Installation and Maintenance Manual for High Shear Duplex Batch Mixer Model KDD

S
Installation,
Operating &
Maintenance
Manual
For
High Shear Duplex
Batch Mixer
Model: KDD
MIXER SERIAL No.
MOTOR SERIAL No.
Silverson Machines Ltd . Waterside . Chesham . Bucks . HP5 1PQ

Tel:(+44) 01494 786331 . Fax:(+44) 01494 791452
BA 111 - KDD ISSUE 3 - December 2008
CONTENTS S
LIST OF ILLUSTRATIONS
ILLUSTRATIONS
Fig. 1 Workheads (Stators) 6
Fig. 2 Lifting the Mixer 7
Fig. 3 Principals of Operation 11
Fig. 4 The KDD Mixer Assembly 13 and 20
Fig. 5 The Bearing Plate Assembly 15
Fig. 6 Measuring The Coupling Concentricity 16
BA 111 - KDD ISSUE 3 - Dec. 2008

Page 2
S
CONTENTS
Page
1.0 INTRODUCTION 4
1.1 Warranty 4
1.2 Technical Service 4
2.0 SAFETY 5
3.0 DESCRIPTION 6
3.1 Workheads (Stators) 6
3.2 Propellers 6
4.0 TRANSPORT & HANDLING 7

4.1 Unpacking 7
4.2 Transporting 7
5.0 INSTALLATION 8
5.1 Installation Mechanical 8
5.1.3 Mounting to Vessel 8
5.2 Installation Electrical 8
5.3 Direction of Rotation 9
6.0 OPERATION 10
6.1 Initial Start - Up 10
6.2 General Operating 10
6.3 Principles of Operation 11
6.4 Cleaning 11
7.0 MAINTENANCE 12
7.1 General Maintenance 12
7.2 Disassembly and Assembly 12
7.3 Changing or Replacing the Lower Workhead 14
7.4 Replacing the Lower Rotor 14
7.5 Replacing The Upper Workhead, Rotor and Bronze Alloy Bush 15
7.8 Removing the Motor 16
8.0 LUBRICATION 17
9.0 RECOMMENDED SPARES 19

9.1 Spares 19
10.0 ILLUSTRATED PARTS LIST 21
ISSUE 3 - Dec. 2008 BA 111 - KDD

Page 3
1.0 INTRODUCTION S
1.0 INTRODUCTION
The purpose of this manual is to provide you with the information needed to set up and operate your Silverson
High Shear Batch Mixer.
With over 50 years of manufacturing experience Silverson has established an unequalled reputation for quality and
reliability and we want you to get the best possible performance from your mixer.
IMPORTANT: Please read this manual carefully before attempting to set up or operate your machine. Neither
Silverson Machines nor their representatives can accept responsibility for damage or injury resulting from
improper set up or use. If you have any questions, please contact our Technical Service Department, or our
representatives who will be pleased to help you.
1.1 WARRANTY
Silverson Machines offer comprehensive after-sales services. If any major fault develops, the mixer should be
returned for repair and / or service
The nature of the fault should be fully described and the Model and serial number of the machine quoted in any
accompanying correspondence
Repair or replacement under warrantee will be effected without charge for up to 1 year from the date of
purchase.
The mixer must only be shipped suitably packed and with the approval of Silverson Machines or their accredited
representatives
1.2 TECHNICAL SERVICE

Spare parts and advice regarding the operation of your machine can be obtained from the Technical Service
Department:
SILVERSON MACHINES LIMITED
WATERSIDE
CHESHAM
BUCKS HP5 1PQ
ENGLAND
TEL:CHESHAM (01494) 786331
FAX:CHESHAM (01494) 791452
or our appointed agents

Page 4
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2.0 SAFETY
2.0 SAFETY
Throughout this manual you will find WARNINGS and CAUTIONS associated with certain procedures.
WARNINGS ARE PROVIDED WHERE THERE MAY BE PHYSICAL DANGER TO

PERSONNEL IF THE WARNING IS IGNORED.
CAUTIONS indicate that the machine may be damaged if care is not taken when
performing the procedure.
2.1 Please observe the Health and Safety regulations applicable to your particular location; these vary from place to
place but their substance is the same - avoid all hazards to personnel and property.
2.2 WARNING: NEVER USE THE MACHINE IN A HAZARDOUS AREA WHERE A

! FLAMMABLE OR EXPLOSIVE ATMOSPHERE MAY BE PRESENT UNLESS THE MACHINE
IS FITTED WITH A FLAMEPROOF MOTOR RATED TO THE RELEVANT STANDARD FOR
THAT AREA.
2.3 WARNING: NEVER TOUCH ROTATING PARTS. FAILURE TO OBSERVE THIS MAY
2.4
! RESULT IN BODILY INJURY.
Use special care when handling the Mixing Assembly - THE ROTOR AREA MAY BE SHARP!
2.5 If using solvents to clean components, use in a well ventilated area and avoid inhalation of fumes. Keep away from
sources of ignition :- No Smoking.
2.6 Never use parts other than those supplied or recommended by Silverson Machines Ltd. The use of such parts
will nullify any warranties and may cause premature wear or more seriously may cause component failure and
possible injury.
2.7 Check that the voltage, phases and cycles (Hz) which are stamped on the electrical data plate are compatible with
the available electricity supply.
2.8 WARNING: ALWAYS DISCONNECT THE MACHINE FROM THE ELECTRIC SUPPLY
! BEFORE CARRYING OUT ANY MAINTENANCE WORK.
Any electrical operation should only be carried out by a suitably qualified electrician.
2.9 WARNING: NEVER CARRY OUT ANY MAINTENANCE WORK OR REMOVE THE MIXING
! ASSEMBLY OR STATOR WHILE THE MACHINE IS RUNNING OR IS STILL CONNECTED
TO THE ELECTRICAL SUPPLY. FAILURE TO OBSERVE THIS MAY RESULT IN BODILY
INJURY.
2.10 Always use lifting equipment where necessary; some components are heavy and can be dangerous to lift without
the correct equipment.
2.11 WARNING: THE MIXER FRAME MUST ALWAYS BE IMMERSED SO THAT FLUID COVERS
! THE ENTIRE WORKING HEAD/SCREEN AND THE BEARING BUSH BEFORE THE
MACHINE IS SWITCHED ON; THE FLUID LEVEL SHOULD BE AT LEAST 250MM ABOVE
THE UPPER BEARING PLATE. IF THIS PRECAUTION IS NOT TAKEN, RAPID
OVERHEATING AND SEIZURE OF THE SHAFT WILL RESULT. NEVER ALLOW THE
MACHINE TO RUN DRY. THE MANUFACTURER WILL NOT ACCEPT
RESPONSIBILITY FOR DAMAGE IF THIS PRECAUTION IS NOT OBSERVED.
2.12 WARNING: FOR FLAMEPROOF APPLICATIONS A FLAMEPROOF LOW LEVEL

! SWITCH/SENSOR SHOULD BE FITTED AND INTER-LINKED WITH THE MIXER'S
ELECTRICAL SWITCHGEAR TO ENSURE THAT THE MIXER IS AUTOMATICALLY
TURNED OFF IF THE FLUID DROPS TO A LEVEL WHICH COULD CAUSE CAVITATION
AROUND THE STATOR/ROTOR AREA; THIS LEVEL WILL VARY ACCORDING TO THE
VISCOSITY AND SPECIFIC GRAVITY OF EACH INDIVIDUAL MIX. THE
SWITCH/SENSOR SHOULD ALSO PREVENT THE MIXER BEING STARTED IF THE
VESSEL IS EMPTY.

Page 5
3.0 DESCRIPTION S
3.0 DESCRIPTION
Silverson Standard Multi-Purpose Batch Mixers are designed to perform the widest
possible variety of applications: Mixing, emulsifying, homogenising, disintegration and
dissolving, dispersing, blending, particle size reduction and de-agglomerating.
3.1 WORKHEADS (STATORS)

A comprehensive range of stators and screens is available for all Silverson high shear mixers.
These rapidly interchangeable stators offer great versatility by allowing any machine to be adapted to perform a
wide range of mixing operations.These include emulsifying, homogenising, disintegrating, dissolving, dispersing,
blending, particle size reduction and de-agglomerating. Changing from one screen to another is quick and simple
(see Maintenance Section 6.3)
The following stator descriptions are provided to assist customers in making the correct choice. If you are in any
doubt as to the suitability of a stator for use with a particular application, please do not hesitate to contact us.
We will be happy to advise and, where feasible, arrange for tests to determine the most suitable type of stator for
your needs.
3.1.1 General Purpose Disintegrating Head (Fig. 1a)

This is the most versatile of all the heads, giving an exceptionally vigorous mixing
action. Ideal for general mixing applications, its uses include the disintegration of
solids and the preparation of gels and thickeners, suspensions, solutions and slurries.
Fig. 1a
3.1.2 Slotted Disintegrating Head (Fig. 1b)
For the disintegration of fibrous materials such as animal and vegetable tissue, as well
as the disintegration and solubilisation of elastic materials such as rubbers and
polymers.
Fig. 1b
3.1.3 Square Hole High Shear Screen (Fig. 1c)
The configuration and fine internal tolerances of this stator provide exceptionally
high shear rates which are ideal for the rapid size reduction of soluble and insoluble
granular solids. It is also suitable for the preparation of emulsions, gels and thickeners
and fine colloidal suspensions.
Fig. 1c
3.2 PROPELLERS
3.2.1 Downthrust Propeller (Fig. 1d)
Fitted to the central drive shaft, the Downthrust Propeller is used where required to increase the overall
circulation within the vessel and assist in the incorporation of light powders. It is
adjustable so that it can be raised and lowered to give the optimum effect.
Fig. 1d

Page 6
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4.0 TRANSPORT & HANDLING
4.1 UNPACKING
Caution: The mixer must not be lifted directly by the frame or shaft under any
! circumstances. Webbing bonds should be used at the stator end of the machine using an
over head gantry or fork lift truck. The motor end should be lifted by fixing the bonds
with shackles.
4.1.1 Remove support packing securing the machine to the case. Where the drive shaft length of the mixer is longer
than standard, timber braces may be fitted to the centre shaft; Do Not remove the centre shaft timber brace at
this stage.
4.1.2 Attach bonds to the machine as shown in Fig.2 and lift the machine straight up until the case can be removed.
4.1.3 Remove the case and continue to lift the motor end of the machine until in the vertical position.
4.1.4 Where fitted, the shaft bracing should be removed immediately prior to mounting into vessel. Refer to paragraph
5.0..
4.1.5 If it is necessary to repack the mixer it should be turned into the horizontal by reversing the above procedure.
4.2 TRANSPORTING
4.2.1 To avoid damage the mixer must not be transported without being packed securely and, where necessary, the
centre rotating shaft braced at its mid point. It is strongly recommended that the mixer is transported in the
original case supplied.
4.2.2 The case should preferably be lifted about each end and not in the middle. Distortion of the mixer may result if
lifted in the middle due to the weight of the motor and the stator.
Caution: Under no circumstances

! should the mixer be transported
mounted in a vessel.
Lifiting Straps
(Not Supplied)
Centre Shaft *Packing Case

Timber Braces
* Note:
Packing cases may
vary in construction
to suit customer tran-
sportation requirements
LIFTING THE MIXER Fig. 2

Page 7
5.0 INSTALLATION S
5.1 INSTALLATION - MECHANICAL

NOTE: If it is impossible to install the mixer using the following procedure due to height restraints etc. contact Silverson Machines
Limited or their accredited agents. If the mixer is dismantled for any reason during installation without first contacting
Silverson Machines Limited or their accredited agents all warranties will be invalidated.
5.1.1 Ensure that the mixer has not been damaged in transit and is clean.
5.1.3 MOUNTING TO A VESSEL:

The mixer should only be lifted via the lifting brackets fitted, these have been designed and manufactured to suit
your mixer and are capable of lifting its weight.
The machine should be presented to the vessel in a vertical position. Ensure that the mating flange of the vessel
is flat and true and that a suitable gasket is fitted where required. If the mating flange is not true it is possible for
the machine to be distorted causing premature wear.
Carefully lower the mixer down onto the vessel mounting flange or channel bearers, rotating as necessary to align
the mounting holes.
Secure the mixer and vessel mounting flanges using appropriate bolts or studs and nuts (Customer supplied);
these bolts should be tightened evenly and in sequence.
CAUTION: Always use the mounting flange provided when installing the mixer. To avoid
! undue distortion stresses being placed on the equipment NEVER weld the mixer in place;
such an installation will invalidate all warranties given by Silverson Machines Limited.
5.2 INSTALLATION - ELECTRICAL
WARNING: ANY ELECTRICAL WORK SHOULD ONLY BE CARRIED OUT BY A SUITABLY

! QUALIFIED ELECTRICIAN. ALL NATIONAL, LOCAL AND SITE REGULATIONS SHOULD
BE OBSERVED. WHEN MAKING ELECTRICAL CONNECTIONS THE SUPPLY SHOULD BE
ISOLATED, FUSES REMOVED AND THE FUSE BOX LOCKED SHUT WITH THE FUSES
AND THE KEY IN THE POSSESSION OF THE ELECTRICIAN UNTIL THE WORK IS
COMPLETE.
WARNING: THE MIXER FRAME MUST ALWAYS BE IMMERSED SO THAT THE FLUID
! COVERS THE ENTIRE WORKING HEAD/SCREEN BEFORE THE MACHINE IS SWITCHED
ON. IF THIS PRECAUTION IS NOT TAKEN, RAPID OVERHEATING AND SEIZURE OF
THE SHAFT WILL RESULT. NEVER ALLOW THE MACHINE TO RUN DRY. THE
MANUFACTURER WILL NOT ACCEPT RESPONSIBILITY FOR DAMAGE IF THIS
PRECAUTION IS NOT OBSERVED.
WARNING: FOR FLAMEPROOF APPLICATIONS A FLAMEPROOF LOW LEVEL
VESSEL IS EMPTY.
5.2.1 Checks and Precautions
Before connecting the KDD mixer to the electrical supply the following checks/precautions must be taken.
5.2.2 Check that the voltage, phases and cycles (Hz) on the name plate attached to the motor are compatible with the
available electricity supply.
5.2.3 All cables, starters etc. should be sized according to the relevant regulations and codes of practice.
5.2.4 Always follow the motor manufacturers instructions and wiring diagram when connecting three phase motors to
the mains. The instructions are generally provided in the form of a printed sheet situated inside the terminal box,
but they are sometimes printed on the terminal box itself or on the terminal box cover.

Page 8
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5.0 INSTALLATION
5.3 DIRECTION OF ROTATION
CAUTION: The mixer frame must always be immersed so that fluid covers the entire
! working head and rotor assembly BEFORE the machine is switched on; the fluid level
should be at least 250mm above the upper bearing plate. If this precaution is not taken
over heating and seizure of the shaft will result. NEVER allow the machine to run dry.
The manufacturer will not accept responsibility for damage if this precaution is not
observed.
CAUTION: Where the mixer is to be used in high ambient temperatures or to mix a very
! hot product (over 100c ) a cold air supply is recommended in order to cool the Mixer
motor. Contact Silverson Machines Ltd. for advice.
WARNING: DO NOT USE THE MACHINE IN A HAZARDOUS AREA WHERE A

THAT AREA.

VESSEL IS EMPTY.
WARNING: NEVER TOUCH ROTATING PARTS. FAILURE TO OBSERVE THIS WARNING

!
5.3.1
MAY RESULT IN BODILY INJURY.
The KDD Mixer must be connected so as to ensure that it runs in the direction shown by the direction arrow
marked on the Silverson nameplate.
WARNING: ENSURE THAT THE MIXER IS ISOLATED FROM THE ELECTRICAL SUPPLY
!
5.3.2
BEFORE CARRYING OUT THE FOLLOWING PROCEDURE:
Before attempting to start the machine, ensure the drive shaft and the rotor can be turned freely. This is carried
out by removing the fan cowl and turning the fan by hand. If the drive shaft does not turn freely consult Silverson
Machines Limited.
5.3.3 If everything is in order, reconnect the electrical supply and check for direction of rotation.
5.3.4 Press the START button on the starter and IMMEDIATELY press the STOP button.This will make the motor turn
only two or three revolutions - sufficient to view the direction of rotation. This should be as the direction arrow
fitted to the mixer - clockwise when viewed from the fan end of the motor.
5.3.5 If the motor rotates in the wrong direction, change over any two of the input phase lines and repeat the
procedure given above.

Page 9
6.0 OPERATION S
6.0 OPERATION
CAUTION: The mixer frame must always be immersed so that fluid covers the entire
! working head and rotor assembly BEFORE the machine is switched on; the fluid level
should be at least 250mm above the upper bearing plate. If this precaution is not taken
over heating and seizure of the shaft will result. NEVER allow the machine to run dry.
The manufacturer will not accept responsibility for damage if this precaution is not
observed.
CAUTION: Where the mixer is to be used in high ambient temperatures or to mix a very
! hot product (over 100c ) a cold air supply is recommended in order to cool the Mixer
motor. Contact Silverson Machines Ltd. for advice.
WARNING: DO NOT USE THE MACHINE IN A HAZARDOUS AREA WHERE A

THAT AREA.

VESSEL IS EMPTY.
WARNING: NEVER TOUCH ROTATING PARTS. FAILURE TO OBSERVE THIS WARNING

! MAY RESULT IN BODILY INJURY.
6.1 INITIAL START-UP

Note: Item numbers in brackets refer to Fig. 4
6.1.1 Check the direction of rotation - refer to para 5.3
6.1.2 Once the rotational check has been carried out the mixer is ready for production.
6.1.3 The Downthrust propeller (14) should be initially adjusted to be approximately 750m below the proposed liquid
level. The vessel should then be filled to the proposed level which should be at least 250mm above the upper
bearing plate and the machine started. The vortex created should be visually assessed. If it is insufficient, the
Propeller should be raised. If it is too great it should be lowered. The purpose of the downthrust propeller is to
increase circulation in the upper part of the vessel and to ensure that there are no dead spots at the periphery
of the vessel at the product surface.
6.1.4 The propeller shroud (12) (if fitted) should be raised or lowered with the propeller. This is carried out by
loosening the U bolt clamps (13/35) and sliding up or down the frame arms (4). Care should be taken when
tightening the clamps to tighten evenly.
6.2 GENERAL OPERATING

6.2.2 Observe the above WARNINGS and CAUTIONS at the start of this page.
6.2.3 Provided that the above WARNINGS and CAUTIONS are observed there are no additional requirements as to
the operation of the mixer. All processing parameters should be determined during commissioning.

Page 10
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6.0 OPERATION
6.3 PRINCIPLES OF OPERATION (See Fig. 3)
6.3.1 The product is subjected to mechanical and hydraulic shear
forces as it passes through the upper and lower head/rotor
assemblies. The upper head will break down lumps of polymer
while the lower head breaks down individual particles.
6.3.2 The product is then expelled out of the workheads towards

the periphery of the vessel where some will travel toward the
base and some toward the surface.
6.3.3 The flow pattern of the product in the lower portion of the
vessel ensures that there are no dead spots of unprocessed
material.
6.3.4 The action of the two downthrust propellers aids general

circulation in the vessel. The one between the bearing plates
ensures that this potentially dead area is kept clear of
unprocessed material which could solvate and stick to the
lower bearing plate (11). The upper propeller will also wet
out the polymer as it is added ensuring that it does not float
or raft.
6.3.5 The combined action of the workheads and the propellers will Fig. 3
result in a figure of eight mixing action in the vessel and if the propellers are correctly
positioned no dead spots at the surface.
B0024
6.4 CLEANING
6.4.1 The High Shear Batch Mixer is in most cases self cleaning, a short run between successive mixing operations in
water, detergent or an appropriate non-flammable solvent should be all that is necessary to clean the wetted
parts. For more thorough cleaning, dismantling is easy and downtime minimal.
WARNING: THE MIXER MUST BE ISOLATED ELECTRICALLY BEFORE IT IS

!
6.4.2
DISMANTLED FOR INSPECTION. OR CLEANING
The wetted parts can be cleaned with household cleaning agents providing that they do not contain solvents and
are non-scratching. Do not scour the parts with sharp objects.
6.4.3 If the machine is to be left idle for any length of time it should first be thoroughly flushed by running for a short
time in a suitable liquid to wash any solids from the clearances between the rotors and the stators. If this is not
done, the solids may dry out and cement the components together to cause damage when the machine is next
started. When circumstances permit, it may suffice to leave the mixing vessel filled with a suitable fluid to prevent
drying out.
WARNING: THE COMPLETE MACHINE ASSEMBLY SHOULD NEVER BE SPRAYED WITH

!
6.4.4
WATER OR IMMERSED IN WATER.
The materials of construction of the wetted parts are compatible with all commonly used cleaning chemicals.
Most sanitising chemicals, such as those that contain active chlorine, iodine etc. are corrosive, to some extent to
stainless steel.Where these chemicals are used, 316 Stainless Steel should be specified.
CAUTION: Where Sodium Hypochlorite solutions are used for sterilising the mixer, their
! maximum concentration should be 150 ppm available Chlorine at a maximum temperature
of 40C, and an absolute maximum time of 20 minutes. Failure to observe this precaution
may result in corrosion of even 316 Stainless Steel.
WARNING: SUITABLE PROTECTIVE CLOTHING SHOULD BE WORN WHEN HANDLING

! AND USING CLEANING CHEMICALS. NATIONAL, LOCAL AND SITE REGULATIONS
SHOULD BE OBSERVED.

Page 11
7.0 MAINTENANCE S
7.1 GENERAL MAINTENANCE

7.1.1 Machines should always be cleaned after use. As a general guideline, where a machine is being used repeatedly to
process the same material it will be sufficient to run the machine for a short time with water, detergent or a
suitable solvent or flushing agent. Refer to the cleaning Instructions for further details.
7.2 DISASSEMBLY AND ASSEMBLY

WARNING: BEFORE PERFORMING ANY ASSEMBLY/DISASSEMBLY PROCEDURE
! ISOLATE THE UNIT ELECTRICALLY. THIS OPERATION SHOULD BE CARRIED OUT BY A
SUITABLY QUALIFIED ELECTRICIAN.
CAUTION: To avoid distortion of the mixer during disassembly/assembly the mixer must
!
7.2.3
be securely mounted in a vertical position.
The following procedures are to be used as an aid to disassembly and reassembly of the machine should it
become necessary to gain access to the components.
For example, a selection of interchangeable stators (see section 3.2) is available to adapt the machine for
different processing duties.The procedures detailed in this section will enable Service and Maintenance Engineers
to change/service the components as quickly and efficiently as possible.
When performing the procedures listed hereunder, take the opportunity to inspect the component parts of the
assembly for wear or damage and renew as necessary. A list of recommended spares is given in Section 8 of this
manual.
CAUTION: Upon assembling any parts of the mixer, failure to ensure that all components
! are correctly and squarely fitted and are seated against relevant shoulders or registers can
lead to rapid wear of the bush and mechanical failure.
NOTE: Item numbers included in the following text cross-refer to Fig. 4

Page 12
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7.0 MAINTENANCE
3
15
4
39
13
32
33 16
35
Shroud is
37 optional 9
and
may not 12
be fitted.
41 46 18
38
40 2
23
31
21 47
22
34 48
17 8
29
4
36
3
7
44 10
43
19
20
14
30 28
11
26
24
Fig. 4 25
The KDD Mixer Assembly 42
45
5
27

Page 13
B0179-3
7.0 MAINTENANCE S
7.3 CHANGING OR REPLACING THE LOWER WORKHEAD

7.3.1 Firstly remove the head retaining nuts (28).
7.3.2 Remove the lower workhead (5) taking care not to damage the cutting screen against the rotor blades.
!
7.3.3
WARNING: THE ROTOR BLADES MAY BE SHARP.
With the workhead removed inspect the rotor tips (6) for wear. If they are excessively worn the rotor should be
replaced. (refer to para 7.4)
7.3.4 Ensure that the underside of the bearing plate (11) is clean and that the register is free of any foreign material; if
cleanliness is not observed the workhead will not seat squarely and will foul the rotor.
7.3.5 Fit the replacement or alternative workhead.
CAUTION: Due to some of the workheads having a tight clearance to the rotor, care
! should be exercised when fitting replacement or alternative workheads, ensure that they
are placed squarely over the rotor.
7.3.6 Refit the workhead retaining nuts (28) and evenly tighten.
7.3.7 The shaft should rotate freely without the rotor (6) rubbing on the workhead. If rubbing of these items is evident
the workhead has either been incorrectly fitted or the bushes (20) are worn and should be replaced. (refer to
para. 7.5).
7.4 REPLACING THE LOWER ROTOR

7.4.1 Inspect the rotor tips for wear. If they are excessively worn the rotor should be replaced.
7.4.2 Remove the workhead as in paragraph 7.3
7.4.3 Bend back the tabs of the tab washer (24) or remove the tab washer retaining screw (45).
7.4.4 Hold one blade of the rotor with an adjustable wrench and using a socket wrench unscrew the rotor nut (42).
This is a normal right hand thread.
!
7.4.5
Remove the rotor (17) from the drive shaft and retrieve the dowel pins (22) if they are loose.
7.4.6 With the rotor removed inspect and replace if necessary the bushes (20).
7.4.7 Ensuring that mating parts are clean and free from foreign matter refit the dowel pins (22) if removed and fit the
replacement rotor to the drive shaft.
7.4.8 Ensure that the new rotor sits squarely on the shoulder on the shaft.
7.4.9 Fit a new tab washer (24) and refit and tighten the rotor nut (42), if an adjustable wrench is used to hold a blade
of the rotor ensure that the jaws of the wrench are packed with a suitable soft material to avoid damaging the
rotor blade.
7.4.10 Fit the tab washer retaining screw (45) and bend the tabs of the washer (24) to prevent rotation of the rotor nut
(42). It may be found easier to fold the tab if the rotor nut is tightened and the line of the fold is marked or
scribed, the nut (42) and rotor (6) temporarily removed and the tab washer bent in a vice. The rotor and nut
should then be refitted and the nut retightened, the tab of the washer can then be bent against the nut.
7.4.11 Refit the workhead (refer to Para 7.3).

Page 14
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7.0 MAINTENANCE
7.5 REPLACING THE UPPER WORKHEAD ROTOR AND BRONZE ALLOY

BUSHES
7.5.1 Remove the lower workhead (5) and lower rotor (6) with reference to paragraphs 7.3 and 7.4. This will expose
the bearing plate assembly which is removed as a single unit.
WARNING: THE BEARING PLATE ASSEMBLY IS HEAVY AND SHOULD BE SUPPORTED

! INDEPENDENTLY DURING THIS OPERATION.
CAUTION: Take care not to place any undue stresses on the shaft (3) or frame arms (4)
!
7.5.2
during the following operation..
Flatten the tabs of the tab washer (26) and unscrew the four frame nuts (25)
in sequence, initially half a turn at a time.
7.5.3 Retrieve the tab washers (26).
7.5.4 Carefully lower the complete bearing plate assembly from the shaft/frame
assembly. The upper rotor (8) will be left in place on the shaft.
7.5.5 The bearing plate assembly should be removed to a clean workbench for
further disassembly.
7.5.6 Remove the upper workhead (7) from the bearing plate assembly by removing
the four socket head cap screws (36). Fig. 5
7.5.7 Separate the two bearing plates (10 and 11) by removing the four pillars (19) The Bearing Plate
and associated nuts and washers (43 and 44). Assembly
7.5.8 Remove the bushes (20) using a suitable draw bolt.
11
29
7.5.9 Ensure that the bush housings are completely clean and burr free and then lightly oil the inner surfaces.
12
7.5.10 Lightly oil the outer surface of the new bushes (20) and using a suitable draw bolt or press insert the bushes into
14
the housings taking great care that they are drawn in square. 13
7.5.11 Re-assemble the pillars (19) and bearing plates (10 and 11) ensuring that the bearing plates seat squarely on the11 28
pillar shoulders, refit the washers (43 and retaining nuts (44) and fully16
tighten evenly and in sequence.
7.5.12 Fit the replacement workhead (7) to the upper bearing plate ensuring that the mating faces are clean and that the
workhead is correctly seated. 14
41
7.5.13 Refit the retaining screws (36) tightening evenly and in sequence.
7.5.14 If it necessary to replace the upper rotor (8), unscrew the hex socket grub screws (29) until well clear of the
shaft (3) and slide the rotor up the shaft. Remove the key (18) and slide the rotor down the shaft to remove.
!
7.5.15
Slide the replacement rotor (8) onto the drive shaft until well above the key recess, refit the key (18) into the key
way, align the rotor with the key and slide the rotor down the shaft until the key sits down fully on the key. Fit
the hex socket grub screws (29) which should locate into 11the pre-drilled dimples in the shaft (3).
7.5.16 Carefully refit the bearing plate assembly onto the frame arms (4) and drive shaft (3) and fit the tab washers (26)
12
and retaining nuts (25) and fully tighten evenly and in sequence, initially half a turn at a time.. Bend one tab of
each washer over the edge of the bearing plate and one tab against the flat of the nut to prevent the nut from
loosening.
13
7.5.17 A visual check should be made that the lower bearing plate is square on all four frame arms and that the lower
rotor is seated correctly and squarely against the shaft. 33
29
16
Page 15
41
7.0 MAINTENANCE S
7.6 REMOVING THE MOTOR

7.6.1 Isolate all electrics etc. and remove cables from terminal box.
7.6.2 While supporting the drive shaft (3) remove the coupling pin (23) by removing split pin (48) and unscrewing the
castle nut (47).
7.6.3 The drive shaft (3) is now released from the coupling and will drop downward by approximately 8mm.
7.6.4 The mixer drive shaft should be steadied or braced; if the original packing timber bracings have been saved they
could be used for this duty.
NOTE:The key (17) will normally hold fast in its position without problems but should ideally be checked.
7.6.5 Remove the motor mounting bolts, nuts and spring washers (39,40,41).
7.6.6 Lift the motor clear, being careful to lift it straight up vertically from the shaft (3). Retrieve key (17).
7.6.7 If the coupling needs to be removed, unscrew the grub screws (31) until well clear of the shaft and remove the
hex head screw (34) and the locking disc (21). Slide the coupling (2) off the shaft and retrieve the key (16).
7.6.8 Refitting is the reverse of removal. Ensure that all mating surfaces, keys, keyways, etc. are clean. Lightly oil the
motor shaft relocate the key (16) and refit the coupling (2) Refit the locking disc (21) and retaining screw (34).
Tighten the grub screws (31).
7.6.9 Note that if a new motor is being fitted the motor shaft must be dimpled to correspond with the grub screws
(31) in the coupling. Fit the coupling (2) onto the motor shaft, refit the locking disc (21) and retaining screw (34).
Ensure that the coupling is seated against the locking disc ie; pulled away from the motor as far as possible, fit one
of the set screws (31) and tighten to retain the coupling in this position.
!
7.6.10
CAUTION: Grub screws must not be located in or near the key way.
Using a 8.5 mm drill located in the remaining set screw hole, dimple the motor shaft with the drill point.
Remove the drill. Using a 7mm drill located in the dimple, drill a hole in the motor shaft to a depth of
approximately 3mm. Thoroughly clean the area and fit the remaining set screw (31). Remove the first set screw
and repeat this procedure. Dial Guage
7.6.11 The concentricity of the coupling (3) must be checked whenever it

has been disturbed, replaced or there is mechanical damage to the Coupling
rotor. Using a dial gauge measure the Total Indicator Reading (TIR) on
the inside diameter, at the end of the coupling which is furthest away
Motor
from the motor. (See Fig. ). The reading should be no more

than 0.025mm (0.001").
7.6.12 Refit the key (17) into the shaft (3) and carefully lower the motor and
coupling assembly down onto the mounting stool (1), as the motor is
lowered ensure that the shaft (3) and key (17) are correctly aligned
with the coupling. Refit the retaining screws (39), washers (41) and
nuts (40) and fully tighten evenly and in sequence.
7.6.10 Raise the shaft until the hole for the coupling pin is aligned and refit
the coupling pin (23) and castle nut (47), fit a new split pin.
7.6.11 Turn the shaft by hand to ensure that it rotates freely.
7.6.12
Fig. 6
Refit into the vessel, re-connect to the electrical supply and carry out the direction of rotation check.
B0083

Page 16
S 8.0 LUBRICATION
8.1 LUBRICATION
8.1.1 Lubrication requirements on the KDD are limited to occasional re-greasing of the motor bearings. This operation
should be carried out every 19,000 running hours running time.
CAUTION: Bearings should not be over packed as this can damage them as much as under
! greasing.
8.1.2 Shell Alvania R.A. or any compatible lithium based grease with a temperature range of -40C to +115C is
suitable.

Page 17
NOTES S

Page 18
S
9.0 RECOMMENDED SPARES
9.1 SPARE PARTS
9.2 It is recommended that the following spare parts are kept in stock to provide for any replacement that may
become necessary due to wear or damage. Please refer to Fig. 4 and accompanying parts in section 10.0 of this
manual for part numbers and descriptions applicable to your machine.
QTY DESCRIPTION ITEM NO
1 Workheads 5&7
1 Upper rotor 8
1 Lower Rotor 6
2 Bush 20
38 Tab Washer 4
9.3 Always quote the Machine Type and Serial Number when ordering spare parts
WARNING: NEVER USE PARTS OTHER THAN THOSE SUPPLIED OR RECOMMENDED

BY SILVERSON MACHINES. THE USE OF SUCH PARTS WILL NULLIFY ANY
GUARANTEES AND MAY CAUSE PREMATURE WEAR OR MORE SERIOUSLY MAY
CAUSE COMPONENT FAILURE AND POSSIBLE INJURY.

Page 19
10.0 ILLUSTRATED PARTS LIST S
3
15
4
39
13
32
33 16
35
Shroud is
37 optional 9
and
may not 12
be fitted.
41 46 18
38
40 2
23
31
21 47
22
34 48
17 8
29
4
36
3
7
44 10
43
19
20
14
30 28
11
26
24
Fig. 4 25
42
The KDD Mixer Assembly 45
5
27

Page 20
B0179-3
9.0IllustrateD Parts lIst
9.0 Illustrated Parts list for silverson Mixer code number 2400-00003
Item Part No. Description Qty

1 VF4324 Mounting Stool 1
2 CAB7B8/1 Coupling 1
3 AC6544/1 Drive Shaft 1
4 VF4055/12 Frame Arm 4
5 2/CAB1G5 Slotted Disintegrating Head 1
6 CAB4E9 Rotor - Lower 1
7 2/CAB2A14 Workhead - Upper (General Purpose Disintegrating Head) 1
8 CAB3H2 Rotor (Upper) 1
9 - Shroud Clamp Plate 4
10 VF1141 Upper Bearing Plate 1
11 VF1142 Lower Bearing Plate 1
12 - Shroud 1
13 - U Bolt 8
14 AC6557 Downthrust Propeller 3
15 - Lifting Bracket 2
16 VF6787/5 Key 1
17 SD499 Key 1
18 - Key 1
19 CAB3H6 Support Pillars 4
20 VF1875/22 Bush - Bronze Alloy 2
21 CAB7B8/2 Locking Disc 1
22 CAB4A6/26 Dowel 4
23 VF2623 Coupling Pin 1
24 SD331 Locking Washer 1
25 Q/MFNF/002 Nut 4
26 - Tab Washer 1
27 Q/MHB12/060 Hex Head Set Screw 4
28 Q/MFN12 Nut 8
29 Q/MGS10/016 Hex Socket Grub Screw 3
30 Q/MCS12/045 Socket Cap Head Screw 2
31 Q/MGS10/016 Hex Socket Grub Screw 2
33 Q/MSW24 Spring Washer 4
35 Q/MFN16 Nut 24
36 Q/MCS12/045 Socket Cap Head Screw 4
37 VF4411 Nut 4
38 - Tab Washer 4
40 Q/MFN/16 Nut 8
42 Q/MFNF/001 Nut 1
44 Q/MFN/16 Nut 8
45 2BA Screw 1
46 Q/MHB06/010 Hex Head Screw 4
47 3/4 BSF Castle Nut 1
48 - Split Pin 1
ISSUE 1 OCT 2003 PL/BA-111-2400-00003

Page 21

Installation and Maintenance Manual for High Shear Duplex Batch Mixer Model KDD

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Installation and Maintenance Manual for High Shear Duplex Batch Mixer Model KDD

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S

MOTOR SERIAL No.

Silverson Machines Ltd . Waterside . Chesham . Bucks . HP5 1PQ

Fig. 2 Lifting the Mixer 7

Fig. 3 Principals of Operation 11

Fig. 4 The KDD Mixer Assembly 13 and 20

Fig. 5 The Bearing Plate Assembly 15

Fig. 6 Measuring The Coupling Concentricity 16

BA 111 - KDD ISSUE 3 - Dec. 2008

4.0 TRANSPORT & HANDLING 7

9.0 RECOMMENDED SPARES 19

10.0 ILLUSTRATED PARTS LIST 21

ISSUE 3 - Dec. 2008 BA 111 - KDD

1.2 TECHNICAL SERVICE

SILVERSON MACHINES LIMITED

BUCKS HP5 1PQ

TEL:CHESHAM (01494) 786331

FAX:CHESHAM (01494) 791452

or our appointed agents

BA 111 - KDD ISSUE 3 - Dec. 2008

WARNINGS ARE PROVIDED WHERE THERE MAY BE PHYSICAL DANGER TO

2.2 WARNING: NEVER USE THE MACHINE IN A HAZARDOUS AREA WHERE A

2.12 WARNING: FOR FLAMEPROOF APPLICATIONS A FLAMEPROOF LOW LEVEL

ISSUE 3 - Dec. 2008 BA 111 - KDD

3.1 WORKHEADS (STATORS)

3.1.1 General Purpose Disintegrating Head (Fig. 1a)

BA 111 - KDD ISSUE 3 - Dec. 2008

Caution: Under no circumstances

Centre Shaft *Packing Case

LIFTING THE MIXER Fig. 2

ISSUE 3 - Dec. 2008 BA 111 - KDD

5.1 INSTALLATION - MECHANICAL

5.1.3 MOUNTING TO A VESSEL:

5.2 INSTALLATION - ELECTRICAL

WARNING: ANY ELECTRICAL WORK SHOULD ONLY BE CARRIED OUT BY A SUITABLY

5.2.1 Checks and Precautions

BA 111 - KDD ISSUE 3 - Dec. 2008

WARNING: DO NOT USE THE MACHINE IN A HAZARDOUS AREA WHERE A

WARNING: FOR FLAMEPROOF APPLICATIONS A FLAMEPROOF LOW LEVEL

WARNING: NEVER TOUCH ROTATING PARTS. FAILURE TO OBSERVE THIS WARNING

ISSUE 3 - Dec. 2008 BA 111 - KDD

WARNING: DO NOT USE THE MACHINE IN A HAZARDOUS AREA WHERE A

WARNING: FOR FLAMEPROOF APPLICATIONS A FLAMEPROOF LOW LEVEL

WARNING: NEVER TOUCH ROTATING PARTS. FAILURE TO OBSERVE THIS WARNING

6.1 INITIAL START-UP

6.1.1 Check the direction of rotation - refer to para 5.3

6.2 GENERAL OPERATING

BA 111 - KDD ISSUE 3 - Dec. 2008

6.3.2 The product is then expelled out of the workheads towards

6.3.4 The action of the two downthrust propellers aids general

WARNING: THE MIXER MUST BE ISOLATED ELECTRICALLY BEFORE IT IS

WARNING: THE COMPLETE MACHINE ASSEMBLY SHOULD NEVER BE SPRAYED WITH

WARNING: SUITABLE PROTECTIVE CLOTHING SHOULD BE WORN WHEN HANDLING

ISSUE 3 - Dec. 2008 BA 111 - KDD

7.1 GENERAL MAINTENANCE

7.2 DISASSEMBLY AND ASSEMBLY

NOTE: Item numbers included in the following text cross-refer to Fig. 4

BA 111 - KDD ISSUE 3 - Dec. 2008

ISSUE 3 - Dec. 2008 BA 111 - KDD

7.3 CHANGING OR REPLACING THE LOWER WORKHEAD

7.3.5 Fit the replacement or alternative workhead.

7.4 REPLACING THE LOWER ROTOR

7.4.2 Remove the workhead as in paragraph 7.3