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MIXER160 CUBIC FOOT
World Headquarters801 Johnson St. • Alpena, Michigan, 49707 • U.S.A.
Phone (989) 354-4111
INSTALLATION MANUAL
466381F0201
APRIL 2003 • US$250
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COMPANY NAME: ..............................................................
SERIAL NUMBER: ..............................................................
ASSEMBLY NUMBER: ..............................................................
WIRING DIAGRAM NUMBER: ..............................................................
INSTALLATION DRAWING NUMBER: ............................................................
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160 Cubic Foot
i
Table of Contents
466381F0201US F1 24AP03
160 CUBIC FOOT MIXER
TABLE OF CONTENTS
LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
MIXER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
PRIMARY MIXER DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi
MIXER ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii
SAFETY BULLETIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x
SAFETY SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi
LIFTING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi
SECTION 1 MIXER OVERVIEW
1.1 INFORMATION ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 MIXER ASSEMBLY OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.4 MIXER INSTALLATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.5 REQUIRED PARTS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . .1-3
SECTION 2 POSITION MIXER
2.1 CHARGING SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 DISCHARGE SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
SECTION 3 PREPARE SITE
3.1 PREPARE THE SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.1.1 Installation At or Below Plant Grade . . . . . . . . . . . . . . . . . . . . . . .3-1
3.1.2 Position the I-Beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.1.3 Installation Below Floor Level . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.1.4 Installation Above Floor Level . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3.2 ELECTRICAL, WATER AND AIR SUPPLY CONSIDERATIONS . . . . . . . .3-6
3.3 CHARGING CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3.3.1 Optimum Charging Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3.3.2 Recommended Charging Area . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3.4 GROUTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
SECTION 4 INSTALLATION GUIDELINES
4.1 LIFTING CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
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Table of Contents
160 Cubic Foot TABLE OF CONTENTS
ii 466381F0201US F1 24AP03
4.2 MIXER INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.2.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.2.2 Elevation and Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24.2.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.3 ELECTRICAL INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . . . .4-2
4.3.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.3.2 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.3.3 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.3.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.4 AIR SUPPLY INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . .4-3
4.5 WATER SUPPLY INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . .4-3
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A Overall Mixer Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi
B Mixer Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv
C Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi
SECTION 1 MIXER OVERVIEW
1.1 Major Components of the Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
SECTION 2 POSITION MIXER
2.1 Typical Platform for Maintenance – Top View . . . . . . . . . . . . . . . . . . . . .2-2
2.2 Typical Platform for Maintenance – Front View . . . . . . . . . . . . . . . . . . . .2-3
2.3 Typical Platform for Maintenance – Side View . . . . . . . . . . . . . . . . . . . . .2-4
SECTION 3 PREPARE SITE
3.1 I-Beam Locations and Load Requirements . . . . . . . . . . . . . . . . . . . . . . .3-2
3.2 I-Beam Elevation Relative to Plant Grade Elevation . . . . . . . . . . . . . . . .3-3
3.3 Anchor Bolt Locations in the I-Beams . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.4 Pit Dimensions for Below Floor Level Installation – Top View – . . . . . . . .3-4
3.5 Pit Dimensions for Below Floor Level Installation – Side View – . . . . . . .3-5
3.6 Typical Platform for Maintenance – Front View . . . . . . . . . . . . . . . . . . . .3-6
3.7 Typical Platform for Maintenance – Top View . . . . . . . . . . . . . . . . . . . . . .3-7
SECTION 4 INSTALLATION GUIDELINES
4.1 Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 Electrical Wiring Block Diagram for aTypical Mixer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
160 CUBIC FOOT
LIST OF FIGURES
TABLE OF CONTENTS 160 Cubic Foot
iii
List of Figures
466381F0201US F1 24AP03
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Notice
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iv 466381F0201US F1 24AP03
NOTICE
Information in this manual is subject to change. Updates will be provided when safety issues arise, orwhen information becomes outdated. The Besser Company drawings and prints provided with your equip-
ment and machinery are current to the date of manufacture.Illustrations in this manual are provided to help you understand the instructions. The illustrations have
not been drawn to scale. Please read and understand this manual and the Operation/Maintenance Manualbefore operating this machinery. Observe all safety signs and OSHA-approved lockout and tagout proce-
dures. If you have questions about these safety procedures, please contact your Besser Sales andService Representative before start-up of the machine.
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TABLE OF CONTENTS 160 Cubic Foot
v
Specifications
466381F0201US F1 24AP03
160 CUBIC FOOT
SPECIFICATIONS
SHIPPING WEIGHT
(APPROXIMATE) 33,000 pounds [14,969 kg]
OVERALL DIMENSIONS W: 9 feet 6 1/4 inches [2902 mm]L: 17 feet 2 1/4 inches [5239 mm]
H: 7 feet 5 1/2 inches [2273 mm]
PRODUCTION CAPACITY
Maximum volume 160 cubic feet [4.5 m3]
Maximum weight 16,000 pounds [7258 kg]
MIXER ELECTRICAL
MOTOR RATING 2 @ 75 hp [56 kW]
BLADE SHAFT SPEED (RPM) 15.7
MIXER AIR REQUIREMENTS
Air inlet supply 76 inches above floor [1930 mm]
Discharge gate, each 2 1/2 cubic feet [0.071 m3]open/close cycle, (36.72 SCFM)at 120 psi [827.4 kPa]
MIXER WATER REQUIREMENTS
Water supply inlet 1 1/2 inches [38 mm] ID
Gallons [liters] per batch 116 gallons [440 L]
SENSOR AND CONTROL PANEL
OPERATING RANGES
Ambient operating temperature 32° to 131° F[0° to 55°C]
Humidity range 5 to 95 percent,noncondensing
Line voltage 85 to 132 VAC
OPERATING CONDITIONS Besser Company machinery and equipment is designed to comply
with the essential health and safety regulations (EHSR) that apply todirectives which are applicable to an industrial environment. Thebuyer shall utilize this equipment in a manner consistent with itsdesign, and only in an industrial environment.
NOTE:
SCFM means standard cubic feet per minute.
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Primary Mixer Dimensions
160 Cubic Foot TABLE OF CONTENTS
vi 466381F0201US F1 24AP03
7 ft - 5.5 in[2273 mm]
9 ft - 6.25 in[2902 mm]
17 ft - 2.25 in[5239 mm]
Figure A Overall Mixer Dimensions
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TABLE OF CONTENTS 160 Cubic Foot
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Electrical Data
466381F0201US F1 24AP03
160 CUBIC FOOT
ELECTRICAL DATA
CAUTION:
To Comply with Articles 110-9 110-10 of the National Electrical Code:• The customer shall supply a branch circuit protective device to protect the control panel.
The protective device shall have a short circuit interrupting rating of no less than the avail-able short circuit current. Failure to do so could result in a rupture of the protective device
while personnel are attempting to clear a fault.• Besser Company recommends the use of protective devices with interrupting ratings of
no less than 200,000 amps RMS symmetrical.
The caution below applies to the 160 cubic foot mixer electrical data.
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Electrical Data
160 Cubic Foot TABLE OF CONTENTS
viii 466381F0201US F1 24AP03
160 CUBIC FOOT
ELECTRICAL DATA
PLANT POWER
SUPPLY(VOLTS)
208V60 HZ
220V
50 HZ
230V60HZ
380V50 HZ
415V50 HZ
460V
60 HZ
575V60 HZ
400
400
400
200
200
200
200
350
300
300
200
175
150
125
2.5 IN64 MM
2.5 IN
64 MM
2 IN51 MM
1.5 IN38 MM
1.5 IN38 MM
1.25 IN
32 MM
1 IN25 MM
BRANCH
CIRCUITDISTRIBUTION
SWITCH(AMPS)
BRANCHCIRCUIT
FUSE FRS-R
(AMPS)
BRANCHCIRCUITFEEDER
THHN
BRANCHCIRCUITFEEDER
CONDUIT
AMPSPER
MOTOR
SHORT
CIRCUITINTERRUPTING
CAPACITY(AIC)
350KCMIL
350KCMIL
350KCMIL
3/0 AWG85 MM
2/0 AWG
67.5 MM
1 AWG42.4 MM
2 AWG33.6 MM
200,000
200,000
200,000
200,000
200,000
200,000
200,000
203.80
193
184
112
103
92
73.50
Table A 160 Cubic Foot Mixer Electrical Data for One Starter per Electric Motor
This information is the same for all 160 Cubic Foot Mixers.
TOTAL HORSEPOWER: 150
NUMBER OF MOTORS/HORSEPOWER: 2/75
TOTAL KILOWATTS: 111.86
NUMBER OF MOTORS/KILOWATTS: 2/55.93
CONTROL PANEL TRANSFORMER: 500 volt amps (if used)
NOTES:• Fuses and wire and conduit are sized for 125% of motor full load amperes.
• Full load amperes may vary from one motor to another.
• Table A data is representative of each motor’s specifications not a combination of both motors.These specifications are used when each electric motor has its own starter. However, BesserCompany recommends the use of a single soft starter, sized to start both motors at the same time.
When a single soft starter is used, refer to Table B.
Consult tables A and B to find the appropriate electrical data for your 160 cubic foot Mixer. First, find your
corresponding plant power supply in the left column. Then find the corresponding electrical data on thesame row as your power plant supply.
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Electrical Data
TABLE OF CONTENTS 160 Cubic Foot
ix466381F0201US F1 24AP03
Example: Your power plant supply is 460V at 60 Hz and you use a single soft starter to start both motorsat the same time. Using the tables and general information, you will get these values:
PLANT POWER SUPPLY: 460 volt – 3-phase – 60 hertz
MIXER MOTORSTotal Horsepower: 150Number of Motors/Horsepower: 2/75
Total Kilowatts: 111.86Number of Motors/Kilowatts: 2/55.93
BRANCH CIRCUIT TO STARTER (TABLE B)
Distribution Switch Recommended: 400 amp
Fuse Recommended [FRS–R]: 250 ampFeeder Recommended [THHN]: 250 KCMILFeeder Conduit Recommended: 2.0 in. [51 mm]Short Circuit Interrupting Capacity: 200,000 AIC
Total Ampere Load 207
EACH MIXER MOTOR
Horsepower: 75Kilowatts: 55.93
CIRCUIT TO MOTOR (TABLE A)Feeder Recommended [THHN]: No. 1 AWG (42.4 mm)Feeder Conduit Recommended: 1.25 in. [32 mm]Ampere/Motor: 92
CONTROL PANEL TRANSFORMER: 500 volt amps (if used)
ELECTRICAL DATA NOTESFor safety purposes, Besser Company requires that this equipment be connected to a lockable
electrical disconnect. Due to the high current required, use of 230 VAC or less is not recommended.
PLANT POWERSUPPLY(VOLTS)
220V50 HZ
230V60HZ
380V
50 HZ
415V50 HZ
440V50 HZ
460V60 HZ
575V
60 HZ
600
600
400
400
400
400
200
500
500
350
300
250
250
200
2.5 IN*64 MM
2.5 IN*64 MM
2.5 IN
64 MM
2.5 IN64 MM
2.0 IN51 MM
2.0 IN51 MM
1.5 IN
38 MM
BRANCHCIRCUIT
DISTRIBUTIONSWITCH
(AMPS)
BRANCHCIRCUIT
FUSE FRS-R(AMPS)
BRANCHCIRCUIT
FEEDERTHHN
BRANCHCIRCUIT
FEEDERCONDUIT
AMPSPER
MOTOR
CALCULATEDTOTAL
AMPS
SHORTCIRCUIT
INTERRUPTINGCAPACITY
(AIC)
350*
KCMIL
350*KCMIL
350KCMIL
350KCMIL
250
KCMIL
250
KCMIL
3/0 AWG85 MM
200,000
200,000
200,000
200,000
200,000
200,000
200,000
193
184
112
103
100
92
73.5
434
414
252
232
225
207
165
NOTE: * 2 Sets of Wires / * 2 Runs of Conduit
Table B 160 Cubic Foot Mixer Electrical Data for One Starter for Both Motors
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Safety Bulletin
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x 466381F0201US F1 24AP03
SAFETY BULLETINThis notice is issued to advise you that some previously accepted shop practices may not be keeping upwith changing Federal and State Safety and Health Standards. Your current shop practices may notemphasize the need for proper precautions to insure safe operation and use of machines, tools, automatic
loaders and allied equipment and/or warn against the use of certain solvents or other cleaning substancesthat are now considered unsafe or prohibited by law. Since many of your shop practices may not reflectcurrent safety practices and procedures, particularly with regard to the safe operation of equipment, it isimportant that you review your practices to ensure compliance with Federal and State Safety and Health
Standards.
IMPORTANTThe operation of any machine or power-operated device can be extremely hazardous unless
proper safety precautions are strictly observed. Observe the following safety precautions:
Always be sure proper guarding is in place for all pinch, catch, shear, crush and nip points.
Always make sure that all personnel are clear of the equipment before starting it.Always be sure the equipment is properly grounded.
Always turn the main electrical panel off and lock it out in accordance with published lockout/tag-out procedures prior to making adjustments, repairs, and maintenance.
Always wear appropriate protective equipment like safety glasses, safety shoes, hearingprotection and hard hats.
Always keep chemical and flammable material away from electrical or operating equipment.
Always maintain a safe work area that is free from slipping and tripping hazards.
Always be sure appropriate safety devices are used when providing maintenance and repairs to allequipment.
Never exceed the rated capacity of a machine or tool.
Never modify machinery in any way without prior written approval of the Besser EngineeringDepartment.
Never operate equipment unless proper maintenance has been regularly performed.
Never operate any equipment if unusual or excessive noise or vibration occurs.
Never operate any equipment while any part of the body is in the proximity of potentially haz-ardous areas.
Never use any toxic flammable substance as a solvent cleaner.
Never allow the operation or repair of equipment by untrained personnel.
Never climb or stand on equipment when it is operational.
It is important that you review Federal and State Safety and Health Standards on a continual basis. Allshop supervisors, maintenance personnel, machine operators, tool operators, and any other person
involved in the setup, operation, maintenance, repair or adjustment of Besser-built equipment should readand understand this bulletin and Federal and State Safety and Health Standards on which this bulletin isbased.
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TABLE OF CONTENTS 160 Cubic Foot
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Safety Signs
466381F0201US F1 24AP03
SAFETY SIGNSSign Description Required1 All Panels ............................................................................................................1
2 Mixer ...................................................................................................................4
3 Concrete Products Machine................................................................................1
Depalleter............................................................................................................2
4 Mixer ...................................................................................................................2
5 Skiploader ...........................................................................................................4
6 Skiploader/Mixer Platforms .................................................................................8
7 Skiploader/Mixer Platforms .................................................................................8
8 Vertical: Pallet Transport System ........................................................................2
Horizontal: LSC-40A/LSC-100 ............................................................................6
Pallet Transport System ......................................................................................4
9 Besser-Matic .......................................................................................................410 Besser-Matic .......................................................................................................4
11 Skiploader ...........................................................................................................4
12 All Panels ............................................................................................................1
13 Overhead Block Transfer.....................................................................................4
14 Block Pusher.......................................................................................................2
Pallet Transfer System ........................................................................................4
15 Concrete Products Machine................................................................................2
16 Conveyors .........................................................................................................12
17 Cuber ..................................................................................................................8
18 Cuber ..................................................................................................................3Block Turnovers...................................................................................................2
Slat Conveyors....................................................................................................2
To order safety decals, contact your local Besser representativeor the Besser Central Order Department.
Thank you!
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Safety Signs
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xii 466381F0201US F1 24AP03
D NGER
PELIGRO
Mixer blade hazard.Close front paneland stay clearduring operation.Follow lockoutprocedure before
servicing.
113237F0410 Mixer Blade Hazard
Width 4 1/2 inch Height 10 1/4 inch
DANGERNGER
PELIGRO
High voltage.Follow lockoutprocedure beforeservicing panel
or machine.
Large: 113236F0409 High Voltage
Width 4 1/2 inch Height 9 5/8 inch
Small: 113236F0204 High Voltage Width 2 inch
Height 4 1/8 inch
D NGER
PELIGRO
Crush hazards.Stay clear ofmachine.Follow lockoutprocedure
before servicing.
Vertical: 113240F0307 Crush Hazard
Width 3 1/2 inch Height 7 1/2 inch
Horizontal: 113239F0604 Crush Hazard
Width 6 5/8 inch
Height 4 inch
D NGER
PELIGRO
Crush hazard.Stay clear.Follow lockoutprocedure beforeservicing.
114688F0906 Crush Hazard
Width 6 1/4 inch Height 9 1/2 inch
D NGER
PELIGRO
Nip points.Stay clear. Followlockout procedurebefore servicing.
114692F1006 Nip Points
Width 5 3/4 inch Height 9 1/2 inch
W RNING
MU HO
UID DO
Fall hazard.Stay clear.
114689F0804 Fall Hazard
Width 4 1/2 inch Height 7 3/4 inch
1 2 3
4 5 6
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TABLE OF CONTENTS 160 Cubic Foot
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Safety Signs
466381F0201US F1 24AP03
Crush hazard.Stay clear of carand crawler.Follow lockout
procedure beforeservicing.
D NGER
PELIGRO
Vertical: 113244F0410 Crush Hazard
Width 4 1/2 inch Height 10 inch
Horizontal: 113245F1005 Crush Hazard Width 10 inch
Height 5 3/4 inch
W RNING
MU HO
UID DO
Falling objects.Hard hat area.
114690F0805 Falling Objects
Width 4 3/4 inch Height 8 inch
D NGER
PELIGRO
Crush hazard.Stay clear oftransfer area.Follow lockoutprocedure before
servicing.
113242F0409 Crush Hazard
Width 4 1/2 inch Height 9 5/8 inch
D NGER
PELIGRO
Shear hazard.Fall hazard.Stay clear. Followlockout procedurebefore servicing.
114691F1006 Shear and Fall Hazards
Width 5 3/4 inch Height 9 3/4 inch
SUGGESTEDLOCKOUTPROCEDURE
1. Announce lockout to other employees.
2. Turn power off at main panel.
3. Lockout power in off position.
4. Put key in pocket.
5. Clear machine of
all personnel.
6. Test lockout by hitting run button.
7. Block, chain or release stored energy sources.
8. Clear machine of personnel before restarting machine.
113249F0410 Safety Instructions Decal –
Suggested Lock-out Procedure Width 4 inch
Height 10 inch
Falling objects.Stay clear oftransfer area.Follow lockoutprocedure beforeservicing.
D NGER
PELIGRO
113243F0410 Falling Objects
Width 4 1/2 inch Height 10 inch
7 9
11
8
10 12
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Safety Signs
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xiv 466381F0201US F1 24AP03
D NGER
PELIGRO
Crush hazard.Stay clear ofmachine. Followlockout procedurebefore servicing.
Crush hazard. Stay
lockout procedurearea. Follow
before servicing.
clear of transfer
D NGER
PELIGRO
113238F1005
Crush Hazard Width 10 inch
Height 5 3/4 inch
113248F1006
Crush Hazard Width 10 inch
Height 6 inch
D NGER
PELIGRO
Crush and pinchpoints. Stay clearof machine. Followlockout procedurebefore servicing.
Nip hazard.
lockout procedureconveyor. Follow
before servicing.
stay clear of
W RNING
MU HO
UID DO
113241F0605 Crush and Pinch Points
Width 6 5/8 inch
Height 4 inch
113246F0704 Nip Hazard
Width 7 inch
Height 4 1/2 inch
Crush hazard.
secure elevatorprocedure and
before servicing.
Follow lockout
D NGER
PELIGRO
D NGER
PELIGROCrush and pinch-points. Stay offconveyor. Followlockout procedurebefore servicing.
113247F1006
Crush Hazard Width 10 inch
Height 6 inch
113250F1006
Crush and Pinch Hazard Width 10 inch
Height 6 inch
13
15
14
17
16
18
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TABLE OF CONTENTS 160 Cubic Foot
xv
Lifting Points
466381F0201US F1 24AP03
LIFTING POINTSBesser Company recommends that the cus-
tomer use a professional rigging crew to hoist theheavy Mixer components The method used to
hoist this equipment may vary, depending uponavailable rigging equipment and the plant layout.
LiftingPoints
Figure B Mixer Lifting Points
To ensure the safety of plant personnel during
Mixer installation, the rigging system must have alifting capacity that meets or exceeds the shipping
weight of the Mixer as listed in MixerSpecifications at the front of this manual.
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Decals
160 Cubic Foot TABLE OF CONTENTS
xvi 466381F0201US F1 24AP03
Decal322271
Decal
299892
Decal112880F0418
Decal112880F0418
Decal113236F0204
Decal113236F0204
Decal113241F0605
Decal
113241F0605
Decal113463F1205
Decal113463F1205
Decal113241F0605
Decal113237F0410
and113249F0410
Decal113237F0410
and113249F0410
Decal313700 and
313761
Decal313700 and
313761
Decal313700 and
313761
Decal313700 and
313761
Figure C Decals
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1-1466381F0201US F1 24AP03
1.2 SAFETY INFORMATION
Review the Safety Bulletin at the front of thismanual before installing or working on the Mixer.
During Mixer installation, be sure to observe allapplicable Federal, State and local safety regula-tions, as well as Cautions and Warnings that are
in this manual.
1.3 MIXER ASSEMBLY OVERVIEW
Figure 1.1 shows the major components
of the Mixer. For complete parts description,identification and illustration, refer to theOperation/Maintenance Manual and the Mixer
Parts Catalog.
1.1 INFORMATION ABOUT THIS MANUAL
The manual will help you install the Mixersafely and correctly.
Refer to Mixer Specifications and Mixer
Electrical Data at the front of this manual to iden-tify certain requirements of your Mixer. The Mixermodel number is on the name and lubricationplate on the Mixer. For installation details that
might not be in this manual, refer to BesserCompany drawings and information provided withyour equipment.
SECTION 1
MIXER OVERVIEW
IMPORTANT:
This manual contains instructions and guide-lines for the correct handling, placement andinstallation of the Besser Mixer. Installing the
Mixer without fully understanding and followingthe material in this manual may result in seriousinjury to personnel or damage to machinery. If
you have questions about any instructions,procedures or guidelines, contact your
Besser Sales and Service Representative forassistance.
INSTALLATION 160 Cubic Foot
SECTION 1
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SECTION 1
160 Cubic Foot INSTALLATION
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Pulley Sleeve BearingLube System
PulleyAssembly
Blade ShaftAssembly
ElectricMotor
Front PanelAssembly
Mixer Head
Mixer Head
Head Liners
Dust Hub
Mixer Drum
Discharge GateAssemblyDischarge
Chute
PulleyGuard
Assembly
GearcaseAssembly
Head Scrapers
ShroudAssembly
Water PipeAssembly
Cleaning Rings
Figure 1.1 Major Components of the Mixer
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1-3466381F0201US F1 24AP03
INSTALLATION 160 Cubic Foot
SECTION 1
1.4 MIXER INSTALLATION OVERVIEW
Much of the work involved in installing theMixer is that which goes into preparing the site
and constructing the foundation on which the
Mixer will be mounted. The following primarysteps must be done to install the Mixer. Refer tothe other sections for detailed procedures and
information.1. Determine the required orientation of the
Mixer at the site. Identify each side andfunction of the Mixer, taking into consider-
ation the function of each side and itsspace requirements for operation andmaintenance.
2. Determine the Mixer site and at whatgrade the Mixer will be installed – below
plant grade, at plant grade, or above plantgrade. The site must be able to safely
support the Mixer and its operating loads.3. Collect the material required for site
preparation and Mixer installation.4. Prepare the site.
5. Install the Mixer and any associatedequipment. Associated equipment mustcharge Mixer properly. Refer to Section
4.6 and Besser Company InstallationDrawings for charging information.
6. Connect the Mixer to the electrical, pneu-matic and water sources. Refer to the
front of this manual and to BesserCompany drawings, for specifications,electrical data and supply requirements.
7. Install ladders, platforms, guarding, and
other materials that will be needed foroperation and maintenance for your plantlayout. Be sure your installation meets all
applicable Federal, State, and local safetycode requirements.
1.5 REQUIRED PARTS AND EQUIPMENT
The following materials and components areneeded for installing the Mixer. These are usuallynot provided by Besser Company.
• Four steel I-beams, 6 inches [152 mm] x 121/2 pound [6 kg], and 6 feet [1829 mm] long• Anchor bolts and nuts
• Conduit to the Mixer for control wiring• Conduit and wire from the Mixer motor
starter to the motor• Incoming power feed, with fuse box, circuit
breaker, and lockable electrical disconnect• Water and air supply lines to the Mixer• Controls for the Mixer, if not supplied as a
Mixer option• Motor starter, if not supplied as a Mixer
option• Ladders, platforms, guarding, and other
materials that will be needed for Mixer oper-ation and maintenance for your plant layout.
Refer to the front of this manual and to BesserCompany drawings, for specifications, electrical
data, and supply requirements.
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SECTION 1
160 Cubic Foot INSTALLATION
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160 Cubic Foot INSTALLATION
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Figure 2.1 Typical Platform for Maintenance – Top View
Interlocked hinged guardfor mixer gate safety stop
shuts down mixer when open.
FOR REFERENCE ONLYCheck your Installation
Drawings for exact dimensions.
NOTE:
The customer is required to purchase ladder,walkways and guarding from Besser Company or
another supplier. If the customer purchases lad-der, walkway and guarding from a source otherthan the Besser Company, the customer assumes
all responsibility for meeting all safety code
requirements.
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INSTALLATION 160 Cubic Foot
SECTION 2
Front PanelFOR REFERENCE ONLYCheck your Installation
Drawings for exact dimensions.
Figure 2.2 Typical Platform for Maintenance – Front View
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Height PerDesign
FOR REFERENCE ONLYCheck your Installation
Drawings for exact dimensions.
Figure 2.3 Typical Platform Maintenance – Charging Side View
160 Cubic Foot INSTALLATION
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INSTALLATION 160 Cubic Foot
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3.1 PREPARE THE SITE
3.1.1 Installation At or Below Plant GradeMixer installation at or below plant grade
requires a concrete foundation.The concretefoundation must have four steel I-beams set with-
in non-shrink grout and located as shown onFigure 3.1 and Mixer installation drawings.
3.1.2 Position the I-Beams
1. Use four 6 inch [152 mm] x 12 1/2 lb[6 Kg] I-beams, 6 feet [1829 mm] long.
2. The top of each steel beam is 1/8 inch[3 mm] above the Mixer elevation. SeeFigure 3.2. If the Mixer elevation isunknown, the height of the steel beams
can be determined from the plant layout.For example, if the Mixer’s plant layoutgrade is at elevation 100 feet [30480 mm],the tops of the beams need to be 1/8 inch
[3 mm] above this elevation, or at 100 feet[30480 mm] plus 1/8 inch [3 mm].
A primary consideration when selecting aMixer site is the grade level needed for the Mixerto function in the overall plant operation. Three
common grade levels are:• below plant grade• at plant grade, or floor level• above floor level
Each type of installation requires a foundationcorrectly designed for the static and operating
loads of the Mixer. Load requirements are shownon Figure 3.1 and on Besser Company installa-tion drawings for your Mixer. Trained professionalsat Besser Company can assist in determining thebest site and design for your facility. Be sure the
plant meets all applicable Federal, State and localsafety code requirements. Be sure to obtain orfabricate ladders, platforms, guarding and othermaterial that will be needed for operation and
maintenance.
SECTION 3
PREPARE SITE
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INSTALLATION 160 Cubic Foot
SECTION 3
3-3466381F0201US F1 24AP03
= ANCHOR BOLTS 1.125 in. [29 mm] Diameter Anchor Bolt Hole (8 Places)
CL
86.625 in.[2200 mm]
54.625 in.[1387 mm]
MIXER
54.625 in.[1387 mm]
86.625 in.[2200 mm]
Figure 3.3 Anchor Bolt Locations in the I-Beams
When installing the I-beams, set them intheir correct locations and level them to within1/16 inch [2 mm] of the required height, using atransit. Pour non-shrink grout between the beams
to secure their locations. When the Mixer isinstalled and after the non-shrink grout has ade-quately set, secure the Mixer either by welding it
to the I-beams, or bolting it to the beams usinganchor bolts. If bolts will be used, locate them asshown in Figure 3.3 before setting the beams.
NOTE:When securing Mixer fill voids between Mixerbase and four I-beams with shims to avoid distort-
ing Mixer base when tightening anchor bolts.
0.125 in.[3.175 mm]
Plant Grade Elevation
Poured ConcreteNon-ShrinkGrout
I-Beam
Figure 3.2 I-Beam Elevation Relative to Plant Grade Elevation
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160 Cubic Foot INSTALLATION
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3-4 466381F0201US F1 24AP03
3.1.3 Installation Below Floor LevelFigure 3.4 and 3.5 shows recommended mini-
mum pit dimensions for installing the Mixer belowfloor level of the plant. When planning a below
grade installation, be sure the plant meets allapplicable Federal, State and local safety coderequirements. Be sure to obtain or fabricate lad-
ders, platforms, guarding, and other material thatwill be needed for operation and maintenance.
Figure 3.4 Pit Dimensions for Below Floor Level Installation – Top View
24 in.[610 mm]
36 in.[914 mm]
CHARGINGAREA
36 in.[914 mm]
Gearcase
Motor
Pulley Guard
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INSTALLATION 160 Cubic Foot
SECTION 3
3-5466381F0201US F1 24AP03
Pulley Guard
Arc OfFront Panel
GATE ORDISCHARGE
SIDE
CHARGINGSIDE
30 in.[762 mm]
89.500 in.[2273 mm]
To Top OfEnd Plate
32.500 in.[826 mm]
2 7 .7 5 0 i n . [ 7 0 5 m m ]
32.500 in.[826 mm]
34 in.[863 mm]
Anchor Holes?
Head Plate
34 in.[863 mm]
46.500 in.
[1181 mm]
46.500 in.
[1181 mm]
117.250 in.[2902 mm]
Figure 3.5 Pit Dimensions for Below Floor Level Installation – Side View
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160 Cubic Foot INSTALLATION
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3.3 CHARGING CONSIDERATIONCentralized introduction of cement will
improve mixing efficiency and reduce mixing time.
3.3.1 Optimum Charging Location
The center of the aggregate and cementcharging area is located on the center of the
Mixer drum and 12 inches [305 mm] in front ofthe Mixer shaft on the down stroke of the Mixerblade. See Figure 3.4 showing the charging area.
3.3.2 Recommended Charging AreaIntroduce aggregate and cement within
36 inches [914 mm] to either side of the center of
the Mixer drum and within 24 inches [610 mm] infront of the Mixer shaft on the down stroke of theMixer blade. See Figure 3.4 showing the charging
area.
NOTE:
For charging location different than above consultBesser Company Engineering Department.
3.1.4 Installation Above Floor LevelFor an above grade installation, see Figure 3.1.
It is crucial to design the support structure to sup-port the Mixer static and operating loads.The sup-
port structure should also be large enough to pro-vide adequate platform area for personnel to safelyoperate and maintain the Mixer. See Figure 3.6 and3.7. Locations of required anchor bolts are shown in
Figure 3.3 and the Mixer installation drawing.When planning an above floor level installa-
tion be sure the plant meets all applicable
Federal, State, and local safety code require-ments. Be sure to obtain or fabricate ladders, plat-forms, guarding, and other material that will beneeded for operation and maintenance.
3.2 ELECTRICAL, WATER AND AIR SUPPLYCONSIDERATIONS
The site must have adequate and correctlyconfigured electrical, water and air supplies.Refer to the front of this manual, BesserCompany installation drawings and Figure 3.1
(Electric Motor Conduit Location) for specifica-tions, electrical data and supply requirements.
Front PanelFOR REFERENCE ONLY
Check your Installation
Drawings for exact dimensions.
Figure 3.6 Typical Platform for Maintenance – Front View
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3-7466381F0201US F1 24AP03
INSTALLATION 160 Cubic Foot
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Interlocked hinged guardfor mixer gate safety stop
shuts down mixer when open.
FOR REFERENCE ONLYCheck your Installation
Drawings for exact dimensions.
Figure 3.7 Typical Platform for Maintenance – Top View
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3.4 GROUTING PROCEDUREThe first batch for a Mixer with blade wear lin-
ers, is referred to as a “grouting batch.” The“grouting batch” fills the void between the backup
blade and blade liners providing support to bladeliners. Often, a Besser Sales and ServiceRepresentative runs the grouting batch. For moreinformation about the grouting procedure, refer to
Besser Company print number 360464.To prepare your new Besser Mixer blades for
operation, follow this grouting procedure for agood seating of Ni-hard liners to the Mixer blade:
1. Run a throw-away first batch a day or twobefore the start of actual production.
2. Use a fine grout mix made of:• 4,000 lbs very fine sand
• 1,000 lbs cement• Water to make 7 – 9 inch slump.
3. Add cement and water at same time to
make cement slurry.4. Slowly add fine sand to make grout.5. When mix is consistent, stop one blade in
submerged position. Allow enough time
for grout to hold in all spaces betweenbackup blade and Ni-hard blade liners.
6. Submerge opposite blade.7. Perform lockout. See Section 2.1 of
Maintenance/Operation Manual.8. Clean Mixer by hand to allow grout inblades to harden before start of produc-
tion operation.
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INSTALLATION 160 Cubic Foot
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4-1466381F0201US F1 24AP03
Besser Company recommends the use a pro-fessional rigging crew to hoist the Mixer into posi-
tion. The method used to hoist this equipmentmay vary, depending upon available riggingequipment and the plant layout. To ensure thesafety of plant personnel during Mixer installation,
the rigging system must have a lifting capacitythat meets or exceeds the shipping weight of theMixer as listed in Mixer Specifications at the front
of this manual. See Figure 4.1.
4.1 LIFTING CONSIDERATIONS
SECTION 4
INSTALLATION GUIDELINES
WARNING:
Failure to use a professional riggingcrew and equipment may result inserious personal injury or propertydamage.
LiftingPoints
Figure 4.1 Lifting Points
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4.2 MIXER INSTALLATION GUIDELINESOnce the site has been prepared, non-shrink
grout is cured and as applicable, the I-beamsfirmly set, the site is ready for Mixer installation.
4.2.1 Safety InformationDuring Mixer installation, be sure to observe
all applicable Federal, State and local safety regu-lations.
4.2.2 Elevation and Leveling
Use a transit to check the I-beams again, tomake sure they are still at the required elevationand are level after any settling. If necessary, place
shims to maintain I-beam top surface level within1/16 inch.
4.2.3 InstallationOnce the elevation and leveling checks have
been completed, hoist the Mixer into position. Ifanchor bolts are used to secure the Mixer, align
the Mixer and anchor bolt holes during position-ing. When the Mixer is in position, secure it bywelding or bolting to the I-beams.
NOTE:When securing Mixer with anchor bolts, fill voidsbetween Mixer base and three I-beams with
shims to avoid distorting Mixer base whentightening anchor bolts.
4.3 ELECTRICAL INSTALLATIONGUIDELINES
4.3.1 Safety Information
Besser Company requires its customers to
adhere to the following:1. When installing the Mixer, observe the
requirements and specifications on
Besser Company electrical drawings anddiagrams.
2. Use a batching control system or equiva-lent alternative controls.
3. Use lockable electrical disconnects onelectric motors. The wiring to the motorfrom the lockable disconnect can be run
through conduit placed in the floor, or
from overhead. See Figure 3.1. Refer toMixer Electrical Data at the front of thismanual, and Besser Company installation
drawings. Run conduit, as necessary, fromthe batching control panel to the Mixer forthe control wiring.
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INSTALLATION 160 Cubic Foot
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4-3466381F0201US F1 24AP03
Mixer ControlStation (if used)
Mixer ControlPanel
(if used)
Mixer StarterPanel
BatchingControls
Gearcase
Motor
PulleyGuard
Figure 4.2 Electrical Wiring Block Diagram for a Typical Mixer Configuration
4.4 AIR SUPPLY INSTALLATIONGUIDELINES
Install compressed air supply lines to theMixer according to applicable federal, state and
local codes. The supply source and lines must becapable of providing a continuous 120 psi[827.4 kPa] air supply, regulated as given in MixerSpecifications at the front of this manual, and onBesser Company installation drawings.
4.5 WATER SUPPLY INSTALLATIONGUIDELINES
Refer to Besser Company installation draw-
ings and front of this manual for water supplyconnection points and gallons per batch to sizeand install the water supply.
4.3.2 ControlsIf ordered as part of the Mixer, the Mixer
includes an electric motor and starter, and manu-al electrical gate and clutch controls. Besser
Company recommends using a soft starter toenable slow starting of the Mixer motor for energyconservation. Automatic controls are usually part
of a batching control panel.
4.3.3 Electrical WiringAn electrical wiring block diagram of a typical
installation is shown on Figure 4.2. Refer toBesser Company electrical drawings and dia-grams for specific wiring information regarding
gate open/close, Mixer disconnect interlock andunderspeed relay.
4.3.4 InstallationIf not provided with the Mixer, install the Mixer
controls. Install any needed conduit and wiringfrom the power source to the control panel and
motor.
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