6 rok \wro Ooty INSTRUCTION MANUAL HIGH PRESSURE HOMOGENIZER o”O OC ALFA-LAVAL Sepsrationstechnil’ GmbH, Subdivision S3, HOMOGENIZER DEFT. D- 2056 GLINOE/b. Hamburg, Telefon: 040/ 727 O1-1, Telex: 217 821 alfadINSTRUCTION MANUAL - BETRIEBSHANDBUCH CONTENTS General description of the ALFA-LAVAL high-pressure hosogenizer Preface to the Instruction Manual Identification Plates Section 1 TECHNICAL OATA Technical data of component parts and ancillaries Lubricants Recommendations Section 2 DESCRIPTION OF ASSEMBLIES General Arrangenent Oriving gear, crankcase O12 cooler in water cooling systen Fluid end / Pump block Condensate systen (with aseptic operation only) Frame vith panels Honogenizing systea Hydraulic Control Drive Section 3 HOw TO INSTALL THE HowOGENZZER Handling and positioning Dimensions of cooling system pipe connections Dimensions of pipe connections at punp cylinder black and homogenizer head Wiring diagram How to adjust the Solenoid Valve Section 4 INITIAL OPERATION OF HOMOGENIZER Check List for initial operation List for checks and work during the howogenizing process O11 Level checks Control of condensate unit (vith aseptic operation only) Shutdown procedure Operating troubles, Cause and Cure Section/Fage Vy 2, 5 a an ae 2B 2h 25 26 an 28 29 an we WS aft WS ah, Me, M3 4h M5 4/6 Wf? M8Tre: INSTRUCTION MANUAL - BETRIEBSHANDBUCH CONTENTS Section 5 MAINTENANCE Inspection and overhaul sheets Standard tools Special tools Torque specifications for bolts vith reduced shank How to reaove and fit the gauge on the puap cylinder block How to reaove and fit suction and pressure valves in cylinder block Dismantling and assenbling of honagenizer head ow to renove and fit punp piston to crosshead extension; Pull and fit crosshead sealing bush How to remove and fit piston bush How to check Y-belt tension; Remove and fit Wrbelts iow to pull and fit reduction gear / shaft nounted How to renove and fit belt pulleys with TAPER LOCK How to disnentle and assenble biguend bearings tow to disnantle and asseable the crankshaft How to pull and fit inner rings of crankshaft bearings How to fit STEP SEALS Punp piston seals assembly tow to fit Lip sealing rings in cylinder block Impact ring damage due to excessive service periods Wear patterns in sealing surfaces of suction and pressure valves Wear patterns in bigvend bearings Section 6 ‘SPARE PARTS Key to correct ordering of spare parts Specinen of how to prepare an order Lists of spare parts, by Assenblies OC aLFa-LAVAL Section/Pase 5/101, 1102, [1.3, [04 16 sf 513, 5/4 5/5 5/6 5/7 5/8 5/9 5/0 sin sie 518 sith SHS 516 si 58 519 5/0 sie 5lee on Pink sheets2 we. INSTRUCTION MANUAL - BETRIESSHANDBUCH OC ALFA-LAVAL GENEREL DESCRIPTION OF THE ALFA-LAVAL HIGH-PRESSURE HOMOGENIZER The ALFACLAVAL hosogenizing rachine is designed as an horizontal three-piston punpy ists 3 high-pressurey positive displacenent pusp delivering through honogenizing valves. : The high-pressure homogenizer is normally rounted on a frane enclosed by stainless steel panels. The electtic aro ce bell a the electrical ané hyoraulic systems (excegt the starter sviteh) are integral parts of the rachine, incorporated within the enclos{ng panels. The higheprescure homogenizer is used for dispersion in applications found in dairy, chesopharaazevtical and allied processes. The products to be processed are eaulsions (Liquid-in-liquid) or suspensions (solid particles in Tiquié) with ce af up to % ~ 20,000 aPas (e.P.) and a solids content of up to 48 - SOR in the dry phase (ToSs)e viscosit the tonogenizing process requires that the feed is adoqutely blended or aixed and thet pumping reqirenents are complied vithe The prinary purpose of bomagenizing is to bresk up the particles in suspension ané to ensure uniform distri- sation af particles to ieprove the physical stability of the product. Depending on the sature of the particles sec their readiness to brpak up, the separation into éifferent phases (sedinentation, crening-un cnagulation) i prverted or consiceraly delayed Highpressure heogenizing also serves to laflusnceviseosity, to enlarge the internal surface thus enhancing the chenical reaction rate, and to obtain cellular disintegration. Depending on nature and condition of the product as well as on the working pressure and tenperature prevailing during honogenization, particles of micron and sub-nicron size are obtainable. the ALTACLAVAL homogenizer is designed as unit-conposed system, allowing for 2 variety of differnt versions being available. These include one- and two-stage honogenizing valves, various punp piston dianeters and piston sealing systens, conical and ball valves (depending on the viscosity involved), and various types of material, etee ALL high-pressure hosogentzers can be operated aseptically, vith appropriate fittings and accessorie: Subsequent changes to other processing rates and pressures are feasible within the scope of the rodel concerned. High-pressure honogenizers incorporating positive displacenent puaps essentially require that the folloving operating conditions are raintained throughout, to ensure reliable and safe performance: and feed should be under pressure appropriate to the product e@ Feed rate should be according to the Layout of the eachine, Involved (HPHS), at all tines, including cleaning periods. nedissolved air aust be contained in the feed No free, ieee sor andfor cleaning agents. Further, product properties, operating and cleaning temperatures, cleaning agentsy quality of cooling watery qperation and aaintenance are factors that will greatly influsnce the service life of the plant and those anponent parts that are particularly subject to inherent vear. This anual is to aake you familiar vith your high-pressure homogenizer, ieee with its proper operation, naintenance and repair. Based on experience, ve also include useful hints on trouble shooting. aturally, sot every source of failure and every precautionary step can be enuneratets But with therough rovledge of the manual you vill be able to operate your Righ-pressure tonogenizer in 2 way that vill ensure satisfactory services It fs for this purpose that the manval vas issued, and we would reconend reading it fron tine to tines Tor further advice and inforaation please apply to your Local ALFACLAVAL company who will be at your service at all tines. pere INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC ALFA-LAVAL PREFACE TO THE INSTRUCTION MANUAL The manual is subdivided in such a way that, apart from giving general information, it also serves to supply advice on the installation, initial/ operation, maintenance and repair, and on ordering spare parts of the homogenizer and/or the high-pressure pump. SECTION 1, TECHNICAL DATA This section covers all the essential technical data of the homogenizing device, the high-pressure pump, its drive/driving gear, and lay out. It also includes cooling water and lubricants recommendations. SECTION 2, DESCRIPTION OF (CONSTRUCTION GROUPS) ASSEMBLIES This section describes all individual assemblies of the homogenizer. illustrate Photographs, diagrams and isometrically drawn control diagrams the text. SECTION 3, HOW TO INSTALL THE HOMOGENIZER installing of the homogenizer. This section describes the handling and ng connections of piping Proper mounting work is supported by diagrams show and electric cables. SECTION 4, INITIAL OPERATION This section contains check lists covering the various checks and working procedures required to ensure trouble-free operation. A list of possible failures and likely causes serves to find the sources of trouble. SECTION 5, MAINTENANCE AND REPAIR Dismantling and reassembling instructions, covering the various assemblies are given in this section. Under the heading of "Preliminary Work" imparative to ensure rational and time-saving mal required are listed to facilitate the procedure. The "Time Required" indicates manpower and the period of time necessary To carry out the work involved, e.g. those jobs are mentioned that are ntenance and repairs. Tools 2 nen vill require 0.6 h 0.6 hours, ive. 36 sinutes to do ‘the jobsrane: re: INSTRUCTION MANUAL - BETRIEBSHANDBUCH (OC aLra-LavaL These guiding values have been established by the MIM - method (METHODS TIME MEASUREMENT) . The "WORKING PROCEDURE" describes, step by step, the required maintenance and repairs to keep the homogenizer and/or high-pressure pump in satisfactory and serviceable condition. Diagrams and photographs serve to illustrate the various jobs. Numerals identifying the various component parts coincide with those mentioned in the descriptions. However, they are not identical with the "Pos.-No." in the spare parts list. SECTION 6, SPARE PARTS The spare parts (lists) of the various assemblies are numbered in ascending order and printed on pink paper. Lists consist of a diagram and parts list section. A specimen order form is inserted/as preface to the spare parts lists. A correctly prepared order form will ensure prompt delivery of the spares required. CC ara-LavaL SEARATINSTEDNIE OH D-2056 GLINDE />.Hasturg Dept.S 3-H (Technical Oocusentation)SECTION 1 Technical Data—_ OX aLra-LAVAL INSTRUCTION MANUAL - BETRIEBSHANDBUCH etal %. 134.217 1979 sweer, Tol 4 eng / ronogenizing "xd Particles content in product > | Specific gravity of density Specific gravity of viscosity + Joeratin vio. Spersting teres! tye vyrper of elungers wreter of oluncers ‘Stroke of slungers “yoo of alunger seals Type and size of valves valve springs Linder read-seals vaterial of Yominal_ wigth of su “ioninal wiath of delivery connec pressure a OF oMDse type of head Size af hovogenizing device Perbunon octrailed ‘aterial of read seal nese Type of acfustrent 9! ATEIALS Material uno rousing rial of cylinder block vee: SHINSTRUCTION MANUAL - BETRIEBSHANDBUCH CC aLra-LavaL 3 [rentecurer | totor type iftestive diareter ; - of 1 ~ telt pulley voltage noaive 010%" (4,) + 250 on Frequerey Fated power Effective diame 7 — of ¥ - belt pulley . _ funder of 3M near" (i) > 280. cn Type of on inetoilers fusber of belts :__4 piece Zz Type of ttelts SPB | tor seize ~anufaeturer Construction of sear ‘unter of stages Q [_2ecuction ratio 6,971 4g | tevolutions at outlet 70. F |_ Revolutions at outlet 280. § 6400 ‘gxinue torque output 6,3 [Vduantity of off ade of ofl LOBRICANTS. SECOMNENDATIONS vanufacturer Sigrens Yanufcturer Type 1LA 3070 4 AB Lge voltage 41S. 1 cetivery eating 1 Frequency 50 Jee steorassure bar [-sosinal current [0.73 2 | yorsfluid terpe | 40 oce & [Rating 025 “ Ling capacity | 76 _- 1 : [Ro 1305 afrin | total weight 9——_—____--_ | recunicay cara CXS aLra-LAVAL INSTRUCTION MANUAL - BETRIEBSHANDBUCH IGN A COOLING Pure HOUSING Construction of the oil cooler TOTAL CONSUMPTION OF COOLING *ATER aprons Consunption of cooling =ater 29ETO% Up C_ not steam condensate g tedium 20prOxe Un Consumption of cooling water uh (7 tS with hardness axe 10-12 dG : Stean required ap0rox. kg/h ‘at 140°C and a pressura of approxe 6 bar TOTAL CONSUMPTION OF STEAM aporoxs i @ | vetnod of Lubrication Splasn Ltrication Lubrication oil suantity 1 20,5 kg race of il Sear Lubricants recorcencation 2 cares £25 207001 oF MCU USER . ce Cay 12Sy Britis Haraness sersan savcress ( kg MaKe OX ALFA-LAVAL Hoi Stings Shackle Lifting Lugs Ball-type Spirit level Tous eeQurReo 4 Stings of equal Length 4 Shackles, 30 an bolt dia. 2 Spanners, adjustable - fi Spirit Level Crane, mobile WORKING PROCEDURE kK toh ie After the machine has been unpacked, it should be maved by mobile crane, ex- clusively. After the top cover of the machine has been removed, four slings of equal ength (2) are shackled (3) to the iftings Lugs (4) and hooked to the crane (1). The floor on which the machine is to be stalled should be level. Floor tiles should be protected by the use of steel tiles on which to rest the ball-type of the machine (5). fo evel up the machine, the spirit Level (6) should be placed on the cylinder block of the high-pressure pump ‘a8 shown in the opposite disgran. The all-type feet of the aachine may be setewed in or out, 25 required. an VERSTELLBEREICR ADAUSTABLE49 err: 2 of 4 05-02.01 SH re: INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC aLra-LavaL DIMENSIONS OF COOLING SYSTEM PIPE CONNECTIONS | crankcase Cooling coi = Pung cylinder bushes Return Line The cooling water connections are supplied with complete cutting ring pipe coupling: Plastic piping may be used for water Gelivery and return Lines up to connec tion "A" and fron conection "8 2"y resp. The ends of the plastic piping stould be strengthened by "reinforcing rings". If the aachine is equipped with 2 condensate sealing system, ‘the cooling coil (2) (for erarkcase oil cooling) is separately connected to the vater delivery line. Plastic piping ray also be used up to and from connections "A". The condensate return Line (4) from connection (B 2) should be steel piping dis- charging into a funnel (5)- STANLROHR AS TTOFF 08 STEEL FE austic ere Ny Schneidring, Schneidring/Cutting ring | Vorstarkerholse/Reinforcing ring ROHRABMESSUNGEN IN MILLIMETER / PIPE DIAMETER IN MILLIMETRE et = puscaTNeaY? STAHLROHRE_/ STEEL PIPES PUSTIC PIPES VERSTARER- ENGINE TYPE FISSENDURCHMESSER | INNENDURCHMESSER HLSE ‘AUSSENDURCHMESSER-OUTER DIAMETER OUTER DIAMETER | INNER DIAMETER we sau 20 a, = @ an 4, = te % = en [un Bx 4.5 SH a, = tm a= tem = 9am [veh Bat sil 30 @, = ta 4, = 2m a = 9am [vsh Wx 15 ‘HL 40 a, = ta 4: tm 4 = 9m [vsh x5 lable *¥ sheet and plastic piping, pipe couplings and reinforcing rings are avai from our service division.6/79 seer 3 of 4 rea.ne: 03-03.01 rere: Si INSTRUCTION MANUAL — BETRIEBSHANDBUCH CX aLra-LAVAL | OIMENSIONS OF PIPE CONNECTIONS AT PUMP CYLINOER 3 > BLOCK (PRODUCT INLET) AND HOMOGENIZER HEAD (DISCHARGE) z=] Ihe pre-pressured feed Line section el should run absolutely straight Ze within 9 distance of 79! 88 SI a ER Ee a VAG $ ILD DISCHARGE PIF uNOUT ay iseharge Line 6 = Product feed 33 > Safety valve 7 Fees pump (rotary) ge © pipe connection, Bs bratving valve <> discharge 9 = Pipe connection, te Initial pressure gauge punp cylinder block 5 = Thernoseter 10 = Freepressured fees Tine section MASCHINENTYE MACHINE TYPE dye | om (on) ee HEAD ZTYLINDERKOPF /C¥ TULAUF/FEED HOMOKOPF/HOMOGENTZER HEAD ABLAUE /DISCHARGE zouetncues TOU /TACHES (315 bar) Rn SH 25 (315 bar) " SH 30 (315 bar) * SH 40 (395 bar) a | Honogenizers are units incl ependend and therefore not descriped in Sone installation rules, however have to Upstrean. and downstream piping, i The precoressured feed line section (10) the cylinder block connection ( Tine suction (10) fron (9) to (7) ~ must initial feed pressu protection of the machine. To enable pips of the feed and discharge Lines to neet hygienic requirenents. feed and dischar (NPSH), a rotary pump (7) should be fitted in the feed Line (6). To i pressure and tenperature, a pressure gouge and thersoneter (ls + 5) should be fitted in the precpressured feed Line (40). If shut-off valves are fitted in the discharge line (1), a safety valve (2) shoulé be provided, for in different processes. Thus the installation of product conduits are process this chapter. be observed: Lines must be connected to the machine as follows: should run absolutely straight within a distance of 11m (approx. 5) from the vhole product feed line (6) - at least the part of the pre-pressured feed nection (9). To obtain Wicate initial feed have the sane size as the cylinder block pipe «i Lines to be drained and cleaned venting valves should be fitted at the Highest points of lines, and drain valves at the lovest points. Screw couplings should be used for the connection Dimensions of pipes and veld-on type taper nipples are shown in the above table. The velding edge angle should be 60°, The velding seans should be ground and polished, internally and externally, 373. INSTRUCTION MANUAL - BETRIEBSHANDBUCH CC aLFa-LavaL | How TO ADJUST THE SOLENOID VALVE Hey TO SIGNS = Screw driver Box spanner Solenoid valve 4 = Lock nut Disk 6 = Magnet core 7 = Resistor = Pressure gauge TOOL uIRED 1 Screw driver 4 Box spanner, 13 me ATTENTION The release pressure of the safety valve in ‘the nydraulic system should be set 10% higher than the control pressure of the solenoid valve! Zz ean. PRoceDU Loosen the Lock nut (4) with the box spanner (2), and the adjusting pin 2 few turns, counterclockwise, vith the screw oriver (1). Gewnschte Druckeinstel ung tow sviten on the control curcent. The valve disk (5) is row pulled tovards the eagnet core (6). tow sviten on the hydraulic systens Turn doun the a6justing pin slowly, clockwise, with the serev drivers Now the oil pressure will build up. Watch the pressure gauge (8). As the pin is being turned dovn further, the pressure suddenly breaks down, and the hand of the pressure gauge returns to Zerdy indicating that excess pressure has occured. tow turn the pin carefully counter-clockuise agein, antil the pressure gauge indicates the desired hoso- genizing pressure. Tighten up the Lock nut (4) whi position with the screw drivers tolding the pin in Tusa the resistor (@ 1") from naxinun to nininun position, as stowne approx. 5 bar. If pressure rops below 5 bar, the resistence of the trinner (Ran ae cgjusteent of the solemid valve repeates. ‘he operating pressure should then drop to see page 2/8) should be vee: SHL& INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC ALFA-LAVAL DREHR ICHTUNG DER HOCHORUCKPUMPE BZi HOMOGENIS IER’ NERKLARUNG. riebverk ufsteckgetriebe eilrienenscheibe 2a _——— rontseite 5 = Honogenisiervarrichtung Drehrichtung der Hochdruckpunpe = u 8 der Pfeilrichtung entsprechen ! ine Touchschnierungs die Uschmierung der Liegend angeorcneten Hochdruckpunpe i Um eine einwandfreie Schaierung aller Teile in Irichyerk (1) zu gevibrleisten ist es daher erforderlich, 6.8 die Orebrichtung der Hachdruckpunpe der Ffeilrichtung entsoricht. Cer "OOIE PFEIL" ist auf den tutsteckgetriebe (2) angebracht. Die Keileienenscheibe (3) nud bei Inbetrietnahne der Horogenisiersaschine unbedingt in Pfeilrichtung Laufen, (4) der Honogenisiermaschine stent. Also zum Betrachter hin, venn er auf der Front Orent die Keilrienenscheibe entgegen Pfeilrichtung, ist der elektrische Anschlu8 des Antriebsrotors unzupolen (Phasentausch).SECTION 4 Operationa INSTRUCTION MANUAL - BETRIEBSHANDBUCH (OC ALFA-LAVAL CHECK LIST FOR INITIAL OPERATION PRELIMINARY WORK AND CHECKS REQUIRED BEFORE THE MACHINE 1S STARTED UP ‘to initial operation of a newly installed homogenizer all conponent parts to vith the product involved should be degreased and cleaned. ned thoroughly. Prior cone into contact ALL pipework connected to the machine should also be e Checking the oil level in the crankcase of the high-pressure pump. In static condition, the oil should be Level vith the mark on the perspex housing covers Use high-grade Lubricating oils only! These should have positive denulsifying properties. Do not use oils with additives that will impart enulsifying tendencies. Refer also to "Lubricants Recommendations" in "Section 1" of this manual. weer: 1 of 8 @ Checking the ofl in the erankoase for condensate conte TF condensate has collected in the crankcasey this should be carefully drained by the sump drain cock. The period of ater separating from the oil ill depend on the tenperature and condition of the tile A period of 8 to 10 hours nay be required. reo.Ne: O1-01,01 @ Checking the oil level Se the hydraulic control systen of the homogenizing systen The ofl level in the papeontaiver shuld Sow beeen the fue panch rks on the dlp sticks Tr the ofl needs toping Uy use hyéralie ofl as recommended in "Section 1 ubriconts Recommendations " Set control valve of hydraulic control systen to TER0. (Two valves are provided with double~ stage homogenizer heads). With renote-controlled systens, the resistor should be set to "ainimun-pressure". (o-nin.) (crankcase). The water vill pass through the coil andy consecutively, through the punp cylinder bushes. With ASCPIIC OPERATION, the cooling coil is separately supplied vith water from mainse ree: SH,59 ean: 04-0201 oraw.no rere; SHL INSTRUCTION MANUAL ~ BETRIEBSHANDBUCH CHECK LIST FOR INITIAL OPERATION VARY WORK AND CHECKS REQUIRED BEFORE THE MACHINE 1S STARTED UP @ Starting up the nydraut fe contral system CC atra-LavaL Set control valve of hydraulic control systen to ZERO. Prior to initial operation and after every oil change the hydraulic oil punp should be vented to elininate priming difficulties or feeding air into the hydrau- ic cylinders of the honogenizer heads. The vert plug of the oil container should be loosened (not resoved) and the punp rotor switched one Then wait until bubble-free ofl will issue from the venting plug. Tighten up the plug and allow the hydraulic systen to run idle, i.e. pressurelesss Repeat this procedure by loosening the vent plug of ‘the honogenizing head (heads). WORK AND CHECK REQUIRED AFTER STARTING UP_THE HOMOGENIZER If the machine is operated under aseptic conditions, the general ops ing and checking jnstructions of the particular plant ~ into which the honagenizer has been integrated — will apply, e. Clesning of the product passage vays Release of product feed structions referring to 2 iS-plant. (VACU-TAEAM INSTANT STERILIZER). Prior to starting actual operation, all product circulating systers and product passage ways should be cleaned with the aid of a flushing fluid. Subsequently, the systen should be flushed liberally With hot water. Js the product is alloved to be fed into the nachine, the residual hot vater is forced out of the processing systen. Before the homogenizing pressure is finally adjusted, the high-pressure punp aust be operating free from air. In rast cases, the aic in the prescureless, Séling pusp will be displaced fron the punp block after 2 few pumping strokes. To nake sure that the purp has been properly de- aerated, the hydraulic pressure control valve should be closed slovly and 2 pressure of Less than 50 bar obtained. If the neetle of the pressure gauge an the punp cylinder block aoves erratically back and forth, this is due to the presence of air in the puno eylinders. Return the control valve to ZERO innediately. Subsequently, repeated closing and opening of the contra] valve will displace the air fron the individual cylinders without difficulty. Oo tat set the pressure higher than 50 bare Liquids, in- herently containing considerable anounts of gas, rust be de-gassed prior to being fed into the.honogenizel Otherwise, excessive shacks in the pump (with erratic gauge needle deflection ranging beyong 30 bar) nay occur. When the pressure gauge needle remains in static position, the final honogenizing pressure may be set as required.INSTRUCTION MANUAL - BETRIEBSHANDBUCH CC ALFA-LAVAL 49 CHECK LIST FOR INITIAL OPERATION PROCEDURE AND. CHECKS REGUERED-AFTER THE ACHING IS STARTED UP tow to adjust the honogenizing pressure ( Single-stage honagenizer_) The homogenizing pressure should correspond to the type and nature of the product being processed. Slowly turn the knob of the pressure control valve fron its ZERO position, in clockwise direction, until the desired operating pressure is indicated by the gauge on the pusp cylinder block. sect: 3 of 8 Pressure in excess of the naxinun permissible pressure, tte vnich the machine was designed and delivered, is absolutely inadnissible. Pressure fluctuations can be eliminated by short-tine ‘opening and closing of the hosogenizing system. If the fluctuations continue, the suction and delivery valves in the cylinder block stoulé be checked, Leaky pipevork may also be the cause of pressure fluctuations. How to adjust the honogenizing pressures (Bouble-stage honogenizer ) The horogenizing pressures should correspond to the type and nature of the product deing processed. Slowly turn the knob of the pressure valve controlling the second stage from its ZERO position, in clock direction, until the pressure gauge on the pune cylinder block indicates 2 pressure of aporox. 50 bar. ano: 04-05.01 Subsequently, slovly turn the knob of the pressure valve controlling the first stage fron its 7&0 position, in clockwise direction, until the desired ting pressure is indicated by the gauge on the punp cylinder block. Pressures in excess of tl pressure, to which the machine was designe is absolutely inadnissible. roxinun persissitle i delivered, Pressure fluctuations can be elininated by short-tine opening and closing of the horagenizing system. 1f tthe fluctuations continue, the pipework should be checked for leaks. However, defective suction and delivery valves in the punp cylinder block may be the cause of these pressure fluctuations. Lay seer: 4 of 8 4 rea.no: Dh-04.01 re: SHL INSTRUCTION MANUAL ~ BETRIEBSHANDBUCH OX ALFa-LAVAL LIST OF CHECKS ANO WORK DURING THE HOMOGENIZING PROCESS e fegular chucks on prossure and temperature of thy teee . Pressure gouge and thersoneter in the feed Line should be watched continually. Keep the temperature of the feed as constant as gossibles Pressure fluctuations, registered by the gavgty indicate irregular feed rate. Qc eset erin eo If required, the setting of the operating pressure should be adjusted with the aid of the knod on the pressure control valve. If the needle in the pressure gauge on the punp cylinder block swings back and forth, find out whether the flow rate of the feed is sufficient. Further, leaky pipe connections and defective suction and delivery valves in the puro cylinder block may be the cause of erratic deflections © settee cine sett ‘The tenperature of the water for crankcase oil cooling and punp piston lubrication will depend on ‘the flow rate of the water 14 the achine is operated under aseptic conditions, the general operating and checking instructions of the sleticutar plant, Jnto which the homogenizer has bean interatec, vill apply. The CONDENSER UNIT f1tked fo the achine in this instance requires adéitional checks. The instructions for the initial operation of the con ene syaten are contained in "Section 4" : " Control of steas pressure and condensate temperature " fegular checks should be nade of: Live steae pressure Stean pressure should be constantly kept at 6 - 7 bare fegular checks should be nace of: Condensate tenperature Condensate temperature, at the beginning of the honogenizing operation, should be 110° C at pressure of 0.5 dar. Pressure and tenperatire should be kept constant under any circunstances. erence cumini vara prtiny th eine foe ats a OF aporoxe 27 L/h. ( Ascertain flow rate by running Fi ate ne neti vv to capacity). Constant strong cloudiness or turbidity ects sgh ae Se ee Pee ae ster els en edb renee The cooling water flow rate should be approx. 100 1/he (Check by neans of neasuring vessel of known capacity). avasneer, 5 of 8 04-05.01 rrre: SH INSTRUCTION MANUAL - BETRIEBSHANDBUCH OX aLra-LavaL OIL LEVEL CHECKS DRIVE GEAR / CRANKCASE, REDUCT! ANO_HYDRAULIC SYSTEM il filler 1 Level fark Oil drain plug Dipstick seat Oil levels in the puap érive gear/erankcase (Fig.1)y in the reduction gear (Fig.2), and in the container of the hycraulic control system (Fig.3) should be checked every tine the machine is put into operation, ieee prior to starting upe 1) should be at the nark (2) in The oil the perspex cover. Also check whether any (condensate) has settled fron the oil. If soy the water must be carefully draii ‘through the cock in the sunp of the housings TAT TENT ONE er, and used of] drained vith it, must be collected in 3 suitable containers It aust mot be allowed to run into the sewage systems Top up the oil charge through the filler (1) nas been lost with the water A dipstick is provided in the gear bor (Fig.2, and the oil level should show between the purcked marks on the dipstick (2). Fresh oil is poured through the filler (1) in the top of the housing. Used oil is erained by opening the plug in the sunp of the gear box and should be collected in 2 suit- able contai esc HVORAULIC CONTROL_SYSTEM 3) is The hydraulic unit (Fic cated in the lover section af the fran. Dil check is by dipstick, as illustrated. the Gil level should show between the punches marks on the dip— stick (2)» fresh ofl is poured through the filler (1). Used ail is drained by opening the plug (5) and should be collec ted in a suitable container. Oil change periods in the oump drive / crankcase, reduction gear and hydraulic systen are mentioned in Section 5: " Maintenance”. For recommended oils refer to Section 1: "Technical Data". 415INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC aLra-LavaL = SHJT-DOWN PROCEDURE WORK REQUIRED PRIOR TO_AND AFTER SHUT=DOMN en product is changed or product feed is interrupted = Turn knob of pressure control valve in the 2 hydraulic control system to ZERO innedtately. ‘ (In double-stage hosogenizers two hydraulic i ‘ pressure control valves are fitted). a Prior to completion of the honogenizing process fesicual honogenized product should be by-passed into vaste tanke (Required only if honogenized and Co ror-honogenized product must be prevented fron ’ being inter-aixed. Turn knob of pressure control valve in the hydraulic i conteal syston slouly to ZERO. (in double-stage i honogenizers two hydraulic pressure control valves are fitted). If renote-control systens are provided, the resistor(s) should be set top, . e shutoff product feed Shut-off feed and run hot water into feed Lines Flush the punp cylinder block, the de-pressurized homogenizing systen and the product discharge Line nti] clear Liquid runs into waste tank. ALTERNATIVELY: Clean and sterilize the machine in conpliance vith local regulations. 2 2 g Shut off cooling vater Depending on the type of installation concerned, the shut-off valve in the delivery Line for the oil cooler in the drive gear/crankcase closes autonatic- ally, or aust be closed by hand. @ Switch off pover drive Carry out specified checks and maintenance, z479 veer. 8 of 8 neo-we: 4-08.01 ve: SH. 7) TROUBLE INSUFFICIENT OUTPUT ERRATIC VEBRATION OF GAUGE NEEDLE DESIRED HOMOGENIZING PRESSLRE NOT OBTAINED HOMOGENTZING PERFORMANCE UNSATISFACTORY INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC ALFA-LAVAL OPERATING TROUBLES CAUSE ANO CURE POSSIBLE CAUSES CURE [oes ee Faulty sealing surfaces of suction and delivery valves Suction and delivery valves sticking Suction Lines Leeking Drop in rapem. due to slipping V-belts Air in cylinder block Leaking suction and delivery valves Leaking piston seals Insufficient hydraulic pressure Honogenizing system leaking Homogenizing systen leaking Hydraulic pressure insufficient Pressure gauge on cylinder block does not work properly (Faulty indication) It should be considered that the efficiency of the honogenizer does not depend on the honoge- aizer system exclusively, but also on the composition of the product to be processed. If efficiency drops, conpared with initial performance, the product should be checked a5 vell for any Likely changes in composition. Valve in by-pass Line is partly or fully opened. ton hosogenized and honogenized product is abxod. Reegrind or replace valves Clean valves and valve guides Tighten up pipe connections and / or replace defective seals Tension V-belts De-aerate cylinders Re-grind valves or replace Replace seals Check hydraulic pressure Contral valve Re-grind cone and cone seats replace if required Re-grind cone and cone seat. Replace if required Check pressure control valves Check hydraulic control system Check gauge and replace if required Close valveSECTION 5 Maintenance479 a ¢ sucrr: 1 of 22 5-01.01 st re, HAUL SHEE | INSPECTION ANO_O wee: SHL Assemauy s_ 100 Inspection and overhaul Code = Inspection 5 = Servicing C = Oil changes In grease applications: Replenish or change grease if required. 0 = Overhaul General overhaul (ALFAALAVAL recosnend: Cverhau} to de carried out under supervision of ALIA-LAVAL engineer) SY = With nev machine s+) = After every overhaul Standard node] DRIVE GeAR/ CRANKCASE ORIVE GEAR/CRANKCASE REDUCTION GEAR Check oil Level 4/5 Oi} change aly 45 General overhaul 5/11,5/%2 Vobelt tension ft woroe Replenish grease e+) = Machine equipped for aseptic operation WT = Wear part (renev) TODS in hours ls stv TeNsnce ~ T INSTRUCTION 2! alel al sl 2 acre rier to Seton i ily iI 7 > spare parts lists eal alle (pink sheets) Check ofl Level 45 O11 change aly 4S wT | General overhaul hy 4155/9955 5115,5/16, 5/24 Every 20.000 hours plate refers) 2500 — 2900 72,000 a aeueer. 1 of 22 ne0-no; 05-0101 sat INSTRUCTION MANUAL - BETRIEBSHANDBUCH ee SHE Ie ASSEMBLY + 200 ASSEMBLY = 200 Inspection and overhaul Code Inspection servicing ‘ange. In grease applications: feplenish or change grease if requireds Wwerhaul jeneral overhaul (AUTACLAVAL recommend: Overhaul to be carried out under supervision fALFARLAVAL engineer. ) Jith new sachine fter every overhaul standard ode] fachine equipped for aseptic operation INSPECTION AND OVERHAUL SHEE1 re FLuTares ear part (renew) OPERATING 18 HOURS — aNTEAANCe . INSTRUCTION 2 3 3|3 2] gle] al sl 2l8 refer to section | 2] S| R] B) SY] SLE = cine PART fer te Sectlon? | Hil Goin sheets) | ¢| S| 8] B| 2] 8/8 crLiNoeR sLOcK wat] Suction valves 2)hy Alby 5/54 51% ial 5/20 ale wat | Pressure valves 2fhy 418, 515y 51? ryt 5(2 uve PISTONS Pistons 4/8, 5/70 ~ vat | Piston bush 4/8, 5/70, 5/17 a vat | PRESSURE cause 4/8, 5f6 a |_| Ria9 sneer 1 of 2 479 nec-no; 05-07.01 ree INSPECTION AND OVERHAUL S! wer :SHL TVPENGiSS- 1 L assmsEnaEREOmOneees meee ASSEMBLY £205, vicing it changes in grease applications: Replenish or change grease if requireée Overhaul General overhasl (ALTAALAVAL recomsendt Qverhoul to be carrieé out under supervision af ALFArLAYAL engineer») YF With new aachine After every overhaul Standard rodel Machine equipped for aseptic operation CONDENSATE. SYSTEM condense Jacket and cofl 25 suGat GLASS var | Glass and sealings 25 PRESSURE GAUGE 25 weamowe reg 25 soueyonD_vAL 25 25 SHUT-OFF VALVES wear part (renew) OPERATING PERLODS _—+ ase olel ele rstRUCTTON | 2| 2/2 er to Section 5 alee = MACHINE PART eel 1] | | | = spare parts lists eels (pink sheets) | 2| 818E a rec-no: 05-0201 SH INSTRUCTION MANUAL - BETRIEBSHANDBUCH INSPECTION ANO OVERHAUL SHEET iN wee: SHL es SHE__ “4 assevaiy = 500 inspection and overhaul Code Inspection change. In grease applications: feplenish or change grease if required. 0 = Overhaul AL = General overhaul CGUACLAVAL recommend: Gverhaul to be carried out under supervision of ALFAHLAVAL engineer.) SY = With new machine **) = After every overhaul +) = Standard sodel as) = Machine equipped for aseptic operation WAl = Wear part (renew) HOMOSENTZING evice 1: s c fopenarinG Pe#I00S IN HOURS a — | MAINTENANCE rnsTauct refer to Section 5 and spare parts lists (pink sheets) -——+—_ TT TTT YT I HOMOGENIZER HEAD ACHING PART 2h — daily 700 —— 750 200 — 1600 2000 —— 2300 2500 —— 2900 5500 — 5800 200 —— 250 Impact ring 2/7, 4/8 5/8 Service life Cone 2/7, 4/8, 5/8 depends on 1 Cone seat 2/7, 4/8, 5/8 praduct involved. = war | Housing seals 27, 4/8, 5/8 | Temi is processes AYORAULIC PISTON WaT | Piston seals 5/8“y sueer 1 of 22 79 ec-Mo; 0501.01 st INSPECTION AND OVERHAUL SHEE wer: SHE wee:SHb assema.y : 50+ Inspection and overhaul Code inspection Servicing 1 change. In grease applications: Replenish or change grease if required. Overhaul General. overhaul CALFALAVAL recomend: WAL engineer.) s+) = After every overhaul +) = Standard model +) = Machine equipped for aseptic operation WAT = Kear part (renew) HYORAULIC CONTROL sysToH (OPERATING PERIODS INSTRUCTION refer to Section 5 = MACHINE PART = ane a soare parts lists (pink sheets) HYORRULIC _UNIT Check oil Level i] change Clean ofl filter Pressure reducing valve Safety valve - a — wily 400 —— 500 700 —— 750 c c a5-02.01 sit INSTRUCTION MANUAL - BETRIEBSHANDBUCH RMA TOOLS CENMULSCALIISSEL SINGLE OPEN END SPANNER DOPPELMAULSCHLUSSEL DOUBLE OPEN END SPARKER DOPPELRINGSCHLUSSEL DOUBLE HEX. RING SPANNER (offset pattern) TINNENSECHSKANT-SCHLUSSEL ALLEN HEAD WRENCH STECSCHUUSSEL-LINSATZ FHEAAGON SOCKET reouzieRsticn ADAPTOR WSCHALTHNARRE RATCHET DREHMOMENTEN-SCHLUSSEL TORQUE WRENCH HAKENSCHLUSSEL HOOK SPANNER ‘SCHRAUBENOREHER ‘SCREW DRIVER TINNENAUS ZIEHER INTERNAL PULLER oe TOO BAR CC aLra-LavaL SHY 13 am, SH 22 me Wx Bam WH 7x Bm 5, 6, 10 na SK 2h am, SW 36 m0 sft = 1/2" ae SW = Wrench opening » 8 120-150 45 mm § x 320 me Lang/longINSTRUCTION MANUAL - BETRIEBSHANDBUCH OC ALFa-LAVAL Wn © SPEZIAL WERKZEUGE SPECIAL TOOLS VENTTLKEGEL ~ HEBEVORRICHTUNG VALVE CONE LIFTING CLAMP 3 of 22 hl VENTILKUGEL ~ SAUGHEBER VALVE BALL SUCTION CUP VENTILNAFIG ~ HEBEVORRICHTUNG VALVE CAGE LIFTING CLAMP 5-03.01 AUSZIEHVORRICHTUNG FUR XOLBENBUCHSE PULLER DEVICE FOR PISTON BUSH CNORUCKVORRICHTUNG FUR KOLBENBUCHSE PRESS@IN DEVICE FOR PISTON BUSH MONTAGEVORRICHTUNG FUR HOMOGENIS IERKOPF - OTCATUNG POUNTING DEVICE FOR HOMOGEMISING HEAD SEAL sit“wy Wa 4 of 22 5-04.01 ye: HL. INSTRUCTION MANUAL - BETRIEBSHANDBUCH SPEZIAL WERKZCUGE SPECIAL TOOLS @: @® = Konbinier OC aLra-LavaL auszTeHvoRRICHTUNG FUR VENTILSIIZE PULLER DEVICE FOR VALVE SEATS AUSZIEHVORRICHTUNG FUR KREUZKOPF -DICHTUNGSBUCHSE PULLER DEVICE FOR CROSS HEAD SEALING BUSH CINZTEWVORRICHTUNG FUR KREUZKOPF -DICHTUNGSBUCHSE MOUNTING DEVICE FOR CROSS HEAD SEALING BUSH ABLIEHVORRICHTUNG FUR AUFSTECKGE TRIEBE PULLER DEVICE FOR ORIVING GEAR ‘Aue ZEEHVORRICHTUNG FUR AUFSTECKGETRIESE MOUNTING DEVICE FOR DRIVING GEAR +t verwendbare Werkzeugteile / Tool cosponents for aultiple usessucer, 5 of 2 6/79 5-05.01 SH INSTRUCTION MANUAL - BETRIEBSHANDBUCH TORQUE SPECIFICATIONS FOR BOLTS WITH REDUCEO SHANK ATTENTION If the specified torque has inadvertently been exceeded, the nut should be completely unscrewed and re-tightened as required. The bolt should not be Left n overestressed condi under any circunstay LOCATION OF BOLTS CC aLra-LavaL Kev 10 Pointer and torque scale Torque wrench Nuts for bolts with reduced shank are tightened up by applying 2 torque wrench. Nuts need not be secured after ‘the bolts have been tensioned to the specified torque. e bolts are specified in The torque to be applied to tt the Toble below If the specifies torque applied to a bolt is to be checked, the nut stould be unsereved, and tightened up again by torque wrench (2), as specified. Prior to tightening, the contact surfaces of the ruts should be cleaned and rubbed filnly with MOLYCOTE ® (grey). The tuts should then be turned down by handy thund-tight. Then aoply torque wrench and tension nuts until the pointer (1) Indicates the specified torque on the scales NACHINE PART Lacarron =T=1-1=l-1-]-l-]-]= OTS eg} s]s] al Rye] s CHLINOE HLOCK cover eo} 80] 120] 180] 0} 340 Torques expressed in NEVION METRE cue Hx 1 haw) bp io PUMP HOUSING. 360] 360] 360] 360] 530] 530 wali 1ANGL_ ; sw] wo] v0] s60] an] 14 CYLINDEA BLOCK i low-pressure machine BIG-UND SLARINGS, A= Highepressure machine CONNECTING RODS 50] 50} 50} 50] 130) 130 HOMDGENTEER HEAD TO CYLINDER BLOCK qh0} 140] THO} 740] 240] 240 | 610] 610 al3 5179 sneer, 6 of 22 O54 vee: SH INSTRUCTION MANUAL - BETRIEBSHANDBUCH Of aLra-LavaL HOW TO REMOVE AND FIT THE GAUGE ON THE CYLING whi cover from the di place the split ring in nd then the gouge and that all components re rub with MOLYCOTE Cor position. Apply torque wrench to nuts and t: specifications " in Section 5). fenove the four nuts of bolts with reduced shank (2) from flange (7) with the 2id of the tor and 130 ze (7) fron eylinde flange and caver plates R = and insert them in the grooves of the fiange. Renove protective gheagn of the new gauge. Push gauge socket through the cover plate and N teplace nuts thurbetight. Correct the fit of the gauge to obtain proper reading linger block jolts with reduced shank Forque wrench split ring cess on gauge socket 5 REQUIRED Torque wrench Hexagon socket Sw 24 sm Adapt 3/4" to 1/2" er sovycoie® (vnite) worvcore®C grey) PREPARATORY WORK De-pressurize the hosogenizing system and ‘ose shut-off valves in product feed and discharge Lines. Suitch off power and secure against unauthorized handling. Shut} off cooling water supply and shut-down condenser system, if fitted. If renote- ) systen is installed, renove lead from gauge. 0.6 h Time E9UIRED 13 Locally, Defective gauges should not de repel but forvarded to manufacturers for © rrench (3)e Lift gouge (10) together with cover (9) ck (Te Pull flange fro gauge socket. Push wards gauge and remove split ring (4). The gauge can now be the bore in the flanges tow renove O-ring (8) and O-ring (6) seans of seriber. Thoroughly clean the split eingy new Derings (6 + 8) sparingly with MOLYCOTE - front of the recess (5) in the gauge socket. First slip the flange fe cover plate on to the bolts with the reduced shaft. Make sure in perfect alignnent. Clean contact surfaces of ruts and sparingly nten up, crosswise, to specified torque. (Refer to" TorqueA INSTRUCTION MANUAL - BETRIEBSHANDBUCH OX ALFA-LAVAL 7) | How TO REMOVE AND FIT SUCTION AND PRESSURE VALVES IN CYLINDER 8LOCK ey 10_SuGNs eT e cage Lifter 6 = Cylinder block linen disrant] ing 2 = Valve cage 7 = Internal puller take note of 3 Valve cone lifter 8 = Valve seat lence, location 4 = Valve cone 9 = Seal and nunber of 5 = Valve seat puller "0 = Noteh for cylinder pin Ea ooLs REQUIRED ~ TTorque wrench 4 Internal puller 8 41 Hexagon socket SW 30mm 1 Valve cage L = 1 Adaptor 3/4" to 1/2" 4 Valve cone Lifter 11 Set of spamers, 30-46 an 1 Tonay bar 5 4 Screw driver 11 Hamer handle 3 41 Valve seat puller NoLYcoTe ( grey) Grinding conpound MOLYCOTE (white) PREPARATORY WORK De-pressurize honogenizing system and close shut-off valves in product feed and cischarge lines. Svitch off power and secure ‘against unauthorized handling. Shut-off cooling water supaly ‘and shut-down condenser systen, if fitted. PROCEDURE 30h TIME REQUIRED (per unit) fenove auts fron bolts with reduced shank of the cylinder co- ver vith the aid of the torque wrench, LiTt cylinder cover off the eylinder block (6), use screw driver to assist lifting, if required. Apply valve cage lifter (1) and Lift the pressure valve cage (2) out of the bore of the cylinder Blocks Apply valve cone lifter (3) and Lift the valve spring and valve cone (4) out of the valve sest (8). Apply internal puller (7) together vith valve seat puller (5) and pull out the valve seat. Then repeat the procedure - in the sane sequence - to disrantle suction valve. {lean all components thoroughly and check for danages (Valve springs are particularly ingortant!). Replace defective parts. Slight pressure arks in the contact surfaces of valve seats sould be ground vith fine grinding cospound. If one or the other valve seat or valve cone has to The sealing be replaced, the new parts should be ground-in thorouat tings of the cylinder cover and valve seats mst be renewed, always! Any deposits on the valve seat bore in the cylinder block should be renoved: (grind lightly). fub all parts, including the valve seat eres sparingly with MALACOTC@D (shite). Refit all parts. Valve seats should be driven hoe with 2 hanner handle. Oo sot forget the valve Springs! CAUTION : The spring Toad may push uo the valve cages (2). en fitting the cylinder cover, particular care should be taken that the cylinder ylinder cover will fit precisely into the natch (10) of the pressure valve cages Clean contact surfaces of the bolt nuts and rub then sparingly with MOL YCOTE®@ (grey). Tighten up nuts of belts with reduced shank crosswise, to the specified torques (Refer to "Torque specifications" in Section 5.) 1f leakage occurs at the cy= Linder cover, do not tighten up the nuts any further, but change the seal in the cylinder cover. (Refer to "Wow to fit Lip sealing rings in cylinder block", Section 5.) Suction-valve seating surface in cylinder block to be [sparingly brushed with LOCTITE@surface sealing compound 5721 sree: SH ETTa gz INSTRUCTION MANUAL - BETRIEBSHANDBUCH OX ALFA-LAVAL DISMANTLING AND ASSEMBLING OF HOMOGENIZER HEAD. § a for nut torques refer to "Torque specifications" in Section 5 2 er To sioas 3 Mey To stcis & 1 = Studs (Product cise i 2 = Hydraulic control piston 3 3 = Centering ring i 4 = Oring 5 = Seat 6 = Studs, cy 0. REQUIRED 7 = Inpact 8 = Cone 1 Torque wrench 4 Hexagon socket ¥ 24 am Pees 1 Adaptor 3/4" to 1/2" 7 “ 1 Allen hea wrench M6 sagan That PREPARATORY WORK 1 Piece of hardwood Ue-pressurize tonogenizing systen. Close shut-off wo yeote B(hite) valves in product feed and discharge lines. Swit off pover and secure against unauthorized handl ing. 7 Shut-off cooling wa y and shut-down conden i cer systen, if fitted. Switch off hydraulic contral g systen, 4.8 time accuteeo Disconnect hyéraulic Line fron cylinder of the control piston (2)» Catch up hydraulic ofl in suitable container. Renove nuts fron studs (1). Rerove product discharge flange from homogenizer head. Screw off housing (9) from cylinder block. Pull the seat (5), the inpact ring (7), and the cone (8) out of the housing of the honogenizer head. In case of difficulty, drive out the cone frox the hydraulic control piston end (2), applying gentle knocks vith 1 and hardwood. Now renove O-ring (4) and back-up ring fron the housing. Clean all par hly. Check seaty inpact ring and cone for danages. (Also refer to "Wear pheronena in inpact rings, due to excessive service periods" in Section 5 : Maintenances) Fit new spares in exchange of wora arts. Seals should alvays be reneved. Rub all parts sparingly with MOLYCOTC@ (white) and insert into the horogenizer head. Check hydraulic controt piston (2) for leakse If oil leaks fron hydraulic piston, the centering ring (3) should be taken up and the piston pulled. Renew piston quige rings and STEP SEAL. The rod guide in the centering ring stould also be changed, Screw the honogenizer head, together vith-the hydraulic control piston, onto the eylinder block. Tighten up cop nuts, crosswise, vith torque wench. RE-fit product discharge flange. Connect hydraulic Line to | cylinder of control piston. Bleed hydraulic systen through vent screw (10). The oil must flow out freevfron g | aie bubbles.5I9 05-09.01 oweer, 9 of 22 Rano vee: SH INSTRUCTION MANUAL - BETRIEBSHANDBUCH (OX aLra-LavaL HOW TO REMOVE AND FIT PUMP PIST( TO CROSSHEAD EXTENSION PULL_AND FIT CROSSHEAD SEALING BUSH KEVAWOISIGS Connecting bush Split ring = Piston Hexe screw with cup spring washer = Conbined puller and nounting device for crosshead sealing bush Crosshead sealing bush Fixing screw 2 3 4 5 8B = Grooved sealing ring 9 = O-ring 10 = Crosshead extension Toous REQUIRED 1 Set of spanners 14 - 24 nm 1 Allen head wrench 6 mm vacrc0T€B(orey) PREPARATORY WORK De-pressurize the hosogenizing systen. Close shut-off valves in product feed and distharge lines. Switch off power and secure ageinst unauthorized handlinge Shut-off cooling water and shut-down the condenser unit. Remove covers Screw out fixing screw (7). PROCEDURE Re hh TIME REQUIRED (per unit) Rerove the three screws with cup sorings (4) fron the crosshead extension (10). Slip conecting bush (1) ovar piston (3). Renove split ring (2) and push piston into the ey- Linder block. Fit puller (5) vith two M6 ~ screws to the crosshead sealing bush (6) and = by turning the crankshaft ~ pull the seal- ing bush together with the crossnesd exten- sion (10) out of the punp drive housing (crankcase). Clean all parts thoroughly. Al~ ways renev defective seals (8 + 9). Aub seals with MOLYCOTE. Revers the puller and fit to crosshead extension with three screws. By turning the crankshaft, the four studs in the device vill force the crosshead sealing bush (6) back into the punp drive housing. Renove mounting device and secure the seal~ ing bush with the fixing screv (7)x Connect piston (3) to crosshead extension (10)~ Do tot forget to fit the split ring (2). Firaly tighten up the sorexs (vith spring washers) (4). The cup springs shoulé be compressed. Finally turn the machine to ascertain proper alignnent and seooth running.a sweer, 10 of 22 e0.No si INSTRUCTION MANUAL - BETRIEBSHANDBUCH (CX aLra-LavaL HOW TO REMOVE AND FIT PISTON BUSH Puller for piston bush rust, m Cylinder pin and bores ering and back-up ring o-ring Piston bush Press~in device fo Crosshead extension Piston connection Piston Hook spanner Toms acura TSet ring spaners ‘Hook spanner B 120 - 130 4 puller 4 Presswin device worvcote ® (white) bust Re oy woRk De-pressurize the homogenizing system 4 Close shut-off valves in product feed and discharge Lines. Switch off pover and secure against unauthorized handl-| ing. Shut-off cooling water and shut= down condenser unit, if fitted. PROCEDU 0.5 fh TIME REQUIRED (per unit) Renove piston connection (9) from crosstead extension (8). Insert puller (1) into the groove of the piston tush (6) in front of the thrust nut (2). tow screv off the thrust nut by book spanner (11), thus pulling the piston tush out of the cylinder bush. Shift crosstead extension to outer dead cen- tre and renove thrust nut. Pull piston (10) together with piston bush out of the eyLinder bushy as illustrated. Ree header ring and spring from the der bushe ean all parts thoroughly and check for defects. Alvays renew all seals! (Refer to" How fit SIEP SEALS " in Section 5 (5/77). Rub all parts spar- ingly with MOLYCOTC@(white). Slip piston bush and seals anto the piston and insert into cylinder bush. Turn piston bush tornake sure that the cylinder pln fits precisely inte the bore (3)e.Sttp preeeein device (1) ovar YWw giston and fit thrust mute fave jem santfoy tue for ety pan busts tte the gages the thread on the cylinder Bush the piston and firsly tighten up the thrust nut. Connect piston with the eresshead extension turn the rachine to ascertain proper alignaent and sacoth runninge Check cooling water syste pressure) for leks. ply ftom bot TyLiniar tush, an tho thrust ut an emve the pressein devige trom Finally uncer© sueer. 11 of 22 ans o5-11,01 ree: SHL INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC aLFa-LAVAL HOW TO CHECK V-BELT TENSION REMOVE ANO FIT V BELTS Key 10. SIGKS ulley, gear shaft ulley, motor rey driver tee) ruler lorque support ToOLs REQUIRED 4 Set of spanners 2b - 55 em 1 Screw driver with vide and blunt edge 4 Steel ruler Excessive heating up, excessive vibration of Vobelts, and noisy running are due to insufficient tension in the belts. Therefore, the Vebelt drive should be checked at regular intervals. HSABSTAND PREPARATORY WORK CENTER DISTANCE A Switch off power and secure against unauthorized handling. Renove enclosing panel. 4.0 Wh TIME REQUIRED uve OF THING 1 vetre center distance| lvill correspond to @ belt depressio' aparoxe 16 am Press serew driver (3) at right angle, vith aoderate force, against ane Vbelt, ine. in the aidéle between staft centres, and measure the eoressiony in relation to the ceighbouring belt, with the steel ruler (4). Hepeat vith all the belts of the drives If the tension of the pelts ig not in compliance vith the opposite RULE OF THUG, the drive should be adjusted as follows: Loosen the lock ut of the torque support ag specified. Then tighten up and lock. If Vebelts aust be reneved, the torque support should be loosened. (6) and turn the adjusting nut up until the \ebelt drive is tensioned nay be necessary to loosen the rotor at NEVER APPLY ANY LEVERAGE TO WES! hen the belts are in Tighten up the aotor on its above. belts are fitted in the pulley grooves WITHOUT FORC its base to ensure that THE BELTS BY USING A SCREW DRIVER OR SIMILAR TOOL TO FORCE BELTS INTO PULLEY position, the two pulleys (1 + 2) should be aligned with the aid of a steel rulers base plate, crosswise, and adjust V-belt tension by means of the torque support, as went ence proved that the drive requires re~ tt initial elongation as well Watch the V-belt drive during the initial hours of operation. Experi tensioning on conpletion of approx. 30 minutes at operating speed. The pernanent ‘as the apparent slack, due to bedding-dovn in the pulley graoves, are thus taken ups5-12.07 swrer: 12 of 22 Ht Linder cover (1) and in the valve seats (6 + 8) should also be abso- lutely clears Rub cylinder bores and all sealing elenents Gy by 9) soaringly with MOL YCOTE @ (white). The contact surface, in the cylinder block, for the seat (8) should be brushed vith a thin coat of LOCTITE sealing compound. "572". nen fitting the valve assenblies, the arrangenent of seals shown in the izaran should be strictly adhered to» seats should be driven hoe vith the aid of 2 hamer tandle or sylon drift. The Lips of seals must rat be d when replacing the cylinder cover (1)y the dovel pin (10) aust fit precisely into the notch of the pressure valve cage (5 Tighten vp the cup nuts of the cy- Linder cover to the specified torque. If any Leakage should occur at the €)- Linder cover, do rot tighten up the cup nuts any further, but change the seals (5 + 4) in the cylinder covers (also refer to the chapters "How to Tenove ané fit suction ané pressure valves in eylinder block", in Section 5, and "Torque specifications for ex- tension bolts", also in Section 5. ery519 @ ssueer. 19 of 22 rea:no: 05-19.01 rvre: SL INSTRUCTION MANUAL - BETRIEBSHANDBUCH CX aLra-LavaL IMPACT RING OAMAGE OUE TO RVICE PERIODS HEY TO SIGNS Inpact ring Yormal cavitat Deep cavitation groove Hono device se: Hono device co Conplete deterioration of ona device cone by cavitation n grooves: Pressure and fiow rate of the product involved will determine the service life of the IMPACT RING in the honogenizer head. The product forced through the annulus forned by the Aono device cone and its seat (5 + 4) will depressurize abruptly. The sudden pressure drop will cause forsation of vapour bubbles, which will attack the inpact ring material and erode. A so-called cavitation groove will fora (2), Within 2 certain service period the cavitation can be Linited to the area of the inpect ring. ine service Life of the inpact ring nay be extended if regular checks are carried out to ascertain the condition of the rings If the cavitation groove (2) has obtained a depth of approx ‘Tea the ring should be cisnantled, reversed and placed back into the horogenizer head, for another service period. 05 DAMAGE QUE 10_ 6x SERVICE PER If the nornal service life of an inpact ring is exceeded, or if the ring has not been reversed at the proper tine, deep cavita- isl can deteriorate the impact ring ‘then extend to the hono device seat tion grooves (3) The erosions in the ma completely. Cavitation wi and the homo device cone (4 + 5) itself. ATTENTION Regular checks of the Sepact ring will pre= vent cost and conse= darage. 5/206/79 sueer, 20 of 22 5-20.01 ea.ne Ht mi INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC aLFa-LavaL WEAR PATTERNS IN CONTACT SURFACES EY TO SIONS falve cone lornal wear pattern iting formation in contact surface ‘low through aarks" in valve cone and seat The service life of suction and pressure valves vill greatly depend on the product involved. Re- gular checks of valves are therefore indispensable. NORMAL WEAR PATTERN (2) The normal wear pattern on valy shovs 2 dull metallic finish, On completion of approx. 100 hours of operation the contact surface vill show 2 slight wear mark on its entire circum ference. This polished inpressi norzale The valve does rot require re-grinding, PITTING FORMATION (3) Pittings are hamered by solids contained in the product to be homogenized. They are the cause of "Blow through aarks” in the valve cone and seat. The nortal wear pattern can be restored by grinding. BLOW THROUGH MARKS IN VALVE CONE AND SEAT (4) Product deposits on sporadic spots of the valve surface have prevented the valve from properly. The product nas "blown through" and eroded the valve cone and seat across the entire vviath of the contact surfaces. Failure of carrying out regular checks and mainte nance will cause danage of this nature. The valve (seat and cone) must de exchanged. ATTENTION Regular checks of the inpact ring vill pre vent cost and conse quential damage.5179 95-21.01 sneer: 21 of 22 onan vee: SH. INSTRUCTION MANUAL - BETRIEBSHANDBUCH WEAR PA RNS_IN BIG-END BEARINGS SCORINGS IN THE BEARING MJ Scorings in the surface of bearing netal are an indication of contasination of Lubricating oil. CRESCENT-SHAPED PATTERNS IN THE VICINITY OF BEARING SHELL JOINTS fearing netal surface ranges fron rough to scar Like of pitted appearance, indicating that corrosion has occurred. WEAR MARK ON THE EDGE OF BEARING SHELL Squeezed or wiped bearing netal at the edge of the bearing shell indicates that the bearing is out of alignnent. DISCOLOURATION OF BEARING SURFACE Extensive discolouration of bearing metal is an indication of insufficient clearance and oil starvation. "TONGUE TIP" FORMATION ON SEARING METAL uring the running-in period of bearings slight wipings of ‘tongue=tip appearance may occur in the bearing surface. These tongue tips! are of no ieportance. After @ certain period of bedding in these phenonena vill disappear and the surface becone sooth again. WORK MARKS ON THE FACES OF BEARING SHELL JOINTS Hanmer sarks in the faces of the shell joints indicate ‘that the bearing shells have not been pre-stressed adequately.SECTION 6 Spare Partsneato: 06-01. ve: SHL INSTRUCTION MANUAL ~ BETRIEBSHANDBUCH CC ALFA-LAVAL KEY TO CORRECT ORDERING OF _SFARE PARTS SPECIMEN ORDER. Order for spare parts In the folloving spare parts Lists all conponent parts of the homogenizer concerned are enunerated and shown in the acconpanying dizorans. When ordering spares, you should observe the following point Please nake sure that the serial nurber on the identification plate of your machine is identical with the nunber appearing on the identification plate reproduced in this manual Find the "Position No." of the iter required in the respective diagram and add the corresponding: TOENTITY NUMBER DESIGNATION of the part, and QUNTITY required. To ensure prompt delivery, address your order to the ALFA-LAVAL COMPANY or to the ALFA=LAVAL_ AGENCY in your country. tp not forget to mention shipping instructions. required in the homogenizer Type: xxx Serial number: xxx Please forward by air freight: POS.-NO. IDENTITY-NO. DESIGNATION QUANTITY 200-02 4 722 1095-01 Bush 1 200-06 4 600 0000-01 Spring 1 200-13 4 722 1180-01 PISTON GUIDE RING 1 200-16 4 302 0491-04 O-ring 1 200-17 4 302 0490-94 O-ring 1 200-18 4 302 0491-05 1(3 naw he: INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC ALFa-LAVAL ASSEMBLY GROUPS - GENERAL ARRANGEMENT The ALFA-LAVAL Honogenizer, type SHL, consists of the folloving asseably groups: Group 700 ELECTRICAL coNTROL (terminal box) not shown £ Group 100 DRIVING GEAR Group 200 FLUID END Group 600 ORIE Group 504 HYDRAULIC CONTROL Group 205 COMDENSAT UNIT Cealy by ase operation). Group 700 ELECTRICAL conFROL Group 400 FRAME 0 PANELS. HOMOGENTZING evice Assembly groups not shown in the ccut-avay view are illustrated and e explained in the section DESCRIPTION OF ASSEMBLY GROUPS.CC ALFA-LAVAL wi INSTRUCTION MANUAL — 05 won 01-16 101-31 101-16 m3 HOUSING lo! GEKAUSE 101-54 0-15 ath tog 101-50 101-05 101-20 101-26 101-30 BETRIEBSHANDBUCH 101-19 4o1-0h 2 WS "Baan, 9 onmwuO 0060 22d 4 20°UrLOL PeN“oay v eee ‘aaa£0. 6/79 1of 2 107-01.03 REA.No.: 4 722 0500 type: SH 25 INSTRUCTION MANUAL - BETRIEBSHANDBUCH LIST OF SPARE PARTS ERSATZTEILLISTE OC aLra-LAVAL CONSTR. ~GROUP, paucruere. —* 101 1 2 3 4 5 6 1 8 = |. we DENTY AUMBCR DESTGNATION 22] woes |= Pose-to = z 'seNO_ | i penTITATS-ak SCZETCHNING DIMENSION MATERIAL JE] ewennoncen | woo | § 722 0300-80 | rive gear compl 1 Iriebverk — kosol. 701-00 ousing coral 7 Gehtuse Korps qwrat | + 7a 0509-2 [Housing CS 7 Gehuse aor-or | 4 722 0935-01 | Housing cover Plexiglas | 7 Gehtusedeckel yoros | & 722 0311-02 | Cover for flange 625 1 Flanschdeckel sor-07 | 4 722 031502 | Flange for bearing we 4 Lager lansch soem | 4 722 1427-01} Sealing bush for crosshead ais | 3 Uichtungsbuchse-Krevzkeph sores | 4 951 8090-09 | 011 filling cover ate ayer ao | 3 ‘Brent1aftungsdeckel Presstoff sort | 4 722 0407-80 } Oil scraper comple omy gia] | st 105 | 4 labstreifer konpl. sorer6 | 4 005 0192-26 | Serew plug R42" x 20 Hs 3 VerschluBschraube IN 367 sorte | 4 003 4400-78 | Threaded pin AN 6 x 30 154 3 Gevindest itt anh gtk sorerg | 4 000 0000-30 | Hex, screw f. housing cover | M 8x20 018953 | | 8.8 * Gxt, Schraube {. Gehy-deckel 01-20 | 4 000 0001-11 | Hexagon screw 72x35 01N 933 | | 88 % Get. Schraube sor26 | § 016 0151-10 | Spring ring ew om | | st 6 Tederring aor-3o. | 4 301 5000-72] Seating for housing cover it 1 Gehtusedeckel dichtung sori | 4 300 0022-00 Seating for screw plug 22x29 145 tw 3 Tjentung f. Verschiuéschr aut sorese | 4 302 0490-55] O-ring f. crosshead cover | # 122 x 4 Perbunan | 3 Rundéichtring f. Krevdkemde 4ore33 | 4 302 0205-01] O-ring f. flange cover $205 x4 erbunan | 1 Runddichtring f. fansehd. sorege | 302 0490-56) C-ring f. flange f. bearing | #312 x4 Perbunan | 7 Runddichtring f. Lagerfl. 191-36 | 4 350 0428-05] Pipe double nipple 142 x54 st 1 Rohrdoppel nipple orn 2990 4ot-3a | 4 076 0040-29] Tube clip sa 50 - 70 WI 4 Schlauchi_ ene ON 3017 il© 9/78 seer: 2 of 2 1-01.05 nEO.Nos 4 722 0300 ree: SHL LIST OF SPARE PARTS ERSATZTEILLISTE INSTRUCTION MANUAL ~ BETRIEBSHANDBUCH OC avra-LavaL CONSTR. GROUP 404 BAUGR UPPE A Pos.-to m8 atte as 40-47 101-48 01-49 401-50 051 10154 01-55 101-56 701-57 101-58 2 TENTY NUMBER DENTITATS-AR § ahh 0193-65 4 305 0075-00 4 307 ba50-10 4 350 0426-27 4 ahh 0193-25 4 078 ook0~12 4 320 0401-04 4 648 0000-05 000 0008-01 4 010 0201-50 4 000 0001-36 4 015 0025-01 4 010 0202-20 DESTGNATION ‘BELEICHNUNG Hose Sehlauch Radial sealing ring Radialvellendichtring Groeved sealing ring sutring Pipe double nipple Rohr doppelnippe! Hose Sehlauch Tube clip SchlauchkLenme Orain cock Entvésserungshahn Plug VerschluBstopfen Hexagon screw Sechskantschraube Hexagon nut Git. Mutter Hexagon screw Gkt. Schravbe Washer Scheibe Hexagon nut okt. Mutter DIMENSION § 4 58x5x1000 A 50x180x15 20-80 34m x 60 DIN 2982 g A 3axb5x1000 us 4 DIN 3017 mM 3/4" DIN 361 15 Deh, 60,7 40x75 DIN 935, 10 ON 93h M 2hx85 DIN 931 Be DING M2h DIN 934 MATERIAL PVC soft Perbuasn Gun, st PVC soft WI Rg 5 PE soft 3.8 88 88 St 8.8 PIECE NIMGER notes BEMERKUNGEN ROR MENGEOC aLra-LavaL INSTRUCTION MANUAL — BETRIEBSHANDBUCH a CRANKSHAFT ® 102 a oO KURBELWELLE 102-22 102-26 102-06 102-42 02-1 102-02 CO 3 2 BO ee) 3 102-02 8 3 102-40 2 102-43 a 0 & ¢ 102-08 102-35 C = ‘oa 8l/2bINSTRUCTION MANUAL - BETRIEESHANDBUCH OX avra-Lavat 9/78 LIST OF SPARE PARTS CONSTR .-GROUP 499 ERSATZTEILLISTE BAUGRUPPE 4 2 3 ‘ sé man 2. 8 TOENTY RUMBER DESIGRATION Sz] wus |e Fos.-No | roeyrrTtS-ak SEZEICANING DIMeSTON WATCHIN Ys 3] scvcnnuncen | . ES = $ } 100 4 722 0300-80} Drive gear compl. 4 2 Triebuerk —konpl. 02-00 Crankshaft comple 10 180 1 Kurbelwelle Koop]. - 102-02 | 4 722 1070-02) Crankshaft S10 180 dace h | 1 ¢ Kurbelvelle B] tozo6 | 4 722 optz-01) disk on 1 a Scheibe = 1 aozoe | 4 720 0752-01) Distance ring cs 1 i Distanzring | 102-22 | 4 000 0001-10} Hexagon screw f. disk M 12x30 DIN 933, 8.8 3 . ‘kt. Schraube f. Scheibe 102-35 | 4 302 0105-00] O-ring xk Perburan | 1 Runddichtring 102-40 | 4 016 0502-70] Locking ring J 2105 1 Sicherungsring om 472 aoo-41 | 4 016 0302-15] Locking ring J 266 1 g Sicherungsring Orn 472 ge | ode | 4 2h 2200-04] Cylindrical roller bearing | AUP 224 DIN 5412 1 eS Yylinderrollentager 3 | t02-45 | 4 241 020410} cylindrical roller bearing | NU 230 OIN 5412 1 : 2ylinderrollenlager © | 02-26 | 4 076 0151-10] Spring ring B12 DIN 727 st 3 Federring © ILL eALFA-LAVAL INSTRUCTION MANUAL - 8ETRIEBSHANDBUCH CROSS-HEAD 103 KREUZKOPF ee 103-04 103-02 WS mead 2040 22 ronmvwa 20°L0-<0L Tass, ‘oa flfeb aD oyOC atra-LavaL INSTRUCTION MANUAL — BETRIEBSHANOBUCH CONNECTING-R00 104 PLEUELSTANGE 104-08 104-093 QWS "mean $060 22h} vowmw ZOrLO-OL ‘os 0 2b cD C2INSTRUCTION MANUAL - BETRIEBSHANDBUCH LIST OF SPARE PARTS CONSTR.~GROUP ERSATZTEILLISTE saucrueee 03/106 1 2 3 4 5 8 i. 3 TDENTY NUMBER OCSTGAATION 22] wes | 2 PoseNo | roewrdTATS-at ACZEICHNING OINASTON MATERIAL J seocanuncen | | 100 | 4 722 0300-81] drive cear compl. | $20 160 1 : Triebwerk ong r 103-00 | 4 722 0302-20 | Cross-head compl. 1 Kreuzkopt konple 73-02 | 4 722 1426-02 | Cross-head 66 60 1 a Kreuzkopf SS | 105-03 | 4 722 0308-01 | Cross-head-pin cB 4 Bg Kreuzkoptbolzen 2S | ros-04 | 4 005 4400-85 | threaded pin Noe oN | |G H 2 3 Govindestift 2 8 14-00 | 4 722 305-80 | Connecting rod compl | 1 Plevelstange konpl.| soba | 4 722 030402 | Connecting rod 2 parts 1 8 Plevelstange © | aowoe | 4 122 1466-01 | Searing brasses 2 parts 1 x Lagerschale 1Di-03. | & 722 0306-01 | Bush” 1 : Buchse 3 E | 10-04 | 4 002 0000-67 | Screw for connecting rod C45 on 2 u Pleuelschraube 8.8 verge 7 WWr-05 | 4 070 4302-02 | Locking nut M12 DIN 7967 | | Fed.st 2 Sicherungsnutter 4Db-06 | 4 010 0201-60 } Hexagon nut Ne ong | [8 2 Gxt. Mutter 104-07 | 4 016 0504-55 | Expansion pin ax2o DIN 1H81 | | FeesSt 1 Spannhtl se aphad | 4 110 3500-10 | Socket pin wid ON 7 st 1 Tylinderstift : 4ob-09 | 4 002 6400-06] Threaded pin woxo onsst | |5S 1 Gevindestitt © g zINSTRUCTION MANGAL - BETRIEBSHANDBUCH OEL COOLER 105 SLKUHLER Kuhlwassereinlad sz ws cleo 22) "ONMVBO ZOU SL "ew oaw Ty aaaes yore 5 >4 3 2 INSTRUCTION MANUAL - BETRIEBSHANDBUCH CC atra-LavaL LIST OF SPARE PARTS CONSTR. ~GROUP . 495, ERSATZTEILLISTE BAUGRUPPE 1 2 3 i 5 | 6 2 8 8 resets | ipiteat| ACME oweson wren | 8) seen | oo | 4 722 0300-80 sweer.1 rive gear comple Triebverk 105-00 1 cooler compl. tether 4 722 8-01 1065-01.03 105-17 | 4 350 Bha2—18 REG.Ne. 05-21 | 4 355 8b01-31 105-23 | 4 300 0078-04 105-53 | 4 ahh 0792-80 105-59. | 4 350 004-59 pnawno.:4 722 0300 rvpe: SHL 5 04 cooler Oukante Bulk~he Schottv jad screw yerschraubung EXbow screwing Winkelverschraubung Flat se Flach Hose Schlauel aling .chtung h Reinforcing bush Verst3rkungstil se wet wae da 2x1, 5x10001g vsh 2x1 secu | 1 asm | 2 ais | 2 Aluniniun| 2 Pvc 1INSTRUCTION MANUAL 106 BETRIEBSHANOBUCH PISTON CONNECTION KOLBENVERBI NOUNG WS tmwaL ooc022e 4 20°LO-90L *enOae T1a3He ¥ ya fab£0. 9/8 INSTRUCTION MANUAL - BETRIEBSHANDBUCH LIST OF SPARE PARTS ERSATZTEILLISTE CONSTR. ~GROUP, BAUGRUPPE 106 sneer: 1 DESIGNATION BEIEICANING Drive gear Triebwerk ; a e_ 2 Ez] wes |e MATERIAL 5] somenuncen | = Piston connection compl. Kolbenverbindung kopl AEa.No.: 10601403 4 722 0500 SHL ype: Bush Buchse ing Ring Hexagon screw wecup spring ‘kt. Schraube a.Tellerfeder Splash protection Spritzvasserabvetser 4.4571 3 Perburan | 3OX aLra-LavaL 200-15_200-18 zen 228 200-16 200-56 200-10 200-06 200-01 200-17 200-57 200.22 INSTRUCTION MANUAL 200 20041 200-42 200-52 BETRIEBSHANDBUCH FLUID END FLUSSIGKEITSTEIL 200-40 200-43 ti 200-27 \ 200-23 200-58 \ 200-3 00-36 200-57 200-38 200-33,200-34 200-35 200-24 200-26 200-27 200-23 NESS 200-25 200-287 | wus ‘OnmvuO. 2010-002 vewoaw Loaaans, a Sfen 8 INSTRUCTION MANUAL - BETRIEBSHANDBUCH CC aLra-LavaL g LIST OF SPARE PARTS CONSTR. “GROUP. 299 ERSATZTEILLISTE BAUGRUPPE c racy noece | wstoutin Bel as |Z 8 MENSION est = vn] POM | roewrsTars-ak BEZCICANUNG ae MATCRIA Ys aenercuncan | = 5 1 zoo-00 | 720 10-80 | fluid end compl. | $45 Nutring i 51/54/95 | Flussigheitsteil konple Kegel ventil aoc {4 722 1457-01 | Cylindrical bush aus 3 Lylinderbuehse | ocr |4 122 1588-01 | tush 1.4580 | 3 5 Buchse | sooo |4 722 1458-01 | scorn nut aah | 3 i Druckeutter | oc-ns [4 110 680-12 | cylindrical pin $6 ex ais | 3 : Tylinderstift zoo-c6 |% 600 0070-02 | Spring 46510 | 3 Feder 200-09 |4 722 0410-01 | Piston $45 tsk | Kolben 200-10 4 722 0385-45" | Header ring Form 8 ais | 3 3 Stating | cover [4 122 0991-05 | érooved sealing ring Perbunan | 3 = futring g | zoe |b 722 H21-02 | turconstepseal nee 10 | 3 : Turcon-stepseal § | zoos |b 722 1h701 | Fottover ne 0 | 3 Kolbenfuhrungsring zonery | 722 1448-09 | Guice nr. 10 | 3 Foheungsring zoors |h 722 7952-14 | Header ring aan [3 stutzring 20-16 [4 302 0497-89 | o-ring $505 | reoprene | 3 Runddichtring zoo-17 | 302 0490-89 | O-ring sean Neoprene | 3 Runddichtring 200-18 [4 302 0491-90 | O-ring bmx Neoprene | 3 funddichtring zoo-zi | 722 7459-01 | Cylinderblock asm [4 2 TyLinderblock = | auc [4 722 0819-02 | valve cage pressure auise | 3 Ventilk3fig : e _|____ —_1__|J©. at 2 of 3 sneer, REG.No.: 200-01.07 omawno.4 722 160 types SH 25 | INSTRUCTION MANUAL - BETRIEBSHANDBUCH CC avra-Laval LIST OF SPARE PARTS CONSTR.«-GROUP . 900 ERSATZTCILLISTE BAUGRUPPE . 1 2 3 4 ‘ 6 7 R TOCNTY NOBER scstoast ion vucns Bz] wis |e Posecto | acu THIS suzttoMNG rmenszoN | MATERIAL YB) cwcanncen | = 200-25 | 4 722 osteae | Valve te» tettite 6 | 6 [see Pos. 59 Venti] 200-24 | 4 722 079te02 | Valve seat tellite 6 | 6 [see Pos. 50 Ventilsitz 200-25 | 600 0000-08 | Valve spring abo | 6 Ventilfeder 200-26 | 4 722 0810-05 | Valve cage suction ass | 3 Nentilkatig 200-27 |4 722 09h2-01 | Grooved sealing ring cylinder tlock Neoprene | 12 Nutring 200-28 4 722 0982-01 | Grooved sealing ring cylinder block Neoprene | 3 Nutring 200-29 | 4 722 0923-01 | Cover 164300 3 Deckel 200-30 | 4 110 6810-12 | Cylindrical pin $6 m6 x 12 44571 3 Minderstitt 200-31 | 010 6240-01 | Cup nut M20 1.4544 v2 fatatter 200-32 | 4 001 5020-06 | {xtention srew GP mn 20%97 464371 ez Denn Stiftsehraute 200-33 | 4 O10 6240-02 | Cup nut Mh 144541 8 wutnutter 200-5 |% 001 5020-07 2h x 188 ain | 8 Dehn Stiftecheaube 200-35 | 4 015 0025-05 | Washer A25 4164301 8 Seneibe 200-36 | 722 0901-80 | Cover for suction pipe 1 Deckel f, Sauale 200-37 [4 010 6107-84 } Cup nut "6 ain | 2 futmutter 200-38 |4 001 4000-40 | Stud bolt 1% x40 ANI? 2 stittsenrabe 200-39 [4 302 0490.9 | o-ring fees Aeoprene | 1 Runddichtring zooeho {4 722 0914-80 | Pressure gauge flange 4 Maroseterflanses aeo-i1 |4 o10 Groth | Cop out 4% ain | 4 itautter L J.o INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC aLra-LavaL LIST OF SPARE PARTS CONSTR. ~GROUP. 999 ERSATZTEILLISTE BAUGRUPPE . L + 2 3 4 5 e| 7 8 Ee ig LOENTY NUMBER DESIGNATION Bz} ons | 2 se] 228% | toes sre 1oANING ormenston MATERIAL) 2) ecoxoaen | = E | 20-42 | 4 001 b00t-a9 | stud bolt NGG same | 4 Stiftschraube c 200-43 | 4 302 0499-56 [O-ring gsx4 Neoprene | 1 | zoos 4 722 0916-80 | Suction flange 4 [see extro tis Saugleitung AnschluBflansch & | 200-5 [4 722 0917-01 | Connection flange 4. [see extra list Z Ansch] uBflansch E | conse [4 010 6107-84 | cup rut 46 sas | 2 i Hutrutter 8 | 200-47 | 001 4000-40 | stus bolt 16 x 0 Aht22 2 . stiftschraube zoos |4302 0490-95 | O-ring 6x4 Neoprene | 1 funddichtring 200-49 Pressure gauge see extra lis Manoeeter ce | 20080. 8 722 1480-54 | Cone valve compl. Pos. 25424 3 Kegelventil konpl. & | zooes1 [4 302 0054-00 | Seating for Voss Gh xP Ob x5 | | Perounan | 4 = Vichtung fir Fos. 44 g | zines [4 302 0025-01 | o-ring for toes 40 $ox5 Perburan | 1 z Rundsichtring fir Pos. 40 | & | 200-53 tush for Fos. 40 Buchse fir Pos. 40 200-54 Supported ring for Pos. 40 Stitering fir Pose 40 200-55 | | 200-56 | 4. 722 1178-14 Back-up ring for Pos. 16 ire Gas | 3 Back-up Ring fur Pose 16 200-57 4 722 1178-23 | Back-up ring for Pos. 17 rire Glas | 3 Back-up Ring far Pos. 77 200-58 [4 722 117812 | Back-up ring for Poss 27.28 rift Glas | % Back-up Rlng flir Poss 27428 © "8 i ia ___© CG CH CG a onawnos 4 72 161 neaunies 201-0102 ‘ss seers 4 z & a2. a. 22 ¢ ge = + 28 q 5 SZ. 2 = e- 3 che Be § ' 2 z = z ° = 5 8 z - b 2 ; 4SHEET: 4 201-07.04 onawno.: # 722 0916 29 LIST OF SPARE PARTS ERSATZTEILLISTE INSTRUCTION MANUAL - BETRIEBSHANDBUCH x ALFA-LAVAL CONSTR.-GROUP, BAUGRUPPE #201 1 Pose-No | 2 3 Zs TENTY UHR oestemation 22] wns TDENTITATS-nR BEZETCHNUNG DIMENSION] MATERIAL J 3) sewcenuncn JORDER/MENGE Saugleitg. AnschluBflansch 200-00 | 4 722 1480-80 | Fluid end compl. Flussigkeitsteil —_konpl. 201 | 4 722 0916-80 } Suction conn. flange ws 4OC ALFA-LAVAL INSTRUCTION MANUAL — 203 BETRIEBSHANDBUCH PRESSURE GAUGE MANOMETER | WS taaan 1-2002 266 FoNmuO 20°L0-E02 ven-oay ct TL apane ‘fat 22 a3 2 INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC aLra-LavaL LIST OF SPARE PARTS CONSTR. ~GROUP ; 999 ERSATZTEILLISTE BAUGRUPPE | * 1 2 3 i ss 2 TOEATY NUvaCR DESIGNATION Zz) wus | Pose roan rriseat sczcTcNs owerston | mara F2 &) soenauncen | = $ | 200-00 ]4 722 0922-80 | Liquid part compl. & Flussigeettsteil —_komple c 203-49 | 4 932 2002-18 0 ~ 600 bar 1 R ¢ 2 a & i 3 = 2 Z = 3 © g gINSTRUCTION MANUAL — BETRIEBSHANDBUCH TS vaean OL 22h tronmvua URW Fewoae con (B/2h ise) oy¢ g INSTRUCTION MANUAL - BETRIEBSHANDBUCH LIST OF SPARE PARTS CONSTR. ~GROUP. 9 ERSATZTEILLISTE BAUGRUPPE 1 2 3 4 5 é 2 8 poseaty | IOEHTY meer DESIGNATION evens rem az vrs | eseAo | ipcarTTATS=AR acTEICANNG 5S] scvcncuncen | = £ | 200-00 | 4 722 0922-60 | Fluid end : compl z Fldssigkeitsteil —konpl c 2oi-00 | 4 722 1170-81 Cooling circulation compl. 1 Kuhlkreisleuf —_koople | ca 2oi-o1 | 4 722 7169-02 | Connection pipe 145M 2 aaa) Verbindungsrohe B | aolo2 | 4 722 1071-02) Connection pipe 1.454 1 = Verbindungsrote 3 | 20s Pipe $x1 Of6n] | 1.4544 1 5 Rohr = | 204-04 | 4 350 8400-87 | Pipe union ce 7M 1.4571 6 Einschraubverschraubung 20h-05 | 4 350 8407-15 | Screwing BR TeeA0L 16r 2 Verschravbung Fa | i § 2 g : |oO Cre, Co of 5) ve: SHL 2 onawno: 4 222 1134 meat. 400-01.02 sweet: 1 12/78 eo. g tz Se eyo] e BETP’ZBSHANDBUCH INSTRUCTION MANUAL — FRAME WITH STAINLESS STEEL cover VERKLE| DUNG GESTELL MIT 400-01 400-06 400-04 400- 40010/28 £0 oN nea.no.: 400-01.03 4 22 1134 SHL Type: rc INSTRUCTION MANUAL - BETRIEBSHANOBUCH OC acra-Lavat LIST OF SPARE PARTS CONSTR.—GROUP. 29q ERSATZTEILLISTE BAUGRUPPE . 1 2 3 4 5 vores BEMERKUNGEN TOENTY NUMBER DESIGNATION IDENTITATS-WR BEZEICHNUNG CiisT} MATERIAL Pose-No PIECE WOMEER stlicxzant ORDER/MENCE 400-00 |h 722 1134-83 |Frane with stainless steel cover compl Gestell ait Verkleidung comp 400-01 |b 722 1024-80 | Frame compl. fincl.4 adjustable 4 Gestell konpl.. foot ls 661 1000-02 | all feet, adjustable I 50 4.4301 Kalottentus 400-02 fh 722 1026-01 | Cover aa | 1 Verkletdungsdeckel 400-03 fa 722 1027-80 | Back wal Ruckvand 400-04 |4 722 1028-80 | Front wall Vordervand 40-05 fh 722 1050-01 | Side wall left aso | 4 Seitenvand 490-06 fo 722 1029-01 | Side voll right aan | 1 Seftenvand 400-07 |4 000 6100-02 | Cheese head screw JAM 6x10 DIN 85 vi500 | 38 Flachkopfschraube 400-09 }4 019 3000-19 | Handle Type 270.3 St 2 Griff verchroat, 4oo-ro [4 722 1438-80 | 011 inspection pipe ‘standsrohe 490-11 [4 000 2000-39 | Cheese head screw am 6306 DIN 8 wt | 6 TyLinderschreube 400-12 fh 010 o20re2b | Hexagon nut m6 omg | | a.t571 | 6 Get. Schroube 400-13 |h 016 0150-75. | Spring ring 6 omar || 1.8300 Federring 400-14 |4 648 0000-04 | Plug F 32 Kurststoff Verschluéstopfen 400-15, UProfile bez, ne10, sob rubber | 1 Profil 311 Longg INSTRUCTION MANUAL - BETRIEBSHANDBUCH & LIST OF SPARE PARTS CONSTR. ~GROUP 54 ERSATZTEILLISTE BauGRUPPE 1 2 3 4 1 8 reecny |e awecr | atStauTON amasin | wren (23) 018 | E No) rocaritit sve SEZCICHNUNG CRIAL Ys 3] acwcewuncen | = 5 4 722 0958-98/| Double stage hosogenizing | 4s /Molkerei a head comple - Doppel-tonogenisierkonf kple soar | 4 722 10th | Piston bush ato | 2 Kolberbuchse Cc sone | 4 722 1077-01 Centering: ring W167 a fs Tentrierring & | 501-03 | 4 722 1016-01 | Hydraulic piston 1.1571 2 & Hydraulikkolben g | Seek | 4 010 orto | cop nut ume mgt | fate | : futnutter | 501-05 | 4 001 5020-05 | Stud bolt abe 8 Stiftschraube 501-06 | 4 309 9000-06} TURCONAStepseal 2 TURCON-Stepseal 501-07 | 4 306 0000-05 | Rod-quide 2 Stangenfhrungsring az | 50%-06 | 4 306 0000-02 | Piston-guide ring 4 s Kolbenfuhrungsring B | soro9 | 4 000 2500-97 | Socket screw wari DINgI2 | | 1.1571 8 a Tyhinderschraube " ¢ ] sorta | § 000 2302-07 | Socket screw wore omg] fats | 2 5 Tylinderschraube 5 | sora | 4 300 0096-16 | Flat sealing ring 165x951 | | Cu 2 7 Flachdichtung IN 7603} sort | 4 001 4000-59 | Stud bolt nro 9938 | frie | 4 Stiftschraube 1 sors |s 722 1613-80 | Outlet flonge os 1 Austrittsflansch 502-00 Honogenizing device compl. 1 fee extre List] Honogenistervorrichtg.konpl. ° 1 503-00 Set of sealings compl. 1 fee extra List 2 Dichtungssatz onpl.| T son-3o | 4 722 1020.01 | Housing 4 1.4300 2 : Gehause m£0. V9 SHEET: DRAWNOS 4 707 0958 Tre sit a-206) 91-206 fi-205 ‘ONNLHOIYONYS 1S INSOOKOH zos 301A30 ONIZINZOONOH HON@GNVHSEIwL3a = — TWANVW NOILINYISNI£0. 9 69 c A SHEET. 502-01.04 4 722 0958 rvee: Sil 25 INSTRUCTION MANUAL - BETRIEBSHANDBUCH CXC ALFA-LAVAL Me tote serene caieaeancuans 4 2 3 4 5 2 | 8 fe si resto | Tete ferc0MNG owersin | rem |S BT soctunan | sitz 500-00 | 722 0958-80 | Single stage homoge head cpl Einfach Honogenisierkoof kpl. soreo0 |4 722 0958-99 | Doubbe stage honog. head cpl Doppel Hosogenisierkopf tpl. 502-00 |4 722 0958-50 | Honogenizing device comp 1 tonagenisiervorrichtung kong s02-26 [4 722 7597-01 | Iapact ring 20/630 stellit 20 | 4 Prallring 502-17 | 4 722 159%01 | Hono device cone 20/630 stellit 20] 1 Stenpel 502-18 | 4 722 1596-01 | Hono device seat § 20 / $30 Stellit 20] 43 z INSTRUCTION MANUAL - BETRIEBSHANOBUCH OC aLra-Lavat LIST OF SPARE PARTS CONSTR.~GROUP. EQ ERSATZTEILLISTE BAUGRUPPE 7 TDENTY NUMBER: DESTGNATION 7 z NOTES : z= Nt = PosecRo. | pewrnnin Sak ZEICANING DIMENSION | MATERIAL Jy SY eucaauncey | 3 | soo-c0 | 722 0958-80 | Single stage honog.head cpl ¢ Cinfach-tonogenisiertoptiol. 501-00 | 4 722 0958-93 | double stage honog.head cpl. Topoelfonogenisierkopf Kol in| 902-00 | 722 0958-75 | Homogenizing device compl. | 9 28 / § 38 1 8 Honagenisiervorricht korple ei aogenisie om | =] sazus {4 eot295-01 | Impact ring $28 (938 Stellite 21 2 fralleing S © | soz-17 | 4 722 1590-01 | forcer p28 / 9 38 Stellite 24 1 Stenpel 5218 | 4 722 1296-01 | Seat 28/938 Stellite 2 1 Sitz 3 i2) 12/78. £0. sneer: 1 503-01.02 REG.Wo. 4 722 0958 ORAWNo.: ‘ree SHL 25 HONGONVHSH3IYL3E ZLYSSONNLHO!O £05 SONIT¥3S 40 135 — TWANVW NOILONYLSNI 2-005 WAVT-WTTY 9g INSTRUCTION MANUAL - BETRIEBSHANDBUCH CC avra-LAvaL LIST OF SPARE PARTS CONSTR. ~GROUP. 5Q3 ERSATZTEILLISTE BaucRuPPE : ao DESIGNATION Ey é TOENTY NUMER GN Bz] noes |S Pose-Ko ) ipenrdTATS-ne BEZEICANING DIMENSION MATCRTAL Ys) ocucenunccn | = 3 | soooa | 4 722 0958-99] ouble stage honog. head cpl Coppel Honogenisierkopt kp c 503-00 Set of sealing comple | O-Perbunan-sS 1 Cc Dichtungssatz Komp. | ( ~ &] 505-20 | 4 502 0057-05) O-ring g5rxs ferbinan | 1 g funddichtring Ry] sos-z1 | 4 302 0492-28) O-ring $23 ferbunan | 2 3 Runddichteing i @ | 563-22 | 4 302 0057-05) O-ring pores Perbunan | 2 3 aunddichtring 503-24 | 4 300 0902-06] Supported ring 2h x 26x 1p | Tee 2 statering z i 6 oe ; g { FLSmeets 9 co. REG.No.: 50401602 MANO. 4 722 1254 SHLD ree 2070S pens. — ——_{ seg ——— | Loos ab-405 2-108 e245 ONN1134S83A -ONYH G ONNY3N3LS weigge | ye BHOSITNYEGAH — $2-408 OuLNOD_GNYH HLM av3H ONIZIZ90N0H 30¥1S 7S 378N0G YO TOYLNOD 31 1NWYOAH HoneGNVHSaauLza = - TWANVW NOILONULSNI8 & INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC ALFA-LAVAL LIST OF SPARE PARTS CONSTR.~GROUP, SQy, ERSATZTEILLISTE BAUGRUPPE . Zz : S TOENTY NUMBER eSTGNAT ON Bz] wis |e * TCATETATS@ sc ICICANNG DIMENSION | MATERIAL Jy ©) genercuncen | = | 504-00 | § 722 1254-81 | Hydraulic control for double a ~82/-85 | stage homogenizing head with hand control cpl. 4 Hydraulische Steuerung 0 Handverstellung konpl. 504-01 | 4 350 4893-01 | Reducer en aft St 2 Reduzierstutzen 504-02 . | 4 353 8302-03 | Elbow. screwing WE 8 - SR St 2 Winkelverschraubung 504-03 | 4 353 8400-53 | Elbow sereving Wea - 3k 4.4571 2 ‘Winkelverschraubung. £ | sor-oh fh 354 a2h1-11 | T-screwing 18-8 st 2 $ ‘T-erschraubung 504-05 | 4 350 8243-13 | Screwing sve-S St 2 Gerade Verschraubung - 504~06 Pipe 8x 1,5 OIN 23791 6 oh 504-07 | 4 015 0006-09 | Washer AGA DIN 15 6 : Scheibe © | somos | 4 000 0006-04 | Hexagon screw M6xt6 IN935 | [1.4571 6 x Gxt. Schraube = | 504-09 | 4 625 9000-03 | Protection ring PvE 2 3 Durchfohrungstdlle z 5 | 5010 Hydraulic off 1 é Hydraulikol 504-11 | 4 708 5160-05 | Hydraulic unit RM 0,27- / 4 Hydraulikaggregat 504-12 | § 620 0000-42 | Drive notor 0,6 KW 1 Antriebsnotor 1500 U/min. . 50b-1g | 4 34 Babt-11 | T-screving T8-s st 1 Te¥erschraubung sobs | 4 722 1032-01 | Holding angle sez | Haltevinkel 504-16 | 4 722 1078-80 | Holding for Hydr. unit 4 Halter 504-17 | 4 000 2300-20 | Socket screw M 10x30 DIN 912 8.8 4 ° Tylinderschraube 504-18 | 4 000 0006-36 | Hexagon screw M 8x20 OTN 933 164571 8 z 6kt. Schraube g ze ttgz INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC aLra-LavaL LIST OF SPARE PARTS CONSTR.~GROUP cy, ERSATZTEILLISTE BAUGRUPPE a. gy TDENTY NUMER DESIGNATION 22) woes |e os | Pose | ronnie SE2c1CNG poveston f warental Ye &) acwanonccn | & | sohetg | 350 4095-07 | Recucer rivera | fst 1 z c 504-20 |4 350 8502-07 | Pipe union Ea- st 1 Einschraubverschraubung 504-23 | 323 0000-06 | Pressure valve 2 Druckventil A 504-24 | 4 353 8302-03 | Elbow screving WEB- SR st 2 Wiskelverschrasbung 504-25 [4 350 8302-07 | Pipe union was st 2 Einschraubverschraubung 504-26 | 4 350 8407-46 | Reducer ri 3/8" x 1/4" st 2 Reduzierstutzen 504-27 | 000 2301-15 | Socket screw Moet IN 912] {1.4571 8 Tylinderschraube 504-28 | 010 0201-25 | Hexagon nut m6 Omg) |a.457 8 Gxt. Mutter 8 2 i 3 r -} 12/78 €0. REG.No.£00-01.02 @31BLNY aAtyO HOMBONVHSS3IL3a — TWNNYW NOILONYLSNI TYPESSHL©. INSTRUCTION MANUAL - BETRIEBSHANDBUCH C4 ALFA-LAVAL nln8 CONSTR.~GROUP. 6 QQ LIST OF SPARE PARTS BAUGRUPPE ERSATZTEILLISTE 1 2 5 6 noes BEMERKUNGEN TOCNTY NUMBER estoNaT ON DEATITATS-AR SEIEICHNING Te rae PIECE NUMBER stticnzant orocR/wence 4 § | 600-00 |4 722 1596-97 | Drive sto 160 1 z Antrieb Cc 600-01 | 4 722 1048-02 | Drive gear smo 180 Aufsteckgetriebe J 600-02 | 4 016 2509-18 | Fitting key KS 28x16 x 260 lod |st 6K | 1 é é PaBfeder DIN 6885/1 5 600-03 | 4 722 1056-01 | Disk 1 3 Endscheite | soos | 111 0900-28 | Cylindrical pin On 6x24 ON 7 st 1 g Tylinderstift ¢ $ | 600-05 [4 016 0011-55 | Locking washer Booms | |.4521 1 Sicherumpsscheibe 600-06 | 4 000 0005-52 | Hexagon serev M 2bx50 01N 935 | [8.8 1 i ~ Gkte Schraube { 600-07 | 4 722 1390-85 | Torque-supporting 1 DOreheonentens totze Z | 600-09 Belt-pulley for gear 4 R Rienenscheibe & | 60-1 Belt-pulley for motor 4 = Riénenscheibe Cog | s00-13 Vtelt $8 : Keilrienen type: SHLae ;SHL 20 MACHINE NO: S340 4 BS INSTRUCTION MANUAL HIGH PRESSURE HOMOGENIZER OC atra-LavaL Bran @ Libbe Gnbl, Postfach 1360, Werkstr. 4, D-2000 NorderstedtoO INSTRUCTION MANUAL - BETRIEBSHANDBUCH CONTENTS General description of the ALFALLAVAL high-pressure honogenizer Preface to the Instruction Manval Identification Plates Section 1 TECHNICAL DATA Technical data of component parts and ancillaries Lubricants Recommendations Section 2 DESCRIPTION OF ASSEMBLIES General Arrangenent Driving gear, crankcase Oil cooler in vater cooling system Fluid end / Punp block Condensate system (with aseptic operation only) frase with panels Honogenizing syste aydraulic Control Drive Section 3 HOW TO INSTALL THE HOMOGENIZER Handling ano positioning Dinensions of cooling systen pipe connections Dinensions of pipe connections at usp cylinder black and homogenizer head Wiring diagran How to a6just the Solenoid valve Section 4 INITIAL OPERATION OF HOMOGENIZER Check List for initial operation List for checks and work during the tonogenizing process O51 Level checks Control of condensate unit (with aseptic operation only) Shutdown procedure Operating troubles, Cause and Cure OC aLFa-LavaL Section/Page WA, V2, V3 ays 2 2fe aps ah 25 26 an 28 29 wf we 33 ah 35 aft, Way 43 uy 45 46 wr 4/8 |E a >) j 2 g g i £ INSTRUCTION MANUAL - BETRIEBSHANDBUCH CONTENTS Section 5 MAINTENANCE Inspection and overhaul sheets Standard tools Special tools Torque specifications for bolts with reduced shank tow to renove and fit the gauge on the punp cylinder Block iow to renove and fit suction and pressure valves in cylinder block Disrantling and assenbling of horagenizer head ow to renove and fit punp piston to crosshead extension; Pull and fit crosshead sealing bush How to renove and fit piston bush How to check Vebelt tension; Renove and fit V-belts reduction gear / shaft sounted How to pull and fi How to renove and fit belt pulleys with TAPER LOCK How to dismantle and assemble big-end bearings How to dismantle and assenble the crankshaft ow to pull and fit inner rings of crankshaft bearings How to fit STEP Seats Pusp piston seals assenbly How to fit Lip sealing rings in cylinder block Inpact ring danage due to excessive service periods wear patterns in sealing surfaces of suction and pressure valves Wear patterns in big-ind bearings Section 6 SPARE PARTS Key to correct ordering of spare parts Specinen of how to prepare an order Lists of spare parts, by Assemblies CC aLra-LavaL Section/Page Bf Stay 1a2s 1 3y 10h 5f2 5/5y 5/% 515 5i6 sit 5/8 5/9 5/0 5m 5/2 5/3 5/th 515 5/%6 sn 5/8 sre 5/20 5/24 lee 6h Pink sheetsseer INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC aLFaA-LAVAL GENEREL JESCRIPTION OF THE ALFA-LAVAL HIGH-PRESSURE HOMOGENIZER The ALFAGLAVAL honogenizing machine is designed as an horizontal three-piston pumpy iets 2 high-pressure, positive displacement puno delivering through honogenizing valves. The high-pressure homogenizer is normally aounted on 2 frane enclosed by stainless steel panels. The electric rotor as vell 25 the electrical and hydraulic systens (except the starter switch) are integral parts of the fachine, incorporated within the enclosing panels. The high-pressure honogenizer is used for dispersion in applicdtions found in dsiry, chenapharsazeutical and allied processes. The products to be processed are emulsions (Liquid-in-liquid) or suspensions (solid particles in liquid) with viscosities of up to 75 ~ 20.000 aPas (c.P.) and a solids content of up to 48 - 50% in the dry phase (05.). the honogenizing process requires that the feed is adequately blended or mixed and that purping requirenents are complied vith. Ihe primary purpose of homogenizing is to break up the particles in suspension and to ensure uniform distei— bution of particles to improve the physical stability of the product. Depending on the nature of the particles snd their readiness to brpak up, the separation into different phases (sedimentation, ereaning-up, coagulation) is prevented or considerably delayed. High-pressure honogenizing also serves to influence viscosity, to enlarge the internal surface thus enhancing the chenical reaction rate, and to obtain cellular disintegration. depending on nature and condition of the product as vell as on the working pressure and temperature prevailing during hosogenization, particles of micron and sub-aicron size are obtainable. The ALFACLAVAL honogenizer is designed 2s unit-coxposed systen, allowing for a variety of differnt versions being available. These include one- and two-stage homogenizing valves, various pump piston dianeters and piston sealing systets, conical and ball valves (depending on the viscosity involved), and various types of waterialy etcy A11 high-pressure hosogenizers can be operated aseptically, with appropriate fittings and accessories. Subsequent changes to other processing rates and pressures are feasible vithin the scope of the model concerned. High-pressure hosogenizers incorporating positive displacenent punps essentially require that the folloving operating conditions are maintained throughout, to ensure reliable and safe performance: and feed should be under pressure appropriate to the product e@ Feed rate stould be according to the layout of the sachiney involved (NPHS), at all tines, including cleaning periods. Ho freey ies non-dissolved air aust be contained in the feed andjor cleaning agents. cleaning agents, quality of cooling vatery further, product properties, operating and cleaning temperaturesy the service Life of the plant and those operation and naintenance are factors that vill greatly influence component parts that are particularly subject to inherent vear. high-pressure honogenizer, i.e. with its proper operation, This manual is to make you faniliar vith your ve also include useful hints on trouble shooting. aintenance and repair. Gased on experience, Naturally, not every source of failure and eve knowledge of the manual you will be able to operate your high-pressure horogeni2 satisfactory service. It is for this purpose that the manual was issued, For further advice and information please apply to yo at all tines. ery precautionary step can be enumerated. But vith thorough jer in a vay that vill ensure and ve wuld recomend reading it fron tine to tine. ur Local ALFACLAVAL caapany vio will be at your serviceINSTRUCTION MANUAL - BETRIEBSHANDBUCH PREFACE TO THE INSTRUCTION MANUAL The manual is subdivided in such a way thet, apart from giving general information, it also serves to supply advice on the installation, initial/ operation, maintenance and repair, and on ordering spare parts of the homogenizer end/or the high-pressure pump. SECTION 1, TECHNICAL DATA This section covers all the essential technical data of the homogenizing device, the high-pressure pump, its drive/ériving gear, and lay out. | also includes cooling water and lubricants recommendations. SECTION 2, DESCRIPTION OF (CONSTRUCTION GROUPS) ASSEMBLIES This section describes all individual assemblies of the homogenizer Photograshs, diagrams end Isometrically drawn control diagrans illustrate the text. SECTION 3, HOW TO INSTALL THE HOMOGENIZER This section describes the handling and installing of the homogenizer. Proper mounting work is supported by diagrams showing connections of piping and electric cables. SECTION 4, INITIAL OPERATION This section contains check tists covering the various checks and work'ng procedures required to ensure trouble-free operation. A list of possible terleres and likely causes serves to find the sources of trouble. SECTION 5, MAINTENANCE AND REPAIR Dismantling and reassembling instructions, covering the various assenb! ies are given in this section. aree2 the heading of "Preliminary Work" those jobs are mentioned that are inparative fo ensure rational and time-saving maintenance and repairs. Tools required are listed to facilitate the procedure. eee seae Required" indicates manpower and the period of time necessary To carry out the work involved, @.9. 2 men will require 0.6 h 0.6 hours, ise ‘% minutes to do ‘the job. L.af re: INSTRUCTION MANUAL - BETRIEBSHANDBUCH These guiding values have been established by the MTM - method (METHODS TIME MEASUREMENT). . The "WORKING PROCEDURE" describes, step by step, the required maintenance and repairs to keep the homogenizer and/or high-pressure pump in satisfactory and serviceable condition. Diagrams and photographs serve to illustrate the various jobs. Numerals identifying the various component parts coincide with those mentioned in the descriptions. However, they are not identical with the "Pos.-No." in the spare parts list. SECTION 6, SPARE PARTS The spare parts (lists) of the various assemblies are numbered in ascending order and printed on pink paper. Lists consist of a diagram and parts list Section. A specimen order form is inserted/as preface to the spare parts lists. A correctly prepared order form will ensure prompt delivery of the spares required. OC atra-vaval Bran & Labbe Gabi Postfach 13 60 Werkstrafe 4 0 2000 Norderstedta | INSTRUCTION MANUAL - BETRIEBSHANDBUCH (OC ALFA-LAVAL IDENTIFICATION OF HOMOGENIZER The nase plate is fixed to the driving gear housing, and it is visible vhen the cover plate is Lifted. The ttane plate shovs the typa designation and serial nu When ordering spares, please verify that the serial nusber on the plate cofncides with t instruction nanual. the number in your YOU ARE OPERATING A HIGH-PRESSURE PUMP TYPE: SHL FOR USE AS vovocenrzine wcamne [7] ATGHLPRESSue Pug CC ALFA-LAVAL HOMOGENTZER MANUFACTURED BY BRAN § LUGBE GMGH 02000 WORDERSTEDT TPE SHL 20 scan Wz er [49] oO MADE IN WESTERN GERMANY O° | | | aa] ponsSECTION 1 Technical DataSECTION 2 Assembly Group DescriptionSECTION 2 Assembly Group DescriptionINSTRUCTION MANUAL - BETRIEBSHANDBUCH ALFA-LAVAL ASSEMBLY GROUPS - GENERAL ARRANGEMENT The ALFA-LAVAL Hotogenizer, type SHL, consists of the folloving assesbly groups: Group 700 LECTRICA Group 100 L DRIVING GEAR conTROL (terminal box) rot shown ! Group 600 Group 200 ORIvE FLUID END Group 50h ayORAULIC conTR. as COMDERSAT UNIT Conly by asept. operation). Group 700 ELECTRICAL one Group 500 Group 400 HOMOGENIZING FRAME AO DEVICE PANELS Assembly groups not shovn in the cut-avay view are illustrated and e explained in the section DESCRIPTION OF ASSEMBLY GROUPS. asi48 Fl i Cc fos (8 i g Ud i a ¢ i INSTRUCTION MANUAL ~ BETRIEBSHANDBUCH OC ALFA-LAVAL SEMBLY 100 GRIVING GEAR HOUS ING Drehrichtung Direction of rotation KEY TO SIGHS Driving gear housing Oil filler = Cover plate, perspex (transparent) Bearing flange Crankshaft, crive end (gear box end) = Hounting Lugs Front end surface to comect vith pump cylinder block = Crossheads ogscazPT ion The driving gear/erankease is part of the high-pressure positive displacerent pump. To obtain continuous delivery, three-throw crankshaft is used, vith 1200 between cranks. Pover is supplied from the notor through Vebelts and shaft nounted reduction gear. The three-throw crankshaft (5) rotates in two cylindrical roller bearings fitted in the driving gear (1). The big-end bearings are of the split type, with dual aetal Linings. The wrist ping rest in crossheads (8) and are secured by threaded studs. The wrist pin bushes are of spur- cast bronze. Crantshatt bearings are splash lubricated, the comecting rds scooping up the oll whic is fed to the bearings ‘through appropriate drillings. Oil from ‘the crank webs is scraped and fed to crossheads and wrist pins. Crossheads are sealed to prevent oil spillage. The transparent perspex cover (3) at the rear end of the driving gear housing allows for 2 constant check of the ofl level and condensed water content The ofl is changed by draining the used oil through sump cock Fresh ofl is poured through the filler (2). The driving gear housing is bolted to the frane by the four mounting lugs (6). 212Sha reo.tte: 02-01.01 nw Nes 20 / 25 / 30 reve: SHE INSTRUCTION MANUAL - BETRIEBSHANDBUCH A ALFA-LAVAL ASSEMBLY 105 : OIL COOLER IN WATER COOLING SYSTEM STANDARD AND SOLENOID VALVE REY 10 SIGNS 41 = Driving gear housing Cooling ‘coil 3= Vater inlet i Water outlet 5 = Puap cylinder bushes 6 » Solenoid valve DESCRIPTION The ofl of the driving gear is cooled by a vater coil systen fitted in the sump of the housing @. ‘The coil (2) consists of a finned pipe. Water inlet and outlet lines (3 + 4)-are connected through the sides of the housing by bulkhead screvs. The cooler ist readily replaceable. ‘The cooling vater {s taken froa nains. It flovs through the coil thus cooling the oil in the driving gear: sump. The varned-up vater circulates through the sealing chanbers of the pusp cylinder bushes (5), thus cooling the pusp pistons. ‘The cooling vater passing through the sealing chanbers also ensures boundary lubrication of the front and rear piston seals. . The used vater is run to the sevage system. Solenoid valve (6) is electrically controlled so that it vill be opened before, hosogenizer is started and closed after shut dou of hosogentzer,INSTRUCTION MANUAL ~ BETRIEBSHANDBUCH AIBY TECHNICAL DATA woMoGENISER SHL 20 . 5 9.404,.8S SERIAL WO. YEAR OF CONSTRUCTION 41984 ah The fluid end / honogenizing head As designed for Prod. - I/h por Mavinyn operating pressure s Maxinun operating tesperature penne: 59,404 ‘TECHNICAL DATA OF HIGH-PRESSURE PUMP TECHNICAL DATA OF HIGH-PRESSRE FIN? Type rusber of plungers Diameter of plungers. | Horizontale 5- piston-pue Stroke of plungers Type of plunger seals ‘ 3 5) Cone valves __[-)_Ball-valves Tos 38 (38) on t0._(32) O ms ype of valves. Hosinal vidth of suction conection (SHH) Woninal vidth of delivery comection = Feed pressure bar | Csinste- ‘TECHNICAL DATA_OF HOMOGENTZING HEAD [pehoubte-stage tosogenizing head Type of head Size of hosogenizing device Pressure setting MATERIALS. Material of pusp housing Material of cylinder block ‘SH. 20 stainless steelINSTRUCTION MANUAL - BETRIEBSHANDBUCH ABBY @ TECHNICAL DATA TECHNICAL DATA OF DRIVE DIMENSION OF V = BELT PULLEYS E Effective disseter f of V ~ belt pulley DRIVE MOTOR (4). = Effective dlaneter of V ~ belt pulley mcEAR” () + Naber of belts Type of Webelts Length of V-belts OF GEAR Manufacturer Construction of gear ) Number of stages Reduction ratio Revolutions at outlet Revoletions at outlet Maxinun torque evtput ‘Quantity of off Grade of ofl CONTROL UNIT HYDRAULIC PUMP. Manufacturer Type. Voltage Frequency Woninal current Rydrefluld teen. Filling capacityINSTRUCTION MANUAL ~ BETRIEBSHANDBUCH 4984 © TECHNICAL DATA MEASUREMENT DESIGNATION ‘DIL COOLING PUMP HOUSING Construction of the oil cooler itted pipe cooler 150 at, 15°C _vith harcness wax. 10-12 06H Consuaption of cooling vater approx RINSING OF PISTONS Rinsing sediue (TS, [Consumption of rinsing medium approx. (SOMDENSATE UNIT Consuaption of cooling vater approx BA voter at 15°C / 11 hot stean condensate wer 3 of 5 = at 5% with hardness axe 10-12 dG a ‘Stean required approx. = at 140°C and 2 pressure of approx. 6 bar & [tora conser oF COOLING WATER approx. fa 8 g TOTAL CONSUMPTION OF STEAM approx. 4} on wueercatins pu vee i Method of lubrication Splash lubrication Lubrication ofl quantity a Grade of of] See: Lubricants re ” (EXTERMAL MEASUREMENT OF HOMDGENISER 2° carnan Hardness (464) = 13 ritish Hardness, ‘Az Installation height = Total height [me __| c= tengt vithvt hoopentsation heads_1 166 {| = | [em __| = tangth vitn hnopentsation tend 1 es Total weight of sachine Machine weight without drive motor SH 20e 10/83 sweet, 4 of 4 on, maw nas rvve: SHL 20 = 40 LUBRICANTS - RECOMMENDATIONS CRAMKCASE OTL REQUIREMENTS (in driving gear of pump) lubricants recoaaended by us ar¢ high-grade, demulsifying GEAR OIL REQUIREMENTS (in reduction gears of purp drive) as a wide temperature rant tendency. The alphabetical order of lubricants Listed hereunder does not imply any superiority of one brand/grade over the other. ‘CRANKCASE OIL INSTRUCTION MANUAL - BETRIEBSHANDBUCH GEAR OIL ‘extended ofl change periods. OX acra-Lavar The Lubricating ofl serves to reduce Triction and vear, and to protect bearings against corrosion. The ‘eral oils. They should also dissipate friction heat from bearings, offer satisfactory lubrication at all operating teaperatures, suppress noise and ensure optimun/service-free operation by long service/life i. The prisary task of a gear of] is to control gear tooth vear, which may occur for various reasons, in such a vay that full serviceability of gears is ensured over an extended period of operation. Gear oils should also meet the folloving requirenents: Satisfactory demulsifying property, high oxidation and temperature stability, satisfactory corrosion protection, low foasing tendency and cospatibility with non ferrous netals. The gear oils reconsended by us neet these requiresents. Hydraulic oils should show specific properties to neet requirenents prevailing in actual practice, vi satisfactory lubricating property, oxidation stability, satisfactory flow and shear stability as vell Ihe oil should also offer anti-corrosion, anti-vaer properties and favourable ater and air releasing ability. It should be compatible with sealing materials and show low foaming HYDRAULIC OIL YOTANOL, HK 100 POTANOL IK 150 Cin driving = Gin reduction ea Gn hydraulic gear of pump) & gear of pump a control systea) = drive) s 201 sae 3,21 2° 95.1 281 zz 631 aor 621. 82 13,01 3 951 ao SS 28,01 gs 951 VITAN DE M6 VISCOSTIY RATE in en2/s (eS) at 40°C ENEREDL C5 100 110 ENERGOL CS. 150 150 EneRDL ALP 4G Noto Noto 100 150 SPARTAN 460 NUTO HG 46 MOBIL: OTE Extra MOBIL DIC Extra Heavy POBILGEAR 634 433 DLE. 5 VETREA 100 VITREA 450 150 viscosity, ratings in an?/s (eS) at 40° C. ss) The 1S0-Viscosity classifacation for industrial lubricants 1s effective since June, 1976. It is essentially identical with ISO standard specification 3448 and ensures internationally unifore TELUS 465/79 02-02.02/1 SH INSTRUCTION MANUAL - BETRIEBSHANDBUCH KEY TO SIGKS ASSEMBLY 200 FLUID END 1 = Spring = Header ring 3 = Sealing, piston 4 = Screwdovn nut purp piston Piston Drive gear housing Suction valve seat Suction valve cone ressure valve cone alve spring falve cage plinder block over ylinder bush = Piston guide ring \ [ aux DESCRIPTION The fluid end of the high-pressure pump comprises tthe following components: Cylinder block (1h) con taining the conical suction and pressure valves (8,9, ‘Wet)and carrying the homogenizing head; the cylinder bushes (16); the pump pistons (5); the piston bushes (6) vith their seals (3) and the screw-dowm outs (4). In the diagran, the piston seals at the cylinder block end are visible only; the piston seals at the opposite end are obscured by the screw-down nut. Ihe cylinder bushes are inserted through the érillings in the face of the drive gear housing (7). The cylinder look, which is forged in one piece, is stt against the cylinder bushes ané tightened up by expansion serexs frox the inside of the drive gear housing. The pump pistons are bolted to the crossheads, vie couplings, and are guided in the piston guide rings (17), in aligaent vith the drive gear. The punp pistons are sealed by special sealings canpatible with the substances to be hosogenized. The front and rear end seals are standard equipnent. The annulus betveen the seals provides a chanber for water cooling of the pistons and boundary lubrication of the seals. aseptic operation, this chanber is fed vith stean condensate, so that it serves as a sterilizing seal able self-contained unit. In Ihe piston bushes (6) together with the pistons (5) and seals (3) form a readily replace The pistons consist of high-grade, high-tensile stainless steel or are chromiua-hardened, alternatively. The readily exchangeable conical valves consist of stellite. Depending on the Layout of the punp, delivery pressures of up to 630 bar are obtainable, 2745/79 «0 sneer, nea-no: 02-0401 sa INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC ALFA-LAVAL ASSEMBLY 400 STAINLESS STEEL PANELS Koy 10 SIGNS Fixture, counter-torque Linkage of shaft mounted gear = Base plate for high-pressure punp Rear panel Side panel, drive end = Ball-type foot, adjustable Frane Motor carrier Front panel Side panel Cover, top ifting lugs escarPrTON The {rane (6) consists of velded box sections. The base plate (2) is velded to the frane and carries the high- pressure punp with shaft ounted reduction gear. the gear box is Linked to the fixture (1), to take up the torque. The motor carrier (7) is located in the lover part of the frae. Another plate carries the hydraulic unit controlling the pressure in the homogenizing heads. The frase rests on tall-type feet (5) which are vertically adjustable. On renoval of the top cover (10), the aachine can be Lifted by the four lugs (11). The frane is enclosed by stainless steel panels (3, 4, 8 and 9), which are bolted to the frames The cover (10) is detachable. The electric and hydraulic controls are positioned in the front panel (8). Side and rear panels ace provided vith lowes for ventlaton, The fran hs 2 sulti-coat protective finish. The stainless steel panels are glass-bead blasted. 2765179 sneer, si INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC aLra-LavaL ASSEMBLY 500 HOMOGENIZING 0 KEY 10 SIONS Honogenizing device Hydraulic control system Product flange discharge Honagenizing head Hono device cone Tnpact ring Hono device seat High-pressure sanifold in cylinder block 9 = Three-piston high-pressure pump escere rio Saugeseite Suction sice The homogenizing head (4), incorporat- ing the horogenizing systen (1) is fed by the three-piston high-pressure punp (9)y ise the head is flanged to ‘the cylinder block of the pump. The homogenizing device represents a throttle valve which is closed by hydraulic pressure. fo avoid excessive ounp pressures, the sachine must al~ ways be started up with opened i.e. pressureless toragenizing valve. Ae SS LY The product, ints the feed, 1s delivered under initial pressure to the suction side of the pute. The pomp pistons force the product into the manifold (8) and via the open homoge nizing valve end disetarge flange (3) into the eischarge Vinee HYDRAULIC PRESSURE To start the hanogenizing process the desired hoeogenizing valve pressure is set with the aid of the hydraulic control syster (2) while the pusp is delivering. The hoto device cone (5) is pressed by the hydraulic piston (2) against the product flow discharges through the seat (7)+ An annulus or ring gap is thus obtained, anounting to the dinension " h © shovn in the dia- gran. The product is forced through the g3p and deoressurized in the process. This release causes 2 high velocity Gf flows the product inpinges ageinst the inner surface of the inpact ring (6) with this high velocity and is re- eased through the cischarge flange (3) of the honogenizing head (4). (oporox. 1 bar) - will couse shear and ispact vill effect the desired homogenization of the The flash-Like energy conversion - from high to low pressur on (vapour phase effects) and turbulence, forces, ca product. 6 and 7) are made of stellite. The hono device seat (7) and the inpact ring (6) he highly strained cosponents (5, in reversed position, for another pericd of operation, thus ob= fare purely wear parts which aay be reused ‘taining double service life. The hoaogenizing process can be effected in one or tuo stages. The use of a secondary stage can inprove the desired effect if a low hydraulic pressure is applied against the primary stage. The pover requirenents of the juno is not affected thereby. The operating pressure prevailing in the prinary stage is the controlling factors 2772 5/82 02-05.06 Druckfernentlastung re: L INSTRUCTION MANUAL ~ BETRIEBSHANDBUCH ASSEMBLY 504 HYDRAULIC CONTROL FOR OOUBLE-STAGE HOMOGEN IZING HEAD, WITH HANO CONTROL with pressure relief © FUMKTIONSSCHALT8ILO (OPERATION DIAGRAM 2 x 0.27 Iain Qe Pay 300/10 bar OC atra-LavaL KEY 10 SIGHS Se 5 tse, mat 18s TL pry 2= inset siston $= onogen, bead, 2nd stage é 4 = Hydraulic piston 5 = Safety valve 2nd stage ; safety valve tst stage 7 = O11 container 8 = Radial piston pump 9 = Pressure control valvey 2nd stage (0 ~ 100 bar) 40 = Pressure control valvey ‘st stage (0 - 300 bar) ‘11 Delivery Iiney2nd stage Uelivery line,tst stage Fluid end 15 = Connon return Line 16 = Oil filter ‘11 = Pressure relief valve tat 6 2nd stage DescaLPrTON The setting of the desired honogenizing pressures in the two tages (1 + 3) is effected by hydraulic pressure. The pump unit of the hydraulic systen is nounted vithin the frane, below the high-pressure honogenizer punp. O11 is delivered by a self prining radial piston uno (8) fron the container (7) through a filter (16) and feed Line (11 + 12) to the hydraulic piston (2 + 4). The oi presses against the hydraulic pistons, thus exerting pressure on the cones and holding then against their seats in the honogenizing heads. The pressure control valves (9 + 10), located at the front panel of the sachine, are set by hand to obtain the desired pressure An the 1st and 2nd stages The control valve for the ‘st stage has a range of 0 - 300 bars the valve for the 2nd stage has a range of 0 ~ 100 bar. The pressure for the 2nd stage is set first. The pressure for the ‘st stage is set subsequently. foth pressures are indicated by the high-pressure gauge nounted on the cylinder block of the fluid end (14). The safety valves (5 + 6) in the delivery lines (11 + 2) protect the hydraulic system against excessive loads and is liniting the naxinun allowable hosogenizing pressure of the nachine. Pressure relief valves (1? ) are reaote controlled solenoid valves which are electrically actuated (pre-set pressure on/off) by switches located in the contralized control station.419 02-06.01 cre: SHL INSTRUCTION MANUAL - BETRIEBSHANDBUCH ASSEMBLY 600 ORIVE (OC ALFA-LAVAL KEY TO SIGNS “= Crabahot routers 3" 2 = Frame 3 = Motor 4 = Torque support 5 = Vebelts DescRTPTION The high-pressure punp of the hone genizar is driven by 2 sotor (3) through V-belts (5) and crankshaft nounted reduction gears (1). The sotor is, as 2 rule, 2 water proofed asynchronous nator Rounted ‘on the lover base plate (2)+ The hollow shaft of the reduction gear is key-fitted on the crank= shaft of the punp. The reactive rnonent of the driving torque is taken up by the "torque support%(4).. The gears are splash Lubricated. The’ over part of the gear box serves ‘as 2 sump. The ofl drain plug is provided with a peraanent magnets Narrow V-belts are used for power transnission. 279SECTION 3 Installationfear me 1183. rvreSHL 20-40 Aufstellungsplan HOMOGENIZER-INSTALLATION DRAWING . SHL 20-40 OC ALFa-LAvVAL SHL_ 20] 25] 30 | 40 A Uist product S85. 38/51 16 |101,6 Eintritt Produkt WW 40] 50180 [100 B Wutlet product Sts BH 1 G8 6 Austritt Produkt mW 40140165 | 80 Soolingwater inlet 8 7 Eintritt Kihlvasser D Cooling-vater outlet § 12x1 DIN 2353 § Austritt Kohlvasser E_ Leak drainage, hore outside Ablauf Stopfbuchsenraua F Giabtathahn Triebverk G Cable gamnection for antor Oil drain cock driving gear A Notor-Xabelanschlud & Terainal box H areteenasten K Electronic box for renote pressure indication Elektronik Teil bei Ferndruckanzeige weight kg net vithout aotor Gewicht kg slab «© @ e f g hb j§ bk 2 = 9 _| ohne Rotor 1487 290 908 1016 1000 1035 +1059 1000 716—«39_—*12%5~—«1097_~=«TND_—*22 860 5 | 531 320 1070 1176 1190 1156 12291500 832_—43—1290_—*1206—sNI 122 1500 | 30 | 60s 389 1680 1524 1470 1588 1562 1500 1060 541794 16781060 _162 2050 w0 | 629470 1608 1750 1634 18001735 1800 1210741916 1058 1200_ 222 4250. * Dimension for double-stage honogenizing head Mat fir Doppel-HosogenisierkopfINSTRUCTION MANUAL - BETRIEBSHANDBUCH CC aLra-LavaL HANDLING AND POSITIONING 4/79 KEY 10 STGAS Hoisting took Stings: Shackle Lifting lugs 5 = Ball-type fe 6 = Spirit Level Toous se quIReD 1 2 3 4 4 Stings of equal Lenoth 4 Shackles, 30 mn bolt dia. 2 Spanmers, adjustable 1 Spirit Level 1 Grane, ecbile WORKING PROCEDURE FV 10 re reuse After the nachine has been unpacked, it ‘should be noved by rabile crane, ex- clusively. After the top cover of the machine fas been renoved, four slings of equal Length (2) are shackled (3) to the Liftings lugs (4) and hooked to the crane (1). The floor on which the nachine is to be installed should be level. Floor tiles should be protected by the use of steel ‘tiles on which to rest the ball-type feet of the machine (5). INSTALLATION HEIGHT "AY see chapter: TECHNICAL DATA of this instruction anual reo.no: 05-01,01 To level up the machine, the spirit Level (6) should be placed on the cylinder block of the high-pressure pump, as shown in the opposite diagran. The ball-type feet of the machine may be screwed in of out, a5 required. MACHINE. WEIGH Cestinated value) SHL 20 = 7380 kg max. SHL 25 = 500 kg wax. SHL 30 = 4200 kg aaxe sit 40 = kg wax VERSTELLBEREICH ADJUSTABLE re: SHINSTRUCTION MANUAL - BETRIEBSHANDBUCH OC abra-Lavat 4179 DIMENSIONS OF COOLING PIPE CONNECTIONS 10 SIGNS Drive gear / crankcase Cooling coil += Pup cylider bushes Return Line Funnel 6 = Cooling water control valye 7-2 Delivery Line 8 = Main vaive(solenoid or pneunatic valve) If not delivered with the aachine| It must be installed on site ! The cooli supplied with complete cutting ring pipe couplings. Plastic piping aay be used for water delivery ané return Lines up to connec tion "4" and from connection "8 2", respe Ihe ends of the plastic piping 2 should be strengthened by "reinforcing § rege? 2 gs" i 16 the machine is equipped vith a condensate sealing systes, i the cooling eoil (2) (for erankease oil cooling) is separately connected to the vater delivery Line. Plastic piping may also aD) ‘erred to ad fran connections MA. The condensate rete N77 Line (4) from connection (8 2) should be steel piping dis- ‘charging into 2 funnel (5)+ STAHLROHR { XUNSTSTOFF-ROHR STEEL PIPE PLASTIC PIPE i 3 & Schneidring/Cutting ring Verstarkerhilse/Reinforcing ring AOHRABPESSUNGEN IN MILLIMETER PIPE DIAMETER IN MILLIME TRE vwscazvenve [__SUAMLROWWE/STEL PES pustic e1rts westinct- en TITRE] CTOTRCESR| LSE [AUSSENOURCHMESSER-OUTER DIAMETER OUTER DIAMETER | INNER DIAMETER re Lge SH 20 4, = tam 4, = 2am 4 = Gem [vsh 2x15, vB 4, = em 4, = tm 4 = 9m [yh @x 05 SH 30 4, = 2am 4, = 2 4 = 9am [vsh Wx 45 cH WO 4, = 2a 42 tm 4 = Gm [vn eS 5 ** steel and plastic piping, pipe couplings and reinforcing rings are available z fron our service division. é a1?5125 fScharge Line 6 = Product feed Line e| 3% Safety valve 7 = Feed punp (rotary) eles Pipe connection, 8 = Draining valve a|-- discharge 9 = Pipe connection, 2 4 Initial pressure gauge _punp cylinder block e 5 = Thernoneter 10 = Precpressured feed Line section MASSTABELLE FUR ROHRE UND ANSCIWEISS-AEGELSTUTZEN MEASUREMENTS FOR PIPES AND WELO-ON-IYP TAPER NIPPLES OMOKOPE /HOMOGENTZER HEAD ZTVLINOCRNOPE (CYLINDER HEAD MASCHINENTYP BLAU /OTSCHARGE TULA /FEED MACHINE TYPE rere; SH 5 INSTRUCTION MANUAL - BETRIEBSHANDBUCH OX ALFa-LAvAL a DIMENSIONS OF PIPE CONNECTIONS AT PUMP CYLINOER 2/81 TANLAGEBEDIN PLANT LAYOUT BLOCK (PRODUCT INLET) AND HOMOGENIZER HEAD (O1SCHARGE) The pre-pressured feed line section should run absolutely straight within a distance of 19! DISCHARGE PI Layout OIN (a) pou. /Incves TOLL/INCHES SHL 20 (up to 315 bar ) SH 25 (up to 315 bar ) SH 30° (up to 315 ber ) SHL 40 (up to 315 bar ) SHL 40 (up to 200 bar) Monogenizers are units included in different processes. Thus the installation of product conévits are process dependend and therefore not descriped in this chapter. Sone installation rules, hovever have to be observed: Upstee and downstream piping, ise. feed and discharge lines must be connected to the machine as follows: Ihe pre-pressured feed Line section (10) should run absolutely straight vithin 2 distance of 11» (approx. 3) from Ghe cylinder block connection (9). The ole product feed Line (6) ~ at least the gart of the ore-pressured feed Line suction (10) fron (9) to (7) - must have the sane size as the cylinder block pipe connection (9). To obtain nitial feed pressure (NPSH), a rotary powp (7) should be fitted in the feed line (6). To indicate initial feed pressure and temperature, 3 pressure gauge and thernoneter (4 + 5) should be fitted in the pre-pressured feed Line (10). If shut-off valves are fitted in the discharge Line (1), a safety valve (2) should be provided, for protection of the machine. To enable pipe Lines to be drained and cleaned venting valves should be fitted at the highest points of Lines, and drain valves at the lovest points. Screv couplings should be used for the connection of the feed and discharge Lines. Dimensions of pipes and veld-on type taper nipples are shown in the above table. The velding edge angle should be 60°. The velding seans should be ground and polished, internally and externally, to net hygienic requirenents. 3735/82 03-04.11 re: SHL 20V~ 220 VAC. INSTRUCTION MANUAL ~ BETRIEBSHANDBUCH VERORAHTUNGSPLAN FUR OIE DRUCKENTLASTUNGS- VENTILE DER HYORAULISCHEN STEUERUNG OC aLra-LavaL WIRING DIAGRAMS FOR THE PRESSURE UNLOADING VALVES ON THE HYDRAULIC CONTROL UNIT ast stage Druckentla- stungsventil fNERKLERUNG ruckleitung 4, Stufe druckleitung 2. Stufe Orckentl astungsventil 4, Stufe Sicherheitsventil 1. stufe Gruckent1astungsventil 2. stufe Sicherheitsventil 2. Stufe Hydraulisches Steuer aggregat Te AnschluBleitung _/ branch Line weve Ye V ALCS Druckentha~ Drackentla= orucketLastungs-| stungsventid stungsventil ventil 1. Ste 4. Stute a, Stufe Pressure relief Fressure hr relief valve relief valve Ast stage Druckentl2- stungsventil SIGus Pressure pipe ‘st stage Pressure pipe 2nd stage Pressure relief valve ‘ast stage (renote control) Pressure relief valve tst stage ( safety valve ) Pressure relief valve renate control) Pressure relief valve 2nd stage (safety valve) Hydraulic control unit te 24 VDAC. ‘st stage Druckentlastungs-| ventil 2. Stufe 2 tte state ; Pressure © Pressure @ Pressure relief valet valve relief valve valve pe Bao stage ad stage AnscaSLEITEN I KLOEASTEN OC KOMGENSTERASCH dayne rows TeGMTAL 88805 vos G)+G strantos = Druk Carvontess = Pressure at Spanang = érucklos cairent) = pressure relisted cee avaSECTION 4 Operation479 sneer ea-no: 4-01.01 ve; SH. INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC ALFA-LAVAL CHECK LI PRELIMINARY. ST FOR INITIAL OPERATION STARTED UP WORK AND CHECKS REQUIRED BEFORE THE MACHINE I Prior to initial operation of a nevly installed horogenizer all component parts to cone into contact vith the product involved should be degreased and cleaned. AIT pipework conected to the sachine should also be cleaned thoreughly. Checking the oil level in the crankcase of the high-pressure punpe In static condition, the oil should be Level with the merk on the perspex housing covers Use high-grade lubricating oils only! These should have positive denul sifying properties Do ot use oils with additives that will inpart enulsifying tendencies. Refer also to "Lubricants Recommendations" in "Section 1 of this manual. Checking the oil_in the crankease for condensate contents If condensate has collected in the crankcase, this should be carefully drained by the sure Grain cock. The period of vater separating from the oil will depend on the tenperature ané condition of the il A period of 8 to 10 tours aay be required. Checking the oil. level in the hydraulic control system of the honogerizing systene The oil Level in the punp-container should show between the tvo punch marks on the dip stick. If the ofl needs topping up, use hydraulic oil as recomended in "Section 1” = "Lubricants Recommendations " ing the homogenizing systene Depressuri Set control valve of hydraulic control systen to ZERO. (Ivo valves are provided with double- stage homogenizer heads)- With renote-controlled systens, the resistor should be set to "ainizupressure". (ponin.) cooling vater circulation, pen water shut-off valve in the delivery Line to the cooling coil in the drive gear housing (crankcase). The water will pass through the coil andy consecutively, through the pup cylinder bushes. With ASEPTIC OPERATION, the cooling coil is separately supplied vith vater from soins. a7i513 4-02.01 rw: Si INSTRUCTION MANUAL - BETRIEBSHANDBUCH ECK LIST FOR INITIAL OPERATION WIRED BEFORE THE MACHINE 1S STARTED UP PRELIMINARY WORE AND CHECKS CC aLra-LavaL Set control valve of hydraulic control systen to ZERO. eM wORK_aND CHECKS nequRED serone HE Oe e Starting up the hydraulic control systen Prior to initial operation afd after every oil change the hydraulic of] punp should be vented to eliainate prining difficulties or feeding air into the hycrau- Lic cylinders of the horogenizer heads. The vent plug of the oil container should be loosened (not removed) and the punp rotor switched on. Then ait until bubble-free oil will issue from the venting fluge Tighten up the plug and allow the hydraulic syster to run idle, ise. pressureless. Repeat this procedure by Loosening the yent plug of the horogenizing head (heads). WORK AND CHECK REQUIRED AFTER STARTING UP THC HOMOGENIZER If the nachine is operated under aseptic conditions, the general operating and checking instructions of the particular plant ~ into which the homogenizer has been integrated ~ Will apply, ege instructions referring to 2 VIIS-plant. (VACI-IHERM INSTANT STERILIZER). Cleaning of the product passage vays Release of product feed Price to starting actual operation, all product circulating systess and product passage ways should be cleaned with the aid of 2 flushing fluid. Subsequently, the system should be flushed liberally with hot water. As the product is alloved to be fed into the nathine, the residual hot water is forced out of the processing systap. Before the honogenizing pressure is finally adjusted, the high-pressure uno rast be operating free {ron air. In sost casesy the air in the pressureless, idling pump will be Gisolaced fron the puop block after a few pumping strokes. To sake sure thot the punp tas been properly de- aerated, the hydraulic pressure control valve Should be closed slovly and 2 pressure of Less than 50 bar obtained. If the needle of the pressure cauge an the punp cylinder block soves erratically back and forth, this is due to the presence of air in the puno cylinders. Return the control valve to 7080 inetiately. Subsequently, repeated closing and pening of the control valve vill éisplace the air fon the individval cylinders without difficulty. fo tot set the pressure higher than 50'bar. Liquids, ine ferently containing considerable anounts of gas, rust be de-gessed prior to being fed into the.hosogenizer. Othervise, excessive stocks in the pump (with erratic gauge needle deflection ranging beyong 30 bar) may secur. When the pressure gauge needle renains in Static position, the final tonogenizing pressure may be set as required. 41249 eo-no; 4-03.01 Te: Sit INSTRUCTION MANUAL - BETRIEBSHANDBUCH CHECK LIST PR URE AND CHECKS R FOR INITIAL OF: How to adjust the honogenizing pressure stage honogenizer_) How to adjust the homogenizing pressures (Double=stage honogenizer ) CC ara-LavaL The honogenizing pressure should correspond to the type and nature of the product being processed. Slowly turn the knob of the pressure control valve from its ZERO position, in clockwise direction, until the desired operating pressure is indicated by the gauge on the punp cylinder blocks Sressure in excess of the saxinun pernissible pressurey to which the machine was designed and delivered, is absolutely inadnissible. Pressure fluctuations can be elisinated by short-tine opening and closing of the homogenizing systen. If the fluctuations continue, the suction and delivery valves in the cylinder black should be checked. Leaky pipework nay also be the couse of pressure fluctuations. The homogenizing pressures should correspond to the type and nature of the product being processed. Slowly turn the knob of the pressure valve controlling tthe second stage from its ZER0 position, in clockxise direction, until the pressure gauge on the punp cylinder block indicates a pressure of approx. 50 bare Subsequently, slowly turn the knob of the pressure valve controlling the first stage from its 2ER0 position, in clockwise direction, until the desired operating pressure is indicated by the gauge on the purp cylinder block. Pressures in excess of the maxinun permissible pressure, to vhich the nachine was designed and delivered, is absolutely inadnissible. Pressure fluctuations can be eliminated by short-tine ‘opening and closing of the homogenizing system. If the fluctuations continue, the pipework should be checked for leaks. However, defective suction and delivery valves in the puep cylinder block may be the cause of these pressure fluctuations. 4/3veer INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC ALFA-LAVAL Operation of Hydraulic Units (177) Bleed pump prior $ to starting! a bleed hose alre provided in the unit by the factory. bleed screw MEx6 DIN 912-8.8 with seating ring Aext0x7 DIN 7603-cu lt flter eck ——_— HEILMEIEK & WEINLEIN | MUNCHEN 80-MEUMARKTER STE. 26 Description of Bleeding Operation ‘Screw the bleed screw fully out prior to fI1ttAg the unit writhnydreulle of, Fill with a proprietary hydraulc oll, lunnal (with acteon Insert) provided (ong the funnel tube for faater filings Te necessary, walt several minutes until the air hes been expelled by the oll from the Interior of the pure. ‘Then fe-tighten the bleed acrew. Switch the purrp on end off several timea, and then Operate it under zoro-preasure circulation for @ short Period of time If the control aystem design Is compe- | ‘with thie mode of operation. Alternatively, the pr imitingvalve shouldbereset to the zero pre Bure condition andthe circulation effected via this vaiv Subsequently, operate the hydraulic installation without Toed several times through all funetlonal movements, iteecessary withthe preasurellmiting valve resat, until those movements are carried out smoothly withinthe predetermined t : Preset the pressure limiting valve up to the specitied ‘value (check with a pressure gauge).cre: SH. INSTRUCTION MANUAL - BETRIEBSHANDBUCH OX ALFA-LAVAL LIST OF CHECKS AND WORK DURING THE HOMOGENIZING PROCESS e@ Regular checks on presse and temperature of the feed ; orassure gauge and thernoeter in the feed Line should be watched continually. Keep the temperature of the feed as constant as possible. Pressure fluctuations, registered by the gauge, indicate irregular feed rt @ een nemnen ee eee should be adjusted with the aid of the knob on the pressure control valves If the needle in the pressure gauge on the punp cylinder block swings back and Forth, find out whether the flow rate of the feed is sufficient. Further, leaky pipe connections and defective suction and delivery valves in the pump cylinder block aay be the cause of erratic deflections of the gauge needles @] tesco at Sea bro ‘cooling and pup piston Lubrication will depend on the flow rate of the water. If the wachine is operated under aseptic conditions, the general operating and checking instructions of Fe particular plant, into which the honogenizer has been integrated, will apply. The CONDENSER UNIT fitted to the seritte in thie instance requires additional checks» The instructions for the initial operation of fhe con enser system are contained in "Section 4" : " Control of teas pressure ond condensate temperature "s Regular checks should be nade of: Live stean pressure Stean pressure should be constantly kept at 6 - 7 bere jensate temperature Condensate teaperature, at the beginning of the honogenizing operation, should be 1109 C at 2 pressure of 0.5 bar. Pressure and temperature should be kept constant under any circuastances. agprot. 27 I/he ( Ascertain flow rate by runing effluent condensate into measuring vessel of known capacity). Constant strong cloudiness or turbicity appearing. in the condensate sight glass is an indica ton of defective puap piston seals which stould be renewed. Regular checks should be made of: Co e@ tegular checks should be nde oft Cooling vater flow cate The cooling water flow rate should be approx. 100 Uh (Cheek by nears of neasuring vessel of known capacity). 4/4519 4-05.01 rvve: SH INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC ALFA-LAVAL i} level tak drain plug = Dipstick seat iL Levels in the punp drive gear/erankcase (Figs), in the reduction gear (Fig.2)y and in the container of the hyoraulic control systen (Fige3) stould be checked every tine the nachine is put into operation {ses prior to starting up. DESCREPTION ORIVE The oi] level should be at the aark (2) in the perspex cover. Also check whether any water (condensate) has settled fron the oil Tf so, the vater must be carefully drained through the cock in the sump of the housi AR/CRANKCASE ATTENTION! Mater, and used oil a suite It must not be alloved| ite run into the sewage systems Top up the oil charge through the filler (1) if any oil has beon lost with the water rained. REDUCTION GEAR A dipstick is provided in the gear box (Fige2), and the ofl level should show between the punched marks on the dipstick (2). Fresh oil is poured through the filler (1) in the top of the housing. Used oil is drained by opening the plug in the sunp of the gear box and should be collected in a suit= able container. SCRIPTION HVORAULTC CONTROL SYSTEM 0 The hydraulic unit (Fige3) is located in the lover section of the frane, Oil check ie by dipstick, as illustrated. The Gil level should show between the punched aarks on the dip- Stick (2)s fresh ofl is poured through the filler (1). Used il is drained by opening the plug (3) and should be collec ted in a suitable container. 0:1 change periods in the punp drive / erankeasey eduction gear and hydraulic systen are nentioned in Section 5 + " Maintenance”. for recommended oils refer to Section 1: “echnical Data". 475INSTRUCTION MANUAL - BETRIEBSHANDBUCH OX ALFA-LAVAL = SHUT-DOWN PROCEDURE WORK REQUIRED PRIOR 10 AND AFTER SHUT-DOWN e@ en product is changed or product feed is interrupted Turn knob of pressure controt valve in the hydraulic control syster to 2€#0 innediately. E (In double-stage horogenizers to hydraulic : pressure control valves are fitted). c e Prior to conpletion of the homogenizing process Residual homogenized product shouldbe by-passed into vaste tarke (Required only if honognized and ton-onogerized product must be prevented fron being inter-nixed. De-pressurize honogenizing systen 0407.01 Turn knob of pressure control valve in the hydraulic control syster slovly to ZERO. (In double-stage horogenizers two hydraulic pressure control velves are fitted). If renote-control systens are provided, the resistor(s) should be set to ps e Shutoff product feed Shutoff feed and run ht water Lato feed Lise Flush the pump cylinder block, the de-pressurized hosogenizing systen and the product discharge line . until clear Liquid runs into veste tank. ALTERNATIVELY: Clean and sterilize the machine in compliance with local regulations. Shut off cooling Aepending on the type of installation concerned, e the shut-off valve in the delivery Tine for the ofl cqcler in the drive gear/erankcase closes autoratic~ ally, or nust be closed by hand. off pover drive Carry out specified checks and maintenance. cre: SH 4/749. 0-08.01 vee: SH INSTRUCTION MANUAL ~ BETRIEBSHANDBUCH OPERATING TROUBLES CAUSE ANO CURE INSUFFICIENT OUTPUT ERRATIC VEBRATION OF RED HOMOGENIZING PRESSURE NOT OBTAINED HOMOGENTZING PERFORMANCE UNSATISFACTORY A POSSIBLE CAUSES Faulty sealing surfaces of suction and delivery valves Suction and delivery valves sticking Suction Lines Leaking Drop in rapeze due to slipping belts Air in cylinder block Leaking suction and very valves Leaking piston seals Insufficient hydraulic pressure Honogenizing systen leaking Horogenizing syster leaking Hydraulic pressure insufficient Pressure gauge on cylinder block does not work properly (Faulty indication) It should be considered that the efficiency of the homogenizer oes not depend on the honoge- nizer systen exclusively, but also on the corposition of the product to be processed. If efficiency drops, compared vith initial performance, the product should be checked a vell for any Likely changes in composition. Valve in by-pass line is partly or fully opened. Non honogenized and honogenized product is nixed. 478 elke CUR Re-grind or replace valves Clean valves and valve guides Tighten up pipe connections and / or replace defective seals Tension Yebelts De-aerate cylinders Re-grind valves or replace Replace seals Check hydraulic pressure Control valve Re-grind cone and cone seats replace if required Reegrind cone and cone seat. Replace if required Check pressure control valve. Check hydraulic control systen Check gauge and replace if required Close valveSECTION 5 Maintenance1/81 sme 1 of 5 tH ee: SH INSPECTION AND OVERHAUL SHEE i Inspection ane overhaul ( Inspecti Servicing 1 changes In grease apol ications: Replenish or change grease if required. werhaul aneral_ overhaul CALFAOLAALreconmends Sverhaul to be catried out under suervision af ALFA-LAYAL engineers) [with new nachine ped for aseptic operation WAT = dear part (renew) INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC atra-Lavat DRIVE GEAR / CRENKCASE 6 ecarons hours and wed ORIVE GEAR/CRANKCASE Check oil level 45 O41 change aby 415 wat | General overhaul REDUCTTON GEAR Check oil level, af iT change Ay 5 General overhaul 5/11,5/%2 WeBELTS V-belt tension 5/1 motor Replenish grease AINTENANCE INSTRUCTION ta Section 5 spare parts Lists (pink sheets) by W15451955/ hy 5151516, 5/21 5/1 — 2300 5000 2h — daily 400 — 500 70 — 750 200 — 1600 72.000 200 — 25 2000 o c aL c c AL r 1 Every 20.000 hours of op. (Hane plate refers)INSTRUCTION MANUAL — BETRIEBSHANDBUCH x ALFA-LAVAL = 1 INSPECTION AND OVERHAUL SHEE LO> ree: SHEL Inspection and overhaul Code ne Inspection S Servicing uum 80 S| Cs Oi changes In grease applications: & eplenish or change grease if required. E ] 0 = overraut AL = General overhaul (ALFACLAVAL recommend: Gveenaul to be carried out under supervision of ALFA-LAYAL engineer.) *) = with new machine **) = After every overhaul +) = Standard model = |») = Machine equipped for aseptic operation Seles (renew) ‘OPERATING PERIODS s ~T 3 MAINTENANCE . : INSTRUCTION 2) elel al | gl2 g refer to Section SB) Ss) eS) S| = MACHINE PART a eae id in stects) | ¢| 8| 8] &| &| 2/8 CYLINDER LOCK vat | Suction valves 2hy MfBy 515, 51s I 5/20 vat | Pressure valves 2fhy By 515, 517s I 5/20 z z PUP PISTONS 5 Pistons 4/8, 5/10 a wat | Piston bush 4/8, 5/10, 5/17 ao PRESSURE. GAUGE 4/8, 5/6 & re181 sneer h of 5 4 rec no; (5-01, AL INSPECTION ANO_UVERHA Inspection and overhaul Code INSTRUCTION MANUAL - BETRIEBSHANDBUCH L_SHEe Inspection servicing it changes In iL recornend ‘to be carried out under supervision LAVAL engineer.) ith new machine fter every overhaul ndard ode] Machine equipped for aseatic operation war war ail © sear part (renew) OPERATING PERIODS IN HOURS _ refer to nS | 1 y \ : w Wy Ly ay (pink sheets) z| s| 2] 2/2] 2/8 HOMOGENIZER HEAD Impact ring 2/7, 4/8, 5/8 Service life Cone 2/7, 4/8, 5/8 depends on Cone seat 2M, 4/8, 5/8 product involved. Nousing seals 2m ys 5/8 | | ir eitk is processes vouuse PIstoN Piston seals 5/8 | 511.3, 5500 — S800weer 5 of 5 ais reco; 05-07.01 vee: Sil INSTRUCTION MANUAL - BETRIEBSHANDBUCH INSPECTION AND OVERHAUL SHEi i wee: SHL assewety 2504 1 changes In grease applications: Replenish or change grease if requires. Wernaul = General overhaul (ALFAALAVAL recomend: Overhaul to be carried out under supervision of Auf LAVAL engineer.) ney machine Atter every overtaul standard sodel achine equipped for aseptic operation ear part (rene CC atra-Lavar HYDRAULIC CONTROL syste MEINTENANCE INSTRUCTION refer to Section 5 sand spare parts lists (pink sheets) MACHINE PART wal zh —— daily avo Check oil level 2/8, 4/5 11 change Clean oil filter 45 Pressure reducing valve 4/5 Safety valve 45 200 — 250 400 — 500 700 — 750 1200 — 1600 2000 — 2300 OPERATING PERIODS IN HOURS 2.000 aL05-02.01 AL INSTRUCTION MANUAL - BETRIEBSHANDBUCH TOOLS OC aLra-LavaL ETIMMULSCHLISSEL ‘SINGLE OPEN ENO SPANNER Sw may Hm corre onuscHLiSSeL DOUBLE OPEN END SPANNER eee UOPPELRINGSCALUSSEL DOUBLE HEX. RING SPANNER 7x9 m (offset pattern) LE SECHSKANT-SCHLUSSEL 5y 6, 10 00 ALLEN HEAD WREACH ve STECKSCHLUSSEL-£INSATZ HEXAGON SOCKET SW 2h me, SW 3 acouress cx a ‘ADAPTOR oat UssciAL TOME , RATCHET a saverscnuissee HOOK SPANNER ea SSCHRAUBENOREBER ‘CHEW DRIVER TANENAUS ZIEHER INTERNAL PULLER VENTILDICHTUNGSCINBAUVORRICHTING VALVE FITTINGS evict ela Wrench opening Py »us 5-03.01 eo. W, st INSTRUCTION MANUAL - BETRIEBSHANDBUCH SPEZIAL WERKZEUGE SPECIAL TOO CX aLra-LavaL VENTILKEGEL ~ HEBEVORRICATING VALVE CONE LIFTING CLAMP VENTILKUGEL ~ SAUGACBER VALVE BALL SUCTION CUP VENT TUCAFIG ~ HEBEVORRICATUNG VALVE CAGE LIFTING CLAMP AUSZIEHVORRICHTUNG FUR KOLBENBUCHSE PULLER DEVICE FOR PISTON BUSH CINDRUICKVORRICHTING FUR KOLBCNBUCHSE PRESS-IN DEVICE FOR PISTON BUSH PONTAGEVORRICHTUNG FUR HOMOGENTS IERKOPF = DICHTUNG MOUNTING DEVICE FOR HOMOGENTSING HEAD SEAL DREWMOMENTEN-SCHLUSSEL TORQUE WRENCHW098 5-04.01 ve: SHL INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC aLra-LAVAL SPEZIAL WERKZCUGE SPECIAL TOOLS AUSZIEHVORRICATUNG FUR VENTILSITZE PULLER OEVICE FOR VALVE SEATS AUSZIEHVORRICHTUNG FUR KREUZKOPF -DICHTUNGSBUCHSE PULLER DEVICE FOR CROSS HEAD SEALING BUSH EINZICHVORRICHTUNG FUR KREUIKOPF-DICHTUNGSBUCHSE MOUNTING DEVICE FOR CROSS HEAD SEALING BUSH ABZICHVORRICHTUNG FUR AUFSTECKGE TRIEBE PULLER DEVICE FOR ORIVING GEAR AUF ZTEHVORRICHTUNG FUR AUFSTECKGETRIEBE MOUNTING DEVICE FOR DRIVING GEAR a® = Koabiniert vervendbare Werkzeugteile / Tool components for sultiple uses| : ; wt hoe Cl aLrA-LAVAL é Nuts {Gr bolls with reduced stank are tightened up by 3 applying a torque wrench. Ruts need not be secured after 3 the bolts have been tensioned to the specified torque. a The torque to be zpplied to the bolts are specified in i the Table below. z Mf the specified torque applied to a bolt is to be checked, ‘the nut should be unscreved, and tightened up again by torque wrench (2), 2s specified. Frior to tightening, the contact surfaces of the nuts stoulé be cleened and rubbed filmy vith HOt COTE ® (grey). The nuts should then be turned down by hand, thuab-tight. Then apoly torque wrench and tension nuts until the pointer (1) ATTLATION ) JAF the specified torque indicates the specified torque on the scale. DB) fies snacvertently been exceeded, the aut should 7 be corpletely unscreved and rectightened as required. The bolt should sot be left in over-steessed condition under any circvéstences. Locet0n or go. 1S LOCATON =]= =[=[-]= oF BOLTS alale|s CYLINDER BOCK cover 780] 130 4 Ho] 340 | 450 [450] torques expressed in von 2 inot/10 bp CHLINOER BLOCK 10 Fu? ¥OUSING 360) 360} 360] 360] 530] 530 | 600 Je00 ate] 40 | 60 Low preesure sachine Wigh-pressure sachine sit519 5-06.02 SH INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC ALFA-LAVAL HOW TO THE EMOVE AND FIT CYLINDER KEY 10. SIONS 1 Split flange aolts with reduced shank Gauge = Torque wrench Cylinder block Goring 7 Back-up ring Bush Toous REvOTRED 1 Torque wrench 1 Hexagon socket SW 24 en 4 Adaptor 3/4" to 1/2" 4 Seriber wovrcore ® (white) warycore ® ( grey) PREPARATORY. WORK De-pressurize the honogenizing syster and close shut-off valves in product feed and dis~ charge lines. Switch off power and secure against unauthorized handling. Shut-off cooling supply and shut-down condenser systen, if fitted. If renote- control systen is installed, re- rove transnitter lead from gaugee procenune 0.5 hh Time 8c0U Uefective gauges should rot be repaired locally, but forvarded fo manufactures for epairs. enove the four nuts of the bolts with reduced shark (2) of the split flange (1). Lift gauge G) together vith the split flange off the cy- Linder block (5). Remove the bush (8), backup ring (7) and c-ring (6) fron the bore in the cylinder blocky by aeons of seriber. fenove protective cover fron the diaphrage of the nev gauges Renew the bush (8), back-up ting (7) and O-ring <6). Rub the new parts sparingly with MOLYCOTE (white) and slips then onto the gaige socket. Yow insert gauge to- gether vith new sealings into the bore of the cylinder broek. Sip the tue halves of the split flange onto the bolts with, redues shark 2). A the rtet tcurfaces of the nuts and the threads of the bolts sparingly with MOLYCOTE@ (grey). Replace nuts thund-tight. sarraee she fit of the gauge to obtain proper reading position. Apply torque wrench and tighten up euts to specification. cations " in Section 5 ) (Refer to Torque sp 5765179 5 & ‘ree: SH sealing rings ! INSTRUCTION MANUAL - BETRIEBSHANDBUCH (OX abra-Lavat HOw TO REMOVE AND FIT SUCTION AND Bs VALVES IN CYLINDER BLOCK KEY TO SIGNS Te vValve cage lifter 6 = Cylinder block When dismantling 2 = Valve cage 7 = Internal puller take note of 3 = Valve cone lifter = Valve seat sequence, location 4 valve cone 9 = Seal and nunber of 5 = Valve seat puller 10 = Notch for cylinder pin LS REQUIRED T Torque wrench 1 Internal puller 4 Hexagon socket SW 50 mn 1 Valve cage lifter 1 Adaptor 3/4" to 1/2" 1 Valve cone Lifter 1 Set of spanersy 30-46 ea 1 Tomy bar 1 Screw driver 11 Hamner handle 4 Velve seat puller MOLYCOTE ( grey) Grinding conpound MOLYCOTE (white) PREPARATORY WORK De-pressurize homogenizing systen and close shut-off volves in| product feed and discharge Lines. Switch off power and secure against unauthorized handling. Shut-off ot supply and shut-down condenser systen, if fitted. PROCEDURE 1.30h TIME REQUIRED (per unit) Renove suts fron bolts with reduces shank of the cylinder co= ver with the aid of the torque wrench. Lift cylinder cover off the cylinder block (6), use screw driver to assist Lifting, if required. Apply valve cage lifter (1) and lift the pressure valve cage (2) out of the bore of the cylinder blocks Apply valve cone Lifter (3) and Lift the valve spring and valve cone (4) out of the valve seat (8). Apply internal puller (7) together vith valve seat puller (5) and ull out the valve seats Then repeat the procedure ~ in the sane sequence - to diseantle the suction valve. Clean all components thoroughly and check for danages (Valve springs are particularly ingortant!). Replace defective parts. Slight pressure tarks in the contact surfaces of valve seats should be ground with fine ound, If one or the other valve seat or valve cone has to be replaced, the new parts should be graund-in thoroughly. The sealing rings of the cylinder cover ané valve seats must be renewed {lvays! Any deposits on the valve seat bare in the cylinder block should be renoved; (grind lightly). ub all parts, including the valve seat bore, sparingly with MILYCOTE®@ (white). Re-fit all parts. Valve seats should be Griven hone with 2 hammer handle. 90 nat forget the valve springs! CAUTION : The spring load may push up the valve cages (2)» wen fitting the cylinder cover, particular care should be taken that the cylinder pin in the cylinder cover will fit precisely into the notch (10) of the pressure valve cage. van contact surfaces of the felt nots and rub then sparingly with MOLYCOTE @ (grey). Tighten up nuts of bolts with reduced shank crosswise, to the specified torque. (Refer to "orque specifications" in Section 5.) If Leakage occurs at the ¢y- Linder cover, do not tighten up the nuts any further, but change the seal in the cylinder cover. (Refer to "iow to fit Lip sealing rings in cylinder block", Section 5.) grinding con Suction-valve seating surface in cylinder block to be sparingly brushed with LOCTITE@surface sealing compound 572! a749 5-08.01 rive: Si INSTRUCTION MANUAL -- BETRIEBSHANDBUCH OC aLra-LAvaAL DISMANTLING AND ASSEI For nut torques refer to “Torque specifications” in Section 5 ev 0 steas Studs (Product discharge flang Hydraulic control piston Centering ring O-ring Seat Studs, cylinder dlock Inpact ring ToOLs REQUIRED 1 Torque wrench ean ‘1 Hexagon socket Sw 24 am Housing 1 Adaptor 3/4" to 1/2" aa Tee See econo 4 Piece of hardwood De-pressurize tomogenizing systers Close shut-off wot vcore ® (nite) valves in product feed and discharge lines. Switch Off power and secure against unauthorized handling. Shuteot? cooling water supply and shut-down conden xoceouee ser systen, if fitted, Seiteh off hydraulic control systens 4.8 ho Time ReQUIECD in suitable container. fF housing (9) from fravlic line fron cylinder of the control piston (2). Catch up hydraulic ofl Disconnect hyd ferove product discharge flange fron honogenizer head, Screw 0 Renove nuts from studs (1). cylinder block. Sit the seat (5), the inpact ring (7)y and the cone (8) out of the housing of the honogenizer Head. In cxse of difficulty, dive out the cone fros the hydraulic control piston end (2), applying gentle Knacks with nallet sad hardvand. Now renove O-ring (4) and back-up ring fron the housing. Clean all parts thoroughly. Check. seats Tnpact ring and cone for danages. (Also refer to "wear phenomena in ispact rings, due to excessive service periods! in Section 5 : Maintenance.) fit new spares in exchange of worn parts. Seals stould slvays be reneveds fub all parts sparingly with MOLYCOTE® (white) and insert into the homogenizer head. Check hydraulic control piston (2) for leaks, {f oil Leaks fron hydraulic piston, the centering ring (3) sould be taken up and th piston pulled. Renev piston guide rings and STEP SEAL. the rod guide in the centering cing shauld also be vratgwde Serev the Rosognizar head together vith the hydraulic contra pistony ono the cylinder boc iTanten up cap nuts, erossuise, with torque wrench. Benflt product discharge Flanges Conect ny aie line to ylinder of control piston. Bleed hydraulic systen through vent serev (10). The oll must flow cut free from air bubbles. 5785/79 nea-no: 05-09-01 sre: SH INSTRUCTION MANUAL - BETRIEBSHANDBUCH (CX ALFA-LAVAL HOW TO REMOVE AND FIT PUMP PISTON TO CROSSHEAD EXTENSION PULL AND FIT CROSSHEAD SEALING BUSH BEY 10 SIGS = Connecting bush t ring Piston Hens screw with cup spring washer 5 = Conbined puller and nounting device for crosshead sealing bust Crosshead sealing bush Fixing screw Grooved sealing ring 9 = O-ring 410 = Crosshead extension 6 7 8 TooLs REgUIRED 4 Set of spanners 14 - 24 mn 4 Allen head wrench 6 mm Hoc eure (grey) PREPARATORY WORK De-pressurize the homogenizing system. Close shut-off valves in product feed and discharge Lines. Switch off power and secure against unauthorized handl ing. Shut-off cooling vater and shut-down the condenser unite Remove cover. Screw out fixing screw (7)~ PROCEDURE re hh TIME REQUIRED (per unit) enove the three screws with cup springs (4) fron the crosshead extension (10). Sli connecting bush (1) over piston (3)« Remove split ring (2) and push piston into the cy- Linder block. Fit puller (5) vith tye M6 - screws to the crosshead sealing bush (6) and “by turning the crankshaft ~ pull the seal ing bush together with the crosshead exter- sion (10) out of the punp drive housing (crankcase). Clean all parts thoroughly. Al ways reney defective seals (8 + 9)- Rub seals ith MOLYCOTE. Revers the puller and fit to crosshead extension with three serewss By turning the crankshaft, the four studs in the] device will force the crosshead sealing bush (6) back into the pusp érive housings Renove nounting device and secure the seal ing bush with the fixing screw (7). Connect piston (3) to crosshead extension (70). 00 fot forget to fit the split ring (2). firmly tighten up the screws (vith spring washers) (4). The cup springs should be compressed. Finally turn the machine to ascertain proper slignnent aed snooth runninge L B79519 neato: (5-10.01 sit INSTRUCTION MANUAL - BETRIEBSHANDBUCH OC aLra-LavaL MOVE AND KEY TO SIGNS uller for piston bush hrust 3 = Cylinder pin and bores Jaring and back-up ring bring 6 = Piston bush ress-in device for bush osshead extension 9 = Piston connection Piston Hook spanner roms acqureeo Tet ring spamers 14 = 2 4 Hook spamer 8 20 - 730 1 1 Pressein device MOLYCOTE® (white) ma PREPARATORY WORK the honagenizing se shut-off valves in praduct f and discharge Lines. Switch off po and secure against unauthorized hondl- ings Shut-off cooling eter and shut down condenser unit, if fitted. DURE De-pressur 0.5 hime ReguiRed (per unit) Resove piston connection (9) froa crosshead extension (8). Insert puller (2) into the greove of the piston bush (6) in front of the thrust nut (2). fow screw off the thrust nut by hook spanner (11), thus pulling the pis’ bush out of the cylinder bush. crossnend exte outer dead ce tre and renave thrust nut. Pull piston (10) together with piston bush out of the cylinder bush, as illustrated. Re- ove header ¢ing and spring from the cylinder bushe Clean all parts thoroughly and check for defects. Always renew all seals! (Refer to" fow fit STEP SEALS " in Section 5 (5/17). Rub all parts spar- ingly vith MOLYCOTE®(vnite). Slip piston bush and seals onto the piston and insert into cylinder bush. Turn piston bush to rake sure that the cylinder pin fits precisely into the bore (3). Slip press-in device (7) over the piston and fit thrust ute Nove crosshead extension slovly fron botton dead centre, thus for~ ing the piston bush into the cylinder bush. When the thrust nut en~ ges the thread on the cylinder bush, resove the press-in device fron the piston and firsly tighten up the thrust nut. Comect piston vith the crosshead extension. fisalhy tu eee eetaine to ascertain proper alignaent and stooth running. Check cooling water system (under pressure) for leaks E7an4/79 sneer 05=11.01 vee: SHL INSTRUCTION MANUAL - HOW TO CHECK V-BELT TENSION AND FIT v Bt fauve OF THUMB 1 Metre center distance] will correspond to 2 elt depression of approx. 16 nm should be adjusted as follo Loosen the lock nut of the torque supp: as specified. then tighten up and Lock. If Vebelts sust be renewed, the torque its base to ensure that the belts are THE BELTS BY USING A SCREW DRIVER OR SI position, the tvo pulleys (1 + 2) shou! base plate, crosswise, and adjust watch the Vebelt drive during the init tensioning on completion of approx. 30 as the apparent slack, due to bedding~ BETRIEBSHANDBUCH OX aLra-LAVAL KE 10 SIONS Pulley, gear shaft 2 = Pulley, motor 3 = Screw driver = Steel ruler 5 = Torque support TOOLS REQUIRED 4 Set of spanners 2h - 55 sm 1 Screw driver with wide and blunt edge 1 Steel ruler Excessive heating up, excessive vibration of V-belts, and oisy running are due to insufficient ° 2 tension in the belt. Thereforey 200 200-00 4 722 1064-60 Mluid end ( Constant parts ) Mossi gkeitstei(Geichteile)} 1 2 | 3 4 5 [6 ie g TDENTY KUMER DESIGAATION Sz] wis |F TOCNTITATS-at BEZCICHNONG DIMERSION MATERIAL J] evcenunccx = 200-04 200-05 200-06 200-29 200-30 200-31 200-32 200-34 200-35, 200-37 4 722 0982-01 4 722 0986.01 4017 4010-75 4 600 0050-16 4 722 1066-01 4 122 1692-01 4 190 6810-12 410 6240-01 4 001 5020-06 4 O70 6240-02 4 001 5020-07 4 015 0025-25, 4 122 1074-80 4 010 6101-84 4 001 4000-40 Gylindrical bush Tylinderbuchse Scev-down nut Drucknut ter Cylindrical pin Tylinderstift Spring Feder tyLinderblock Tylinderblock Gover Deckel Cylindrical pin Tylinderstift Cup nut tuteutter Extention screw Dehn-Stiftschraube Cop nut Huteutter Extention screw Dehn-Stiftsehraube Washer Scheie cup nut huteut ter Stud bolt stiftschraube 200-40 200-4 4 122 1522-01 4 010 6107-84 Pressure gauge flange Ponoreterflasch cup mut ruteutter Cover for suction pipe Beckel far Saugleitung #5 6 na Ka Ae K16 "16 fbx? #5 x 55x80 ax PK 20x97 6PM 2 x 188 N16 x40