Alfalaval LeviMag User manual

100001148-EN1 2019-03
Original manual
Instruction Manual
Alfa Laval LeviMag®–AlfaLavalLeviMag
®UltraPure
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Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC Declaration of Conformity ....................................................................... 5
2. Safety and information ............................................................................... 6
2.1. Important information ............................................................................. 6
2.2. Warning signs ..................................................................................... 6
2.3. Safety precautions ................................................................................ 7
2.4. Intended use ...................................................................................... 8
2.5. Unpacking/delivery ............................................................................... 8
2.6. Recycling information ............................................................................. 10
3. Installation .............................................................................................. 11
3.1. Weld plate ......................................................................................... 11
3.2. Male bearing ...................................................................................... 12
3.3. Impeller ............................................................................................ 13
3.4. Drive Unit - WP50 ................................................................................. 14
3.5. Drive Unit - WP81 ................................................................................. 15
3.6. Directions of rotation verification ................................................................ 17
3.7. Start-up ............................................................................................ 18
4. Operation ............................................................................................... 19
4.1. Mixing .............................................................................................. 19
4.2. Speed .............................................................................................. 19
4.3. Temperature ....................................................................................... 19
4.4. Cleaning ........................................................................................... 20
5. Maintenance ........................................................................................... 21
5.1. General maintenance ............................................................................. 21
5.2. Inspection ......................................................................................... 22
5.3. Dismounting of the drive unit .................................................................... 23
5.4. Disassembly of the drive unit .................................................................... 24
5.5. Dismounting of the impeller ...................................................................... 25
5.6. Replacement of the male bearing ............................................................... 26
5.7. Replacement of the female bearing ............................................................. 28
6. Checklist ................................................................................................ 30
6.1. Start-up ............................................................................................ 30
6.2. Installation ......................................................................................... 30
6.3. Operation .......................................................................................... 30
6.4. Qualification ....................................................................................... 31
6.5. Maintenance ....................................................................................... 33
7. Technical data ......................................................................................... 34
7.1. Technical data, LeviMag®UltraPure ............................................................ 34
7.2. Technical data, LeviMag®........................................................................ 35
7.3. Mounting angle .................................................................................... 36
7.4. Tightening torque for screwed connections .................................................... 37
7.5. Connection of motor ............................................................................. 38
7.6. Connection to frequency inverter ................................................................ 38
8. Trouble shooting ....................................................................................... 39
8.1. Troubleshooting ................................................................................... 39
9. Parts lists / Service kits .............................................................................. 40
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Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
9.1. Product overview - WP50 ........................................................................ 40
9.2. Product overview - WP81 ........................................................................ 42
9.3. Drive unit - WP50 ................................................................................. 44
9.4. Drive unit - WP81 ................................................................................. 46
9.5. Tools ............................................................................................... 48
10. Appendix ............................................................................................... 52
10.1.Drive unit instructions ............................................................................. 52
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1 EC Declaration of Conformity
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
LeviMag®
LeviMag UltraPure®10.000 - 100.000
Designation Serial no(s)
WP = 50, 81
Impeller size, xxx = 100, 150, 200, 250, 300
Material = 316L
Qdoc, x = Qdoc, S (surface roughness), W (weld log), SW
IE4, xxx = blue, Cl.Room
Angle = 0-22°, 23°-45°
WPxx – xxx – 316L – Qdoc-x – IE4-xxx – xx – x Console height = S (standard), E (extended)
Type Type variation
is in conformity with the following directives:
Machinery Directive 2006/42/EC++
Regulation (EC) 1935/2004
The person authorised to compile the technical file is the signer of this document
Global Product Quality Manager
Pumps, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name
Kolding 2019-01-01
Place Date Signature
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2 Safety and information
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
Always read the manual before using the mixer!
This instruction manual is the primary document for safety, installation, operation and maintenance of the Alfa Laval LeviMag®.
This document does not contain the welding guide for the weld plate.
For this information read the "Welding guidelines for Alfa Laval LeviMag®".
2.1 Important information
The following safety terminology is used to indicate the hazard level:
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the mixer.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
The following safety symbols are used to indicate the hazards level:
General warning:
Dangerous electrical voltage:
Caustic agent:
Strong magnetic fields hazard:
Hazard for wearers of electrically controlled medical devices:
(e.g. cardiac pacemaker)
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2 Safety and information
All warnings in the manual are summarised on this page.
Pay special attention to the instructions below so that severe personal injury and/or damage to the mixer are avoided.
2.3 Safety precautions
Installation:
Always follow this manual thoroughly.
Never expose the mixer to undue vibrations or shocks.
Never start the mixer in the wrong rotation direction - see chapter 3.6 Directions of rotation verification.
Ensure that the tank media is not corrosive to the mixer.
Only install the mixer in environments within temperature limit: -20°C and +40°C.
Only install the mixer in altitudes less than 1000 m above sea level.
!
Always have the mixer electrically connected by authorized personnel.
Always keep electrically controlled medical devices away from mixing unit.
(e.g. cardiac pacemaker)
Operation:
Always read this manual thoroughly.
Ensure that gear motor oil does not reach temperatures higher than 105 °C during operation, CIP or SIP. !
Never touch the moving parts while the mixer is connected to the power supply.
Always handle CIP and SIP lye and acids with great care.
Always handle hot gear motor with care – use gloves to protect hands. !
Maintenance:
Always read this manual thoroughly. !
Always disconnect the power supply when servicing the mixer.
Always keep electrically controlled medical devices away from mixing unit.
(e.g. cardiac pacemaker)
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2 Safety and information
Transportation:
Always ensure that no leakage of lubricants can occur.
Always ensure that the unit is securely fixed during transportation.
Always use original packaging or similar during transportation.
Avoid drive unit to be attached to weld plate during transportation – if necessary avoid undue vibrations or shocks.
Avoid mixing head and drive rotor to be exposed to magnetic particles as they will stick to the parts and will require manual
removal.
Incorrect installation, mounting and use, removal of security elements, lack of inspections, lack of maintenance and improper
connections may cause severe personal injury or property damage. Therefore, it is important that the mixer is being transported,
handled, installed, started, controlled, serviced and repaired correctly exclusively by qualified personnel.
2.4 Intended use
1. The Alfa Laval LeviMag®is only for mixing/stirring of liquids in a tank.
2. The mixer is only for mounting positions / angles as specified on the nameplate and in 7.3 Mounting angle.
3. The different duties and operation like pressure, speed and media temperature which the mixer is designed for must be
followed.
4. If the mixer is installed in pressurized tanks, local regulations and legislations must be met.
2.5 Unpacking/delivery
The instruction manual is part of the delivery.
Study the instructions carefully.
Always use adequate lifting equipment when handling the mixer.
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Step 1
Inspect the delivery for visible transportation damages - all issues to be reported to carrier.
Inspect for oil leaks from gear motor caused by leaking vent valve protection (see chapter 3.7 Start-up) – if leakage is observed -
oil level in gear motor must be verified (total oil amount in gear motor to be found on gear motor name plate).
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2 Safety and information
Step 2
Check the delivery for:
1. Complete mixer
2. Nameplate designations
3. Delivery note
4303-0006
Step 3
Lifting instructions:
Always use adequate lifting equipment (see mixer weight on name plate).
Locate centre of gravity before moving the mixer. !
CAUTION
Alfa Laval recommends NOT to use shaft and drive rotor as lifting point.
Gear motor may be used for lifting the assembled drive unit
4307-0011
Always keep electrically controlled medical devices away from mixing unit.
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2 Safety and information
Step 4
During transportation:
1. Always protect shaft and the drive rotor.
Foreign magnetic particles can be attracted by the drive rotor due to the magnetic field.
2. Never expose the mixer to undue vibrations or shocks.
3. Inspect for oil leakage on gear’s with vent screw – if leakage due to incorrect position / angle of gear motor, oil
level must be verified - total oil quantity in gear motor is to be found on gear motor name plate.
!
2.6 Recycling information
Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
- Wood and cardboard boxes can be re-used, recycled or used for energy recovery.
- Plastics should be recycled or burnt at a licensed waste incineration plant.
- Metal straps should be sent for material recycling.
Maintenance
- During maintenance, oil and wear parts in the machine are replaced.
- All metal parts should be sent for material recycling.
- Worn out or defective electronic parts should be sent to a licensed handler for material recycling.
- Oil and all non-metal wear parts must be disposed of in accordance with local regulations.
Scrapping
- At the end of use, the equipment must be recycled according to the relevant, local regulations.
Besides the equipment itself, any hazardous residues from the process liquid must be considered and dealt with in a proper
manner. When in doubt, or in the absence of local regulations, please contact your local Alfa Laval sales company.
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3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully and pay special attention to the warnings!
The mixer is for permanent fastening.
Make sure that the motor corresponds to the environment.
Always read the manual thoroughly.
Only install this mixer in mounting angle according to the name plate – see chapter 2.5 Unpacking/delivery.
Always use lifting equipment when handling the mixer - see chapter 2.5 Unpacking/delivery.
Always have safety elements removed by authorized personnel.
Never cover or remove the nameplate.
!
Never connect to power supply during installation or service.
Always have the mixer connected to power supply by authorized personnel.
Install the mixer in following order of assembly:
Step 1 AImpeller
Weld plate - see chapter 3.1 Weld plate. B Male bearing
CWeldplate
Step 2 DDriveUnit
Male bearing - see chapter 3.2 Male bearing.
Step 3
Impeller - see chapter 3.3 Impeller.
Step 4
DriveUnit–seechapter3.4DriveUnit-WP50andchapter
3.5 Drive Unit - WP81.
4307-0016
A
B
C
D
NOTE
Before installing any parts, make sure the tank is clean – rinse thoroughly with clean water and secure that no particles are
magnetized onto any surfaces.
Tools used in the sections are optionally available - see chapter 9.5 Tools.
Spare Parts and tools for Alfa Laval LeviMag®can also be found in the Spare Part list.
3.1 Weld plate
Follow the guide in "Welding guidelines for Alfa Laval LeviMag®" for welding of the weld plate into the tank.
CAUTION
Only use authorized personnel to weld in the weld plate.
Alfa Laval cannot be held responsible for incorrect installation.
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3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully and pay special attention to the warnings!
The mixer is for permanent fastening.
Make sure that the motor corresponds to the environment.
3.2 Male bearing
It is assumed that the weld plate is installed in the tank – if not, follow the guide in "Welding guidelines for Alfa Laval LeviMag®".
CAUTION
Protect the bearing surface from physical damage and keep it free from particles.
Do not use grip tools on the bearing surfaces.
Handle the male bearing with care - Alfa Laval highly recommend use of service tool for the male bearing.
Step 1
Place the O-ring on the male bearing.
For minimal friction, lubricate the O-ring with a small amount of
water.
Ensure the bearing surface is clean.
4307-0017
Step 2
(Optional)
Place the male bearing with O-ring in the male bearing tool – rotate
the bearing slightly by hand enabling it to go completely into the
socket with the O-ring in place.
NOTE
For large tanks, lifting rod may be needed to perform the
installation.
4307-0018
Step 3
Using the male bearing tool (optional with rod), place the male
bearing female thread on the weld plate male thread and turn
clockwise to install.
CAUTION
Ensure that the thread connection on the weld plate and the male
bearing are clean, dry and free from foreign material.
4307-0019
Step 4
Tighten the bearing to a full stop applying torque seen in chapter 7.4 Tightening torque for screwed connections.
CAUTION
Do not over-tighten.
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3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully and pay special attention to the warnings!
The mixer is for permanent fastening.
Make sure that the motor corresponds to the environment.
Step 5
(Optional)
Remove the male bearing tool from the bearing by pulling it
upwards.
4307-0020
3.3 Impeller
WARNING
It is important that the impeller is mounted before installing the drive unit.
Always keep electrically controlled medical devices away from mixing unit (e.g. cardiac pacemaker).
CAUTION
Always be sure that the weld plate is correctly installed in the tank and that it has not been deformed during the welding process.
See guide in "Welding guidelines for Alfa Laval LeviMag®".
Step 1
Remove foreign magnetic particles from the mixing head (can
be time consuming or difficult if mixing head has been exposed
to magnetic particles which must be removed mechanically and
manually).
NOTE
If the mixing head must be placed on a table, place the magnets
upward to prevent magnetic particles to stick to the magnetic
surface of the mixing head.
4307-0021
Step 2
(Optional)
Use the impeller lifting device to install the impeller in the tank.
Lift the impeller carefully with the impeller lifting device.
NOTE
If needed - mount the impeller lifting device to the lifting rod.
4307-0022
1
2
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3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully and pay special attention to the warnings!
The mixer is for permanent fastening.
Make sure that the motor corresponds to the environment.
Step 3
Place the impeller carefully on the male bearing.
Rotate the impeller slowly 360 degrees (one rotation) ensuring that
there is no collision between the mixing head and tank bottom /
weld plate.
Remove the impeller lifting device by rotating fast 45 degrees in
the opposite direction, freeing the arms from the impeller wings.
NOTE
Make sure the female/impeller bearing is fully set onto the male
bearing.
WARNING
The impeller must be mounted before installing the drive unit.
360°
4307-0023
1
2
3.4 Drive Unit - WP50
WARNING
It is critical for the impeller to be mounted before installing the drive unit.
Protect the magnetic drive rotor on the drive unit from collecting particles.
CAUTION
Always be sure that the weld plate is correctly installed in the tank and that it has not changed shape during welding – see
"Welding guidelines for Alfa Laval LeviMag®".
Step 1
Ensure the bearing and impeller (1) is mounted before mounting
the drive unit (2).
WARNING
Beware of risk of crushing fingers due to the strong magnetic
forces between the drive unit and the impeller.
NOTE
During the installation, be sure that the drive unit is supported to
avoid tipping over or dropping to the floor.
1
2
4307-0024
Step 2
Hold the drive unit firmly and align the drive unit with the weld plate. Apply the clamp ring without tightening it fully. The motor
must always be pointing upwards.
Step 3
Adjust gear motor orientation in order for this to clear tank legs and according to chapter 7.3 Mounting angle. The motor must
always be pointing upwards. Tighten clamp ring according to chapter 7.4 Tightening torque for screwed connections.
Step 4
Ensure the upper part of the flange is flush with the lower side of the weld plate.
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3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully and pay special attention to the warnings!
The mixer is for permanent fastening.
Make sure that the motor corresponds to the environment.
Step 5
CAUTION
Check for levitation!
Push the impeller downwards against the weld plate – possibly
using the lifting rod tool – the impeller should travel axially minimum
0.5 mm – otherwise it is not levitated correctly.
If not, ensure both bearings are installed correctly, flange is flush
against the bottom of the weld plate. Lubricate the bearings with
e.g. water and recheck levitation.
4307-0025
NOTE
For programming and installation of frequency converter see chapter 7.6 Connection to frequency inverter.
3.5 Drive Unit - WP81
WARNING
It is critical for the impeller to be mounted before installing the drive unit.
Protect the magnetic drive rotor on the drive unit from collecting particles.
CAUTION
Always be sure that the weld plate is correctly installed in the tank and that it has not changed shape during welding – see
"Welding guidelines for Alfa Laval LeviMag®".
Step 1
Ensure the bearing and impeller (1) is mounted before mounting
the drive unit (2).
WARNING
Beware of risk of crushing fingers due to the strong magnetic
forces between the drive unit and the impeller.
NOTE
During the installation be sure that the drive unit is supported to
avoid tipping over or dropping to the floor.
4307-0026
1
2
Step 2
Hold the drive unit firmly and align the drive unit with the weld plate. Adjust gear motor orientation in order for this to clear tank
legs and according to chapter 7.3 Mounting angle. The motor must always be pointing upwards.
Step 3
Apply mounting bolts without tightening these fully.
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3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully and pay special attention to the warnings!
The mixer is for permanent fastening.
Make sure that the motor corresponds to the environment.
Step 4
Making certain the weld plate and drive unit flange are completely flush, tighten the mounting bolts according to chapter 7.4
Tightening torque for screwed connections.
Step 5
CAUTION
Check for levitation!
Push the impeller downwards against the weld plate – possibly
using the lifting rod tool – the impeller should travel axially minimum
0.5 mm – otherwise it is not levitated correctly.
If not, ensure both bearings are installed correctly, flange is flush
against the bottom of the weld plate.
Lubricate the bearings with e.g. water and recheck levitation.
4307-0027
NOTE
For programming and installation of frequency converter see chapter 7.6 Connection to frequency inverter.
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3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully and pay special attention to the warnings!
The mixer is for permanent fastening.
Make sure that the motor corresponds to the environment.
3.6 Directions of rotation verification
It is recommended that the customer install an emergency stopping device and a circuit breaker for their full tank/mixer
processing system.
Step 1
After confirming the impeller is levitated, connect motor according to chapter 7.5 Connection of motor and frequency converter
according to chapter 7.6 Connection to frequency inverter.
WARNING
Ensure the correct power is used for the frequency converter. Incorrect power supply can permanently damage components.
Step 2
Start up the mixer running slowly below 5 RPM and verify the
impeller is rotating clockwise.
CAUTION
If the impeller is rotating counter-clockwise, the frequency
converter must be reprogrammed reversing direction of rotation.
NOISE OR VIBRATION:
If there is excessive noise or vibration, please ensure:
- impeller is levitated.
- male bearing is seated correctly.
- female bearing is seated correctly.
- drive unit is seated completely and flush with the weld plate.
- impeller is rotating clockwise.
- there is no contact between tank bottom and impeller.
- one of the bearings have not come loose during
counterclockwise rotation.
4307-0028
If the noise or vibration persists, please contact your Alfa Laval representative.
CAUTION
Alwaysdisconnectdriveunitbeforeworkingwiththeimpellerorbearing.
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3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully and pay special attention to the warnings!
The mixer is for permanent fastening.
Make sure that the motor corresponds to the environment.
3.7 Start-up
Step 1
CAUTION
Remove the rubber plug in gear.
1) Standard vent plug
2) Transport securing device to
be removed
Step 2
Alfa Laval require that a frequency converter is used running the mixer – please see chapter 7.6 Connection to frequency inverter.
Step 3
1. Always allow at least a 10 sec ramping up to set speed.
2. Always allow at least a 10 sec ramping down to full stop.
CAUTION
The maximum impeller speed – please see chapter 4.2 Speed and chapter 7 Technical data.
Step 4
Go through chapter 6 Checklist.
Step 5
Your Alfa Laval LeviMag®is now ready for operation.
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4Operation
The mixer should only be operated when mounted in a tank.
Never place objects or tools inside the tank when operating the mixer.
4.1 Mixing
Step 1
Fill the tank with the desired amount and type of media.
4307-0029
Step 2
Start up the mixer according to your specific mixing requirements.
4.2 Speed
The allowable maximum speed for the impeller is depending on several factors such as fluid viscosity, tank dimensions, tank and
baffle design and geometry.
The recommended maximum speeds in a fully baffled tank - mixing products with water like viscosity – can be found in chapter
7.1 Technical data, LeviMag®UltraPure and chapter 7.2 Technical data, LeviMag®.
Alfa Laval LeviMag®can run dry once it has been submerged, however it is not recommended to run dry above 50 RPM.
Dry-running below 50 RPM is safe during a complete draining as well as during CIP.
To avoid damage to the bearings when running dry, please do not exceed speeds of 50 RPM.
4.3 Temperature
During operation: max. 90°C and ensure that the media is not boiling
Using non-lubricating media (e.g. WFI) up to: TBA
During CIP (max. 50 RPM): max. 95°C
During SIP (do not run): max. 150°C
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4Operation
The mixer should only be operated when mounted in a tank.
Never place objects or tools inside the tank when operating the mixer.
4.4 Cleaning
Step 1
For optimal performance and service life of the mixer, proper CIP and SIP procedures should be followed.
The mixer is designed for use with CIP, please study the instructions carefully and pay special attention to warnings!
Always handle CIP and SIP lye and acids with great care.
Always use
rubber gloves!
Always use
protective goggles!
Step 2
The mixer can run at 50 RPM or less during cleaning processes.
Do not run the mixer during SIP. Permanent damage may occur.
NOTE
If CIP or SIP temperatures are more than 150°C, it is important to remove the impeller including the female bearing. The male
bearing and elastomers can handle temperatures up to 200°C.
Ensure that gear motor oil does not reach temperatures higher than 105°C during CIP and SIP.
If higher than above stated temperatures are needed, please remove drive unit.
Ensure that the impeller is not exposed to temperature shocks.
See chapter 5 Maintenance for instructions regarding maintenance.
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