polymixer operation and maintenance manual - … installation operation... · operation and...

PI007; Rev.1 of 32

355 Pioneer Way Mountain View, CA 94041

1-800-882-3886 www.asepco.com

POLYMIXER™

Operation and Maintenance Manual

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Table of Contents 1 General 3

1.2 Warranty 3 1.3 Technical Service 3

2 Safety 4 3 Description 5

3.1 Impeller 6 3.2 Male Bearing 7 3.3 Weldment/Mounting Post (WMP) 8 3.4 Drive Unit 9 3.5 Tachometer Pickup and Tachometer 10 3.6 Dimensions and Weights 11 3.7 Noise Level and Vibrations 11

4 Transport & Handling 12 4.1 Transport 12 4.2 Handling 12

5 Installation 13 5.1 Weldment/Mounting Post (WMP) 13 5.2 Electrical or Air Installation 13 5.3 Commissioning Drive Unit 14 5.4 Male Bearing 15 5.5 Drive Unit 16 5.6 Impeller 17 5.6.1 – removing the impeller 18 5.7 Start-up 18

6 Operation 20 6.1 Operating Limits 20 6.2 Principles of Operation 20 6.3 Cleaning Procedure for the PolymixerTM 22

6.3.1 Cleaning Inside Vessel 22 6.3.2 Cleaning by Re-Circulation 24 6.3.3 Cleaning the Impeller Separately 25

6.4 Sterilization Procedure for the PolymixerTM 26 6.4.1 Sterilization by Injection of Pressurized Steam 27 6.4.2 Sterilization by Super-Heated Water 27 6.4.3 Sterilization by Steam Autoclaving 27

7 Service/Maintenance 28 7.1 Inspection of Bearings 29 8 Recommended Spare Parts 30 9 Troubleshooting 31 10 Start-up Checklist for PolymixerTM 32

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1. General Information 1.2 Warranty ASEPCO offers comprehensive after-sales service. If any adverse issue (material defect, mixer function, etc.) with your mixer develops, please contact ASEPCO immediately to determine the most effective resolution for the issue. ASEPCO offers a two-year warranty on workmanship for our mixers. When returning a mixer, contact ASEPCO for a RMA number . Please package the mixer appropriately to prevent damage in transit. Please label boxes, packing slips and correspondence with the RMA number provided by ASEPCO. NOTE! Modifying the mixer voids any warranty. 1.3 Technical Service Spare parts and advice regarding operation of your ASEPCO PolymixerTM can be obtained by contacting ASEPCO at 1-800-882-3886.

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2. Safety All ASEPCO mixers are supplied as components and are to be mounted onto process vessels before use. The mixers must not be modified in any way or run beyond the limits specified in this manual, or addendums to this manual. Each warning or prohibition is marked in the manual with one of the symbols as shown below:

WARNING: Negligence to this warning can result in personal injuries and or material

PROHIBITION: Ignoring these prohibitions will definitely cause damage to personnel and or components

People carrying any electrically controlled medical devices (pacemakers, etc.) should not be involved in the close handling of magnetic mixers. When operating the mixer it must be installed in a vessel. The magnetic items (Impeller and Magnetic Drive Unit) should, on a routine basis, be checked for foreign material that can get magnetically stuck to their surfaces. It is important to check that all components of a complete unit are of the same size. To avoid burns stay away from all heated parts as well as the Drive Unit. Never install any components (dip-tubes, sensors, etc) in the immediate vicinity of rotating parts. Do not perform mixer maintenance unless the vessel and piping system where the mixer is installed is at atmospheric pressure, cooled down to max 25C, completely drained of liquids or gases, and not showing any trace of dangerous products. Do not use motors in explosion proof environments unless motor plate and documentation state motor is explosion proof.

It is the customer’s responsibility to check the safety of the mixer each time it is used in a new application. It should be checked with regard to:

External loads due to traffic, wind, seismic activity etc. Reaction forces and moments that result from any supports, attachments, piping etc. Corrosion and erosion, fatigue etc. Decomposition by unstable fluids

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3. Description ASEPCO PolymixersTM are available in a variety of models and sizes. The ASEPCO PolymixerTM is designed to be used in liquid process vessels primarily in pharmaceutical/biotechnology applications and for liquid products. To choose a mixer for your application, see the Selection Procedure. All parts described below have their own ID-No. and size code, which correspond to the actual documentation.

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3.1 Impeller All Impellers consist of the same type of parts:

Impeller hub – This contains the magnets. Female bearing – press fit into ID of Impeller hub. Blades – a variety of different types of blades can be affixed to the Impeller hub.

The standard types are: o Marine o Low Shear (Elephant) o Foil o Axial o Rushton

PolymixerTM impellers are designed to operate in aseptic pharmaceutical/biotechnology processes. They are constructed free from pits, crevices, cavities, hidden areas, etc. and are polished to a smooth finish (25 Ra or less depending on customer specifications).

The magnetic forces must be kept away from any contaminating magnetically attractive particles that will be attracted by the magnetic fields. Avoid operating at temperatures >135 °C. To retain the high quality surface finish and prevent damage to the impeller it must be handled with great care.

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3.2 Male Bearing All male bearings are designed according to the following principal:

The bearing is notched to fit over the pin on the Weldment/Mounting Post (WMP). The bearing is a single piece unit made of Tungsten Carbide or Silicone Carbide. The bearing is sealed at both ends with Tef-SteelTM seals. The bearing and seals are held in place by the bearing nut that threads into the WMP.

Do not handle bearing carelessly or allow hard impacts on bearing to occur or there will be damage to the bearing surface.

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3.3 Weldment/Mounting Post The WMP is made from one uniform piece of material, and includes:

Threaded hole for the male bearing assembly. Connection flange for the Drive Unit.

The WMP is an integrated part of the vessel on which it is mounted. So, it has to be approved according to the valid pressure vessel code. Each WMP is marked with its heat number.

Before the WMP is welded into the vessel make sure that the separate Welding guidelines for the WMP are read and understood. Ignoring these guidelines might cause deformation of the post and further malfunction of the entire mixing unit If the vessel and WMP are to be electropolished, ensure that the inside of the entire vessel is equally grounded and manually polished before electro polishing is performed. (See further installation instructions.)

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3.4 Drive Unit PolymixersTM consist of a four parts:

Impeller WMP Motor Drive Unit Supplied as a single unit Controller (optional)

For further motor data see PolymixerTM documentation.

Protect the drive magnet assembly and shaft from impact damage. If this part becomes misaligned it will lead to a malfunction of the mixer.

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3.5 Tachometer Pickup and Tachometer (optional) The Tachometer indicates the true rotational speed of the Impeller unit. The tachometer pickup works as a PNP, closing circuit. The PolymixerTM can have the Tachometer pickup and Tachometer added at the factory or added in the field at any time.

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3.6 Dimensions and Weights Due to the variety of impeller shapes and motor configurations available weights and dimensions are noted on assembly prints.

3.7 Noise level and Vibrations For information regarding noise level and vibrations, refer to individual motor and applied standards.

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4. Transport and Handling

4.1 Transport The PolymixerTM must not be transported without being packed securely to avoid damage during transport or storage. Keep the Impeller, Male Bearing, WMP and Drive Unit in their packaging as long as possible in order to protect the equipment from dirt or impacts.

4.2 Handling When the mixer is received and unpacked, take precautions to prevent scratching the polished surfaces of the Impeller or WMP. Be aware that any contact between the stainless material and other non-stainless materials will result in a material contamination that can lead to corrosion spots. To retain the surface finish and prevent damage to the Impeller it must be handled with great care. When the Impeller has been removed from the vessel and is not in use, it should be placed on a table according to the figure below or stored in its original packing materials. Since the Impeller and the Drive magnet assembly are highly magnetized, avoid contact with magnetically attractive particles and other magnetized material. To avoid damaging the adapter, the PolymixerTM Drive Unit should always be put in such a position, that there is no risk of the Drive Unit flipping over and thereby damaging the adapter when it is not installed in the vessel. To avoid damaging the drive magnet assembly it should be placed in a container to prevent it from contact with magnetically attractive materials.

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5. Installation Before installing the Male Bearing, Impeller or the Drive Unit into a new process system, make sure the system has been properly cleaned. New process systems will always carry a heavy burden of foreign material that must be removed before the system can be put into use. These materials could contain magnetically attractive particles that will be caught by the magnetic fields of the Impeller. Keep the Impeller and Male Bearing in the plastic transport wrapping until they are to be installed in the process vessel. If they have become dirty during handling, a cleaning procedure, as the one described in this manual, must be performed.

Before any kind of maintenance work, make sure the vessel has been cooled down, emptied, de-pressurized and has had any gases or dangerous products ventilated. Disconnect all media during maintenance work.

5.1 Weldment/Mounting Post Before initial use, ensure that the Welding Guidelines for PolymixerTM WMP have been carefully followed and all necessary certificates, approvals, etc. have been received and documented.

After the welding is performed, make sure that there is no distortion, by using the included gauge to test the id. (see the Welding Guideline for PolymixerTM WMP, section 4) An authorized welder must perform all welding work.

5.2 Electrical or Air Installation When a Control Unit delivered by ASEPCO is used, the actual manual for the Control Unit must be carefully followed. All incoming power must be equipped with an emergency stop (installed near the controller) and an on/off switch with locking capabilities. Use only cables with correct voltage and current ratings. Use of shielded cables is recommended. It’s also important that the electrical equipment is well grounded. Make sure that the motor-cable is long enough, so that it is possible to disconnect and remove the Drive Unit from the vessel.

NOTE! Make sure that the electric cables between the Drive Unit and connecting cabinet are of such length, that it is possible to disconnect and remove the Drive Unit from the vessel.

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5.3 Commissioning Drive Unit

The following instructions apply only to our standard mixer assemblies which have a RETRACTABLE DRIVESHAFT. For other models contact ASEPCO for added precautions.

After installation, it is very important to check that the motor is rotating in a CLOCKWISE direction as seen from above. If not, the Impeller will come off the bearing and cause damage in the vessel and/or the bearing will become unscrewed. To perform this test, the Drive Unit should be placed on the floor or on a table. In order to check that the PolymixerTM WMP is correctly welded into the vessel and has not been altered, the Drive Unit should be connected to the vessel and run. Install the Drive Unit according to the instructions given in chapter 5.7 in this manual. Run the Drive Unit and its Drive Magnet Assembly inside the WMP at a low speed and listen for any interference noises.

NOTE! The Impeller should not be installed in the vessel when this test is performed. After testing the Drive Unit according to the instructions, the Drive Unit should be removed from the vessel. Installation instructions should be followed according to the chronological order described in this manual.

Do not run the Drive Unit in excess of the recommended speeds

Before installing the Impeller please check that the Drive Unit has been removed.

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5.4 Male Bearing The following are instructions for installing the PolymixerTM male bearing onto the WMP:

1. Place the lower (Tef-SteelTM) seal (2) around the step at the top of the WMP (1). 2. Slide the male bearing (3) onto the WMP (1), so that the pin groove on the bearing slides over the bearing

pin (6). 3. Place the Upper (Tef-SteelTM) seal (4) over the step on the bearing nut (5). 4. Thread bearing nut (5) into WMP (1) and tighten by hand. Then turn 1/8th turn with a 1/2” open-end

wrench.

The vessel must be clean and completely dry inside, before the installation of the male bearing. Ignoring this warning can result in material damage.

The WMP thread must be cleaned before installation of the male bearing.

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5.5 Drive Unit Installation

With RETRACTABLE DRIVESHAFT models never install the Impeller while the Driveshaft is engaged. The powerful magnetic forces can cause severe damage to the bearing and/or the operator.

Ensure that the four nuts are threaded onto the studs protruding from the WMP. Only thread them on until the nut is flush with the end of the studs. Ensure the impeller is NOT on the weld post (ref figure below). If it is the driveshaft will be engaged by the magnetic force from the impeller and certain injury will result. To prevent damage to equipment and/or personnel, when handling the drive unit use the appropriate lifting equipment. Line up the holes on the drive unit with the studs and slide over the nuts on the studs. Twist the drive unit until the nuts are over the elongated slots. Tighten the four bolts evenly to 50 ft-lbs each. Impeller removed. Line up Drive Unit

with studs

Thread holes over studs

Rotate drive unit and tighten bolts

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5.6 Impeller Installation The Impeller should be mounted AFTER the drive unit to prevent damage to the bearing surfaces. This ensures that no bearing damage can occur by the significant magnetic forces drawing the impeller to the magnets of the Drive Unit. Clean and inspect the Impeller to ensure that it does not contain any foreign particles, especially on the ID below the bearing. Ensure the driveshaft has been retracted from the drive unit and held in this position by the supplied tool, or on larger models, screw the handwheel to retract the driveshaft. Using either your hands or the installation tool install the Impeller very carefully and place it onto the WMP.

Do not drop the Impeller onto the male bearing. The bearing surfaces can be damaged under impact, especially when the bearings are Silicone Carbide.

Rotate Impeller by hand to verify that unit is properly installed and to ensure that it isn’t touching the vessel.

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5.6.1 Removing The Impeller To avoid the risk of personal injury or damage to the bearing, the drive shaft MUST BE RETRACTED before the Impeller can be removed from the WMP.

1. Verify that power is off and locked before attempting to retract the drive shaft. 2. Retract the driveshaft 3. Engage tool to hold the driveshaft in the retracted position (or on larger units use the

drivewheel to retract the driveshaft) 4. One the driveshaft is properly retracted the impeller can be removed

5.7 Start-up Before and during Start-up the vessel must be filled up with enough liquid to cover the Impeller. The bearings will be damaged if it is run without a lubricating liquid film.

Ignoring above prohibitions will definitely cause damage to the bearing

Dry operation will immediately cause damage to the bearing! Make sure that nobody is working inside the vessel when operating mixer. Never work close to the Drive Unit while it is connected to power and running.

Do NOT start with low liquid level Cover impeller with fluid before start-up

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The following matters must be considered during the start-up of a mixing system: Before start-up; it is necessary that the installation procedures according to chapters 5.4, 5.5, 5.6 and 5.7 are completely understood and followed.

Keep away from moving parts To avoid magnetic decoupling during start-up and continuous production, it is important that the acceleration, deceleration time and speed level are adjusted appropriately. ASEPCO recommends 30sec for acceleration and deceleration settings.

Connect the Drive Unit to the controller.

1. Adjust the max./min. speed to a value applicable to the actual product and volume. 2. Start the PolymixerTM for a few seconds, ENSURE THAT THE IMPELLER IS ROTATING CLOCKWISE

(seen from above) Start the mixer and slowly increase the speed to its full rpm.

If any signs of malfunction, abnormal noise, smells, etc. occur; THE MIXER SHOULD IMMEDIATELY BE STOPPED, the cause investigated and the necessary adjustments should be made.

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6. Operation 6.1 Operating limits Process medium: Newtonian liquids from 1 to 800 cp Medium temp: Up to 135 ° C Pressure: See appropriate calculation for the actual pressure vessel Vessel ratio: 1:1 - 1:2 (D:H)

6.2 Principles of operation Charging Guidelines: Always fill up enough liquid in the vessel and run the mixer before solid material is charged. Avoid the build-up of a large quantity of solids in the bottom of the vessel, as this might cause magnetic decoupling of the Impeller.

Optimal Mixing:

The optimal mixing effect is obtained when the liquid movement shows turbulence and begins to vortex slightly.

Dry running:

In the manual, it is repeatedly emphasized that the mixer should not be run dry. A physically dry bearing surface will shear, start screaming and finally break. The definition of a physically dry surface is that it is completely clean and free from any liquid film that can act as lubrication for the bearing. During certain processes this situation can develop and precautions must be taken to avoid it.

Typical applications where such precautions must be taken are if the mixer is run:

1. At high speed 2. In hot WFI 3. At atmospheric pressure 4. During and after steam sterilization

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Dry running (con’t): It is important that these four factors are carefully considered during process validation work and controlled so that significant damage does not occur. Completely dry surfaces can rapidly be developed between the male and female part due to sudden liquid boiling or cavitation. A typical scenario is: High frequency noise >> Rumbling >> Magnetic decoupling >> Possible bearing damage

1. Stop the mixer immediately and inspect the male bearing to ensure that it is tight. 2. Make certain that the impeller is not hitting any tank surfaces. 3. Check the bearings for cracks and damage.

The following adjustment will reduce or eliminate the above, described scenario: Reduce mixer speed to the minimum for the process. Pressurize the vessel to avoid internal liquid boiling.

pH-limit:

The bearing material, Tungsten Carbide (male and female) will tolerate continuous contact with solution in the pH-range of 3-10. Outside this range (and max. 2-12) the contact should be limited to max. 15 min. per treatment, Routine treatment of these conditions will have a big impact on the lifetime of the bearing material. The bearing material, Silicone Carbide (male & female), allows the pH-limit to be increased to 1-14.

Temperature:

Make sure that the motor does not operate with higher ambient temperature than 70 °C.

If the mixer is to be used for blending of media during batch sterilization, the mixer speed must be adjusted to the minimum for the application.

Do not exceed maximum operating temperature of 135°C inside the vessel.

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6.3 Cleaning procedure for the PolymixerTM (CIP) All ASEPCO mixers are designed with an open structure that enables the Impeller, male bearing and the WMP to be easily cleaned while they are installed in the processing vessel. This procedure is generally called CIP (Cleaning In Place). The CIP procedure described below will clean the parts adequately on a routine basis. The operating personnel should, however, be aware that the Impeller should be removed from the vessel on a routine basis to check if magnetically attractive particles from the raw materials have been collected on the internals of the Impeller. Accumulation of magnetically attractive particles on the inside of the Impeller can cause corrosion and damage the Impeller. A higher torque can be experienced with a great amount of particles, which can cause the Impeller to come off and damage the vessel. CIP procedure CIP- procedures can be performed in several different ways depending on various conditions prescribed by the actual application and specific processing conditions. Two main methods are identified in section 6.3.1 and 6.3.2.

6.3.1 Cleaning inside vessel In this case, the vessel is cleaned by wash and rinse solutions that are sprayed into the vessel through a spray ball located inside the vessel. 1. The bottom outlet valve is left open so the

wash and rinse solutions can be continuously drained. If the spray ball is covering all the surfaces including the Impeller, total CIP will be accomplished. This is due to the open structure of the Impeller. It will be cleaned in the same manner and to the same level of cleanliness as the inner surfaces of the vessel. The mixer should be run between 50 and 100 rpm during the CIP process.

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2. If the spray ball is only covering the upper part and sidewalls of the vessel: a) Close the bottom outlet valve.

b) Fill the vessel with wash or rinse c) solution until the Impeller is d) completely covered.

e) Run the Impeller at approx. 100 f) rpm for 10 min.

g) Drain the vessel.

h) Repeat until the equipment is

adequately cleaned according to your residuals requirements. (Normally 1 wash + 2 rinse sequences).

The impeller can run continuously during and between the sequences, if they are performed without interruptions.

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6.3.2 Cleaning by re-circulation In this case, when pumps are involved, the vessel must keep a certain liquid volume to feed the pumps. This liquid volume should also cover the Impeller. 1) Proceed as follows:

a) Close the bottom outlet valve. b) Fill up the vessel through the spray c) ball to cover the Impeller + the dead volume in the

external piping etc. d) Run the mixer at approx. 100 rpm. e) Start the circulation pump, open the f) bottom outlet valve and let it run g) according to your standard procedures. h) Repeat until the equipment is i) adequately cleaned according to your residuals

requirement. (Normally 1 j) wash + 2 rinse sequences).

The impeller can run continuously during and between the sequences, if they are performed without interruptions.

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6.3.3 Cleaning the Impeller Separately The above-described cleaning methods will clean the Impeller, the Male Bearing and the WMP on a day-to-day basis. However, if any of the raw materials that are used in the formulation contain magnetically attractive particles these will be caught in the magnetic field on the inside surfaces of the Impeller and will not be removed by the normal CIP procedure. To remove these particles the Impeller has to be removed from the vessel and cleaned manually as follows:

1) Disconnect and remove the Drive Unit from the vessel according to the procedure described in this manual.

2) Remove the Impeller from the vessel and check for particles stuck to the inside of the Impeller. If necessary clean the Impeller as follows:

1) Spray the Impeller with a high velocity jet cleaner. 2) Clean with a soft brush or a sponge and a standard detergent (soap). 3) Magnetically attractive particles should be cleaned with an ultrasonic cleaner.

After cleaning replace the Impeller into the vessel, connect the Drive Unit and run a standard CIP procedure as described in your SOP’s.

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6.4 Sterilization procedure for the PolymixerTM (SIP) All ASEPCO mixers of are designed with an open structure that enables the Impeller, Male Bearing and WMP to be sterilized while they are installed in the processing vessels. This procedure is generally called SIP (Sterilization In Place). The three most commonly used methods for SIP are: 1) Injection of pressurized steam into the processing vessels to achieve a steam temperature of minimum

121°C. 2) Re-circulation of Superheated Water that has been heated up to a minimum 121°C and kept under

pressure. 3) Dry heat (Air) obtained in an oven.

This sterilization method means that the entire process vessel including the Impeller is placed inside a sterilization oven. The only precaution to be taken with the mixer is that the Drive Unit must be removed from the vessel, and the vessel should be kept in an up-right position. The equipment that is to be sterilized is placed in a steam autoclave into which pressurized steam is injected. Normally a minimum temperature of 121°C is used.

The Drive Unit must be removed from the vessel and the vessel should be kept in an upright position during sterilization in autoclave/oven If the Drive Unit is unattached during transportation and sterilization in an autoclave or oven, the drive magnet assembly must remain mounted to ensure safe handling of the male and female bearing.

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6.4.1 Sterilization by injection of pressurized steam The PolymixerTM can be Sterilized In Place with the Drive Unit connected to the vessel. In order to remove air from inside the vessel and connected parts in the sterilization process the sterilization starts as follows: Before steam is injected, a pre-vacuum period is initiated to remove most of the air inside the system. Live steam blown through the system at ambient pressure should flow into the vessel for approximately 3 to 5 min. After this time, “bump” the mixer at 100 rpm for no longer than 30 seconds. (This will serve to eliminate any air pockets between the two bearing surfaces.) After this “bump”, the agitator will remain off for the rest of the SIP cycle. The mixer can, but does not have to be run or “ bumped” during this step. After the sterilization cycle the mixer shall be shut off for the rest of the sterilization procedure. After a completed sterilization cycle the Impeller and its Female Bearing as well as the Male Bearing will be completely dry and can, in such condition, be damaged if the mixer is run. Therefore, avoid running the mixer before any liquid has wetted the Impeller.

6.4.2 Sterilization by Superheated Water The PolymixerTM can be Sterilized In Place with the Drive Unit connected to the vessel. In order to remove air from inside the vessel and connected parts in the sterilization process the sterilization starts as follows: This sterilization method is based on a situation where the process vessel is partly filled with WFI that is heated up to a sterilization temperature of minimum 121°C. In some cases the sterilization is limited to the vessel only, in other cases the heated water will be pumped through the entire process-system. As the Impeller will be fully soaked in Superheated Water during the whole sterilization period - No action needs to be taken with the mixer. Leave the mixer "shut off".

6.4.3 Sterilization by Steam Autoclaving This sterilization method means that the entire process vessel including the Impeller is placed inside a steam autoclave where the temperature is raised to the actual sterilization temperature, normally 121°C. This process includes a pre-vacuum period, to remove most of the air inside the equipment that shall be sterilized.

The motor and gearbox must be removed from the vessel and the vessel should be kept in an upright position during sterilization in autoclave/oven. The drive magnet assembly should remain in the vessel to prevent damage to the bearings during transportation. After an autoclaving process the Impeller and its Female Bearing as well as the Male Bearing will be completely dry and can, in such condition, be damaged if the mixer is run. Therefore, avoid running the mixer before any liquid has wetted the Impeller.

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7. Service / Maintenance The inspections below should be performed on a routine basis, (every 6 months) to ensure trouble free operation of the mixing system. Abrasive or high solid contents can wear out the bearings more rapidly. Rumbling, de-coupling, high pitch noise or other unfamiliar noises can indicate that the bearings are worn out.

During actions, make sure that warnings and prohibitions are considered, and that the instructions mentioned earlier in this manual are followed.

COMPONENT OBJECT CHECK FOR

TEST METHOD

SYMPTOM ACTION DONEBY

USER

DONEBE

ASEPCO

Impeller SURFACE: Female bearings

Foreign particlesScratches Tolerance

Surface damage

Visual Visual

Measuring gaugeVisual

The magnet shows adhering of foreign

material The surfaces show

any damage The no-go gauge

fits the female bearing.

The surfaces show damage

Cleaning Re-polishing

Replace bearing Replace bearing X

(X) - -

- X X X

Male Bearing Assembly

Male Bearing Bearing Nut

Seals

Tolerance Damage to

thread Damage to OD

Damage

Measuring gaugeNut gauge

Visual Visual

The no-go gauge fits on bearing Gauge doesn’t thread onto nut

Scratches, dings Seal is discolored,

cracked, etc.

New bearing Re-thread

Polish New seal

(X) (X) - X

X X X -

Weldment/ Mounting Post

Upper thread Damage to thread

Damage to OD

Screw gauge Visual

Go gauge doesn’t fit Scratches, dings

Re-thread Polish, EP X

X - -

Drive Unit Magnet Drive shaft Gearbox

Motor

Foreign particlesLeaks/noises Power cable

failure

Visual Visual/Audio

Visual

Magnet shows adherence of

foreign particles Oil dripping,

sounds too noisy or different

Damaged power cable

Cleaning Repair/exchan

ge Exchange

cable

X - X

- X -

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7.1 Inspection of the Bearing After using the mixer for a period of time it is recommended to remove the impeller and inspect the bearing for wear.

1) If the bearing is chipped or shows excessive signs of wear it must be replaced 2) Bearings that are not visually showing wear should be accurately measured for

wear by following the below procedure Measurement of the bearing for wear

1) Using an appropriate measurement tool measure the ID of the Female Bearing and the OD of the Male Bearing.

2) Compare the readings to the chart below 3) If either bearing is out of tolerance replace it immediately. We recommend

replacing both bearings at the same time.

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8. Recommended Spare Parts It is recommended that the following spare parts be kept in stock to provide for any replacement that may become necessary due to wear or damage. It is also recommended that spare parts be kept in stock in order to avoid major stops in production. Please refer to the data sheet and accompanying parts listed in the final documentation file delivered with your PolymixerTM.

SPARE PARTS NUMBER OF POLYMIXERTMS IN USE

1 2-4 5 or more

Male bearing X X

Seal set X X X

Impeller X

Never use parts other than those supplied or recommended by ASEPCO. Use of parts not supplied or recommended by ASEPCO will nullify any Warranty and may cause premature wear, or more seriously, may cause component failure and possible injury of personnel.

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9. Trouble Shooting When actions are taken, follow the instructions mentioned earlier in this manual. A correct installation is also essential.

SYMPTOM Period of occurrence

POSSIBLE CAUSES SOLUTIONS

Motor/Impeller does not rotate 1 No power Inspect power supply

Inspect power cable

1,2 Overload protection switched off Check the setting amp, value or the ambient temperature

1,2 Heavy load of particles stuck to magnetic surface

Clean per section 6.3

High amp value 1,2 Ambient temperature too high Cool environment

1,2 Motor mechanically overloaded Check transmission lines

Impeller scratches on vessel ID 2 Bearing worn out Replace bearing

1,2 Damage to the bearing holder Impeller needs repair

1,2 Lose male bearing Tighten bearing and check rotation direction



Magnetic drive unit rubbing against WMP

1 Warped shaft Replace shaft

1,2 Warped hole-shaft in gearbox Replace gearbox

2 Drive unit not properly installed Re-install drive unit per section 5.5

2 Heavy load of particles stuck to magnetic surface


De-coupling 1,2 Charging failure or "dry running" Follow guidelines in section 6.2

2 Unexpected viscosity changes Investigation and modification in conjunction with ASEPCO

1 Rotation in wrong direction Tighten bearing and reverse rotation direction



Impeller is spinning eccentrically 2 Bearings worn out Replace bearings

Loss of speed 1 Incorrect, incoming power Check AC, DC or air-source

1,2 Missing phase(s) (AC) Check fuses

1 - During installation/start-up 2 - During routine use

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10. Start-Up checklist for PolymixerTM. Check off during start-up: The PolymixerTM manual has been carefully read and understood, especially section #2 regarding

safety. Check that there is an ASEPCO WMP installed in the vessel.

Check that the Electric or Air source is connected to the PolymixerTM.

If a tachometer is delivered with the PolymixerTM, check that the tachometer pickup is connected.

Perform commissioning on the Drive Unit according to the instructions given in chapter 5.3 in the

PolymixerTM manual. Install the Male Bearing according to the installation instructions given in chapter 5.4 in the

PolymixerTM manual. Install the Impeller according to the installation instructions given in chapter 5.5 in the PolymixerTM

manual. Install the Drive Unit according to the installation instructions given in chapter 5.6 in the PolymixerTM

manual. Fill the vessel in which the mixer is installed with a preferred liquid media before running the mixer.

Do not exceed the operating limits for the PolymixerTM, see chapter 6.1 in the PolymixerTM manual.

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