Tri-Clover® Dual Stage Tri-Blender
Contents
1. CONTENTS Thank you for purchasing a Tri Clover Product This manual contains installation operation cleaning and repair instructions with parts lists for Dual Stage Tri Blenders manufactured by Tri Clover Inc Kenosha Wisconsin It also provides a troubleshooting chart to assist in determining blender malfunction READ THIS MANUAL carefully to learn how to service the Tri Blender Failure to do so could result in personal injury or equipment damage SAFETY IMPORTANT SAFETY INFORMATION INTRODUCTION DESCRIPTION BASIC OPERATION INSTALLATION INSTALLATION GUIDELINES PIPING HINTS MAINTENANCE CLEANING DISASSEMBLY REASSEMBLY SETTING THE DRIVE COLLAR AND SEAL REPLACEMENT TROUBLESHOOTING TROUBLESHOOTING GUIDELINES PARTS LIST MODEL DS3218 EXPLODED VIEW SAFETY IMPORTANT SAFETY INFORMATION Safety is very important DO NOT attempt to modify any Tri Clover product To do so could create unsafe conditions and void all warranties DO NOT place any Tri Clover product in an application where general product service ratings are exceeded The following DANGER WARNING AND CAUTION signs and their meanings are used within these instructions A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury The word Danger is used in the most extreme cases A WARNING Indicates a potentially hazardous situation which if not avoide2. Loosen the mounting bolts 43 securing the drive motor 50 to the base 39 The bolt holes are elongated to permit belt adjustment Slide the motor 50 toward the blender and remove the drive belts 45 Remove the bolts 44b securing the blender pulley 44c Use the same bolts as a forcing screw and thread it into the forcing holes finger tight With a suitable wrench turn the bolt 44b until the pulley 44c releases from the bushing 44a Remove the forcing screw and remove the pulley Slide tapered bushing 44a from the shaft 31 Loosen the set screws 53 securing the collar 30 to the shaft 31 and remove the deflector collar Loosen the six capscrews 43 securing the adapter ring spacers 37 Hold the adapter ring 23 to prevent it from falling Remove the capscrews and remove the adapter and spacers Set the blender down on its legs 41 Remove the four capscrews 36 and lockwashers 36a securing the bearing housing 34 to the base 39 Grasp the bearing housing 34 firmly in both hands and lift it out of the blender base 39 10 Remove the retaining ring 38 and press the shaft 81 out of the housing 34 Using a suitable puller remove the bearing 33 from the shaft and remove the other bearing from the housing 11 Inspect the shaft 81 sealing surface for nicks or scratches Inspect all components for cracks and distortion Inspect the adjusting legs for worn threads and insp
3. MAINTENANCE 12 Tip the base on its side 39 and install the motor 50 Tighten the bolts enough so that they contact the bottom of the base You ll use the bolts later to adjust the belt tension 13 Install the blender pulley key 44d pulley 44b and bushing 44c and tighten the bolts 44a Place the pulley in position using the correct mounting holes for the bolts securing the pulley LA 8 Deflection 1 64 per inch 6 of span For 19 span deflection is 5 16 7 9mm N Z _ 6mm JI 46b III N e US YV L N Length lt Span Len 19 482 44b 14 Install the motor pulley key 46d pulley 46b and bushing 46c and tighten the bolts 46a Make sure that both pulleys are horizontally aligned Draw the pulley tight with the mounting bolts by alternately tightening each bolt a small amount until all three bolts are tight 15 Place the drive belt 45 on the motor pulley 46b and the blender pulley 44b lt may be necessary to move the motor toward the blender to place the belts on the pulleys Tighten the belts by moving the drive motor away from the blender housing until there is a deflection of 16 7 9 mm using 5 to 7 pounds of force on the belt Tighten the motor bolts 16 Turn the blender upright 17 Assemble the seal Refer to Setting the Drive Collar and Seal Replacement section all motors at this point Then return to Step 1
4. s sole and exclusive remedy and Tri Clover Inc s maximum liability for claims arising hereunder or for negligence for any and all losses and damages resulting from any cause shall be either the repair or replacement of defective items or at Tri Clover Inc s option the refund of the purchase price for such items In no event including in the case of a claim for negligence shall Tri Clover be liable for incidental or consequential damages including loss of profits No person including any representative employee or agent of Tri Clover is authorized to assume on behalf of Tri Clover Inc any liability or responsibility in addition to or different from that described inthis provision Any and all representations promises warranties orstatements that are in addition to or different from the terms of this provision are of no force or effect Distribution Centers in Union City California and St Charles Missouri Export Division PHONE 1 314 447 1555 FAX 1 314 447 1447 Tri Clover Mexico Recursos Petroleros No 7 Fracc Ind La Loma 54060 Tlalnepantla Edo de Mexico PHONE 52 5 397 0601 FAX 52 5 362 3246 e Alfa Laval TB DS SM 97 2 5M Printed in Nov 1997
5. This section provides a means of determining and correcting most of your Tri Blender problems The motor manufacturer should be contacted for specific repair instructions on the motor TROUBLESHOOTING The chart below has been prepared on the basis that the Tri Blender as installed is properly suited to its application Should problems arise where the remedies listed below chart do not cure the situation impeller cavitation may be the problem Symptoms of cavitation such as noisy operation insufficient discharge and vibration can result when the auxiliary pump or suction tube are not properly applied If these conditions are present check the system and reevaluate the application If assistance is required contact Tri Clover 1 2 PROBLEM No suction Insufficient discharge PROBABLE CAUSE Wrong supply pump or need of discharge pump Leak on the suction side of the supply pump or blender Carbon seal is worn Wrong direction of rotation Inlet port on wrong side Splashing in the suction throat of the Tri Blender High viscosity High temperature High viscosity with screen in casing No liquids Product too viscous or discharge head too great 16 REMEDY Verify that pumps are sized correctly to suit application Contact Tri Clover if you require assistance Tighten all clamps fittings replace worn out gaskets Replace carbon seal on blender and or supply pump Reve
6. port or inlet is pointed upward The inlet piping consists of a patented tube within a tube arrangement Hopper This serves to keep the liquid and dry ingredients separated until they are in the mixing chamber The tube within a tube arrangement eliminates prewetting one of the major problems of wet dry mixing Suction and Our patented U S Patent 4 850 704 dual stage Tri TA EE Blender incorporates the proven design characteristics 3 Liquid Inlet of our popular Single Stage Tri Blender but takes the concept a step further for even more efficiency The Dual Stage concept provides for double blending The product passes through the initial liquid dry ingredient blending chamber directly below to a secondary chamber which effectively acts as a discharge pump Due to its close proximity the dual or second chamber concept actually increases rather than decreases vacuum The vacuum from the suction of the second pumping stage is added to that of the first stage greatly improving product addition rates The double blend feature improves end product consistency providing a smoother more uniform blend With the Dual Stage in applications up to 500 CPS and up to 50 feet 15m of discharge head no discharge pump is required This is a significant improvement over the Single Stage units which normally require an auxiliary discharge pump at 25 feet 7 5m of discharge head and above On some applica
7. Inc at its Kenosha Wisconsin or Distribution Center offices only No assignment of the purchaser s rights may be made without consent of Tri Clover Inc Each Tri Clover item is warranted to be free from manufactur ing defects for a period of one 1 year from the date of shipment providing it has been used as recommended and in accordance with recognized piping practice and providing ithas not been worn out due to severe service such as encountered under extremely corro sive or abrasive conditions This warranty is expressly in lieu of any other warranties express or implied including but not limited to any implied warranty of merchantability or fitness for a particular pur pose All claims must be in writing and must be mailed or delivered by purchaser within thirty 30 days after purchaser learns of the facts upon which such claim is based Any claim not made in writing Tri Clover Inc Food amp Dalry Division Blo Pharm Division 9201 Wilmot Road PHONE 1 800 511 5444 Kenosha Wisconsin 53141 1413 FAX 414 694 2454 PHONE 1 800 242 4000 FAX 414 694 7104 Distribution Centers Tri Clover Canada St Charles MO 101 Milner Avenue PHONE 1 800 238 0142 Scarborough Ontario M1S4S6 Union City CA PHONE 416 297 3400 PHONE 1 800 852 3178 FAX 416 299 5095 E mail address TCWEBMASTER alfalaval com Visit our web site at www tri clover com and within the time period specified above shall be deemed waived Purchaser
8. on nameplate 3 Description and part key number from the parts list The exploded views and accompanying parts list facilitate ordering repair parts from the factory All parts of the Tri Blender are exploded and keyed to the parts list Key o ZA c Q n Description 40 hopper 60 hopper Clamp Gasket Manual Butterfly Valve Difuser amp Suction Tube Clamp Gasket Inlet Adapter Upper Casing Lower Casing Impeller Screen Screw upper impeller 0 Ring upper impeller Upper Impeller Lower Impeller O Ring casing Backplate Clamp Casing Adapter Ring Carbon Seal O Ring Cup Spring Deflector Drive Shaft Bearings Bearing Housing Part Number D3218 55 40 01 D3218 55 60 01 13MHHM 2 S 40MP U 2 B51A 4 E S F3218 05 316 13MHHM 4 S 40MP U 4 F3218 217 316 DS3218 1B 01 316L DS3218 1A 316L DS3218 215 316 DS3218 26 316L 17 15 U DS3218 2B 02 316 DS3218 2A 02 316 17 327 U DS3218 11 316 DS3218 75 S DS3218 71 1 S 328E 80 1A Mat l 328 80 2 U 328D 80 3P 328D 80 4 F3218 40E S DS3218 06 316L D3218 18 F4329 99 S Qty 1 1 2 2 1 1 2 2 1 1 1 2 1 1 1 1 2 1 1 1 1 3 1 1 1 1 3 1 Key No 35 36 36a 37 38 39 40 41 42 43 44 44 44d 45 46 46 49 51 52 53 54 54a 66 66a 67 67a 68 69 18 Description Seal Gaurd Screw Bearing Housing Lockwasher Bearing Housing Spacer Retaining Ring Base Plate O Ring Adjustable Leg A
9. 7 18 Slide the lower impeller 15b with the o ring onto the shaft 31 and down into the lower casing 11b 19 Slide the shaft sleeve 54 with two o rings 54a onto the shaft 31 54a o 12 MAINTENANCE Install the upper impeller 15a onto the shaft 31 with the impeller nut 13 and o ring 14 Loosen all spacer bolts 43 to set the clearance between the lower casing and the lower impeller Select three alternating adapter ring spacers 37 to adjust for a 015 to 020 inch clearance between the lower casing and the lower impeller Adjust the spacers to obtain a level adjustment Tighten the three spacers using the base plate screws 43 to secure the setting Recheck the clearance to ensure proper adjustment Adjust the three remaining spacers 37 to take up the gap between the end of the spacer and the base plate Also takes up slack in the threads of the first 3 spacers to prevent casing movement due to thread clearances Tighten the three remaining screws 48 of the spacer to the base plate connections Remove the upper impeller 15a CO Place the lower screen 12 inside the lower casing 11b with the pin on the screen facing upward and lined up with the step in the lower casing Install the diffuser plate 51 on the lower casing 11b ensuring that the pin in the plate fits in the notch in the lower casing The pin in the lower screen must also fit inside the notch on the diff
10. asing o ring 16 Remove the upper screen 12 Using a suitable wrench remove the nut 13 securing the upper impeller 15a to the stub shaft Remove the impeller nut o ring 14 upper impeller 15a and backplate 17 Remove the diffuser plate 51 and lower o ring 16 Remove the shaft sleeve 54 and o rings 54a Remove the lower impeller 15b and lower screen 12 Remove the o ring 26 from the lower impeller 15b Loosen the three casing bolts and lift the lower casing 11b off of the adapter ring Remove four screws 66 securing the seal gland 67 to the lower casing 11b Inspect all parts of the seal for damage or wear and replace as required For the DG seal use caution when handling the casing to avoid damage to the surfaces around the opening for the carbon seal Remove the carbon seal 25 o ring seal 26 cup 27 spring 28 and drive collar 52 from the stub shaft To remove the drive collar loosen the setscrews 53 and lift the drive collar off of the shaft If you need to disassemble the stub shaft and motor refer to Stub Shaft and Motor Removal following this section MAINTENANCE STUB SHAFT AND MOTOR REMOVAL Note When removing drive components it is necessary to tip the entire blender and base on its side with the motor end toward the floor Remove the hopper valve tubing casing impeller seal guard and seal components before tipping to make the unit easier to lift
11. d may result in minor or moderate injury May also be used to alert against an unsafe operating or maintenance practice A CAUTION Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Safety labels are placed on every Tri Blender Do not remove any labeling on any Tri Clover product Immediately replace any label that is missing AWARNING ROTATING SHAFT DO NOT OPERATE WITHOUT GUARD IN PLACE Part Number 38 241 INTRODUCTION DESCRIPTION The Dual Stage Tri Blender consists of two basic sections the dry material section and the liquid material section The Dual Stage Tri Blender is mounted on a base plate It is mounted adjacent to the drive motor and is driven by belts running between pulleys under the base plate The manually controlled Butterfly valve is standard equipment On this model the connection ends the diffuser and the suction tube the inlet adapter the casing screens washer the impellers and backplate are made of 316 stainless steel The hopper is made of 304 stainless steel All of the tubes are fastened with quick couple Tri Clamps for easy care and fast access The four legs supporting the Tri Blender are adjustable for easy leveling of the blender during installation BASIC OPERATION The Tri Blender basically consists of a centrifugal pump head and impeller mounted so that the normal suction
12. djustable Leg Washer Spacer amp Motor Screw Spacer amp Motor Blender Pulley 50 Cycle Blender Pulley 60 Cycle Blender Pulley Key V Belt Motor Pulley 50 Cycle Motor Pulley 60 Cycle Washer Motor Diffuser Plate Drive Collar Setscrew Shaft Sleeve O Ring Shaft Sleeve Bolt Gland Ring Lockwasher Gland Ring Gland Ring DG Seal Stainless Steel Seat PTFE Gasket Seal Seat Part Number F3218D 131 S C1510H SS LWA1500 SS Qty DS3218 71A 316L DS3218 177 DS3218 23 S 01 1154 13 34 U R3 1 23 03 S LWA1700 SS SC1712H SS DS3218 106 5 3V5 0x1 500 DS3218 106 5 3V6 0x1500 D3218 46 D3218 3VX600 DS3218 108 5 3V8 0x1 875 DS3218 108 5 3V8 0x1 875 WA1700 SS DS3218 5 316L SP328D 23P S SC1105A SS DS3218 14 316L 17 51 U SC1310H SS LWA1300 SS SP328G 17 316L DS3218 17 316L SP328G 80 1 2 G SP328G 80 1 1 Mat EXPLODED VIEW YBOS 9281S ss lulels jqe vejd y g 2 E 99 2 19 Tri Clover manufactures a complete line of TRI WELD fittings TRI CLAMP fittings BEVEL SEAT fittings POSITIVE PUMPS CENTRIFUGAL PUMPS AUTOMATIC Air Actuated VALVES STAINLESS STEEL TUBING AUTOMATED FLOW CONTROL SYSTEMS Terms Warranty Provisions Notice of Claims and Limitation of Liability Prices and all terms and conditions of sale are established in current price sheets and are subject to change without notice All orders are subject to acceptance by Tri Clover
13. ect all o rings for damage 12 Replace any worn or damaged components IMPORTANT _ The three bearings in the bearing housing are sealed and lifetime lubricated If either of the bearings are worn or damaged make certain they are replaced with exactly the same type of bearings and replaced as a set 10 MAINTENANCE REASSEMBLY Install the o ring 26 in the deflector collar 30 Install two bearings 33 on the shaft 31 from the bottom until they rests against the shoulder Install the shaft into the bearing housing 34 Install the other bearing 33 on the shaft 31 through the bottom of the housing 34 Install the retaining ring 88 on the bottom of the shaft 31 Install the bearing housing 34 on top of the base 89 and tighten the bolts Install the deflector 30 on top of the bearing housing 34 Screw the six spacers 37 into the adapter ring 23 and bolt the spacers onto the baseplate 39 9 Install the DG insert into the gland ring with gaskets 68 Note If you are using a stainless steel replaceable seat you won t have an insert and you ll only use one gasket between the lower casing and the seat 10 Install the lower casing 11b over the shaft 31 and onto the adapter ring Use the three casing bolts 11c shown above to secure the casing to the adapter ring 11 Alternately tighten the spacer bolts 37 to center the shaft 31 in the lower casing 11b 11
14. inch 0 8mm and secure the drive collar in this location with the set screws Remove the impeller screw and the upper impeller Insert the lower impeller screen with the pin up to align with the hole in the diffuser Install the diffuser with an o ring in the lower casing Install the backplate onto the diffuser Insert the upper impeller screen so the pin faces down and when rotated clockwise rests against one of the 4 tabs of the backplate Attach the upper impeller to the shaft with the impeller screw and o ring Attach the upper casing and o ring with the large Tri Clamp to the lower casing while aligning the backplate tabs with the upper casing grooves Assemble the remaining tubes and seals securing each section with the proper size clamps With the blender assembled and casing clamp tightened if the drive collar is properly positioned and the seal components are properly installed the blender shaft should rotate freely by hand If excessive effort is required to rotate the shaft check to be sure that all components are properly installed and the drive collar is properly positioned 12 Assemble seal guard and tighten nut After above setting instructions have been followed return to the Reassembly section for final steps 15 TROUBLESHOOTING GUIDELINES Tri Blenders are relatively maintenance free with the exception of sanitizing and inspection Like any piece of machinery however occasional problems can arise
15. n and damage to equipment Whenever practical the diameter of the piping at the inlet should be increased in size An eccentric tapered reducer should be used in lieu of a concentric tapered reducer to help direct the flow into the offset tee to minimize turbulence O lt inlet gt outlet MAINTENANCE CLEANING C I P CLEANING The Dual Stage Tri Blender can be cleaned in place If the Tri Blender is to be cleaned the butterfly valve must be removed and cleaned separately Refer to separate valve service manual In addition the dry ingredients inlet adapter tube must be capped off DISASSEMBLY GENERAL The Tri Blender is relatively maintenance free requiring normal cleaning and inspection to ensure optimum performance Inspect all seals for cuts or abrasions and inspect seal faces for nicks and cracks Replace worn or damaged parts as necessary REPAIR INFORMATION Repair of the Tri Blender is normally accomplished by replacing defective parts The only moving parts are the control valve the impellers the drive shaft the seal the belt and the motor armature shaft It is recommended that all parts of the Tri Blender be periodically inspected to prevent malfunctions caused by worn or broken parts For repair or replacement of the drive motor refer to the motor manufacturer For repair and service of the Butterfly valve on your blender refer to B Series Butte
16. rfly Valve Service and Installation Manual B51SM available from Tri Clover Refer to the parts list for replacement data for the Tri Blender parts TRI BLENDER DISASSEMBLY e ADANGER Remove power before servicing to prevent unintended start of the blender a A WARNING im Relieve pressure and 5 remove all fluid from blender prior to disassembly 3 O 4 1 Remove the clamp 3 securing the hopper 1 to the blender and remove the ff j h ket 4 opper and gasket 4 S 2 Remove the clamp 3 securing the control valve 5 and remove the valve and lt 2 9 gasket 4 Hold the valve while loosening the clamp to prevent the valve from Do 10 falling 8 3 Remove the clamp 8 securing the diffuser and suction tube 7 and remove the lt 9 diffuser and suction tube and gasket 9 4 Remove the clamp 8 securing the inlet adapter 10 and remove the inlet adapter and gasket 9 MAINTENANCE 5 Remove the clamp 22 securing the upper casing 11a to the lower casing 11b Grasp the upper casing firmly in both hands and pull the casing straight up and off of the lower casing IMPORTANT Do not use a tool to pry the casings apart Any object inserted between the casing and gasket could cause damage to the gasket and casing sealing surface resulting in leakage after reassembly Remove and inspect the c
17. rse a three phase motor by switching any of the three power leads at the motor or controller on blender or supply pump Remove inlet adapter housing and relocate so it is correctly positioned as shown on the exploded view pages High Flow oversized supply pump see 1a above see 1e above See 3b Reduce temperature below 140 F 60 C Remove screen Check supply pump Add discharge pump PROBLEM Excessive power consumption Tri Blender is noisy Excessive vibration Tri Blender leaks PROBABLE CAUSE High viscosity with screen in head Magnetic hum in motor Motor bearings are worn Tri Blender bearings are worn Foreign matter is rotating with impeller Blender is not leveled properly Impeller is damaged Foreign matter in casing Seal failure Casing gasket worn or damaged 17 TROUBLESHOOTING REMEDY Remove screen Install discharge pump on discharge end of the Tri Blender Consult motor manufacturer Consult motor manufacturer Replace bearings Remove casing and remove foreign matter inspect for damage Check supply flow to blender Level blender Replace impeller Remove casing and remove foreign matter inspect for damage Replace seal Replace gasket PARTS LIST MODEL DS3218 All orders for repair parts must contain the following data 1 Complete model number located on nameplate 2 Tri Blender serial number located
18. tions with higher CPS a discharge pump may be necessary By incorporating the discharge pump function into the blender itself you can achieve e significantly higher vacuum rates over a wider range of process conditions The increased vacuum provides for fast consistent product flow rates with no drop off through your entire production run INSTALLATION INSTALLATION GUIDELINES UNPACKING EQUIPMENT When unpacking your equipment inspect all of the contents for damage that may have occurred during shipping Report any damage to the carrier LOCATION AND INSTALLATION The Tri Blender unit should be located within 3 feet of the liquid source for best performance and ina position where the supply piping can be short and direct with a minimum number of elbows and fittings The liquid to the blender must be supplied by an auxiliary source It should also be readily accessible for cleaning and inspection The Tri Blender unit is ready to install as received from the factory A minimum space of 32 x 47 81cm x 119cm is required Install the adjustable legs in the base of the unit and position the blender in the area it will be used Turn the adjusting leg with a wrench and individually adjust the legs until the unit is level Attach the supply and discharge piping Be sure that both the inlet and outlet tubes are correctly positioned and that supply and discharge piping are properly supported to avoid strain on the blender casing The
19. tube OD of the inlet and outlet connections of the blender casing are Liquid Inlet Liquid Outlet Powder Inlet 1 38 1mm 2 50 8mm 3 76 2mm IMPORTANT If your blender is equipped with the electrically controlled Butterfly valve be sure the valve is wired to an auxiliary 110V power source The axillary wiring will let the Butterfly operate independently from the blender motor and will allow the valve to be closed if the drive motor stops running If the auxiliary 110V power source also fails the Butterfly valve is equipped with a manual override to close or open the valve by applying a suitable size wrench to the flats on the coupling adapter INSTALLATION PIPING HINTS GENERAL This section provides some hints on piping installation which will aid in obtaining maximum efficiency and service from your Tri Blender Piping should be independently supported at both the inlet and discharge outlet Care should be taken that piping is properly aligned and does not put any strain on the Tri Blender casing The piping should have minimum line restriction INLET PIPING The inlet piping should be short and follow a direct route with a minimum number of elbows and fittings Elbows should not be used at the inlet as friction would be greatly increased resulting in head loss Excessive friction losses in the inlet line could cause cavitation in the blender casing causing poor performance noise vibratio
20. user plate Install the back plate 17 12a s o 14 28 Install the upper impeller 15a onto the shaft with the impeller nut 13 and o ring 14 29 Install the upper screen 12 with the pin down Rotate the screen counterclockwise until it rests against one of the tabs on the back plate 17 13 MAINTENANCE 30 Install the upper casing with o ring ensuring that the pins on the upper casing fit into the notches on the lower casing and install and tighten the clamp 31 Install the seal guard 36 32 Install the inlet adapter 10 on the casing 11 securing it with a clamp IMPORTANT Be sure to position the adapter 10 correctly The adapter inlet should be opposite the casing outlet 11 See figure at right 33 Install the diffuser and suction tube 7 and gasket in the adapter 10 and secure it with a clamp 34 Install the butterfly valve 5 and gasket and secure it with a clamp 3 35 Install the hopper 1 and gasket 4 and secure it with a clamp 3 14 MAINTENANCE SETTING THE DRIVE COLLAR AND SEAL REPLACEMENT Complete these steps before returning to final reassembly steps in preceding section 1 Slide the drive collar and seal assembly toward the seal seat until the nose of the drive collar pushes the o ring and carbon seal tight against the seal seat 3 32 2 5mm Slide the drive collar away from the seal seat 1 32
Download Pdf Manuals
Related Search