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Alfa Laval LeviMag, Instruction Manual, Page: 34 / 68

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Alfa Laval LeviMag Instruction Manual Download Page 34

6 Checklists

To ensure correct installation, before using the Alfa Laval LeviMag

®

, make sure to complete each step in the checklists below.

Beware of additional checklist for ATEX option see section 7.7 Additional maintenance for ATEX.

6.4

Qualification

Ensure that all important information has been noted for future use.
Use this checklist for each tank and mixer to ensure correct installation qualification.

6.4.1 General information

Name

Tank number

Tank type

Tank manufacturer

Country

Site location

LeviMag

®

type

Alfa Laval representative

6.4.2 Alfa Laval LeviMag

®

information

Name

Serial/cert./batch number

Item no.

Notes

Weld plate

Drive unit

Impeller

Male bearing

Female bearing

O-rings

34

Summary of Contents for LeviMag

Page 1: ...100001148 EN5 2021 03 Original manual Instruction Manual Alfa Laval LeviMag Alfa Laval LeviMag UltraPure...

Page 2: ......

Page 3: ...2 Speed 20 4 3 Temperature 21 4 4 Cleaning 21 5 Maintenance 22 5 1 General maintenance 22 5 2 Inspection 23 5 3 Dismounting of the drive unit 25 5 4 Disassembly of the drive unit 26 5 5 Dismounting o...

Page 4: ...ass1 Div1 Group D 45 8 8 Mounting angle 46 8 9 Tightening torque for screwed connections 47 8 10 Connection of motor 48 8 11 Measuring of total run out 49 8 12 Connection to frequency converter 50 8 1...

Page 5: ...Type variation is in conformity with Machinery Directive 2006 42 EC and the following harmonized standard is used DS EN ISO 12100 2011 Safety of Machinery Risk Assessment is in conformity with Ex ATEX...

Page 6: ...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 inju...

Page 7: ...trolled 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 operati...

Page 8: ...ntended 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 name plate and in 8 8 Mounting angle 3 The d...

Page 9: ...nment it is installed in 4303 0098 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...

Page 10: ...cled 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 w...

Page 11: ...e mixer in following order of assembly Step 1 A Impeller Weld plate see section 3 1 Weld plate B Male bearing C Weld plate Step 2 D Drive Unit Male bearing see section 3 2 Male bearing Step 3 Impeller...

Page 12: ...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 be...

Page 13: ...d 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...

Page 14: ...irection 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 36...

Page 15: ...ully The motor must always be pointing upwards Step 4 Adjust gear motor orientation in order for this to clear tank legs and according to section 8 8 Mounting angle The motor must always be pointing u...

Page 16: ...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 3 Hold the drive unit firmly and align the drive unit w...

Page 17: ...one of the four screws free of choice fastening the console to the gear motor shown in section 10 3 Drive unit WP50 and on below illustration Drive unit WP81 The Speed Sensor must be mounted on one o...

Page 18: ...ncy 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 rot...

Page 19: ...nt plug 2 Transport securing device to be removed Step 2 Alfa Laval require that a frequency converter is used running the mixer please see section 8 12 Connection to frequency converter Step 3 1 Alwa...

Page 20: ...ons 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 section 8 1 Technical data LeviMag UltraPure an...

Page 21: ...dy 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...

Page 22: ...e during maintenance WARNING Follow the dismantling and assembly instructions to the letter Ensure the mixer is in a safe state before any service and maintenance After maintenance section 3 8 Start u...

Page 23: ...plans If any component is found damaged during inspection please contact Alfa Laval for repair and or replacement parts All wear parts or damaged parts should be replaced only with genuine Alfa Laval...

Page 24: ...0030 Calculation of clearance female bearing inner diameter ID male bearing outer diameter OD clearance The highest wear is normally found at the upper and lower inner surface of the female bearing Ea...

Page 25: ...e maintenance ensure the main power switch is off and power is disconnected Step 2 WP 50 Loosen the clamp ring 1 do not remove WP 81 Loosen the mounting screws 1 do not remove Step 3 Make preparations...

Page 26: ...0 and remove washer 9 and Fastening element 8 1 B NOTE The Drive Rotor 1 can be fastened for rotation using a hook wrench that is inserted into the hole 6 for Size WP50 and 7 for Size WP81 above the t...

Page 27: ...nd in section 8 9 Tightening torque for screwed connections 5 5 Dismounting of the impeller Step 1 Ensure that the drive unit is removed 4307 0037 Step 2 Remove the impeller with the optional lifting...

Page 28: ...on upper part of bearing and press firmly down until the tool arms click out partly 3 2 1 3 4307 0042 Step 3 Turn the male bearing tool counter clockwise a 1 4 rotation loosening the bearing part and...

Page 29: ...nd in section 10 4 Drive unit WP81 Tightening torques can be found in section 8 9 Tightening torque for screwed connections Step 5 Push the male bearing and O ring free from the top of the tool with a...

Page 30: ...l part on the female bearing The stainless steel part on the female bearing catches the magnetic impeller easily 4307 0046 Step 2 Use the female bearing tool to loosen the female bearing and O rings f...

Page 31: ...before moving it over the threads 4307 0050 Step 6 NOTE Ensure the protection shield is mounted onto the impeller Place the female bearing from the downside into the impeller using the female bearing...

Page 32: ...ing female bearing 1 Mount the impeller on the male bearing 2 Ensure the impeller rotates smoothly 3 Install the drive unit 1 Ensure all incoming power is connected with an emergency stop or an on off...

Page 33: ...e to complete each step in the checklists below Beware of additional checklist for ATEX option see section 7 7 Additional maintenance for ATEX 6 3 Operation Step Description Checked 1 Fill the tank wi...

Page 34: ...tion Ensure that all important information has been noted for future use Use this checklist for each tank and mixer to ensure correct installation qualification 6 4 1 General information Name Tank num...

Page 35: ...7 7 Additional maintenance for ATEX 6 4 3 Check list Frequency converter settings Ensure that all motor data from Table 1 in section 8 10 Connection of motor is programmed correctly into the frequency...

Page 36: ...it 1 Damage on cables 2 Leakage from the gear motor 3 Noise from the gear motor 4 Damage on shaft and drive rotor 5 Damage on flange and screws 6 Check the magnetic drive rotor run out to maximum 0 2...

Page 37: ...ignition source can become effective The properties of the liquid are limited by the following fluid must be Newtonian maximum density 1 1 g cm3 maximum viscosity 50 cP Ensure that there is enough con...

Page 38: ...motor shall be followed Temperature monitoring devices must meet the requirements in the directive 2014 34 EU and EN1127 1 In addition to the speed of the mixer the operating limits according to below...

Page 39: ...fety integrity level Ensure the liquid level during operation is always above the impeller to prevent dry running Tank size media properties and operating mode have an influence on the operating limit...

Page 40: ...Ensure monitoring of the frequency converter is installed according to the specified ATEX zone 4 Ensure positioning of the level switch is installed according to section 7 5 Positioning of level swit...

Page 41: ...00 hours of operating Drive rotor Before each mounting of drive unit Check total run out before every mounting Gear x Clean vent screw x Check for oil leakage x Check temperature sticker x Motor x Cle...

Page 42: ...0 RPM 48 5 Hz Impeller size 200 480 RPM 82 7 Hz Impeller size 250 230 RPM 39 6 Hz Impeller size 300 200 RPM 34 5 Hz 8 2 Technical data LeviMag Internals Product wetted parts surface finish Ra 0 8 m me...

Page 43: ...ilable at the location of operation Supply from frequency converter to motor 217 VAC 3 59 A 8 4 Drive unit data IE4 clean room Gear motor Gear High efficiency helical bevel right angle gear motor Surf...

Page 44: ...Gear High efficiency helical bevel right angle gear motor Surface finish Paint coat 3 0 standard RAL 5010 Gentian blue Maximum mounting angle 0 22 or 23 45 Angle intervals based on configuration See...

Page 45: ...roup D Motor WP50 Frequency nominal 60Hz Power nominal 0 36kW Voltage nominal 208 230V 460V Current nominal 2 1 2 0A 1 0A Enclosure motor protection IP66 Safety class LV Explosion Proof Motor Motor WP...

Page 46: ...ive unit WP81 can be selected in different configurations and regarding mounting angles in two different configurations for The gear motor should be mounted with motor pointing upwards 0 and 0 If the...

Page 47: ...9 Tightening torque for screwed connections CAUTION Do NOT use air powered tools M4 M8 M10 Clamp Female Bearing Male Bearing A2 A4 70 A2 A4 70 A2 A4 70 WP50 WP50 WP81 WP50 WP81 3Nm 26Nm 51Nm 20Nm 10N...

Page 48: ...1 Motor data IE4 CAUTION The synchronous motor is for converter duty only as they are designed with permanent magnets in the rotor package The motor can only be operated by converters made for operati...

Page 49: ...otal run out on the drive rotor position 1 on the drive unit has to be measured Make sure the total run out of the drive rotor surface in the radial direction is less than 0 2 mm at any point on the s...

Page 50: ...h non magnetic tank material The impeller prepared for sensor has an extra permanent sensor magnet built into it NOTE The Speed Sensor must be connected to an isolating switching amplifier of a type e...

Page 51: ...that the motor flange is seated completely and flush to the bottom of the weld plate 4 Check that the impeller is rotating clockwise 6 Noise from mixer Squeaking noise from bearing 1 Lower the speed...

Page 52: ...10 Parts lists Service kits Product overview WP50 10 1 Product overview WP50 4307 0055 52...

Page 53: ...Service kit Female bearing UltraPure Q doc incl Female bearing tool see 10 6 Tools 9615470301 Service kit Male bearing incl Male bearing tool see 10 6 Tools 9615463101 Service kit Male bearing UltraP...

Page 54: ...10 Parts lists Service kits Product overview WP81 10 2 Product overview WP81 4307 0056 54...

Page 55: ...Service kit Female bearing UltraPure Q doc incl Female bearing tool see 10 6 Tools 9615470501 Service kit Male bearing incl Male bearing tool see 10 6 Tools 9615462901 Service kit Male bearing UltraP...

Page 56: ...10 Parts lists Service kits Drive unit WP50 10 3 Drive unit WP50 4307 0057 56...

Page 57: ...gth 223 mm 7 1 Parallel Key 8 1 Gear motor 8 1 1 Fastening Element 8 2 1 Cover 8 3 4 Screw 9 1 Washer 10 1 Screw 11 1 Clamp NOTE Length and must match each other NOTE Pos 8 See 8 8 Mounting angle part...

Page 58: ...10 Parts lists Service kits Drive unit WP81 10 4 Drive unit WP81 4307 0058 58...

Page 59: ...ft length 255 mm 7 1 Parallel Key 8 1 Gear motor 8 1 1 Fastening Element 8 2 1 Cover 8 3 4 Screw 9 1 Washer 10 1 Screw NOTE Length and must match each other NOTE Pos 8 See 8 8 Mounting angle parts are...

Page 60: ...10 Parts lists Service kits Speed Sensor variants 10 5 Speed Sensor variants 4307 0117 60...

Page 61: ...10 Parts lists Service kits Speed Sensor variants Parts list Pos Qty Denomination 1 1 Speed Sensor WP81 2 1 Speed Sensor WP50 Standard Console height 3 1 Speed Sensor WP50 Extended Console height 61...

Page 62: ...10 Parts lists Service kits Tools 10 6 Tools 4307 0059 62...

Page 63: ...Pos Qty Denomination Female Bearing Tool kit WP81 consisting of 3 1 Female Bearing tool 3 1 1 Protection Shield Female Bearing WP81 Parts list Pos Qty Denomination Female Bearing tool kit WP50 consist...

Page 64: ...10 Parts lists Service kits Tools 4307 0060 64...

Page 65: ...Lifting Rod Handle kit consisting of 3 1 Lifting Rod Handle 5 1 Lifting Rod 200 mm 7 2 Clip Parts list Pos Qty Denomination Lifting Rod kit 700 mm consisting of 4 1 Lifting Rod Connection Piece 6 1 L...

Page 66: ...e unit instruction manual by below link https www nord com cms en documentation manuals details_1139 detail_42075 jsp 11 2 Speed Sensor instructions Inside the Speed Sensor is a magnetic inductive pro...

Page 67: ...67...

Page 68: ...s the responsibility of the user of this document to comply with all applicable intellectual property laws Without limiting any rights related to this document no part of this document may be copied r...

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