

11.00 MAINTANANCE 47-52

Greaves Cotton Limited 1

Using this manual will

• Help you to become acquainted with the Plant

• Avoid malfunctions caused by unprofessional operation

Observing the maintenance instruction will

• Increase the reliability of the Plant

1.01 No warranty claims can be lodged for damages resulting from:

1.02 Please Note!

Greaves Cotton Limited 2

• All electrical woks and connections to be handled by an Electrical Expert.

2.01 Electrical Installation

2.02 Diesel Generator ( DG ) Requirement

2.03 Power Failure

2.04 Welding in Plant

2.05 Protective and Safety Devices

Greaves Cotton Limited 4

Compressor motor:……………………………………….. 1.5 KW / 2 HP

Load Cell Details:

Input Resistance : 350 Ohms ± 2 Ω

Load Cell Wiring Details:

Brake Rectifier Details

Greaves Cotton Limited 5

4.02 SYSTEM DESCRIPTION

5.00 EQUIPMENT DESCRIPTION

5.01 LOAD CELL

Type Single ended Shear Beam Type / S -Type

5.02 LOAD INDICATOR

Greaves Cotton Limited 8

MICRO CONTROLLER BASED ADC (IA-PT-420-01A):

CPU, ADC & POWER SUPPLIES

Following are the DC voltages:

b. V2 : + 7 v ( 12 V AC, 0.2 A) &

c. V+ : +15V (18V AC, 0.2A)

Greaves Cotton Limited 9

Greaves Cotton Limited 10

Greaves Cotton Limited 13

Refer enclosed drawing for the detailed component layout.

For load indicator/ signal conditioner in case of erratic display

Resistance should be as follows:

Greaves Cotton Limited 14

Sl.No Fr.No Description Remarks

Greaves Cotton Limited 15

Sl.No Fr.No Description Remarks

Greaves Cotton Limited 16

7.00 OPERATION PROCEDURE