Winget Crocker RP1500XD User manual

CUMFLOW RP1500XD
ROTATING PAN MIXER
PARTS
&
OPERATION MANUAL
WINGET LIMITED
PO BOX 41
EDGEFOLD INDUSTRIAL ESTATE
PLODDER LANE
BOLTON
LANCS
BL4 OLS
Tel:++ 44 (0) 1204 854650
Fax:++ 44 (0) 1204 854663
[e-mail]
[email protected]
[e-mail]
www.winget.co.uk

INDEX
SECTION 1 GENERAL INFORMATION
1.1. Company Details
1.2. Important Notice
1.3. Mixer Operational and Safety Requirements
1.4 Installation Drawing
1.5 Test Certificates (Where applicable)
SECTION 2 INSTALLATION AND OPERATING INSTRUCTIONS
2.1. Pre Installation Notes
2.2. Installation Instructions
2.3. Operating Instructions
SECTION 3 TECHNICAL SPECIFICATION AND MAINTENANCE
3.1. Technical Specification
3.2. Shutdown Procedure and Maintenance
3.3. Maintenance of Mixer
3.4. Maintenance and Lubrication
3.5. Lubrication Layout
SECTION 4 MIXER SPARE PARTS
4.1. General Arrangement
4.2. Arrangement of Pan, Wear Plates, Pan Rollers and Pan Drive
4.3. Pan Support Roller Assembly
4.4. Pan Side Locating Roller Assembly
4.5. Pan Base, Side and Rack Arrangement
4.6. Star Drive Arrangement
4.7. Arrangement of Discharge Blade and Fixed Blade
4.4. Arrangement of Discharge Door & Pneumatic Cylinder
4.5. Layout of Guards
4.6. Pan Sealing Arrangement
4.7. Decals and Logos
SECTION 5 ANCILLIARY EQUIPMENT SPARE PARTS
5.1 Arrangement of Winch Unit
5.2 Arrangement of Loader Runway
5.3 Arrangement Loading Hopper
5.4 Arrangement of Split Shaft Whirler from S/No 6066
5.5 Arrangement of Split Shaft Whirler
5.6 Arrangement of Fixed Shaft Whirler

5.7 Arrangement of Weigher
5.8 Wire Rope Renewal Procedure
5.9 Wire Rope Safety Notes
5.10 180 Litre Water Tank
SECTION 6 ELECTRICAL SYSTEM
6.1 Electrical Instructions
6.2 Wiring Diagrams (Where applicable)
6.3 Component Listing (Where applicable)
6.4 Interlock Switch Mounting (Where applicable)
SECTION 7 PNEUMATIC SYSTEM
7.1 Pneumatic Instructions – Shutdown Procedure
7.2 Circuit Diagrams
SECTION 8 MISCELLEANEOUS
8.1 Noise
8.2 Special Pan Covers & Inlets
8.3 Miscellaneous Items
SECTION 9 ELECTRONIC LOADCELL & READOUT BOX
The contents of this handbook although correct at the time of publication, may be subject to
alteration by the manufacturers without notice and Winget Limited can accept no responsibility for
any errors or omissions contained within the following pages. Nor can we accept any liability
whatsoever arising from the use of this manual howsoever caused.
Winget Limited operate a policy of continuous product development. Therefore, some illustrations
or text within this publication may differ from your machine
Winget Limited can accept no responsibility for incorrectly supplied spare parts unless the part
number and a full description of the items required is given when the order is placed.
NOTE
Imperial fixings (bolts, setscrews, nuts, washers etc) have been progressively changed to Metric. If
in doubt as to whether you have a Metric or Imperial fixing please order the metric items listed, i.e.
bolt or setscrew and associated or flat and spring washers to replace the existing items
NOTE
Electrical cables particularly those with copper conductors suffer from a condition known as
‘relaxation’ which may cause wiring to work loose over a period of time, it is recommended
that the tightness of wiring connections and terminals are checked following the first month
in service.

OPERATING
AND
MAINTENANCE MANUAL
SECTION 1
GENERAL INFORMATION

COMPANY DETAILS AND GENERAL INFORMATION
For any spares or service work, please contact:-
Winget Limited
P.O. Box 41
Edgefold Industrial Estate
Plodder Lane
Bolton
Lancs U.K.
BL4 OLS
Telephone No: ++ 44 (0)1204 854650
Facsimile No: ++ 44 (0)1204 854663
‘E Mail’ [email protected]
[email protected]
[email protected]
ORDERING SPARES
To help us to complete your order promptly and correctly we need:-
•Machine type and serial number
•Description and quantity of parts required
•The full address to which the parts are to be sent
Winget Limited can accept no responsibility for incorrectly supplied spare parts unless the
part number and a full description of the items required is given when the order is placed.

IMPORTANT NOTICE
The CUMFLOWRP1500XDis a high performance mixer
The following precautions are necessary to obtain the best results and to avoid
damage to the MIXING STAR and DRIVE
ENSURE TRANSIT BAR AND RING ARE REMOVED FROM DOOR
BEFORE STARTING MACHINE.
AGGREGATES
Strict control of graded aggregates must be maintained
Maximum size 38mm
Oversize lumps of aggregate or rogue materials must be prevented from
entering the Pan
MIXING STAR BLADES
They are to a special shape and material to prolong wear life. They should not
be modified in any way and only replaced with GENUINE ‘CROKER’ spares
Obtained from WINGET LIMITED.
A daily check is advisable to ensure that the Blades/Wearing parts are secure
and undamaged.
PAN RIM & BASE WEARING PLATES
They must be replaced before excessive wear causes distortion.
MAXIMUM BATCH LOADS
UNDER NO CIRCUMSTANCES should the Maximum Batch Loads quoted
be exceeded nor should the mixer be or re-started when there is a mix in the
Pan
MIXING PAN
Ensure that the Mixing Pan is rotating concentrically and that the pan base is
Rotating in horizontal place, otherwise damage may occur to the door
mechanics.

WARNING
THE MANUFACTURER ACCEPTS NO RESPOSIBILITY FOR ANY
DAMAGE OR FAILURE RESULTING FROM OPERATIONAL
MISUSE OR MALPRACTICE. ANY MODIFICATIONS TO THE
MACHINE WILL AFFECT ITS WORKING PARAMETERS AND
SAFETY FACTORS. REFER TO THE MANUFACTURERS BEFORE
FITTING ANY NON STANDARD EQUIPMENT OR PARTS.
THE MANUFACTURERS ACCEPT NO RESPONSIBILITY FOR ANY
MODIFICATIONS MADE AFTER THE MACHINE HAS LEFT THE
FACTORY, UNLESS PREVIOUSLY AGREED IN WRITING. THE
MANUFACTURERS WILL ACCEPT NO LIABILITY FOR DAMAGE
TO PROPERTY, PERSONNEL OR THE MACHINE IF FAILURE IS
BROUGHT ABOUT DUE TO SUCH MODIFICATIONS, OR THE
FITMENT OF SPURIOUS PARTS.

RP1500XD
OPERATIONAL AND SAFETY
REQUIREMENTS
PRE-DELIVERY INSPECTION (Also see separate Document)
1.1 Drive coupling alignments, pan and star meshing of pan rack and drive gear.
1.2 Operating clearances star blade to pan. Fixed blade to pan wall.
1.3 Discharge blade to pan base.
1.4 Rollers to register ring.
1.5 Correct oil level in gearboxes. All grease points charged. Gear teeth greased.
1.6 Air system tested.
1.7 Door operation and seating.
1.8 No load test. Correct rotations.
PRE INSTALLATION
2.1 Check consignment.
2.2 Offload equipment using certified lifting gear of suitable capacity, by a competent
person (see separate chart for nett weight).
INSTALLATION
3.1 Refer to contract arrangement and site instructions.
3.2 Mixer to be mounted on supports of adequate strength and rigidity to prevent undue
vibration when mixing and securely bolted.
3.3 Mixer frame to be level on structure, add packers as required.
3.4 Check that pan is correctly seated on Rollers and that pan rack and drive gear are in
correct mesh.
3.5 Check locating rollers to register ring.
3.6 Check operating clearances star blade to pan. Fixed blade to pan wall. Discharge
blade to pan base. See maintenance section Ops Manual.

ELECTRICAL SERVICES
Refer to wiring diagram in Ops Manual. All wiring to be undertaken by competent
electrician. NOTE: electrical cables particularly those with copper conductors suffer from a
condition known as ‘relaxation’ which may cause wiring to work loose over a period of
time, it is recommended that the tightness of wiring connections and terminals are checked
following the first month in service.
4.1 Refer to pneumatic circuit diagram in Ops Manual. Connect compressor. Supply
compressed air 5.5 bars as required (80psi).
4.2 Refer to wiring diagram in Ops Manual when connecting air control valves.
4.3 Remove transit bar and ring from door BEFORE starting mixer.
4.4 Ensure starters are mounted away from mixer on supports free of vibration.
4.5 Ensure starters are fitted with correct overloads – see technical specification power
units.
OPERATION
5.1 Correct oil level, Gearboxes and Air line lubricator.
5.2 Mixing pan clear of loose nuts and bolts to prevent damage to fingers and blades.
5.3 Check correct rotation – mixing star – anti clockwise; mixing pan – anti clockwise.
All when viewed from the top.
5.4 Discharge door and blade correct operation.
5.5 Blade operating clearances adjust in line with maintenance instructions.
5.6 Never exceed manufacturer’s maximum capacity as detailed in specification.
SHUTDOWN
6.1 Prior to any work being carried out mixer to be isolated and physically locked off.
Recommended equipment double key exchange system.
6.2 Follow procedure detailed in company and users’ Health and Safety Policy at
all times.
6.3 Ensure all storage bins containing materials to be mixed are isolated.

6.4 Shut off water supply and drain off water tank or flowmeter
MAINTENANCE
7.1 Ensure that all maintenance is carried out in accordance with the Parts and
Operating manuals and proprietary manufacturer’s specific instruction.
7.2 Isolate electrical and other services to the mixer as section 6 above.
7.3 Service at recommended intervals.
7.4 Use Croker manufactured replacement parts supplied by WINGET LIMITED.
GENERAL
8.1 Under no circumstances should the Maximum Batch Loads be exceeded by
either weight and volume as stated in Technical Specification.
8.2 Mixer star blades to be checked daily for damage.
8.3 Pan rim and base wearing plates must be replaced before excessive wear causes
distortion.
8.4 Ensure mixing pan is rotating concentrically and pan base is rotating in
horizontal plane.
8.5 Mixer must not be stopped and started when there is mix in the pan.
8.6 Refer to Contract Drawing for scope of supply. Site instruction notes outlining
weights etc.
8.7 Refer to Method Statement when installation and commissioning is
responsibility of Winget Limited.
Nett Weights Max (kgs)
9.1 RP50XD 788 RP1250XD 4840
RP100XD 814 RP1500XD 4980
RP200XD 1400 RP3000XD 7112
RP400XD 2000 FP1000 4040
RP550XD 2150 FP1500 4065
RP850XD 2600 FP2000 4100
9.2 Refer to technical specification for nett weights of ancillary equipment.
9.3 Refer to contract drawing for nett weights of ancillary equipment.

Miscellaneous
10.1 Noise measured in accordance with Directive 79/113 EEC 85LPA.

RP1500XD GENERAL ARRANGEMENT

RP1500XD GENERAL ARRANGEMENT WITH
LOADER

INTENTIONALLY BLANK PAGE

OPERATING
AND
MAINTENANCE MANUAL
SECTION 2
INSTALLATION AND OPERATING
INSTRUCTIONS

PRE-INSTALLATION
On arrival of the equipment it is advisable to check that all packages listed on
the consignment note have been received.
The equipment must be offloaded using certified lifting gear of suitable
capacity, by a competent person.
When unloading the mixer, care must be taken to ensure the discharge chute
remains clear of obstructions as the chute and door hang below the chassis.
An outline drawing and bolt hold plan is normally sent prior to the despatch of
the machine and will enable preparations to be made for the installation. With
the `picture` of what the machine will look like when it is assembled, the
ancillary equipment dismantled for transport can easily be identified.

INSTALLATION
Please refer to contract arrangement and site instructions as applicable.
It is recommended that a concrete foundation (to take foundation bolts – not
supplied) of at least 0.6m2by 0.3m thick to take M20 bolts should be provided
for each leg of the support structure and runway when fitted. When the machine
is supplied without a support structure it should be mounted on supports of
sufficient strength and rigidity to prevent undue vibration when the machine is
working. When making provision for a loading hopper pit it is strongly
recommended that the pit is concreted out so that it can easily be kept clean and
free from any build up which could prevent the bottom limit switch from
operating correctly.
Before completing the installation, check that the main mixer frame is level
with a spirit level. Packings should be inserted as required under the structure
legs or main frame. The packings under the mixing pan roller brackets are set
during manufacturing and must not be disturbed under any circumstances.
Check that the pan is seated and that the pan rack and drive gear are in mesh..
Also check that all the blade clearances are in line with the maintenance
instructions.
On connecting to the power supply, the wiring diagram must be referred to.
A check that the wiring is correct is the rotation of the following:-
•The mixing pan and mixing star rotate anti-clockwise when looking from
the top.
•The loader winch rotates anti-clockwise looking from the rope drum end
when the raise button is pressed.
•The whirler unit rotates clockwise when looking from the top.
It is advisable to mount the starters away from the machine on supports free
from vibration. Ensure that the starters are fitted with suitable overloads – see
technical specification – power units. Note:- it is recommended that the
mains electrical supply is taken via an earth leakage circuit breaker.
A simple Water Flow Meter is available as an option to the water tank, this has
a range of 0-100 litres and features an adjustable flow indicator with a reset
facility allowing very accurate measurement of water flow irrespective of the
pressure. The Flow Meter is normally fitted with a manual ‘on/off’ valve and is
protected by a washable in line strainer.

A supply of compressed air at 5.5 bars is required. The inlet for the connection
from the air line is tapped ½” B.S.P. A drop in pressure will cause incorrect
operation of the pneumatic system.

OPERATING THE MACHINE
Before starting production the following points should checked:-
(1) That there is oil in (a) the Star Drive Gearbox
(b) the Pan Drive Gearbox
(c) the Loader Winch Gearbox (when fitted)
(d) the Air Line lubricator
(2) The Mixing pan should be clear of loose nuts, bolts, spanners etc., as
these will damage the fingers and blades.
(3) Check that the Discharge Door and Discharge Blade are operating
correctly.
(4) Check that the blade clearances are correct and if necessary adjust, in line
with the maintenance instructions.
(5) Check that the limit switches on the loader stop the Loading Hopper in
the required positions at the top and bottom of the runway.
(6) Check that the Water tank is set to the required amount and is filling up
to this level. (See later page for further information on Water Tank
operation).
(7) When Weigh Gear is fitted check that the setting arrangements and
lubrication requirements have been carried out.
(8) If a Flow Meter is fitted check that the pointer is reset to zero and the
strainer is clean and free from debris.
IMPORTANT:
The CUMFLOW is a high performance Mixer.
The following precautions are necessary to obtain the best results and to avoid
damage to the Mixing Star and Drive.
AGGREGATES:
Strict control of graded aggregates must be maintained. Maximum Size 38mm.
Oversize lumps of aggregate or rogue material must be prevented from entering
the Pan.

MIXING STAR BLADES:
They are of a special shape and material to prolong wear life. They should not
be modified in any way and only replaced by genuine ‘WINGET CROKER’
spares.
Daily check is advised to ensure that the Blades/Wearing Pieces are securely
bolted and undamaged.
PAN RIM & BASE WEARING PLATES:
They must be replaced before excessive wear causes distortion.
MAXIMUM BATCH LOADS:
Under no circumstances should the Maximum Batch Loads quoted be
exceeded nor should the Mixer be stopped and re-started when there is a mix in
the Pan.
After each mix the contents of the pan must be completely discharged
before attempting to close the discharge door. At the end of each period of
operation the mixing pan, mixing blades, discharge blade and fingers,
discharge chute, discharge door and seating must be washed down to
prevent concrete setting on them and so impairing the efficiency of the
machine.
WARNING:
THE MAUFACTURER ACCEPTS NO RESPONSIBILITY FOR ANY
DAMAGE OR FAILURE RESULTING FROM OPERATIONAL MIS-
USE OR MALPRACTICE.
OPERATING INSTRUCTIONS FOR WEIGH GEAR
MECHANISM
HYDROSTATIC LOADCELL & GAUGE
The Hydrostatic Load Cell is connected by a flexible capillary tube (approx 9.7
metres long) to a 300mm (12”) diameter weigh gauge.
The whole system is assembled and filled with fluid under vacuum and under
no circumstances should any of the components be disconnected, in the event
of component damage the complete assembly should be returned to Winget
Limited for repair.