Tri-Clover DS3218 Manuel utilisateur
TB-DS-SM-97
Tri-Clover®
Dual Stage Tri-Blender
Model DS3218
Service & Installation Manual
2
3
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 .......................................................................................... 4
INTRODUCTION
DESCRIPTION................................................................................................................................ 5
BASIC OPERATION ....................................................................................................................... 5
INSTALLATION
INSTALLATION GUIDELINES ........................................................................................................ 6
PIPING HINTS ................................................................................................................................ 7
MAINTENANCE
CLEANING...................................................................................................................................... 8
DISASSEMBLY ............................................................................................................................... 8
REASSEMBLY .............................................................................................................................. 11
SETTING THE DRIVE COLLAR AND SEAL REPLACEMENT..................................................... 15
TROUBLESHOOTING
TROUBLESHOOTING GUIDELINES ........................................................................................... 16
PARTS LIST
MODEL DS3218............................................................................................................................ 18
EXPLODED VIEW ........................................................................................................................ 19
4
IMPORTANT SAFETY INFORMATION
SAFETY
DANGER
WARNING
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.
Indicates a potentially hazardous situation which, if not
avoided,
may
result in minor or moderate injury. May
also be used to alert against an unsafe operating or
maintenance practice.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided,
could
result in death or serious injury.
!
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.
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.
WA R N I N G
ROTATING SHAFT
DO NOT OPERATE
WITHOUT GUARD IN PLACE
Part Number 38-241
5
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
port, or inlet, is pointed upward. The inlet piping
consists of a patented tube-within-a-tube arrangement.
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.
Our patented (U.S. Patent # 4,850,704) dual stage Tri-
Blender incorporates the proven design characteristics
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 applications 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.
6
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 in a
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 tube OD of the inlet and outlet connections of the blender casing are:
Liquid Inlet Liquid Outlet Powder Inlet
1½" (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.
7
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, vibration, 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.
8
MAINTENANCE
CLEANING
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 Butterfly 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
1. Remove the clamp (3) securing the hopper (1) to the blender and remove the
hopper and gasket (4).
2. Remove the clamp (3) securing the control valve (5), and remove the valve and
gasket (4). (Hold the valve while loosening the clamp to prevent the valve from
falling.)
3. Remove the clamp (8) securing the diffuser and suction tube (7), and remove the
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).
Relieve pressure and
remove all fluid from blender
prior to disassembly.
Remove power before
servicing to prevent
unintended start of the
blender.
WARNING
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
98
10
98
7
4
3
5
4
3
1
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.
6. Remove and inspect the casing o-ring (16).
7. Remove the upper screen (12).
8. 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).
9. Remove the diffuser plate (51) and lower o-ring (16).
10. Remove the shaft sleeve (54) and o-rings (54a).
11. Remove the lower impeller (15b), and lower screen (12).
12. Remove the o-ring (26) from the lower impeller (15b).
13. Loosen the three casing bolts, and lift the lower casing (11b) off of the
adapter ring.
14. 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.
15. 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.
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.
11a
13
14
15a
12
17
68 69
68
67
66a
66
25 26
27
28
52 53
16
51
54
54a
54a
12
15b
26
16
11b
22
10
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.
1. Loosen the mounting bolts (43) securing the drive
motor (50) to the base (39). (The bolt holes are
elongated to permit belt adjustment.)
2. Slide the motor (50) toward the blender and
remove the drive belts (45).
3. 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.
4. 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.
5. Slide tapered bushing (44a) from the shaft (31).
6. Loosen the set screws (53) securing the collar
(30) to the shaft (31) and remove the deflector
collar.
7. 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.
8. 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).
9. 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 (31) 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 (31) sealing surface for nicks or scratches. Inspect all components for cracks
and distortion. Inspect the adjusting legs for worn threads and inspect 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.
Table des matières
