Steridose 120 H/220, 60/75, 85/100, 85/140, 120/150, 120/190, 210/275, 210/350, SMMS 85, 120 Sterimixer Installation and Operation Manual

STERIMIXER

®

Installation and Operation Manual

(including welding guide)

2

Read this user manual carefully before unpacking Sterimixer

®

!

Customer

Order No:

Steridose

Order No:

60/75

85/100

85/140

85

120/150











AC

Air



Motec



DC





120/190

120

120H/220

210/275

210/350











SMO

SMA





SMMS



Sign: TC

SiC





www.steridose.com

STERIDOSE SALES

Head Office

Himmelsbodavägen 7 · P.O.Box 120 · SE-147 22 TUMBA · SWEDEN

Phone: +46-8 449 99 00 · Fax: +46-8 449 99 90 [email protected] · www.steridose.com

Regional Office

5020 World Dairy Drive · Madison, WI 53718 · USA

Phone: +1-608 229 5225 · Fax: +1-608 227 9599 [email protected] · www.steridose.com

Rev B, October 2015

Sterimixer

®

– Installation and Operation Manual

Table of Contents

1

2

Safety Information

1.1

Introduction

1.2

Important information

1.3

Signs

1.4

General statement

1.5

Safety precautions

General description of the Sterimixer

®

3

Handling

4

Installation and mounting

4.1

Welding guide

4.2

Mounting of bearing unit and impeller

4.3

Bearing and impeller mount tool (optional)

4.4

Mounting and dismounting of drive unit

4.5

Power Installation

4.6

Installation check and calibration

5. Technical data

5.1

Sterimixer® main parts

5.2

Guideline mixer size

5.3

Parts in contact with the product - internal parts

5.4

External parts

6. Operation

6.1

Guide for operation of the Sterimixer

®

6.2

Guide for cleaning of SMA style Sterimixers ®

6.3

Guide for sterilising the Sterimixer ®

6.4

Additional instructions when using the Sterimixer

®

in ATEX applications

7

Maintenance

7.1

Routine maintenance during start up/running in

7.2

At least once a year - interval dependent upon application

8

Troubleshooting

76

Steridose Sales AB reserves the right to alter instructions and/or specifications without prior notice.

61

61

61

67

70

75

75

75

25

25

42

47

49

10

10

16

18

19

22

23

8

9

5

5

5

5

6

6

3

Rev B, October 2015

4 www.steridose.com

NOTE! For bespoke designs to customer specifications, the supplied

Sterimixer® can differ from the descriptions within this user manual.

Roplan AB/Steridose® does not give any warranty for products that have not been approved by Roplan AB/Steridose® including but not limited to similar products and/or copies of original

Roplan AB/Steridose® products. All Steridose® products are validated to work in cooperation with Steridose® products and Steridose® validated products only.

Rev B, October 2015

Sterimixer

®


1 Safety Information

!

1.1 Introduction

Read the safety information chapter very carefully as it concerns your own and others safety as well as the safe function of the Sterimixer

®

. This introduction describes how the safety information is presented in this manual and it gives general information about which safety precautions to take when you work with the Sterimixer

®

.

Always read the user manual before installing or using the Sterimixer

®

!

Special instructions for use in ATEX complying environments is included in section 6,

Òperation´.

1.2 Important information

Unsafe practices and other important information are emphasized in this manual by means of special signs.

WARNING! Indicates that there is a great risk of personal injury as well as serious damage to the Sterimixer

®

if the warning text is ignored.

CAUTION! Indicates that minor personal injury as well as damage to the

Sterimixer

®

or major operating faults can occur if the caution text is ignored.

NOTE! Draws attention to important information, which facilitates the reading of the instructions.

1.3 Signs

The following warning signs are used within the user manual to further emphasize important information.

General warning

5

Dangerous electrical voltage

Corrosive agents

Strong magnetic fields

No cardiac pacemakers allowed

Rev B, October 2015

6

!


1.4 General statement

Undertaking any work envisaged by this manual may either directly or indirectly create risks to the safety and health of the person undertaking the work or the Sterimixer

®

and/or its components whilst the work is being undertaken.

It is the responsibility of the user to ensure that appropriate controls and precautions are identified and applied in relation to the work envisaged by this document in accordance with relevant statutory, legal and industry requirements to protect the health and safety of the persons undertaking the work.

Neither this document, nor its use, in any way absolves the user from their responsibility to ensure that the controls and precautions referred to in this chapter are implemented.

If, whilst undertaking any work envisaged by this document, you become aware of any

Steridose product design related feature which could create risk to a person undertaking work or to the Sterimixer

®

and/or its components please contact Steridose immediately.

1.5 Safety precautions

Find below all warnings in this installation and operation manual summarized. Pay special attention to the instructions to ensure severe personal injury or damage to the Sterimixer

®

are avoided.

1.5.1 Installation

 Always observe the technical data (refer to section 5 `Sterimixer

®

Main Parts´).

 Never start in the wrong direction of rotation.

 Never put your fingers inside the vessel or anywhere close to rotating shaft.

 The Sterimixer

®

must be electrically connected by authorized personnel.

Rev B, October 2015

Sterimixer

®


1.5.2

!

!

Operation

 Always observe the technical data (refer to section 5 ”Sterimixer

®

Main Parts”).

 Never touch the Sterimixer

®

when processing hot media.

 Never step on the Sterimixer

®

.

 Only handle hazardous media as per their supplier instructions.

 Applicable health and safety regulations with regards to processed media must be considered.

1.5.3 Maintenance

 Always observe the technical data (refer to section 5 “Sterimixer

®

Main Parts”).

 The Sterimixer

®

must never be serviced when hot.

 The Sterimixer

®

must be electrically disconnected when being serviced.

7

Rev B, October 2015

8

2 General description of the Sterimixer

®


The Sterimixer

®

is a magnetically driven highly aseptic mixer for pharmaceutical, food and other relevant applications where cleaniness is a requirement. The Sterimixer

®

may be supplied as separate components or a complete unit (see picture). The picture below specifies the different components of the Sterimixer

®

.

Control box

Impeller

Bearing unit

Weld plate

Magnetic rotor

Drive unit

The Sterimixer

®

has a mixing capacity for vessels with volumes ranging from 5 to 15000 litres and for other applications such as stirring up to 40000 litres. The Sterimixer

®

is available with a wide range of different options providing flexibility for different applications.

The impeller “aseptic type”, SMA, is ideal for critical applications due to the creation of a minimum of shear forces. For efficient CIP and/or SIP performance the SMA impeller uses a patented feature involving horizontal flowchannels. The differential pressure created during rotation, ensures continuous purging of liquid through the bearing from beneath the impeller.

The impeller òpen type´, SMO, is used within applications where the requirement for low shear forces and high CIP and/or SIP performance are not critical.

The impeller SMMS, is a medium shear impeller in comparison to the low shear design of the

SMA and SMO. This style of impeller is ideal for incorporation of light or hydrophobic solids into solutions.

For more information on the different components of the Sterimixer

®

, refer to section 5

“Sterimixer

®

Main Parts”.

Rev B, October 2015

Sterimixer

®


3 Handling

Upon receipt always:

 Check the delivery note against the goods received.

 If drive unit is included, check that the drive instructions are available.

 Inspect the packaging for signs of damage in transit.

 Carefully remove the packaging.

 Inspect the Sterimixer

®

for any visible signs of damage.

 Clean away the packaging from cavities.

 Report any damage to the carrier.

Weight of the different components of the Sterimixer® is specified within section 5

“Sterimixer® Main Parts”.

WARNING! The Sterimixer

®

impeller and magnetic rotor includes strong magnets thus personnel equipped with pacemaker shall not handle these components.

NOTE! The Sterimixer

®

impeller and magnetic rotor includes strong magnets thus magnetic cards, e.g. credit cards, can be permanently damaged if being close to the components specified.

CAUTION! Ensure that lifting equipment chosen is suitable and properly used.

CAUTION! If the Sterimixer® is not to be installed immediately, the

Sterimixer® should be repacked in the original package and stored in a suitable storage after receipt and inspection. The following should be considered with regards to storage:

The storage shall be a clean, dry location free from vibration. If a moist or dusty atmosphere is used for storage, further protect the Sterimixer

®

with a suitable cover.

!

!

9

Rev B, October 2015

10

4


Installation and mounting

4.1 Welding guide

4.1.1 About the welding guide

The welding procedure described in this guide has been used for welding the weld plates into

Steridose vessels. The guidelines refer only to the technical aspects of welding operations. Do note that welding currents, time frames etc are approximate and may vary in practice.

NOTE! Ensure that the vessel is compliant with relevant standards for pressure vessels.

The most common fault occurring for the weld plate, is deformation introduced when welding the weld plate into the dished end of the vessel. To minimise the risk of faults occurring after delivery from Steridose, it is therefore essential that the welding guide is thoroughly studied and that only properly trained, experienced and qualified personnel are employed in the welding operations.

4.1.2 General

A weld plate may be welded into the lower dished end, before or after the dished end is welded to the jacket. For purely practical reasons, it is usually easier to weld the weld plate to the dished end before the jacket and the dished end are welded together. All other welding on the lower dished end must however be completed before making a hole for the weld plate.

Rev B, October 2015

Sterimixer

®


4.1.3

4.1.3.1

Positioning and orientation of Weld Plate

Information for design and orientation of Weld Plate

 The normal position for the drive unit is 270° as shown in figure.

 The lock nuts on the weld plate shall then be positioned in direction 0° - 180° as shown in figure.

 For drive unit 120H/220 and

210/275 there are four lock nuts. For these drive units the position has to be 0° - 180° and 90° - 270°.

 If the drive unit will have another direction, the weld plate has to be positioned in accordance to that direction.

60/75 120/150 - 190 120H/220

85/100 - 140

NOTE! For best performance, the weld plate has to be mounted as close as possible to the center of the tank.

210/275

11

Rev B, October 2015


4.1.3.2 Distance between welds

Ensure the distance in between the weld-in components are in accordance to relevant pressure vessel regulation. min, distance


4.1.3.3 Distance from outer edge

Ensure that the weld plate is positioned in accordance to relevant pressure vessel regulation.

Normally, these specify that the weld plate shall be positioned in such way that no part of its weld is outside the large radius R2 (refer to figure below).

Rev B, October 2015

4.1.4 Optimum alignment of Sterimixer impeller axis

The weld plate should be positioned in the lower dished end allowing the impeller axis to be aligned as close as

L possible to a diagonal through the center of the vessel. This ensures maximum mixing effect and minimum risk of creating a vortex and subsequently the intake of air into the product.

For best mixing result the dimension

L shall be equal at the top and bottom.

L

L

L

Bottom dished end Bottom conical end

Sterimixer

®



13

As a guide the following formula

Vessel Diameter Ø L

can be used, for location of <1000 mm Ø *0,5 * 0,5

Weld Plate. >1000 mm Ø *0,5 *0,3 - 0,5

Limitation described under 4.1.3.2 will overrule any conflicts in these calculations.

4.1.5 Making and Preparation of Hole in the Dished End

Mark the hole diameter on the outside of the lower dished end. Refer to table for proper hole diameter.

Cut a hole with appropriate equipment along the mark on the dished end.

Prepare a suitable weld gap between the dished end and the weld plate by grinding

Weld plate

60/75

Diameter

Ø60

85/100-140 Ø90

120/150-190 Ø149

120H/220 Ø150

210/275-350 Ø280

Hole diameter

Diameter of the weld plate +1 mm

(maximum) for the weld joint. the edge of the cut hole.

This weld groove should be kept as small as possible. The weld plate can be used as a template.

Prepare the hole for welding by grinding a

45



angle, sloping outwards (see figure).

A straight edge about 1 to 2 mm should be left towards the inside of the vessel.

Rev B, October 2015


4.1.6 Tack welding the weld plate (TIG)

1. The weld plate shall not have the bearing unit or any screws fitted during welding operation.

2. Position the weld plate in the cut hole of the dished end, ensuring it is properly orientated in the correct position (refer to 4.1.3.1).

3. Tack weld the weld plate at two points on the inside, (1 and 2 in the figure) using a correct filler (filler material depends upon the material in the dished end and weld plate).

4. Check how the weld plate is fitted. It shall be flush with the inside of the lower dished end.

5. Tack weld the weld plate at two more points from the inside (3 and 4 in the figure).

6. Turn over the dished end and place it on a flat bench. Seal it between the bench and dished end with the

NOTE!

aid of tape or similar. Fill the dished end with argon gas. It will normally take about 3 or 4 minutes to replace the air with the inert argon gas.

7. Tack weld the weld plate from the outside. The sequence 5-16 as shown in the figure shall be followed

(diagonal welding).

Use as little heat as possible and weld in small steps with low current. Allow the dished end and the weld plate to cool slowly on completion of each step of welding. No cooling medium other than air shall be used.

Rev B, October 2015

Sterimixer

®

– Installation and Operation Manual 15

4.1.7 Final Welding

The final welding shall start closest to the center of the dished end. The filler material should be the same as used previously.

Weld continuously from point 1 to point 2 alternating in between path A and B (refer to figure) until the weld groove is filled.

The dished end should be inverted again and welded from the inside to even out the weld joint.

NOTE! Use as little heat as possible and weld in small steps with low current.

Allow the dished end and the weld plate to cool slowly on completion of each step of welding. No cooling medium other than air shall be used.

4.1.8 After Welding

1. Allow the dished end and the weld plate to cool slowly on completion of welding. No cooling medium other than air shall be used.

2. Grind and polish the inside and outside of the weld to the required finish.

3. Re-assemble the screws for the bayonet connection. Tighten and secure the screws to the weld plate with appropriate thread locking, e.g. Loctite 243.

4. Fit the bearing unit to the weld plate. Tighten the bearing unit with a torque as per the table.

Weld plate / Bearing unit Max torque

60/75 6 Nm

85/100-140

SMMS 85

120/150-190 20 Nm

SMMS 120

120H/220

210/275-350

5. Fit the impeller on the bearing unit and turn a few revolutions by hand to ensure adequate clearance to the weld plate and the vessel. If interference is present, necessary corrections have to be performed.

6. Fit the drive unit to the vessel as per instructions (refer to section 4.4) to ensure adequate clearance to the weld plate and the vessel. If interference is present, necessary corrections have to be performed.

Rev B, October 2015


4.2 Mounting of bearing unit and impeller

The bearing materials used are either Tungsten Carbide (TC) or Silicon Carbide (SiC), which are very hard but brittle materials. It is therefore important that the bearing is protected from physical damage. It is also of the utmost importance that the bearing surfaces are kept free from particles to avoid damage or disturbances of the bearing function during operation.

WARNING! Ensure the impeller and vessel are clean. Do also ensure the vessel has been cooled, depressurised and ventilated from any possible gases, and that processed media are not, and cannot be, allowed to enter the vessel during maintenance work.

CAUTION! Before the bearing unit and the impeller are to be mounted, the vessel, pipes and other installed parts must be thoroughly cleaned from dirt and in particular loose metal particles (can occur in new vessels). Wetted Sterimixer

®

components can otherwise be permanently damaged.

4.2.1 Mounting of bearing unit

Carefully fit the bearing unit together with the PTFE washer to the weld plate and tighten to a proper torque listed below. Make sure that the PTFE washer has not been incorrectly trapped during this operation.

NOTE! Replace the PTFE washer each time the bearing is dismounted.

Bearing unit size

60/75; 85/100 – 140; SMMS 85

120/150 – 190; SMMS 120; 120H/220;

210/275-350

Bearing unit size

60, 85, 120H

120, 210

Torque

6 Nm

20 Nm

Tool Size

8 mm

14 mm

Rev B, October 2015

Sterimixer

®


4.2.2 Mounting of impeller

Before mounting the impeller, be sure of that the drive unit is NOT mounted to the vessel.

The impeller is to be mounted before the drive unit, thus avoiding any damage caused by crushing, and making sure that the bearing is not damaged by the magnetic charges arising from the drive unit magnets.

Carefully position the impeller onto the bearing unit and spin by hand to ensure that the impeller runs freely.


®

impeller includes strong magnets thus personnel equipped with pacemaker shall not handle these components.

CAUTION! Due to the strong magnetic forces generated by the magnets, the impeller must be mounted before the drive unit to avoid any damage on the bearings.

NOTE! Extreme care should be taken to prevent damages to the bearings when mounting the impeller.


®


17

Rev B, October 2015

18

4.3 Bearing and impeller mount tool (optional)

To change impeller and male bearing in applications when it is difficult to enter the tank, a special

`Bearing and impeller mount tool´ can be used. It consists of the following parts:

 Handle

 Bearing mount tool

 Impeller mount tool

 “Hair pin”

To allow easy mounting of the male bearing it is recommended to apply a small amount of suitable grease onto the PTFE washer. This prevents the PTFE washer from loosening from the bearing unit during mounting.

The “Bearing and impeller mount tool” is to be ordered separately.


Handle

“Hair pin”

Bearing mount tool

Impeller mount tool

Rev B, October 2015

Sterimixer

®


4.4 Mounting and dismounting of drive unit

A SMO or SMA drive unit consists of a motor (either an AC, MOTEC, DC or Air driven), gearbox, flange and rotor (some differences occurs depending on type of drive and size). An SMMS drive unit consists of a motor (AC), flange and rotor.

4.4.1 Mounting of drive unit

There is two different ways of attaching the drive unit to the flange of the vessel, depending on Sterimixer

®

size, by a bayonet coupling or by a threaded joint.

Ensure the magnetic rotor is not damaged and properly aligned preventing physical contact with the weld plate upon installation and operation.

Be certain that you can handle the weight of the drive unit. For an SMO or SMA low shear mixer, it is often best to grip the gearbox in order to balance the weight of the drive unit and to minimize the risk of damage caused by crushing when dismounting. For SMMS medium shear mixers, the motor must be gripped. Use appropriate lifting device for the larger models,

SM 120 and larger.

60/75; 85/100 & 85/140

1. Lift the drive unit up and let the welding plate’s screws pass through the slots in the drive unit flange.

2. Turn the drive unit counter clockwise into position.

3. Lock the drive unit in position by tightening the locking nuts.

120/150 & 120/190

1. Lift the drive unit up and let the welding plate’s screws pass through the slots in the drive plate.



120H/220 & 210/275 & 210/350

1. Lift the drive unit up and let the flange screws pass through the holes in the drive unit flange.

2. Lock the drive unit by tightening the locking nuts.

SMMS 85 & 120

1. Lift the drive unit up and let the welding plate’s screws pass through the slots in the drive unit flange.



Rev B, October 2015

20



®

magnetic rotor includes strong magnets thus personnel equipped with pacemaker shall not handle these components.


®


WARNING! Ensure the power supply is disconnected and not possible to accidentally be connected.

CAUTION! The drive unit can be heavy, refer to section 5 “Sterimixer

®

Main Parts”. www.steridose.com

!

Rev B, October 2015

Sterimixer

®


4.4.2 Dismounting of drive unit

Dismount the drive unit by following the mounting instructions in reverse order.

Be certain that you can handle the weight of the drive unit. For an SMO or SMA low shear mixer, it is often best to grip the gearbox in order to balance the weight of the drive unit and to minimize the risk of damage caused by crushing when dismounting. For SMMS medium shear mixers, the motor must be gripped. Use appropriate lifting device for the larger models,

SM 120 and larger.


®




®


WARNING! Ensure the power supply is disconnected and not possible to accidentally be connected.

CAUTION! The drive unit can be heavy, refer to section 5 “Sterimixer

®

Main Parts”.

!

Rev B, October 2015


4.5 Power Installation

The motor applied to the Sterimixer

®

could be either an AC, MOTEC, DC or Air driven type.

Any electrical connections shall be carried out by an authorised electrician in accordance with applicable regulations, standards and directives.

Never use the Sterimixer (drive unit) without a frequency converter.

If a control box is used, the drive unit is connected to the control box, which in turn is connected to the external power supply.

The Sterimixer comes standard with 4-pole AC motors (except the 60/75).

Models 60/75 (2-pole), 85/100, 85/140, 120/150 are fitted with a i = 5:1 gearbox.

Models 120/190, 120H/220, 210/275, 210/350 are fitted with a i = 7.5:1 gearbox.

Models SMMS 85, 120 do not have a gearbox and are directly coupled to the motor.

The actual speed varies with the properties of the application. To measure the real impeller speed it is recommended to use a IMS (Impeller Monitor Sensor, see 5.4.3).

The theoretical rotational speed at different frequencies and number of poles can be listed as:

Impeller speed -  - (rev/min, rpm)

Frequency Motor speed Impeller speed [rpm]

[Hz] [rpm] i = 5:1 i = 7.5:1

10

20

30

40

50

60

300

600

900

1200

1500

1800

60

120

180

240

300

360

40

80

120

160

200

240

70

80

90

100

2100

2400

2700

3000

420

480

540

600

280

320

360

400

Note: In the case of the SMMS medium shear which is directly coupled, the impeller speed would theoretically match that of the motor speed.

An electrical drawing/wiring diagram is supplied with the motor (drive unit) and control box upon delivery when applicable. Technical information for the motor (drive unit) and the control box is found within the documentation enclosed with the equipment.

Compressed air driven motor: The air intake to the control box is to be dry, free from particles

(<5µm), and the pressure should be between 6 and 7 bar.

The total length of the air supply hoses from the control box to the motor is not to exceed 10 meters (6 mm inner diameter for SM 60/75 - 85/140 and 10 mm inner diameter for SM

120/150 - 120/190). The oil mist lubricator for the compressed air is located in the control box.

The amount added to the air should be 2-3 drops per minute.

Rev B, October 2015

Sterimixer

®


4.6

4.6.1

Installation check and calibration

Verify the direction of rotation for the impeller

1. Make sure that there is a film of fluid between impeller and bearing unit by filling the vessel with water having the impeller fully immersed.

2. Set the speed potentiometer/regulator to zero.

3. For DC applications - Start the

Sterimixer

®

and carefully increase to a low speed (max 50 rpm).

4. For AC applications – The

Sterimixer

®

starts at low speed.

5. Visually check the direction of rotation for the impeller, which should be clockwise when looking from above. If the Sterimixer rotates counter clockwise, refer to section 8 `Troubleshooting´.

6. Stop the Sterimixer

®

immediately after completed verification.

WARNING! Dry operation of the Sterimixer

®

will damage the bearings.

23

!

Rev B, October 2015


4.6.2 Calibration of the Sterimixer®

The most important parameters in maintaining proper operation and thereby a long operational life for the Sterimixer

®

are pre-set on delivery. The pre-set parameters include acceleration time, deceleration time, max speed, and min speed.

Acceleration time and max speed will depend very much upon the application. Max speed must not be set too low, as a cleaning process usually requires a relatively high speed

(approximately 300 rpm) to achieve best performance. The max speed shall not exceed the specified max speed for each Sterimixer

®

size, refer to section 5 `Technical data´.

For verification of the speed of the Sterimixer

®

, use a hand tachometer and the recess provided on the gearbox shaft.


®


!

Rev B, October 2015

Sterimixer

®


5. Technical data

5.1 Sterimixer® main parts

The Sterimixer® consists of the Following components.

Each component is described in technical data.

SMA (Sterimixer Aseptic) and SMO (Sterimixer Open).

Type SMA Type SMO Type SMMS

25

Rev B, October 2015


5.1.1 Sterimixer® 60/75

Impeller, bearing unit and weld plate.

Specifications

Material:

Bearing material:

Surface finish:

Max temp (short time):

Max temp (operation):

Max speed:

Wingtip speed at 450 rpm:

Weight:

E.No. 1.4404 (AISI 316L)

Tungsten Carbide

Ra0.2 µm or better

+225°C

+140°C

450 rpm

1.77 m/s

0.6 kg

Material:

Bearing material:

Washer material:

O ring material:

Surface finish:

(product contact surfaces)

Weight:

Material:

Surface finish:


Max pressure:

Min pressure:

Weight:

E.No. 1.4404 (AISI 316L)

Tungsten Carbide

PTFE

Fluoroelastomer

Ra0.2 µm or better

< 0.1 kg

E.No. 1.4404 (AISI 316L)

Ra0.2 µm or better

+7 bar g

-1 bar g

0.16 kg

Options

Material:

Bearing material:

Surface finish:

Surface treatment:

Upon request

Silicon Carbide

Electro polished

Passivation

Impeller

SMA 60/75

Material:

Bearing material:

O ring material:

Surface finish:

Surface treatment:

Upon request

Silicon Carbide

Upon request

Electro polished

Passivation

Bearing unit

Material: Upon request Weld plate

Rev B, October 2015

Sterimixer

®


5.1.1.1 Sterimixer® 60/75 AC

Drive unit and Control box

Specifications

Power:

Speed:

Voltage:

Current:

75 W

2700 rpm (50 Hz)

230 VAC

0.40 A VAC

Protection: IP54

Operating temperature: -25°C to +40°C

Weight: 3.3 kg

Gearbox ratio:

Gearbox type:

Extension (E=0):

Conforms to:

5:1

Worm gearbox

A = 8 mm

CE / UL

Options

Protection:

Extension (E=27):

Thermal contact

Impeller monitor

IP65

A = 35 mm

Thermistor

Sensor

Connector 10 pin male harting

Motor cable (length): 5 m

Drive unit

(principal drawing)

27

Frequency inverter:

Main voltage:

Current:

Frequency input:

Speed setting impeller potentiometer = 0:

Speed setting impeller

0.75 kW

230 VAC

16 A

50/60 Hz

50 rpm = 5 Hz potentiometer = max: 450 rpm = 60 Hz

Material cabinet: E.No. 1.4301

(AISI 304)

Protection:

Weight:

Connector:

Conforms to:

IP65

10.5 kg

10 pin female harting

CE / UL

Min impeller speed:

Max impeller speed:

Sound level:

50 rpm

450 rpm

<70 dBa

Weight (approx): 4.2 kg

Torque magnet coupling: 0.75 Nm

Impeller monitor display

Timer

Main voltage: 120VAC

Control box

Sterimixer ® excluding control box


Rev B, October 2015

28

5.1.1.2 Sterimixer® 60/75 DC


Specifications

Power:

Speed:

Voltage:

Current:

55 W

3000 rpm

180 VDC

0.46 A at 180 VDC

Protection: IP55


Weight: 3.3 kg

Gearbox ratio:

Gearbox type:

Extension (E=0):

Conforms to:

5:1

Worm gearbox

A = 8 mm

CE

Options

Extension (E=27):

Impeller monitor

Connector

A = 35 mm

Sensor

10 pin male harting


Speed controller:

Main voltage:

Current:

360 W

230 VAC

Frequency Input:


6.3 A

50/60 Hz

0 rpm

Speed setting impeller potentiometer = max: 450 rpm


Protection:

Weight:

Connector:

Conforms to:

(AISI 304)

IP65

6.5 kg


CE

Min impeller speed:

Max impeller speed:

Sound level:

Weight (approx):

0 rpm

450 rpm

<70 dBa

7.4 kg



Timer

Main voltage: 120VAC


Drive unit


Control box

Sterimixer

® excluding control box


Rev B, October 2015

Sterimixer

®


5.1.1.3 Sterimixer® 60/75 Air

Not available, please use Sterimixer

®

85/100 Air.


Specifications

Power:

Speed:

Air flow:

Pressure:

240 W

450 rpm (840 rpm)

8,5 l/s

6.3 bar

Protection: IP55


Weight: 2 kg

Connector:

Lubrication free:

Conforms to:


ISO G 1/4

Yes

CE potentiometer = 0: 0 rpm



Protection:

Weight:

Connector:

Conforms to:

(AISI 304)

IP65

6.5 kg

CE

Options

Intrinsically safe:

Impeller monitor


Timer

Eex II 2 G T4 IIC

(D 110°C)

Eex II 2 G ia T6 IIC

Min impeller speed:

Max impeller speed:

Sound level:

0 rpm

450 rpm

<70 dBa

Weight (approx): 5 kg


Drive unit


Control box

Sterimixer



29

Rev B, October 2015

30

5.1.2 Sterimixer® 85/100 - 140

Impeller, bearing unit and weld plate

Specifications

Material:

Bearing material:

Surface finish SMA:

E.No. 1.4404

(AISI 316L)

Tungsten Carbide

Ra0.2 µm or better

Surface finish SMO: Ra0.5 µm or better

Max temp (short time): +225°C

Max temp (operation): +140°C

Max speed: 450 rpm

Wingtip speed at 450 rpm: m/s

SM 100 - 2.36

Weight SMA 85/100:

SM 140 - 3.30 m/s

1.1 kg

Weight SMA 85/140: 1.2 kg

Weight SMO 85/100: 1.0 kg


Options

Material:

Bearing material:

Surface finish:

Surface treatment:

Material:

Bearing material:

Washer material:

E.No. 1.4404

(AISI 316L)

Tungsten Carbide

PTFE

O ring material:

Surface finish:

Fluoroelastomer

Ra0.2 µm or better


Weight: < 0.1 kg

Material: E.No. 1.4404

(AISI 316L)

Surface finish: Ra0.2 µm or better


Max pressure: +7 bar g

Min pressure:

Weight:

-1 bar g

0.4 kg

Material:

Bearing material:

O ring material:

Surface finish:

Surface treatment:

Material:

Upon request

Silicon Carbide

Electro polished

Passivation

Upon request

Silicon Carbide

Upon request

Electro polished

Passivation

Upon request


Impeller

SMA 85/100-140

SMO 85/100-140

Bearing unit

Weld plate

Rev B, October 2015

Sterimixer

®


5.1.2.1 Sterimixer® 85/100 - 140 AC


Specifications

Power:

Speed:

Voltage:

Current:

Frequency:

Protection:

180 W

1400 rpm

230/460 VAC

0.64 A at 460 VAC

50/60 Hz

IP65


Weight: 7 kg

Gearbox ratio: 5:1

Gearbox type:

Extension(E=0):

Conforms to:

Worm gearbox

A = 14 mm

CE / UL

Options

Intrinsically safe:

Direct coupled

Eex de IIB T4

Eex de IIC T4 frequency drive system: MOTEC

MOTEC cable (length): 2,5 m

Extension (E=75): A = 89 mm

Thermal contact

Impeller monitor

Impeller monitor

Thermistor


Sensor

Connector 10 pin male harting


Frequency inverter:

Main voltage:

Current:

0.75 kW

230 VAC

Frequency input:


16 A

50/60 Hz

50 rpm = 10 Hz

Speed setting impeller potentiometer = max: 450 rpm = 85 Hz

Material cabinet:

Protection:

E.No. 1.4301

(AISI 304)

IP65

Weight:

Connector:

Conforms to:

7 kg


CE / UL


Timer

Main voltage: 120 VAC

Drive unit


Control box

31

Min impeller speed:

Max impeller speed:

50 rpm

450 rpm

Sound level: <70 dBa

Weight SMA (approx): 8.7 kg

Weight SMO (approx): 8.5 kg




Rev B, October 2015

32



Specifications

Power:

Speed:

Voltage:

Current:

110 W

3000 rpm

180 VDC

0.6 A at 180 VDC

Protection: IP55


Weight: 4.4 kg

Gearbox ratio:

Gearbox type:

Extension (E=0):

Conforms to:

5:1

Worm gearbox

A = 29 mm

CE

Options

Extension (E=75):

Impeller monitor

Connector

A = 104 mm

Sensor

10 pin male harting



Drive unit


Speeed control:

Main voltage:

Current:

Frequency:


360 W

230 VAC

6.3 A

50/60 Hz

0 rpm


Material cabinet:

Protection:

Weight:

Connector:

Conforms to:

E.No. 1.4301

(AISI 304)

IP65

6.5 kg


CE

Min impeller speed:

Max impeller speed:

Sound level:

0 rpm

450 rpm

<70 dBa





Timer


Control box



Rev B, October 2015

Sterimixer

®




Specifications

Power:

Speed:

Voltage:

Current:

200 W

3000 rpm

180 VDC

0.23 A at 180 VDC

Protection: IP55


Weight: 4.4 kg

Gearbox ratio:

Gearbox type:

Extension (E=0):

Conforms to:

5:1

Worm gearbox

A = 29 mm

CE

Options

Extension (E=75):

Impeller monitor

Connector

A = 104 mm

Sensor

10 pin male harting


Speed control:

Main voltage:

Current:

Frequency:


360 W

230 VAC

6.3 A

50/60 Hz potentiometer = 0:


0 rpm potentiometer = max: 450 rpm

Material cabinet:

Protection:

E.No. 1.4301

(AISI 304)

IP65

Weight:

Connector:

Conforms to:

Min impeller speed:

6.5 kg


CE

0 rpm

Max impeller speed: 450 rpm






Timer


Drive unit


Control box



33

Rev B, October 2015

34

5.1.2.4 Sterimixer® 85/100 - 140 Air


Specifications

Power:

Speed:

Air flow:

Pressure:

380 W

450 rpm (840 rpm)

8.3 l/s

6.3 bar

Protection: IP65


Weight: 1.0 kg + växel

Connector:

Lubrication free:

Conforms to:


ISO G 1/4

Yes

CE potentiometer = 0: 0 rpm



Protection:

Weight:

Connector:

(AISI 304)

IP65 kg

Options

Intrinsically safe:

Impeller monitor


Timer

Eex II 2 G T5 IIC

(D 85°C)


Min impeller speed:

Max impeller speed:

Sound level:

0 rpm

450 rpm

<70 dBa




Drive unit


Control box

Sterimixer



Rev B, October 2015

Sterimixer

®


5.1.3 Sterimixer® 120/150 - 190


Specifications

Material:

Bearing material:

Surface finish SMA:

E.No. 1.4404

(AISI 316L)

Tungsten Carbide

Ra0.2 µm or better




Max speed SM 150:

Max speed SM 190:


450 rpm

350 rpm m/s

Wingtip speed at 350 rpm: m/s





SM 150 - 3.53

SM 190 - 3.48

Options

Material:

Bearing material:

Surface finish:

Surface treatment:

Material:

Bearing material:

Washer material:

E.No. 1.4404

(AISI 316L)

Tungsten Carbide

PTFE

O ring material:

Surface finish:

Fluoroelastomer

Ra0.2 µm or better


Weight: 0.2 kg

Material:

Bearing material:

O ring material:

Surface finish:

Surface treatment:

Material:

Surface finish:


E.No. 1.4404

(AISI 316L)

Ra0.2 µm or better

Max pressure:

Min pressure:

Weight:

+7 bar g

-1 bar g

1.9 kg

Material:

Upon request

Silicon Carbide

Electro polished

Passivation

Upon request

Silicon Carbide

Upon request

Electro polished

Passivation

Upon request

Impeller

SMA 120/150-190

SMO 120/150-190

Bearing unit

Weld plate

35

Rev B, October 2015

36



Specifications

Power:

Speed:

Voltage:

Current:

Frequency:

750 W

1400 rpm

230/460 VAC

1.9 A at 460 VAC

50/60 Hz

Protection: IP65


Weight: 15 kg

Gearbox ratio:

Gearbox type:

Extension (E=0):

Conforms to:

5:1

Worm gearbox

A = 17 mm

CE / UL

Options

Intrinsically safe: Eex de IIB T4

Eex de IIC T4

Direct coupled frequency drive system: MOTEC


Extension (E=100):

Thermal contact

Impeller monitor

A = 119 mm

Thermistor


Impeller monitor

Connector

Sensor

10 pin male harting



Drive unit



(AISI 316L)

Drive plate

Control box Frequency inverter:

Main voltage:

Current:

0.75 kW

230 VAC

Frequency input:


16 A

50/60 Hz

50 rpm = 10 Hz



Protection:

Weight:

Connector:

Conforms to:

(AISI 304)

IP65

10.5 kg


CE / UL

Min impeller speed:

Max impeller speed:

Sound level:

50 rpm

450 rpm

<70 dBa



Torque magnet coupling: 14 Nm


Timer


Sterimixer



Rev B, October 2015

Sterimixer

®




Specifications

Power:

Speed:

Voltage:

Current:

1100 W

1400 rpm

230/460 VAC

2.4 A at 460 VAC

Frequency:

Protection:

50/60 Hz

IP65


Weight:

Gearbox ratio:

Gearbox type:

Extension (E=0):

Conforms to:

21 kg

7.5:1

Worm gearbox

A = 21 mm

CE / UL

Options

Intrinsically safe:

Direct coupled

Eex de IIB T4




Thermal contact

Impeller monitor

Impeller monitor

Connector


Sensor

10 pin male harting



(AISI 316L)

Drive unit


Drive plate

37

Control box Frequence inverter:

Main voltage:

Current:

Frequency input:



1.5 kW

230 VAC

20 A

50/60 Hz



(AISI 304)

Protection:

Weight:

Connector:

Conforms to:

IP65

12 kg


CE / UL

Min impeller speed:

Max impeller speed:

Sound level:

50 rpm

350 rpm

<70 dBa





Timer


Sterimixer



Rev B, October 2015

38

5.1.4 Sterimixer

®

120H/220


Specifications

Material:

Bearing material:

Surface finish SMA:

E.No. 1.4404

(AISI 316L)

Tungsten Carbide

Ra0.5 µm or better




Max speed: 350 rpm


Weight SMA:

Weight SMO:

4.1 kg

4,1 kg

4.03 m/s

Material:

Bearing material:

Washer material:

E.No. 1.4404

(AISI 316L)

Tungsten Carbide

PTFE

O ring material:

Surface finish:

Fluoroelastomer

Ra0.5 µm or better


Weight: 0.1 kg

Options

Material:

Bearing material:

Surface finish:

Surface treatment:

Material:

Bearing material:

O ring material:

Surface finish:

Surface treatment:

Material:

Surface finish:

E.No. 1.4404

(AISI 316L)

Ra0.5 µm or better



Min pressure:

Weight:

-1 bar g

2.0 kg

Material:

Upon request

Silicon Carbide

Electro polished

Passivation

Upon request

Silicon Carbide

Upon request

Electro polished

Passivation

Upon request


Impeller

SMA 120H/200 SMS 120H/220

SMO 120H/220

Bearing unit

Weld plate

Rev B, October 2015

Sterimixer

®


5.1.4.1 Sterimixer

®

120H/220 AC


Specifications

Power:

Speed:

Voltage:

Current:

1500 W

1400 rpm

230/460 VAC

3.2 A at 460 VAC

Frequency:

Protection:

50/60 Hz

IP65


Weight:

Gearbox ratio:

Gearbox type:

Extension(E=0):

Conforms to:

24 kg

7.5:1

Worm gearbox

A = 22 mm

CE / UL

Frequency inverter:

Main voltage:

Current:

Frequency input:



1.5 kW

230 VAC

20 A

50/60 Hz

50 rpm = 15 Hz potentiometer = max: 350 rpm = 94Hz


Protection:

Weight:

Connector:

Conforms to:

(AISI 304)

IP65

12 kg


CE / UL

Min impeller speed:

Max impeller speed:

Sound level:

50 rpm

350 rpm

<70 dBa



Options

Intrinsically safe:

Direct coupled

Eex de IIB T4




Thermal contact

Impeller monitor

Impeller monitor

Connector


Sensor

10 pin male harting



Timer


Drive unit


Control box

Sterimixer



39

Rev B, October 2015

40

5.1.5 Sterimixer® 210/275-350


Specifications


Bearing material:

(AISI 316L)

Tungsten Carbide

Surface finish SMA/SMO: Ra0.5 µm or better



Max speed: 350 rpm

Wingtip speed at 350 rpm: 5.04 m/s, 6,41

Weight SMA: 10.0, 10,5 kg

Weight SMO:

Material:

12.0, 12,5 kg

E.No. 1.4404

Bearing material:

Washer material:

O ring material:

(AISI 316L)

Tungsten Carbide

PTFE

Fluoroelastomer

Surface finish:


Ra0.5 µm or better

Weight: 0.1 kg

Options

Material:

Bearing material:

Surface finish:

Surface treatment:

Material:

Bearing material:

O ring material:

Surface finish:

Surface treatment:

Material:

Surface finish:

E.No. 1.4404

(AISI 316L)

Ra0.5 µm or better



Min pressure:

Weight:

-1 bar g

6.5 kg

Material:

Upon request

Silicon Carbide

Electro polished

Passivation

Upon request

Silicon Carbide

Upon request

Electro polished

Passivation

Upon request


Impeller

SMA 210/275

SMO210/275

Bearing unit

Weld plate

Rev B, October 2015

Sterimixer

®


5.1.5.1 Sterimixer® 210/275-350 AC


Specifications

Power:

Speed:

Voltage:

Current:

2200 W/ 3000 W

1400 rpm

230/460 VAC

4.8 A at 460 VAC

Frequency:

Protection:

50/60 Hz

IP65


Weight:

Gearbox ratio:

Gearbox type:

Extension (E=0):

Conforms to:

32 kg 39 kg

7.5:1

Worm gearbox

A = 20 mm

CE / UL

Frequency inverter:

Main voltage:

Current:

Frequency input:


2.2 kW

230 VAC

20 A

50/60 Hz potentiometer = 0:



Material cabinet:

Protection:

Weight:

Connector:

Conforms to:

Min impeller speed:

E.No. 1.4301

(AISI 304)

IP65

12 kg


CE / UL

50 rpm

Max impeller speed:

Sound level:

Weight (approx):

350 rpm

<70 dBa

47.4 kg/ 55kg


Options

Intrinsically safe:

Direct coupled

Eex de IIB T4




Thermal contact

Impeller monitor

Impeller monitor

Connector


Sensor

10 pin male harting



Timer


Drive unit

(principal drawing)

Control box

Sterimixer® excluding control box

(principal drawing)

41

Rev B, October 2015

42

5.1.6 SMMS 85


Specifications


Bearing material:

(AISI 316L)

Tungsten Carbide

Surface finish SMMS: Ra0.5 µm or better



Max speed: 1,200 rpm

Wingtip speed at 1,200 rpm:

Weight SMMS 85: 0.91 kg

5.6 m/s

Options

Material:

Bearing material:

Surface finish:

Surface treatment:

Material:

Bearing material:

Washer material:

O ring material:

Surface finish:

E.No. 1.4404

(AISI 316L)

Tungsten Carbide

PTFE

Fluoroelastomer

Ra0.2 µm or better


Weight: < 0.1 kg

Material:

Surface finish:

E.No. 1.4404

(AISI 316L)

Ra0.2 µm or better



Min pressure:

Weight:

-1 bar g

0.4 kg

Material:

Bearing material:

O ring material:

Surface finish:

Surface treatment:

Material:

Upon request

Silicon Carbide

Electro polished

Passivation

Upon request

Silicon Carbide

Upon request

Electro polished

Passivation

Upon request

Impeller

SMMS 85


Bearing unit

Weld plate

Rev B, October 2015

Sterimixer

®


5.1.6.1 SMMS 85 - AC


Specifications

Power:

Speed:

Voltage:

Current:

Frequency:

Protection:

550 W

1400 rpm

230/460 VAC

1.53 A at 460 VAC

50/60 Hz

IP65


Weight: 8.2 kg

Conforms to: CE / UL

Options

Intrinsically safe:

Direct coupled

Eex de IIB T4



Thermal contact Thermistor

Impeller monitor

Impeller monitor

Connector


Sensor

10 pin male harting



Timer


Frequency inverter:

Main voltage:

Current:

0.75 kW

230 VAC

Frequency input:


16 A

50/60 Hz

140 rpm = 5 Hz



Protection:

Weight:

Connector:

Conforms to:

(AISI 304)

IP65

7 kg


CE / UL

Drive unit


Control box

43

Min impeller speed:

Max impeller speed:

50 rpm

1,200 rpm


Weight SMMS(approx): 9.2 kg




Rev B, October 2015

44

5.1.7 SMMS 120


Specifications


Bearing material:

(AISI 316L)

Tungsten Carbide

Surface finish SMMS: Ra0.5 µm or better



Max speed SMMS 120: 1,800 rpm

Wingtip speed at 1,800 rpm:

Weight SMMS 120: 2.5 kg

12.1 m/s

Options

Material:

Bearing material:

Surface finish:

Surface treatment:

Material:

Bearing material:

Washer material:

E.No. 1.4404

(AISI 316L)

Tungsten Carbide

PTFE

O ring material:

Surface finish:

Fluoroelastomer

Ra0.2 µm or better


Weight: 0.2 kg


(AISI 316L)

Surface finish:


Ra0.2 µm or better


Min pressure:

Weight:

-1 bar g

1.9 kg

Material:

Bearing material:

O ring material:

Surface finish:

Surface treatment:

Material:

Upon request

Silicon Carbide

Electro polished

Passivation

Upon request

Silicon Carbide

Upon request

Electro polished

Passivation

Upon request


Impeller

SMMS 120

Bearing unit

Weld plate

Rev B, October 2015

Sterimixer

®


5.1.7.1 SMMS 120 - AC


Specifications

Power:

Speed:

Voltage:

Current:

3000 W

1400 rpm

230/460 VAC

6.0 A at 460 VAC

Frequency:

Protection:

50/60 Hz

IP65


Weight:

Conforms to:

27.5 kg

CE / UL

Options

Intrinsically safe:

Direct coupled

Eex de IIB T4



Thermal contact

Impeller monitor Eex II 2 G ia T6 IIC

Impeller monitor

Connector

Sensor

10 pin male harting



Timer


Frequence inverter:

Main voltage:

Current:

Frequency input:

3 kW

230 VAC

20 A

50/60 Hz

Speed setting impeller potentiometer = 0: 140 rpm = 5 Hz



(AISI 304)

Protection:

Weight:

Connector:

Conforms to:

IP65

12 kg


CE / UL

Min impeller speed:

Max impeller speed:

Sound level:

50 rpm

1,800 rpm

<70 dBa

Weight SMMS (approx): 30.2 kg


Drive unit


Control box

Sterimixer



45

Rev B, October 2015


5.2 Guideline mixer size

Find below a simple guideline to estimate a nominal tank size matching the Sterimixer

® capacity. Do note that to get the accurate mixing performance, tests in a real system is required.

Some basic parameters are:

 Volume

 Shape of the tank

 Viscosity

 Mixing time

 Type of mixing, gentle, stirring, dissolving

Contact Steridose for further technical assistance.

5.2.1 SMA/SMO Low Shear Mixer:

1200

1000

800

600

400

200

0

1

5.2.2

Rev B, October 2015

Mixer SMMS 85: Working volume vs viscosity

10 100

Volume (liters)

1000 10000

Sterimixer

®


5.2.3 Mixer SMMS 120: Working volume vs viscosity

47

Sterimixer size

SMA 60/75

SMA 85/100

SMO 85/100

SMA 85/140

SMO 85/140

SMA 120/150

SMO 120/150

SMA 120/190

SMO 120/190

SMA 120H/220

SMO 120H/220

SMA 210/275

SMO 210/275

SMA 210/350

SMO 210/350

Sterimixer size

SMMS 85

SMMS 120

Mixing volume

(ref. water)

5-50 l

50-100 l

50-500 l

300-1000 l

300-3000 l

1000-7000 l

3000-15000 l

3000-30000 l

Mixing volume

(ref. water)

50-2000 l

1000-7000 l

Max transferable power at

350 rpm 400 rpm

27,5 W 31,5 W

92 W 105 W

0,55 kW 0,6 kW

0,95 kW

1,4 kW

1,4 kW

Max transferable power at

1200 rpm 1800 rpm

0.33 kW

1.76 kW 2.64 kW

0,7 kW

450 rpm

35,5 W

118 W

P



M v



n

9 , 55

P = power

M v

= torque n = speed

P



9 , 55

n



M v

Rev B, October 2015


5.3 Parts in contact with the product - internal parts

The impeller, bearing, and the upper part of the weld plate are all parts that come into contact with the processed product and therefore have a high surface quality in order to fulfil aseptic requirements.

CAUTION! The Sterimixer

®

is a product manufactured with precision having high demands on surface finish and tolerances. The

!

product shall therefore to be handled with care to prevent damage.

5.3.1 Impeller

The impeller is the heart of the Sterimixer

®

. The low shear SMA/SMO impellers generate in comparison to other mixers such as propellers and the Rushton turbine, a minimum of shear forces during operation, and thereby a low risk of damage to sensitive products. Alternatively, the medium shear SMMS is best suited for for incorporation of light or hydrophobic solids into solution.

The drive is transmitted to the impeller through a magnetic coupling, thus avoiding the problems presented by through-going shafts.


®


The unique Sterimixer

®

design allows cleaning and sterilisation in place (CIP/SIP), without the need for disassembly of the unit. The especially designed flow channels and wings in the impeller provide a continuous flow of fluid through the impeller during rotation. This fluid flow ensures an effective cleaning of the inside of the impeller including the bearings. For more information on cleaning and sterilisation of the Sterimixer

®

, refer to section 6 Òperation´.

5.3.2 Bearing Unit

The standard bearing material used for bearings is Tungsten Carbide (TC) having Silicon

Carbide (SiC) as an option. As both materials are by nature brittle it is important keeping the bearing protected from accidentally being hit. It is also vital that the bearing surfaces are kept free from particles to avoid damage or disturbances in the bearing function.

The male bearing and the female bearing must be of the same material, TC or SiC. Do also ensure both male and female bearings are replaced upon refurbishment of the impeller.

Rev B, October 2015

Sterimixer

®


5.3.3 Weld Plate

After the weld plate has been welded into the vessel it becomes an integral part of the vessel, allowing fitment of the bearing and drive unit.

The outside of the weld plate has a threaded joint or bayonet coupling for the attachment of the drive unit. The threaded joint will differ depending upon the size of the mounting flange.

The function, however, is the same allowing the drive unit to be easily mounted and dismounted.

5.4

5.4.1

External parts

Drive Unit

The drive unit consists of a drive (AC; MOTEC; DC; Air) together with the gearbox, flange and drive rotor. On Sterimixer

®

120/150 and 120/190 there are also a drive plate as an interface between the gearbox and the weld plate. The drive plate can be ordered separately. For

Sterimixer SMMS, there is no gearbox and the motor is directly coupled to the drive rotor.


®


5.4.1.1 Gearbox

All gearboxes are permanently lubricated. Find below the technical data for each motor size.

Sterimixer

®

: 60/75AC, 60/75DC, 85/100DC

Size 311.25- 311.31 gear reducers come pre-filled with Shell Alvania GL00, a grease suitable for permanent lubrication. The grease is applicable to temperatures from -20°C up to +100°C. The units are supplied plugged, as the lubrication is permanent, i.e. any service is not required.

Sterimixer

®

60/75 AC, 60/75 DC

85/100 DC

Gearbox Quantity of grease [ml]

311.25 30

311.31 50

Supplier

SHELL

KLÜBERSYNTH

Grease

ALVANIA GL00

GH-680

Rev B, October 2015


Sterimixer

®

: 85/140 AC, 85/140 DC, 120/150 AC, 120/190 AC, 12OH/220 AC and 210/275 AC

Size 030- 050- 063- 075- gear reducers come pre-filled with IP TELIUM VSF, a synthetic gear oil suitable for permanent lubrication. The synthetic oil is applicable to temperatures from -25°C up to +50°C. The units are supplied plugged, as the lubrication is permanent, i.e. any service is not required.

Sterimixer

®

Gearbox Quantity of oil [ml]

85/140 AC,

85/140 DC

120/150 AC

120/190 AC

030

050

063

120H/220 063

210/275-350 075

40

150

300

300

550

Supplier

IP

SHELL

AGIP

MOBIL

CASTOL

Synthetic oil

TELIUM VSF

TIVELA OIL SC320

BLASIA S320

GLYCOYLE 30

ALPHASYN PG320

Mineral oil

MELLANA OIL 220

OMALA OIL 220

BLASIA 220

MOBILGEAR 220

ALPHA MAX 220

5.4.1.2 Motor

Refer to motor cable installation instruction for each motor size and type, enclosed with the motor.

5.4.2 Control Box

The control box has a main power switch, start and stop buttons as well as equipment for speed setting with either a frequency converter (AC) or a thyristor (DC), depending upon model used. Where the Sterimixer

®

is part of a process system or similar, the control box functions are built into the process system’s control box.

The Sterimixer

®

can also be supplied and used without control box.

Rev B, October 2015

Sterimixer

®


5.4.3 Impeller monitor (optional)

5.4.3.1 General description

The Impeller Monitor unit is a system that is able to detect and present the impeller speed.

Depending upon the specific application, the Impeller Monitor can be used in two ways. It can either be used to detect that the impeller of the Sterimixer® is in rotation, or supply a signal for measurement of the actual impeller speed.

The operation of the Impeller Monitor is based upon the principle that the impeller contains a number of equally spaced magnets arranged in a circle in the hub of the impeller. The Impeller

Monitor detects the rotation of these magnets and generates a pulsed signal with varying frequency depending upon impeller speed.

The Impeller Monitor consists of:

 One magnetic sensor.

 One sensor wiring socket.

 One sensor holder (shape will differ depending upon mixer size and type of drive).

 Two distance sleeves (Optional for Sterimixer

®

60/75 DC, 85/100 DC & 85/100 - 140

AC extended drive units).

The Impeller Monitor is available with a display, which shows the actual impeller rotational speed. As standard, the display is delivered with an analogue output, 4 – 20 mA / 0-10 V.

The impeller monitor fitted to the drive unit.

Rev B, October 2015


5.4.3.2 Installation and mounting of Impeller Monitor

1. Fasten the holder onto the flange. Do note that there are specific instructions below for each size and model of the Sterimixer

®

.

2. Mount the drive unit to the vessel. Do not install the sensor until the drive unit is installed as the sensor can be accidentally damaged due to rough handling.

3. Screw the magnetic sensor into the holder and through the lock nut as per figure below. Tighten the sensor until it touches the vessel.

4. Loosen the sensor one or two turns, having no longer contact with the vessel.

5. Lock the sensor in place with the nut. As the holder is threaded, a single nut is enough to lock the sensor in position.

6. Connect the electrical socket to the sensor.

5.4.3.3 Sensor holder 60/75

The sensor holder for Sterimixer

®

60/75 DC is installed on the lower part of the flange, as shown in the three figures below. The holder is fixed to the flange with two of the screws that are used to fix the flange to the gearbox.

60/75 DC

Positioning of the sensor holder, see the figure of the drive unit above.

Rev B, October 2015

Sterimixer

®


5.4.3.4 Sensor holder 85/100 – 140 and SMMS 85

The sensor holders for Sterimixer

®

85/100 DC, 85/100-140 AC and SMMS 85 are mounted in the same way. The holder is installed on the lower part of the flange, as shown in the three figures below. The holder is fixed to the flange with two of the screws that are used to fix the flange to the gearbox.

When the drive unit has an extension, longer screws and distance sleeves are required.

Design of holders as of 2013:

Positioning of the sensor holder, see the figure of the drive unit above.

Design of holders pre 2013

85/100 DC 85/100-140 AC

85/140 DC

5.4.3.5 Sensor holder 120/150 – 190 and SMMS 120

The holder for the Sterimixer

®

120/150-190 and SMMS120 is assembled on the upper part of the flange, as the figure shows. The holder is fixed to the flange with the screws that are used to fix the drive plate against the flange.

Since the holder is installed on the upper flange, the mounting instructions are identical for units with extended drive units.

120/150 AC

85/100-140 AC

85/140 DC with extension

Rev B, October 2015


5.4.3.6 Sensor holder 120H/220 and 210/275

The holder for the Sterimixer

®

120H/220 is assembled on the upper part of the flange, similar to the 120/150-190. But as the 120H/220 do not have a separate drive plate, the screws that fix the flange to the vessel are used.

The sensor for the Sterimixer

®

210/275-350 is screwed into a threaded hole in the weld plate.

5.4.3.7 Technical Specifications

Magnetic sensor

The magnetic sensor is identical for all sizes.

3-wire DC PNP Normally open

Operating voltage:

Current rating (max continuous load):

Current rating (consumption):

Switching frequency:

Real sensing range:

Output status indication:

Operating temperature:

Protection:

Housing material:

Connection:

Wiring:

10...30 VDC

300 mA

<10 mA

5000 Hz

60 mm

LED yellow

-25...+75

IP67

Stainless Steel

M12x1 Connector

Sensor wiring socket

The socket is the same for all sizes and can be delivered with or without a cable.

Protection:

Voltage rating:

Wiring:

IP67

10...55 V DC

0.5 mm 2 / PG 7

Rev B, October 2015

Sterimixer

®


5.4.3.8 Sensor holder

The sensor holder is especially designed for the following Sterimixer

®

sizes and motors.

60/75 AC

55

85/100 DC

85/100 - 140 AC

85/140 DC

120/150 AC

120/190 AC

120H/220 AC

Rev B, October 2015

56

210/275-350 AC

SMMS 85

SMMS 120

Weld plate


Rev B, October 2015

Sterimixer

®


5.4.3.9 Display for Impeller Monitor, Wiring Diagram

Input voltage

85-265 V AC

(47 - 63 Hz)

Display: art no.

OPTSM-10452

Display Sensor wiring socket Magnetic sensor

57

Brown

Black

Blue

Rev B, October 2015


5.4.3.10 Programming

NOTE! This is factory set at delivery of a complete unit.

1. Entering the program mode. NOTE: If the optional analogue output board is installed, entering the program mode will cause the analogue output to go to its minimum value regardless of the input signal.

Connect program enable input terminal to Ground. Press and hold the front panel program key, (

PGM

), until the display presents `run´.

PGM PGM

2. Navigate through the parameter list by using the program key ( arrow ( ) key is pressed. When the program key ( shows the value of the selected parameter.

PGM

PGM

) and the up ( ) and down ( ) arrow keys.

While holding the program key (

PGM

PGM PGM

), the unit scrolls down one parameter each time the down arrow ( ) key is pressed, and scrolls up one parameter each time the up

) is released, the display

PGM PGM

3. Change the value of the selected parameter by using the right ( ), up ( ) and down ( ) arrow keys.

For parameter that have a selection lists such as display, display decimal point and scaler decimal point, the value will descent one selection through the list each time the right arrow ( ) key is pressed.

PGM PGM

For numeric values such as scaler, display update time, display zero time, analogue output offset value and analogue output full scale value, press the right arrow ( ) key to select which digit to change (flash). Then use the up ( ) and down ( ) arrow keys, to change the value of the flashing digit.

Press the program key (

PGM

) to go back to the parameter list.

PGM

4. When the programming is done, navigate back through the parameter list to the parameter named run and then release the program key (

PGM

).

5. To lock the program mode, disconnect the program enable input terminal from

Ground

Rev B, October 2015

PGM

PGM

PGM

PGM

PGM

PGM

PGM

PGM

PGM

PGM

PGM

PGM

PGM

PGM

Sterimixer

®


5.4.3.11 Parameter List

The following list shows all programming parameter names, and the values recommended.

Parameter

Name

Recommended

Value

Description

Display rate.

This selection sets `ratemeter´, tachometer mode (necessary value).

Display decimal point location.

This selection sets the `ratemeter´ display decimal point. No decimal is recommended

(only recommended value).

59

Scaler decimal point.

Sets the decimal point location for the scaler.

The scaler is entered in the parameter below

(necessary value).

Scaler.

Enter the scale, depending on the mixer size, here. The different scales are shown on next page (necessary value).

Display update time.

Sets the minimum time, in seconds, between display updates (only recommended).

Display zero time.

Sets the maximum time that the unit will wait between pulses before resetting the display to zero (only recommended).

The following values are valid to the optional display:

PGM PGM

Se table

Analogue output offset value.

Enter the rate that corresponds to the minimum analogue output (0V or 4mA), see next page (only recommended).

PGM PGM

Se table

Analogue full-scale value.

Enter the rate that corresponds to the maximum analogue output (10V or 20mA), see next page (only recommended).

Rev B, October 2015


5.4.3.12 Mixer depending values

Scaler:

The parameter scaler, are calculated out of

NOS and PPI.

Scaler = NOS / PPI

NOS = Numbers of seconds in one time unit,

Sterimixer ®

Size

60/75

85/100-140

120/150-190 rotation. (Rpm  NOS = 60)

PPI = Pulses per rotation, number of magnets.

120H/220

210/275-350

SMMS 85

SMMS 120

The following values are valid to the optional display.

Analogue output offset value:

Sterimixer ®

Drive Unit

DC

AC

PPI

4

8

12

12

24

8

12

Scaler Value

=60/PPI (rpm)

15

7.5

5

5

2.5

7.5

5

Analogue output offset value

0

50

Enter the rate that corresponds to the minimum analogue output (0V or 4mA). This value is equal to the minimum speed of the impeller. The minimum speed differs between drive units, such as AC or DC motors.

Sterimixer

®

Size

Analogue full-scale value

60/75

85/100-140

120/150

120/190

120H/220

210/275-350

SMMS 85

SMMS 120

450

350

1,200

1,800

Analogue full-scale value:

Enter the rate that corresponds to the maximum analogue output (10V or 20mA). This value is equal to the maximum speed of the impeller. The maximum speed varies between different

Sterimixer

®

sizes.

Rev B, October 2015

Sterimixer

®


6. Operation

CAUTION! The Sterimixer

®

is only to be operated when mounted in a vessel, thus avoiding impact damage and loose objects from becoming entangled in the rotating parts.

!

Temperature limits:

The permanent magnets in the impeller and drive rotor must not be exposed unless for a short time to temperatures higher than +225°C.

The motor and gearbox shall not be exposed to temperatures exceeding +40°C.

Chemical limitations:

The impeller and bearing are not to be exposed to strong chemicals. Nominal pH range for TC bearings is 3 - 11 but SiC bearings are applicable to pH 0 to 14. Contact Steridose for further assistance.

Operational limits:

For proper function of the

Sterimixer

®

and the bearings it is essential to ensure it does not run dry. For the SMA the following can be used as a guideline.

During operation of the

Sterimixer

®

a liquid film of the processed fluid is generated in between the male and female bearing, aided by the rotation of the impeller, providing cooling and lubrication of the bearings. As

Dry operation of the Sterimixer

®

will damage the bearing. a negative pressure is created on the backside of the impeller wings, the processed liquid will be transported from the inside of the impeller through the holes to the outside of the impeller.

Rev B, October 2015


Fluid 200mm above impeller

If the impeller is fully covered by process fluid, there will be enough to fulfil this. However, when the impeller starts to rotate, the processed fluid will centrifuge from the impeller and when the speed is high enough, the impeller is rotating in a “dry” hole.

As there is no flow of processed fluid through the impeller, the bearing will lack both lubrication and cooling and subsequently run dry.

To avoid dry running the speed has to be adjusted in accordance to the level in the tank.

This will depend upon the following:

 The diameter of the tank

 The shape of the bottom of the tank

 The viscosity, as higher the viscosity is the less is the flow through the impeller.

Due to these parameters it is not possible to give any exact data for the maximum speed.


®


NOTE! For the SMO and SMMS the function of the flow through of the impeller is different, but the level above the impeller is as important as for the SMA.

NOTE! During SIP there is a risk that the bearing will run dry. Please find further information in section 6.3, “Guide for sterilizing the

Sterimixer

®

”.

!

Rev B, October 2015

Sterimixer

®


6.1 Guide for operation of the Sterimixer

®

The impeller is factory cleaned prior to delivery. However, before it is put into service it must be cleaned in an appropriate manner i.e. in a dishwasher or high pressure cleaning, as per the requirements of the application.

The operational parameters are pre-set in the control box. In extreme working conditions, disconnection of the magnetic coupling can occur, i.e. the motor rotates, but not the impeller.

To avoid any disconnection of the magnetic coupling, the acceleration time and the max rpm should be adjusted to conform to the specific application.

For a Sterimixer

®

supplied without a control box, soft manual start of the motor is required to prevent the magnetic coupling being disconnected. A suitable acceleration time up to the max rpm can be anything from ten seconds to a couple of minutes depending upon the application.

CAUTION! Never insert foreign objects in the vessel when the mixer is rotating.

No foreign objects in the vessel!

Rev B, October 2015


6.2 Guide for cleaning of SMA style Sterimixers

®

The Sterimixer

®

is designed for optimum performance in cleaning in place (CIP) without any need for dismounting. The flow channels in the impeller provide a processed fluid flow through the bearings. In order to achieve this, the impeller should be covered with fluid and rotated at a certain minimum speed. The flow of the processed fluid through the flow channels is very much determined by the rotational speed of the impeller.

The result of the cleaning is dependent on many parameters such as temperature, time, and chemical composition of the cleaning agent, mechanical conditions, speed and the type of product to be removed. It is therefore recommended that the cleaning cycle is validated before taken into service.

The cleaning usually consists of several cycles e.g. pre-rinse, cleaning with base and/or acid cleaning agents, main rinse following acid or base cleaning, and a final rinse.

NOTE! To achieve the optimal cleaning effect the impeller should be covered with cleaning agent and be rotating.

Figure 11. Optimal cleaning

CAUTION! Caution with high concentrations of phosphoric acid. Please contact Steridose for guidance.

!

Rev B, October 2015

Sterimixer

®


Example of CIP Procedure:

1. Drain the vessel from processed media.

2. Close the outlet and fill with cleaning agent having the fluid level above the impeller with at least 150 - 200 mm.

3. A suitable speed is approximately 300 rpm with filled vessel (depending on the size).

4. Normal cycle time is 5 - 20 minutes.

65

NOTE! The exact operational conditions for CIP must be validated for each individual application.

NOTE! The above cleaning method does not remove any magnetic particles. Due to the strong magnets inside the impeller all magnetic particles will be stuck inside the impeller. To have these removed, the impeller must be removed and cleaned separately.

CAUTION! The impeller must be covered with fluid to avoid damage to the bearings.


®


CIP GUIDELINES FOR SMO AND SMMS STYLE STERIMIXERS

!

!

The following document provides general guidelines for CIP procedures for Sterimixers with

SMO or SMMS style impellers.

PRINCIPLE OF OPERATION DURING CIP:

The bearing assembly on the SMO and SMMS impeller heads is exposed. When directing flow from a spray ball to the impeller head, the bearing surface will get in contact with the CIP fluid.

The openings on top of the SMO and SMMS impeller heads also allow the CIP fluid to hit the weld-plate under the impeller. In order to hit all surfaces, the impeller head needs to rotate at low speed during the CIP cycle. Please refer to Figure 12.

Typical mixer speed during the CIP cycle is 100 rpm.

Rev B, October 2015

66

Figure 12. SMO IMPELLER

Rev B, October 2015

Figure 13. SMMS IMPELLER


Sterimixer

®


TYPICAL CLEANING PROCEDURE FOR SMO AND SMMS STYLE IMPELLERS:

The cleaning procedure can be divided in two steps:

Step 1:CIP solution cleaning

Start CIP solution flow through the sprayball at the recommended flow rate. Open the tank outlet valve completely to allow full drainage. Operate mixer at low speed (around 50-100 rpm).

Avoid running the mixer at high speed. This may cause the bearing to run dry.

Ensure that the sprayball flow is hitting the impeller head. Typically, coverage test with riboflavin (usually performed during FAT) will provide evidence that the impeller head is fully wetted by the cleaning solution.

The duration of the cycle depends on the application and requires to be validated by swabbing vessel and mixer surfaces.

Step 2: WFI flushing

Repeat step 1 using WFI through the sprayball.

6.3 Guide for sterilising the Sterimixer

®

The Sterimixer

®

is designed for optimum performance in sterilisation in place (SIP) without any need for dismounting. The selection of method from those listed below depends on the individual conditions.

NOTE! The permanent magnets in the impeller and the rotor are heat stable up to +225°C. Never expose these parts to higher temperatures. The drive unit and gearbox shall not be exposed to ambient temperatures above +40°C.

A certain delay in the rise of temperature between the inside of the impeller and the vessel is caused by the mass of the impeller head. This delay is influenced by:

 Sterimixer

®

size: The larger the Sterimixer

®

is, the longer the delay.

 Sterilisation method:

Steam sterilisation gives the shortest delay.

Hot air sterilisation gives the longest delay.

When evaluating sterilisation temperature you should focus on the area inside the impeller. A thermal element should be used if the system is sterilised in a hot air oven or autoclave. For applications with SIP/SHW where the impeller rotates, the validation should be carried out by biological tests.



®


!

!

Rev B, October 2015


6.3.1 Steam Sterilisation in Place (SIP)

The vessel with the impeller and the mounted drive unit is steam sterilised.

Example of SIP procedure:

 To remove any condensation inside the impeller during sterilisation, rotate the

Sterimixer

®

at a low speed i.e. 50 rpm a few seconds, approx. every five minutes. NB!

This is a critical phase for dry running.

 When the sterilisation temperature in the vessel has been achieved, the rotation of the Sterimixer

®

shall be stopped.


®


!

6.3.2 Super Heated Water Sterilisation in Place (SHW)

The vessel and the mounted drive unit are sterilised with super heated water.

Example of SHW procedure:

 The vessel is filled with WFI (Water For Injection) to a suitable level.

 During heating, sterilisation and cooling the Sterimixer

®

should rotate.

 Vortexes (suction whirlpools) must not arise. The water level and speed controls this.

 During the emptying phase the Sterimixer

®

must not rotate.

!



®


!

6.3.3 Sterilisation in Autoclave or Hot Air Oven

Dismount the drive unit as per section 4.4.2 “Dismounting of the drive unit”.

CAUTION! The vessel and the impeller (without the drive unit) must be sterilised in an upright position in an autoclave or hot air oven to prevent the impeller sliding off the bearing. To prevent this, a magnetic drive dummy can be installed to avoid any risk of damage and hold the impeller in place.

Example of autoclave procedure:

 Dismount the drive unit.

!

 Install the eventual magnetic drive dummy.

 At least one pre-vacuum period must be used to eliminate air pockets on the inside of the impeller.

 The vessel, with the impeller in place, is sterilised at a maximum temperature of

+140°C in the autoclave.

Example of hot air oven procedure:

 Dismount the drive unit.

 Install the eventual magnetic drive dummy.

Rev B, October 2015

Sterimixer

®


 The vessel and the impeller are sterilised in the hot air oven at a maximum temperature of +225°C.

69

Rev B, October 2015

70

6.4 www.steridose.com

Additional instructions when using the Sterimixer

®

in ATEX applications

Only original part from the supplier must be used to achieve the level of protection stated.

6.4.1 General

Manufacturer: Roplan AB/Steridose®

Skyttbrinksvägen 20

SE-147 39 Tumba

Sweden www.steridose.com

Tel: +46-8-449 99 00

Fax: +46-8-449 99 90 mail: [email protected]

Type denomination:

General:

Sterimixer

®

This incorporation manual applies to the Sterimixer

®

fitted into applications covered by the ATEX directive 94/9/EC.

Do note that applicable health and safety regulations with regards to processed media and eventual buffer or barrier fluid shall be considered by the end-user.

The electrical motor, gear-box and impeller monitor (optional) shall be installed and operated as per the manufacturers’ instructions supplied with the Sterimixer

®

.

Protection class: II 2 G c Tx

Type of protection: EN 13463-1:2001 `c´ `k´

Safety zones applicable: Zone 1 & 2

Maximum surface The maximum surface temperature of the Sterimixer

®

are very much temperature: dependant upon the temperature of the media processed by the pump. In the table below the maximum temperature of the processed fluid within the pump is specified to ensure that the maximum surface temperature of the mechanical seal components does not exceed the corresponding temperature class.

Temperature Class

T1

T2

T3

T4

T5

T6

Maximum surface temperature

450°C

300°C

200°C

135°C

100°C

85°C

Maximum temperature of processed fluid

225°C

220°C

140°C

88°C

Does not comply with

Does not comply with

4

Max temp (short time):

Max temp (operation):

Rev B, October 2015

+225°C

+140°C

Sterimixer

®


6.4.2 Safety instructions

71

General: By design, Sterimixer

®

bearings are sliding rotary motion devices. For the proper function, the bearings are depending upon the presence of cooling and lubrication of the processed media to limit frictional heat generation.

Poor lubrication and cooling of the bearings will cause excessive temperatures. To avoid excessive temperatures following conditions must not happen:

 The Sterimixer

®

operates without any process fluid in the vessel.

 The Sterimixer

®

operates with a too low level of process fluid (refer to section 6,

“Operation” for guidance).

 The Sterimixer

®

operates at too high of a speed.

 The Sterimixer

®

operates with a fluid having too high viscosity reducing the flow through the bearings.

Chemical compatibility: To prevent hazardous reaction between processed fluid and materials of construction the materials of construction shall be ensured to be suitable for the application. The Sterimixer

®

involves different materials of construction being specified in the technical documentation.

Contact Steridose for further guidance.

Rev B, October 2015


Start-up: Before start-up of the Sterimixer

®

the following shall be controlled and verified:

- The Sterimixer

®

being correctly installed as per section 4, “Installation and mounting”.

- Materials of construction chosen are suitable for the application.

- The application is within operating parameters originally specified.

Operation: The Sterimixer

®

shall not operate beyond the operating limits specified in section 5, “Technical specifications”.

Assembly: The Sterimixer

®

shall be installed as per section 4, “Installation and mounting”.

Disassembly: The Sterimixer

®

shall be disassembled as per section 4, “Installation and mounting”.

Maintenance: Refer to section 7, “Maintenance”. To this, the following is added;

Zone 1 Daily; Zone 2 Weekly

Verify the function of any alarms applied.

Every two years or 9000 hrs of operation whichever comes first:

Replace the Sterimixer

®

with a new or a professionally refurbished Sterimixer

®

.

Do note that the used Sterimixer

®

usually can be refurbished thus it is essential to handle this with care to prevent unnecessary damages.

Do note that the life time of the Sterimixer

®

depends upon the application thus shorter service life might apply.

Installation: The Sterimixer

®

shall be installed as per section 4, “Installation and mounting”.

Set-up: The set-up of the Sterimixer

®

shall be performed as per section 4, “Installation and mounting”.

Rev B, October 2015

Sterimixer

®


Education:

Operators must have the necessary knowledge about the Sterimixer

®

before handling the

Sterimixer

®

. Necessary knowledge includes the understanding of the following topics:

 - function of the Sterimixer

®

.

 - installation of the Sterimixer

®

.

 - safety instructions within this incorporation and operation manual.

 - operational limits for the Sterimixer

®

.

Operational limits:

The Sterimixer® shall not operate beyond the operating limits specified in section 5, “Technical specifications”.

Special conditions which by experience proved likely to occur

 If the Sterimixer® is to be used within another application than originally intended there will be a risk of chemical incompatibility in between the processed fluid and the materials of construction creating a possible hazard. Each and every application shall be handled individually to ensure the safety conditions are maintained.

 If the Sterimixer® is subjected to poor lubrication this will create excessive wear and heat and subsequently premature failure.

 If the Sterimixer® is exposed to rough handling permanent damages can occur. It is therefore essential that personnel involved receive the specified education above.

 If the Sterimixer® is incorrectly installed conditions could very likely be similar to poor lubrication creating excessive wear and heat and subsequently premature failure. It is therefore important that the operator has received the specified education above.

 If the Sterimixer® is operated beyond its operating limits severe damage might occur subsequently creating a failure. It is essential that the operator has received the specified education above together with the full understanding of the Sterimixer® and the education related thereto.

 If the weld plate has been incorrectly fitted to the vessel deformation can cause contact with the impeller and/or magnetic rotor.

 Worn out bearings will cause physical contact in between the impeller and the weld plate. Specified maintenance shall be performed.

 Through poor handling the magnetic rotor can be misaligned causing physical contact in between magnetic rotor and weld plate. Do always upon installation ensure the magnetic rotor to be correctly aligned.

 If the impeller is subjected to excessive torque it might loosen from the magnetic coupling. Do ensure compliance with operational limits and set-up specification.

 Media with tacky properties and/or particles can possibly clog the flow channels within the impeller reducing the cooling and lubricating flow. The applications shall therefore be validated to ensure proper function.

 Incorrect direction of rotation can cause the impeller to loosen from the magnetic coupling. Do ensure proper direction of rotation as per description in installation section is complied with.

Important accessories:

There are no additional important accessories required for the use of the Sterimixer

®

apart from those being presented in this installation and operation manual.

Rev B, October 2015


Drawings and diagrams:

No special drawings or diagrams are required for the safe operation of the Sterimixer

®

apart from those being presented in this installation and operation manual.

Maintenance and service

The Sterimixer

®

requires a minimum amount of maintenance. Regular inspection of all parts, and any consequent action is usually sufficient.

WARNING! Ensure the Sterimixer

®

is in a safe state before performing any service.

Before performing maintenance and service ensure;

!

 the impeller and vessel are fully cleaned from any processed media and that any processed media cannot enter the vessel during maintenance.

 the vessel is fully vented from any possible gases.

 the vessel is depressurised.

 the main power is switched-off and cannot be accidentally switched on during maintenance.

 the vessel has been cooled to a temperature below 50°C (or a limit set by local regulations).

Dismount the drive unit as per section 4.4.2 “Dismounting of the drive unit”.

Mount the drive unit as per section 4.4.1 “Mounting of the drive unit”.

Rev B, October 2015

Sterimixer

®


7 Maintenance

75

7.1 Routine maintenance during start up/running in

The following maintenance schedule should be performed at start up and/or running in of the

Sterimixer

®

.

 Remove and check the impeller.

 If particles are stuck to the impeller they have to be removed.

 Due to the strong magnets inside the impeller all magnetic particles will get stuck inside the impeller. Therefore, check the inside of the impeller in particular.

 The impeller must not be scratched or in any way damaged. If it has been damaged, the impeller and bearing must be replaced. The impeller can be sent to Steridose for refurbishment.

 If a refurbished impeller is to be installed the bearing unit shall be replaced with a new.




®


7.2 At least once a year - interval dependent upon application

Following maintenance schedule should be performed at least once a year. Do note that the interval will be highly dependent upon the application.

 Remove and check the bearing and the impeller for signs of surface damage and general wear of the bearings.

 Change the bearing and the impeller if the surface is coarse or uneven, scratched or if fragments have been knocked out from the bearing. The impeller can be sent to

Steridose for refurbishment.

 Change the PTFE washer when dismounting the bearing.

 Make a general inspection of the motor, gearbox and other Sterimixer

® parts. Make sure the gearbox is not leaking oil.




®


NOTE! The male bearing and the female bearing must be of same material, TC or SiC. If a refurbished impeller is installed, a new bearing unit shall be mounted as well.

Rev B, October 2015

76

8


Troubleshooting

Fault

1. The Sterimixer

®

does not start.

2.

3.

4. Poor mixing.

The impeller does not rotate.

Poor motor effect.

Possible cause

Fault in power supply.

Male bearing or magnetic drive not mounted.

Motor incorrectly connected.

Impeller rotating in wrong direction.

5. The Sterimixer

®

does not reach the required maximum rpm.

Incorrectly set parameters in the

VFD (Variable Frequency Drive).

6. Slow and inefficient compressed air driven

Clogged motor housing. motor.

7. Noise from the Sterimixer ® . a) Impeller has rotated without fluid between the male and female bearing. b) Worn out bearings. c) Missing male bearing.

8 Noise from the drive unit.

9. Magnetic coupling disconnected.

Gearbox problems.

Running dry from oil. a) Acceleration too rapid. b) Speed too high for the application.

10. Many particles in the impeller.

11. Insufficient cleaning of the impeller.

Magnetic particles from associated media.

Poor fluid flow in the impeller; a) due to low fluid level. b) due to low speed. c) due to high speed.

Action

Check power supply.

Dismount the drive unit, detach the impeller, and mount the male bearing, impeller and magnetic drive.

Check wiring diagram.

Check the drive installation.

AC: Phase reverse power cables.

DC: Pole reversed power cables.

AIR: Swap the air supply and the outlet hoses. Verify the impeller rotates clockwise as seen from above.

Adjust and calibrate the VFD.

Flush with paraffin as per maintenance instructions. a) Stop the Sterimixer ® until the fluid level covers the impeller. b) Replace the bearing and the impeller. c) See point 2.

Refer to gearbox manual for maintenance.

. Do not restart a) Check start up and adjust ramp up time. b) Reduce speed and adjust setting of max. speed.

Check and take action with regard to the presence of particles/contents of associated media and raw materials.

Magnetic particles are not re-moved during normal cleaning. The impeller must be removed and cleaned separately. a) Increase fluid level. b) Increase speed. c) Reduce speed (to prevent vortexes).

Rev B, October 2015

Steridose 120 H/220, 60/75, 85/100, 85/140, 120/150, 120/190, 210/275, 210/350, SMMS 85, 120 Sterimixer Installation and Operation Manual

Assistant Bot

STERIMIXER

®

Installation and Operation Manual

(including welding guide)

Read this user manual carefully before unpacking Sterimixer

!

Table of Contents

1 Safety Information

2 General description of the Sterimixer

®

3 Handling

CAUTION! Ensure that lifting equipment chosen is suitable and properly used.

The storage shall be a clean, dry location free from vibration. If a moist or dusty atmosphere is used for storage, further protect the Sterimixer

with a suitable cover.

4

Installation and mounting

Allow the dished end and the weld plate to cool slowly on completion of each step of welding. No cooling medium other than air shall be used.

CAUTION! Due to the strong magnetic forces generated by the magnets, the impeller must be mounted before the drive unit to avoid any damage on the bearings.

WARNING! Ensure the power supply is disconnected and not possible to accidentally be connected.

CAUTION! The drive unit can be heavy, refer to section 5 “Sterimixer

Main Parts”.

5. Technical data

Not available, please use Sterimixer

85/100 Air.



9 , 55



Se table

Se table

6. Operation

Figure 12. SMO IMPELLER

Figure 13. SMMS IMPELLER

7 Maintenance

8

Troubleshooting

Key Features

Frequently Answers and Questions

What is the maximum operating temperature of the Sterimixer?

How do I mount the drive unit to the vessel?

What is the direction of rotation for the impeller?

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