manual vt+660

1 VT660 instruktion engelsk 31.08.2000

��INSTRUCTION MANUAL

SSHE, TYPE VT+660

SERIAL NO. :

ORDER NO. :

DATE :

CUSTOMER :

NB! THIS MANUAL SHOULD BE READ CAREFULLY BEFORE STARTING UP

�� APV , UNIT SYSTEMS · Pasteursvej · DK-8600 Silkeborg · DenmarkTlf: +45 70 278 278 · Fax: +45 8922 8901 / +45 70 208 990


TABLE OF CONTENTS

TABLE OF CONTENTS -------------------------------------------------------------- 2

DECLARATION OF CONFORMITY ------------------------------------------------- 3

1 - SAFETY INSTRUCTIONS ------------------------------------------------------- 4

1.1 GENERAL INFORMATION ----------------------------------------------------------- 4

1.2 ELECTRICAL CONNECTION -------------------------------------------------------- 4

1.3 HOT SURFACES ---------------------------------------------------------------------- 4

1.4 START UP ----------------------------------------------------------------------------- 4

1.5 SPECIFICATIONS --------------------------------------------------------------------- 5

2 - RECEIPT-------------------------------------------------------------------------- 6

2.1 RECEIPT - INSPECTION ------------------------------------------------------------- 6

2.2 GUARANTEE -------------------------------------------------------------------------- 6

3 - INSTALLATION ------------------------------------------------------------------- 6

3.1 LOCATION ----------------------------------------------------------------------------- 6

3.2 ELECTRICAL CONNECTIONS------------------------------------------------------- 7

3.3 PRODUCT CONNECTIONS (CYLINDER) ------------------------------------------- 7

3.4 MEDIUM CONNECTIONS (JACKET) ------------------------------------------------ 7

3.5 CONNECTION OF FLUSH WATER TO SHAFT SEAL ----------------------------- 7

4 - CLEANING ----------------------------------------------------------------------- 8

4.1 CIP CLEANING ------------------------------------------------------------------------ 8

4.2 MANUAL CLEANING ----------------------------------------------------------------- 9

5 - METHOD OF NORMAL OPERATION------------------------------------------- 9

5.1 START-UP------------------------------------------------------------------------------ 9

5.2 STOP ----------------------------------------------------------------------------------- 9

6 - INSPECTION AND MAINTENANCE -------------------------------------------- 10

6.1 DISMANTLING TOOLS --------------------------------------------------------------- 11

6.2 PROCEDURE FOR DISMANTLING FOR ORDINARY CHECK-UP --------------- 11

6.3 SHAFT SEAL -------------------------------------------------------------------------- 16

7 - SPARE PARTS LIST ------------------------------------------------------------- 21


DECLARATION OF CONFORMITY

Manufacturer:

Company name: APV, UNIT SYSTEMSAddress: Pasteursvej 1Postal code / Town: 8600 SilkeborgCountry: DenmarkTel.: +45 70 278 278Fax: +45 8922 8901 / +45 70 208 990

Hereby declare that:

Machine:

Type: SSHE VT+ 660Serial no.:

is in conformity with:

the COUNCIL DIRECTIVE of 14 June 1989 on mutual approximation of the laws of theMember States on the safety of machines 89/392/EEC with amendments with specialreference to enclosure 1 from the Directive regarding essential demands on safety andhealth in connection with the construction and manufacture of machines. Furthermore,the SSHE VT+660 complies with: The Low Voltage Directive 73/23/EEC and the EMCDirective 89/336/EEC.

Furthermore, the machine is constructed in conformity with the following standards andinstructions:

Instruction on design of technical aids: AT no. 561Instruction on amendment of design of technical aids: AT no. 669Instruction on pressure vessels and pipe systemsunder pressure: AT no. 746Instruction on construction of pressurised equipment AT no. 743EEC directive on pressurised equipment 97/23/EFUnfired Pressure Vessel Standard EN 13445TRB (construction standard for pressure vessels) AD-MerkblätterMachine Safety: EN 292-2/A1Machines for the food industry: Demands on safety andhygiene: Basic terms – Part 1: Demands on Safety: EN 1672-1

Part 2: Demands on Hygiene: EN 1672-2

Company:

Signature/Date:


1 - SAFETY INSTRUCTIONS

1.1 GENERAL INFORMATIONIMPORTANT:

This instruction manual must be read carefully if the scraped surface heat exchanger is tobe installed, operated and maintained without risk of injury, and furthermore shall provide agood and troublefree operation of the machine.

The scraped surface heat exchanger SSHE VT+660 can, owing to its function, be danger-ous if it is incorrectly installed and used. Therefore, it is required that installation and op-eration is carried out by qualified personnel.

1.2 ELECTRICAL CONNECTION

Electrical connection and electrical modifications of the SSHE VT+660 must only be doneby authorised electricians in order to ensure that the technical, electrical safety regulationsare observed. – For further information regarding electrical connection, please see section3.2.

If there are any signs of damages on f.inst. wires, connections or terminal boxes, thepower must be cut out immediately, and the repair must following be carried out by anauthorised electrician.

The motor is of splash-proof type, but water must never be splashed directly on the motorduring cleaning of the outside of the scraped surface heat exchanger.

Dismantling and service of the machine must only take place when the power supply iscut out. It must not be possible to connect the power when the service is being carriedout.

1.3 HOT SURFACES

In certain situations the SSHE VT-660 can reach temperatures on the surfaces that cancause burning when touching it. In such cases it is necessary to fence these hot surfacesto avoid unintentional touching. This should also include the connected steam pipes.

In case of service and dismantling of the machine, the supply of cooling/heating mediummust be interrupted, and a suitable temperature awaited.

1.4 START UP

Before start-up it must be ensured that the machine is correctly assembled and con-nected. In particular it must be checked that all clamps are firmly tightened (especially thelarge 6” bottom console clamp). Furthermore, it must be checked that the coupling safetyfence is correctly mounted.


IMPORTANT:A constant flow of flush water around the shaft seal of the machine in the console is re-quired. Therefore, it must be ensured that the flush water inlet and outlet are correctlymounted, and that the flush water intake is open (flow: 10-20 L/h).

The scraped surface heat exchanger must under no circumstances be started up before ithas been checked that the above instructions have been carried out. For more detailsabout the shaft seal see paragraph 3.5 and 6.3.

1.5 SPECIFICATIONS

Model: SSHE VT+660Serial no:Weight: 150 kgsDimensions: See section 3.1Recommended product flow: 2 – 10 m3/hRecommended medium (jacket) flow: 2 – 15 m3/hMedium (jacket): Steam/Ice waterDasher model: ø mmDasher, revolutions per minute: 255 rpmCylinder inside diameter: ø150 mmNumber of cylinders: 1Cylinder swept surface: 0.68 m2 each cylinderCylinder volume, ø89 mm dasher: 16 litresCylinder volume, ø114 mm dasher: 11 litresMax. prod. pressure: ø89 mm dasher: 12 bar

ø114 mm dasher: 18 barMax. medium pressure (jacket): 10 barMax. temp. cylinder+jacket: 150°CProduct contacting materials: EN.1.4404/AISI 316LOther materials: EN.1.4301/AISI 304Product contacting surfaces Ra: 0.8 µmOther surfaces Ra: 1.6 µmRubber materials: EPDM – SiliconeScraper blade, material: PEEKConnection fittings:Shaft seal: Double with water flushing / asepticWearing surface: Silicon Carbide – Silicon CarbideMax. pressure flush water: Product pressure + 1 barRecommended flush water flow: 10 – 20 L/hGear: 1:11,76 Helical BevelMotor: kW 3000 rpm. High efficiencyVoltage – frequency: 3 x 220/380V – 50 HzMotor protection: IP55 – with thermistor


2 - RECEIPT

2.1 RECEIPT - INSPECTIONThe equipment is inspected before dispatch and packed in accordance with normalstandard. However, APV, UNIT SYSTEMS cannot guarantee receipt in good condition.The customer is therefore asked to carry out a careful check-up in accordance with thepacking list. Small parts may be packed separately and placed on the box bottom. Incase of damaged euipment due to transport, please contact the transport company.

In case of missing parts please contact APV, UNIT SYSTEMS.

2.2 GUARANTEERegarding guarantee, APV, UNIT SYSTEMS refer to the guarantee conditions stated in theterms of sales and delivery.

3 - INSTALLATIONInformation on safetyBefore starting the installation of the SSHE VT+660 the safety instructions statedin section 1 should be read carefully.

3.1 LOCATIONSufficient space must be available for dismantling of cylinder for a routine check-up.(See dimension sketch).

The scraped surface heat exchanger is delivered with adjustable ball type feet forcorrect levelling of the machine. Use of block level is recommended.Never adjust the level by pulling or pushing at the top of the cylinder.


3.2 ELECTRICAL CONNECTIONS

The SSHE VT+660 is driven by a gear motor, which is placed under the table. The electri-cal data will appear from the name plate on the motor.

The electrical connection of the SSHE VT+660 must only be done by an authorised elec-trician in order to ensure a proper earth connection and that all technical, electrical regula-tions are observed.

Seen from the top the SSHE VT+660 must rotate clockwise as indicated by the arrow onthe gear box.

3.3 PRODUCT CONNECTIONS (CYLINDER)

The product pipes must be properly supported to avoid stress on the cylinder pipefittings. The product inlet is placed horisontally in the bottom, and the outlet vertically inthe top of the scraped surface heat exchanger.

3.4 MEDIUM CONNECTIONS (JACKET)

The medium pipes must also be properly supported to avoid stress on the cylinder pipefittings. The medium flow direction must be in counter current to the product flow. Themedium must therefore be led in at the top and out at the bottom of the jacket. If steam isapplied as medium, it must be introduced at the jacket top, so that condensate can bedischarged from the bottom via a horisontally placed steam trap. Pipe size to the steamtrap should not be reduced. In connection with multicylinder units it is possible to apply acommon manifold for all medium inlets and one for all outlets.

If valves are mounted both before inlet to and after outlet from the jacket, a safety valve(max. pressure 10 bar) must be installed to prevent building up of an overpressure in thejacket during CIP (in case both valves are closed).

3.5 CONNECTION OF FLUSH WATER TO SHAFT SEAL

Circulation of flush water (typically potable water) around the shaft seal is crucial. Thedasher must under no circumstances rotate without flush water, as the wearing surface ofthe shaft seal will be destroyed immediately. For aseptic operation the water is replaced bysteam. (Saturated steam at 121°C at a pressure of approx. 1 bar).

In special cases, where water around the shaft seal is unwanted, a low viscous, foodapproved vegetable oil can be used instead. However, it is recommended to contactAPV, UNIT SYSTEMS for further technical details.

Seal water flow: 10-20 L/hSeal water max. pressure: Product pressure + 1 bar


4 - CLEANING

4.1 CIP CLEANING

The scraped surface heat exchanger is intended for ordinary CIP cleaning.

The recommended procedure for CIP cleaning of the SSHE VT+660 is as follows:

1. Thoroughly flush the plant for product with ordinary cold water.

2. Circulate a basic cleaning agent, f.ex. lye (NAOH) through the plant:

• Max. concentration: 1-2 % (percentage by weight)• Max. temperature: 70-80°C• Circulation time: Approx. 30 min. or according to need• Recommended flow: 5 – 10 m3/h

3. After finished circulation, flush the plant with water.

4. Circulate nitric acid (HNO3) through the plant:

• Max. concentration: 1% (percentage by weight)• Max. temperature: 60°C• Circulation time: Approx. 30 min. or according to need• Recommended flow: 5 – 10 m3/h

5. After finished circulation, flush the plant with sufficient quantities of clean water.

In order to protect the rubber gaskets in the SSHE against oxidation and the metal partsagainst corrosion, the above mentioned demands on temperature and concentrationsmust not be exceeded. If using different concentrated chemicals for CIP, these chemicalsmust be correspondingly diluted before use, and the temperature must not exceed 60 –80°C during CIP.

The medium flow must be interrupted during CIP. The machine must not be used forheating of cleaning agents.

Never leave cleaning agents in the machine overnight.

In all CIP sequences it is recommended to let the dasher rotate in order to generate thenecessary turbulence.


Disinfection:For use of disinfectants, the following demands and procedures must be observed:

- Never use disinfectants containing chlorine (CL) in heated condition- Never leave disinfectants in the plant. After disinfection the chemicals must be thoroughly washed out with water, before using the machine again.

4.2 MANUAL CLEANING

The SSHE VT+660 can of course also be manually cleaned, if desired, and this could bedone in connection with the dismantling for routine checks. Before starting up and in caseof standstill of long duration the machine should be cleaned manually. – See section 6 fordismantling of the machine. At the same time it is recommended to inspect all rotatingcomponents visually.

5 - METHOD OF NORMAL OPERATION

Information on safetyBefore starting the installation of the SSHE VT+660, the safety instructions stated in sec-tion 1, should be read carefully.

5.1 START-UP

1. Always turn on the flush water for the shaft seal. Flow: 10 – 20 L/h.

2. Following flush water through the plant.

3. Start the motor.

4. Start the circulation of cooling/heating medium through the jacket, in order to adjustthe product temperature and to be able to start a sterilisation of the SSHE.

5. Drain out the water on the product side.

6. Immediately thereafter, run product through the plant, and make a fine adjustment ofthe product temperature.

5.2 STOP

1. Drain out product by flushing the SSHE with clean water.

2. Interrupt the circulation of medium through the jacket.

3. Clean the machine (see section 4)

4. Stop the motor.

5. Shut off the supply of flush water to the shaft seal(always after the motor has been turned off).


6 - INSPECTION AND MAINTENANCE

General information:It is necessary to carry out a frequent inspection of the SSHE VT+660 to secure a correctfunction and a good condition of maintenance.

When starting up a new machine – or a used machine under new running conditions – itis recommended to carry out an inspection prior to putting the machine into service.Thereafter, it would be advantageous to inspect the machine after 50 – 100 hours ofoperation to check if the function is OK. This could be done in co-operation with an APVinstallation engineer, who could teach the personnel to use and maintain the SSHE at thesame opportunity.Under all circumstances it is recommended to dismantle the cylinder and the dasherapprox. every 600 hours of operation - depending on the operation conditions – to per-form an inspection of the inner parts of the SSHE.

Typical wear parts to be inspected:

Scraper blades Pos. 3 See spare part list (section 7)Top bearing: Pos. 5 See spare part list (section 7)Dasher top: Pos. 19 See spare part list (section 7)

It is advisable to keep an eye on the SSHE VT+660 during operation. The machine mustbe working quietly and without any vibrations (only weak scraping sounds should beheard from the rotation of the blades).


The gear motor must not get overheated and “sweat out” oil. – If this is the case, theSSHE must be stopped and inspected.

There must not be any essential leaks from the shaft seal, if so the shaft seal should betaken apart according to the instructions in chapter 6.3.

APV, UNIT SYSTEMS can of course always be contacted in case of irregularities.

6.1 DISMANTLING TOOLS

The included tools required for dismantling of the scraped surface heat exchanger inconnection with inspection of dasher, scraper blades and top bearing:

- 1 Lifting fork Pos. 15 section 7- 1 Locking fork Pos. 16 section 7- 1 Pull-out slider Pos. 18 section 7

Further is included:

- 1 Centering bar for dismantling the shaft seal. Pos. 14 section 7

6.2 PROCEDURE FOR DISMANTLING FOR ORDINARY CHECK-UPDismantling of the shaft seal is not needed for this inspection.

Information on safety:Dismantling and service must never be carried out when the power supply is on.It must be secured that the power supply cannot be unintentionally re-estab-lished during dismantling and the service is being carried out.Furthermore, please read the safety instructions stated in section 1.

Also the medium flow, product flow and flush water are stopped before dismantling andservice is being carried out.


Medium and product pipes are dismantled. The coupling safety fence is removed asshown on the picture. Note the small lock-ing pin on one of the bottom console legs,securing the fencing.

The special locking bolt is removed bypushing the small button and pulling thelocking bolt out of the joint.

The locking fork is slid on the dasher shaft top. It is important that the position is correct,as shown on the picture, to prevent it from falling off when tipping the cylinder pipe.


The large 6” bottom clamp is removed.

The lifting fork is placed ensuring that thedents fit the backstops.

Cylinder + dasher are lifted up and freefrom the shaft seal by pushing the liftingfork.

Cylinder and dasher are turned to horizon-tal position. Note: Hold on to the smallclamp connection as shown on the picture.Cylinder and dasher are lowered again, andthe lifting fork removed.


The 4 wing nuts are tightened onto thetelescopic lifting device.

The pull-out slider is led in underneath thedasher body.

The locking fork is removed from thedasher top.

The dasher is pulled out of the cylindercarefully.

Scraper blades and inside of cylinder to bechecked for possible wear. In case of wearthe scraper blades are replaced by bendingthem and pushing them off as hown on thepicture.

The sharp edge must face the cylinder wallas shown on the picture.


Dasher and top bearing must be checked for wear damages and replaced if necessary.

Dasher top to be dismantled by means of aspanner or the locking fork. Note that it isleft threaded.

When assembling the scraped surface heat exchanger, follow the same proce-dure as for dismantling, however in the reverse order.


In case of leakage, it is most probably theupper rotating lip O-ring Pos. G, fig 1,which has been damaged. It is easily re-placed without dismantling the shaft seal.

If the shaft seal is still leaking after replacement of lip O-ring, it will be necessary to dis-mantle the shaft seal.Note that this must be done carefully, and that the below described instructionsmust be strictly followed.

Fig. 1

Pos. Description Pcs.

A Rotating top element 1

B Stationary top element with 4 teeth 1

C Stationary bottom element 1

D Rotating spring bottom element 1

E Locking screw M6 4

F Stop screw M10 2

G Rotating lip O-ring P716200 1

H Stationary lip O-ring P716450 1

I Stationary O-ring P716451 1

J Inner rotating O-ring P716452 1

K Outer rotating O-ring P716453 1

6.3 SHAFT SEAL

IMPORTANT:

Under normal circumstances the shaft seal in the bottom console should not bedismantled, as it is maintenance-free.However, the shaft seal can be dismantled in case of essential leaks and other irregulari-ties.

The crucial factor for the effective life time of the shaft seal is above all that flushShaft water is always flowing when the machine is running. Furthermore, it mustbe correctly mounted and centred.

Shaft seal P715789


Then remove the 4 M10 screws ensuringthe bottom console by means of a 17 mmspanner.

Now the whole bottom console with theshaft seal can be removed for inspection ona clean working table.

At first the 4 M6 pivot locking screws Pos.E, fig. 1, are unscrewed (to some extent)from the bottom rotating element to someextent by means of a 3 mm Allen key.Note that it is extremely important toretighten these 4 M6 pivot lockingscrews after reassembling of the shaftseal before it is rotated. Omitting thiswill cause serious damages to the shaftseal, dasher and coupling.


The spring effect is checked by compres-sing the rotating spring bottom element.A certain resistance is required. In case thespring effect is not functioning, then con-tact APV, UNIT SYSTEMS.

The shaft seal consists of 4 mainelements, see fig. 1:

Pos. A The rotating top elementPos. B The stationary top element

with the 4 teethPos. C The stationary bottom elementPos. D The rotating spring bottom

element

The 2 M10 stop screws Pos. F, fig. 1, areloosened a bit by means of a 5 mm Allenkey.

The shaft seal can now be dismantledcarefully.


For mounting the shaft seal the reverse order of dismantling must be followed.However, also remember to check a few but important points:

If some of these components are damaged, replacement with new parts will be required.Please contact APV, UNIT SYSTEMS. – See fig. 1 page 16.

Generally, the shaft seal must be cleaned and especially ensured that there is no dirt orgrease on the ceramic rings Pos. A, B, C, D, fig. 1.

The inner rotating O-ring Pos. J, fig. 1, inthe spring bottom element is inspectedand, if necessary, lubricated with greaseapproved for food.

The ceramic rings on Pos. A, B, C, D, fig.1must be inspected for wear and cracks.


Make sure that the 2 M10 stop screws Pos.F, fig. 1, fit into the corresponding holes onthe stationary top element Pos. B, fig. 1. After mounting of the 2 stationary elements

Pos. B & C, fig. 1, the rotating top elementPos. A, fig. 1 is mounted, and finally therotating spring bottom element Pos. D,fig. 1.

The 4 M6 locking screws Pos. E, fig. 1, arescrewed into the corresponding holes onthe rotating spring bottom element Pos. D,fig. 1, to the extent that the shaft sealsprings are pre-compressed.

The bottom console with the shaft seal isplaced loosely on the coupling on the table.Then the centring bar is placed carefully onthe shaft seal to centre it.

The bottom console is tightened firmlyby means of the 4 M10 screws.


IMPORTANT TO REMEMBER:

The 4 M6 locking screws Pos. E, fig. 1, are tightened towards the coupling inorder that the rotating shaft seal parts are forced to rotate with the coupling. Ifthis procedure is not followed, the result can be heavy damages to the shaft seal,dasher and coupling.

After finishing the assembly it should be checked that the shaft seal is centred and linedup correctly, that the bottom element is rotating with the shaft seal so that there will be nowobbling when the SSHE is running.

The shaft seal is checked for leaks. It must not leak neither product nor cleaning liquids.

7 – SPARE PART LISTPos. Description Pcs. Pos. No.

1 3” Top clamp 1 P706552

2 3” Top clamp gasket 1 P706591

3 Scraper blade 14 P714578

4 Top bearing O-ring 1 P724020

5 Top bearing 1 P712851

6 Shaft seal (see page 16) 1 P715789

7 6” Bottom console O-ring 1 P715791

8 6” Clamp gasket 1 P713539

10 Bottom plate gasket 1 P271044

11 Rubber disc 1 P278025

12 Locking pin 1 P271129

13 Safety fence 1 P271043

14 Centering bar 1 P271047

15 Lifting fork 1 P271057

16 Locking fork 1 P276949

17 Wing nut 4

18 Pull-out slider: ø89 / ø114 1 P277433/32

19 Dasher top 1 P271328

20 Dasher top O-ring 1 P716202

21 Shaft seal lip O-ring 1 P716200

21

manual vt+660

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