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Summary of Contents for Alfa Laval ESE02185-EN8
- Page 1 Instruction Manual Alfa Laval Rotary Jet Mixer IM 20 Covering: Standard Machines Machines Delivered with ATEX Certification in Accordance with Directive 2014/34/EU First published: 2009-12 TE91I350-EN8 ESE02185-EN8 2016-06 Original manual...
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Page 3: Table Of Contents
7.2. Rotary Jet Mixer IM 20 with 4 nozzles ............7.3. Performance data ................. 8. Product programme .................. 8.1. Standard configuration for Alfa Laval Rotary Jet Mixer IM 20 ........ 8.2. Available add-ons ................. 9. Trouble shooting guide ................10. Part lists and drawings, service kits and tools ........... - Page 4 Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice 11.3. How to contact Alfa Laval Kolding A/S ............12. Miscellaneous ..................12.1. ATEX - Special conditions for safe use...
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Page 5: Ec/Eu Declaration Of Conformity
Company Name Albuen 31, DK-6000 Kolding, Denmark Address +45 79 32 22 00 Phone No. hereby declare that Alfa Laval Rotary Jet Mixer Designation IM-20 Type From serial number 2016-0001 to 2030-99999 is in conformity with the following directive with amendments:... -
Page 6: Safety
2 Safety Unsafe practices and other important information are emphasized in this manual. Warnings are emphasized by means of special signs. Always read the manual before using the tank cleaning machine! 2.1 Important information 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 tank cleaning machine NOTE... -
Page 7: Introduction
Introduction This manual has been prepared as a guide for the persons who will be operating and maintaining your Alfa Laval Rotary Jet Mixer IM 20. The key to long life for your mixer will always be a system of carefully planned maintenance procedures; you will appreciate that a mixer which has a rough job to do will need more frequent attention than one working in ideal conditions. -
Page 8: Intended Use
Alfa Laval Kolding A/S, 2011. All rights reserved. Alfa Laval Rotary Jet Mixer IM 20 product has patents in the EPO member states and in other countries. The Alfa Laval logotype is a trademark or a registered trademark of Alfa Laval Corporate AB. Other products or company names mentioned herein may... -
Page 9: Atex Marking
Changes to the machine are not allowed without approval by the person responsible for the ATEX certification at Alfa Laval. If changes are made – or spare parts other than Alfa Laval original spare parts are used - the EC Type Examination certification (the ATEX Directive) is no longer valid. -
Page 10: Installation
4 Installation ESE02185 4.1 General description The Alfa Laval Rotary Jet Mixer IM 20 is a media driven and media lubricated tank/reactor mixer. The Rotary Jet Traditional Mixing technology Mixing technology Round pumping Propeller mixing A = Rotary Jet Mixer... -
Page 11: Functioning
4.2 Functioning The Alfa Laval Rotary Jet Mixer IM 20 is placed inside the tank/reactor under the liquid surface of the liquid volume to be mixed. The mixer is combined with an external recirculation loop. The fluid of the tank/reactor is recirculated through this loop and reintroduced in the tank/reactor through the Alfa Laval Rotary Jet Mixer IM 20. - Page 12 4 Installation ESE02185 Machines with 2 nozzles The combined motion of the mixer body and the nozzles ensures a fully indexed tank mixing. After 11¼ revolutions of the Hub with nozzles (10 revolutions of the mixer body), one coarse movement pattern has been established which when projected on the tank surface looks as Figure 1.
- Page 13 It is possible to add fluid, gas or solids in the recirculation loop. These ingredients will very effectively be mixed into the entire tank/reactor volume. When the tank/reactor is empty the Alfa Laval Rotary Jet Mixer IM 20 can be used as a tank cleaning machine.
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Page 14: General Safety And Installation Instructions
4.3 General safety and installation instructions The Alfa Laval Rotary Jet Mixer IM 20 should be installed in vertical position (upright or upside down). It is recommended to install a filter in the supply line in order to avoid large particles to clog inside the mixer. Before connecting the mixer into the system, all supply lines and valves should be flushed to remove foreign matter. - Page 15 4 Installation ESE02185 Method for tightening the nozzles With 2 nozzles 1. Clamp machine firmly in a vice: Place machine on top of vice with Hub w. nozzles down wards as illustrated on the figure. Clamp on the Hub. To protect machine use rubber jaws on the vice 2.
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Page 16: Special Conditions For Safe Use In Accordance With Atex Certification
4 Installation ESE02185 4.4 Special conditions for safe use in accordance with ATEX Certification Directive 2014/34/EU ATEX Warning: The unit may be operated, in a hazardous area, only when filled with the process fluid. ATEX Warning: The maximum permitted process fluid temperature is 95°C, with an ambient temperature range of 0°C to 140°C. -
Page 17: Operation
After-use cleaning After use flush the mixer with fresh water. Fluids should never be allowed to dry or set-up in the Alfa Laval Rotary Jet Mixer IM 20 system due to possible "salting out" or "scaling" of the ingredient. -
Page 18: Maintenance
6.1 Preventive maintenance In order to keep your Alfa Laval Rotary Jet Mixer IM 20 servicing you as an efficient tool in your mixing operations, it is essential to maintain its high performance by following a simple preventive maintenance programme, which will always keep your mixer in good condition. -
Page 19: Service And Repair Of Atex Certified Machines
ESE02185 6.2 Service and repair of ATEX certified machines All service and repair of ATEX certified machines can be performed by Alfa Laval Kolding A/S, Denmark or by an Alfa Laval service center approved by Alfa Laval Kolding A/S. ATEX... -
Page 20: Top Assembly
6 Maintenance ESE02185 6.3 Top assembly Disassembly 1. Remove 1/4" screws (pos. 17). Loosen and unscrew with a socket wrench (tool no. 962A). 2. Lift off top cone (pos. 1). 3. Remove guide/guide ring (pos. 2). The guide has a groove in the outer diameter. The guide is easily lifted out of the stem by means of two ordinary screwdrivers inserted into the groove. - Page 21 6 Maintenance ESE02185 4301-0036...
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Page 22: Bottom Assembly
6 Maintenance ESE02185 6.4 Bottom assembly Disassembly 1. Turn mixer upside down. 2. Remove 3/16" screws (pos. 31) from bottom cover (pos. 30). 3. Remove bottom cover (pos. 30) and gasket (pos. 32). 4. Remove 3/16" screw (pos. 15) and spring washers (pos. 16) along the circumference of gear frame (pos. 29). Draw out gear subassembly (holes in gear frame are excellent for holding gear subassembly). - Page 23 6 Maintenance ESE02185 Bottom Assembly...
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Page 24: Hub Subassembly
6 Maintenance ESE02185 6.5 Hub subassembly Disassembly 1. Remove nozzles (pos. 20). Nozzles are untightened with a wrench on the faces of the nozzles. 2. Remove 3/16" screws (pos. 31) from hub cover (pos. 19). 3. Draw out hub (pos. 21) together with hub cover (pos. 19), ball race (pos. 26), hub gasket (pos. 25), ball retainer with balls (pos. - Page 25 6 Maintenance ESE02185 Hub Subassembly 4301-0038...
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Page 26: Stem Subassembly
6 Maintenance ESE02185 6.6 Stem subassembly Disassembly 1. Place mixer in upright position. 2. Push out main bush (pos. 5). 3. Turn mixer upside down. 4. Remove 1/4" screws (pos. 8) in gear wheel (pos. 7). To prevent rotation of stem (pos. 3) mount two 1/4" screws in two holes opposite one another in BIG end of stem. - Page 27 6 Maintenance ESE02185 4301-0039...
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Page 28: Gear Subassembly
6 Maintenance ESE02185 6.7 Gear subassembly Disassembly 1. Hold turbine shaft (pos. 6) against 1 stage Worm wheel (pos. 33) with one hand and loosen 3/16" screws (pos. 15) in pinion (pos. 9) and horizontal shaft (pos. 27) with the other hand. 2. - Page 29 6 Maintenance ESE02185 Gear Subassembly 4301-0040...
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Page 30: Replacement Of Collar Bushes
6 Maintenance ESE02185 6.8 Replacement of collar bushes 1. Place gear frame (pos. 29) upside down with a firm support under the flange. Use for instance jaws of a vice. Do not clamp on machined surfaces. With pusher (tool no. 81B031, see page 47) knock out collar bush. 2. - Page 31 6 Maintenance ESE02185 Removal of old Collar bushes. TD523310 Support TD523311 Support TD523312 Mounting of new Collar bushes: TD523585...
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Page 32: Replacement Of Ball Races
6 Maintenance ESE02185 6.9 Replacement of ball races In body 1. A. With big end downwards knock several times body with bearings (pos. 28) hard against firm wooden support until ball race (pos. 28.3) drops out. 2. B. If it is not possible to knock out ball race in this way, it is necessary first to screw out main collar lower (pos. 28.2). Carefully push off old ball race without damaging main collar lower. - Page 33 6 Maintenance ESE02185 Replacement of Ball races Support TD523591 Support...
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Page 34: Replacement Of Main Collars
26.4) in body. The procedure to do this is described below. Warning: Replacement of Main collars involves risk of damaging the special threads and accordingly the body. It is recommended to let an authorized Alfa Laval sales office do the replacement. Main collar upper 1. - Page 35 6 Maintenance ESE02185 Replacement of Main Collars TD523592...
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Page 36: Technical Data
7 Technical data ESE02185 7.1 Rotary Jet Mixer IM 20 with 2 nozzles Weight of machine: 13 kg (28.6 lbs) Working pressure: 2-12 bar (30-175 psi) Recommended inlet pressure: 3-8 bar (45-120 psi) Working temperature max.: 120°C (248°F) Max. temperature: 140°C (284°F) Ambient temperature: 0-140°C (120°C -140°C when NOT operated) -
Page 37: Rotary Jet Mixer Im 20 With 4 Nozzles
7 Technical data ESE02185 7.2 Rotary Jet Mixer IM 20 with 4 nozzles Weight of machine: 13 kg (28.6 lbs) Working pressure: 2-12 bar (30-175 psi) Recommended inlet pressure: 3-8 bar (45-120 psi) Working temperature max.: 120°C (248°F) Max. temperature: 140°C (284°F) Ambient temperature: 0-140°C (120°C -140°C when NOT operated) -
Page 38: Performance Data
7 Technical data ESE02185 7.3 Performance data Flow rate Throw length Volumetric flow rate [m Reach of jet [m] m³/h Inlet pressure Inlet pressure A) d = 10 mm A) d = 10 mm D) Cleaning B) d = 9 mm B) d = 9 mm E) Mixing Nozzles... -
Page 39: Product Programme
8 Product programme ESE02185 8.1 Standard configuration for Alfa Laval Rotary Jet Mixer IM 20 Item no. Nozzles (mm) Connection Turbine/Inlet Guide Item no. E-gear 3/4” thread connection 4 x ø8 TE32B081 TE32E081 100% 4 x ø9 TE32B091 TE32E091 4 x ø9... -
Page 40: Trouble Shooting Guide
9 Trouble shooting guide ESE02185 Symtom: Slow or no rotation of mixer Fault finding Possible Causes No or insufficient liquid flow a). Check if supply valve is fully open. b). Check if inlet pressure to mixer is correct. c). Check supply line/filter for restrictions/clogging. d). - Page 41 9 Trouble shooting guide ESE02185 Fault finding Possible Causes Wear a) Slide bearings See page 18. b) Main bush See page 18. c) Worm wheels See page 18. d) Collar bushes See page 18. e) Turbine shaft Check clearance in main bush and in slide bearing. Transverse movement should not exceed 0.5 mm.
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Page 42: Part Lists And Drawings, Service Kits And Tools
10 Part lists and drawings, service kits and tools ESE02185 10.1 Parts drawing and list - IM20 with 2 nozzles TD523581... - Page 43 Washer *Note: Pos. 26 is not sold as single spare part component. Only sold as part of a machine maintenance/repair order. For further information please contact Alfa Laval Customer Support. ¬ Configuration according to delivery note/order. Parts marked with ◆ are included in the Minor Service Kit TE32B299...
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Page 44: Parts Drawing And List - Im20 With 4 Nozzles
10 Part lists and drawings, service kits and tools ESE02185 10.2 Parts drawing and list - IM20 with 4 nozzles TD523580... - Page 45 Washer *Note: Pos. 26 is not sold as single spare part component. Only sold as part of a machine maintenance/repair order. For further information please contact Alfa Laval Customer Support. ¬ Configuration according to delivery note/order. Parts marked with ◆ are included in the Minor Service Kit TE32B299...
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Page 46: Service Intervals
10 Part lists and drawings, service kits and tools ESE02185 10.3 Service intervals Service intervals 4000 hours 4000 hours 4000 hour • Continues As per above: As per above: As per above: Service Kit: Service Kit: Service Kit: TE32B299 TE32B299 TE32B299 (*) Service check (*) Service check... -
Page 47: Tools
10 Part lists and drawings, service kits and tools ESE02185 10.4 Tools Standard Tool kit for IM 20 Rotary Jet Mixer, article no. TE81B075 Description Tool No. Unbraco key for screw 1 pcs. TE134 TE134A 1 pcs. Unbraco Screwdriver Unbraco key for screw 1 pcs. - Page 48 10 Part lists and drawings, service kits and tools ESE02185 Sketch of tools for replacement of Main collars Available on request A: TE81B131 Tool for upper collar (2” TCM) compl. B: TE81B132 Tool for lower collar (2”+ 3” TCM) compl. TD523315...
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Page 49: General Information
11 General information 11.1 Service & repair Upon every return of a product, no matter if for modifications or repair, it is necessary to contact your local Alfa Laval office to guarantee a quick execution of your request. You will receive instructions regarding the return procedure from your local Alfa Laval office. Be sure to follow the instructions closely. - Page 50 12 Miscellaneous 12.1 ATEX - Special conditions for safe use...
- Page 52 © 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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