Beruflich Dokumente
Kultur Dokumente
DRAWING SPECIFICATION
The Drawing Specification is the key identification for the process equipment. It is to be filed separately under safe conditions.
Issue date:
19/02/2009
Technical Manual
CONTENTS SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . DATA Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive maintenance recommendations . . . . . . . Service media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CERTIFICATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . TAG 1 2 3 4
TEM_TOC_EU_EN.fm
5 6 7 8 9 10 11
1 Safety precautions
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Safety precautions
To ensure maximum safety for the operator, always read this section carefully before carrying out any work on the equipment.
DANGER!
WARNING!
Failure to observe this information can result in major personal injury or loss of life
Caution!
Failure to observe this information can result in minor personal injury or damage to the equipment.
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Tetra Pak
Safety precautions
General
Only trained personnel are allowed to operate the machine. The machine may only be used in accordance with the instructions given in the manuals delivered with the equipment. If the Safety precautions are not followed, there is risk of personal injury. The machine is normally started by an external signal, therefore: always keep all covers closed during operation, rotating wheels and moving pistons may cause severe injuries make sure the mains power is turned off and secured before the service covers are opened/removed regard all electrical equipment as live, make sure the doors for the starter panel are closed During operation: stay outside the safety area (approximately 1m (3 feet) around the machine) DANGER! regard all pipes including pulsation dampers as hot watch out for leakage/blasts from hot media at pipe connections and from pressurized parts of the machine always use hearing protection never throttle down the product flow to or from the machine
Risk of explosion - Immediate danger to life Make sure that the product outlet pipes not are blocked in any way. Due to high pressure, this will make a high risk of exploded pipes and dampers. Risk of scalds This machine works under pressurised conditions and high temperatures. To avoid jets of hot liquid, steam or cleaning solution, make sure that any operation sequence is finalised, the machine is cooled down and without pressure before disassembling any parts. Before carrying out maintenance and repair: turn off the external mains power switch and lock it in position OFF allow the machine to cool down inform the operator and other relevant personnel about the work you intend to do post warning signs in prominent places when handling heavy parts; carry ou the lift in a safe way and use only with safe lifting equipment
WARNING!
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Safety precautions
Emergency precautions
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If swallowed If you happen to swallow cleaning solution: drink large amounts of lukewarm water (in order to dilute the cleaning solution); then seek medical attention immediately. Contact with eyes If cleaning solution is splashed into your eyes: wash the eyes thoroughly with lukewarm water for 15 minutes (keep eyelids widely apart); then seek medical attention immediately.
Contact with skin or clothes If cleaning solution comes into contact with skin or clothes: rinse immediately with plenty of water thoroughly wash the clothes before they are worn again. If skin burns appear, seek medical advice immediately. If inhaled If you experience irritation or pain due to having inhaled vaporized cleaning solution: leave the affected area to get fresh air. If the symptoms become worse, seek medical advice.
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Safety precautions
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2 General information
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General information
General information
Machine introduction
WARNING! To ensure maximum safety for the technicians, always read the Safety precautions pages before doing any work on the machine or making any adjustments. Intended use of this Tetra Pak equipment This unit is intended for use according to the specifications in Technical data (see Technical Manual) and related documents. Tetra Pak will not be held responsible for injury or damage if the equipment is used for any other purpose. Service In case of problems when operating the machine, contact the nearest Tetra Pak service station. Manufacturer This Tetra Pak equipment was produced by: Tetra Pak Processing Components AB Ruben Rausings gata S-221 86 LUND Sweden Machine identification All units carry a machine plate stating: unit identification data unique to the unit Have this information available before contacting Tetra Pak concerning this particular unit.
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Tetra Pak
Machine Type Drawing Spec. Machine No. Manufacturer
Year of manufacture
Tetra Pak
General information
Document information
Product Documentation The documentation for this equipment consists of the following parts: Operation Manual Technical Manual It is important that you: keep the manuals for the life of the equipment, pass the manuals on to any subsequent holder or user of the equipment. Design modifications The directives in this document are in accordance with the design and construction of the machine at the time it was released by the Tetra Pak machine production facility. Document producer This document has been produced by: Tetra Pak Processing Components AB Ruben Rausings gata S-221 86 LUND Sweden Further copies Additional copies can be ordered from nearest Tetra Pak service station. When ordering technical publications, always quote the document number. Copyright 2002 Tetra Pak Processing Systems Division All rights reserved. No part of this document may be reproduced or copied in any form or by any means without the written permission of Tetra Pak Processing Systems Division.
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3 Installation data
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Table of contents
Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prior to operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
Preparatory work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3 4 5 6 8 9
Installation instructions . . . . . . . . . . . . . . . . . . . . . . . .
Requirements on personnel . . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unloading and transportation . . . . . . . . . . . . . . . . . . . .
2.235853-01.toc
13
13 14 14 14 15
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil amount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19 23
25
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Table of contents
ii
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2.235853-01.toc
Installation
Introduction
Introduction
Prior to operation
Prepare the site according to the information given in Preparatory work and Technical data. When installing the machine, follow the instructions in Installation instructions. Before starting up, make the checks according to Check after installation. Technical data Some pages refer to the following machine unique information: Mass and centre of gravity Piston diametre Consumption data This information is found in Technical data. Example of Technical data
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ver. 1.1
T584553xxxx
Working pressure: 250 bar Ambient temperature: <40 C Piston diameter: 50
NN
Inlet pressure: 3-10 Total mass: 3480 Sound effect level (acc. to ISO 3746): B(A)
bar kg
Noise reduction:
Centre of gravity (a=): Sound pressure level (distance=1m): 1354 mm dB(A) Piston packing: Grooved
Wetend design:
Piston design: mm Stainless steel Chromium plated Ceramic coated Ceramic solid X Remote ind. of product pressure: X
V-packing
Drive Motor:
Manufacture: ABB Power: 90
Hydraulic Unit:
Manufacture: Bosch Model: 4722-5471-80 Model: M2AA71B 6 kW Voltage: 415 Number of tracks: 4 Model: TV151 V Revolution: 920 Frequency: 50 Protection: rpm IP55 Hz Rated current: 0,9 Amp.
Hydraulic Motor:
Manufacture: ABB Power: 0,25
Drive Unit:
V-belt type: SPC Motor pulley diameter: Gearbox pulley diameter: V-belt length 250 mm 500 mm 2650 mm Reduction: 5,890 Steam valve: Solenoid
Reduction Gear:
Manufacture: Benzler Crankshaft speed sensor: Press. relief valve: 1st Stage X
Valves:
Cooling water valve: Solenoid X Voltage: V AC Pneumatic X Pneumatic 2nd Stage Voltage: 24 V DC 24 V DC X
Compressed air supply: Voltage: 4-7 bar Consumption: 1260 Consumption: 45 Sign: AM Temperature: <25 V AC
Steam supply:
Pressure: 2-4 Date: 1997-09-04 bar
Condensate:
Temperature: kg/h 110-115 C Revision: 0
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Introduction
Installation
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Installation
Preparatory work
Preparatory work
General dimensions
Measures: mm (inch)
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1300 (51.2")
1250 (49.2")
(4.92"- 5.91")
125-150
GF201979
1160 (45.7")
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Preparatory work
Installation
Service area
Measures: mm (inch)
SERVICE AREA
1000 (39.4")
1300 (51.2")
125-150 (4.92-5.91")
1800 (70.9")
1250 (49.2")
1000 (39.4")
Tetra Pak
SERVICE AREA
Installation
Preparatory work
Floor
Weight of machine, see Technical data. Measures: mm (inch)
165 (6.5")
934 (36.8")
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190 (7.5")
786 (30.9")
120 (4.72")
GF201978
(4.92"- 5.91")
125-150
Tetra Pak
Preparatory work
Installation
Product supply
The machine connections have to be welded to the product inlet- / outlet pipes. The pipe line, inlet and outlet, shall contain as few elbows as possible. Quality of piping and welding Piping: Local regulations as to pressure vessel codes and material quality vs. product properties have to be met Welding: Methods according to standards that are acceptable for the transport of liquid food. A Testweld should always be carried out and the sample piece examined by qualified persons and particularly to establish that there are no pockets, cracks, pinholes or crevices that could not be thoroughly cleaned under practical conditions. Recommended inlet pressures
Product Low viscous products e.g. milk, juice High viscous products e.g. sauces, ketchups Outlet pressure P2 P1 bar (psi) 3 - 10 (45 - 150) 4 - 10 (60 - 150)
P2 P1
GF200226
Caution!
Risk of machine damage The machine should never be allowed to run without product. Make sure that the machine is always fed with cleaning solution during CIP.
DANGER!
Risk of explosion - Immediate danger to life Do not install a shut off valve Make sure that the outlet pipes not are blocked in any way. Due to high pressure, this will make a high risk of exploded pipes and dampers.
GF200225
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Preparatory work
mm A B
A B C
C D E F
D E
GF201932
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Customer piping
GF200355
Product pipes
Piston diameter Outer diameter Pipe material thickness mm mm inch mm inch
() 32
Product inlet
() 36 () 40 - 50 () 32
Product outlet
() 36 () 40 - 50
Tetra Pak
Preparatory work
Installation
Water supply
For dimensioning pipes and drainage, see Technical data for consumptions. Requirements on service media, see Service media.
GF201870
12 mm (0.47")
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1 Cooling water inlet 2 Cooling water outlet from cooler in gearbox 3 Cooling water outlet
Installation
Preparatory work
Electrical supply
Power consumption, see Technical data. WARNING! Electrical hazard Work to be done by authorized personnel only! Install a mains power switch before the external starter panel.
DANGER!
Before starting the machine, make sure that: all cables are undamaged the cables are correctly connected
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Connection box
GF201980
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Preparatory work
Installation
Wiring diagram
6-4722936200_AA
(Cont'd)
10
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POWER SIGNAL
Installation (Cont'd)
Preparatory work
M801 M802 S802 S8051 S8052 P805 S805 Y810 (V55) Y811 (V48) R818 Y820 Y821 Y822 Y823 Y824 Y825 B826 B827 B8272 B828 B829 B830 B835
Motor - Main Motor - Hydraulic Unit Switch - Hydraulic Unit Stop Start Hour meter Emergency Stop Cooling Water - Standard (Pneumatic = Option 11) Steam (Standard - Aseptic (Pneumatic = Option 11) Thermistor in Main Motor Cooling Water Circuit - CIP 1 (Option 36) Cooling Water Circuit - CIP 2 (Option 36) Remote On/Off Setting Hydraulic Pressure Stage 1 (Option 17) Remote On/Off Setting Hydraulic Pressure Stage 2 (Option 17/18) Remote Continuous Setting Stage 1 (Option 19) Remote Continuous Setting Stage 2 (Option 19/20) Speed Sensor (Extra) Remote Ind. Product Pressure (Option 14) Remote Ind. Product Pressure (Extra) Remote Ind. Hydraulic Pressure Stage 1 (Option 15) Remote Ind. Hydraulic Pressure Stage 2 (Option 15/16) Steam Temperature (Aseptic, Option 12)) Oil Level Guard - High Level Oil Level Guard - Low Level (Option 28) Oil Temperature Crankcase (Option 28) Flow/Pressure Guard (Option 28) Inlet Pressure Guard (Option 28)
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Preparatory work
Installation
12
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Installation
Installation instructions
Installation instructions
Requirements on personnel
Caution! Certified according to local regulations
Unauthorized personnel Operation by unauthorized personnel may endanger personnel and property
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Installation instructions
Installation
Storage
Temperatures: +10C - +40C (+50F - +104F) Humidity: 20% - 85% Avoid storage in the same facilities as open drums with cleaning solutions due to risk for corrosion. Caution! Noncompliance with requirements may damage the equipment!
GF200353
Centre of gravity
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If a mobile crane must be used to position the machine, position the crate before unpacking.
Packing list
2 2
GF200352
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Installation
Installation instructions
GF201981
GF200349
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Installation instructions
Installation
Level the machine Measure the level of the machine both ways with a machinists level placed on the pump block. Adjust the level by turning the ball feet. Note! In order to minimize vibrations: keep distance between machine and floor as low as possible tighten all ball feet equally against the floor
16
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Installation Pulsation dampers (Used to level out pressure variations). Adjust to vertical position.
Installation instructions
90
GF201447
Put oil in the crankcase Caution! Running the machine without oil will cause damage to the crankshaft. The crankcase is at delivery empty of oil. Top up to the Max. level marked on the sight glass. (The gearbox and the hydraulic unit are at delivery filled with oil).
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Max Min
GF200341
Connect product supply service media supply electric power according to Preparatory work
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Installation instructions
Installation
18
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Installation
Lubrication
Lubrication
Recommended oil
Crankcase
Recommended oil: Cirkulation/gearbox oils with EP additives which do not harm slidebearings (yellow metals)
Mineral Type
Producer BP/Castrol Exxon/Mobil Shell Type Energol GR-XP Mobilgear 600 XP Omala Oil Viscosity* 220 220 220
Synthetic Type**
Producer BP/Castrol Exxon/Mobil Shell
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Food GradeType***
Producer BP/Castrol Exxon/Mobil Shell Type Optileb GT DTE FM Cassida GL Viscosity* 220 220 220
* **
Viscosity in mm2/sec (cSt) at 40C (104F) A synthetic oil for the crank case must be of PAO ( poly alfa olefine) type , like the Omala, that is mixable with mineral oils and does not affect rubber, sealings and paint. Conform with FDA 21 CFR 178.3570 and classified in NSF H1.
*** Note!
Green oils is for the time beeing not availabe, but for some viscosities, and their lubricacion performance is not yet good enough for use in our type of heavy duty machines. (Cont'd)
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19
Lubrication
(Cont'd) Gearbox
Recommended oil: Gearbox oil
Installation
Mineral Type
Producer BP/Castrol Exxon/Mobil Shell Type Energol GR-XP Mobilgear 600 XP Omala Oil Viscosity* 320 320 320
Synthetic Type**
Producer BP/Castrol Exxon/Mobil Shell Type Enersyn HTX SHC 630-632 Omala RL Viscosity* 220-320 220-320 220-320
Food GradeType***
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Viscosity in mm2/sec (cSt) at 40C (104F) If the gear box temperatur is kept to max. 70 C ( 158F), 220 cSt is sufficient. A synthetic oil for the gear box must be of PAO ( poly alfa olefine) type, like the Omala, that is mixable with mineral oils and does not affect rubber, sealings and paint. (Cont'd)
**
20
Tetra Pak
Lubrication
Mineral Type
Producer BP/Castrol Exxon/Mobil Shell Type Bartran Mobil DTE Excel Tellus Viscosity* 68 68 68
Synthetic Type**
Producer BP/Castrol Exxon/Mobil Shell Type Mobil SHC 526 Tellus Viscosity* 68 68
Food GradeType***
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Viscosity* 68 68 68
* **
Viscosity in mm2/sec (cSt) at 40C (104F) A synthetic oil for the hydraulic unit must be of PAO ( poly alfa olefine) type , like the Omala, that is mixable with mineral oils and does not affect rubber, sealings and paint. Conform with FDA 21 CFR 178.3570 and classified in NSF H1. (Cont'd)
***
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21
Lubrication
(Cont'd) Main drive motor
Recommended grease Producer BP/Castrol Exxon/Mobil Shell Type Energrease LS EP 1 Mobilith SHC Alvania grease RL3
Installation
Food GradeType***
Producer BP/Castrol Exxon/Mobil Shell Type Mobil grease FM 101 Cassida RLS 2 Viscosity* 100 150
*** Conform with FDA 21 CFR 178.3570 and classified in NSF H1.
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Installation
Installation instructions
Oil amount
Crankcase
Approx. 20 litres (5.3 U.S. gallons)
Gearbox
Approx. 3 litres (0.8 U.S. gallons)
Hydraulic unit
Approx. 6 litres (1.6 U.S. gallons)
GF200326
GF202053
GF200601
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23
Installation instructions
Installation
24
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Installation
Direction of rotation for the: crankcase shaft (as illustrated) hydraulic pump (marked on the pump unit)
GF200340
That product with correct feed pressure is available Cooling water circulation; check the drainage outlet That the covers are closed That the power consumption corresponds to the test protocol
Caution!
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Installation
26
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4 Maintenance
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GF201889
2.235897-01.fro
Table of contents
0 INTRODUCTION
Service preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1
1.1
1.1-1 1.1.1-1 1.1.2-1
FRAME
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Covers - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Gas springs - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Insulation (optional) - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2
1.2-1
Vibration elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Vibration elements - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2
2.1
2.1-1 2.1-2
3
DRIVE UNIT
Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive motor - clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Drive motor - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2
2.2.1-1 2.2.1-2 2.2.2-1
V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
V-belts - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 V-belts - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Belt pulleys - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3
2.3-1 2.3-2 2.3.1-1 2.3.1-2 2.3.2-1 2.3.2-2 2.3.3-1
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gearbox - remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Gearbox - fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Oil - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Oil - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Seal rings - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Seal rings - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Vibration elements - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3
3.1
3.1-1 3.1-2
CRANK CASE
Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Oil - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Oil - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2
3.2-1
3.3
3.3-1
Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Thermometer - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4
3.4-1
Crankshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Crankshaft bearings - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Table of contents
3.5
3.5-1
3.6
3.6.1-1 3.6.1-2 3.6.2-1 3.6.2-2
Piston area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Connections - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connections - set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bellows - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bellows - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 24 25 25
3.7
3.7-1
3.8
3.8-1
Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Oil cooler - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4
4.1
4.1-1 4.1-2 4.1-3 4.1.1-1
WET END
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Valves - disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves - assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seals - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 30 31 32
3
4.2
4.2-1 4.2-2 4.2-3 4.2-4 4.2.1-1 4.2.2-1
Piston unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Piston unit - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston unit - remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston unit - disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston unit - assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston packing - change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 34 35 36 36 36
4.3
4.3-1 4.3-2
Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pressure gauge - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Pressure gauge - change O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5
5-1 5-2 5-3 5.1
5.1-1 5.1-2 5.1.1-1 5.1.1-2 5.1.2-1 5.1.2.1-1
HOMOGENISATION HEAD
Homogenisation head - check . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Homogenisation head - remove. . . . . . . . . . . . . . . . . . . . . . . . . 40 Homogenisation head- assemble . . . . . . . . . . . . . . . . . . . . . . . 40 Homogenisation device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Homogenisation device - disassemble . . . . . . . . . . . . . . . . . . . . . . Homogenisation device - assemble . . . . . . . . . . . . . . . . . . . . . . . . . Seat - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat - turn/change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forcer - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forcer disc - turn/change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Doc No. TeM-1235897-01
41 42 43 43 44 44
ii
Tetra Alex 20
Table of contents
5.2
5.2.1-1
Hydraulic end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Seals - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.3
5.3-1
Product connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Product connections - change gaskets . . . . . . . . . . . . . . . . . . . . . . 46
6
6-1 6.1
6.1-1 6.1-2 6.1-3 6.1-4 6.1.1-1
HYDRAULIC SYSTEM
Hydraulic system - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Hydraulic unit - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic unit - disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic unit - change parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety valve - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 48 49 50 51
6.2
6.2-1
3
Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Pressure gauge - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.3
6.3-1
6.4
6.4-1
6.5
6.5-1
7
7.1
7.1-1
7.3
7.3-1
Regulating valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Regulating valves - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.4
7.4-1
Water valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Water valve - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.7
7.7-1
7.8
7.8-1
Tetra Alex 20
iii
Table of contents
8
8-1 8.1
8.1-1
ELECTRICAL SYSTEM
Wiring diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cables - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.2
8.2.1-1
8.3
8.3-1
8.4
8.4-1
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Emergency stop - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9
9.1 9.2
MISCELLANEOUS
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Recommended oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Oil amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3
9.3 9.4
iv
Tetra Alex 20
0 Introduction
Service preparations
WARNING!
2.2tf201590.en
Risk of personal injury After each service, always make sure that all covers are installed
Tetra Pak
1.1 Covers
1 Frame
1
1 Gas spring 2 Hinge
GF201875
Tetra Pak
2.2tf201592.en
1 Frame
2.2tf201826.en
GF201985
Tetra Pak
2 Drive unit
WARNING!
2 2
GF200409
Tetra Pak
2 Drive unit
2.2 V-belts
2.2.1-1 V-belts - check
Check if the belts are worn. Replace any worn belt, see 2.2.1-2 Check the belt tension as follows: measure the distance Lf. apply a force of 75 N at one of the belts and measure the deflection te. Adjust the belt tension until te = 2.8 x Lf /100. Note! An incorrectly tensioned V-belt will wear out quickly.
te = 2.8 x Lf /100
2.2tf201594.en
Lf
te
75 N
GF200536
Tetra Pak
2 Drive unit
1 Nut
GF200635
GF200633
Tetra Pak
2.2tf201594.en
2 Drive unit
2.3 Gearbox
2.3 Gearbox
2.3-1 Gearbox - remove
Disconnect the cooling water hoses from the gear box. Attach a sling to the gear box and hook it up to the lifting device. Undo the nuts (1), lower the gear box until the adjusting bolt (2) is free from the torque arm (3). Remove the V-belts according to 2.2.1-2.
2 1
2.2TF202357.en
(Cont'd)
Tetra Pak
2.3 Gearbox
(Cont'd)
2 Drive unit
Depending on the dimension for the belt pulley (6), it may be necessary to remove it in order to remove the lid (4). If needed, expand the slot (5) in the belt pulleys bushing in order to remove it from the shaft/key. Remove the lid (4). Position the lifting device above the gearbox and remove the slack from the sling. Push/pull out the gearbox. Caution! Hydraulic tool to press out the gear box may be needed.
Risk of jam. Remove the spacer sleeve from the crank shaft.
6
GF200665
Tetra Pak
2.2TF202357.en
2 Drive unit
2.3 Gearbox
2.2TF202357.en
GF200666
Install the V-belts, the belt tensioner and set the belt tension, see V-belts. Fit the cooling water hoses to the gearbox. Install the cladding.
Tetra Pak
2.3 Gearbox
2 Drive unit
1 3
1 2 3 4 Filler cap Drain plug Venting plug Dipstick
GF200636
10
Tetra Pak
2.2TF202357.en
2 Drive unit
2.3 Gearbox
14
13
11
2.2TF202357.en
GF202404
Tetra Pak
11
2.3 Gearbox
2 Drive unit
2 1 3
1 2 3 4
GF202049
12
Tetra Pak
2.2TF202357.en
3 Crankcase
3.1 Oil
Bleed the drain hose. Type and amount of oil, see Lubrication.
1 Drain valve 2 Thermometer 3 Oil gauge glass (Valid for TA 25, TA 30 and TA S40 only)
1
Max Min
GF201437
Tetra Pak
13
3 Crankcase
GF201481
14
Tetra Pak
2.2tf201596.en
3 Crankcase
3.3 Thermometer
3.3 Thermometer
3.3-1 Thermometer - check
Check function of thermometer (1). Temperature transmitter (optional), see issue 8.3. Note! Max oil temperature at running: 55 C
GF201480
2.2tf201596.en
Tetra Pak
15
3 Crankcase
Drain the crankcase oil and remove the sight glass (1).
1
1 Sight glass
GF200416
Remove the lock nuts (8) and the bolts (3) from the connecting rod (4). Push the cross head (2) forward and lock it in this position by help of the grub screw. Remove the plane bearing cap (7) and the plane bearings (5) and (6). 2
2 3 4 5 6 7 8 Cross head Bolt Connecting rod Plane bearing Plane bearing Plane bearing cap Lock nut
3 4 5
GF200417
(Cont'd)
16
Tetra Pak
2.2tf201918.en
3 Crankcase (Cont'd)
Support the crankshaft by a piece of wood (8) and remove: a) the bearing flange (11); put two bolts in the threaded holes and press out the bearing flange, b) the lid (10), c) the ring (9) for the roller bearing, d) the torque arm (1), e) the bearing flange (4); the seal (2) and the outer ring of the roller bearing (3) comes out with the bearing flange, f) the key (5) by help of a screw, g) the spacing ring (6).
2.2tf201918.en
GF201426
11 9 8 10
1 2 3 4 5 6 7 8 9 10 11
Bracket Seal Outer ring, roller bearing Bearing flange Key Spacing ring Inner ring, roller bearing Support (wood) Ring, roller bearing Lid Bearing flange
(Cont'd)
Tetra Pak
17
3 Crankcase
Apply some grease, Molycote (grey), to the shaft before fitting the lifting tool (13). Use the outer hole (12) for the lifting device when fitting the lifting tool to the crankshaft.
12 13
14
GF200419
(Cont'd)
18
Tetra Pak
2.2tf201918.en
3 Crankcase (Cont'd)
Remove the slack from the sling and remove the crankshaft. Note! Note! Take care not to damage the sensors (18, 19, 20). Make sure the crankshaft freely passes: the connecting rod (15), the oil distributer (16); If needed, lock the oil distributer in its top position, the cooler (17).
15
16
15 16 17 18
2.2tf201918.en
Connecting rod Oil distributer Cooler Temperature transmitter (optional) 19 Sensor for cooling water regulator (optional) 20 Sensor for thermometer
20 19 17 18
GF201482
Replacing roller bearings Put the crankshaft on a suitable support and heat the roller bearings inner ring evenly by help of a welding torch and pull them of the shaft. If required, knock lightly with a hammer to loosen the rings. Caution! Wear heat protective gauntlets. .
GF200421
(Cont'd)
Tetra Pak
19
3 Crankcase
Clean the ring seat. If required, smooth the ring seat surface with oil stone and rub sparingly with Molycote (grey). Heat the new inner rings in oil bath to approximately 80C, slip them up to their seats and let them cool down. Caution! Wear heat protective gauntlets.
GF200422
Note!
check the cross head and the connecting rod, activity 3.5-1
Fitting, crankshaft Fabricate and install a support for the roller bearing before installing the crankshaft.
GF200423
Rub parts with Molycote (grey) and install in reverse order. (Cont'd)
20
Tetra Pak
3 Crankcase (Cont'd)
Fitting, plane bearings Clean and oil the plane bearings. Fit the plane bearing (5) to the connecting rod (4). Fit the plane bearing cap (7) and the plane bearing (6) to the crankshaft and push back the connecting rod. Note! Oil shuffle (18) turned as illustrated; oil-groove opposite the oil inlet hole. Fit the bolts (3) and install new lock nuts (8). Tighten them evenly before applying the right torque. See Torque specifications. Check that the crankshaft can be turned smoothly and without any un-normal noise. 3 4
3 4 5 6 7 8 18
Bolt Connecting rod Plane bearing Plane bearing Plane bearing cap Lock nut Oil shuffle
2.2tf201918.en
8 18 7 6 (Cont'd)
GF200424
Tetra Pak
21
3 Crankcase
In order to ensure proper lubrication for the cross heads, cross head pins and connecting rods, the oil distributer (16) must be free from deposits and be correctly set. Clean the oil distributer. Make sure that the distributer pipes not are clogged. Adjust the gap A between the oil distributer (16) and the cam (20) according figure. Same gap at both sides. Check the oil distribution while running. Remove the three plugs (19) to inspect.
A = 1.5 0.5 mm
19 16
20
GF202047
Install: the bellows, the drive motor, if removed, the gearbox, the V-belts. Clean and install the sight glass. Refill the crankcase oil.
22
Tetra Pak
2.2tf201918.en
3 Crankcase
the oil holes (4) in crosshead and connecting rod are turned upwards the base bearing cap (6) is fitted to the correct connecting rod (5) (they are fabricated in pair) there is free passage for the oil when fitting the base bearing to the base bearing cap the base bearing cap is turned with the oil shuffle (7) heading upwards, as illustrated
1 2 3 4 5 6 7 8 9 10
Threaded hole Groove Cross head Oil hole Connecting rod Base bearing cap Oil shuffle Pin Bushing Base bearing surface
2 1 3 4 5
6 7 8 9 10
GF201894
Tetra Pak
23
3 Crankcase
1
1 2 3 4 5 6 7 8 9 10 11 12 Piston Screw Hose clamp Plate Shims Hose clamp Piston connection ring Bellow ring, front Bellows Crosshead O-ring Bellow ring, rear
10
11
12
GF202142
24
Tetra Pak
2.2tf202041.en
3 Crankcase
1
1 2 3 4 5 6 7 8 9 10 11 12 Piston Screw Hose clamp Plate Shims Hose clamp Piston connection ring Bellow ring, front Bellows Crosshead O-ring Bellow ring, rear
10
11
12
GF202142
2.2tf202041.en
Tetra Pak
25
3 Crankcase
GF202407
A = 4 mm
26
Tetra Pak
2.2tf202360.en
3 Crankcase
GF202408
2.2tf202361.en
Tetra Pak
27
4.1 Valves
4 Wet end
GF201428
28
Tetra Pak
2.2tf201600.en
4 Wet end
4.1 Valves
5 6 7
2.2tf201600.en
1 13 2 3 4
8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13
Valve cover Support ring Valve seal Cylinder Valve cage Valve spring Valve Valve seal Support ring Valve seat Support ring Valve seal Distance
GF201516
Tetra Pak
29
4.1 Valves
4 Wet end
Fig. 1
6
2.2tf201600.en
Fig. 2
2 3 4 5
1 2 3 4 5 6
GF201430
30
Tetra Pak
4 Wet end
4.1 Valves
2.2tf201600.en
Fig 1
Fig 2
Fig 3
GF200528
Tetra Pak
31
4.1 Valves
4 Wet end
1 2
32
Tetra Pak
2.2tf201600.en
4 Wet end
16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Pressure nut Lid Piston O-ring Split support ring O-ring Piston bushing Guide band Piston packing Spring Support ring Piston packing Compression ring Guide band Spacer ring Crankcase housing
10 11 4 5 12 13 14 15
7 8 9
2.2tf202297.en
GF202743
Tetra Pak
33
DRAFT
4 Wet end
17
GF201918
18
16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Pressure nut Lid Piston O-ring Split support ring O-ring Piston bushing Guide band Piston packing Spring Support ring Piston packing Compression ring Guide band Spacer ring Crankcase housing
3
2.2tf202297.en
DRAFT
10 11 4 5 12 13 14 15
7 8 9
GF202743
34
Tetra Pak
4 Wet end
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Pressure nut Lid Piston O-ring Split support ring O-ring Piston bushing Guide band Piston packing Spring Support ring Piston packing Compression ring Guide band Spacer ring
1 2 3 4 5 6 7 8 10 11 12 13 14 15
GF202744
Tetra Pak
35
DRAFT
4 Wet end
16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Pressure nut Lid Piston O-ring Split support ring O-ring Piston bushing Guide band Piston packing Spring Support ring Piston packing Compression ring Guide band Spacer ring Crankcase housing
10 11 4 5 12 13 14 15
7 8 9
GF202743
DRAFT
36
Tetra Pak
2.2tf202297.en
4 Wet end
2.2tf202393.en
GF202429
Tetra Pak
37
4 Wet end
1
GF202428
2
1 Screw 2 O-ring
38
Tetra Pak
2.2tf202393.en
5 Homogenisation head
1
2.2tf201607.en
2 3
GF201882
Tetra Pak
39
5 Homogenisation head
Replace all O-rings and support rings. Rub the parts with silicon grease before assembly. Fit the parts in reverse order to dissasembly. Note! Vent plugs (6) heading upwards. Tighten the nuts (7) with a torque wrench. See Torque specifications.
1 2 3 4 5 6 7 Pipe connection Hydraulic end Housing Hydraulic end Housing Vent plug Nut
5 4 6 7 3 6 2 7
GF201865
1 7
40
Tetra Pak
2.2tf201607.en
5 Homogenisation head
4 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Screw O-ring O-ring Support ring Seat O-ring Forcer disc O-ring Forcer shaft O-ring Support ring Guide band Product drain hole O-ring Guide band
2.2tf201817.en
1 2
3 4 5 6 7 8 9 10 11 12 13 14 15
GF201785
Tetra Pak
41
5 Homogenisation head
4 3
16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Screw O-ring O-ring Support ring Seat O-ring Forcer disc O-ring Forcer shaft O-ring Support ring Guide band Product drain hole O-ring Guide band Locking compound TP No. 90157-16
1 2
3 4 5 6 7 8 9 10 11 12 13 14 15
GF202016
42
Tetra Pak
2.2tf201817.en
5 Homogenisation head
Deep caviation
Seat
GF201788
Seat
GF201787
Tetra Pak
43
5 Homogenisation head
Forcer disc
GF201790
Apply some locking fluid (6) of medium strength on the threads of screw (1). Tighten the screw hard enough to get metallic contact between the forcer disc (3) and the forcer shaft (5). Assemble according to activity 5.1-2.
Locking compound Force to open: 3 N/mm2 Temperature: -20 to +150 C -4 to + 302 F
1 2 3 4 5 6
Screw O-ring Forcer disc O-ring Forcer shaft Locking compound TP No. 90157-16
1 2 3 4
GF202017
44
Tetra Pak
5 Homogenisation head
5 6 7 8
8 5 6
GF201885
7
2.2tf201610.en
Replace guide bands (1) and (4), the O-ring (3) and the support ring (2). Apply some silicon grease to the parts, and fit the guide bands and the O-ring by hand. Tighten the nuts (6) with a torque wrench. See Torque specifications. Vent the hydraulic system by help of the vent plug (5).
1
1 2 3 4 5 6 Guide band Support ring O-ring Guide band Vent plug Nut
2 3 4 5 6
GF201786
Tetra Pak
45
6 Hydraulic system
18
90
19
17
3 4 5 9 17 18 19 23 Inlet Gasket Damper Gasket Gasket Outlet Gasket Damper Gasket Gasket
3
GF202410
46
Tetra Pak
2.2tf202363.en
23
6 Hydraulic system
4 6 6 9 5 8 5
2.2tf201612.en
GF201888
1 2 3 4 5 6 7 8 9
Hydraulic unit Safety valve Pressure adjusting valve Hydraulic pressure gauge Hydraulic end Vent plug Pressure relief valve (optional) Sensor, hydraulic pressure (optional) Remote setting valve (optional)
Tetra Pak
47
6 Hydraulic system
1 3
2
GF444
48
Tetra Pak
2.2tf202404.en
6 Hydraulic system
2 2
1 2 3 4 5 6 7 8 9 10 11 12 13 Screw Pipe Screw Pipe Pump Screw Lock ring Strainer Connection Connection Carrier Packing Filler cap
2.2tf202404.en
13 11
6 10 7 8
9 5 12
1
GF201949
Tetra Pak
49
6 Hydraulic system
2
14 3 16 13 15 11
2.2tf202404.en
6 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Screw Pipe Screw Pipe Pump Screw Lock ring Strainer Connection Connection Carrier Packing Filler cap Shaft cupling Shaft coupling Rubber cross
9 5 12
7 8
1
GF202445
50
Tetra Pak
6 Hydraulic system
2.2tf202405.en
1 Safety valve
GF200979
Tetra Pak
51
6 Hydraulic system
GF201893
52
Tetra Pak
2.2tf201627.en
6 Hydraulic system
2.2tf201012.en
GF200980
Tetra Pak
53
6 Hydraulic system
54
Tetra Pak
2.2tf202362.en
1 2 3 4 5
GF201611
5 3 2 1
2.2tf201261.en
Description 1 2 3 4 5 Cooling water valve Cooling water flow meter (optional) Cooling water regulating valve Cooling water regulator (optional) Cooling water regulating valve
Function Shut of valve Indicates flow rate and accumulated value Flow rate, see Technical Data Regulation of crank case oil temperature Max. 55 C (131 F) Automatic control of crank case oil temperature Regulation of gear box oil temperature
Tetra Pak
55
7.1 Piping
7.1 Piping
7.1-1 Piping - check
Check: all connections for leakage.
1 2 3 4 5
GF201611
5 3 2 1
2.2tf201261.en
1 2 3 4 5
Cooling water shut off valve Cooling water flow meter (optional) Cooling water regulating valve Cooling water regulator (optional) Cooling water regulating valve
56
Tetra Pak
GF201430
2.2tf201266.en
Tetra Pak
57
GF201431
1 Cooling water shut off valve, solenoid (standard) 2 Cooling water shut off valve, pneumatic (optional)
2.2tf201267.en
58
Tetra Pak
1 2 3 4 5
Flow direction
2.2tf201269.en
GF201434
Tetra Pak
59
0 - 999 litres
0 0 0 5 7 6 5 2
Flow direction
2.2tf201270.en
GF201435
60
Tetra Pak
8 Electrical system
POWER
2.2TF208680.en
SIGNAL
6-4722936200_AA
(Cont'd)
Tetra Pak
61
8 Electrical system
W10 W11 W18 W20 W21 W22 W23 W24 W25 W26 W27 W272 W28 W29 W30 W35
Remote On/Off Setting Hydraulic Pressure Stage 1 (Option 17) Remote On/Off Setting Hydraulic Pressure Stage 2 (Option 17/18)
2.2TF208680.en
Remote Continuous Setting Stage 1 (Option 19) Remote Continuous Setting Stage 2 (Option 19/20) Speed Sensor (Extra) Remote Ind. Product Pressure (Option 14) Remote Ind. Product Pressure (Extra) Remote Ind. Hydraulic Pressure Stage 1 (Option 15) Remote Ind. Hydraulic Pressure Stage 2 (Option 15/16) Steam Temperature (Aseptic, Option 12)) Oil Level Guard - High Level Oil Level Guard - Low Level (Option 28) Oil Temperature Crankcase (Option 28) Flow/Pressure Guard (Option 28) Inlet Pressure Guard (Option 28)
62
Tetra Pak
8 Electrical system
8.1 Cables
8.1 Cables
8.1-1 Cables - check
WARNING! Electrical hazard Make sure the power supply to the homogeniser is shut of and prevented from accidentally being turned on. Check all cables and cable connections.
DANGER!
2.2TF208680.en
Tetra Pak
63
8 Electrical system
GF200449
64
Tetra Pak
2.2TF208680.en
8 Electrical system
2.2TF208680.en
105 110
115
GF202414
Tetra Pak
65
8 Electrical system
WARNING!
Failure to make these checks can result in major personal injury or damage to the machine
66
Tetra Pak
2.2TF208680.en
9 Miscellaneous
9.1 Tools
GF200454 GF202226
GF200453
2.2tf201615.en
GF200456
GF200457
(Cont'd)
Tetra Pak
67
9.1 Tools
(Cont'd)
9 Miscellaneous
Tool not included in tool kit Drawings for local fabrication can be ordered
b a
GF200458
68
Tetra Pak
9 Miscellaneous
9.2 Lubrication
9.2 Lubrication
Recommended oil
Crankcase
Recommended oil: Cirkulation/gearbox oils with EP additives which do not harm slidebearings (yellow metals)
Mineral Type
Producer BP/Castrol Exxon/Mobil Shell Type Energol GR-XP Mobilgear 600 XP Omala Oil Viscosity* 220 220 220
Synthetic Type**
Producer BP/Castrol Exxon/Mobil Shell
2.2tf208729.en
Food GradeType***
Producer BP/Castrol Exxon/Mobil Shell Type Optileb GT DTE FM Cassida GL Viscosity* 220 220 220
* **
Viscosity in mm2/sec (cSt) at 40C (104F) A synthetic oil for the crank case must be of PAO ( poly alfa olefine) type , like the Omala, that is mixable with mineral oils and does not affect rubber, sealings and paint. Conform with FDA 21 CFR 178.3570 and classified in NSF H1.
*** Note!
Green oils is for the time beeing not availabe, but for some viscosities, and their lubricacion performance is not yet good enough for use in our type of heavy duty machines. (Cont'd)
Tetra Pak
69
9.2 Lubrication
(Cont'd) Gearbox
Recommended oil: Gearbox oil
9 Miscellaneous
Mineral Type
Producer BP/Castrol Exxon/Mobil Shell Type Energol GR-XP Mobilgear 600 XP Omala Oil Viscosity* 320 320 320
Synthetic Type**
Producer BP/Castrol Exxon/Mobil Shell Type Enersyn HTX SHC 630-632 Omala RL Viscosity* 220-320 220-320 220-320
Food GradeType***
2.2tf208729.en
Viscosity in mm2/sec (cSt) at 40C (104F) If the gear box temperatur is kept to max. 70 C ( 158F), 220 cSt is sufficient. A synthetic oil for the gear box must be of PAO ( poly alfa olefine) type, like the Omala, that is mixable with mineral oils and does not affect rubber, sealings and paint. (Cont'd)
**
70
Tetra Pak
9.2 Lubrication
Mineral Type
Producer BP/Castrol Exxon/Mobil Shell Type Bartran Mobil DTE Excel Tellus Viscosity* 68 68 68
Synthetic Type**
Producer BP/Castrol Exxon/Mobil Shell Type Mobil SHC 526 Tellus Viscosity* 68 68
Food GradeType***
2.2tf208729.en
Viscosity* 68 68 68
* **
Viscosity in mm2/sec (cSt) at 40C (104F) A synthetic oil for the hydraulic unit must be of PAO ( poly alfa olefine) type , like the Omala, that is mixable with mineral oils and does not affect rubber, sealings and paint. Conform with FDA 21 CFR 178.3570 and classified in NSF H1. (Cont'd)
***
Tetra Pak
71
9.2 Lubrication
(Cont'd) Main drive motor
Recommended grease Producer BP/Castrol Exxon/Mobil Shell Type Energrease LS EP 1 Mobilith SHC Alvania grease RL3
9 Miscellaneous
Food GradeType***
Producer BP/Castrol Exxon/Mobil Shell Type Mobil grease FM 101 Cassida RLS 2 Viscosity* 100 150
*** Conform with FDA 21 CFR 178.3570 and classified in NSF H1.
2.2tf208729.en
72
Tetra Pak
9 Miscellaneous
Oil amount
Crankcase
Approx. 20 litres (5.3 U.S. gallons)
Gearbox
Approx. 3 litres (0.8 U.S. gallons)
Hydraulic unit
Approx. 6 litres (1.6 U.S. gallons)
GF200326
GF202053
GF200601
2.2tf208730.en
Tetra Pak
73
9 Miscellaneous
(133 ft lbf) (103 ft lbf) (103 ft lbf) (103 ft lbf) (265 ft lbf) (32 ft lbf) (37 ft lbf) Torque
(4.4 ft lbf) (15 ft lbf) (37 ft lbf) (66 ft lbf) (85 ft lbf) (125 ft lbf) (140 ft lbf) (199 ft lbf)
2.2tf201622.en
12 mm 14 mm 17 mm
1 4
2 7 2
GF201897
74
Tetra Pak
9 Miscellaneous
Suction and discharge valves dirty or damaged Speed drop due to slipping V-belt Gas / air in wetend or piping Gas / air in product Capacaty of feed pump to small Piston packing damaged Valves stucked
Clean / change valves Adjust belt tension Vent wetend or piping Deaerate product Increase capacity of feed pump Replace piston packing Disassemble the wetend and check for damages or obstacles
2.2tf201621.en
Suction and discharge valves dirty or damaged Gas / air in cylinder block, possibly in only one or two cylinders Hydraulic end seal leaking Pressure fluctuations or pressure drop in the hydraulic system Pressure gauge for homogenisation pressure not working
Clean / change valves Vent the wetend Replace seal Check pressure adjusting valve Vent the hydraulic system Check, and if necessary, replace pressure gauge
Insufficient hydraulic pressure at homogenisation head Homogenisation head worn Pressure adjusting valve in hydraulic system is leaking Hydraulic pump worn Hydraulic pump not rotating
Check pressure valve Vent the hydraulic system Check forcer and seat Clean the pressure adjusting valve Note! The maximum set pressure must not be changed Replace the pump Check electrical connections
(Cont'd)
Tetra Pak
75
9 Miscellaneous
Possible cause Pulsation dampers full Valves worn Piston packing damaged To low inlet pressure To high inlet pressure
Action Drain Replace valves Check for product in cooling water Increase pressure Decrease pressure
To low inlet pressure Pulsation damper full Feed system empty while changing balance tank
Increase pressure Drain Shut off the hydraulic pressure while switching tank
76
Tetra Pak
2.2tf201621.en
9 Miscellaneous
2.2tf201621.en
Tetra Pak
77
5 Technical data
2.25_.en
Tetra Pak
Tetra Pak
2.25_.en
5856819007
Working pressure: 160 bar Ambient temperature: <40 C Piston diameter: 50
bar kg
Wetend design:
Piston design: mm Stainless steel Chromium plated Tungsten carbide Ceramic solid X X Remote ind. of product pressure: Feed: V DC Signal: mA V-packing
Drive Motor:
Manufacture: ABB Power: 30 Manufacture: Bosch kW Model: M3AA200MLB 4 H Voltage: 380 Model: 6-4722 5471 81 Model: M2VA71A 4 kW Voltage: 380 Model: Voltage: kW V Number of tracks: 3 Model: BT-51 V Revolution: 1375 Frequency: 50 Revolution: rpm Power: Frequency: Hz Rated current: Amp. Protection: rpm IP55 Hz Rated current: 0.95 Protection: Amp. V Revolution: 1470 Frequency: 50 Protection: rpm IP55 Hz Full load current: 58 V DC Starting current: Amp. 395 Amp.
Hydraulic Unit:
Hydraulic Motor:
Manufacture: ABB Power: 0.25 Manufacture:
Drive Unit:
V-belt type: SPB Motor pulley diameter: Gearbox pulley diameter: V-belt length 280 mm 315 mm 2000 mm Reduction: 5,760 Steam valve: Solenoid Press. relief valve: 1st Stage X Voltage: 24 V DC 0.75 Amp.
Reduction Gear:
Manufacture: Benzlers
Valves:
Cooling water valve: Solenoid X Voltage: Pneumatic Pneumatic Compressed air supply: V DC bar VA Hardness: <10 2nd Stage Voltage: 24 V DC 0.75 Amp. X
Compressed air supply: Voltage: bar 24 V DC 16 VA Consumption: 130 Consumption: bar kg/h Temperature: <25
Steam supply:
Pressure:
Condensate:
Temperature: C
Other:
Fluorescent tube: Voltage: V AC Date: 2009-03-17 Sign: TC Door safety lock: Voltage: V DC W Revision: 1 Crankshaft speed sensor: Feed: V DC mA
BL0081EN:3
Tetra Pak
2.25_.en
6 Test record
2.26_.en
Tetra Pak
Tetra Pak
2.26_.en
Tetra Alex 20
Customer:
5856819007
Republic of Moldovia
Performance data
Inlet pressure: Test liquid: Test voltage:
2,0 bar
Testing time Homogenizing Stage 1 pressure Hydraulic Signal pressure (h) (bar) (bar) (mA)
Water 40-70C
Stage 2 Hydraulic Signal pressure (bar) (mA) Capacity
380 V
Crankshaft revolution (rpm) Current Frequency consumption (Amp) (Hz)
(l/h)
50 100 150
42 78 87
33 33 33 33
15 25 37 41
50 50 50 50
160
Manufacturing No.
Main motor 0939921510001 Pump block A3873 Hydraulic motor 3GVA072001-BSD Pressure lubrication Motor Gearbox 990400-001 Crankcase , (TA 400)
Date:
20090317
Date: Test approved by:
20090317
BL0106EN:2
Tetra Pak
2.26_.en
7 Parts list
2.27_.en
Tetra Pak
Tetra Pak
2.27_.en
7 SPC
Machine No.
Group Description
Page No
Tetra Pak
TA20 - 5856819007
Tetra Alex 20
7-1
Tetra Pak
Assembly drawing
7-2
Version: PL-0
OF-0
Page No
6-4722 7516 80
6-4722 1982 80
6-4722 1991 80
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . 4
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . 8
6-4722 8155 80
Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6-4722 6977 80
6-4722 8450 80 6-4722 8451 80 6-4722 8452 80 6-4722 8453 80
COOLING CIRCUIT . . . . . . . . . . . . . . . . . . 12
Cooling System Water Inlet . . . . . . . . . . . . . Cooling System Gearbox Outlet. . . . . . . . . . Cooling System Crankcase Circuit. . . . . . . . Cooling System Piston Circuit . . . . . . . . . . . 14 16 18 20
6-4722 6676 80
6-4722 8132 80
6-4722 8144 50 6-4722 8161 80
WETEND . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Piston Cartridge . . . . . . . . . . . . . . . . . . . . . . 24 Valve Cartridge . . . . . . . . . . . . . . . . . . . . . . 26
6-4722 7040 80
6-4722 8763 80
HOMOGENIZING HEAD . . . . . . . . . . . . . . 28
Flange Manometer . . . . . . . . . . . . . . . . . . . . 30
6-4722 7563 80
6-4722 5471 81
HYDRAULIC UNIT . . . . . . . . . . . . . . . . . . . 32
Hydraulic Unit. . . . . . . . . . . . . . . . . . . . . . . . 34
6-4722 7963 80
6-4722 7966 80 6-4722 7964 80
6-4722 8360 80 6-4722 8361 80 6-4722 8362 80 6-4722 8363 80
6-4722 6580 80
6-4722 8163 80 6-4722 8166 80
DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . 50
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6-4722 6835 80
6-4722 8122 80 6-4722 8123 80
PRODUCT CONNECTIONS . . . . . . . . . . . 56
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6-4722 6671 80
ELECTRICAL PARTS . . . . . . . . . . . . . . . . 62
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
7-3
Tetra Pak
Crankcase
7-4
Group number: 6-4722 7516 80 Assembly Drawing: 751600_1_AA Pos 1 25 36 48 49 56 57 58 63 78 79 80 81 150 Part No 6-4722 1982 80 312105-0495 6-4722 6943 01 6-4722 9469 01 6-4018 0040 12 312105-0633 315105-0186 312601-0324 6-4722 5538 02 6-4722 6790 01 6-4722 8082 01 6-4722 5251 01 6-4722 7445 01 6-4722 8155 80 SP h UN Qty PC PC PC M PC PC PC PC PC PC PC PC ML PC 1 9 1 1 1 4 4 4 3 3 3 9 25 1 Description CRANKCASE COMPLETE ALEX 20 Screw M6S ISO 4017 M10x30 A480 NIPPLE PIPE 3/4 Hose 25 x 4.5 HOSE CLIP 26-38 /12 Screw M6S ISO 4014 M16x65 A480 Washer BRB 17X30 RFR Hexagon Nut, DIN 934 M16 8 FZB Hose clamp 64-75 Bellow ring front TA20 Piston connection ring ALEX 20 Screw MLC6S 6 x 16 FZB 8.8 DIN 7984 Flange sealing OIL SYSTEM ALEX 20 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Crankcase
6-4722 7516 80
7-5
Tetra Pak
Crankcase
7-6
Group number: 6-4722 1982 80 Assembly Drawing: 198280_1_AA Pos 1 2 4 5 6 7 8 11 13 14 15 16 17 18 19 20 22 23 24 26 30 31 32 33 34 35 40 41 42 43 44 51 54 55 59 60 61 62 64 67 82 83 84 Part No 6-4722 0968 02 6-4722 2000 02 6-4722 0935 01 6-4722 0970 02 6-4722 0971 01 6-4722 0972 02 6-4722 0973 01 6-4722 6792 01 6-4931 8090 09 6-4722 0978 80 6-4722 0975 01 6-4722 5174 01 90030-0030 90459-0276 312105-0455 312101-0538 312101-0534 6-4300 0018 04 312105-0543 315401-0178 6-4301 5000 11 6-4722 5181 01 315202-0237 6-4302 0490 72 6-4302 0490 40 6-4302 0075 05 6-4016 0302 15 6-4016 0301 80 6-4241 2200 02 6-4241 0010 57 6-4305 0012 50 6-4648 0000 05 312104-0506 312601-0320 342718-0107 315105-0165 6-4722 8055 01 6-4722 1987 01 6-4722 5538 04 6-4722 2455 02 6-4722 1991 80 6-4722 2021 02 6-4722 2453 03
Machine No.
Issue: 2009-03-11
SP h
UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC 1 1 1 1 1 1 1 3 1 1 1 3 2 3 14 6 3 2 6 6 1 3 3 1 1 1 1 1 1 1 1 3 2 4 2 14 1 3 3 3 3 3 3
Description
Page No
SP h
UN Qty PC PC PC PC PC 3 6 3 1 1
Description Plain bearing ALEX 20 Hexagon Nut, Ny-Lock M12 fzb Screw MLC6S 6 x 16 FZB 8.8 DIN 7984 Spacer tube Screw M6S M8x45H FZB
Page No
CRANK HOUSING TA20 Crank shaft SHL 20 LEVEL WINDOW TA20/25 Bearing cover TA20 Washer Bearing SHL 20 Bearing flange TA20 Spacer ring SHL 20 (SZO 140) Bellow ring rear TA20 Filler cap 1.5 OIL SCRAPER ALEX 20 Oil cooler TA20/25 Screw Conn. Bulkhead SV12L71 Screw Hex.Sock.Set Conept.MS6SS M6x25 A2 Screw M6S ISO 4017 M8x30 A480 Screw M6S M12x35 fzb Screw M6S M12x25 fzb Sealing ring 18 x 22 DIN 7603 Screw M6S ISO 4014 M12x55 A480 Washer FBH12,2FZB Housing gasket TA20/25 Seal 21 x 26 x 1.5 O-ring 99,1x5,7 mm O-ring 172 x 4 O-ring 242 x 4 O-ring 75 x 4 Circlip 215x5 DIN 472 Circlip 180 x 4 DIN 472 Roller bearing right ALEX 20 NUP220 Roller bearing left ALEX 20 NU224 SEALING BOX 125 x 150 x 12 DIN 3760 Plug 10.7 Screw M6S M10x75H FZB Hexagon Nut, M10 8 FZB, ISO 4032 Support sleeve VH10MSX Washer BRB 8,4x16 RFR Frame Bellows TA20 Hose clamp 109-120 Plate Connecting rod complete ALEX 20 Cross head ALEX 20 Cross head bolt TA20
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Crankcase
6-4722 1982 80
7-7
Tetra Pak
Connecting Rod
7-8
Group number: 6-4722 1991 80 Assembly Drawing: 6-4722199100_1_AC Pos 1 3 4 5 6 Part No 6-4722 2004 02 6-4722 1995 01 6-4722 2008 01 312810-0322 6-4002 6400 06 SP h UN Qty PC PC PC PC PC 3 3 6 6 3 Description Connecting rod ALEX 20 Bearing bushing ALEX 20 Connecting rod bolt Hexagon Nut, Ny-Lock M12 fzb Stop screw M6x10 DIN 551 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Connecting Rod
6-4722 1991 80
7-9
Tetra Pak
Oil System
7-10
Group number: 6-4722 8155 80 Assembly Drawing: 6-4722815500_1_AB Pos 49 50 98 105 118 119 120 133 138 Part No 6-4018 0040 12 6-4722 5675 01 6-4722 6945 01 6-4722 6928 01 6-4722 6943 01 6-4722 6935 01 6-4722 6944 01 6-4722 9469 01 6-1995 106 510 SP h UN Qty PC PC PC PC PC PC PC M PC 3 1 1 1 2 2 1 16 2 Description HOSE CLIP 26-38 /12 BALL VALVE PLUG RSK 2451 OUT 1/2 Thermometer NIPPLE PIPE 3/4 CLAW CONNECTION OUT 3/4 PLUG RSK 2451 OUT 3/4 Hose 25 x 4.5 Stripes black TY 5232MX 200X2,4mm Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Oil System
6-4722 8155 80
7-11
Tetra Pak
Cooling Circuit
7-12
Group number: 6-4722 6977 80 Assembly Drawing: 6-472269770_1_AD Pos 1 2 3 4 Part No 6-4722 8450 80 6-4722 8451 80 6-4722 8452 80 6-4722 8453 80 SP h UN Qty PC PC PC PC 1 1 1 1 Description Page No Pos Part No SP h UN Qty
Issue: 2006-11-09
Description
Page No
COOLING SYSTEM WATER INLET ALEX 20 Cooling system Gear box outlet ALEX 20 COOLING SYSTEM CRANKCASE CIRCUIT ALEX 20 COOLING SYSTEM PISTON CIRCUIT ALEX 20
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Cooling Circuit
6-4722 6977 80
7-13
Tetra Pak
7-14
Group number: 6-4722 8450 80 Assembly Drawing: 6-4722845000_1_AC Pos 6 7 13 17 26 27 28 29 33 35 53 54 55 58 63 120 Y810 Part No 6-4722 6093 01 6-4722 6094 01 90030-0058 90030-0106 6-4722 6095 01 6-4722 5213 01 6-4722 5186 01 342991-0101 312115-0372 312115-0376 6-4722 8426 15 6-4722 8426 13 6-4722 8426 16 6-4722 8426 08 6-4722 8426 13 6-4350 8400 78 6-4722 7312 03 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC 1 2 1 1 2 2 1 2 2 2 1 1 1 1 1 2 1 Description Trim valve R 3/8 Screw connection 12 R10 Conn. T-Pipe T-12 Conn. Pipe G-12 Spacer 12 x 8.2 x 15 PIPE HOLDER RAP112X Hose 10 x 16 Hose Clip,Worm Drive Type (13)-16 Screw ISO4762 M6x25 A4 80 Screw ISO4762 M6x35 A4 80 Cooling pipe 12 Cooling pipe 12 Cooling pipe 12 Cooling pipe 12 Cooling pipe 12 Straight connection GE 12 L/R3/8 Water valve 3/8 24V DC Page No Pos Part No SP h UN Qty
Issue: 2006-11-08
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
6-4722 8450 80
7-15
Tetra Pak
7-16
Group number: 6-4722 8451 80 Assembly Drawing: 6-4722845100_1_AB Pos 29 51 Part No 342991-0101 6-4722 5186 01 SP h UN Qty PC PC 2 1 Description Hose Clip,Worm Drive Type (13)-16 Hose 10 x 16 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
6-4722 8451 80
7-17
Tetra Pak
7-18
Group number: 6-4722 8452 80 Assembly Drawing: 6-6-4722845200_1_AB Pos 6 7 17 26 27 33 35 37 43 59 75 77 Part No 6-4722 6093 01 6-4722 6094 01 90030-0106 6-4722 6095 01 6-4722 5213 01 312115-0372 312115-0376 312115-0382 6-4722 6310 01 6-4722 8426 14 6-4722 8426 25 6-4722 8426 27 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC 1 2 2 4 5 2 4 2 2 1 1 1 Description Trim valve R 3/8 Screw connection 12 R10 Conn. Pipe G-12 Spacer 12 x 8.2 x 15 PIPE HOLDER RAP112X Screw ISO4762 M6x25 A4 80 Screw ISO4762 M6x35 A4 80 Screw ISO4762 M6x60 A4 80 JOINT NUT M6 x 14 Cooling pipe 12 Cooling pipe 12 Cooling pipe 12 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
6-4722 8452 80
7-19
Tetra Pak
7-20
Group number: 6-4722 8453 80 Assembly Drawing: 6-4722845300_1_AB Pos 14 17 24 26 27 33 35 52 57 60 61 62 Part No 6-4350 8400 78 90030-0106 90030-0096 6-4722 6095 01 6-4722 5213 01 312115-0372 312115-0376 6-4722 8426 02 6-4722 8426 07 6-4722 8426 10 6-4722 8426 11 6-4722 8426 12 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC 6 2 2 2 2 2 2 1 1 1 2 2 Description Straight connection GE 12 L/R3/8 Conn. Pipe G-12 Conn. Elbow W12L71 Spacer 12 x 8.2 x 15 PIPE HOLDER RAP112X Screw ISO4762 M6x25 A4 80 Screw ISO4762 M6x35 A4 80 Cooling pipe 12 Cooling pipe 12 Cooling pipe 12 Cooling pipe 12 Cooling pipe 12 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
6-4722 8453 80
7-21
Tetra Pak
Wetend
7-22
Group number: 6-4722 8132 80 Assembly Drawing: 6-4722813200_1_AB Pos 20 21 28 29 32 33 34 35 88 Part No 6-4722 8144 50 6-4722 6844 01 6-4722 8161 80 6-4722 2911 01 6-4722 7446 01 6-4010 6240 02 6-4722 6852 38 6-4015 0025 05 6-4722 5084 02 SP h UN Qty PC PC PC PC PC PC PC PC PC 3 1 3 3 12 8 8 8 2 Description Piston cartridge ALEX 20 50 BASIC PUMP BLOCK 65 US-3A VALVE CARTRIDGE 65 MUSHROOM Valve cover Mushroom valve Screw M6S 20 x 55, A2-70 Cap nut M24 Stud bolt M24 x 168 Washer BRB 25 DIN125 Guide pin CP m6 20 x 80 SMS 2374 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Wetend
6-4722 8132 80
7-23
Tetra Pak
Piston Cartridge
7-24
314671
Group number: 6-4722 8144 50 Assembly Drawing: 6-4722814450_1_AD Pos 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 56 57 Part No 6-4722 6912 02 6-4722 6129 02 6-4722 6122 13 6-4722 6897 01 311103-0306 6-4722 5843 02 312105-0287 6-4722 6807 01 6-4722 0386 12 6-4722 9026 08 6-4722 9026 08 6-4722 2264 12 6-4722 1418 10 6-4722 1552 49 6-4722 9042 49 6-4722 9042 41 6-4722 9042 49 6-4722 1178 17 6-4722 1178 23 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC 3 3 3 3 3 3 12 3 3 3 3 3 6 3 3 3 3 3 3 Description Cylinder bushing 50 US-3A Piston bushing 50 US-3A Cover 50 Pressure nut 50 Parallel pin ISO 2338 5m6x12 A1 Spring 7.0 x 65 x 80 x 6 US-3A Screw M6S ISO 4017 M4x8 A470 Piston 50-CR Support ring 50 Basic Piston seal 50 PSB2 Piston seal 50 PSB2 Compression ring 50 Guide band 50x9.5 Spacer ring 50 US-3A O-ring 75 x 5 EPDM 80 E8502 O-ring 62 x 4 EPDM 80 E8502 O-ring 75 x 5 EPDM 80 E8502 Support ring 85 Support ring 74 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Piston Cartridge
6-4722 8144 50
7-25
Tetra Pak
Valve Cartridge
7-26
Group number: 6-4722 8161 80 Assembly Drawing: 6-4722816100_1_AB Pos 23 24 25 26 27 58 59 Part No 6-4722 6648 02 6-4722 6649 03 6-4722 6652 01 6-4722 6657 01 6-4722 0942 02 6-4722 1178 18 6-4722 6651 01 SP h UN Qty PC PC PC PC PC PC PC 6 6 6 6 15 15 3 Description Mushroom valve 65 Valve seat 65 Valve spring 65 Valve cage 65 Valve sealing 55 x 65 x 8 Support ring 65 Spacer 65 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Valve Cartridge
6-4722 8161 80
7-27
Tetra Pak
Homogenizing Head
7-28
Group number: 6-4722 7040 80 Assembly Drawing: 6-4722704000_2_AG Pos 1 2 3 4 5 6 7 8 9 10 11 13 17 18 19 21 22 24 26 27 28 29 30 32 33 34 35 40 43 94 Part No 6-4722 7041 01 6-4722 9019 01 6-4722 7042 01 6-4010 6240 09 6-4722 6852 43 6-4722 6562 47 6-31353 0362 1 6-4306 0000 05 6-4722 9042 35 312115-0364 6-4722 5233 01 6-4722 9042 08 6-4722 9018 01 6-4722 7044 01 6-4722 6852 44 6-4722 9042 03 6-4722 9042 15 6-4722 7151 03 6-4722 1418 16 6-4722 9042 05 6-4722 7152 03 6-4722 7153 03 6-4722 7045 01 90087-0015 6-4722 9018 01 6-4722 7044 01 6-4722 7045 01 6-4722 8763 80 6-4722 9042 08 6-4722 9322 02 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC 2 2 2 8 4 2 2 4 2 2 2 2 1 1 4 2 5 2 4 2 3 2 1 2 1 1 1 1 1 1 Description Hydraulic cylinder 75 Forcer shaft Hydraulic piston 75 Cap nut M16 Stud bolt M16 x 296 O-ring 62.87 x 5.33 Screw ARC/SMO/SRC Guide band 75 O-ring 16.3x2.4 EPDM 80 E8502 Screw ISO4762 M6x10 A4 80 Sealing ring 6 x 10 O-ring 40.87x3.53 EPDM 80 E8502 Forcer disc 53/63 Seat 53/62 Stud bolt M16 x 220 O-ring 24.99x3.53 EPDM 80 E8502 O-ring 69.44x3.53 EPDM 80 E8502 Support ring axial 3.53 x 32.2 Guide band 32x5.5 O-ring 31.34x3.53 EPDM 80 E8502 Support ring radial 3.53 x 79.8 Support ring axial 5.33 x 75 Housing Plug, Ext. Thread Hex. Socket VSTI 1/4-E Forcer disc 53/63 Seat 53/62 Housing Pressure gauge flange O-ring 40.87x3.53 EPDM 80 E8502 Intermediate flange 86 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Homogenizing Head
6-4722 7040 80
7-29
Tetra Pak
Flange Manometer
7-30
Group number: 6-4722 8763 80 Assembly Drawing: 6-4722876300_1_AA Pos 40 42 49 52 53 Part No 6-4722 8752 01 312105-0631 6-4722 6396 01 6-4722 9042 52 6-4722 8753 01 SP h UN Qty PC PC PC PC PC 1 2 1 1 1 Description Pressure gauge flange Screw M6S ISO 4014 M16x55 A480 Pressure gauge O-ring 23.39x3.53 EPDM E8502 Back-up Ring Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Flange Manometer
6-4722 8763 80
7-31
Tetra Pak
Hydraulic Unit
7-32
Group number: 6-4722 7563 80 Assembly Drawing: 6-4722756300_1_AE Pos 1 2 5 7 15 18 19 23 25 26 27 28 29 30 32 34 36 37 40 44 47 48 49 50 55 59 61 65 67 70 78 85 122 Part No 6-4722 5471 81 6-4722 5265 01 6-4722 9247 01 6-4722 9245 01 6-4932 2002 25 6-4932 2002 26 6-4722 6515 01 342741-0103 342741-0103 342731-0103 342731-0103 342731-0103 6-4350 8405 07 342731-0103 342747-0103 6-4350 8302 00 342741-0103 90087-0015 6-4722 6487 03 6-4722 6746 11 6-4722 6746 09 6-4722 6746 13 6-4722 6746 13 6-4722 6746 13 6-4722 8369 01 312115-0366 312115-0335 90458-0072 312115-0459 312105-0451 315105-0165 6-4722 5539 01 312812-0318 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC 1 1 2 2 1 1 8 2 1 1 1 1 2 1 1 1 1 2 2 1 1 1 1 1 1 4 8 8 1 4 4 2 1 Description Hydraulic unit Bosch Motor 220/380V/50Hz 0,25kW Pressure adjusting valve Pressure relief valve 24V DC NO Hydraulic pressure gauge 250bar Hydraulic pressure gauge 60bar O-ring 9,25x1,78 NBR Conn. T-Pipe TA-8-R1/4 Conn. T-Pipe TA-8-R1/4 Conn. Elbow WE 8LRCF Conn. Elbow WE 8LRCF Conn. Elbow WE 8LRCF CONNECTION LR/G 1/4 Conn. Elbow WE 8LRCF Conn. T-Pipe T-8 Pipe coupling GE 8 LR/A3C Conn. T-Pipe TA-8-R1/4 Plug, Ext. Thread Hex. Socket VSTI 1/4-E HYDRAULIC PIPE 8x1.5 Hydraulic hose 1100 Hydraulic hose 900 Hydraulic hose 1300 Hydraulic hose 1300 Hydraulic hose 1300 PANEL PLATE ALEX 20 Screw ISO4762 M6x12 A4 80 Screw ISO4762 M5x30 A4 80 Screw ISO 7380 S M6x12 A2 Screw ISO4762 M8x40 A4 80 Screw M6S ISO 4017 M8x20 A480 Washer BRB 8,4x16 RFR HOSE BRACKET Hexagon Nut, Ny-Lock M8 A480 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Hydraulic Unit
6-4722 7563 80
7-33
Tetra Pak
Hydraulic Unit
7-34
Group number: 6-4722 5471 81 Assembly Drawing: 6-4722547100_1_AE Pos 5 8 9 10 11 24 32 33 34 35 36 38 39 40 41 Part No 6-4722 6542 01 6-4722 6541 02 6-4722 7553 01 6-4722 7554 01 6-4722 7552 01 90287-0049 6-4722 7550 01 6-4722 7551 01 312318-0289 6-4722 7555 01 90087-0015 90087-0024 312605-0316 315701-0203 6-4722 7549 01 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC 2 1 1 1 2 8 1 1 1 1 1 1 1 1 1 Description VALVE PRESSURE LIMIT Pump two stages Bosch Sight glass Filter Filter Screw MLC6S 5x12 10.9 Shaft coupling Rubber cross Screw ISO4029 M4x10 A4 Key 2 x 2 6 DIN 6888 Plug, Ext. Thread Hex. Socket VSTI 1/4-E Plug, Ext. Thread Hex. Socket VSTI 1/2-E Hexagon Nut, M6M M6 A280 Parallel key w. round ends 5x5x25 mm Gasket Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Hydraulic Unit
6-4722 5471 81
7-35
Tetra Pak
7-36
Group number: 6-4722 7963 80 Assembly Drawing: 6-47227963001 Pos 1 2 4 5 6 8 Part No 6-4722 7966 80 6-4722 7964 80 6-4722 8505 01 6-4722 8503 01 6-4722 8504 01 6-1 648133 02 SP h UN Qty PC PC PC PC PC PC 1 1 1 1 1 4 Description FRAME ALEX 20 COMPLETE M-TYPE BODY ALEX 20 STRIPE BLUE B=70 MM, L=8.5 M STRIPE Tetra Pak WHITE H=42 STRIPE Tetra Alex WHITE H=42 Base plate (support leg) Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
6-4722 7963 80
7-37
Tetra Pak
Frame Complete
7-38
Group number: 6-4722 7966 80 Assembly Drawing: 6-4722796600 Pos 1 2 3 4 5 6 7 8 9 10 30 31 32 Part No 6-4722 7968 01 90458-2744 6-31801 2329 1 6-4722 7975 01 6-4722 7974 01 6-4722 8798 01 6-4722 6385 01 312605-0316 312605-0318 312105-0449 6-4722 7970 01 6-4000 0006 01 315105-0153 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC 1 4 4 1 1 4 4 4 8 2 1 4 4 Description WELDED FRAME Plug, VL 100X40X4 Plastic plug Plate Plate Spindle BARRIER NUT Hexagon Nut, M6M M6 A280 Hexagon Nut, M6M M8 A280 Screw M6S ISO 4017 M8x16 A480 Belt shield Screw M6S-h 6 x 10 DIN 933 Washer BRB 6,4X12 RFR Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Frame Complete
6-4722 7966 80
7-39
Tetra Pak
M-Type Body
7-40
Group number: 6-4722 7964 80 Assembly Drawing: 6-4722796400 Pos 10 15 20 25 Part No 6-4722 8360 80 6-4722 8361 80 6-4722 8362 80 6-4722 8363 80 SP h UN Qty PC PC PC PC 1 1 1 2 Description CLADDING MIDDLE COMPLETE ALEX 20 CLADDING FRONT COMPLETE ALEX 20 CLADDING REAR COMPLETE ALEX 20 Lid complete ALEX 20 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
M-Type Body
6-4722 7964 80
7-41
Tetra Pak
7-42
Group number: 6-4722 8360 80 Assembly Drawing: 6-4722836000_1_AB Pos 10 15 20 25 35 40 300 500 505 510 600 605 610 Part No 6-4722 8364 01 6-4722 8365 01 6-4722 8366 01 6-4722 8372 01 6-4722 9357 01 6-4722 2203 02 6-31801 2329 1 6-990471 29 312311-0455 312105-0447 312812-0316 312715-0116 315105-0165 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC 1 1 1 2 1 5 4 14 4 1 10 4 1 Description UPPER FRAME Plate Plate BRACKET Brace RUBBER DAMPER 30 x 30 x M8 Plastic plug Screw K6S M6x10H A2-70 Screw ISO4028 M8x30 FZB Screw M6S ISO 4017 M8x12 A480 Hexagon Nut, Ny-Lock M6 A480 Wing nut DIN 315 A2 MVM-K M6 Washer BRB 8,4x16 RFR Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
6-4722 8360 80
7-43
Tetra Pak
7-44
Group number: 6-4722 8361 80 Assembly Drawing: 6-4722836100 Pos 10 15 20 25 30 500 505 510 600 605 Part No 6-4722 8370 01 6-4722 8367 01 6-4722 8372 01 6-4722 8371 01 6-4722 2203 02 6-990471 29 312311-0455 90459-0325 312812-0316 312605-0318 SP h UN Qty PC PC PC PC PC PC PC PC PC PC 1 1 1 2 2 7 2 10 7 2 Description UPPER FRAME Plate BRACKET BRACKET RUBBER DAMPER 30 x 30 x M8 Screw K6S M6x10H A2-70 Screw ISO4028 M8x30 FZB Blank Rivet 4,8x14 Hexagon Nut, Ny-Lock M6 A480 Hexagon Nut, M6M M8 A280 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
6-4722 8361 80
7-45
Tetra Pak
7-46
Group number: 6-4722 8362 80 Assembly Drawing: 6-4722836200 Pos 10 15 20 25 30 500 505 510 600 605 Part No 6-4722 8370 01 6-4722 8368 01 6-4722 8372 01 6-4722 8371 01 6-4722 2203 02 6-990471 29 312311-0455 90459-0325 312812-0316 312605-0318 SP h UN Qty PC PC PC PC PC PC PC PC PC PC 1 1 1 2 2 7 2 10 7 2 Description UPPER FRAME Plate BRACKET BRACKET RUBBER DAMPER 30 x 30 x M8 Screw K6S M6x10H A2-70 Screw ISO4028 M8x30 FZB Blank Rivet 4,8x14 Hexagon Nut, Ny-Lock M6 A480 Hexagon Nut, M6M M8 A280 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
6-4722 8362 80
7-47
Tetra Pak
Lid Complete
7-48
Group number: 6-4722 8363 80 Assembly Drawing: 6-4722836300_1_AB Pos 10 15 20 25 300 505 510 515 520 600 605 610 615 Part No 6-4722 8374 01 6-4722 7508 01 6-4722 8373 01 6-4722 8250 01 6-4722 7574 02 6-990471 30 6-990471 31 312105-0463 6-4722 5208 01 312605-0318 312812-0316 315105-0153 315105-0165 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC 2 2 2 4 2 4 2 4 4 10 8 2 2 Description Lid HANDLE BRACKET HINGE Gas spring G19 - 150 - 400N Screw K6S M8x10H A2-70 Screw K6S M6x20H A2-70 Screw M6S ISO 4014 M8x60 A480 Screw MC6S 5 x 10 Hexagon Nut, M6M M8 A280 Hexagon Nut, Ny-Lock M6 A480 Washer BRB 6,4X12 RFR Washer BRB 8,4x16 RFR Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Lid Complete
6-4722 8363 80
7-49
Tetra Pak
Drive Unit
7-50
Group number: 6-4722 6580 80 Assembly Drawing: 6-4722658000_1_AB Pos 1 2 18 19 20 26 27 Part No 6-4722 8163 80 6-4722 8166 80 312601-0324 315105-0186 312105-0633 6-4015 0571 02 315402-0186 SP h UN Qty PC PC PC PC PC PC PC 1 1 4 4 4 4 4 Description DRIVE UNIT ALEX 20 DRIVE UNIT Hexagon Nut, DIN 934 M16 8 FZB Washer BRB 17X30 RFR Screw M6S ISO 4014 M16x65 A480 Washer RBS 17 DIN 9021 Lock washer FBB 16,2 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Drive Unit
6-4722 6580 80
7-51
Tetra Pak
Drive Unit
7-52
Group number: 6-4722 8163 80 Assembly Drawing: 6-4722816300 Pos 1 2 3 4 5 6 7 8 11 12 13 16 17 21 22 23 24 25 31 32 35 36 37 38 39 40 41 42 43 44 Part No 6-4722 6457 02 6-4722 6573 01 6-4722 1089 01 311103-0353 312101-0672 6-4722 6461 01 6-4722 5415 01 6-4722 5457 01 315111-0205 6-4016 0011 30 6-4722 5618 01 6-4722 5621 01 6-4722 6464 01 6-4722 6134 01 6-4722 6132 01 6-4722 6131 01 315751-0119 315751-0122 312115-0366 315105-0153 6-4722 6574 01 6-4722 6591 01 6-4722 6592 01 6-4722 6593 01 6-4722 6594 01 6-4722 6595 01 6-4722 6596 01 342701-0205 6-4722 5186 01 342991-0101 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 2 1 2 2 1 1 1 1 2 1 1 1 1 2 Description Gear box BT51 TA20 SS Wedge 20 x 12 x 162 Washer SHL 20 Parallel pin ISO 2338 6m6x20 A1 Screw M6S M20x40 fzb TORQUE ARM TA20 Adjusting bolt TA25 Sleeve 30 x 60 x 55 Washer TBRB33x58FZB Washer 21 DIN 432 NUT M6M 30 NUT ML6M 30 Spacer sleeve Benzler BT51 Spacer Bushing Joint Retaining ring for Shaft DIN 471 25 SS Retaining ring for Shaft DIN 471 30 SS Screw ISO4762 M6x12 A4 80 Washer BRB 6,4X12 RFR CANTILEVER LEVEL TUBE WN 398 B 3/8 -130 BARRIER NUT 3/8 HOSE CLAMP 3/8 Washer 14 x 20 x 1.5 Nipple 90 1/4 BANJO SCREW 1/4 Bushing,INT./EXT.G-THREAD G1/2-G1/4 Hose 10 x 16 Hose Clip,Worm Drive Type (13)-16 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Drive Unit
6-4722 8163 80
7-53
Tetra Pak
Drive Unit
7-54
Group number: 6-4722 8166 80 Assembly Drawing: 6-4722816600_1_AC Pos 1 2 3 4 5 6 Part No 6-4722 5996 23 6-4722 5900 02 6-4722 5965 09 6-4722 5901 02 6-4722 5965 03 6-4722 5857 05 SP h UN Qty PC PC PC PC PC PC 1 1 1 1 1 3 Description Motor M3AA200MLB 4H 30kW 380V/50Hz Pulley 3 SPB 280 Bushing 3020 D55 Pulley 3 SPB 315 Bushing 3020 D38 V-Belt SPB 2000 MC Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Drive Unit
6-4722 8166 80
7-55
Tetra Pak
Product Connections
7-56
Group number: 6-4722 6835 80 Assembly Drawing: 6-4722683500 Pos 30 40 62 63 72 Part No 6-4722 8122 80 6-4722 8123 80 312105-0622 6-4722 9042 12 312105-0624 SP h UN Qty PC PC PC PC PC 1 1 2 1 4 Description Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
PRODUCT CONNECTIONS INLET ALEX 20 PRODUCT CONNECTIONS OUTLET ALEX 20 Screw M6S ISO 4017 M16x25 A480 O-ring 53.57x3.53 EPDM 80 E8502 Screw M6S ISO 4017 M16x30 A480
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Product Connections
6-4722 6835 80
7-57
Tetra Pak
Inlet
7-58
Group number: 6-4722 8122 80 Assembly Drawing: 6-4722812200_1_AA Pos 1 2 3 4 5 6 7 8 9 10 25 27 28 Part No 6-4722 6816 01 6-2110 54 6-881 17113 6-4722 6085 01 6-881 17113 6-2110 54 6-4722 6081 01 6-2110 54 6-881 17113 6-9611 34 2051 6-4722 6525 04 312601-0320 315105-0173 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC 1 1 1 1 1 1 1 1 1 1 1 2 2 Description Inlet flange 51 Clamp single hinge A13MHM-2-S Seal ring H-Line H40-X-2 Silicone Damper basic Clamp 51 Seal ring H-Line H40-X-2 Silicone Clamp single hinge A13MHM-2-S Attachment pipe Clamp 51 Clamp single hinge A13MHM-2-S Seal ring H-Line H40-X-2 Silicone Ferrule 3A H-line-female 2 AISI316L Support 100 D51x89 Hexagon Nut, M10 8 FZB, ISO 4032 Washer BRB 10,5X22 RFR Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Inlet
6-4722 8122 80
7-59
Tetra Pak
Outlet
7-60
Group number: 6-4722 8123 80 Assembly Drawing: 6-4722812300_1_AA Pos 26 27 28 15 16 17 18 19 20 21 22 23 24 Part No 6-4722 6525 02 312601-0320 315105-0173 6-4722 7049 06 6-2110 53 6-881 17112 6-4722 6086 01 6-881 17112 6-2110 53 6-4722 6084 01 6-2110 53 6-881 17112 6-9611 34 2050 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC 1 2 2 1 1 1 1 1 1 1 1 1 1 Description Support 260 D38x254 Hexagon Nut, M10 8 FZB, ISO 4032 Washer BRB 10,5X22 RFR Outlet flange Clamp 38 2-ST Clamp single hinge A13MHM-1 1/5-S Seal ring H-Line H40-X-1 1/2 Damper basic Clamp 38 Seal ring H-Line H40-X-1 1/2 Clamp single hinge A13MHM-1 1/5-S Attachment pipe Clamp 38 Clamp single hinge A13MHM-1 1/5-S Seal ring H-Line H40-X-1 1/2 Ferrule 3A H-line-female 1.5 AISI316L Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Outlet
6-4722 8123 80
7-61
Tetra Pak
Electrical Parts
7-62
Group number: 6-4722 6671 80 Assembly Drawing: 6-4722919500 Pos Part No 6-4722 7592 80 6-4722 9195 80 6-4722 8967 80 6-4722 7022 80 6-4722 7592 80 6-4722 9354 01 6-4722 9355 01 6-4722 9356 01 6-4722 9377 01 90459-3352 6-990475 10 90135-0035 315105-0165 312105-0449 6-4722 9195 80 6-4722 6949 01 6-4722 6950 01 6-4722 9371 01 6-4722 9156 01 6-4722 5429 01 6-4722 6982 01 6-4722 5528 01 6-4722 5430 01 6-4722 6942 01 6-990475 10 90099-0003 90135-0035 90135-0040 90165-0056 90165-0058 352103-0110 312115-0368 312812-0316 312125-0287 312125-0323 312605-0318 315105-0146 315105-0153 90005-0114 6-990475 08 6-4722 8938 19 6-4722 8941 29 6-4722 9198 16
Machine No.
Issue: 2009-03-11
SP h
UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC 1 1 1 1 1 1 1 1 1 3 4 1 2 1 1 1 1 1 1 1 1 2 2 1 6 1 1 1 2 7 1 4 4 9 5 2 4 4 1 4 1 1 1
Description COMMON ELECTRIC PARTS CONNECTION BOX TA 20, 25, 30 CABLING TA 20, 25, 30 CABLING COMMON ELECTRIC PARTS MANOEUVRE BOX Hour Meter 24V DC Gauge Anti Slip Ring Reducing sleeve M20/15,2 (Pg9) Flat pin socket, 6,3x0,8 Lock washer 8,2x14x0,8 Earth wire, L=250 mm 16 mm2 Washer BRB 8,4x16 RFR Screw M6S ISO 4017 M8x16 A480 CONNECTION BOX TA 20, 25, 30 CONNECTION BOX 280 x 380 Sheet TERMINAL BLOCK POWER TERMINAL BLOCK/SIGNAL Flange 9x19+5x15,5/22,5 FLANGE 4 x Pg11/21 + 7 x Pg16 Lock screws Gasket GROUNDING SCREW Lock washer 8,2x14x0,8 Nut Pr 22,5 Earth wire, L=250 mm 16 mm2 Earth wire, L=150 mm 16 mm2 Pipe Clip for Tube d=4 mm Pipe Clip for Tube d=2,5 mm Cable gland, STR 16, PR22,5/PG16 Screw ISO4762 M6x16 A4 80 Hexagon Nut, Ny-Lock M6 A480 Screw ISO 1207 M4x8 A4 Screw ISO 1207 M5x8 A4 Hexagon Nut, M6M M8 A280 Washer BRB 5,3x10 RFR Washer BRB 6,4X12 RFR Washer Plain Round 5,3(M5)/15, H=1 Lock washer 5,3x10x0,6 A4 Wiring 02, Motor - Hydraulic unit Wiring 05, Start - Stop Wiring 18, Thermistor
Group Description
Page No
Part No 6-4722 8953 21 6-4722 8953 21 6-4722 8938 19 352135-0106 352136-0127 352137-0130 353250-0020 351150-0413 6-4722 8941 29 352135-0106 352136-0127 352136-0130 353250-0020 351150-0406
SP h
UN Qty PC PC 1 1
Description Wiring 22/23, Press relief Wiring 22/23, Press relief Wiring 02, Motor - Hydraulic unit Spiral Conduit Di=16 mm Gland fitting PR 18,6 Gland fitting Gland, Lock nut M20x1,5 Cable Olflex 4Gx1,5 mm2 light/grey Wiring 05, Start - Stop Spiral Conduit Di=16 mm Gland fitting PR 18,6 Gland fitting M20x1.5 Gland, Lock nut M20x1,5 Cable Olflex 7x0,75 mm2 light/grey
Page No
1 40 41 50 60 70 71 72 73
PC 1 M 225 PC 2 PC 1 PC 1 M 27 PC 1 M 29 PC 1 PC 1 PC 1 M 345
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Electrical Parts
6-4722 6671 80
7-63
Tetra Pak
Labels
Assembly drawing
7-64
No Drawing
Group number: 6-4722 6675 80 Assembly Drawing: Pos 9 10 15 Part No 6-4722 5686 01 6-4722 5696 01 359705-0002 SP h UN Qty PC PC PC 1 1 2 Description Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
SIGN CLEANING OF PIPE SYSTEM ENG/GER SIGN CHECK WATER IN OIL ENG/GER Warning Sign ISO, Entanglement
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Labels
6-4722 6675 80
7-65
Tetra Pak
Commissioning Kit
Assembly drawing
7-66
Group number: 6-4722 6660 80 Assembly Drawing: Pos Part No 6-4722 6660 80 6-4722 6663 80 6-4722 7569 01 90458-0863 90458-0861 6-4722 6332 01 6-4722 5642 01 6-4722 5642 02 6-4722 5642 03 6-4722 6663 80 6-4722 6681 80 6-4722 8144 91 6-4722 8161 91 6-4722 7040 89 6-4722 8763 91 6-4722 6835 91 6-4722 8144 91 6-4722 9026 08 6-4722 9026 08 6-4722 1418 10 6-4722 9042 49 6-4722 9042 49 6-4722 1178 17 6-4722 8161 91 6-4722 0942 02 6-4722 1178 18 6-4722 7040 89 6-4722 6562 47 6-4722 9042 35 6-4722 9042 08 6-4722 9042 03 6-4722 9042 15 6-4722 7151 03 6-4722 9042 05 6-4722 7152 03 6-4722 9042 08 SP h UN Qty PC PC L L L PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC 1 1 20 3 6 3 3 3 3 1 1 3 3 1 1 1 3 3 3 6 3 3 3 3 15 15 1 2 2 2 2 5 2 2 3 1 Description COMMISSIONING KIT COMMISSIONING KIT ALEX 20 Oil mineral 220 cSt Oil mineral 320 cSt MOBIL DTE 26, 68 cSt ATTACHMENT PIPE WATER/STEAM Shim 0.1 Shim 0.2 Shim 0.3 COMMISSIONING KIT ALEX 20 TOOLS ALEX 20 COMM. KIT PISTON CARTRIDGE ALEX 20 BASIC COMM. KIT VALVE CARTRIDGE 65 MUSHROOM COMM. KIT HOMOGENISING HEAD COMM. KIT FLANGE MANOMETER COMM. KIT PRODUCT CONNECTIONS ALEX 20 COMM. KIT PISTON CARTRIDGE ALEX 20 BASIC Piston seal 50 PSB2 Piston seal 50 PSB2 Guide band 50x9.5 O-ring 75 x 5 EPDM 80 E8502 O-ring 75 x 5 EPDM 80 E8502 Support ring 85 COMM. KIT VALVE CARTRIDGE 65 MUSHROOM Valve sealing 55 x 65 x 8 Support ring 65 COMM. KIT HOMOGENISING HEAD O-ring 62.87 x 5.33 O-ring 16.3x2.4 EPDM 80 E8502 O-ring 40.87x3.53 EPDM 80 E8502 O-ring 24.99x3.53 EPDM 80 E8502 O-ring 69.44x3.53 EPDM 80 E8502 Support ring axial 3.53 x 32.2 O-ring 31.34x3.53 EPDM 80 E8502 Support ring radial 3.53 x 79.8 O-ring 40.87x3.53 EPDM 80 E8502 Page No Pos Part No 6-4722 8763 91 6-4722 9042 52 6-4722 8753 01 6-4722 6835 91 6-4722 9042 12 SP h UN Qty PC PC PC PC PC 1 1 1 1 1
Issue: 2009-03-11
Description COMM. KIT FLANGE MANOMETER O-ring 23.39x3.53 EPDM E8502 Back-up Ring
Page No
52 53
63
11 12 14 16 18 56
27 58
6 9 13 21 22 24 27 28 43
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Commissioning Kit
6-4722 6660 80
7-67
Tetra Pak
Tools
7-68
Group number: 6-4722 6681 80 Assembly Drawing: 6-4722668100_1_AA Pos 1 14 14 17 18 19 20 23 24 25 26 Part No 6-4722 8025 82 6-4722 9508 01 6-1995 109 012 6-4722 6800 01 6-4690 0260 00 6-4722 6803 81 6-4722 8026 01 6-4722 8038 01 6-4722 1839 01 6-4722 7435 01 6-4722 8287 03 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC 1 1 1 1 1 1 1 1 1 1 1 Description Standard tools ALEX 20, 25 Assembly paste, tube 100 g UNISILICONE Extractor plate 162 Puller 21/5 30-37 Extractor extension Tongs VALVE MOUNTING TOOL 65/55 Hook spanner 116 Tool piston bushing Puller ring ALEX 20 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Tools
6-4722 6681 80
7-69
Tetra Pak
Standard Tools
7-70
-80
-81
-82
-83
4722-8025
Group number: 6-4722 8025 82 Assembly Drawing: 6-47228025 Pos 1 2 3 4 5 5 5 5 5 6 6 6 6 7 8 Part No 6-4722 8024 01 6-4722 8021 01 6-4722 8022 01 6-4722 8023 01 6-4722 8016 18 6-4722 8016 24 6-4722 8016 27 6-4722 8016 30 6-4722 8016 36 6-4722 8017 07 6-4722 8017 19 6-4722 8017 22 6-4722 8017 46 6-4722 8018 01 6-4722 8020 01 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description Tool box CATCH HANDLE 3/4 REDUCING ADAPTER 3/4 -1/2 EXTENSION 125 x 1/2 HEXAGON SOCKET 18 x 1/2 HEXAGON SOCKET 24 x 1/2 HEXAGON SOCKET 27 x 1/2 HEXAGON SOCKET 30 x 1/2 HEXAGON SOCKET 36 x 3/4 BOX WRENCH 7 BOX WRENCH 19 BOX WRENCH 22 BOX WRENCH 46 ALLEN KEY SET OFFSET END WRENCH SET Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
Standard Tools
6-4722 8025 82
7-71
Tetra Pak
Assembly drawing
7-72
Group number: 6-4722 6660 80 Assembly Drawing: Pos Part No 6-4722 6677 80 6-4722 6677 80 6-4722 1982 85 6-4722 8144 92 6-4722 8161 92 6-4722 6835 84 6-4722 1982 85 6-4722 1987 01 6-4722 2455 02 6-4722 5251 01 6-4722 8144 92 6-4722 6807 01 6-4722 9026 08 6-4722 9026 08 6-4722 2264 12 6-4722 1418 10 6-4722 9042 49 6-4722 9042 41 6-4722 9042 49 6-4722 1178 17 6-4722 1178 23 6-4722 8161 92 6-4722 6652 01 6-4722 0942 02 6-4722 1178 18 6-4722 6835 84 6-881 17113 6-881 17113 6-881 17113 6-881 17112 6-881 17112 6-881 17112 6-4722 9042 12 SP h UN Qty PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC 1 1 1 1 3 1 1 3 3 3 1 3 6 6 3 12 6 3 6 6 3 3 6 15 15 1 1 1 1 1 1 1 1 Description SPARE PARTS STD SPARE PARTS STD Spare parts Crankcase ALEX 20 SPARE PARTS PISTON CARTRIDGE ALEX 20 STD SPARE PARTS VALVE CARTRIDGE 65 MUSHROOM SPARE PARTS PRODUCT CONNECTIONS ALEX 20 Spare parts Crankcase ALEX 20 Bellows TA20 Plate Screw MLC6S 6 x 16 FZB 8.8 DIN 7984 SPARE PARTS PISTON CARTRIDGE ALEX 20 STD Piston 50-CR Piston seal 50 PSB2 Piston seal 50 PSB2 Compression ring 50 Guide band 50x9.5 O-ring 75 x 5 EPDM 80 E8502 O-ring 62 x 4 EPDM 80 E8502 O-ring 75 x 5 EPDM 80 E8502 Support ring 85 Support ring 74 SPARE PARTS VALVE CARTRIDGE 65 MUSHROOM Valve spring 65 Valve sealing 55 x 65 x 8 Support ring 65 SPARE PARTS PRODUCT CONNECTIONS ALEX 20 Seal ring H-Line H40-X-2 Silicone Seal ring H-Line H40-X-2 Silicone Seal ring H-Line H40-X-2 Silicone Seal ring H-Line H40-X-1 1/2 Seal ring H-Line H40-X-1 1/2 Seal ring H-Line H40-X-1 1/2 O-ring 53.57x3.53 EPDM 80 E8502 Page No Pos Part No SP h UN Qty
Issue: 2009-03-11
Description
Page No
62 67 87
9 11 12 13 14 16 17 18 56 57
25 27 58
3 5 9 17 19 23 63
Machine No.
Group Description
Group Number
Page No
Tetra Pak
TA20 - 5856819007
6-4722 6660 80
7-73
2.2TF202563.en
Tetra Pak
Tetra Pak
2.2TF202563.en
TPMS - Description
The maintenance system used for equipment from Tetra Pak is called the Tetra Pak Maintenance System (TPMS). If you are using TPMS, the checklists will be delivered directly from your local Tetra Pak service station. The TPMS checklists are designed to match and keep pace with the ongoing development of new and existing equipment from Tetra Pak, and to meet the demands set by our customers for even higher efficiency and better economy. If you require further information regarding TPMS, please do not hesitate to contact your local Tetra Pak office
! Important information
2.2TF202563.en
The recommendations related to wear and tear parts are given general average figures for the product portfolio Tetra Alex. The data relates typically to white milk, homogenized at equal or less than 250 bar at 80% of the maximum crankshaft speed of the machine. The machine should be installed according to the installation instructions. Please note, that for example abrasive products, higher crankshaft speed or increased pressure as well as unresolved dry matter or air in the product will reduce the life time of the parts in contact with the product. In the same way will optimum conditions increase the indicated life time of these parts. The initially given data should be seen as starting point for the tool. Adjustments based on experience from the actual products will give correct intervals for each machine over time. (Cont'd)
Tetra Pak
9
1(5)
10
Group No.
Denomination
Type
Interval (h)
Action
Description
Denomination
PREVENTIVE MAINTENANCE CHECKS 999 999 999 999 6 999 315 999 1 1 1 1 1 6 1 94 FRAME AND BODY 6-4722 7189 80 Frame Cladding 6-4722 8075 80 DRIVE UNIT 6-4722 8166 80 6-4722 8166 80 6-4722 8166 80 6-4722 8166 80 6-4722 8166 80 6-4722 8166 80 6-4722 7110 80 6-4722 6660 80 Tag 4, section 1 TeM 1.1-1 TeM 1.1.1-1 TeM 1.1 Tag 4, section 2 TeM 2.1-1 TeM 2.1-2 TeM 2.2.1-1 TeM 2.2.1-1 TeM 2.2.1-1 5 1 1 5 20 10 1 1 1 50 50 50 50 6000 3000 1500 1500 12000 Check Check Check Check Clean Lubricate Check Check Check Machine Shoe Doors and covers Gas spring Sound insulation (option) Drive Motor - Cooling Fan Drive Motor Drive Motor; V-Belt - Tension Drive Motor; V-Belt - Wear Drive Motor; V-Belt - Alignment 90347-0175 6-4722 6143 05 7 2 5 5 5 5 10 10 10 10 Check Check Check Check Leakage, Noise, Vibration Product pipes - Leakage Drive - Noise, Vibrations Steam systems - Leakage
6-4722 6028 23 6-4722 6028 23 6-4722 6028 23 6-4722 6028 23 6-4722 6028 23
1 1 1 1 1
GF202589
1 Label Pos No. on Drawing and Bill of Material in TeM - 7 Parts list 2 Group No. Number of Bill of Material (Group Number) in TeM - 7 Parts list 3 Doc No. Reference Activity no. in TeM - 4 Maintenance Instructions where more information can be found 4 Work time The approx. time in minutes to perform the action 5 Interval Recommended service interval in production hours during normal running conditions and with white milk as product
6 Action Description of action: Check, Change, Clean, Lubricate e.t.c. 7 Description What to perform the action on 8 Spare Part No. Article number of the spare part, Part No. in TeM - 7 Parts list 9 Qty The required number of spare parts 10 Filter Buttons Use these to select type of maintenance, interval, etc.
Tetra Pak
2.2TF202563.en
1(6)
Tetra Alex 20
Group No.
Denomination
Type
Interval (h)
Action
Description
Denomination
PREVENTIVE MAINTENANCE CHECKS 999 999 999 FRAME AND BODY DRIVE UNIT 6-4722 8166 80 6-4722 8166 80 6-4722 8166 80 6-4722 8166 80 6-4722 6660 80 6-4722 6660 80 6-4722 8163 80 6-4722 8163 80 6-4722 6457 02 6-4722 6457 02 6-4722 6457 02 6-4722 6457 02 6-4722 6457 02 6-4722 6457 02 Tag 4, section 1 TeM 1.1 Tag 4, section 2 TeM 2.1-1 TeM 2.1-2 TeM 2.2.1-1 TeM 2.2.1-2 TeM 2.3.1-1 TeM 2.3.1-2 TeM 2.3.2-2 TeM 2.3.2-2 TeM 2.3.2-1 TeM 2.3.2-1 TeM 2.3.2-1 TeM 2.3.2-2 TeM 2.3.2-2 TeM 2.3.2-2 5 5 5 1 20 10 1 20 5 20 1 30 1 1 1 180 1 1 10 Check 10 Check 10 Check 50 Check 6000 3000 1500 6000 250 6000 1500 12000 1500 1500 1500 12000 12000 6000 Clean Lubricate Check Change Check Change Check Change Check Check Check Change Change Change Leaks, noise and vibrations Product pipe - Leakage Drive - Noise and vibrations Cover - Function Drive motor - Cooling fan Drive motor V-belt - Tension / wear V-belt Gear box - Oil - Level / Water Gear box - Oil Gear box - Adjusting bolt - Vibration damper Gear box - Sleeve Gear box - Seal ring Gear box - Seal ring Gear box - Seal ring Gear box - Seal ring Gear box - Seal ring Gear box - Seal ring
6-4722 5857 05 6-4722 5857 05 90458-0863 90458-0863 6-4722 5415 01 6-4722 5457 01 90459-1278 90459-1282 90459-1283 90459-1278 90459-1282 90459-1283
3 3 3 3 1 1 1 1 1 1 1 1
2(6)
Tetra Alex 20
Denomination
Type
6-4722 8155 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80 6-4722 1982 80
Doc No. Reference Tag 4, section 3 TeM 3.1-1 TeM 3.1-2 TeM 3.2-1 TeM 3.6-1 TeM 3.4-1 TeM 3.4-1 TeM 3.4-1 TeM 3.4-1 TeM 3.4-1 TeM 3.4-1 TeM 3.4-1 TeM 3.4-1 TeM 3.4-1 TeM 3.4-1 TeM 3.4-1 TeM 3.4-1 TeM 3.4-1 TeM 3.4-1 TeM 3.5-1 TeM 3.5-1 TeM 3.6-1 TeM 3.6-1 TeM 3.6-1 TeM 3.6-1 TeM 3.6-1 TeM 3.6-1 TeM 3.6
Interval (h) 10 3000 1500 500 3000 12000 12000 12000 24000 24000 24000 24000 24000 24000 24000 24000 12000 12000 12000 12000 500 6000 500 24000 1500 6000 500
Action
Description
Denomination
Check Change Check Check Check Clean Check Check Change Change Change Change Change Change Change Change Change Change Check Check Check Change Check Change Check Change Check
Crankcase - Oil - Level / Water Crankcase - Oil Oil level switch (Option) Cross head - Piston - Play Oil scraper Oil scraper Roller bearing Roller bearing Gasket O-ring O-ring O-ring O-ring Roller bearing Roller bearing Sealing box Plain bearing Lock nut Cross head Cross head - Bolt Bellows Bellows Plate Plate Screw Screw Connections - Leakage
6-4722 7569 01
20
6-4241 2200 02 6-4241 0010 57 6-4301 5000 11 315202-0237 6-4302 0490 72 6-4302 0490 40 6-4302 0075 05 6-4241 2200 02 6-4241 0010 57 6-4305 0012 50 6-4722 2161 01 312810-0322
1 1 1 3 1 1 1 1 1 1 3 6
6-4722 1987 01 6-4722 1987 01 6-4722 2455 02 6-4722 2455 02 6-4722 5251 01 6-4722 5251 01
3 3 3 3 3 3
3(6)
Tetra Alex 20
Group No. WETEND Valves and seals 6-4722 8161 80 6-4722 8161 80 6-4722 8161 80 6-4722 8161 80 6-4722 8161 80 6-4722 8161 80 6-4722 8161 80 6-4722 8161 80 6-4722 8161 80 6-4722 8161 80 6-4722 8161 80 6-4722 8161 80 Piston cartridge 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50 6-4722 8144 50
Denomination
Type
Doc No. Reference Tag 4, section 4 TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM 4.1-3 4.1-1 4.1-1 4.1-1 4.1-1 4.1-1 4.1-3 4.1-1 4.1-1 4.1-1 4.1.1-1 4.1.1-1 4.2-1 4.2-1 4.2-1 4.2-1 4.2-1 4.2-1 4.2-1 4.2-1 4.2-1 4.2-1 4.2-3 4.2-3 4.2-3 4.2-3 4.2-3 4.2-3 4.2-3 4.2-3 4.2-3 4.2-3
Interval (h)
Action
Description
Denomination
23 24 25 26 27 58 23 24 25 26 27 58 9 11 12 13 14 16 17 18 56 57 9 11 12 13 14 16 17 18 56 57
60 1 1 1 1 1 60 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 150 1 1 1 1 1 1 1 1 1
1500 1500 1500 1500 1500 1500 6000 6000 12000 18000 3000 3000 500 500 500 500 500 500 500 500 500 500 4000 2000 2000 4000 2000 2000 12000 2000 2000 12000
Check Check Check Check Check Check Change Turn Change Change Change Change Check Check Check Check Check Check Check Check Check Check Change Change Change Change Change Change Change Change Change Change
Valve Valve seat Spring Valve cage Valve seal / O-ring Support ring Valve Valve seat Spring Valve cage Valve seal / O-ring Support ring Piston Piston seal Piston seal Compression ring Guide band O-ring O-ring O-ring Support ring Support ring Piston Piston seal Piston seal Compression ring Guide band O-ring O-ring O-ring Support ring Support ring
6-4722 6648 02 6-4722 6649 03 6-4722 6652 01 6-4722 6657 01 6-4722 0942 02 6-4722 1178 18 6-4722 6648 02 6-4722 6649 03 6-4722 6652 01 6-4722 6657 01 6-4722 0942 02 6-4722 1178 18 6-4722 6807 01 6-4722 9026 08 6-4722 9026 08 6-4722 2264 12 6-4722 1418 10 6-4722 9042 49 6-4722 9042 41 6-4722 9042 49 6-4722 1178 17 6-4722 1178 23 6-4722 6807 01 6-4722 9026 08 6-4722 9026 08 6-4722 2264 12 6-4722 1418 10 6-4722 9042 49 6-4722 9042 41 6-4722 9042 49 6-4722 1178 17 6-4722 1178 23
6 6 6 6 15 15 6 6 6 6 15 15 3 3 3 3 6 3 3 3 3 3 3 3 3 3 6 3 3 3 3 3
4(6)
Tetra Alex 20
Group No. HOMOGENIZING HEAD 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 Hydraulic end 6-4722 7040 80 6-4722 7040 80 6-4722 7040 80 Manometer flange 6-4722 8763 80 6-4722 8763 80 6-4722 8763 80
Denomination
Type
9 11 13 17 17 18 18 21 22 24 26 27 28 33 34 43 6 8 29 49 52 53
Doc No. Reference Tag 4, section 5 TeM 5.1-2 TeM 5.2.1-1 TeM 5.1-2 TeM 5.1.2-1 TeM 5.1.2-2 TeM 5.1.1-1 TeM 5.1.1-1 TeM 5.1-1 TeM 5.1-2 TeM 5.1-2 TeM 5.1-2 TeM 5.1-2 TeM 5.1-2 TeM 5.1.2-1 TeM 5.1.1-1 TeM 5.2.1-1 TeM 5.2.1-1 TeM 5.2.1-1 TeM 5.2.1-1 TeM 4.3-1 TeM 4.3-2 TeM 4.3-2
Interval (h) 6000 6000 6000 1500 6000 1500 6000 6000 6000 6000 6000 6000 6000 1500 1500 6000
Action
Description
Denomination
Change Check Change Check Turn Check Turn Change Change Change Change Change Change Check Check Change
O-ring Sealing ring O-ring Forcer disc / Forcer Forcer disc / Forcer Seat Seat O-ring O-ring Support ring Guide band O-ring Support ring Forcer disc / Forcer Seat O-ring O-ring Guide band Support ring Pressure gauge O-ring Support ring
6-4722 9042 35 6-4722 5233 01 6-4722 9042 08 6-4722 9018 01 6-4722 9018 01 6-4722 7044 01 6-4722 7044 01 6-4722 9042 03 6-4722 9042 15 6-4722 7151 03 6-4722 1418 16 6-4722 9042 05 6-4722 7152 03 6-4722 9018 01 6-4722 7044 01 6-4722 9042 08 6-4722 6562 47 6-4306 0000 05 6-4722 7153 03 6-4722 6396 01 6-4722 9042 52 6-4722 8753 01
9000 Change 9000 Change 9000 Change 1500 Check 6000 Change 6000 Change
5(6)
Tetra Alex 20
Group No.
Denomination
Type
1 95 95 5 8 8 10 11 32 33 2 5 15 18 7 9 17 13 63 63 3 3 5 5 9 9 17 17 19 19 23 23
HYDRAULIC SYSTEM 6-4722 7563 80 6-4722 6660 80 6-4722 6660 80 6-4722 5471 81 6-4722 5471 81 6-4722 5471 81 6-4722 5471 81 6-4722 5471 81 6-4722 5471 81 6-4722 5471 81 6-4722 7563 80 6-4722 7563 80 6-4722 7563 80 6-4722 7563 80 6-4722 7563 80 6-4722 7563 80 6-4722 7563 80 6-4722 7563 80 PRODUCT CONNECTIONS 6-4722 6835 80 6-4722 6835 80 Inlet 6-4722 8122 80 6-4722 8122 80 6-4722 8122 80 6-4722 8122 80 6-4722 8122 80 6-4722 8122 80 Outlet 6-4722 8123 80 6-4722 8123 80 6-4722 8123 80 6-4722 8123 80 6-4722 8123 80 6-4722 8123 80
Doc No. Reference Tag 4, section 6 TeM 6.1-1 TeM 6.1-1 TeM 6.1-2 TeM 6.1.1-1 TeM 6.1-4 TeM 6.1-4 TeM 6.1-3 TeM 6.1-3 TeM 6.1-4 TeM 6.1-4 TeM 6-1 TeM 6-1 TeM 6.2-1 TeM 6.2-1 TeM 6.3-1 TeM 6.4-1 TeM 6.4-1 TeM 6.5-1 Tag 4, section 5
Interval (h) 250 250 9000 1500 9000 18000 9000 9000 9000 9000 3000 3000 1500 1500 1500 1500 1500 1500
Action
Description
Denomination
Check Check Change Check Check Change Clean Clean Check Change Check Check Check Check Check Check Check Check
Hydraulic unit Hydraulic unit - Oil level Hydraulic unit - Oil Safety valve Hydraulic pump Hydraulic pump Filter Filter Coupling Rubber cross Motor Pressure adjusting valve Pressure gauge - Function Pressure gauge - Function Pressure relief valve (Option) Proportional valve (Option) Proportional valve (Option) Pressure transmitter (Option) O-ring O-ring Silicone gasket Silicone gasket Silicone gasket Silicone gasket Silicone gasket Silicone gasket Silicone gasket Silicone gasket Silicone gasket Silicone gasket Silicone gasket Silicone gasket
6 6 1 1
6-4722 7551 01
1 1
3000 Check 6000 Change 3000 6000 3000 6000 3000 6000 3000 6000 6000 3000 3000 6000 Check Change Check Change Check Change Check Change Change Check Check Change
6-4722 9042 12 6-4722 9042 12 6-881 17113 6-881 17113 6-881 17113 6-881 17113 6-881 17113 6-881 17113 6-881 17112 6-881 17112 6-881 17112 6-881 17112 6-881 17112 6-881 17112
1 1 1 1 1 1 1 1 1 1 1 1 1 1
TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM TeM
5.3-1 5.3-1 5.3-1 5.3-1 5.3-1 5.3-1 5.3-1 5.3-1 5.3-1 5.3-1 5.3-1 5.3-1
1 30 1 1 1 1 1 30 1 1 1 1
6(6)
Tetra Alex 20
Denomination
Type
6-4722 8450 80 C S inlet 6-4722 8450 80 C S inlet 6-4722 8450 80 C S inlet 6-4722 8452 80 C S crankcase 6-4722 8452 80 C S crankcase ELECTRICAL SYSTEM
Doc No. Reference Tag 4, section 7 TeM 7.1-1 TeM 7.3-1 TeM 7.4-1 TeM 7.8-1 TeM 7.7-1 TeM 7.3-1 Tag 4, section 8 TeM 8.2-1 TeM 8.2-1 TeM 8.2-1 TeM 8.3-1 TeM 8.4-1
Interval (h) 250 1500 1500 1500 1500 1500 1500 12000 12000 1500 1500
Action
Description
Denomination
Check Check Check Check Check Check Clean Change Change Check Check
Connections - Leakage Trim valve Cooling water valve Flow meter (Option) Cooling water regulator (Option) Trim valve Cooling fan - Filter Cooling fan - Filter, AM 400P 216 x 216 Cooling fan - Filter, AM 700P 283 x 283 Temperature transmitter, PT-100 (Option) Emergency stop
6-990408 75 6-990408 76
9 Service media
2.29_.en
Tetra Pak
9 Service media
Tetra Pak
2.29_.en
Data
Service media
Service media
Water
General requirements For consumption and pressure data, see Technical data. The supply pressure must be constant.
Water hardness If the water is hard (high concentration of Calcium carbonate, CaCO3), the wear and tear of the piston and piston seals will be excessive. Hardness: < 10 dH max 180 mg/l CaCO3
2.2tf200017.en
Abrasiveness If the water contains to much of solid particles, the pistons will rapidly wear down Turbidity: max. 3 NTU
Caution!
(Cont'd)
Tetra Pak
Service media
(Cont'd)
Data
Water used for cooling, product flushing, rinsing and cleaning should meet the WHO guidelines (stated below) or the European drinking water directive.
Characteristics Taste Smell Turbidity Colour Oxygen demand Tot. dissolved solids pH Hardness Ammonium Ammonia Iron Manganese Nitrate Sulphate Chlorine (M, S) Chloride (M, S) Aggressive carbon acid Total amount of bacteria Total amount of 35C coliform bacteria Total amount of 44C coliform bacteria Copper Zinc none none max. 3 NTU max. 20 mg/l Pt max. 20 mg/l KMnO4 max. 500 mg/l 7 - 8.5 <10 dH (max. 180 mg/l CaCO3) trace amounts max. 0.5 mg/l NH4 none none max. 30 mg/l NO3 max. 100 mg/l SO4 max. 0.2 mg/l Cl2 max. 30 mg/l Clmax. 0 mg/l CO2 max. 100/ml max. 1/100 ml 0/100 ml max. 0.05 mg/l Cu max. 1.0 mg/l Zn
2.2tf200017.en
Tetra Pak
10 Cleaning
2.210_.en
Tetra Pak
Tetra Pak
2.210_.en
Data
Cleaning
WARNING! Chemical hazard Cleaning solution contains Caustic soda (NaOH) or Nitric acid (HNO3). These chemicals may cause severe burning to skin and eyes. Use protective clothes, goggles and gloves during handling. If exposed - wash with water for at least 15 minutes. Seek medical assistance. Follow the instructions given by the supplier. Risk of scalds This machine works under pressurised conditions and high temperatures. To avoid jets of hot liquid, steam or cleaning solution, make sure that any operation sequence is finalised, the machine is cooled down and without pressure before disassembling any parts.
WARNING!
CIP
When Cleaning In Place observe following: Max 2 % at max 85C (185 F) Lye Max 1.5 % at max 85C (185 F) Acid Inlet pressure > 2 bar (30 psi)
2.2tf200021.en
Cleaning
Cleaning program as for the process equipment. The minimal required cleaning flow is 100% of maximal requested production flow.
Sterilisation
Max 85C (185 F) at 30 minutes
Tetra Pak
Cleaning
Data
Tetra Pak
2.2tf200021.en
11 Certificates
2.211_01.en
Tetra Pak
Tetra Pak
2.211_01.en
DECLARATION OF CONFORMITY
Tetra Pak Processing Components AB Ruben Rausings gata S-221 86 Lund Sweden declare that this machine/ equipment/ complex installation: Homogenizer Tetra Alex 20 Machine No 5856819007 is in conformity with the following harmonized standards:
EN ISO 12100-1:2003 EN ISO 12100-2:2003 EN 294: 1992 EN ISO 13850: 2006 EN 61000-6-2:2001EN 61000-6-2:2001EN 61000-6-2:2001 EN 61000-6-4:2001 EN 60204-1: 1997 EN 1672-2: 2005
S-221 86 Lund
2009-01-16
Tetra Pak
2.211_01.en