Installation User Guide Maintenance · The mixing head rotates on inserts of tungsten carbide certificate manufactured under controlled conditions to obtain the correct size, grain

Quality System Certified ISO 9001

AMT Installation and User Guide Rev.8.doc Page 1 of 29

Aerre Inox s.r.l.

MAGNETIC MIXER

AMT Series

Installation User Guide Maintenance

THIS MANUAL SHOULD BE READ CAREFULLY BEFORE UNPACKING AMT MIXER

mailto:[email protected]

http://www.aerreinox.it/



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Contents Operator and Equipment Safety AMT Mixer Description AMT Mixer Components

Internal parts External parts

Required Tools and Optional Equipment Installation and Operating Parameters

Noise level and Vibrations

Positioning and Installation Welding Plate Installation Static Bearing Installation Mixing Head Installation Drive Unit Installation Disassembly Storage Recycle and Disposal

Operation Check and Calibration Starting the Mixer Operating Notes: Cleaning in Place (CIP) Sterilizing in Place (SIP)

Maintenance and Service Routine maintenance

Identification and Labeling Spare Parts Troubleshooting ATEX Certification EC Declaration of Incorporation PED Certification Standard Warranty

Components of the Agitator

In the interests of development and improvement of the product, we reserve the right to alter specifications without prior notice.

Get the information you need and more at : [email protected]






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The instruction manual is only a reminder of the main operations on device, leaving the training of personnel to a specific preparation. The operating and maintenance is an integral part of the technical documentation for the machine. The manual should be carefully preserved and made available to all interested people. These instructions have been produced after the evaluation of an analysis of "Risk Assessment" and "Danger Reduction". In case of lost or damaged, you can request a copy of the manual by quoting the serial number, type, year of manufacture, stamped on the CE nameplate of the machine.





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Operator and Equipment Safety

AMT Mixer is only to be operated when mounted in a vessel. This is to avoid impact damage from external bodies. People with pacemaker should observe caution close and during removal mixing head and drive unit. Magnetic cards can be damaged if they kept in the vicinity of mixing head or drive unit.

To avoid injury from electrical shock, make sure that, in maintenance or not operation, the main power supply is in "OFF" position and IEC plug connection is unplugged.

To avoid possible skin lesions from electrical shock, burns and contact with chemicals or volatile liquid, make sure, that before working on the mixer, the tank will result in operator safety, heat-treated at atmospheric pressure and sufficient time has elapsed to cooling at a temperature not dangerous (≤ 35 ° C).

Do not insert foreign objects into the tank when the mixer is rotating as this may result in personal injury and can damage the mixer.

MOUNTING: the mixing head is to be mounted before drive unit, to avoid any damage, specially at the brittle tungsten carbide bearings. ALWAYS FOLLOW THE INSTRUCTIONS IN THE MANUAL.

DISMOUNTING: the drive unit must be disassembled before the mixing head, after that, the impeller can be raised with caution, without forcing, avoiding damage to tungsten carbide bearings. Before removing drive unit, check the weight of the equipment installed, may be heavy, and acting accordingly for your safety, make sure the main power switch is locked on a switch-off position.

NOTES:

• All installers, operators and maintenance personnel of the equipment must read and

understand this manual before installation use and application. Failure to follow the

operating instructions and installation may cause injury or equipment damage.

• Any attempt to use the AerreInox AMT mixer improperly specified in this manual or any

unauthorized modification can cause damage and void the product warranty and end

user must remove CE plate.

• Any of the following events can damage the mixer: external load, the reaction forces,

torque, corrosion, erosion, fatigue and decomposition of unstable fluids

• Before starting, the device must be fully assembled according to the instructions

contained in this manual.





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• If the control is done by the operator directly exposed, use appropriate personal

protective equipment and eye protection when operating the equipment.

• Protect motor unit against dust and dirt.

• The engine has a weight, use appropriate equipment to prevent crushing injuries.

• Install the impeller before installing drive unit.

• Do not install components close to the rotating parts of the Mixer AMT.

• During mixing, mixer components may become hot to the touch.

• Do not insert your fingers in equipment, may result in injury.

• Check the magnetic parts of the Mixer AMT after maintenance there should be no

foreign material.

• Do not run with an empty vessel.

• Ensure that the mixing head rotates clockwise.

• Check that all components of the mixer are the correct size.

• Handle the mixing head and the static bearing with care; the material of the bearing is

hard and brittle.

• Keep remote controlled medical devices and magnetic storage devices away from

magnetic parts of the AMT mixer.

• The mixing head must always be, partially or completely, submerged.

• Follow the instructions and limitations applicable to Ex AMT mixer ATEX.

• The system must be connected to the grounding system.

• Wiring of the motor in accordance with the instructions and performed only by qualified

technicians.

• The engine must match the Atex zone assigned.

• If the motor is only suitable for use in NOT hazardous or dangerous areas, should not be

used in hazardous areas classified as Zone 0, Zone 1, Zone 2.

• The stirring process will be less efficient and will cause serious damage to the static

bearing if the agitator rotates in the wrong direction. Follow the arrows indicating the

direction to check the correct rotation.

• Check that the electrical overload protection are correctly dimensioned.

• The impeller of mixer must be inserted and immersed in the liquid before starting the

machine. Not follow this arrangement involves a premature and excessive wear of the

bearing, in addition to a consequent release of particles and corpuscular.





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• Do not insert any object improper (for example bolts, screws) in the product that must be

mixed. Because of the vigorous mixing, these objects could be attracted from the

impeller and it is possible that the blades or other being impaired, if this happens, stop

immediately the machine.

• Never insert hands or other body parts or tools inside the vessel when the stirrer is

running, without proper safety equipment or before the machine is isolated from the

power source and in complete safety.

• The machine must be disconnected from the engine before performing any type of

maintenance or repair. Indicate with appropriate notice or indication that the machine is

in repairs or maintenance.

• Current electric motors have high working temperatures and the windings can even

reach 120°C, making the coverage dangerous due to the temperature. Indicate with

appropriate reporting that accidental contact can be dangerous to operators or

generally for anyone who is exposed.

• Treating the installation so that it is not possible for the operator accidentally come into

contact with moving parts of the machine during operation. Treating the geometry of

the container and provide it with security systems such that interrupt the movement of

the machine in case of inspection.

• Emergency stop should be placed close to the stirrer in place perfectly accessible and

visible (if supplied electrical control cabinet).

• The time interval between a control and the next will depend on the hours of operation of

the machine and also on the types of product in use. We recommend that they should

be always available a KIT of static bearing to shorten the downtime during

maintenance.

• Depending on the products you use and your operating procedures, there is also the

danger of violent projections of product operators. This is more likely if they are used

minimal amounts of product to be mixed. The security measures will depend on your

correct assessment of danger.

• The mixer is cleaned with automatic CIP systems together with the vessel and with

different systems by means of an appropriate solvent. It is necessary that the machine

is cleaned before being taken out of service. The presence of residues produced in the

area of rotation and centering of the bearing may cause jamming with consequent

seizure.

• Risk electric shock. Switch off the power supply to the control panel and wait 5 minutes

before you start working on the equipment. (This time serves to allow the capacitor to

be able to download). Our control panels are tested before shipping. Various

adjustments and settings must be agreed with the manufacturer.





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• Always insert the impeller inside the vessel before entering the motor. Always disconnect

the geared motor before removing from the container the impeller. Ensure that it

always performs the operations of insertion and extraction in this order. Any operation

performed otherwise may cause damage to equipment due to the strong attraction of

the magnets. Avoid putting the impeller using hands are not adequately protected:

danger of crushing gear engaged.

The mixer is a unit used generally on vessels and tanks in which it is necessary to maintain a product in suspension, or create a vortex that allows to incorporate powders and / or liquids. The magnetic stirrer is a simple, easy to install and of low maintenance. The type of application of the agitator avoids rotary seals which could cause leakage and put in communication the product with the external not controlled environment.





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AMT MIXER DESCRIPTION

The magnetic stirrer AMT series is designed for specific use in the pharmaceutical and biotechnology industries,

ultra sterile applications where high standards are required for aseptic applications construction.

The most obvious advantage of the magnetic mixer is that it allows to maintain the total integrity of the vessel.

The inner surface of the tank is continuous and without mechanical seals to ensure a hygienic design without

the risk of contamination or loss. This prevents leakage and / or spillage of toxic or very expensive, preserving

the sterility of the tank and its contents.

AerreInox has long recognized and promoted the benefits of magnetic stirrer for applications in the

pharmaceutical, biotechnology and cosmetic industries.

Designed to conform to the current pharmaceutical requirements.

The geometry of the impeller (mixing head), allows an optimal axial distribution, with flow rate and cutting speed

very low suitable for different applications, such as: mix, dilute, maintain in suspension, avoid stratification in

thermal exchanges ...

The impeller is rotated by a running drive unit mounted externally to the vessel.

The mixer is designed for speeds from 50-380rpm with the application of a frequency converter (inverter).

Depending on the size and volume of the vessel and the impeller size, it can reach levels of agitation by gentle

to vigorous. You can also mix very small volumes, not feasible with conventional type mixers.

The mixer AMT offers great flexibility to use up to 800cps viscosity.

The geometry of the wings and their profile are designed to optimize the levels of agitation and allocate part of a

fluid through the impeller itself for an optimum washout.

The mixing head rotates on inserts of tungsten carbide certificate manufactured under controlled conditions to

obtain the correct size, grain structure and hardness.

All parts in contact with the product are made of stainless steel 1.4404 or 1.4435, with a finish surface mirror

polished, optional finishing for electropolishing.

Suitable for C.I.P. and S.I.P. in situ or autoclave, the mixer AMT has a drive unit which can be removed quickly

and easily. The application from the bottom allows to obtain the top of the vessel free for easy access to the

inside of the tank.

A further advantage is the use of a single interchangeable drive unit shared between multiple tanks.

A flange, machined from raw bar, is welded on the bottom of the tank (usually with a certain offset from a central

discharge bottom valve).

Inside the rotating head is a ring of special magnets, encapsulated in a stainless steel container. Welded to this

body, the mixing blades, which form overall the mixing head.





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AMT MIXER COMPONENTS

Catalog and the specifications for the components can be requested to AerreInox.

INTERNAL PARTS

All parts described in this section (including the upper part of the welding flange) in contact with the product, have surface quality and tolerance in order to meet aseptic requirements. Handle with care and attention these products in order to avoid damage, leaving the mixing head and the static bearing in their packaging as long as possible to protect it from dust, bumps and impacts.

MIXING HEAD (IMPELLER) Handle the mixing head with care. The material of the bearing is hard and brittle. Keep magnetic body away from any iron particles that may adhere to it and contaminate the steel surface. The driving force is transmitted to the mixing head by means of magnetic coupling. The shape of the wings facilitates cleaning and sterilization (CIP / SIP) without the need for disassembly.

1 – magnetic body 2 – wings 3 – dynamic tungsten carbide bearing 4 – serial number

STATIC BEARING Static bearing keeps in the correct position, the mixing head inserted on 'welding plate' inside the vessel. The bearing is very fragile, it is therefore important to avoid impacts and shocks, and maintain the clean surface free of contaminating particles; when the mixing head is in operation must always be immersed.

5 – static tungsten carbide bearing 6 – disk TFM PTFE / o-ring EPDM 7 – serial number 8 – locking nut 9 – disk TFM PTFE / o-ring EPDM

WELDING PLATE Each weld plate is marked with a serial number and code for full traceability. The welding flange is welded to the tank and is considered an integral part of the vessel. Welding plates are provided in conformity with PED Category IV of Directive 97/23/EC. In the inner part (tank) there is a threaded end for attachment of the static bearing through the locking nut. The outer part is provided with connection (of different sizes depending on AMT models) to allow the connection of drive unit.

10 – connection screw 11 – welding edge 12 – drive connection flange 13 – serial number





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EXTERNAL PARTS

DRIVE UNIT The unit drive delivers torque to the mixing head and is applied on the outside of the tank against flange dedicated. The entrainment (14) of the drive unit is magnetic and has to be stored in the package as long as possible to protect it from damage, dirt, shocks and impacts.

230/400v AC

14 – magnetic outer drive head

15 – tank plate connection flange

16 – gearbox unit

17 – motor

18 – AMT serial number label

24v DC

14 – magnetic outer drive head

15 – tank plate connection flange

16 – gearbox/motor unit





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REQUIRED TOOLS and OPTIONAL EQUIPMENT

TOOL The instrument shown is usable for the introduction and extraction the impeller of the AMT magnetic mixer.

This instrument has a dual purpose: on the one side to introduce and remove the mixing head and the static bearing; from the other side allows to screw and unscrew the locking nut, during assembly or maintenance. This tool is supplied as optional for AMT mixer (excluding model AMT-04 dedicated only for small tanks).

SPEED SENSOR Speed sensor of the inductive type, is a device especially used during all processes that require an effective monitoring and adjust the speed of the impeller. The sensor is housed inside a capsule of AISI 316L which is rigidly fixed to the impeller. The external sensor is applied on the connection plate with a stainless steel support. Adjust the position of the sensor by changing the thread trying to maintain the minimum distance possible between the two components. Connect the sensor (PNP) according to the instructions.

external sensor is applied on the adaptor flange plate using a stainless steel bracket.

internal sensor is housed inside an AISI 316L support rigidly fixed to the impeller.





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INSTALLATION and OPERATING PARAMETERS

Please refer to the appropriate product specification sheet (next table) for more information.

MIXING HEAD - STATIC BEARING Limit of the operating parameters inside the tank

PARAMETER MINIMUM MAXIMUM Temperature -10° C 152°C

pH 1 14

Viscosity 1 cP 800 cP (*)

Media Media may not contain magnetic particles

Rotation Speed See product specification sheet

Minimum acceleration and deceleration time

5 sec. (specific to each application; set accordingly)

(*) For non-aqueous solutions or various products contact AerreInox. Be sure to use an appropriate program start-up, and a engine with a good acceleration ramp.

Attention Tungsten Carbide Bearing, may be attacked and oxidized by hydrogen peroxide.

WELDING PLATE

PARAMETER MINIMUM MAXIMUM Temperature -80° C 200°C

Pressure -1 barg 10 barg

DRIVE UNIT Define the operating parameters outside the vessel

PARAMETER MINIMUM MAXIMUM Ambient temperature 0° C 40°C

PRODUCT SPECIFICATION SHEET

MODEL working

volume (lt) shaking

vigorously shaking bland

visc. MAX (cPoise)

Power supply

power (Kw)

power (EX Kw)

RPM RPM

regulation weight

(kg)

AMT-02 05 - 20 5 15/20 150

230/400 v 3ph (AC)

0,06 Kw 0,09 Kw

50÷380 Inverter

10-50 Hz

4

AMT-04 10 - 50 10 50 200 0,12 Kw 0,25 Kw 6,5

AMT-06 50 - 150 50 150 200 0,25 Kw 0,25 Kw 12

AMT-08 150 - 500 150 500 500 0,55 Kw 0,55 Kw 18

AMT-12 300 - 2000 300 2000 800 0,75 Kw 0,75 Kw 31

AMT-20 1000 - 3000 1000 3000 500 1,50 Kw 1,10 Kw 45

AMT-32 2000 - 6000 2000 6000 600 2,20 Kw 2,20 Kw 55

AMT-64 3000 - 15000 3000 10000 25000

700 5,50 Kw 5,50 Kw 114





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MODEL working

volume (lt) shaking

vigorously shaking bland

visc. MAX (cPoise)

power supply

power (W)

power (EX W)

RPM RPM

regulation weight

(kg)

AMT-02 05 - 20 5 15/20 150

24 v DC

64 W //

50÷380 elettronic

drive

4

AMT-04 10 - 50 10 50 200 84 W // 6,5

AMT-06 50 - 150 50 150 200 250 W // 8

NOISE LEVEL and VIBRATIONS Noise levels are measured in accordance with ISO 1680 standard, and are within the maximum limits imposed by the CEI 2-24 / IEC 34-9. The vibration level falls in the class N standard, in accordance with standard CEI 2-23 / IEC 34-14.

POSITIONING and INSTALLATION

Install the AMT mixer components in the following order:

1- Welding plate 2- Static bearing 3- Mixing head 4- Drive unit

Follow all installation recommendations, precautions and warnings contained in this manual.

1 - WELDING PLATE Installation

The welding flange must be placed in a position on the bottom tank according to the following rules and conditions:

Liquid When the flanges are welded in containers subject to pressure, the requirements of the code calculation pressure of the tank must be met. For tanks designed and constructed in BS 5500 the outermost part of the flange must be within 10% of the diameter of the receptacle (see Figure 3.5.4 (0) of BS5500).

The distance between the welding flange and any other welding must be at least 4 times the thickness of the receptacle (15 mm minimum).

the hole for the welding flange does not have to be performed across a welded joint in the bottom of the vessel or adjacent components.

For receptacles not by pressure, welding in the region of the end fitting convex must be avoided.

the flange of the agitator must be positioned so that its axis passing through the center of the vessel appears to about 2/3 of the height of the liquid (H).

The dimension "A" is relative to the type of agitation to be obtained. Consult AerreInox for the optimal size.

Welding pad positioning





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PREPARATION FOR WELDING

Refer to the figure on the left: for this type of connection of the flange, the same requires machining with bevels from work on it as shown in the second figure on the left. The flange can be supplied with a bevel design made, if requested at time of order.

Once the position of the welding plate has been determined, is to be track the hole on the outer surface of the convex bottom. The hole must be performed with plasma cutting, ensuring a dimension as indicated in the table. Is essential that between the hole and caulking the flange is performed for a proper filling.

MODEL Ø hole (mm) MODEL Ø hole (mm)

AMT-02 55 AMT-12 140

AMT-04 60 AMT-20 175

AMT-06 75 AMT-32 240

AMT-08 115 AMT-64 268

(a) Hole preparation (b) Machining detail for welding pad mixer

The flange must be positioned in the hole oriented correctly, start with the execution of a series of points from the inside of the container to eight positions in the sequence shown in the first figure on the left, check at this step the flange, ensuring that is resting on the bottom and normal.

Refer to the second picture. From inside the tank, made a pass 360° continuous TIG run from point A with filler wire of 1.2 mm in diameter from 30 to 40 volts / 110 to 120 Amps. Make a second pass from the point B. In case of need for a third pass should be carried out from point A to point B.

Finally, it should be resumed in reverse and continuously at 360° fill TIG welding across the flange, with filler wire 1.6 mm in diameter. If necessary, the welding can be performed in two or three steps.

Sequence for tack welds Continuous root runs

FINAL GRINDING and POLISHING STAGE

After the flange was allowed to cool by natural convection to ambient temperature, the welds must be brushed and / or polished until it reaches the desired finish. If necessary, any excess of material or scratch can be identified and re-polished.





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2 - STATIC BEARING Installation

NOTE

- Make sure that the tank appears clean and completely dry inside;

- Do not use any abrasive or improper on the support surface;

- Handle with care static bearing;

- Make sure the static bearing and locking nut are clean;

- If necessary to enter in the tank, follow all local regulations regarding operator safety.

STEP TO INSTALL STATIC BEARING

1) Ensure the correct position of the washers / o-ring on the bushing static and locking nut.

2) To ensure minimum friction, lubricate the visible part of the washer / o-ring with a small veil of purifiedwater.

3) Make sure the flange is clean, dry and free of foreign material.

4) Position the static bearing with locking nut with a suitable tighten tool.

5) Make sure that the instrument chosen to tighten fit the nut, then screw to pack the nut and washers / o-ring and static bearing to the face of welding flange. Tighten the lock nut to the torque recommendedappropriate.

3 - MIXING HEAD Installation

NOTE

- ALWAYS install the mixing head before installing the drive unit;

- Handle with care mixing head;

- Be very careful when mounting the mixing head on static support, the bearings of the mixer are fragile;

- Do not mount the drive unit before installing the mixing head (the powerful magnetic force between the mixing head and the external magnetic drive can cause serious damage to the bearings, and personal injury);

- If necessary to enter in the tank, follow all local regulations regarding operator safety.

STEP TO INSTALL MIXING HEAD

1) Remove any foreign particles from the magnetic mixing head. If the mixing head must be placed on thetable, position the dynamic bearing toward the floor to prevent magnetic particles that go to adhere tothe magnetic surface of the mixing head.

2) Remove the drive unit.

3) Install the mixing head with the appropriate tools. Because of the dimensions of the mixing head thesizes 04 - 32 - 64 must be installed by hand.

4) Carefully position the mixing head with small movements while go down on static support.

5) Place the mixing head and make sure that rotates smoothly.

4 - DRIVE UNIT Installation

NOTE

- Never operate on drive unit without frequency converter (inverter);

- Handle the drive unit with caution to avoid personal injury and damage crush to equipment;





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- ATTENTION! because of the strong magnetic attraction of components, do not pair the mixing head with the drive unit;

- The drive unit has a weight, use suitable equipment to avoid injury from crushing;

- See installation technical bulletins of electric motors for the power information;

- Connection to power supply must be performed by a licensed electrician in accordance with the regulations, directives and the code's safety.

- Ensure that all incoming power is equipped with emergency stop and with on/off locked switch in both positions;

- Make sure that the motor cables are shielded (to avoid interference);

- Make sure the drive is properly connected to ground;

- Store the engine in a non-humid and water proof room. Make sure that during maintenance the motor is on a stable surface to avoid falls or vibration;

- The bearing of the mixing head should be moistened with liquid before starting the unit;

- Check the direction of rotation: start the engine, make sure that magnetic outer drive head rotate clockwise, a mark on the drive unit indicates the correct direction of rotation.

INSTALL AMT-02 / AMT-04 / AMT-06 DRIVE UNITS

AMT-02 , AMT-04 and AMT-06 models use a connection type clamp that allows a random orientation of the welded flange.

1) Install the drive unit on the weld plate.

2) Without using gasket, position the clamp (1”1/2”, 2" or 2"1/2) around the weld plate and the flange of thedrive unit.

3) Tighten the clamp connection just found the correct orientation.

INSTALL AMT-8 DRIVE UNIT

The AMT-08 model has two shaped pins on mounting flange of mixer. The normal orientation of the buttonhole assembly is as shown in Figure A in such a way as to bring the axis of the mixer on the center line of the vessel.

1) Insert the two shaped pins in welding plate.

2) Install the drive unit on the welding plate and let the two pins fit into the buttonhole on the drive unit.

3) Rotate the drive unit counterclockwise until the stop position (about 10°).

4) Tighten the two nuts with a wrench.





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Position when Mixer dismounted

Angle through which Mixer rotates in order to be

dismounted

Figure A

Position when Mixer mounted

Figure B

INSTALL AMT-12 / AMT-20 / AMT-32 / AM-64 DRIVE UNITS

Model AMT-12 have 8 M8 threaded holes in the flange of the mixer.

Model AMT-20 have 9 M8 threaded holes in the flange of the mixer.

Models AMT-32 and AMT-64 are screwed (n.8xM12) in the flange of the mixer and are not designed for quick removal due to the size and weight of the drive unit.

The normal orientation of the mounting bolts is offset from the central axis of the tank (see Figure B) so as to place the axis of the mixer on the center line of the vessel.

1) Install the drive unit on the weld plate.

2) Align the holes in the flange of the drive unit to the threaded holes of the plate welding.

3) Tighten the screws in the welding plate and then tighten with a wrench.

DISASSEMBLY

IMPORTANT: Remove the mixer in the following order to avoid personal injury and damage to the equipment:

1- Drive unit 2- Mixing head 3- Static bearing

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

ATTENTION: Before dismounting the drive unit, ensure that:

- The circuit breaker is locked in the OFF position;

- The tank is empty, and at atmospheric pressure;

- The temperature of the vessel is less than 35°C, and all utilities connected are intercepted;

If you need to enter into the vessel, follow all local safety regulations before do it.

Be sure that you can handle the weight of the motor unit which can be heavy, use a lifting device for the larger models.





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STORAGE

Interpose wood or other non-magnetic material between the floor and the equipment to avoid direct contact with risk areas. Do not store the unit in places exposed to weather or moisture. For a period of storage exceeding 60 days, protect all mating surfaces, such as flanges and shaft on the drive system with a suitable anti-oxidation product. For storage periods longer than 6 months, rotate the external rotor head (magnetic outer drive head) on drive system every 1-2 months.

RECYCLE and DISPOSAL

Recycle and dispose of equipment according to local laws and regulations.

OPERATION

CHECK and CALIBRATION IMPORTANT: Do not starting AMT Mixer dry this can damage the bearing.

Make sure that the installation was successful.

Make sure that you are not working in the tank and never work next to the drive unit while it is connected to its power source.

Make sure that a sufficient level of fluid covers the mixing head and the static bearing to ensure sufficient lubrication, otherwise disassemble the drive unit to remove the mixing head and immerse it in clean water.

Reset the speed potentiometer leading / regulator to zero.

Start the mixer AMT at low speed (50 rpm) and carefully, slowly increase the speed.

Check that the direction of rotation of the mixing head is in a clockwise direction looking from above. If turned counterclockwise, see troubleshooting and contact your electrician / maintenance.

Stop the mixer and check immediately if any signs of malfunction, abnormal noise, or smoke or smell.

The most important parameters (acceleration time, deceleration, speed max, min. Rpm) for the normal work must be set case by case and depend on the specific application.

MAX RPM must not be adjusted to threshold / set too low, because the cleaning process requires relatively high speeds in order to obtain the best results. The RPM MAX should not be regulated by exceeding the maximum threshold as a function of max rpm specific, see the technical data of any size mixer.

STARTING MIXER The mixing head is delivered clean 'factory', but not sterile. Before being used must undergo proper treatment of cleaning with CIP systems.





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Fill the tank to the minimum level that it completely covers the mixing head and the bushing static to provide sufficient lubrication to the bearing.

Check that the operating parameters of your control panel (if supplied) are correct for your device. If you have not already planned your electrical panel, you simply perform a manual start at minimum speed. Now, you can start AMT Mixer.

In extreme working conditions, can occur disconnection of the magnetic coupling, (ie the engine is running but the mixing head does not rotate) if this happens, the bushing can be damaged by impact and be damaged. To avoid any inconvenience, the acceleration time and the max. rpm must be adapted to the specific application.

make sure that foreign objects do not enter in the tank when the mixer is in rotation, this can affect the operation of the device.

OPERATING NOTES

- Fill the tank with the liquid, start the mixer and then add solid material.

- Avoid the accumulation of large amounts of solids on the bottom of the container.

- Always make sure that the mixing head be always covered with liquid during operation in ATEX zone.

- If the mixer has run dry, start the mixer maintenance to check the bearing and consult the troubleshooting section.

CLEANING in PLACE (CIP)

The AMT mixer model is designed to fit into cycles of cleaning (CIP). The groove in the mixing head are to guarantee that the flow of the fluid is distributed through its internal parts. To achieve this, the mixing head must be immersed and rotated at a speed determined minimum. The result of the cleaning depends on many parameters such as: temperature, time, the chemical composition of the detergent, mechanical condition, speed and type of product to be removed.

In the absence of a minimum level it is possible to use these alternative methods: washing heads static or rotary or cleaning by immersion. Make sure that the bearing are continuously lubricated (or submerged).

Cleaning usually consists of several cycles ie, pre-rinse, clean with base and / or acid detergent, rinsing after cleaning the main acidic or basic and final rinse.

The exact operating conditions for CIP must be validated for each application.

These cleaning methods do not remove the magnetic particles, to achieve this mixing head must be removed (after having removed the drive) and cleaned separately. Magnetic particles can cause corrosion and damage also cause a decoupling and cause disconnection of the mixing head and seriously damaging the tank.





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STERILIZING in PLACE (SIP)

AMT mixer is perfect designed for sterilization in place (SIP) without any need for dismounting. Based on individual conditions you can choose one of following methods.

ATTENTION: permanents magnets in the mixing head and the rotor are heat stable up to +225°C, NEVER expose these parts therefore to higher temperature. The drive unit and gearbox should not be exposed to ambient temperature above +70°C.

Ensure that mixing head must be covered with fluid before starting following sterilization.

Steam SIP The vessel with the mixing head and the mounted drive unit are steam sterilized.

- Into heating phase, start the AMT mixer at a low speed and rotate a few seconds, approx. every five minutes.

- When the sterilization temperature in the vessel has been reached, stop AMT mixer.

- To remove any condensation inside the mixing head, during sterilization rotate AMT mixer a few seconds approx. every five minutes.

Super Hot Water SIP (SHW) The vessel with the mixing head and the mounted drive unit are sterilized with super heated water.

- Fill the vessel with WFI (water for injection) to a suitable level.

- During heating sterilization and cooling AMT mixer should rotate. Vortexes (suction whirlpools) must not arise, check this by water level and speed.

- During the emptying phase AMT mixer must not rotate.

Sterilization in Autoclave or Hot Air Oven ATTENTION: Before dismounting the drive unit, ensure that:

- the main power switch is locked on a switch-off position;

- Be certain that you can handle the weight of the drive unit that may be heavy;

- use a lifting device for the larger models;

The vessel and the mixing head without drive unit is sterilized in an upright position in an autoclave or hot air oven; otherwise the mixing head will slide off the static bearing. This will damage the mixing head, bearings and vessel.

AUTOCLAVE: dismount drive unit. At least one pre-vacuum period must be used to eliminate air pockets. The vessel with mixing head in place, are sterilized at a max. temperature of +140°C in the autoclave.

HOT AIR OVEN: dismount drive unit. The vessel with mixing head in place, are sterilized in hot air oven at a max. temperature of +225°C.





Aerre Inox s.r.l.

MAINTENANCE and SERVICE

WARNING Ensure the main power switch is locked on a switch-off position, the vessel is clean, cooled, depressurized, ventilated from any possible gases and that connected media are not, and can’t be connected.

ATTENTION Dismounting: drive unit must be dismounted before mixing head; Mounting: mixing head must be mounted before drive unit.

ROUTINE MAINTENANCE

START-UP / RUNNING-IN Remove and check inside the mixing head in particular: it must not be scratched or in any way damaged. Mixing head can be sent to AerreInox for refurbishment of bearing.

- Inspect tungsten carbide on dynamic bearing for damage;

- Inspect magnetic body for particles;

- Inspect wings for marks and scratches;

- Check mixing head rotates easily, listen for noise.

DURING OPERATION In Addition to checks for START-UP/RUNNING-IN above, make some more check on static bearing:

- Inspect tungsten carbide on static bearing for cracks or damage;

- Inspect the locking screw;

- Make sure disk / o-rings are not damage (best is change them);

- Check for welding plate thread deformation.

- Inspect welding plate for scratches, marks and/or damage.

AT LEAST ONCE A YEAR In addition at checks above, remove and check the mixing head and static bearing for signs or surface damage. Change the bearing and the mixing head if the surface is coarse or uneven, scratched or if fragments have been knocked out from the bearing. Mixing head can be sent to AerreInox for refurbishment of bearing. Change disk / o-ring when re-mounting static bearing. Make a general inspection of the drive unit, check:

- cables for damage;

- the gearbox for leakage and noise;

- for any contact mark on welding plate

- shaft and outer drive head rotation and wobbling movement

- outer drive head for damage caused by contact with welding plate

- bolts, screws, nuts and flanges are in good condition and free of damage.

Tungsten carbide bearings are to be changed after about 4000 operating hours.





Aerre Inox s.r.l.

IDENTIFICATION and LABELING

1st plate (left)

Identification plate

STANDARD plate

Type = Code of AMT mixer that indicates the Model of mixer Serial Number = Univocal number which identify in detail the AMT mixer

2nd plate (right)

ATEX plate

II = gruop II (surface) 2 = category 2 (zone 1) G = explosion atmosphere with gas or vapour D = explosion atmosphere with dust IIB = gruop of gas IIIC = gruop of dust (conductive dust) T4 = temperature class depending of intercepted fluid T135°C = max surface temperature depending of intercepted fluid Gb, Db = EPL X = special condition of use (see ATEX safety instruction) Tmax fluid = max fluid temperature Ref = acknowledges receipt of technical documentation Serial Number = Univocal number which identify in detail the AMT mixer Type = Code of AMT mixer that indicates the Model of mixer

SPARE PARTS

AerreInox recommends the following equipment be kept in stock:

- FEP o-rings / FFKM o-rings / PTFE for static bearing;

- Static bearing;

- Mixing head.

If you need to order some pieces, to avoid misunderstanding, please indicate in your purchase order the model of your AMT mixer and its serial number.





Aerre Inox s.r.l.

TROUBLE SHOOTING

Many of the technical problems that arise can be eliminated with minimal intervention; for this reason, before contacting our TECHNICAL SERVICES department, we suggest you carefully consult this manual.

Don’t disassemble or work on the drive unit without authorization by Aerre InoxIf you are unable to eliminate the breakdown or problem and for any clarification you might require, contact our Technical Support service at:

During troubleshooting, follow the instructions in this manual. ATTENTION: Before performing maintenance on AMT mixer, ensure that:

- the main power switch is locked on a switch-off position;

- the vessel is empty (free of harmful products), ventilated and at atmospheric pressure;

- the vessel temperature is below 25°C, and all connected media is shut off;

FAULT Possible CAUSE SOLUTIONS 1 The AMT mixer don’t

start

a) Fault in powerb) Heavy load of particles stuck to themagnets c) Overload protection tripped

a) Check power supplyb) Clean the unitc) Inspect the setting amp value andambient temperature.

2 Poor motor effect Motor incorrectly connected Inspect motor connection with an electrician; incorrect connection can cause burn motor.

3 High amp value a) Ambient temperature too highb) Motor mechanically over-loaded

a) Chill the environmentb) Check all transmissions

4 Outer drive head scratches

a) Deformation of tank plate during weldingb) Loose outer driven headc) Bent shaftd) Bent hole-shaft in gearboxe) Drive unit not properly in placef) particles stuck to the magnets

a) verify tolerances using appropriategauges b) position the outer driven head onto itslower end position against the shaft and tighten c) contact AerreInoxd) contact AerreInoxe) re-install drive unit correctlyf) remove particles

4 Loss of running speed a) Missing phase (AC)b) Incorrect incoming power

a) Check the fusesb) Inspect the power supply

5 AMT mixer does not Incorrectly set parameters try to adjust and calibrate the AMT mixer






Aerre Inox s.r.l.

reach the required max. rpm

6 Mixing head does not rotate or rotate in wrong direction

a) Static bearing not mountedb) Motor incorrectly connection

a) dismount drive unit, pull out mixing head,then mount static bearing mixing head and drive unit b) check cable connection: DC polereversed cable; AC phase reversed power cables.

7 Noise from mixing head a) mixing head rotate dryb) worn bearingsc) missing static bearing

a) stop mixer and restart only when fluidlevel covers mixing head b) Replace static bearing and/or contactAerreInox for dynamic bearing c) see point 6.a)

8 Mixing head scratches a) Deformation after weldingb) Loose static bearingc) Static bearing worn outd) Dynamic bearing is damagede) Particles stuck to the magnets

a) verify tolerances using appropriategauges b) inspect static baring and welding plate fordamage, check rotation direction of mixing head c) replace static bearingd) contact AerreInox for repaire) remove particles

9 Mixing head running eccentrically

a) Bearings worn outb) Static bearing is not properly in place

a) Replace static bearing and/or contactAerreInox for dynamic bearing b) inspect static baring and welding plate fordamage, check rotation direction of mixing head

10 Magnetic coupling disconnected

a) AMT mixer accelerate too quicklyb) speed too high for the current applicationc) incorrect rotate directiond) unexpected viscosity/density of mediae) incorrect order of addition of substances,dry running

a) check start-upb) reduce speed, possible adjustment ofmax. rpm c) see point 6.b)d) see point 5e) see this guideline at “Starting the Mixer”

11 Particles in the mixing head

Magnetic particles from associated media Check and take action with regard the presence of particles associated media and raw material.

12 Abnormal noise a) Dry runningb) Deep vortexc) Cavitation

a) see point 10.e)b) reduce speed, ensure mixing headalways covered by fluid c) check: pressure, temperature, speed

13 Insufficient cleaning of the mixing head

Poor fluid flow in the mixing head a) due to low fluid levelb) due to low speedc) due to high speed

a) increase fluid levelb) increase rpmc) reduce rpm to prevent whirlpool occurring





Aerre Inox s.r.l.

ATEX CERTIFICATION





Aerre Inox s.r.l.

EC DECLARATION of INCORPORATION





Aerre Inox s.r.l.

PED CERTIFICATION





Aerre Inox s.r.l.

STANDARD WARRANTY

AerreInox warrants its products will meet their applicable published specifications when used in

accordance with their applicable instructions for a period of one year from shipment of the products.

AERREINOX MAKES NO OTHER WARRANTY; EXPRESSED OR IMPLIED. THERE IS NO

WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The

warranty provided herein and the data, specifications and descriptions of AerreInox products

appearing in AerreInox’s published catalogues and product literature may not be altered except by

express written agreement signed by an officer of AerreInox. Representations, oral or written, which

are inconsistent with this warranty or such publications are not authorized and if given, should not be

relied upon. In the event of a breach of the foregoing warranty, AerreInox’s sole obligation shall be to

repair or replace, at its option, the applicable product or part thereof; provided the customer notifies

AerreInox promptly of any such breach. If after exercising reasonable efforts, AerreInox is unable to

repair or replace the product or part, then AerreInox shall refund to the customer all monies paid for

such applicable product or part. AERREINOX SHALL NOT BE LIABLE FOR CONSEQUENTIAL,

INCIDENTAL, SPECIAL OR ANY OTHER INDIRECT DAMAGES RESULTING FROM ECONOMIC

LOSS OR PROPERTY DAMAGE SUSTAINED BY ANY CUSTOMER FROM THE USE OF ITS

PRODUCTS.





Aerre Inox s.r.l.

MIXER COMPONENTS

PART. DESCRIPTION

01 NUT SECURING BUSHING

02 WASHER FOR NUT

03 STATIC BEARING

04 WASHER FOR BEARING

05 MIXER HEAD

06 WELDING PLATE

07 MAGNETIC OUTER DRIVE HEAD

08 DRIVE SHAFT

09 CONNECTION FLANGE

10 DRIVE UNIT

11 COVER

12 NUTS AND STDS FASTENING



®

Fig. 1 TK- CONNECTIONAvailable in size from ¾” up to 4”, DN10 up to DN100 in four different thikness : std, 25 mm, 38 mm, 51 mm According to ASTM A269 /270, ISO 1127or DIN 11851. Material 1.4404 – 1.4435 – Hastelloy C22 – C276 on request. Designed for use of standard clamp gaskets. According to PED 97/23/CE directive and ASME VIII Div.2

Fig. 2 TK- CONN BLOCK HOUSINGFor special applications onto tank welding. According to ASTM A269 /270, ISO 1127 or DIN 11851. Material 1.4404 – 1.4435 - Hastelloy C22 – C276 on request.Non-standard product, custom thicknesses, avoids warping.

Fig. 3 TK- CONN ANGLED HOUSINGAngle profile cutted TK-Connections customized. For tank welding where orthogonal connections required Special execution High/angle as to be agree. Material 1.4404 – 1.4435 - Hastelloy C22 – C276 on request

Fig. 4 TK- CAP Standard TK-Connections in various size machined directly in a special 8 -10 or 12” clamp tank cover cap for pharma and biotechnology applications, custom made on request Std. material 1.4404, 1.4435 on request

Fig. 5 TK- CONN JACKET HOUSINGTK-Connections with special profile dedicated for pharmaceutical reactors with cool/heat jacket or thermal insulation cladding.

For non-standard TK-CONN options please contact: [email protected]

®

TK CONNASEPTIC TANK CONNECTION, WITH BOLTED SPLIT RINGS

Замечания

Условия поставки: DDP склад г. Киев

Заметки Время поставки рассчитано согласно дате предложения и изменяется в зависимости от даты подтверждения заказа. Размещая заказ, покупатель принимает предложение и все спецификации, характеристики и условия, указанные в данном документе.

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http://k-tep.com.ua/

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Documents

Installation User Guide Maintenance · The mixing head rotates on inserts of tungsten carbide certificate manufactured under controlled conditions to obtain the correct size, grain