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SERVICE MANUAL

1. 20 0152 HL300 AND HL400 LEGACY MIXERS TRANSMISSION ATTACHMENT 14 Remove worm gear shaft 17 Remove planetary seal and ring NOTE Retain key from worm gear shaft for use during transmission assembly WORM GEAR EN SHAFT LOADING SPRING Page 21 of 52 25250 August 2007 HL300 AND HL400 LEGACY MIXERS TRANSMISSION ATTACHMENT 20 Remove cap screws 21 Remove attachment hub ATTACHMENT HUB ASSEMBLY AND INSTALLATION NOTE Ensure all parts are clean before assembly Remove old grease from parts being reused 1 Clean sealant from flat and rounded surfaces of attachment hub and transmission case 2 Coat surface of attachment hub casting with gasket sealer Permatex 2 before reassembly 3 Install attachment hub to transmission case NOTE Be certain to install hub with opening towards bottom F25250 August 2007 TOWARDS BOTTOM 4 Install washer and gear drive attachment Drive Attachment w 5 Install spring loading washer SPRING LOADING WASHER 6 Install ball bearing and worm shaft Page 22 of 52 HL300 AND HL400 LEGACY MIXERS TRANSMISSION ATTACHMENT NOTE Be certain to install key onto worm shaft WORM SHAFT 10 Install input shaft spacer on worm gear shaft INPUT SHAFT P
2. cp e D J2 6 LATCHING _ 4PBSTART 5 as 9 D BOWL GUARD Q J1 12 RUN D CONTACTS ATCHING CONTACTS C J1 13 TIMER BOARD 2LS BOWL o HL300 LEGACY MIXER RECIPE TIMER BOARD 100 120 50 60 1 200 240 50 60 1 200 240 50 60 3 380 460 50 60 3 2046 41 of 52 25250 August 2007 HL300 AND HL400 LEGACY MIXERS ELECTRICAL OPERATION HL400 Mixer Standard Timer Board L1 277 12 Le x z 13 ONLY USED THREE GROUND PHASE VOLTAGES MOTOR DRIVE 1CR 8 6 T1 BLUE 9 9 T 5 NOTES 4 2 T2 BROWN IMTIR AK 1 CONTACTS 30B C OPEN FOR 1 SEC 230 60 3 1 WHEN TIME EXPIRES T3 ORANGE IF ALARM OCCURS CONTACTS 30B C OPEN UNTIL FAULT IS CLEARED 2 K1 RUN CONTACTS PROIVDE MIXER 1 RUN SIGNAL TO FWD TERMINAL 2 0VDC 3 M TIMER READY OUTPUT SPEED SELECTOR SWITCH TIME ADJUSTMENT POTENTIOMETER 1PB START 2PB STOP CN4 1 1LS gt BOWL GUARD Q 5 4 RUN CONTACTS q CN2 10 q CN2 11 COCN2 14 215 BOWL 400 LEGACY MIXER STANDARD TIMER BOARD 200 230 50 60 1 200 230 50 60 3 400 460 50 60 3 F25250 August 2007 42 of 52 HL300 AND HL400 LEGACY MIXERS ELECTRICAL OPERATION HL400 Mixer Recipe Timer Board L1 277 12
3. k S ERU 13 ONLY USED THREE GROUND PHASE VOLTAGES MOTOR DRIVE 1CR 8 6 T1 BLUE 9 2 T 5 NOTES 4 2 T2 BROWN 1MTR HA 1 CONTACTS 30B C OPEN FOR 1 SEC 230 60 3 1 WHEN TIME EXPIRES T3 ORANGE IF ALARM OCCURS CONTACTS 30B C OPEN UNTIL FAULT IS CLEARED 2 RUN CONTACTS PROIVDE MIXER 1 RUN SIGNAL FWD TERMINAL x2 0VDC x3 CM TIMER READY OUTPUT SPEED SELECTOR SWITCH A N24 STEPS TIME ADJUSTMENT POTENTIOMETER CN4 1 115 BOWL GUARD O CN2 10 h CN4 2 CN2 11 LATCHING CONTACTS CONTACTS TIMER BOARD V OCN2 14 2LS BOWL 6 O HL400 LEGACY MIXER RECIPE TIMER BOARD 200 230 50 60 1 200 230 50 60 3 400 460 50 60 3 43 of 52 J F25250 August 2007 HL300 AND HL400 LEGACY MIXERS ELECTRICAL OPERATION WIRING DIAGRAMS HL300 Mixer AINO SAIL 341234 NO 351 S A3U 99676 41 SOl1VLI NI S138V1 ONY S108 AS wou 9NIMIM d31NINd 30 S310N30 3NI1 30 9NISIM 1109319 1 ONIYIMAYd 03X14 5 3NIT 1H911 1VN331X3 S310N3Q 3NI T1 AAV3H NOI193NNOO 318 435 NOI103NNOO 318V3SVd3SNI 1102 AV13M TOMINOO LYVLS NOLING A C O N dOLS NOLLNG O N HOLIMS LINII S1 EE ET SA3M WYYIOUd 1235 A
4. 32 Removal and Replacement 11 Speed Select Switch Test 11 12 Timer Boafd Gane al dean ED 2 9 Component Function 32 Timer Options eu ena hA ES a Fa pez 3 Timer Options 3 Rune de 62 5 Transmission Attachment Hub 19 Assembly and Installation 22 Bevel Gears Meshing Adjustment 25 Removal and Disassembly 19 Transmission Case 26 Troubleshooting 46 Alarm Codes 49 General Al Models 47 Quick Reference Flow Chart 46 VWXYZ Wiring Diagrams 44 Printed in U S A
5. H L3 ONLY USED ON THREE GROUND PHASE VOLTAGES MOTOR DRIVE 1CR NOTES 4 1 CONTACTS 30B C OPEN FOR 1 SEC WHEN TIME EXPIRES IF ALARM OCCURS CONTACTS 30B C OPEN UNTIL FAULT IS CLEARED 2 1K RUN CONTACTS PROIVDE MIXER RUN SIGNAL TO FWD TERMINAL 1MTR 230 60 3 0VDC 24VDC TIMER READY OUTPUT VARIABLE COM SPEED nz 5 SELECTOR 2 A T SWITCH 10 g 12 1 TIME ADJUSTMENT 2 POTENTIOMETER TIME DISPLAY 1PB E START 42 6 J3 4 D 1LS BOWL GUARD J3 2 LATCHING CONTACTS 1K RUN CONTACTS TIMER BOARD 441 15 41 16 1 215 BOWL HL300 LEGACY MIXER STANDARD TIMER BOARD 100 120 50 60 1 200 240 50 60 1 200 240 50 60 3 380 460 50 60 3 F25250 August 2007 40 of 52 HL300 AND HL400 LEGACY MIXERS ELECTRICAL OPERATION 300 Mixer Recipe Timer Board L1 L2 _ L L30NLYUSEDON GROUND THREE PHASE VOLTAGES MOTOR DRIVE NOTES 1MTR 1 CONTACTS 30B C OPEN FOR 1 SEC 9 230160 3 WHEN TIME EXPIRES IF ALARM OCCURS CONTACTS 30B C OPEN UNTIL FAULT IS CLEARED 2 1K RUN CONTACTS PROIVDE MIXER RUN SIGNAL TO FWD TERMINAL 0VDC TIMER READY OUTPUT SPEED SELECTOR SWITCH eje 55 2 9 TIME ADJUSTMENT POTENTIOMETER 12 1
6. FRONT VIEW RECIPE TIMER BOARD F25250 August 2007 Page 36 of 52 HL300 AND HL400 LEGACY MIXERS ELECTRICAL OPERATION TIMER BOARD LAYOUT HL400 CN2 WIRING HARNESS CONNECTOR CN6 SPEED SELECTOR SWITCH CONNECTOR OPENING FOR SPEED CN4 BOWL SWITCH CONNECTOR RECIPE SELECTOR SWITCH 2 BUZZER STO SEGI SEGI SEG2 _ P SEG4 T 8 BBBIB _ LED DISPLAY OPENING FOR SPEED SELECTOR SWITCH FRONT VIEW TIMER BOARD OS Big Zs oN S oN gH 5 SEG6 B 1 B 5 ig SPEED BH OPENING FOR SPEED RECIPE SELECTOR SWITCH FRONT VIEW RECIPE TIMER BOARD Page 37 052 F25250 August 2007 HL300 AND HL400 LEGACY MIXERS ELECTRICAL OPERATION SEQUENCE OF OPERATION HL300 Mixer Standard Timer Board Refer to wiring diagram 12036 for the electrical sequence of operation NOTE The position of the time knob selects timer mode countdown or count up Set mix time between 00 10 seconds and 15 00 minutes press 1PB start switch and timer counts down to zero then stops Rotate the time knob CCW until timer displays Hold 7 and 5 count up mode Press start switch and the timer counts up continuously until 2PB stop switch is pressed 1 Conditions A Mixer connected to correct supply voltage and is properly grounded 1 Motor drive energized and self check performed 2 Motor drive passes self che
7. Display must be blank before reapplying power F25250 August 2007 Page 46 of 52 HL300 HL400 LEGACY MIXERS TROUBLESHOOTING NOTE If ALARM code is displayed board refer to ALARM CODES for complete description GENERAL ALL MODELS SYMPTOM POSSIBLE CAUSE Mixer will not run no timer board display Mixer will not run timer board display on Mixer will not run but timer board counts up down when start button is pushed Mixer runs but stops when 1PB start switch is released Mixer runs continuously but will stop when 2PB stop Switch is held IN or bowl guard is opened or bowl is lowered Mixer motor hums and does not run Mixer shuts off during operation Page 47 of 52 No voltage to machine Timer board malfunction Wiring harness connections loose or malfunction Motor drive malfunction 1LS bowl guard switch open or malfunction Verify magnet in place on bowl guard and bowl guard Switch operation 2LS bowl switch open or malfunction Verify magnet in place on bowl rear and bowl switch operation Timer board malfunction 1K run contacts are open no input signal to motor drive FWD terminal 1PB start switch or 2PB stop switch malfunction 1CR control relay malfunction Motor drive malfunction timer ready contacts 30 B C are open Motor malfunction Wiring harness connections loose or malfunction 1CR control relay malfunction
8. HOBART SERVICE MANUAL Legacy HL300 ML 134351 HL300C ML 134358 HL400 ML 134348 HL400C ML 134359 NOTICE This Manual is prepared for the use of trained Hobart Service Technicians and should not be used by those not properly qualified If you have attended a Hobart Service School for this product you may be qualified to perform all the procedures described in this manual This manual is not intended to be all encompassing If you have not attended a Hobart Service School for this product you should read in its entirety the repair procedure you wish to perform to determine if you have the necessary tools instruments and skills required to perform the procedure Procedures for which you do not have the necessary tools instruments and skills should be performed by a trained Hobart Service Technician Reproduction or other use of this Manual without the express written consent of Hobart is prohibited A product of HOBART Troy Ohio 45374 F25250 August 2007 HL300 AND HL400 LEGACY MIXERS TABLE OF CONTENTS GENERAL he qe tere e de e Introd ctiom e Souza yu o Este d wA pod da a Reference Material wed e det VAL Sa a wA qd eed d ede ew wg wo Timer se nts alli cie ive ka ie uei LLL Specifications Re SA tie Qa
9. GHI 3 Introduction 3 JKL 2 3 kept e 5 MNO siu eed datus die s 15 Component Function 32 Motor Current 16 Motor Winding Resistance 16 Removal and Replacement 15 Motor Drive 13 Bus Voltage Bleed down 13 Bus Voltage Test 14 Component Function 32 Internal Resistance Test 14 Motor Drive 34 Motor Drive Torque Values 5 Removal and Replacement 13 F25250 August 2007 PQR Pedestal ee eu ENS 27 ls i ew RERUM Re 17 Assembly and Installation 18 Internal Gear 18 Removal and Disassembly 17 Reference Material 3 STU Schematic Diagrams 40 Sequence of Operation 38 Specifications 4 Bowl Size 4 Electrical Data 4 Motor Drive Torque 5 Operating Speeds and RPM 4 Torque Values 5 Speed Selector Switch 11 Component Function
10. PLANETARY WORM WHEEL SHAFT NUT AND WASHER PLANETARY SHAFT LOCKNUT 6 Remove planetary upper bearing retainer Remove worm wheel upper bearing retainer REMOVE SCREWS 4 REMOVE SCREWS 4 worm WHEEL UPPER BEARING RETAINER PLANETARY UPPER BEARING RETAINER Page 19 of 52 7 Remove screws from transmission cover REMOVE SCREWS REMOVE SCREWS 8 Toremove transmission cover use fully threaded hardened if possible bolts 2 as jack screws Turn each bolt 1 2 revolutions and alternate until transmission cover separates from case THREAD BOLTS INTO HOLES AND USE AS JACK SCREWS 9 Remove upper planetary spacer and input shaft spacer F25250 August 2007 HL300 AND HL400 LEGACY MIXERS TRANSMISSION ATTACHMENT 10 Remove bevel gear and worm gear INPUT SHAFT NOTE In order to remove remaining parts from transmission and attachment hub it will be necessary to slide motor shaft out of the way MOTOR SHAFT C 11 Drive planetary shaft from transmission case and remove NOTE Use a block of wood or a soft face special hammer when removing planetary shaft F25250 August 2007 REMOVE PLANETARY SHAFT NOTE Retain key from planetary shaft for use during transmission assembly 12 Remove bevel pinion from attachment hub ATTACHMENT HUB BEVEL PINION a 4
11. 465 in Ibs MOTOR DRIVE TORQUE VALUES Location pee Main Circuit Screws mar L1 L L2 N GND U amp W Control Circuit Screws M2 Y1 PLC X1 X2 X3 11 12 13 FWD amp CM Control Circuit Screws 4 3 5 in lb LUBRICATION Mobilith Transmission Case AW 2 grease 40 oz Coat Chevron FM Planetary beater P 272 areas pinion Planetary Casting Void 1 8 in lb Chevron FM area between agitator 2 3 full shaft bearings 2 grease Chevron FM Internal Gear EP 2 grease Coat Pre Motor bearings lubricated Light coat Slideways mates surfaces Beater Shaft Bearings TT 5 of 52 TOOLS Standard Standard set of hand tools Digital Multi meter DMM with sensitivity of at least 20 000 ohms per volt Clamp on ammeter Special Permatex 2 Part No 508462 Used to seal cover to transmission case RTV 732 Dow clear silicone Part No 513886 or equivalent Used to secure bowl guard switch to switch holder RTV 732 Dow grey silicone Part 515194 or equivalent Used to fill seam between wrap and column Drive Bleeder Tool Part No 874561 wire wound resistor in PVC housing with probes Used to bleed down motor drive bus circuit voltage Field service grounding kit Part No TL 84919 2 0 long bolts 2 required full thread hardened preferred Used as jack
12. A Remove locknut from motor shaft then remove the worm gear assembly parts To Install A Install worm gear assembly parts onto motor shaft and secure with locknut GREASE DEFLECTOR LOCKNUT WASHER KEY WORM BUSHING WHEN LOCKNUT IS TIGHTENED 1 TO 2 SHAFT THREADS SHOULD BE VISIBLE B Coat worm gear with Mobilith AW 2 grease C Position motor with lead wires down and install motor to transmission case Tighten motor mounting screws in an alternating pattern to 24 30 in lb of torque D Turn motor shaft manually opposite drive end to ensure it rotates freely 6 Connect motor lead wires 7 Check for proper operation Page 15 of 52 V R F25250 August 2007 HL300 AND HL400 LEGACY MIXERS MOTOR MOTOR CURRENT NOTE Because of the nature of electronic motor drive technology variable switching frequencies accurate output voltage measurements from the motor drive to the motor cannot be made with a standard DMM or analog VOM NOTE Motor current draw is not the same as the line service current draw of the mixer For checking current draw of each phase of the motor use a clamp on ammeter 1 Press stop 2 Remove PEDESTAL COVER 3 Select the speed setting of Stir and press start 4 Measure current on each phase of the motor lead wires Use the motor wiring table to identify motor lead wires MOTOR WIRING Motor Lead Wires Motor Drive Marked Terminals U thru
13. Flow Chart 22 ber ebay dete Y Oe e gc General 5 eerie t t p aka srt dee dale dle bee ahaa abies Alarm CodeS 3 5 tovt pawa sire ino ds Lo HOBART 2007 F25250 August 2007 Page 2 of 52 HL300 AND HL400 LEGACY MIXERS GENERAL GENERAL INTRODUCTION TIMER OPTIONS The HL300 and HL400 mixers utilize a timer board with digital display for the operator interface and electronic motor drive to control the operation of the mixer The timer board allows the operator to select the SERED desired mix time and mix speed for the product The electronic motor drive stores the last selected mix time for each speed setting Continuous mixing with Uu count up timing is also available when the Hold Mode is selected SIART The HL300 and HL400 models are available with an optional programmable recipe timer board A mixer with the recipe timer board allows for the same operation but includes programing options for the operator to store and retrieve up to four recipes with five steps each for the HL300 and six recipes with six steps each for the HL400 The electronic motor drive provides high torque variable speed output from the motor to fixed ratio drive gears By utilizing the motor drive technology agitator speed is controlled electronically which permits changing mixing speeds anytime during mixer op
14. GEARS MESHING ADJUSTMENT 4 WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES NOTE For proper gear meshing the teeth between the bevel gear assembly attachment hub and the planetary shaft bevel gear should engage with a clearance of 005 to 020 and be aligned as shown below PLANETARY SHAFT BEVEL GEAR SPACER THRUST WASHER S PLANETARY SHAFT Ses BEVEL GEAR ASSEMBLY 10182 Page 25 of 52 1 2 Remove attachment hub plug To determine if clearance is within tolerance use bevel gear assembly movement as an indicator Push on the bevel gear assembly while checking for movement 005 to 020 If movement is out of tolerance then access the bevel gears as outlined under TRANSMISSION ATTACHMENT A Inspect bevel gear teeth for wear and bevel gear alignment 1 Ifthe gear teeth are excessively worn or damaged install replacement bevel gears and check clearance and alignment reassemble and check for proper operation 2 Ifthe gears are not worn or damaged continue with procedure To adjust clearance A Remove the bevel gear assembly and add or remove thrush washer s behind the spacer until clearance is within tolerance Reassemble as outlined under TRANSMISSION ATTACHMENT HUB F25250 August 2007 HL300 AND HL400 LEGACY MIXERS WRAP WRAP Removal Replacement 9 Fill seam between
15. MIXERS TROUBLESHOOTING ALARM CODES Fault Description Possible Causes Suggested Actions Output phase loss to motor OH1 Over heating at heat sink Protects motor drive OL1 Electronic thermal 012 overload relay tripped Protects motor F25250 August 2007 1 Lead wire or connection malfunction to motor Open circuit in motor windings Single phase motor installed or motor not wired for 3 phase 1CR control relay malfunction Motor drive malfunction no output voltage or output voltage phase lost Motor drive heat sink temperature above 194 F Motor drive malfunction Mixing in Stir speed Batch size too large Low supply voltage causing low motor torque Motor malfunction Motor drive malfunction Page 50 of 52 Check motor lead wire connections for tightness and continuity If connections are loose then tighten If a problem is found with the lead wires from motor drive to motor replace the malfunctioning component wiring harness or motor Check motor resistance Motor drive requires a 3 phase AC motor Verify this type of motor is installed and is wired for 3 phase Check for 24VDC at 1CR relay coil If voltage is present but 1CR contacts 6 8 or 2 4 are not closing replace 1CR control relay If 24VDC is not present check voltage at motor drive terminals 30C to PLC and verify 1LS bowl switch and 2LS bowl g
16. Wiring harness connections loose or malfunction Timer board malfunction Motor drive malfunction timer ready contacts 30 B C are open Motor malfunction Timer board malfunction 1K latching contacts not closing Timer board malfunction 1PB start switch momentary contacts not opening or 1K latching contacts not opening Supply voltage out of tolerance 1CR control relay malfunction Motor drive malfunction Motor malfunction Transmission malfunction Batch size too large See REFERENCE MATERIAL under GENERAL Supply voltage out of tolerance Batch size too large See REFERENCE MATERIAL under GENERAL Wiring incorrect from motor drive to motor Motor overheated or malfunction Motor drive overheated or malfunction Timer board malfunction 2LS bowl switch open or malfunction 1LS bowl guard switch open or malfunction F25250 August 2007 HL300 AND HL400 LEGACY MIXERS TROUBLESHOOTING GENERAL ALL MODELS SYMPTOM POSSIBLE CAUSE 1 Supply voltage out of tolerance 2 Batch size too large See REFERENCE MATERIAL under GENERAL 3 Wiring incorrect from motor drive to motor 4 Motor drive malfunction 5 Motor malfunction 6 Transmission malfunction 1 Wiring from motor drive to motor Mixer motor runs backwards 2 Motor drive malfunction 1 Motor malfunction 2 Transmission gears worn improperly meshing
17. oed atat uude Dodd s tes EVID CATIONS oleae ae MUS ACA HL Bk dU ar TOONS tas oct Meer COVERS aene uk eund gae dus apakah iu un suut dale be cate ate BOWL GUARD ASSEMBLY ees EI vae vu e gae fu a pk QR BOWL SWITCH 2 25 e tren ette re rice iet ct ec e ed TIMER BOARD quyta eed e ec SPEED SELECTOR SWITCH 1 4 quee atte as BOWL LIFT ASSEMBLY vi caia redet aaa ua ROPA Red RA os BOWL TO BEATER CLEARANCE ADJUSTMENT ELECTRICAL OPERATIGON REAL EA es Component Function Component Location 0 0 8 Motor Drive Layout lt apace at hogs IET ESTE Sequence of Operation schematic Diagrams sator hace Su husk M para Wiring DIGITS a eror ee iet aie o i ee dnl TROUBLESHOOTING 2 222 4 ELI era Dt iei due uideo aat eet Quick Reference
18. that corresponds to the fault The mixer will not operate until the alarm is cleared To manually reset cycle power to mixer Wait till display goes out then reconnect power ALARM CODES Fault Description Possible Causes Suggested Actions Over current Low supply voltage Check supply voltage to mixer 2 Momentary power 2 Cycle power to mixer Wait till display Protects motor drive interruption goes out then reconnect power Batch size too large Reduce batch size See REFERENCE MATERIAL under GENERAL Motor drive terminals U V or Check motor lead wire connections W short circuited or Check motor resistance grounded Check resistance between motor drive terminals U V amp W Over voltage High supply voltage Check supply voltage to mixer DC Bus voltage 2373V Under voltage Low supply voltage Check supply voltage to mixer Leave DMM connected and check for sudden DC Bus voltage drops in supply voltage when mixer is 255V turned ON under load along with other equipment on the same line Momentary power Cycle power to mixer Wait till display interruption goes out then reconnect power Motor drive malfunction Check DC bus circuit voltage at terminals P amp If voltage reading is consistently low and supply voltage is within tolerance replace motor drive Page 49 of 52 F25250 August 2007 HL300 AND HL400 LEGACY
19. wrap and column with 4 WARNING DISCONNECT THE aluminum colored RTV 732 Sy ELECTRICAL POWER TO THE lt MACHINE AND FOLLOW LOCKOUT 10 Reinstall remaining components that were 5 TAGOUT PROCEDURES removed to access wrap Z 11 Check proper operation Remove top cover Remove timer control assembly Remove attachment hub and motor o cm To prevent paint damage to column cut through sealant with a sharp knife near column REMOVE SEALANT 5 Remove hardware securing wrap to transmission case Remove wrap Clean old sealant from column A Clean wrap if it is to be reused 8 Install wrap onto column and secure with hardware F25250 August 2007 26 of 52 Remove top cover HL300 AND HL400 LEGACY MIXERS TRANSMISSION CASE TRANSMISSION CASE WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES Remove control panel Remove bowl guard cage bowl agitator and back splash guard Remove motor Remove TRANSMISSION ATTACHMENT HUB Remove WRAP Support transmission case Remove hardware securing transmission case to pedestal 9 Remove transmission case from pedestal 10 Reassemble in reverse order 11 Check for proper operation Page 27 of 52 F25250 August 2007 HL300 AND HL400 LEGACY MIXERS BASE BASE 4 WARNING DISCONNECT
20. 1CR 8 6 V thru 1CR 4 2 W 1MTR to terminal 5 Repeat procedure for all mixer speeds A Current may vary between phases but should be balanced If current draw on any phase is 5 higher or lower than the other phases verify that the motor drive is properly wired 1 If wiring is correct check motor winding resistance 2 If motor checks ok replace motor drive F25250 August 2007 MOTOR WINDING RESISTANCE If unable to check current draw using the motor current test and the motor is suspect check the motor winding resistance 1 Perform BUS VOLTAGE BLEED DOWN 2 Disconnect motor lead wires A T1 amp T2 from 1CR at terminals 2 amp 6 B from motor drive terminal W 3 Measure resistance ohms between all three motor leads Use the motor wiring table to identify motor lead wires Motor Lead Wires Resistance Ohms Resistance values at 77 F room ambient Tolerance is 15 A If resistance is out of tolerance for the room ambient temperature replace motor 4 Measure resistance between motor leads and unpainted motor frame surface ground A If resistance measured is below 500K ohm replace motor Page 16 of 52 HL300 AND HL400 LEGACY MIXERS PLANETARY PLANETARY WARNING DISCONNECT THE PLANETARY DISASSEMBLY ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT 1 Remove friction plug retaining ring agitator TAGOUT PROCEDURES shaft pinio
21. BUS VOLTAGE BLEED DOWN 3 Disconnect lead wires from motor drive DISCONNECT gt LEAD WIRES DISCONNECT J LEAD WIRES DISCONNECT LEAD WIRES 4 Remove nuts securing motor drive to mounting plate Page 13 of 52 Be N 18193 NOTE Refer to MOTOR DRIVE TORQUE VALUES for proper tightening of terminal screws 5 Reassemble in reverse order and check for proper operation BUS VOLTAGE BLEED DOWN WARNING DISCONNECT THE amp ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT 2457 TAGOUT PROCEDURES WARNING WAIT ONE MINUTE FOR THE CAPACITIVE BUS VOLTAGE TO BLEED DOWN 1 Remove PEDESTAL COVER 2 SetDMM to DC voltage 7 N J P 25250 August 2007 HL300 AND HL400 LEGACY MIXERS MOTOR DRIVE A Measure bus voltage across P amp N terminals on motor drive to ensure the voltage is below 50VDC B If bus voltage is higher than 50VDC 1 Verify jumper is in place between terminals P and P1 on motor drive NOTE Terminal spacing on motor drive does not permit the drive bleeder tool to connect with terminals P amp for bleed down However with the jumper connecting P and P1 the same voltage potential exists at both terminals 2 Place drive bleeder tool across the jumper at P1 amp N terminal for at least one minute to discharge the bus circuit 3 Remove dri
22. E TIMER BOARD ONLY PHASE VOLTAGE 41 COMMON OUTPUT TO TIME ADJ POTENTIOMETER W OUTPUT TO MOTOR 42 40VDC INPUT TO MOTOR DRIVE FROM TIME ADJ OUTPUT VOLTAGE DEPENDS 13 OVDC OUTPUT TO TIME ADJ POTENTIOMETER ON SPEED SETTING AND MIX CM COMMON LOAD FWD TO MOTOR DRIVE TO ACTIVATE PHASE VOLTAGE OUTPUT TO MOTOR 0 0 ON 30B C TIMER READY RELAY CONTACTS PROVIDES COMMON OvDC OUTPUT TO CONTROL CIRCUIT RS485 COMMUNICATIONS BETWEEN MOTOR DRIVE AND TIMER BOARD 19259 Page 35 of 52 25250 August 2007 HL300 AND HL400 LEGACY MIXERS ELECTRICAL OPERATION TIMER BOARD LAYOUT HL300 WIRING HARNESS CONNECTOR 2 SPEED SELECTOR SWITCH CONNECTOR OPENING FOR SPEED RECIPE SELECTOR SWITCH STOP SWITCH 0 START SWITCH 0 START SWITCH TIME ADJUSTMENT MODE POTENTIOMETER OPENING FOR SPEED STD RECIPE SELECTOR SWITCH J3 BOWL SWITCH CONNECTOR ro BUZZER 80000000M1 16000000009 REAR VIEW TIMER BOARD OR RECIPE TIMER BOARD BBIBIB LED DISPLAY TIME ADJUSTMENT POTENTIOMETER OPENING FOR SPEED SELECTOR SWITCH FRONT VIEW TIMER BOARD SELECT PRG 9 LEDS SW5 LED4 LED3 LED DISPLAY D2 LE SW6 LED1 g fe
23. EE 8 Install planetary shaft NOTE Be certain to install key onto planetary shaft UPPER INPUT SHAFT SPACER 12 Install bevel gear onto planetary shaft NOTE Be certain key is in place on planetary shaft 9 Install worm gear on worm gear shaft Page 23 of 52 F25250 August 2007 HL300 AND HL400 LEGACY MIXERS TRANSMISSION ATTACHMENT 15 Add 40 oz Of Mobilith AW 2 grease to transmission case Coat all gears throughly with grease 16 Clean and dry the mating surfaces of the transmission case and the transmission cover 17 Apply gasket sealer Permatex 2 to the perimeter of the transmission cover PLANETARY SPACER 14 Install motor to transmission case NOTE Position motor with lead wires down Tighten motor mounting screws in an alternating pattern to 24 30 in lb of torque SEALER 18 Install cover onto transmission case Tighten screws in an alternating pattern to 175 275 in lb of torque F25250 August 2007 a Page 24 of 52 HL300 AND HL400 LEGACY MIXERS TRANSMISSION ATTACHMENT 19 Install lock nut on planetary shaft 20 Install lock washer and lock nut on worm gear shaft LOCKWASHER AND LOCK NUT LOCK NUT 21 Install front cover mounting strap and tighten two screws to 175 275 in lb 22 Install PLANETARY BEVEL
24. L SWITCH 215 BOWL SWITCH 215 REMOVAL ky WARNING DISCONNECT THE ELECTRICAL POWER THE S MACHINE AND FOLLOW LOCKOUT CN 5 PROCEDURES 1 Lower bowl remove 2 Remove wire cage beater Remove screws securing bowl switch to splash cover 7 Remove bowl switch SPACERS 4 PLACES 3 Disconnect bowl switch at 2 pin connector 4 Remove nuts from mixer pedestal INSTALLATION NOTE When reinstalling splash cover to mixer make sure spacers are in place 1 Reassemble in reverse order 2 Check mixer for proper operation 5 Remove splash guard from mixer Page 9 of 52 F25250 August 2007 HL300 AND HL400 LEGACY MIXERS TIMER BOARD TIMER BOARD WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES CAUTION Certain components in this system are subject to damage by electrostatic discharge during field repairs A field service grounding kit is available to prevent damage The field service grounding kit must be used anytime the control board is handled 1 Remove TOP COVER 2 Loosen set screws then pull knobs from shaft 3 Remove mounting nut and lock washer from speed selector shaft 4 Remove screws securing timer control assembly to wrap LOOSEN SET SCREWS 97 gt Act HOBART 5 Disconnect wiring harness connector speed s
25. LECTOR SWITCH A Check continuity between pin 6 wiper and Check conti Pin 2196 Pin 3155 pen B If readings agree then the speed selector switch is functioning properly If readings do not agree then check the speed selector switch wiring harness 1 If readings agree then the speed connections and terminal connections at selector switch is functioning properly the motor drive 2 If readings do not agree then check the speed selector switch wiring harness connections and terminal connections at the motor drive SPEED SELECT SWITCH TEST HL400 NOTE This test will check the speed selector switch 1 Remove CONTROL PANEL 87 118192 2 Disconnect speed select switch wiring from timer board 3 Set meter to measure continuity or resistance Q A Check continuity between pin 6 wiper and pins 1 thru 3 F25250 August 2007 12 of 52 HL300 AND HL400 LEGACY MIXERS MOTOR DRIVE MOTOR DRIVE WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES CAUTION Certain components in this system are subject to damage by electrostatic discharge during field repairs A field service grounding kit is available to prevent damage The field service grounding kit must be used anytime the control board is handled REMOVAL AND REPLACEMENT 1 Remove PEDESTAL COVER 2 Perform
26. SL 81 1109 YOLOVLNOD NOO 70 LYVLS NOLING HSAd 8 727 dOLS NOLING 8d O7 N HOLIMS LIWII S1 OND 90107 CO N 935019 ATIVWHON LOV 1 09 O N N3dO A11VAHON 19V1NOO YOLOW LONGN ov LS6ve J WO S39V1 09 08 09v 00v 09 0S8 0 6 00 L 09 0S 0 2 00 0 20 7 HO1IMS AV1IdSIQ 59183 5031 A34 341234 8 1ndino AQv3M 4 ASVHd NO 835 AINO 21 35 10N N 90193135 43335 Ll SNS IN3ALSnfPQV ANIL F25250 August 2007 Page 45 of 52 HL300 AND HL400 LEGACY MIXERS TROUBLESHOOTING TROUBLESHOOTING QUICK REFERENCE FLOW CHART Verify mixer is powered Timer display on Y Error code displayed Remove power from mixer and then reapply Drive display on Replace motor drive Timer adjusts Replace timer board per SM Error code displayed Operate mixer under load preferred Replace speed selectector switch per SM in SM Repair per procedure in SM See troubleshooting in SM 215 functioning properly 1LS Bowl Guard Switch 2LS Bowl Switch position SM Service Manual 1674
27. THE x ELECTRICAL POWER TO THE lt MACHINE AND FOLLOW LOCKOUT 55 TAGOUT PROCEDURES Remove PEDESTAL COVER Perform BUS VOLTAGE BLEED DOWN Disconnect input voltage lead wires from motor drive terminals L1 L L2 N and GND 4 Atthe joint between base and pedestal cut through paint with a sharp knife to prevent paint damage 5 Position mixer to gain access to mounting hardware 6 Remove hardware Remove base from pedestal Reassemble in reverse order Tighten bolts in an alternating pattern to 900 1100 in lb of torque 9 Check for proper operation F25250 August 2007 28 of 52 HL300 AND HL400 LEGACY MIXERS BOWL SUPPORT BOWL SUPPORT 7 Remove mounting screws from right side slideway 4 WARNING DISCONNECT THE xv ELECTRICAL POWER TO THE CMS lt MACHINE AND FOLLOW LOCKOUT PROCEDURES Remove PEDESTAL COVER Remove bowl guard bowl agitator and back splash guard N Place bowl lift handle in up position Remove LOWER APRON NOTE If paint fills the joint between the slideway and pedestal cut through paint at the joint with a sharp knife to prevent paint damage 8 Remove stop nut spring and washers from bowl lift rod REMOVE SCREWS 5 Remove bowl lift springs 9 Remove right side slideway then remove bowl support 10 Remove old grease from slideways and mating surfaces o
28. V1dS1d YOLOW 9 N 035012 ATIVNYON LOVINOO O N N3dO ATIVAWHON 19V 1NOO 5 1 1 1 438 108W4S 011504 XIN 435012 N3dO 39 2 1M08 NOILSOd XIN NI 1 04 5 jji NOILSOd XIN 1no 14041 340 1109389 NOj11GNOO HOLIMS 118 1 31 15 HOLIMS NOI 1 NO I 1 I 74297 OIHO AOMI AHVHOH 09 08 09v 08 09 08 0v2 00c 09 09 072 002 09 04 001 001 00 IH L L HOLIMS 1M0OH S16 5 NI G31NI3d 53009 1V21312313 1V201 M3Hl10 3O QNV 3009 1991529313 1VNOIIVN 3Hl 40 SNOILMOd 318VOl1ddV HLIM A1dNOD 1 5 01123 02 1V21312313 ON I NSVM 539 110 3SVHd 319NIS NO AINO 0350 9019 39V110A 3SVHd 333Hl NO AINO Q3Sf 1 D 31A OLA 3AIN0 HOLIMS M 1M08 adi 1 1 8 015 SIl NAY 33X IN 0194135 lt 03395 adt SWI pu Page 44 of 52 F25250 August 2007 HL300 AND HL400 LEGACY MIXERS ELECTRICAL OPERATION HL400 Mixer SNIMIM YO IN3AdI003 140 5310 30 3 11 Q3HSVG YSHLO 9NISIM 1109319 O9NISIM3Nd G3X14 S310N30 3NIT 1H911 1VN331X3 5310 30 3NI 1 AAV3H NOI193NNOO 318V3Vd3S NOI1O3NNOO 318V3Vd3SNI YANYOISNVYL 1 3505 83 ayog IVNIWY
29. age output to 1M motor NOTE The motor drive varies the frequency and voltage output depending on speed setting and mix load B Speed selector switch routes the motor drives internal voltage signals of OVDC or 24VDC to motor drive X1 amp X2 1 Motor drive evaluates the voltage signals at X1 amp X2 and selects the speed C 1M motor is energized thru 1CR contacts D Timer starts countdown or count up 1 Depending on time knob position the time adjustment potentiometer provides OVDC to 10VDC from J 6 to motor drive 12 Motor remains energized until one of the following occurs A 2PB stop switch opened B 1LS bowl guard switch opened C 215 Bowl switch opened D Timer reaches 00 00 When 2PB stop switch is opened or bowl guard is opened or bowl is unlocked or lowered A 1CR relay coil de energized and 1CR 8 6 amp 4 2 contacts open 1 Power removed from 1M motor B 1K relay coil de energized and 1K latching circuit contacts open 1 1K run contacts open and remove common signal OVDC from motor drive FWD With signal removed from FWD motor drive stops mixer operation 2 Motor drive de activates U V amp W 3 phase voltage output HL300 AND HL400 LEGACY MIXERS ELECTRICAL OPERATION 3 Motor drive timer ready contacts 30 B C open for 1 second to remove common signal OVDC from control circuit and then re close 4 Remaining mix time is shown in display 10 When timer reac
30. arness malfunction Motor drive malfunction Motor malfunction Mixer runs in one speed only Changing speed selector switch has no affect F25250 August 2007 Page 48 of 52 HL300 AND HL400 LEGACY MIXERS TROUBLESHOOTING GENERAL ALL MODELS SYMPTOM POSSIBLE CAUSE Timer board problems Can not adjust time 1 Timer board malfunction time adjustment Can not select Hold Mode continuous mixing potentiometer or other problems with the board with count up timing 2 Wiring harness connections from motor drive Timer display does not count up 5485 to timer board are disconnected malfunctioning Motor drive malfunction timer ready contacts 30 B C are not opening for 1 second at the end of timed cycle Timer display does not count down Timer display blank Segment missing from timer display Mixer will not shut off at end of timed cycle Grease leaking from planetary 1 Spacer o ring on planetary shaft Grease leaking from attachment hub 1 Quad ring in attachment hub NOTE The motor drive constantly monitors its operation while the mixer is running If an alarm occurs during mixer operation the motor drive recognizes a fault condition and immediately tries to reset the fault twice within 0 5 second intervals If mixer operation continues the automatic reset was successful If the alarm was not reset the motor drive enters Alarm Mode and displays a 3 digit alarm code
31. ary until the correct bowl to beater clearance is achieved 5 Install apron Page 31 of 52 Check for proper operation F25250 August 2007 HL300 AND HL400 LEGACY MIXERS ELECTRICAL OPERATION ELECTRICAL OPERATION COMPONENT FUNCTION Motor Drive Supplies power to 1MTR motor thru 1CR contacts stores mixing time for each speed setting and controls motor speed Removes power from control circuit thru N C timer ready contacts 30 B C when mix time expires and sounds buzzer countdown mode only Monitors current voltage frequency and temperature during operation Removes power from motor and displays alarm code on timer board if value exceeds the alarm setting 1MTR Motor Turns transmission to mix product Timer Board Provides remote motor drive control and operator interface Displays mix time and alarm codes Includes 1PB start switch 2PB stop switch time adjustment potentiometer 1K relay and buzzer Recipe Timer Board Provides the same control functions as the timer board but includes a programing option for the operator to store and retrieve up to four recipes with five steps each various mix speeds amp times Includes 3PB recipe mode Switch 4PB standard mode switch and 2K relay 1PB Start Switch N O Provides initial power to control circuit momentary on 2PB Stop Switch Removes power from control circuit m
32. asting until bearing seats against shoulder inside the casting 4 Fill planetary casting void 2 3 full with Chevron FM EP 2 grease 5 Press upper bearing into planetary casting until 3 Install bearing seats against shoulder inside the A Install internal gear with threaded holes for casting drip cup screws 3 to the front and sides of 6 Install upper seal into planetary casting until the mixer Tighten internal gear mounting seal is flush with casting screws in an alternating pattern to 175 275 in lb of t 7 Insert key and beater pinion onto agitator shaft with shoulder against upper bearing then secure with friction plug 8 Coatbeater pinion with Chevron FM EP 2 grease 9 Check for proper operation INSTALL INTERNAL GEAR WITH THREADED HOLES AS SHOWN 9735 B Coatinternal gear with Chevron FM EP 2 grease 4 Install PLANETARY 5 Check for proper operation F25250 August 2007 18 of 52 HL300 AND HL400 LEGACY MIXERS TRANSMISSION ATTACHMENT TRANSMISSION ATTACHMENT HUB WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT AS TAGOUT PROCEDURES REMOVAL AND DISASSEMBLY Lower bowl support Remove BOWL GUARD Remove top cover and front cover strap Place drive into the service position ensure capacitive bus voltage is below 50VDC 5 Perform PLANETARY REMOVAL outlined in
33. ck and displays mix time or Hold NOTE The mix time will be the last time setting used for the speed selection stir speed 1 speed 2 speed 3 3 Motor drive PLC provides 24VDC to control circuit 4 Motor drive timer ready N C contacts 30 B C provide the common to control circuit common 0VDC B 1PB start switch N O contacts open 1 1K N O latching circuit contacts open 2 1K N O run contacts open C 2PB stop switch N C contacts closed 1CR relay N O contacts 8 6 amp 4 2 open E 115 bowl guard switch open 1 Wire cage of bowl guard open F 2LS bowl switch open 1 Bowl down and swung out 2 Bowl placed on support as instructed in operator manual 3 Bowl swung in raised to mix position and locked A 215 bowl switch closed 4 Wire cage of bowl guard closed A 115 Bowl guard switch closed Set time and speed 1PB start switch operated closed F25250 August 2007 38 of 52 A relay coil initially energized thru 2PB stop switch and 1LS bowl switch 1 1K run contacts close and provide the common signal OVDC to motor drive FWD 2 When 1PB start switch is released 1K relay coil remains energized thru 1K latching circuit contacts B 1CR relay energized and 1CR contacts 8 6 amp 4 2 close With the common signal OVDC present at FWD motor drive controls and monitors mixer operation A Motor drive activates U V amp W 3 phase volt
34. elector switch and bowl guard switch connector from timer board NOTE HL300 timer board shown HARNESS ONNECTOR SPEED SELECTOR SWITCH SWITCH CONECTOR F25250 August 2007 STOP BA j Q 300 NOTE HL400 timer board shown SWITCH 6 Remove timer board 7 Reassemble in reverse order Page 10 of 52 HL300 AND HL400 LEGACY MIXERS SPEED SELECTOR SWITCH SPEED SELECTOR SWITCH CAUTION Certain components in this system are subject to damage by electrostatic discharge during field repairs A field service grounding kit is available to prevent damage The field service grounding kit must be used anytime the control board is handled REMOVAL AND REPLACEMENT 1 Loosen set screw then pull knob from shaft HOBART HOLD 1 L300 18187 2 MOUNTING NUT AND LOCK WASHER 3 Remove screws securing timer control assembly to wrap 4 Disconnect speed selector switch connector from timer board Page 11 of 52 SPEED SELECTOR SWITCH 5 Reassemble in reverse order and check for proper operation SPEED SELECT SWITCH TEST HL300 NOTE This test will check the speed selector switch 35 4554 88 8 00 2 Disconnect speed select switch wiring from timer board 3 Setmeter to measure continuity or resistance F25250 August 2007 HL300 AND HL400 LEGACY MIXERS SPEED SE
35. eration REFERENCE MATERIAL STOP t 6 START HL 300 Catalog of Replacement 43136 Parts e HL400 Catalog of Replacement F43137 Parts Instruction Manual for Installation F34975 Operation and Care Lubrication Manual for current F20067 lubricants and quantities Use and Applications Handbook F34901 Mixer Capacity Chart All Models F7701 HL400 RECIPE TIMER BOARD Page 3 of 52 m 825250 August 2007 HL300 AND HL400 LEGACY MIXERS GENERAL SPECIFICATIONS HL300 ELECTRICAL DATA Voltage n 120 50 60 1 240 50 60 1 DE TS 2 5HP 25HP 25HP 2 5HP 230 460V 230 460V 230 460V 230 460V 3 phase 3 phase 3 phase 3 phase Tolerance 10 HL400 ELECTRICAL DATA 200 240 50 60 1 200 240 50 60 3 380 460 50 60 3 hw ps 1 5 H P 1 5 H P 3 0HP 3 0HP 208 230 460V 208 230 460V 208 230 460V 3 Phase 3 Phase 3 Phase Tolerance 10 OPERATING SPEEDS AND RPM BOWL SIZE 30 qt bowl 40 qt bowl F25250 August 2007 Page 4 of 52 HL300 AND HL400 LEGACY MIXERS GENERAL TORQUE VALUES Component Base to Pedestal Transmission Case to Pedestal 900 1100 in lb 372 465 in lb 175 275 in lbs 175 275 in lbs Slideways to Pedestal Internal Gear to Transmission Case Transmission Cover Bolts 175 275 in lbs Motor to Transmission Case 24 30 in lbs Bottom Planetary Screw 372
36. f bowl support 11 Apply light coat of Lubriplate 630 AA to mating surfaces of slideways 6 L bowl lift handle 12 Reassemble in reverse order Tighten slideway mounting screws to 175 275 in lb of torque 13 Perform BOWL LIFT HANDLE ADJUSTMENT as outlined under SERVICE PROCEDURES AND ADJUSTMENTS Page 29 of 52 F25250 August 2007 HL300 HL400 LEGACY MIXERS BOWL LIFT ASSEMBLY BOWL LIFT ASSEMBLY ky WARNING DISCONNECT THE BOWL LIFT HANDLE 5 ELECTRICAL POWER TO THE WY gt S MACHINE AND FOLLOW LOCKOUT ADJUSTMENT V RM pe ISOMPPROUEDURES NOTE The bowl lift handle is in the up position when 4 lt bowl is down To raise the bowl pull the bowl lift handle down When the bowl support stops against REMOVAL AND REPLACEMENT the pedestal the spring the bowl lift rod is compressed to exert spring tension on the bowl lift 1 Remove bowl guard bowl agitator and back arm ana hold the bowl in position splash guard 1 Raise bowl Verify bowl stays in the up position 2 Remove TOP COVER A If force required is not too difficult for the 3 Remove MOTOR operator and bowl stays in the up position bowl is adjusted properly 4 R II pin f TON PITE Mon DONE NEU anm B If adjustment is required continue with procedure 2 Verify BOWL TO BEATER CLEARANCE ADJUSTMENT before adjusting bowl lift arm Remove PEDESTAL COVER 4 Raise bo
37. hes 00 00 minutes countdown mode only A D Motor drive timer ready contacts 30 B C open for 1 second to remove common signal OVDC from control circuit and then re close 1CR relay coil is de energized and 1CR 8 6 amp 4 2 contacts open 1 Power is removed from 1M motor 1K relay coil de energized and 1K latching circuit contacts open 1 1K run contacts open and remove common signal OVDC from motor drive FWD With signal removed from FWD motor drive stops mixer operation 2 Motor drive de activates U V amp W 3 phase voltage output 3 Motor drive activates Y1 and provides the common for 1 second to energize buzzer buzzer sounds then turns off NOTE The common from Y1 is provided thru the electronic control circuit of the motor drive and the external jumper connection between Y1E and 4 Mixtime shown in display Mixer is ready for next time and speed operation or bowl removal 11 When timer reaches 15 00 minutes count up mode only A Motor drive activates Y1 and provides the common for 1 second to energize buzzer buzzer sounds then turns off Timer resets to 00 00 Timer and mixer operation continue until 2PB stop switch is pressed or power is removed from mixer Page 39 of 52 F25250 August 2007 HL300 AND 400 LEGACY MIXERS ELECTRICAL SCHEMATIC DIAGRAMS HL300 Mixer Standard Timer Board L1 12 5
38. lear the slots 1 Removed OP S OVER and remove cage 2 Remove screws securing timer control assembly to wrap A Remove timer control assembly from wrap B Support timer control assembly 221 LIFT WIRE CAGE UNTIL ARRIERS CLEAR SLOTS 2 Lower bowl support and remove agitator REMOVE SCREWS 4 PLACES 3 Remove drip cup 3 Note connection points of guard switch connector and wiring harness connector Disconnect both connectors Page 7 of 52 Y F25250 August 2007 HL300 HL400 LEGACY MIXERS BOWL GUARD ASSEMBLY WIRING HARNESS 4 Pull bowl guard switch by the lead wires to remove from switch holder BOWL GUARD SWITCH NOTE Bowl guard switch is inserted into switch holder and held in place with a light application of RTV 5 To install A Check switch holder for loose debris in the bottom and remove debris B Insert bowl guard switch into switch holder Ensure the switch is fully inserted C Apply a bead of RTV 732 at the top of bowl guard switch to secure the switch to the switch holder 6 Connect bowl guard switch to timer control board Re connect wiring harness connector Reinstall timer control assembly Reinstall drip cup wire cage bowl and top cover 10 Raise bowl into mix position 11 Check unit for proper operation F25250 August 2007 Page 8 of 52 HL300 HL400 LEGACY MIXERS BOW
39. low on grease or damaged 3 Bevel gear assembly or planetary shaft bevel gear worn improperly meshing or damaged Mixer noisy 4 Internal gear and beater pinion of planetary are worn improperly meshing or low on grease 5 Worn bearings agitator shaft planetary shaft or worm wheel shaft 6 Wiring incorrect from motor drive to motor 7 Motor drive malfunction Mixer lacks power 1 Key sheared at A Worm on motor shaft B Worm wheel shaft C Middle key on planetary shaft D Lower key on planetary shaft 2 Planetary or worm wheel shaft broken Mixer motor runs but planetary does not rotate 1 Upper key sheared on planetary shaft 2 Bevel gear assembly or planetary shaft bevel gear worn improperly meshing or damaged Agitator will not turn 1 Key sheared at beater pinion on agitator shaft Bowl to beater clearance set incorrectly Batch recipe incorrect See REFERENCE MATERIAL under GENERAL Mixer planetary operates but attachment hub does not rotate Not mixing ingredients at bottom of bowl Incorrect agitator for recipe Speed selector switch malfunction Motor drive X1 X2 X3 or CM terminal connections loose wired incorrectly or wiring harness malfunction Motor drive malfunction Motor malfunction Mixer appears to run in wrong speed Speed selector switch malfunction Motor drive X1 X2 X3 or CM terminal connections loose wired incorrectly or wiring h
40. n and key from agitator shaft RING REMOVAL 1 Remove wire cage and drip cup as outlined under BOWL GUARD ASSEMBLY 2 Remove screw lock washer and planetary washer FRICTION PLUG 3 Remove planetary from mixer FRICTION PLUG C5 RETAINING RING AGITATOR SHAFT PINION UPPERSEAL 3 2 Drive agitator shaft lower ball bearing and lower seal from planetary BALL BEARING O NOTE When removing use a brass drift to remove PLANETARY LOWER LOWER BEARING _ BALL BEARING PLANETARY WASHER Ts LOCKWASHER AGITATOR SHAFT L SEAL SCREW LL DRIFT AGITATOR SHAFT 3 Drive upper bearing and upper shaft seal from AGITATOR PIN planeta ry x 2041 Page 17 of 52 F25250 August 2007 300 AND HL400 LEGACY MIXERS PLANETARY INTERNAL 4 WARNING DISCONNECT THE ELECTRICAL POWER TO THE lt MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES ASSEMBLY AND INSTALLATION NOTE Ensure all parts are clean before assembly Remove old grease from parts being reused 1 Slide agitator shaft seal and lower ball bearing onto agitator 2 Press lower bearing onto agitator shaft until inner race of bearing seats against shoulder of agitator shaft 3 Press agitator shaft with lower bearing seated on the shaft into planetary c
41. omentary off Time Adjustment Potentiometer Sets mix time from 00 10 seconds to 15 00 minutes countdown mode only or selects Hold Mode continuous mixing with count up timing B zzer vex xr Signals end of mix time countdown mode only or signals 15 00 minutes of continuous mix time has elapsed count up mode only Buzzer sounds for one second then stops Speed Selector Switch lI Sets agitator speed or recipe number 1 thru 4 recipe timer board only 1CR Control Relay Removes power from 1MTR motor when relay coil is de energized by motor drive timer ready contacts 30 B C mix time expires or alarm 2PB stop Switch 1LS bowl guard switch or 2LS bowl switch 1LS Bowl Guard Switch N O Ensures bowl guard covers mixing bowl reed switch closed before mixer operation can begin 2LS Bowl Switch N O Ensures bowl is raised into mixing position reed switch closed before mixer operation can begin F25250 August 2007 32 of 52 HL300 AND HL400 LEGACY MIXERS ELECTRICAL OPERATION COMPONENT LOCATION SPEED MOTOR TIMER SELECTOR BOARD SWITCH BOWL GUARD SWITCH 4 BOWL SWITCH DRIVE 18233 MIXER WITH STANDARD TIMER BOARD HL300 SHOWN CONTROL Page 33 of 52 F25250 August 2007 HL300 AND HL400 LEGACY MIXERS ELECTRICAL OPERATION MOTOR DRIVE LAYOUT HL300 1 PLC
42. ower input wires broken Terminal screws for the main circuit power input at the inverter are not tight enough Single phase voltage applied to three phase input of inverter Page 51 of 52 Reduce batch size See REFERENCE MATERIAL under GENERAL Check bottom vent cover for clogging Check motor drive heat sink fins for clogging Remove debris Reduce room ambient temperature or move mixer to a cooler location away from heat sources Cycle power to mixer Wait till display goes out then reconnect power If this does not clear the alarm code replace motor drive Check plugs for proper insertion into Sockets RJ45 and 16 pin Check RS485 lead wire connections J1 1 thru J1 4 for tightness and proper insertion into 16 pin sockets and plugs from motor drive to timer board If no continuity replace the malfunctioning harness Replace timer board if harness ok Replace motor drive if timer board and harness ok Cycle power to mixer Wait till display goes out then reconnect power If this does not clear the alarm code replace motor drive Cycle power to mixer Wait till display goes out then reconnect power If this does not clear the alarm code replace motor drive Measure input voltage Tighten terminal screws to the recommended torque Check the inverter type Apply three phase power Three phase inverter cannot be driven by single pha
43. screws to lift transmission cover Torque wrench capable of measuring up to 1200 in lb F25250 August 2007 HL300 AND HL400 LEGACY MIXERS COVERS COVERS TOP COVER ky WARNING DISCONNECT THE Ses ELECTRICAL POWER TO THE S MACHINE AND FOLLOW LOCKOUT CN 5 PROCEDURES 1 Remove top cover 5 5 REMOVE SCREWS 2 Raise top cover and remove 3 Reassemble in reverse order NOTE When re assembling top cover to mixer be sure top cover seal is properly seated on mixer F25250 August 2007 TOP COVER SEAL PEDESTAL COVER 1 Remove pedestal cover Ey 4 PEDESTAL COVER REMOVE SCREWS 2 Reassemble in reverse order Page 6 of 52 HL300 HL400 LEGACY MIXERS BOWL GUARD ASSEMBLY BOWL GUARD ASSEMBLY REMOVAL AND REPLACEMENT 4 WARNING DISCONNECT THE xv ELECTRICAL POWER TO THE 5 MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES 1 Rotate wire cage until the three carriers align with slots in drip cup 4 Reassemble in reverse order and check for proper operation 4 _ BOWL GUARD SWITCH 1LS F O V o NIN A lt 7 4 WARNING DISCONNECT THE 5 N ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT p Vs lt TAGOUT PROCEDURES 7218174 A Lift wire cage until carriers c
44. se power supply F25250 August 2007 HL300 AND HL400 LEGACY MIXERS INDEX INDEX ABC Attachment Hub 19 Bevel Gears Meshing Adjustment 25 lie ae ade 28 Bowl Guard Assembly 7 Bowl Guard Switch 7 Drip CUP cesset UR SA ER 7 Removal and Replacement 7 Wire Cage 7 Bowl Lift Assembly 30 Bowl Lift Handle Adjustment 30 Removal and Replacement 30 Bowl Support 29 Bowl Switch 9 Component Function 32 eI 9 Removal oed pter Pre 9 Bowl to Beater Clearance 31 Bowl Height Screw 31 Control Relay 32 s us u aigua RO Gay es ROS RA Gel u 6 Pedestal Cover 6 Cover DEF Electrical Operation 32 Component Function 32 Component Location 33 Motor Drive Layout 34 Schematic Diagrams 40 Sequence of Operation 38 Wiring Diagrams 44
45. uard switch are closed If a problem is found with 1LS 2LS or motor drive replace the malfunctioning component Replace motor drive Disconnect power to mixer and allow motor drive to cool Check bottom cover vent for clogging Check motor drive heat sink fins for clogging Remove debris Reduce room ambient temperature or move mixer to a cooler location away from heat sources If over heating occurs repeatedly replace motor drive Select Speed 1 or Speed 2 for mixing Reduce batch size See REFERENCE MATERIAL under GENERAL Check supply voltage to mixer Check motor resistance Replace motor drive Code OLU Er1 Er2 Er3 ErF Lin HL300 AND HL400 LEGACY MIXERS TROUBLESHOOTING ALARM CODES Fault Description Possible Causes Suggested Actions Motor drive over 1 loaded 2 Protects motor drive Memory error Timer board communication error CPU error Data save error during undervoltage Input phase loss Batch size too large Motor drive ambient temperature above 122 F Momentary power interruption or power loss while motor drive was storing data 85485 wiring connections loose disconnected or malfunctioning Timer board malfunction Motor drive malfunction Motor drive malfunction Momentary power interruption or power loss while motor drive was storing data Main circuit p
46. ve bleeder tool 4 Recheck bus voltage with meter If necessary bleed bus circuit until voltage is below 50 VDC BUS VOLTAGE TEST 1 Remove PEDESTAL COVER 2 Verify input voltage to motor drive at terminals L1 L amp L2 N Check data plate for correct voltage A If not correct see TROUBLESHOOTING B If correct proceed to next step Perform BUS VOLTAGE BLEED DOWN Set DMM to DC voltage A Connect BLK meter lead on and RED meter lead on P terminals of motor drive Connect power A DC voltage reading of the meter should be approximately 340VDC The acceptable DC bus voltage range is 256VDC to 372VDC Start mixer in Stir lowest speed with no load in bowl A Repeat procedure operating the mixer in each speed with no load in bowl MOTOR DRIVE INTERNAL RESISTANCE TEST Perform BUS VOLTAGE BLEED DOWN Disconnect lead wires from motor drive terminals U V amp W Measure resistance ohms between motor drive terminals U V amp W F25250 August 2007 A If resistance measured is below 1 replace motor drive HL300 HL400 LEGACY MIXERS MOTOR MOTOR 4 WARNING DISCONNECT THE x ELECTRICAL POWER TO THE lt MACHINE AND FOLLOW LOCKOUT SS TAGOUT PROCEDURES S REMOVAL AND REPLACEMENT Remove TOP COVER and PEDESTAL COVER Disconnect motor lead wires T1 thru T9 Remove motor mounting screws 4 5
47. wl to access the bowl lift rod stop nut A Toincrease lift handle force turn nut clockwise approximately 75 turn To decrease lift handle force turn nut counterclockwise approximately 7 turn BOWL LIFT B Verify bowl lift arm operation and repeat HANDLE the adjustment as necessary 4 1 5 Remove bowl lift handle from pedestal 6 Reassemble in reverse order 7 Perform BOWL LIFT HANDLE ADJUSTMENT F25250 August 2007 P C 30 of 52 HL300 AND HL400 LEGACY MIXERS BOWL TO BEATER CLEARANCE ADJUSTMENT BOWL TO BEATER CLEARANCE ADJUSTMENT 6 4 WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURES NOTE Set the bowl to beater clearance using B beater 1 Verify bowl to beater clearance is between 0 054 to 0 115 allowable tolerance B BEATER CLEARANCE 054 TO 115 9697 A If adjustment is required continue with procedure 2 Remove beater unlock bowl and swing out of way Remove apron from pedestal Adjust each bowl height screw equally to obtain the correct bowl to beater clearance A Turn screw clockwise to increase or counterclockwise to decreases the clearance Each half turn of the set screw equals approximately 0 025 of travel B Swing bowl into locked position and install beater C Check bowl to beater clearance for correct dimension D Repeat adjustment as necess
48. x1 x2 x3 11 12 13 CM FWD 30B C RS485 LEGEND CONTROL CIRCUIT TERMINALS COMMON 0 00 OUTPUT BUZZER COMMON OVYDC OUTPUT Y4 24vDC OUTPUT TO CONTROL CIRCUIT OR 24vDC ON OFF INPUT FROM SPEED SELECTOR SWITCH ON RECIPE TIMER BOARD ONLY COMMON OUTPUT TO TIME ADJ POTENTIOMETER 0 TO 10 0 INPUT TO MOTOR DRIVE FROM TIME ADJ POTENTIOMETER OUTPUT TO TIME ADJ POTENTIOMETER COMMON INPUT TO MOTOR DRIVE TO ACTIVATE 3 PHASE VOLTAGE OUTPUT MOTOR OVDC ON TIMER READY N C RELAY CONTACTS PROVIDES COMMON O YDC OUTPUT TO CONTROL CIRCUIT COMMUNICATIONS BETWEEN MOTOR DRIVE AND TIMER BOARD MAIN CIRUCIT TERMINALS LINE 1 AC VOLTAGE IN L2 N LINE 2 OR NETURAL L3L L LINE VOLATGE IN 6 GROUND U v PHASE VOLTAGE OUTPUT OUTPUT VOLTAGE DEPENDS ON SPEED SETTING AND MIX LOAD 18257 F25250 August 2007 34 of 52 HL300 AND HL400 LEGACY MIXERS ELECTRICAL OPERATION MOTOR DRIVE LAYOUT HL400 LEGEND CONTROL CIRCUIT TERMINALS MAIN CIRUCIT TERMINALS Y4 COMMON OVDC OUTPUT TO BUZZER 14 LINE 1 AC VOLTAGE IN COMMON OV VDC OUTPUT TO 1 L2 N LINE 2 OR NETURAL PLC 24VDC OUTPUT TO CONTROL CIRCUIT L3L L LINE 3AC VOLATGE IN X1 OVDC OR 24VDC ON OFF INPUT GROUND X2 FROM SPEED SELECTOR SWITCH u X3 ON RECIP

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