Alfa Laval ALB Instructions


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Alfa Laval ALB Instructions | Manualzz

Instruction Manual

Alfa Laval Agitator - ALS / ALB

ESE03338-EN5

Original manual

2020-10

Table of contents

The information herein is correct at the time of issue but may be subject to change without prior notice

1.

EC Declaration of Conformity .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

5

2.

Safety . . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

6

2.1. Important information . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

6

2.2. Warning signs . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

6

2.3. Intended use . . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

6

2.4. Safety precautions . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

7

3.

Installation . . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

8

3.1. Unpacking/delivery .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

8

3.2. Installation . . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

11

3.3. Pre-use check . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

22

3.4. Recycling information . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

25

4.

Operation .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

26

4.1. Operation/Control .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

26

4.2. Troubleshooting . . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

27

4.3. Cleaning - recommendations .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

28

4.4. Temperature limits . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

28

4.5. Pressure limits . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

29

5.

Maintenance . .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

30

5.1. General maintenance . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

30

5.2. Replacement of drive unit (with bearing frame) . . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

31

5.3. Replacement of drive unit (without bearing frame) . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

33

5.4. Replacement of drive unit (Motor and shaft unit) .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

35

5.5. Dismantling and mounting shaft (with bearing frame except BC160) . .. . .. . .. . .. .. . .. . .. .. .

36

5.6. Replacement of bearings, type B20, B25, B25/30, B35, B35/40, B45, B45/50, B55,

B55/60 . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

38

5.7. Replacement of bearings, type BC160DH . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

40

5.8. Replacement of bearing, type BC160D . . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

42

5.9. Replacement of bearings type BC160 . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

44

5.10. Replacement of shaft seal, type D .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

46

5.11. Replacement of shaft seal, type DC .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

49

5.12. Replacement of shaft seal, type S1 . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

52

5.13. Replacement of shaft seal, type S2 . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

54

5.14. Replacement of shaft seal, type S3 . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

56

6.

Technical data . . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

58

6.1. Technical data . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

58

6.2. Mounting angle for side mounted Agitator type ALS . .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

58

6.3. Mounting angle for bottom mounted Agitator type ALB .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

59

6.4. Connecting flush – Seal type D . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

60

6.5. Connecting flush – Seal type DC . . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

62

6.6. Tightening torques for bolt connections . . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

64

6.7. Shaft alignment . . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

65

6.8. Spider coupling . . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

67

6.9. Storage .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

67

7.

Parts lists and drawings, service kits and tools .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

68

7.1. Agitator main components, drive end . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

68

7.2. Agitator main components, wet end .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

70

3

Table of contents

The information herein is correct at the time of issue but may be subject to change without prior notice

7.3. Bearing frame, B20, B25, B25/30, B35, B35/40, B45, B45/50, B55, B55/60 . .. . .. . .. . .. .

72

7.4. Bearing frame BC160/35, BC160D/30, BC160DH/30 .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .

76

7.5. Shaft seal, type D . .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

78

7.6. Shaft seal, type DC . . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

80

7.7. Shaft seal, type S1 .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

82

7.8. Shaft seal, type S2 .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

84

7.9. Shaft seal, type S3 .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

86

7.10. Tools . . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

90

8.

Appendix . . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

91

8.1. Drive unit instructions .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .

91

4

1 EC Declaration of Conformity

Revision of Declaration of Conformity: 2016-01-01

The Designated Company

Alfa Laval Kolding A/S

Company Name

Albuen 31, DK-6000 Kolding, Denmark

Address

+45 79 32 22 00

Phone No.

hereby declare that

Agitator - EnSaFoil

Designation

ALX-ME-(GX)-BC160D(H)/30(L)F-SX-SH-PXXXXYYYY

ALX-ME-(GX)-BC160/35(L)F-SX-SH-PXXXXYYYY

ALX-ME-(GX)-BXX/XX(L)F-SX-SH-PXXXXYYYY

ALX-ME-(GX)-BC160D(H)/30(L)F-D(C)-SH-PXXXXYYYY

ALX-ME-(GX)-BC160/35(L)F-D(C)-SH-PXXXXYYYY

ALX-ME-(GX)-BXX/XX(L)F-D(C)-SH-PXXXXYYYY

ALX-ME-(GX)-ZZ(L)F-SX-SH-PXXXXYYYY

ALX-ME-(GX)-ZZ(L)F-D(C)-SH-PXXXXYYYY

Type is in conformity with the following directives:

Machinery Directive 2006/42/EC++

Regulation (EC) 1935/2004

Serial number from AAC000000001 to AAC999999999

Serial number from 10.000 to 100.000

Serial number from 100700000001 to 100799999999

Serial no(s)

ALX = ALB or ALS

GX = GC, GR or GP

BXX/XX = B25/30, B35, B35/40, B45, B45/50, B55, B55/60

SX = S1, S2, S3

SH = S200-S2000

PXXXX = E125, E150, E175, E200, E225, E250, E300, E350

E400, E450, E500, E550, E600, E650, E700, E750

E800, E900, E1000, E1100, E1300, E1500, E1700

YYYY =

E1900

D2P, D2LP, D3P, D3LP, D2G, D2LG, D3G, D3LG

U2P, U2LP, U3P, U3LP, U2G, U2LG, U3G, U3LG

ZZ = 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 90

Type variation

The person authorised to compile the technical file is the signer of this document

Global Product Quality Manager

Pumps, Valves, Fittings and Tank Equipment

Title

Lars Kruse Andersen

Name

Kolding

Place

2020-02-01

Date (YYYY-MM-DD) Signature

5

6

2 Safety

Unsafe practices and other important information are emphasised in this manual.

Warnings are emphasised by means of special signs.

Always read the manual before using the Agitator!

Illustrations are only to illustrate the problem and is NOT a drawing of the current Agitator!

2.1

Important information

WARNING

Indicates that special procedures must be followed to avoid serious personal injury.

CAUTION

Indicates that special procedures must be followed to avoid damage to the Agitator!

NOTE

Indicates important information to simplify or clarify procedures.

2.2

Warning signs

General warning:

Dangerous electrical voltage:

!

2.3

Intended use

The Alfa Laval Agitator is only for mixing/stirring of liquids in a tank.

The Agitator is only for mounting positions as specified on the nameplate by the first group of letters of the type designation.

ALT(B)- is for top mounting, ALS- is for side mounting and ALB- is for bottom mounting.

The exact mounting angle is specified on the Name Plate and must be followed. Definitions on mounting angles can be

seen in section 6.2 Mounting angle for side mounted Agitator type ALS and section 6.3 Mounting angle for bottom mounted

Agitator type ALB.

The different duties and operation data like pressure, speed and media temperature, which the Agitator is designed for, can be found in the Alfa Laval quotation agreement 1) and may not be exceeded by all means.

If the Agitator is installed in pressurized tanks local regulations and legislations must be met.

1) The Alfa Laval quotation agreement has been exchanged during the quote process between a technical purchaser and Alfa Laval. If you are not in hold of the Alfa Laval quotation agreement, please get through to your local Alfa Laval contact, inform the Agitator serial number and article number which is stated on the Name Plate and you will obtain the Alfa Laval quotation agreement.

2 Safety

All warnings in the manual are summarised on this page.

Pay special attention to the instructions below so that severe personal injury and/or damage to the Agitator are avoided.

2.4

Safety precautions

Installation:

Always read the technical data thoroughly (see chapter 6 Technical data).

Always follow installation instructions thoroughly (see chapter 3 Installation).

Never expose the Agitator to undue vibrations or shocks.

Never start Agitator in the wrong rotation direction.

Ensure that the tank media is not corrosive to the Agitator.

Only install the Agitator in environments within temperature limit: -20°C and +40°C.

Only install the Agitator in altitudes less than 1000 m above sea level.

Never touch the moving parts while the Agitator is connected to the power supply.

!

Operation:

Always read the technical data thoroughly (see chapter 6 Technical data).

Always read supplier instructions thoroughly (see chapter 8 Appendix).

Never start Agitator in the wrong rotation direction.

Always rinse well with clean water after cleaning.

Beware of temperature limitations.

Beware of Agitator in operation can produce sound levels in excess of 85dB(A).

Never operate continuously within 20% of critical oscillation speed (see chapter 6 Technical data).

Never touch the moving parts while the Agitator is connected to the power supply.

Maintenance:

Always read the technical data thoroughly (see chapter 6 Technical data).

Always follow the maintenance instruction thoroughly (see chapter 5 Maintenance).

Always follow the maintenance instruction from drive unit supplier (see chapter 8 Appendix).

Always study the parts list and assembly drawing carefully (see chapter 7 Parts lists and drawings, service kits and tools).

!

Never touch the moving parts while the Agitator is connected to the power supply.

Always disconnect the power supply while servicing the Agitator.

Ensure correct rotation direction of impeller before startup and after any maintains there might have impact on the direction.

Transportation:

Always transport the Agitator in original packaging.

Always support the shaft adequately, to protect shaft and bearings.

Never expose the Agitator to undue vibrations or shocks.

Control for oil leakage on gears with vent screw.

!

7

3 Installation

The instructions manual is part of the delivery.

Study the instructions carefully

3.1

Unpacking/delivery

Always use lifting equipment when handling the Agitator (see Step 3).

CAUTION

Alfa Laval cannot be held responsible for incorrect unpacking.

Alfa Laval cannot be held responsible for incorrect unpacking.

Step 1

Inspect the delivery for visible transportation damages - all issues to be reported to carrier.

Step 2

Check the delivery for:

1. Complete Agitator

2. Nameplate designations

3. Delivery note

4. Separate instruction manuals from suppliers (see chapter 8 Appendix).

Step 3

Lifting instructions:

Always use the correct lifting equipment (see Agitator weight on name plate).

Locate Centre of gravity before moving the Agitator.

4303-0051

8

The instructions manual is part of the delivery.

Study the instructions carefully

TD605-103

WARNING

Do NOT use eye bolts on gear motor to lift the Agitator. They are only for gear motor removal.

TD605-101

WARNING

Do NOT use eye bolts on shroud (if any) to lift the Agitator.

They are only for shroud removal.

3 Installation

9

3 Installation

The instructions manual is part of the delivery.

Study the instructions carefully

CAUTION

Alfa Laval recommends NOT to use shaft as lifting point but long shafts must be supported adequately during lifting to protect shaft, bearings and seals arrangements.

Gear motor / motor may be used for lifting the assembled Agitator.

Step 4

During transportation

1. Always support the shaft adequately, to protect shaft and bearings.

2. Never expose the Agitator to undue vibrations or shocks.

3. Control for oil leakage on gears with vent screw.

10

3 Installation

Study the instructions carefully and pay special attention to the warnings!

Always check the Agitator before operation - see chapter 3.3 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

3.2

Installation

Always read the technical data thoroughly (see chapter 6 Technical data).

Only install this Agitator in mounting angle according to the name plate (see chapter 6 Technical data).

Always use lifting equipment when handling the Agitator (see Step 2).

Always have safety elements removed by authorized personnel.

Never cover or remove the nameplate.

Never connect to power supply during installation or service.

Always have the Agitator connected to power supply by authorized personnel.

NOTE

Alfa Laval highly recommend to install motor protection guard to protect the motor from overloading.

Never install a none Alfa Laval shroud on the Agitator as it can lead to overheat and a breakdown of the motor.

Welding flange:

CAUTION

Only authorized personnel to weld in flanges.

Alfa Laval cannot be held responsible for incorrect installation.

Step 1

Dismantle the welding flange if fitted onto the Agitator.

1

TD605-004 2

11

3 Installation

Study the instructions carefully and pay special attention to the warnings!

Always check the Agitator before operation - see chapter 3.3 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Step 2

Ensure that the tank, where the welding flange are to be welded in, can handle the forces applied by the Agitator: Torque Mv, Bending torque Mb and Side thrust Fs.

The values are depending on the Agitator configuration. The following information is required to calculate the forces:

P: Power of the motor in [kW] n: Speed of Agitator shaft [RPM]

S: Shaft length according to Agitator type designation -Sxxxxin [mm]

D: Largest impeller diameter according to Agitator designation

-Pxxx- in [mm]

The values can be calculated as follows:

Type ALS/ALB:

Mv [Nm] = 23873 x P / n

Fs [N] = 4.5 x Mv x 1000 / D

Mb [Nm] = Fs x S / 1000

Step 3

During the design phase of the tank, ensure sufficiently rigidity of the tank.

Ensure that the max. bending angle (A), at loads from Step 2 does not exceed according to below scheme

RPM:

A° (max bending angle at applied loads):

<100

0.1

>100

0.05

A

Fs

Mb

Mv

Fs

Mb

Mb

Fs

Mb

Fs

12

3 Installation

Study the instructions carefully and pay special attention to the warnings!

Always check the Agitator before operation - see chapter 3.3 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Guidelines for installing Flat Shaped Welding Flange (FSWF), ALS Agitator:

(for mounting flange without nose)

CAUTION

Alfa Laval recommend that all other welding tasks on the tank are finished before installing welding flange in tank.

ALS Agitator must be installed in the tank as shown in chapter 6.2 Mounting angle for side mounted Agitator type ALS which can

be achieved as shown on the illustration below.

1

1. Tank wall

2. Cone for welding flange

3. Welding flange

2

1

3

2

3

4305-0005

4305-0004

13

3 Installation

Study the instructions carefully and pay special attention to the warnings!

Always check the Agitator before operation - see chapter 3.3 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Guidelines for installing Flat Shaped Welding Flange (FSWF), ALB Agitator:

(for mounting flange with nose)

CAUTION

Alfa Laval recommend that all other welding tasks on the tank are finished before installing welding flange in tank.

ALB Agitator must be installed in the tank as shown in chapter 6.3 Mounting angle for bottom mounted Agitator type ALB

which can be achieved as shown on the illustration below.

In case of installation of Welding Flange parallel to tank bottom surface (shaft perpendicular to tank bottom surface) it is always recommended to use a bead/cone. This is to ensure that tank bottom stresses / forces are not transmitted directly to the

Welding Flange increasing the risk of leakages.

1

2

3

1. Tank bottom

2. Cone for welding flange

3. Welding flange

4305-0007

1. Tank bottom

2. Cone for welding flange

3. Welding flange

4. Weldings

3

1

2

4305-0008

2

4 *

3

CAUTION

Ensure that no weldings are applied to the outside surface of the welding flange* as the Agitators mounting flange has the same size as the welding flange. If weldings by mistake are applied to the surface of the welding flange it must be removed by grinding, or the like, to ensure a correct fit and installation of the mounting flange.

14

3 Installation

Study the instructions carefully and pay special attention to the warnings!

Always check the Agitator before operation - see chapter 3.3 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Welding procedure FSWF, ALS Agitator:

(for mounting flange without nose)

Step 1

Always allow flange to cool to ambient temperature after each section has been welded

Position the flange correctly

TD605-006

Step 2

Spot weld from outside.

A

D

A

C

TD605-007

A

B

D

TD605-010

B Adjust alignment!

C

Step 3

Weld the following sections first from outside then from inside, and cool with air between each section.

D

TD605-011

B

C

D

3

TD605-014

A

1

2

C

4

B

15

3 Installation

Study the instructions carefully and pay special attention to the warnings!

Always check the Agitator before operation - see chapter 3.3 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Step 4

Ensure that the surface flatness tolerance equals 0,25 after welding.

Grind and polish the welding flange.

Use a solid straight ruler and a feeler gauge to determine the flatness.

16

3 Installation

Study the instructions carefully and pay special attention to the warnings!

Always check the Agitator before operation - see chapter 3.3 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Welding procedure FSWF, ALB Agitator:

(for mounting flange with nose)

NOTE

Alfa Laval recommend a welding tool with, if possible, build in cooling by flowing water, to be made and fixed to the FSWF to ensure shape and form of the FSWF during welding and installation.

In general Alfa Laval recommend to weld the welding flange onto a bended rim of the tank bottom plate – this is to secure adequate flexibility at high loads, e.g. when the tank is filled. If a bended rim is impossible to obtain due to a high plate thickness, Alfa Laval recommend to weld the welding flange onto a cone shaped plate section.

If not following the above recommendations there will be a risk that the flange can deform, especially at high tank fillings, which can cause a leakage between the welding flange and the Agitator mounting flange.

Step 1

Position the flange correctly.

Always allow flange to cool to ambient temperature after each section has been welded.

Step 2

Spot weld from outside.

A

Adjust alignment!

D

TD605-215

B

TD605-214

C

Step 3

Spot weld from inside

3

7

10

TD605-216

2

11

6 12

5

4

1

8

9

17

3 Installation

Study the instructions carefully and pay special attention to the warnings!

Always check the Agitator before operation - see chapter 3.3 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Step 4

Weld the following sections first from inside then from outside and cool to ambient temperature after each section has been welded

Step 1

A

1

Step 2

A

8

Step 3

A

H E H E H E

4

3

D

TD605-217

B D

TD605-218

B D

TD605-219

B

6

7

G F

G

F G F

C

Cool with air!

2

5 C

Cool with air!

C

Cool with air!

Step 5

Remove the welding tool.

Ensure that the surface flatness tolerance equals ±0.1mm.

Grind and polish the welding flange.

18

3 Installation

Study the instructions carefully and pay special attention to the warnings!

Always check the Agitator before operation - see chapter 3.3 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Mounting Agitator:

CAUTION

Always ensure that mounting is carried out according to description shown in chapter 6.2 Mounting angle for side mounted

Agitator type ALS and chapter 6.3 Mounting angle for bottom mounted Agitator type ALB.

Always refer to tightening torques in chapter 6.6 Tightening torques for bolt connections when tightening bolts.

Step 1

Place impeller device(s) in the tank.

Ensure that tank and Agitator surfaces are clean.

Ensure that drain (I) is pointing downwards.

For gears with vent screw, ensure the vent is pointing upwards and the rubber plug (III) is removed (see chapter 8.1 Drive unit instructions).

III

4303-0053

I

Step 2

Mount the Agitator onto the tank.

1) Standard vent plug

2) Transport securing device

19

20

3 Installation

Study the instructions carefully and pay special attention to the warnings!

Always check the Agitator before operation - see chapter 3.3 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Step 3

Mount impeller device(s) onto shaft.

3 x

TD605-037

Hub diameter [mm]

Ø30

Ø40

Ø55, Ø80, Ø120

3 x a

TD605-038 a a - dimension [mm]

1,1

1,8

2,8

All-weld propeller to shaft with one welding seam at a time, cool with air and continue with one welding until welding is according to illustration. Use welding procedures which introduce as less heat, tension and bending to the shaft as possible.

TD605-036

TD605-0

35

TD605-031 x 4 x 1

TD605-033

TD605-032

TD605-034

3 Installation

Study the instructions carefully and pay special attention to the warnings!

Always check the Agitator before operation - see chapter 3.3 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Step 4

Ensure the impeller device orientation is correct according to the direction of the desired flow. The direction is determined by the letter "D" or "U" in the last part of the Agitator type description. E.g. -E400D3P has the letter "D" which means the flow direction is away from the drive unit. -E400U3P has the letter "U" which means the flow direction is towards the drive unit.

Step 5

Ensure the impeller is positioned, keeping minimum radial distance to the tank.

Further installation requirements regarding the position can

be found in chapter 6.2 Mounting angle for side mounted

Agitator type ALS and chapter 6.3 Mounting angle for bottom mounted Agitator type ALB to ensure optimum

performance.

4303-0144

Clearance > S/15 and

Clearance > 20mm

Step 6

If propellers has been all-welded to the shaft (not if it has been all-welded to the shaft-end) it can be necessary to align the shaft,

using heat and or bending forces according to specifications and instructions in chapter 6.7 Shaft alignment.

WARNING

CAUTION

Do NOT connect the power supply until installation is completed.

Follow instructions in chapter 8.1 Drive unit instructions.

Ensure that the rotation direction is according to nameplate.

Always perform pre-use check before operation (see chapter 3.3 Pre-use check).

NOTE

On closed tanks, Alfa Laval recommends installing a manhole circuit breaker, cutting power supply if hatch is open.

21

3 Installation

Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation. The

Agitator is only designed to operate according to data given in chapter 2.3 Intended use, 6.2 Mounting angle for side mounted

Agitator type ALS and 6.3 Mounting angle for bottom mounted Agitator type ALB. Check the rotation direction before operation.

3.3

Pre-use check

Never install the Agitator in environments which deviate from those given in chapter 2.3 Intended use and 6 Technical data.

Always ensure that all alignment specifications given in chapter 6.7 Shaft alignment are followed.

Always make sure that the motor corresponds to the environment.

Step 1

Go through chapter 2.4 Safety precautions.

Step 2

Check the fastenings.

Step 3

Check o-ring and impeller are correctly fitted.

Step 4

Check impellers CANNOT collide with tank vessel at any point during a full rotation.

Clearance > S/15 and

Clearance > 20mm 4303-0144

Step 5

Seal type S1, S2, S3

Ensure the sealing surfaces are not stuck together, by slowly turning shaft by hand.

Ensure that the seal is always submerged during operation.

NOTE

Dry running will damage the seal faces.

22

3 Installation

Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation. The

Agitator is only designed to operate according to data given in chapter 2.3 Intended use, 6.2 Mounting angle for side mounted

Agitator type ALS and 6.3 Mounting angle for bottom mounted Agitator type ALB. Check the rotation direction before operation.

Step 6

Seal Type D

Ensure the sealing surfaces are not stuck together, by slowly turning shaft by hand.

Ensure that the seal never runs dry.

Ensure flush connections are installed in such way that air pockets are avoided.

TD605-079

TD605-078

Step 7

Seal Type DC

Ensure the sealing surfaces are not stuck together, by slowly turning shaft by hand.

Ensure that the seal never runs dry.

Ensure flush connections are installed in such way that air pockets are avoided.

Ensure that the distance pieces (1) on the seal are mounted as shown on illustration.

1

OUT

TD605-170

IN

23

3 Installation

Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation. The

Agitator is only designed to operate according to data given in chapter 2.3 Intended use, 6.2 Mounting angle for side mounted

Agitator type ALS and 6.3 Mounting angle for bottom mounted Agitator type ALB. Check the rotation direction before operation.

Step 8

Ensure that drain (I) is pointing downwards.

For gears with vent screw, ensure the vent is pointing upwards and the rubber plug (III) is removed (see chapter 8.1 Drive unit

instructions and mounting instructions in Step 1 on page 19.

III

4303-0053

I

Step 9

(Only for Agitators with bearing frame)

Ensure that the PreVent valve is refitted in the bearing frame.

Step 10

Ensure that the rotation direction is according to nameplate, before starting the Agitator.

TD605-180

Step 11

If frequency converter drive is used, it must be ensured NOT to operate continuously within +/-20% of critical oscillation

speed (see chapter 2.3 Intended use and 6 Technical data).

Step 12

Alfa Laval recommend a soft starter or a frequency converter for the Agitator to reduce the load on tank and Agitator. For

operation instructions from suppliers see 8 Appendix.

The ramp up and ramp down time should be about 2-5 seconds.

24

3 Installation

3.4

Recycling information

• Unpacking

Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.

Wood and cardboard boxes can be re-used, recycled or used for energy recovery.

Plastics should be recycled or burnt at a licensed waste incineration plant.

Metal straps should be sent for material recycling.

• Maintenance

During maintenance, oil and wear parts in the machine are replaced.

All metal parts should be sent for material recycling.

Worn out or defective electronic parts should be sent to a licensed handler for material recycling.

Oil and all non-metal wear parts must be disposed of in accordance with local regulations.

• Scrapping

At the end of use, the equipment must be recycled according to the relevant, local regulations. Besides the equipment itself, any hazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt, or in the absence of local regulations, please contact your local Alfa Laval sales company.

25

4 Operation

Study the instructions carefully and pay special attention to warnings! Always check the Agitator before operation (see

chapter 3.3 Pre-use check).

Alfa Laval recommend a soft starter or a frequency converter for the Agitator to reduce the load on tank and Agitator. For

operation instructions from suppliers (see chapter 8 Appendix).

4.1

Operation/Control

If deviation from normal operation and intended use shown in chapter 2.3 Intended use, immediately switch off the Agitator and

find the cause of failure (see chapter 4.2 Troubleshooting).

The Agitator is designed to max 5 starts per hour.

Inspect the Agitator regularly

Drive unit

Motor

- Clean surfaces - to avoid overheating

Gear

- Clean vent screw (if any)

- Check for oil leakage

Flange

Clean drain

Sealing

Mechanical seal

- NOT flushed: S1, S2, S3

- Flushed: DC, D

Bearing frame

Clean PreVent screw

Check spider clearance

Check gaskets

Lubricate radial seals

Impeller device

Sticky media

- Clean impeller device

Abrasive media

- Check blade thickness*

Check fastening of pointed set screws

Supplier instruction x x

Inspect / Clean / Lubricate

Weekly x x x x

Monthly x x x x x x

* If any suspicion of reduction in blade thickness, contact Alfa Laval and inform serial no stated on the name plate.

Half-yearly x x x

26

4 Operation

Study the instructions carefully and pay special attention to warnings! Always check the Agitator before operation (see

chapter 3.3 Pre-use check).

Alfa Laval recommend a soft starter or a frequency converter for the Agitator to reduce the load on tank and Agitator. For

operation instructions from suppliers (see chapter 8 Appendix).

4.2

Troubleshooting

Problem

Not starting

Drive unit

Cause/result

- Defect

- Fault at power supply

Agitator

Bearing frame

Vibrations

Impeller device

Shaft

Other

Unuasual noise

Bearing frame

Drive unit

Sealing

- Obstructed

- Damaged

- Unbalanced impeller

- Damage to shaft seal

- Damaged

- Deviation from normal operation

- Increased / decreased temperature

- Bearing gap

- Wear or damaged bearings

- Defect

- Bearing gap

- Increased / decreased power

- No grease

- Wear sealing

- Seal are not flushed

- Seal surfaces stick together

Other - Deviation from normal operation

- Circuit overload

Leakage

Gear

Sealing

Continuously breakdown

Drive unit

- Oil leakage

- CIP fluid or other

- Defect

- Too high frequency

- Deviation from normal operation Other

Performance

Drive unit

Agitator

Other

- Wrong frequency

- Reverse direction

- Deviation from normal operation

1)

See chapter 2.3 Intended use.

Remedy

Dismantle drive unit, check for correct rotation. Replace drive unit

Check power supply connection

Check voltage and frequency correspond with name plate

Check frequency converter adjustment correspond to name plate

Check Agitator can rotate freely without striking anything

Ensure that retainer bolt has been removed

Contact Alfa Laval

Clean impeller device

Replace sealing

Contact Alfa Laval

Operation circumstances must equal to those it was designed for 1)

Replace bearings and all gaskets in bearing frame immediately

Replace bearings and all gaskets in bearing frame

Replace drive unit

Renovate or change the drive unit immediately

Switch of power supply

Replace drive unit

Replace sealing

Replace sealing and ensure that the seal never run dry

Separate surfaces carefully and clean them - ensure that seals are sufficient cleaned before still stand

Operation circumstances must be equal to those it was designed for

Operation circumstances must be equal to those it was designed for

1)

1)

Renovate or change the gear immediately

Replace sealing

Replace motor

Regulate frequency down

Operation circumstances must be equal to those it was designed for 1)

Check frequency connection

Inspect the Agitator carefully

Operation circumstances must be equal to those it was designed for 1)

27

4 Operation

Study the instructions carefully and pay special attention to warnings! Always check the Agitator before operation (see

chapter 3.3 Pre-use check).

Alfa Laval recommend a soft starter or a frequency converter for the Agitator to reduce the load on tank and Agitator. For

operation instructions from suppliers (see chapter 8 Appendix).

4.3

Cleaning - recommendations

Ensure the drain in flange is not clogged up, by cleaning drain regularly.

Ensure that all surfaces in contact with product are totally clean in order not to contaminate the product.

Pay special attention to:

- Impeller device surfaces

- Surfaces between impeller devices and shaft

- Surfaces around sealing

- Surfaces around weldings

CAUTION

Mechanical seals are designed for cleaning in place (CIP) and sterilising in place (SIP).

CIP = Cleaning In Place. SIP = Sterilising In Place.

Always rinse well with clean water after cleaning.

4.4

Temperature limits

The highest allowable ambient temperature is 40ºC.

For applications without bearing frame (not ATEX):

The highest allowable continuous temperature of the SHAFT that goes into the gear motor is 105°C. Shorter periods with higher application temperatures, eg. 10-20 minutes during a sterilization phase or the like, can be allowed and accepted without changing the oil service interval and without reducing the lifetime of the gear motor. If longer periods with exceeded application temperatures are required, the actual temperature of the oil in the gear motor must be measured. The highest allowable oil temperature is 140°C and the oil service interval, which at 70°C is about 40.000 hours, will be reduced by 50% for each 15K the oil temperature is increased above the 70°C.

For applications with bearing frame (not ATEX):

The highest allowable continuous temperature of the SHAFT that goes into the bearing frame is 105°C. Shorter periods with higher application temperatures, eg. 10-20 minutes during a sterilization phase or the like, can be allowed and accepted without changing the service interval and without reducing the lifetime of the bearings. If longer periods with exceeded application temperatures are required, the actual temperature of the bearings must be measured. The highest allowable bearing temperature, without changing the service interval, is 120°C.

28

4 Operation

Study the instructions carefully and pay special attention to warnings! Always check the Agitator before operation (see

chapter 3.3 Pre-use check).

Alfa Laval recommend a soft starter or a frequency converter for the Agitator to reduce the load on tank and Agitator. For

operation instructions from suppliers (see chapter 8 Appendix).

4.5

Pressure limits

The ALS and ALB agitator can be equipped with different shaft seal types with different operating properties. The shaft seal is selected according to the application. In below table you will find the maximum allowable tank pressure during operation for the different seal types.

Seal type

-S1-

-S2-

-S3-

-D-

-DC-

Tank pressure [barg]

Min.

-0.5

-0.5

-0.5

-1.0

-1.0

Max.

6.0

6.0

6.0

4.5*

6.0

Designation

Single mechanical shaft seal, High pressure and high speed

Single mechanical shaft seal, High pressure and high speed

Single mechanical shaft seal, High pressure and high speed

Double mechanical shaft seal w. flush, Medium pressure and high speed

Double mechanical shaft seal w. flush, High pressure and high speed

*If the seal faces are submerged, the maximum tank pressure can be increased to 6.0bar(g).

NOTE

Above pressures are not taking limitations on flange connections according to local pressure regulations into consideration.

Be aware that the operating pressure limits for the shaft seal can be lower than the tank design pressure.

29

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.1

General maintenance

Maintenance of the Agitator should only be performed by authorized personnel.

For maintenance instructions from suppliers, see chapter 8 Appendix.

Ensure totally clean surfaces during maintenance.

If possible, always dismount the Agitator from tank before dismantling it.

For lifting instruction, please refer to chapter 3 Installation.

Always read the technical data thoroughly (see chapter 6 Technical data).

Always ensure that the mounting is according to Agitator described in chapter 2.3 Intended use and chapter 6 Technical data.

Always refer to tightening torques in chapter 6 Technical data.

Always disconnect the power supply when servicing the Agitator.

Always use proper tools.

Always replace sealing elements before reassembling.

WARNING

Follow the dismantling and assembly instructions to the letter.

After maintenance, chapter 3.3 Pre-use check must be read thoroughly before operation.

NOTE

All scrap must be stored/disposed of in accordance with current rules/directives.

Use original Alfa Laval spare parts.

PREVENTIVE MAINTENANCE

To ensure that your Alfa Laval machine operates efficiently, it is essential to follow a simple preventive maintenance programme, which will keep your machine in good working conditions. Good maintenance requires careful attention at regular intervals!

The following recommended preventive maintenance procedures are based on the average operating conditions of most Alfa

Laval machines. However, you will appreciate that a machine, which is subject to rough and dirty conditions, will need more frequent attention than one working in ideal conditions. We trust that you will adjust your maintenance programme to meet the demands of your normal operating conditions.

500 hour or yearly

1000 hour or yearly

Replace every:

3000 hour or yearly

6000 hour or every 3rd year

10000 hour or every 3rd year

Sealing

Mechanical seal

-NOT flushed: S1, S2, S3

-Flushed: DC, D

Bearing frame

Spider type coupling (if any)

Static seals

Radial seals

Bearings, rpm < 700

Bearings, rpm > 700 x x x x x x x

30

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.2

Replacement of drive unit (with bearing frame)

Step 1

Remove shroud, if any.

2

1

1

TD605-109

1

Step 2

Loosen cap nuts.

CAUTION

If dismantling motor from gear:

Follow supplier instructions.

Ensure that the gear oil is contained.

A cog wheel may be mounted onto the motor shaft.

Step 3

Release the gear motor from the Agitator.

CAUTION

There is a spider type coupling mounted onto the gear motor shaft.

Step 4

Lift up the drive unit and pull it away.

2

1

TD605-042

2

1

TD605-043

Step 5

1. Loosen coupling screws.

2. Pull the coupling of the gear motor shaft.

1

2

TD605-129

31

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

Step 6

Replace drive unit.

Mount coupling.

NOTE

Coupling part can be heated to 80-120°C for easier mounting onto gear motor shaft.

CAUTION

Ensure that the axial position of the coupling is according to

illustration. The value XX is to be found in chapter 6.8 Spider coupling.

Step 7

Replace spider if necessary.

Use Loctite® 243 before fastening screws.

Always refer to tightening torques in chapter 6 Technical data when tightening bolts.

Step 8

Mount drive unit reverse as dismantling.

XX

TD605-072

32

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.3

Replacement of drive unit (without bearing frame)

Step 1

Remove shroud, if any.

2

Step 2

1. Dismantle Agitator from welding flange.

2. Lift up Agitator.

1

1

TD605-109

1

1

2

TD605-075

Step 3

Before dismantling drive unit, please see instructions in 5.10 Replacement of shaft seal, type D to 5.14 Replacement of shaft seal, type S3, depending on seal type.

Step 4

Loosen cap nuts.

CAUTION

If dismantling motor from gear:

Follow supplier instructions.

Ensure that the gear oil is contained.

A cog wheel may be mounted onto the motor shaft.

1

TD605-042

2

33

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

Step 5

Release the gear motor from the Agitator. Refer to supplier instructions.

CAUTION

There is a Nord-lock® washer mounted on the gear fastening the shaft.

The washer consists of two parts attached to each other with some silicone as shown on the picture. It is important that the two parts are positioned as shown.

TD605-050

Step 6

Lift up the drive unit and pull it away.

2

TD605-043

1

Step 7

Replacement drive unit.

Step 8

Use Loctite® 243 before fastening screws.

Always refer to tightening torques in chapter 6 Technical data.

Step 9

Mount drive unit reverse as dismantling.

34

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.4

Replacement of drive unit (Motor and shaft unit)

Step 1

Remove shroud, if any.

2

Step 2

Loosen cap nuts.

1

1

TD605-109

1

2

1

Step 3

Release the motor from the Agitator.

CAUTION

Motor and shaft are one complete unit.

Step 4

Lift up the drive unit and pull it away.

Step 5

Replace drive unit.

Step 6

Use Loctite® 243 before fastening screws.

Always refer to tightening torques in chapter 6 Technical data.

Step 7

Mount drive unit reverse as dismantling.

35

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.5

Dismantling and mounting shaft (with bearing frame except BC160)

Step 1

1. Dismantle Agitator from welding flange.

2. Lift up Agitator.

1

2

TD605-075

1 Step 2

1. Dismantle drive unit as described in chapter 5.2 Replacement of drive unit (with bearing frame).

2. Remove PreVent valve.

TD605-047

Step 3

Looking through the PreVent valve hole, rotate shaft until shaft locking hole aligns.

TD605-048

Step 4

1. Mount retainer bolt tool for shaft locking.

2. Remove centre bolt.

NOTE

Extra retainer bolt tool can be acquired if needed (see chapter

7.10 Tools) or Spare Part Manual.

1

TD605-049

2

36

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

Step 5

Remove spider and coupling part.

2

1

43030007

Step 6

Dismantle shaft by mounting extractor bolt tool.

Keep turning extractor bolt until shaft is forced from the bearing frame.

NOTE

Extra extractor bolt tool can be acquired if needed (see chapter

7.10 Tools or Spare Part Manual).

Step 7

Mount shaft reverse as dismantling

CAUTION

Ensure that oil trap ring, if any, is refitted correct during mounting.

2

TD605-051

1

37

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.6

Replacement of bearings, type B20, B25, B25/30, B35, B35/40, B45, B45/50, B55, B55/60

13

11

12

14

3

15 2

10 9 1 4 5 8 7 6

TD605-059

NOTE

Positions referred to in following instructions can be seen in the above illustration.

Step 1

1. Dismantle shaft as described in chapter 5.5 Dismantling and mounting shaft (with bearing frame except BC160).

2. Remove retainer bolt in Step 4 in chapter 5.5 Dismantling and mounting shaft (with bearing frame except BC160).

Step 2

1. Remove cap nuts (2).

2. Remove lantern or mounting flange if no lantern is used from bearing frame.

1

2

Step 3

1. Push cover (12) into bearing frame.

2. Remove o-ring (11).

12

11

2 1

Step 4

Remove cover (12) including radial seal (3) and spring (13).

1 2

13

12

38

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

Step 5

Remove outer circlip (10) carefully. Use suited pliers.

10

Step 6

1. Pull out drive shaft (4) including bearings (8, 9).

2. Remove o-ring (7)

Step 7

1. Remove inner circlip (14) carefully. Use suited pliers.

2. Remover bearings (8, 9).

14

9

4

1

TD605-057

8

2

7

8

1

2

14 9

2

TD605-058

Step 8

1. Replace bearings (8, 9) and o-rings (6, 7, 11, 15).

2. Assembly of bearing frame is reverse as dismantling.

CAUTION

Only apply force to inner bearing rings when mounting bearings on drive shaft.

Only apply force to outer bearing rings when mounting drive shaft with bearings into bearing frame.

39

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.7

Replacement of bearings, type BC160DH

6

10

9

3

14

11 2

12 4

13 1

8 7

TD605-046

NOTE

Positions referred to in following instructions can be seen in the above illustration.

Step 1

Dismantle shaft as described in chapter 5.5 Dismantling and mounting shaft (with bearing frame except BC160).

Step 2

1. Remove cap nuts (2).

2. Remove lantern or mounting flange if no lantern is used from bearing frame.

1

Step 3

Remove radial seal (3).

NOTE

Alfa Laval recommends replacing the radial seal.

Step 4

Remove outer circlip (10) carefully. Use suited pliers.

3

2

10

TD605-063

40

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

Step 5

1. Pull out drive shaft (4) including bearings (8, 9).

2. Remove O-rings, (7), (11).

Step 6

1. Remove spring ring (13).

2. Remove inner circlip (14) carefully. Use suited pliers.

3. Remove bearings (8, 9).

2

3

14

8

9

3

1

13

Step 7

1. Replace bearings (8, 9) and o-rings (6, 7, 11).

2. Assembly of bearing frame is reverse as dismantling.

CAUTION

Only apply force to inner bearing rings when mounting bearings on drive shaft.

Only apply force to outer bearing rings when mounting drive shaft with bearings into bearing frame.

TD605-064

41

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.8

Replacement of bearing, type BC160D

10

9

3

14

11 2

12 5 4 13 1 8 7

6

15

16

17

TD605-061

NOTE

Positions referred to in following instructions can be seen in the above illustration.

Step 1

Dismantle shaft as described in chapter 5.5 Dismantling and mounting shaft (with bearing frame except BC160).

Step 2

1. Remove cap nuts (2).

2. Remove lantern or mounting flange if no lantern is used from bearing frame

1

Step 3

Remove radial seal (3).

NOTE

Alfa Laval recommends replacing the radial seal.

Step 4

Remove outer circlip (10) carefully. Use suited pliers.

3

2

10

TD605-063

42

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

8b Step 5

1. Pull out drive shaft (4) including bearings (pos 8a, 9).

2. Pull out circlip (12) or let it stay in bearing frame.

NOTE

Outer bearing ring (8b) should stay in bearing frame

9

12

4

8a

TD605-068

14

Step 6

1. Remove upper circlip (13) carefully. Use suited pliers

2. Push out, using applicable tool, the outer bearing ring (8b).

3. Remove o-rings (7, 11).

11

13 8b

7

3

2

1 3

Step 7

1. Remove inner circlip (14) carefully. Use suited pliers.

2. Remove bearings (8a, 9)

2

1

TD605-069

9 12 8a

2

14

Step 8

1. Replace bearings (8a, 8b), (9) and o-rings (6, 7, 11).

2. Assembly of bearing frame is reverse as dismantling.

CAUTION

Only apply force to inner bearing rings when mounting bearings on drive shaft.

Only apply force to outer bearing rings when mounting drive shaft with bearings into bearing frame

TD605-144

43

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.9

Replacement of bearings type BC160

2

11 14 5 1 8 7

4

3

10

9

6

13

12

TD605-060

NOTE

Positions referred to in following instructions can be seen in the above illustration.

Step 1

Dismantle drive unit as described in chapter 5.2 Replacement of drive unit (with bearing frame).

Step 2

1. Remove cap nuts (2).

2. Remove lantern or mounting flange if no lantern is used from bearing frame.

1

Step 3

Remove radial seal (3).

NOTE

Alfa Laval recommends replacing the radial seal.

Step 4

Remove outer circlip (10) carefully. Use suited pliers.

3

2

10

TD605-063

44

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

Step 5

1. Pull out shaft (4) including bearings (pos 8, 9).

2. Remove o-rings (7, 11).

Step 6

1. Secure shaft (4), without causing surface damage to it.

2. Remove coupling (12) by turning it the opposite direction indicated by arrow on nameplate

4

9

11

8

1

TD605-065

12

7

2

12 1

4

Step 7

1. Remove bearing (8).

2. Remove inner circlip (14) carefully. Use suited pliers.

3. Remove bearing (9).

Step 8

1. Replace bearings (8, 9) and o-rings (6, 7, 11).

2. Assembly of bearing frame is reverse as dismantling.

CAUTION

Only apply force to inner bearing rings when mounting bearings on drive shaft.

1

8

3

9

2

14

TD605-067

45

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.10

Replacement of shaft seal, type D

21

22

23

TD605-165

20

15

14

13

12

11

10

7

6

5

9

8

19

18

17

16

4

3

2

1

NOTE

To replace seals easier, use detergent.

Ensure subsequent to seal replacement, that all seal faces are totally clean, using alcohol.

Positions referred to in following instructions can be seen in the above illustration.

NOTE

If possible, always dismantle the Agitator from the tank before dismounting any parts.

Step 1

1. Dismantle Agitator from welding flange.

2. Lift up Agitator

1

2

TD605-075

Step 2

1. Remove flush connections (21).

2. Remove guards from lantern.

1

3

2

3

1

TD605-084

46

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

Step 3

Move oil trap ring and o-rings, if any, along the shaft.

2

1

3

2

3

1

TD605-087

Step 4

1. Loosen pointed screw (19).

2. Move the rotary seal housing (20) and rotary seal part (15, 16,

18) carefully along the shaft.

2

1

Step 5

Dismantle drive unit as described in chapter 5.2 Replacement of drive unit (with bearing frame).

Step 6

1. Dismantle shaft as described in section 5.2 Replacement of

drive unit (with bearing frame) or 5.5 Dismantling and mounting shaft (with bearing frame except BC160), depending on actual

Agitator type.

2. Remove shaft and rotary seal parts (3, 4) carefully, avoiding contact.

TD605-112

CAUTION

Ensure rotary seal housing and rotary seal part do NOT fall when shaft is removed.

47

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

Step 7

1. Remove nuts (23) and washers, securing stationary seal housing.

2. Remove stationary seal housing.

1

2

Step 8

1. Replace all seal parts.

2. Assemble Agitator reverse as dismantling.

CAUTION

Ensure clearance between rotary and stationary seal housing is 2,75 mm.

+0.5

2.75 0

TD605-125

48

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.11

Replacement of shaft seal, type DC

16 15

17

14

9

8

7

6

5

4

13

12

TD605-163 1

2

NOTE

To replace seals easier, use detergent. Ensure subsequent to seal replacement, that all seal faces are totally clean, using alcohol.

Positions referred to in following instructions can be seen in the above illustration.

Step 1

1. Dismantle Agitator from welding flange.

2. Lift up Agitator.

1

2

TD605-075

Step 2

1. Remove flush connections (17).

2. Remove guards from lantern.

1

3

2

3

1

TD605-084

49

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

Step 3

1. Rotate distance pieces as shown in Step 9.

2. Loosen pointed screws (the pointed screws are not the screws that fasten the distance pieces).

3. Loosen cap nut, securing the seal

4. Ensure the seal can move along the shaft (up to 10 mm).

Step 4

Move oil trap ring and o-rings, if any, along the shaft.

2

1

3

2

3

1

TD605-087

Step 5

1. Remove cap nuts, securing mounting flange.

1

2

Step 6

Dismantle shaft, as described in chapter 5.2 Replacement of drive unit (with bearing frame) or 5.5 Dismantling and mounting shaft (with bearing frame except BC160) depending on Agitator type and carefully remove lantern.

Step 7

Lift lantern and drive unit flange.

Step 8

Remove DC seal.

50

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

Step 9

1. Replace sealing.

2. Assemble Agitator reverse as dismantling.

4303-0118

During mounting / dismounting

NOTE

Ensure distance pieces are oriented correctly during mounting or dismounting.

Before start

51

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.12

Replacement of shaft seal, type S1

TD605-157

4

3

2

1

NOTE

To replace seals easier, use detergent.

Ensure subsequent to seal replacement, that all seal faces are totally clean, using alcohol.

If possible, always dismantle the Agitator from the tank before dismounting any parts.

Step 1

1. Dismantle Agitator from welding flange.

2. Lift up Agitator.

2

1

Step 2

1. Move o-ring (1) along the shaft.

2. Move counter ring (2) along the shaft.

3. Move rotary seal ring (3) along the shaft.

TD605-075

1

2 3

4

1

2

3

Step 3

Remove guards from lantern if lantern is used.

TD605-089

52

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

Step 4

1. Remove cap nuts (if still here).

2. Move the mounting flange, including stationary seal ring (4), carefully along the shaft.

1

Step 5

Move oil trap ring and o-rings, if any, along the shaft.

2

2

1

3

2

3

1

TD605-087

Step 6

If necessary, dismantle drive unit as described in chapter 5.2 Replacement of drive unit (with bearing frame).

Step 7

Push stationary seal ring (4) out of the mounting flange.

TD605-082

Step 8

Remove all seal parts from shaft.

Step 9

1. Replace all seal parts.

2. Assemble Agitator reverse as dismantling.

53

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.13

Replacement of shaft seal, type S2

TD605-15

8

8

7 10

6 9

1

NOTE

To replace seals easier, use detergent.

Ensure subsequent to seal replacement, that all seal faces are totally clean, using alcohol.

NOTE

If possible, always dismantle the Agitator from the tank before dismounting any parts.

Step 1

1. Dismantle Agitator from welding flange.

2. Lift up Agitator

2

1

TD605-075

Step 2

Remove guards from lantern if lantern is used.

Step 3

Move oil trap ring and o-rings, if any, along the shaft.

2

1

3

2

3

1

TD605-087

Step 4

Remove carefully the shaft without dismantling drive unit.

54

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

Step 5

Remove rotary seal part from shaft.

TD605-122

Step 6

Remove stationary seal part and o-ring from mounting flange.

Step 7

1. Remove screws.

2. Remove retainer ring.

3. Remover spring and stationary drive ring.

Step 8

1. Replace all seal parts.

2. Assemble Agitator reverse as dismantling.

TD605-123

1

2

3

55

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

5.14

Replacement of shaft seal, type S3

TD605-159

8

7

6

5

4

3

2

1

9

NOTE

To replace seals easier, use detergent.

Ensure subsequent to seal replacement, that all seal faces are totally clean, using alcohol.

If possible, always dismantle the Agitator from the tank before dismounting any parts.

The seal (see chapter 2.3 Intended use) is designed for dry running, so a whining noise during operation is quite normal.

Positions referred to in following instructions can be seen in the above illustration.

Step 1

1. Dismantle Agitator from welding flange.

2. Lift up Agitator

1

2

TD605-075

TD605-127

Step 2

1. Loosen pointed screws (1), securing rotary seal housing onto the shaft.

2. Move the seal housing, including rotary seal part, by pulling it carefully along the shaft, avoiding contact.

NOTE

Use mild detergent to reduce friction.

1

2

56

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in chapter 6 Technical data.

Step 3

1. Remove guards from lantern.

2. Remover cap nuts.

3. Move the mounting flange, including stationary seal ring, carefully along the shaft, avoiding contact.

1

2

1

Step 4

Move oil trap ring and o-rings, if any, along the shaft.

3

TD605-092

2

1

3

2

3

1

TD605-087

Step 5

1. Push stationary seal ring (7) out of the mounting flange.

Step 6

Remove all seal parts from shaft.

Step 7

1. Replace all seal parts.

2. Assemble Agitator reverse as dismantling and position the rotating seal element according measure x.

Shaft size:

Ø30, x=36

Ø35, x=36

Ø40, x=38

4303-0172

8

7

6

5

4

3

2

1

9

TD605-148

57

6 Technical data

All dimenstions in mm unless otherwise stated.

6.1

Technical data

The Alfa Laval Agitator is available in various configurations and is configured to solve the specific application. Therefore specific information like weight, size, critical oscillation speed and duties can be found in the supplied Alfa Laval quotation agreement.

Important installation information about weight and mounting angle can be found on the supplied Agitator name plate as shown on the illustration.

6.2

Mounting angle for side mounted Agitator type ALS

To ensure optimal agitation the side mounted Agitator must be installed in the mounting angle specified on the name plate, as described in the Alfa Laval quotation agreement and as shown on the illustration.

The side mounted Agitator must also be installed in either an offset distance (E) from the center of the tank or it must be installed an offset angle (E*) from the center of the tank as shown on illustration section A-A

The distance (E) can be calculated as follows:

E = C x tan(5-7°), where C = tank radius

If the offset angle is chosen it must be as follows: E* = 5-7°

NOTE

In certain cases the offset angle E* is recommended to be larger - e.g. 10-12°.

- it will be communicated via the Alfa Laval quotation agreement.

43030008

4303-0009

58

All dimenstions in mm unless otherwise stated.

6.3

Mounting angle for bottom mounted Agitator type ALB

To ensure optimal agitation the bottom mounted Agitator must be installed in the mounting angle specified on the name plate, as described in the Alfa Laval quotation agreement and as shown on the illustration.

6 Technical data

43030010

59

6 Technical data

All dimenstions in mm unless otherwise stated.

6.4

Connecting flush – Seal type D

Flush connection:

In and out: Male 1/2"-14 BSP (ISO 7/1-Rp)

Flushing pressure max. 2.0 bar(g)

Flush media pressure recommendation to prevent flush media contamination by the product media:

(flush media pressure > tank operating pressure)

Flushing pressure

(Tank operating pressure + 0.1 bar)

NOTE

Tank pressure cannot be higher than 1.9 bar(g) due to the maximum flushing pressure. If higher tank pressure is needed the next flush media pressure recommendation must be followed.

Flush media pressure recommendation to prevent product media contamination by the flush media:

(tank operating pressure > flush media pressure)

Flushing pressure

(Tank operating pressure – 0.1 bar)

(Tank operating pressure – Flushing pressure)

2.5 bar

NOTE

If the tank pressure is more than 2.5 bar(g) greater than the flushing pressure, there will be a risk of dry running on the primary seal faces when the seal faces is not submerged. When the seal faces are submerged there is no limit on the pressure difference during operation.

Flush media flow recommendation:

Flushing flow rate > 0.25 ltr/min

Lower flushing flow rate is allowed as long as the temperature difference between in- and outlet is < 10°C

Flush media type recommendation:

White oils

Water

Wet steam

Alcohol

60

6 Technical data

All dimenstions in mm unless otherwise stated.

Flush media type recommendation:

Always use appropriately in- and outlet temperatures given for current seal elastomers

Inlet temperature to be 15°C below actual fluid boiling point (temperature and pressure dependent)

Always use wet steam (H

2

O) if steam is used as flushing fluid

Inlet temperature

121°C

Sterile barrier at seal type D and DC:

Use a sterile supply system with preferred sterilization temperature and water / wet steam as flush type and ensure that above recommendations are followed

Ensure flush connections are not installed or oriented in such way that air pockets will appear. In some cases initial air pockets near the seal surfaces (e.q. at bottom mounted Agitators ALB) cannot be avoided. It has been tested and verified that an initial flow rate without air at 5 ltr/min lasting for 30 seconds while the Agitator is running ensures that all air in seal and flushing chamber will be flushed out.

TD605-079

TD605-078

NOTE

Alfa Laval recommends installing a pressure relief valve to ensure pressure never exceed specifications.

Alfa Laval recommends installing a non-return valve onto the inlet connection, to ensure that the seal never runs dry.

If higher flushing pressure is desired, please contact Alfa Laval for advice.

61

6 Technical data

All dimenstions in mm unless otherwise stated.

6.5

Connecting flush – Seal type DC

Flush connection:

In and out: Male 1/2"-14 BSP (ISO 7/1-Rp)

Flushing pressure max. 7.0 bar(g)

Flush media pressure recommendation to prevent flush media contamination by the product media:

(flush media pressure > tank operating pressure)

Flushing pressure

(Tank operating pressure + 0.1 bar)

Flush media pressure recommendation to prevent product media contamination by the flush media:

(tank operating pressure > flush media pressure)

Flushing pressure

(Tank operating pressure – 0.1 bar)

(Tank operating pressure – Flushing pressure)

2.5 bar

NOTE

If the tank pressure is more than 2.5 bar(g) greater than the flushing pressure, there will be a risk of dry running on the primary seal faces when the seal faces is not submerged. When the seal faces are submerged the is no limit on the pressure difference during operation.

Flush media flow recommendation:

Flushing flow rate > 0.25 ltr/min

Lower flushing flow rate is allowed as long as the temperature difference between in- and outlet is < 10°C

62

All dimenstions in mm unless otherwise stated.

Flush media type recommendation:

White oils

Water

Wet steam

Alcohol

Flush media type recommendation:

Always use appropriately in- and outlet temperatures given for current seal elastomers

Inlet temperature to be 15°C below actual fluid boiling point (temperature and pressure dependent)

Always use wet steam (H

2

O) if steam is used as flushing fluid

Inlet temperature

121°C

Sterile barrier at seal type D and DC:

Use a sterile supply system with preferred sterilization temperature and water / wet steam as flush type and ensure that above recommendations are followed

Ensure that connection of outlet and inlet is correct, with regard to Agitator rotation direction!

Ensure that the distance pieces (1) on the seal are mounted as shown on illustration.

1

6 Technical data

OUT

TD605-170

IN

NOTE

Alfa Laval recommends installing a pressure relief valve to ensure pressure never exceed specifications.

Alfa Laval recommends installing a non-return valve onto the inlet connection, to ensure that the seal never runs dry.

If higher flushing pressure is desired, please contact Alfa Laval for advice.

63

6 Technical data

All dimenstions in mm unless otherwise stated.

6.6

Tightening torques for bolt connections

CAUTION

Use Loctite ® before fastening.

Do NOT use air powered tools.

M4

3Nm

M5

6Nm

M6

11Nm

M8

26Nm

M10

51Nm

M12

88Nm

M14 M16 M18 M20 M22 M24

141Nm 218Nm 308Nm 439Nm 582Nm 724Nm

64

All dimenstions in mm unless otherwise stated.

6.7

Shaft alignment

Shaft to be aligned in bearing frame or in gear motor.

RPM up to:

U (max radial tolerance, ALS/ALB)

50

0.4

100

0.3

500

0.2

1000

0.1

2800

0.05

6 Technical data

U

4303-0056

After propellers has been welded onto the shaft and / or two shaft parts has been welded together - the shaft must be aligned. If the shafts has been welded according to Alfa Lavals recommendations shown below – the required alignment will be very little as the amount of introduced heat to the shaft is minimized and due to the fact that all shafts has been aligned before delivery from Alfa Laval.

“All-weld shaft connections and propellers to shaft with one welding seam at a time, cool with air and continue with one welding until welding is according to illustration. Use welding procedures which introduce as less heat, tension and bending to the shaft as possible.”

Required tool:

1. A gas-welding torch supplied with a mixture of Acetylene and Oxygen gas.

2. A dial indicator.

65

6 Technical data

All dimenstions in mm unless otherwise stated.

Procedure:

1. Alignment of the shaft is carried out in steps from the bearing frame / gear motor and down to the shaft end.

2. If the shaft has been exposed to uneven heat around “A” (due to welding of shaft connection or welding of propeller onto shaft) a possible bend can be introduced around “A”.

3. The dial indicator is located about 500-2000 mm below “A” (but above the next bend “B”) and the shaft is rotated until the shaft is pointing to the left as shown on the picture.

4. The welding torch is used on the opposite site of the bend (the right side of the shaft in this example) about 25-50 mm further up or down from the welding area “A”. The welding torch is positioned very near the shaft surface without moving it and the surface of the shaft is rapidly heated up (1-10 seconds depending on shaft bend) until a Ø2-10 mm red spot is observed. Observing the dial indicator the shaft will, during the heating process, bend even more to the wrong direction but during cooling it bends back to a “more” align position.

5. The shaft is cooled down with compressed air until the temperature of the part of the shaft around A is the same as the rest of the shaft and the surrounding temperature (2-10 minutes depending on amount of heat introduced).

6. Step 3), 4) and 5) are repeated until the alignment is according the specified “U” (which is a function of speed and

Agitator type).

7. The next position “B” where the shaft has been exposed to uneven heat is located (due to welding of shaft connection or welding of propeller onto shaft).

8. The dial indicator is located 500-2000 mm below “B” (but above the next bend) or at the shaft end if the shaft does not have any other bends and the shaft is rotated until the shaft is pointing to the right as shown on the picture.

9. The welding torch is used on the opposite site of the bend (the left side of the shaft in this example) about 25-50 mm further up or down from the welding area. The welding torch is positioned very near shaft surface without moving it and the surface of the shaft is rapidly heated up (1-10 seconds depending on shaft bend) until a Ø2-10 mm red spot is observed.

10. The shaft is cooled down with compressed air until the temperature of the part of the shaft around A is the same as the rest of the shaft and the surrounding temperature (2-10 minutes depending on amount of heat introduced).

11. Step 8), 9) and 10) are repeated until the alignment is according the specified “U” (which is a function of speed and

Agitator type).

12. The spot areas where the shaft has been heated and aligned using the welding torch must be cleaning using chemical pickling and or mechanical abrasive polishing.

66

6 Technical data

All dimenstions in mm unless otherwise stated.

6.8

Spider coupling

Axial alignment and tooth thickness [mm]:

BC160/35

BC160D/30

BC160DH/30

Bearing frame type:

B20

B25

B25/30

B35

B35/40

B45

B45/50

B55

B55/60

X:

Ynew:

Ymin:

2

8.5

5.6

2

8.5

5.6

2.5

10.9

7.9

3

13.3

10.3

3.5

17.7

13.7

CAUTION

During check of spider ensure that all dust is removed before reassembly.

Y

TD605-070

X

6.9

Storage

Store the Agitator in dry and clean environments.

Rotate shaft every second week to ensure seal faces do not stick together.

67

7 Parts lists and drawings, service kits and tools

Agitator type ALS / ALB, main components - drive end

7.1

Agitator main components, drive end

68

7 Parts lists and drawings, service kits and tools

Agitator type ALS / ALB, main components - drive end

6 ♦

20 

21 

22 

23 

24 

25 

26 

27 

34 

35 

36 

37 

38 ♦

39 ♦

7 ♦

8 ♦

9 ♦

10 ♦

11 ♦

13

16 

17 

18 

19 

Parts list

Pos.

1 

2 

3 

4 

5 ♦

1

1

1

X

1

1

1

1

1

1

1

1

1

1

1

1

1

X

X

X

X

1

1

1

1

Qty

1

1

1

1

1

Denomination

GR gear motor, hollow shaft

GP gear motor, hollow shaft

GR gear motor, output shaft

GC gear motor, output shaft

Bearing frame B20, B25, B25/30,

B35, B35/40, B45, B45/50, B55,

B55/60

Bearing frame, BC160/35,

BC160D/30, BC160DH/30

Shaft seal type R

Shaft seal type G

Shaft seal type V

Shaft seal type S

Shaft seal type S3

O-ring

Screw

Welding flange

Mounting flange, standard

Mounting flange, raised

Stud

Cap nut

Washer

Screw

Washer, Nord Lock

Fixing element

Lantern, complete

Drive unit flange

Flat gasket

Coupling

Motor and shaft unit

Motor

Shaft seal type D

Shaft seal type DC

¬ Article number available upon request by serial number or article number of the Agitator.

Article number is to be found in the Spare part manual ESE03339, available from the on-line Alfa Laval product catalogue

Anytime or the Close at hand spare part catalogue.

X Quantity may vary depending on Agitator type, will be informed upon request.

69

7 Parts lists and drawings, service kits and tools

Agitator type ALS / ALB, main components - wet end

7.2

Agitator main components, wet end

70

4303-0013

7 Parts lists and drawings, service kits and tools

Agitator type ALS / ALB, main components - wet end

Parts list

Pos.

12

14 

15 

16 

28 

29 

30 

31 

32 

33 

Qty

1

1

1

X

1

1

1

1

1

1

Denomination

O-ring

Shaft

Parrallel key

Screw, pointed

Impeller device, EnSaFoil, (ESF), w. thread

Impeller device, EnSaFoil Low level, (ESFL), w. thread

Impeller device, EnSaFoil, (ESF), w. screws

Impeller device, EnSaFoil Low level, (ESFL), w. screws

Impeller device, EnSaFoil, (ESF), welding

Impeller device, EnSaFoil Low level, (ESFL), welding

¬ Article number available upon request by serial number or article number of the Agitator.

Article number is to be found in the Spare part manual ESE03339, available from the on-line Alfa Laval product catalogue

Anytime or the Close at hand spare part catalogue.

X Quantity may vary depending on Agitator type, will be informed upon request.

71

7 Parts lists and drawings, service kits and tools

Bearing frame, B20, B25, B25/30, B35, B35/40, B45, B45/50, B55, B55/60

7.3

Bearing frame, B20, B25, B25/30, B35, B35/40, B45, B45/50, B55, B55/60

72

7 Parts lists and drawings, service kits and tools

Bearing frame, B20, B25, B25/30, B35, B35/40, B45, B45/50, B55, B55/60

Parts list

Pos.

11 

12 

13 

14 

15 

16 

17

18

19

20

21

22

23

25

1

2

3

4

5

6

7

8 

9 

10 

Service kits

Qty

1

1

1

8

2

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

Denomination

Bearing frame - housing

Drive shaft

Coupling

Cover

Pin

Pin

Tool, retainer bolt

Spider

Bearing

Bearing

PreVent Valve

Seal, radial

O-ring

O-ring

O-ring

O-ring

Circlip, inner

Spring, wave

Screw

Extractor bolt

Cap nut

Pin

Circlip, outer

Washer

Denomination B20 B25 B25/30 B35

Assembly Kit

 Assembly Kit, Bearing frame B20, B25, B25/30, B35 . . . . . . . . . TE261301266B TE261301267B TE2613066880 TE261301269C

NOTE

Article numbers are to be found in the Spare part manual ESE03339, available from the on-line Alfa Laval product catalogue

Anytime or the Close at hand spare part catalogue.

73

7 Parts lists and drawings, service kits and tools

Bearing frame, B20, B25, B25/30, B35, B35/40, B45, B45/50, B55, B55/60

74

7 Parts lists and drawings, service kits and tools

Bearing frame, B20, B25, B25/30, B35, B35/40, B45, B45/50, B55, B55/60

Parts list

Pos.

11 

12 

13 

14 

15 

16 

17

18

19

20

21

22

23

25

1

2

3

4

5

6

7

8 

9 

10 

Service kits

Qty

1

1

1

8

2

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

Denomination

Bearing frame - housing

Drive shaft

Coupling

Cover

Pin

Pin

Tool, retainer bolt

Spider

Bearing

Bearing

PreVent Valve

Seal, radial

O-ring

O-ring

O-ring

O-ring

Circlip, inner

Spring, wave

Screw

Extractor bolt

Cap nut

Pin

Circlip, outer

Washer

Denomination B35/40 B45 B45/50 B55 B55/60

Assembly Kit

 Assembly Kit, Bearing frame B35/40, B45,

B45/50, B55, B55/60 . . . . . . . . . . . . . . . . . . . . . . . .

TE261304566B TE261301100B TE261305434A TE261301102B TE2613065530

NOTE

Article numbers are to be found in the Spare part manual ESE03339, available from the on-line Alfa Laval product catalogue

Anytime or the Close at hand spare part catalogue.

75

7 Parts lists and drawings, service kits and tools

Bearing frame BC160/35, BC160D/30, BC160DH/30

7.4

Bearing frame BC160/35, BC160D/30, BC160DH/30

76

4303-0059

7 Parts lists and drawings, service kits and tools

Bearing frame BC160/35, BC160D/30, BC160DH/30

Parts list

Pos.

1

2

3

4

5

6

7 

8 

9 

10 

11 

12 

13 

14 

15

16

17

18

19

20

22

23

Service kits

Qty

1

7

1

1

1

1

1

8

1

1

1

2

1

1

1

1

1

1

1

1

1

1

Denomination

Bearing frame - housing

Drive shaft

Coupling

Pin

Pin

Tool, retainer bolt

Spider

Bearing

Bearing

PreVent valve

Seal, radial

O-ring

O-ring

O-ring

Circlip, inner

Seeger ring

Screw

Extractor bolt

Cap nut

Circlip, outer

Circlip, outer

Circlip, inner

Denomination

BC160/35

(right) BC160/35 (left) BC160D/30 BC160DH/30

Assembly Kit

 Assembly Kit, Bearing frame BC160/35, BC160D/30,

BC160DH/30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE261303783B TE261303783B TE261303672B TE2613071680

NOTE

Article numbers are to be found in the Spare part manual ESE03339, available from the on-line Alfa Laval product catalogue

Anytime or the Close at hand spare part catalogue.

77

7 Parts lists and drawings, service kits and tools

Shaft seal, type D

7.5

Shaft seal, type D

78

7 Parts lists and drawings, service kits and tools

Shaft seal, type D

Parts list

Pos.

1 ♦

2 ♦ 



3

4

5

6

7 

♦ 

8 

♦ 

9

10

11

12

13

14

15  ♦ 

Service kits

Qty

2

4

4

1

1

1

1

1

1

2

1

4

1

1

1

1

1

1

1

1

1

Denomination

Seal

Seal

Seal

Seal

Seal

Seal

Ring, counter**

Ring, counter

Pin

Screw

O-ring

O-ring

O-ring

O-ring

Spacer

Flush, connection 1/2"-14 BSP

Stud

Nut

Seal housing

Oil trap

O-ring, FPM

Denomination Ø30 Ø40

Seal kits

 Seal Kit, D, C/SiC-C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000121 TE2613000122

Seal Kit, D, C/SiC-C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000123 TE2613000124

 Seal Kit, D, SiC/SiC-C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000125 TE2613000126

 Seal Kit, D, SiC/SiC-C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000127 TE2613000128

**Pos. 3: Welded onto shaft - maintenance must be carried out by Alfa Laval.

NOTE

Article numbers are to be found in the Spare part manual ESE03339, available from the on-line Alfa Laval product catalogue

Anytime or the Close at hand spare part catalogue.

79

7 Parts lists and drawings, service kits and tools

Shaft seal, type DC

7.6

Shaft seal, type DC

80

7 Parts lists and drawings, service kits and tools

Shaft seal, type DC

Parts list

Pos.

2

3

1 

4

5

6

7  ♦ 

Service kits

Qty

4

4

1

2

1

2

4

1

1

1

Denomination

DC seal

DC seal

DC seal

DC seal

Flush

Cap nut

Washer

Stud

Oil trap

O-ring

Denomination size: Ø30 size: Ø35 size: Ø40 size: Ø45

Seal kits

 Seal Kit, DC, C/SiC-C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000137 TE2613000138 TE2613000139 TE2613000140

Seal Kit, DC, C/SiC-C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000144 TE2613000145 TE2613000146 TE2613000147

 Seal Kit, DC, SiC/SiC-C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000151 TE2613000152 TE2613000153 TE2613000154

 Seal Kit, DC, SiC/SiC-C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000158 TE2613000159 TE2613000160 TE2613000161

Parts list

Pos.

1 

2

6

7  ♦ 

Service kits

Qty

2

1

1

1

1

1

2

Denomination

DC seal

DC seal

DC seal

DC seal

Flush

Oil trap

O-ring

Denomination size: Ø50 size: Ø55 size: Ø60 size: Ø70

Seal kits

 Seal Kit, DC, C/SiC-C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000141 TE2613000142 TE2613000143 9615478601

Seal Kit, DC, C/SiC-C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000148 TE2613000149 TE2613000150 9615478701

 Seal Kit, DC, SiC/SiC-C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000155 TE2613000156 TE2613000157 9615478801

 Seal Kit, DC, SiC/SiC-C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000162 TE2613000163 TE2613000164 9615478901

NOTE

Article numbers are to be found in the Spare part manual ESE03339, available from the on-line Alfa Laval product catalogue

Anytime or the Close at hand spare part catalogue.

81

7 Parts lists and drawings, service kits and tools

Shaft seal type S1

7.7

Shaft seal, type S1

82

7 Parts lists and drawings, service kits and tools

Shaft seal type S1

Parts list

Pos.

1 

2

3 

 ♦

4

5  ♦ 

Service kits

Qty

1

1

1

1

1

2

Denomination

S1 seal

Ring, retainer

O-ring, FPM

O-ring, EPDM

Oil / Fluid trap

O-ring

Denomination size: Ø30 size: Ø35 size: Ø40 size: Ø45

Seal Kits

 Seal Kit, S1, SiC/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000050 TE2613000051 TE2613000052 TE2613000053

Seal Kit, S1, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000054 TE2613000055 TE2613000056 TE2613000057

 Seal Kit, S1, SiC/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000058 TE2613000059 TE2613000060 TE2613000061

 Seal Kit, S1, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000062 TE2613000063 TE2613000064 TE2613000065

NOTE

Article numbers are to be found in the Spare part manual ESE03339, available from the on-line Alfa Laval product catalogue

Anytime or the Close at hand spare part catalogue.

83

7 Parts lists and drawings, service kits and tools

Shaft seal type S2

7.8

Shaft seal, type S2

84

7 Parts lists and drawings, service kits and tools

Shaft seal type S2

Parts list

Pos.

1 

2

5

6

3

4

7  ♦ 

8

Service kits

Qty

1

1

4

1

2

1

2

1

Denomination

S2 seal

Ring, counter**

Pin

Ring, retainer

Screw

Oil / Fluid trap

O-ring, FPM

Spacer

Denomination size: Ø30 size: Ø40

Seal kits

 Seal Kit, S2, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000066 TE2613000068

Seal Kit, S2, SiC/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000067 TE2613000069

 Seal Kit, S2, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000070 TE2613000072

 Seal Kit, S2, SiC/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000071 TE2613000074

**Pos. 2: Welded onto shaft - maintenance must be carried out by Alfa Laval.

NOTE

Article numbers are to be found in the Spare part manual ESE03339, available from the on-line Alfa Laval product catalogue

Anytime or the Close at hand spare part catalogue.

85

7 Parts lists and drawings, service kits and tools

Shaft seal, type S3

7.9

Shaft seal, type S3

86

7 Parts lists and drawings, service kits and tools

Shaft seal, type S3

Parts list

Pos.

4

5

6

1 

2

3  ♦

Service kits

Qty

1

1

1

1

1

2

1

Denomination

S3 seal

S3 seal

Oil trap

O-ring

Locking pin

Locking plate

Screw

Denomination size: Ø30 size: Ø35 size: Ø40 size: Ø45

Seal Kits

 Seal Kit, S3, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000087 TE2613000090 TE2613000091 TE2613000093

Seal Kit, S3, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000104 TE2613000106 TE2613000107 TE2613000108

Parts list

Pos.

4

5

1 

2

3  ♦

6

Service kits

Qty

1

1

1

1

1

2

1

Denomination

S3 seal

S3 seal

Oil trap

O-ring

Locking pin

Locking plate

Screw

Denomination size: Ø50 size: Ø55 size: Ø60 size: Ø65

Seal Kits

 Seal Kit, S3, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000095 TE2613000096 TE2613000098 TE2613000099

Seal Kit, S3, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000109 TE2613000110 TE2613000112 TE2613000113

NOTE

Article numbers are to be found in the Spare part manual ESE03339, available from the on-line Alfa Laval product catalogue

Anytime or the Close at hand spare part catalogue.

87

7 Parts lists and drawings, service kits and tools

Shaft seal, type S3

88

7 Parts lists and drawings, service kits and tools

Shaft seal, type S3

Parts list

Pos.

5

6

1 

2

3  ♦

4

Service kits

Qty

1

1

1

1

1

2

1

Denomination

S3 seal,

S3 seal

Oil trap

O-ring, FPM

Locking pin

Locking plate

Screw

Denomination size: Ø70 size: Ø75 size: Ø80 size: Ø90

Seal Kits

 Seal Kit, S3, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000100 TE2613000101 TE2613000102 TE2613000103

Seal Kit, S3, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000116 TE2613000117 TE2613000118 TE2613000120

NOTE

Article numbers are to be found in the Spare part manual ESE03339, available from the on-line Alfa Laval product catalogue

Anytime or the Close at hand spare part catalogue.

89

7 Parts lists and drawings, service kits and tools

Tools

7.10

Tools

1

2

TD605-040

90

8 Appendix

Appendix

8.1

Drive unit instructions

The drive unit is supplied by sub supplier and all important installation requirement is transferred to the Agitator instruction manual. For further information regarding maintenance and storage of the drive unit please find the drive unit instruction manual by below links

For Agitators with gears please find the drive unit instruction manual by below link: https://www.nord.com/cms/en/documentation/manuals/details_1139/detail_42075.jsp

For Agitators with direct drive (motor only) please find the motor instruction manual by below link: http://www.hoyermotors.com/Catalogues-30304.htm

91

How to contact Alfa Laval

Contact details for all countries are continually updated on our website.

Please visit www.alfalaval.com to access the information directly.

© Alfa Laval Corporate AB

This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of this document to comply with all applicable intellectual property laws. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate AB will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.

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