Design and manufacture of agitators since INSTALLATION MANUAL Start-up and maintenance. Top-entry agitators

Transcription

1 Design and manufacture of agitators since 94 Top-entry agitators

2 CONTENTS Page - Introduction - Precautions prior to start-up 4 - Safety recommendations 6.. Protection against the risk of explosion 6.. Transport and location 6.. Connections 7.4. Operation 8 4- Choosing the agitator model 8 5- Detachable Agitators 0 6- Basic characteristics of the equipment > Top-Entry Agitators 6.. Series SSC-6 / SSC Series SSC-8 / SSC Series SSC- / SSC Series SSC-40R / SSC-4R / SSC-45R / SSC-47R Series SSC-40A / SSC-4A / SSC-45A / SSC-47A 6 7- Warranty 7

3 - Introduction This technical manual contains the necessary instructions for the installation, start-up and maintenance of Agitaser agitators and accessories and must be used by trained staff who are responsible for such tasks. It is essential to perform all the checks listed in the first section "Precautions prior to start-up" (p. 4). Should any problem arise while the agitator is being installed or started up, the manufacturer should be contacted and none of its components manipulated, otherwise the warranty may become void, as specified in point 7.

4 - Precautions prior to start-up Before start-up, it is essential to perform the following checks on the agitator:.. The motor voltage shown on the nameplate must match the mains supply voltage... The motor's mechanical and thermal protection must be in order, so that it may operate correctly... The motor housing must always be earthed..4. The screws attaching the agitator's flange or backing plate to the structure must be correctly tightened and not loose..5. The coupling screws joining the agitator's head to the shaft must be correctly tightened. Should the agitator be joined to the shaft with rigid coupling plates, before assembly remove any traces of dirt from the faces of these plates that come into contact with the shaft. (See maintenance corresponding to each agitator series or model). Make sure the speed reduction gear (if applicable) has the right level of lubricant, as per the manufacturer's instructions. 4

5 .6. Make sure the screws attaching the propeller to the shaft are correctly tightened, as per the different models available. (See figures in enclosed box). If there are several propellers on the same shaft, check that the distances from each propeller to the flange are those specified in the corresponding documentation. Different models of agitator elements and their tightening systems There are different ways of attaching agitator elements to the shaft, be they turbines, marine propellers or dispersers, among others. Below are the most common examples. 4 5 These are the most customary attachment systems to position the agitator elements: B- / B-4 Propellers attached to the shaft via M0 or M0 right-hand threaded nuts. B- Turbines and sliding propellers attached using hexagon nuts. B- Detachable turbines via hex nuts located on the bushing. B-5 Detachable turbines via hex nuts and plates welded to the agitator shaft. Agitator elements must only be dismantled and assembled using the right tools and by trained staff. Agitator elements must only be manipulated once the agitator has been disconnected from the electricity or pneumatic supply. 5

6 - Safety recommendations Furthermore, where necessary, the agitator must be equipped with a suction system for any toxic gases or airborne dust that might be caused by agitation and related work processes.. Protection against risk of explosion Before installing the agitator, check that the model selected is suited to the classification of the area in which it is to be installed. Users are responsible for adapting the electrical equipment to the characteristics of the classified area in accordance with the applicable laws and regulations. TEMPERATURE CLASSIFICATION T T T T4 T5 T6 450 ºC 00 ºC 00 º C 5 ºC 00 ºC 85 ºC Classification of potentially explosive ATMOSPHERES The ATEX Directive defines the equipment categories and protection systems that can be used in the corresponding zones according to the following table. Zone Equipment Gas Dust category Presence of explosive atmosphere 0 0 Continuously or for long periods > 000 hours/year Occasionally, between 0 and 000 hours/year IP 65 Rarely < 0 hours/year IP 55. Transport and location When the agitator is handled once its packaging has been removed, a means of suspension must be used that is appropriate to the model's weight, taking its centre of gravity into account. Never subject the agitator shaft to any stress. Account must be taken of the space required to perform installation and maintenance work without exposure to unnecessary risks. 6

7 . Connecting the agitator Before switching on the motor, check that the tank where the agitator is going to be installed is free from any foreign bodies and that the propeller's movement is not impeded. The agitator is supplied without cables so any cables used must be suitable for the motor's amperage and voltage. When the motor is switched on, check that the agitator's direction of rotation coincides with the direction indicated by the arrow on the agitator. If not, the phase sequence must be changed. STAR CONNECTION TRIANGLE CONNECTION Phase Phase Phase High Phase Phase Phase Low Voltage Type The agitator's direction of rotation is always specified on the agitator turret or at least on the flange attaching it to the tank by means of a label shown below. DIRECTION OF ROTATION NO LUBRICATION REQUIRED 7

8 .4 Operation Before turning the agitator on, check that the safety devices are operative to ensure operator safety and prevent any part of the body from coming into contact with moving parts. Check the oil level every years and after a maximum of 0,000 hours Danger signs and instructions are represented by labels located on the agitator turret or at least on its flange mount. DANGER CHAINS AND CABLES Do not insert your hands into any zones where there are support chains or cables. 4- Choosing the agitator model In order to choose the best agitator for the task in question we must first define the product we want to work with, its physical and chemical properties and the kind of process to be carried out. The agitators designed by Agitadores Agitaser, S.L. can perform different kinds of applications including homogenisation, flocculation, dispersion or mixing and one model or another should be chosen depending on the product's viscosity, density or volume and on the mix percentages. 8

9 All agitator models and mounts made by Agitadores Agitaser, S.L. have labels indicating the agitator model, reference no., date of manufacture, basic characteristics of the motor or motor reducer, as well as the EC certification of the machine and information on the manufacture. Mod. Nº Date Power/Rev. Mod. Nº Date Power/Rev. Other labels we might find on our agitators are those related to the ATEX Directive. Area: Category: Overhaul interval: Change bearing each: Maximum temperature hub: 9

10 5- Detachable Agitators These agitators have an optimised dismantling system to make them easy to transport and maintain, by simply carrying out easy steps. Model with detachable system: SSC-6-DC / SSC-7-DC / SSC-8-DC / SSC-9-DC / SSC--DC / SSC-7-DC Detachable Agitators with coupling plate Instructions First loosen and remove the screws no. to be able to separate the motor from its position. Once the motor has been removed, you can dismantle and remove the shaft agitator no. 4. Accessing the anchor screws via the side drill hole of the turret no. 6, the 4 interior screws must be loosened to remove the shaft agitator. The agitator structure contains the seals and bearings, as well as the bushing, making it possible to dismantle the agitator quickly and easily. Exploded diagram / Gearmotor Screws DIN9 - Washers 4 Shaft agitator 5 Agitator element 0

11 Detachable agitators with bushing Instructions First loosen and remove the screws no. to be able to separate the motor from its position. Once the motor has been removed, you can dismantle and remove the shaft agitator no. 4. Accessing the screws on the rigid coupling plate no. 6, the 4 screws must be loosened to be able to remove the shaft agitator. The agitator structure contains the seals and bearings, as well as the bushing, making it possible to dismantle the agitator quickly and easily. Exploded diagram / Gearmotor Screws DIN9 - Washers 4 Shaft agitator 5 Agitator element

12 6- Basic characteristics of the equipment > top-entry agitators Top-entry agitators, with reference to model SSC, are agitators with a flange to be coupled at the top of the tank. With an electric or pneumatic motor and all possible variations in terms of protection (IP55, EEx dll BT4, etc.). includes bearing to absorb any radial movement of the agitator shaft. The shaft can be fixed or detachable. Stainless steel or carbon steel shaft and propeller. They can also be supplied covered in polyester, PP, PVC, ebonite, etc. These agitators can be supplied with one or more agitator elements (marine propeller, dispersion disk, axial turbines, etc.) The structure of these agitators means that they can be in operation while the tank is being filled and/or emptied. Electric or pneumatic motor with all possible variations in terms of protection (IP55, IP65, EExdllT4, etc.). This characteristic part of the machines designed and manufactured by Agitadores Agitaser, S.L. means that the internal bearings and seals can be positioned to absorb any radial movement of the agitator shaft and improve the turret's seal. Reducer Reduces the speed of the motor, offering the most suitable range of slow speeds for each application. Flange mount This element can be made of cast aluminium, painted carbon steel or stainless steel AISI04L or 6L. This part is used to position and couple the agitator at the top of the tank. Agitator element The agitator element can perform different types of agitation. Agitator units can have one or more agitator elements such as marine propellers, axial turbines, dual flow, dispersers, etc. Agitator shaft The agitator shaft can be detachable or rigid in a single piece. It can be guided at the bottom using a Teflon guide sleeve, depending on its length and diameter. Its structural features will depend on a prior study carried out by the Technical and Engineering Department of Agitadores Agitaser, S.L.

13 6.. Series SSC-6 / SSC-7 Top-entry agitators with flange to be coupled at the top of the tank. With electric or pneumatic motor and all possible variations in terms of protection (IP55, EEx dll B T4, etc.). Maximum power: 0.75 kw These agitator units can be supplied with one or more agitator elements (marine propeller, dispersion disk, axial turbine, etc.). AGITATOR EXPLODED VIEW Reducer Pneumatic Shaft Rod Re 0 RHP0 0x47x7 5 RHP5 5x5x7 0 RHP0 0x6x7 (Rod) (Re) Bearing Seal Material AISI6 or AISI04 4 holes

14 6.. Series SSC-8 / SSC-9 Top-entry agitators with flange to be coupled at the top of the tank. With electric or pneumatic motor and all possible variations in terms of protection (IP55, EEx dll B T4, etc.). These agitator units can be supplied with one or more agitator elements (marine propeller, dispersion disk, axial turbine, etc.). AGITATOR EXPLODED VIEW Shaft Rod Re Reducer Reducer 5 RHP5 5x5x7 0 RHP0 0x6x7 5 RHP5 5x7x0 (Rod) Bearing (Re) Seal Material AISI6 or AISI04 4 holes 4

15 6.. Series SSC-/ SSC-7 with flange to be coupled at the top of the tank. With electric or pneumatic motor and all possible variations in terms of protection (IP55, EEx dll B T4, etc.). These agitator units can be supplied with one or more agitator elements (marine propeller, dispersion disk, axial turbine, etc.). AGITATOR EXPLODED VIEW Reducer Reducer Shaft Rod Re 5 RHP5 5x6x7 40 RHP40 40x80x0 50 RAE50 50x90x0 (Rod) (Re) Bearing Seal Material AISI6 or AISI04 Flange DIN576 DN5 PN0 8 holes 5

16 6.4. Series SSC-40R / SSC-4R / SSC-45R / SSC-47R 6.5. Series SSC-40A/ SSC-4A / SSC-45A / SSC-47A Top-entry agitators with flange to be coupled at the top of the tank. With electric or pneumatic motor and all possible variations in terms of protection (IP55, EEx dll B T4, etc.). These agitator units can be supplied with one or more agitator elements (marine propeller, dispersion disk, axial turbine, etc.). Reducer AGITATOR EXPLODED VIEW Shaft Rod Re 50 RAE50 50x90x0 60 RAE60 60x0x0 75/70 RAE60 70x0x0 90/ x90x0 (Rod) (Re) Bearing Seal Material AISI6 or AISI04 Flange DIN576 DN50 PN0 Flange DIN576 DN00 PN0 Flange DIN576 DN50 PN0 6

17 7- Warranty Declaration by the Manufacturer AGITASER - AGITADORES AGITASER, S.L. Castillejos, bajos BARCELONA (SPAIN) Agitadores Agitaser, S.L. guarantees the supply of its products for a period of ONE YEAR as from the delivery date. Warranty coverage: - Defects in the operation of the machine/s. - Defective assembly of the machine/s at our workshops. - Defective supply of any of the machine component. - Flaws in the machine design. - Any manipulation must be performed at the workshops of Agitadores Agitaser S.L. The Warranty does not cover: - Improper handling of the machine/s. - Damage caused by improper electrical connection. - Deterioration in the machine caused by improper use or lack of maintenance. - Replacement of the original parts with others without due written authorisation from AGITASER. - Wear and tear of parts due to use. - Repairs performed outside our workshops. - The warranty is not extended if it is replaced or modified during the warranty period. Joaquín ABAD PUIG Technical Director 7

18 Declaration by the Manufacturer AGITASER - AGITADORES AGITASER, S.L. Castillejos, bajos BARCELONA (SPAIN) Declares that all its machines are produced in accordance with the following Directives: - Machinery Directive 006/4/EC - Low Voltage Directive 006/95/EC - Electromagnetic Compatibility Directive 004/08/EC Our machines cannot be used until they have been declared as compliant with the provisions of the applicable Directives in the installation where they are to be incorporated. Joaquín ABAD PUIG Technical Director 8

19 seal Certificate Castillejos bjs - Barcelona SPAIN Tel Fax agitaser@agitaser.com