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Summary of Contents for Alfa Laval LeviMag
- Page 1 Instruction Manual ® ® Alfa Laval LeviMag – Alfa Laval LeviMag UltraPure 100001148-EN5 2021-03 Original manual...
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Page 3: Table Of Contents
7.3. Equipment Protection Level and safety devices ..........7.4. Monitoring the frequency converter ............7.5. Positioning of level switch ............... 7.6. Additional checklist for ATEX ..............7.7. Additional maintenance for ATEX ............... 8. Technical data ..................® 8.1. Technical data, LeviMag UltraPure ............ - Page 4 Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice ® 8.2. Technical data, LeviMag ................ 8.3. Drive unit data – IE4 standard blue ............. 8.4. Drive unit data – IE4 clean room ..............
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Page 5: Ec/Eu Declaration Of Conformity
1 EC/EU Declaration of Conformity Revision of Declaration of Conformity: 2019-01-01 The Designated Company Alfa Laval Kolding A/S Albuen 31, DK-6000 Kolding, Denmark +45 79 32 22 00 Company name Address Phone no. hereby declare that ® LeviMag ® LeviMag UltraPure 10.000 - 100.000... -
Page 6: Safety And Information
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. ®... -
Page 7: Safety Precautions
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. -
Page 8: Intended Use
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. - Page 9 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 4307-0096 ♥...
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Page 10: Recycling Information
- 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. -
Page 11: Installation
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. -
Page 12: Male Bearing
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. -
Page 13: Impeller
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... -
Page 14: Drive Unit - Wp50
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 ". WARNING It is critical for the impeller to be mounted before installing the drive unit. - Page 15 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 2 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.
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Page 16: Drive Unit - Wp81
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 ". WARNING It is critical for the impeller to be mounted before installing the drive unit. -
Page 17: Speed Sensor (Accessory)
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 Speed Sensor (accessory) NOTE The Speed Sensor only works properly if the used impeller is prepared for sensor (see name plate designation and section 1 EC/EU Declaration of Conformity). -
Page 18: Directions Of Rotation Verification
- there is no contact between tank bottom and impeller. - one of the bearings have not come loose during counterclockwise rotation. If the noise or vibration persists, please contact your Alfa Laval representative. CAUTION Always disconnect drive unit before working with the impeller or bearing. -
Page 19: Start-Up
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. Always allow at least a 10 sec. ramping up to set speed. -
Page 20: Operation
® ® 8.1 Technical data, LeviMag UltraPure and section 8.2 Technical data, LeviMag CAUTION Below does NOT apply when having an explosive atmosphere above liquid level. Please see chapter 7 ATEX specific conditions for safe use if there is an explosive atmosphere. -
Page 21: Temperature
4 Operation The mixer should only be operated when mounted in a tank. Never place objects or tools inside the tank when operating the mixer. 4.3 Temperature max. 90°C and ensure that the media is not boiling During operation: During operation: min. -
Page 22: Maintenance
The following recommended preventive maintenance procedures are based on the average operating conditions of most Alfa Laval machines. A mixer which is subject to abrasive fluids, will need more frequent attention than one working in ideal conditions. The maintenance program should be adjusted to meet the demands of your normal operating condition. -
Page 23: Inspection
25 hours run-in. Alfa Laval recommend that the bearings and O-rings should be checked for cleanability and wear after one month of operation. If there is abnormal wear on either component, contact Alfa Laval for further instructions. - Page 24 Handle the mixer with care and follow the recommended inspection to prevent unnecessary damage. The clearance between female and male bearing should not exceed 0.15 mm. If the value exceeds – Alfa Laval recommend changing both bearings. A: Female bearing Ø...
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Page 25: Dismounting Of The Drive Unit
5 Maintenance It is important that the drive unit is dismounted before removing the impeller. The maintenance interval for the mixer depends on the application - shorter or longer service interval may appear. Handle the mixer with care and follow the recommended inspection to prevent unnecessary damage. 5.3 Dismounting of the drive unit Step 1 Before maintenance, ensure the main power switch is off and power is disconnected. -
Page 26: Disassembly Of The Drive Unit
5 Maintenance Assembly drawings with position numbers (#) can be found in section 10.3 Drive unit - WP50 and in section 10.4 Drive unit - WP81. Tightening torques can be found in section 8.9 Tightening torque for screwed connections. 5.4 Disassembly of the drive unit Step 1 Unscrew the four screws (8.3). -
Page 27: Dismounting Of The Impeller
5 Maintenance Assembly drawings with position numbers (#) can be found in section 10.3 Drive unit - WP50 and in section 10.4 Drive unit - WP81. Tightening torques can be found in section 8.9 Tightening torque for screwed connections. 5.5 Dismounting of the impeller Step 1 Ensure that the drive unit is removed. -
Page 28: Replacement Of The Male Bearing
5 Maintenance Assembly drawings with position numbers (#) can be found in section 10.3 Drive unit - WP50 and in section 10.4 Drive unit - WP81. Tightening torques can be found in section 8.9 Tightening torque for screwed connections. 5.6 Replacement of the male bearing Step 1 Optionally use the male bearing tool with a lifting rod to remove the male bearing and O-ring in one step. - Page 29 5 Maintenance Assembly drawings with position numbers (#) can be found in section 10.3 Drive unit - WP50 and 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 round stud.
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Page 30: Replacement Of The Female Bearing
5 Maintenance Assembly drawings with position numbers (#) can be found in section 10.3 Drive unit - WP50 and in section 10.4 Drive unit - WP81. Tightening torques can be found in section 8.9 Tightening torque for screwed connections. 5.7 Replacement of the female bearing Step 1 4307-0046 Mount the protection shield to protect the impeller surface from... - Page 31 5 Maintenance Assembly drawings with position numbers (#) can be found in section 10.3 Drive unit - WP50 and in section 10.4 Drive unit - WP81. Tightening torques can be found in section 8.9 Tightening torque for screwed connections. Step 5 Mount the new O-rings on the new female bearing.
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Page 32: Checklists
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. 6.1 Unpacking/delivery... -
Page 33: Operation
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. 6.3 Operation... -
Page 34: Qualification
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. - Page 35 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. 6.4.3 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 converter.
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Page 36: Maintenance
The maintenance interval for the mixer depends on the application - shorter or longer service interval may appear. Handle the mixer with care and follow the recommended inspection to prevent unnecessary damage. All wear parts or damaged parts should be replaced only with genuine Alfa Laval components. Step... -
Page 37: Atex Specific Conditions For Safe Use
7.1 Recommendation Alfa Laval recommend while operating with ATEX to use an inert gas in the vapor space in the tank to eliminate all possible ignition hazards. The installation must be according to the requirements for safety use of an inert gas. -
Page 38: Equipment Protection Level And Safety Devices
7 ATEX specific conditions for safe use 7.3 Equipment Protection Level and safety devices The Equipment Protection Level (EPL) must be realized and integrated completely in the ignition protection system according to the directives 2014/34/EU, EN ISO 80079-36 and EN ISO 80079-37 §6. The functions of these ignition protective systems must be checked before start-up according to the manual from the manufacturer of the system. -
Page 39: Positioning Of Level Switch
7 ATEX specific conditions for safe use 7.5 Positioning of level switch To prevent dry running, a level switch must be installed to shut down the mixer and depending on the ATEX zone classification inside the tank, the level switch must correspond to different safety levels inside the tank: - Zone 0 - the level switch must correspond to b2 according to EN 80079-37. -
Page 40: Additional Checklist For Atex
7 ATEX specific conditions for safe use To ensure correct installation, before using the Alfa Laval LeviMag®, make sure to complete each step in chapter 6 Checklists and below as additional for ATEX options. 7.6 Additional checklist for ATEX Unpacking/delivery... -
Page 41: Additional Maintenance For Atex
7 ATEX specific conditions for safe use It is important that the drive unit is dismounted before removing the impeller. The maintenance interval for the mixer depends on the application - shorter or longer service interval may appear. Handle the mixer with care and follow the recommended inspection to prevent unnecessary damage. Make sure to follow section 5.2 Inspection and below as additional maintenance for ATEX options. -
Page 42: Technical Data
8 Technical data ® 8.1 Technical data, LeviMag UltraPure Internals: Product wetted parts, surface finish: Ra < 0.38 µm, mechanical & electropolished Working pressure: -1 to 7 bar(g) Impeller diameters: 100, 150, 200, 250 & 300 mm Weld plate: For impeller size 100 & 150 mm: WP50 (clamp connection) For impeller size 200, 250 &... -
Page 43: Drive Unit Data - Ie4 Standard Blue
Integrated Permanent Magnet Synchron Motor (IPMSM) which must be operated with a frequency converter for IE4 motors. The frequency converter (not Alfa Laval supply) must be ordered for the voltage available at the location of operation. Supply from frequency converter to motor: 217 VAC, 3.59 A... -
Page 44: Drive Unit Data - Cus Premium Standard Blue
8 Technical data 8.5 Drive unit data – CUS Premium standard blue Gear motor: High efficiency helical bevel right angle gear motor Gear: Surface finish: Paint coat 3.0 standard RAL 5010 Gentian blue α = 0°-22° or α = 23°-45° Maximum mounting angle: Angle intervals based on configuration See section 8.8 Mounting angle... -
Page 45: Drive Unit Data - Class1 Div1 Group D
8 Technical data 8.7 Drive unit data – Class1 Div1 Group D Gear WP50 & WP81: High efficiency helical bevel right angle gear motor Gear: Surface finish: Paint coat 3.0 standard RAL 5010 Gentian blue α = 0°-22° or α = 23°-45° Maximum mounting angle: Angle intervals based on configuration See section 8.8 Mounting angle... -
Page 46: Mounting Angle
8 Technical data 8.8 Mounting angle The gear motor is are filled with oil that enables it to be mounted as described below – please ensure that the position of the weld plate lives up to the requirements below. γ β... -
Page 47: Tightening Torque For Screwed Connections
8 Technical data 8.9 Tightening torque for screwed connections CAUTION Do NOT use air powered tools. Clamp Female Bearing Male Bearing WP50 WP50 WP81 WP50 WP81 A2/A4-70 A2/A4-70 A2/A4-70 26Nm 51Nm 20Nm 10Nm 30Nm 10Nm... -
Page 48: Connection Of Motor
8 Technical data 8.10 Connection of motor CAUTION The motor is for converter duty only. CAUTION The motor must be connected in DELTA (low voltage) to the converter. The motor may not be started or operated with the mains supply, but may only be operated with a frequency converter. All NORD frequency converters can operate the motors. -
Page 49: Measuring Of Total Run-Out
8 Technical data 8.11 Measuring of total run-out Before every mounting of the drive unit, installation and maintenance the total 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 surface. The indicator must be moved parallel to the datum axis A as the drive rotor is rotated. -
Page 50: Connection To Frequency Converter
8 Technical data 8.12 Connection to frequency converter For programming of frequency converter please follow the converter’s manual. All required data for programming the converter can be found on the name plate of the motor or in section 8.3 Drive unit data – IE4 standard blue.- 8.7 Drive unit data –... -
Page 51: Trouble Shooting
9 Trouble shooting 9.1 Troubleshooting Fault Action Possible Causes The mixer does not start. Fault in power supply. Check power supply. The impeller does not Male bearing or magnetic drive not mounted. Dismount the drive unit, detach the impeller rotate. and mount the male bearing, impeller, magnetic drive and drive unit. -
Page 52: Parts Lists/Service Kits
10 Parts lists/Service kits Product overview - WP50 10.1 Product overview - WP50 4307-0055... - Page 53 ......8010005957 For information on item numbers, please refer to the Spare part manual, available from the online Alfa Laval product catalogue...
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Page 54: Product Overview - Wp81
10 Parts lists/Service kits Product overview - WP81 10.2 Product overview - WP81 4307-0056... - Page 55 ......8010005959 For information on item numbers, please refer to the Spare part manual, available from the online Alfa Laval product catalogue...
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Page 56: Drive Unit - Wp50
10 Parts lists/Service kits Drive unit - WP50 10.3 Drive unit - WP50 4307-0057... - Page 57 Pos. 8: See 8.8 Mounting angle * parts are included in the gear motor For information on item numbers, please refer to the Spare part manual, available from the online Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.
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Page 58: Drive Unit - Wp81
10 Parts lists/Service kits Drive unit - WP81 10.4 Drive unit - WP81 4307-0058... - Page 59 Pos. 8: See 8.8 Mounting angle * parts are included in the gear motor For information on item numbers, please refer to the Spare part manual, available from the online Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.
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Page 60: Speed Sensor Variants
10 Parts lists/Service kits Speed Sensor variants 10.5 Speed Sensor variants... - Page 61 10 Parts lists/Service kits Speed Sensor variants Parts list Pos. Denomination Speed Sensor WP81 Speed Sensor WP50, Standard Console height Speed Sensor WP50, Extended Console height...
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Page 62: Tools
10 Parts lists/Service kits Tools 10.6 Tools 4307-0059... - Page 63 10 Parts lists/Service kits Tools Parts list Pos. Denomination Male Bearing Tool - WP81 Male Bearing Tool - WP50 Parts list Pos. Denomination Female Bearing Tool kit - WP81 consisting of: Female Bearing tool Protection Shield Female Bearing - WP81 Parts list Pos.
- Page 64 10 Parts lists/Service kits Tools...
- Page 65 10 Parts lists/Service kits Tools Parts list Pos. Denomination Impeller Lifting Device WP81 Impeller Lifting Device WP50 Parts list Pos. Denomination Lifting Rod Handle kit consisting of: Lifting Rod Handle Lifting Rod 200 mm Clip Parts list Pos. Denomination Lifting Rod kit, 700 mm consisting of: Lifting Rod Connection Piece Lifting Rod 700 mm...
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Page 66: Appendix
11 Appendix 11.1 Drive unit instructions The drive unit is supplied by sub supplier and all-important installation requirement is transferred to this manual. For further information regarding maintenance and storage of the drive unit please find the drive unit instruction manual by below link: https://www.nord.com/cms/en/documentation/manuals/details_1139/detail_42075.jsp 11.2 Speed Sensor instructions... - Page 68 © Alfa Laval Corporate AB This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is 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, reproduced or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval Corporate AB.
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