Alfa Laval ALT Instruction manual


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Alfa Laval ALT Instruction manual | Manualzz

Instruction Manual

Alfa Laval Agitator - ALT / ALTB

ESE03504-EN10

Original manual

2022-06

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 . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

24

4.

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

25

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

25

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

26

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

27

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

27

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

28

5.

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

29

5.1. General Maintenance . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

29

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

30

5.3. Replacement of drive unit . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

32

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

34

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

35

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

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

37

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

39

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

41

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

43

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

45

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

48

5.12. Replacement of shaft seal, type S (and type S with dust trap) . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. .

51

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

55

5.14. Replacement of shaft seal, type R or G . . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

58

5.15. Replacement of shaft seal, type V .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

61

5.16. Replacement of wear bushing in intermediate bearing support .. . .. . .. .. . .. . .. . .. .. . .. . .. .. .

63

5.17. Replacement of wear bushing in bottom support . . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

64

6.

Technical Data . . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

65

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

65

6.2. Mounting angle for top mounting agitator type ALT .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

66

6.3. Mounting angle for top mounting agitator type ALTB .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

68

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

69

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

71

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

73

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

74

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

76

6.9. Bottom support alignment .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

77

6.10. Bottom support positioning . . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

78

3

Table of contents

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

6.11. Storage . .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

79

7.

Part lists, part drawings and service kits . . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .

80

7.1. Agitator Main Components, Drive end .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .

80

7.2. Agitator Main Components, Wet end . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .

82

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

84

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

88

7.5. Shaft seal, type S . .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

90

7.6. Shaft seal, type S with dust trap . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .

92

7.7. Shaft seal, type S3 .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

94

7.8. Shaft seal, type D . .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

98

7.9. Shaft seal, type DC . . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

100

7.10. Shaft seal, type R . .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

104

7.11. Shaft seal, type G . .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

108

7.12. Shaft seal, type V . .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

112

7.13. Intermediate support .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

114

7.14. Bottom support, type 3 .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

116

7.15. Tools . . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .

118

8.

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

120

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

120

4

1 EC Declaration of Conformity

Revision of Declaration of Conformity: 2018-02-01

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 / EnSaFerm

Designation

ALT(B)-ME-(GX)-BC160D(H)/30(L)F-SX-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-BC160/35(L)F-SX-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-BXX/XX(L)F-SX-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-BC160D(H)/30(L)F-D(C)-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-BC160/35(L)F-D(C)-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-BXX/XX(L)F-D(C)-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-BC160D(H)/30(L)F-R-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-BC160/35(L)F-R-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-BXX/XX(L)F-R-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-BC160D(H)/30(L)F-G-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-BC160/35(L)F-G-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-BXX/XX(L)F-G-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-ZZ(L)F-SX-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-ZZ(L)F-D(C)-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-ZZ(L)F-R-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT(B)-ME-(GX)-ZZ(L)F-G-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX)

ALT-ME-ZZF-V-SH-PXXXXDYY

Type is in conformity with the following directives:

Machinery Directive 2006/42/EC++

Regulation (EC) 1935/2004

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

Serial number from AAC000000001 to AAC999999999

Serial number from 10.000 to 100.000

Serial number from 100700000001 to 100799999999

Serial no(s)

GX = GC, GR or GP

BXX/XX = B20, B25, B25/30, B35, B35/40,

B45, B45/50, B55, B55/60

SX =

SH =

PXXXX

S, S3

S500-S15000

E125, E150, E175, E200, E225, E250, E300

E350, E400, E450, E500, E550, E600, E650

E700, E750, E800, E900, E1000, E1100

E1300, E1500, E1700, E1900

F450, F500, F550, F600, F650, F700, F750,

F800, F900, F1000, F1100, F1300, F1500

F1700, F1900

LXXXX = L600, L800, L900, L1100, L1300,

L1500, L1700

DY = D2, D3

Y =

BSXX

MSXX =

ZZ =

P, G

BS3P, BS3G

MS2P, MS2G

20, 25, 30, 35, 40, 45, 50, 55, 60, 65,

70, 75, 80, 90

Type variation

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 top mounting agitator type ALT.

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 Part lists, part drawings and service kits).

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.

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.

NOTE

If possible, lift the Agitator in horizontal position, and in two points.

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 section 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.

Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilogram and a shaft diameter between Ø30 and Ø60 (see section 7.15 Tools).

Welding flange - Flat Shaped Welding Flange (FSWF):

CAUTION

Only authorized personnel to weld in flanges.

Alfa Laval cannot be held responsible for incorrect installation.

Step 1

Dismantle the FSWF 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 section 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 ALT / ALTB:

Mv [Nm] = 23873 x P / n

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

Type ALT:

Mb [Nm] = Fs x S / 1000

Type ALTB:

Mb [Nm] = Fs x S / 5333

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 section 3.3 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Guidelines for cutting hole in tank for Flat Shaped Welding Flange (FSWF)

CAUTION

Alfa Laval recommend that all other welding tasks on the tank are finished before cutting the hole for the flange.

Chamfer inner and outer hole edge 45°.

45°

TD605-023

45°

13

3 Installation

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

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

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Welding procedure, flange (FSWF) 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

2

C

4

1

B

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.

14

3 Installation

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

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

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Welding procedure, flange (FSWF) 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

11

2

6 12

5

4

1

8

9

15

3 Installation

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

Always check the Agitator before operation - see section 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.

16

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

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

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Welding procedure for divided shaft with thread connection:

NOTE

Only relevant for divided shafts prepared for welding.

Step 1

Ensure that shaft ends are screwed completely together.

Step 2

Spot weld and cool with air.

Step 3

All-weld shaft connections 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 tension and bending to the shaft as possible.

Step 4

If shaft sleeve is used weld as described in step 3.

Step 5

Align the shaft, using heat and or bending forces according to specifications in section 6.7 Shaft alignment.

3 Installation

17

3 Installation

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

Always check the Agitator before operation - see section 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 section 6.2 Mounting angle for top mounting agitator type ALT and 6.3 Mounting angle for top mounting agitator type ALTB.

Always refer to tightening torques in section 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 section 8.1 Drive unit instructions).

III

4303-0053

I

1) Standard vent plug

2) Transport securing device

Step 2

Mount the Agitator onto the tank.

NOTE

Alfa Laval recommends using shaft retainer tool during mounting and dismantling (see section 7.15 Tools).

Step 3

(Only for ALTB machines with Intermediate steady bearing)

Mount the intermediate steady bearing onto the shaft.

Ensure before welding that the intermediate steady bearing is perpendicular to the mounting flange.

Position wear bushings according to shaft diameter.

TD605-137

18

3 Installation

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

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

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Step 4

Mount impeller device(s) onto shaft.

3 x

Hub diameter [mm]

Ø30

Ø40

Ø55, Ø80, Ø120

TD605-037

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

TD605-035

TD605-031 x 4 x 1

TD605-032

TD605-033

TD605-034

Step 5

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. -P400D3P has the letter "D" which means the flow direction is away from the drive unit. -P400U3P has the letter "U" which means the flow direction is towards the drive unit.

19

3 Installation

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

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

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Step 6

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

Further installation requirements regarding the position can be found in 6.2 Mounting angle for top mounting agitator type ALT and 6.3 Mounting angle for top mounting agitator type ALTB to ensure optimum performance.

Clearance > S/15xsin(V)

NOTE

In special cases clearance can be reduce to 20mm+actual deflection, please advice with Alfa Laval.

Step 7

(Only when shaft is divided)

Assemble all shaft parts as shown on the figure.

TD605-026

V

Clearence

Step 8

Align the shaft, using heat and or bending forces according to specifications and instructions in section 6.7 Shaft alignment.

20

3 Installation

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

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

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Step 9

(Only for ALTB machines)

Adjust legs according to tank bottom shape and position the bottom support in angle (V) according to horizontal of 12°

+/- 1.5° as illustrated.

CAUTION

If the angle is not respected an increased risk for vibration can occur.

V

4303-0162

20º

WARNING

Do NOT connect the power supply until installation is completed.

CAUTION

Follow instructions in section 8.1 Drive unit instructions

Ensure that the rotation direction is according to nameplate.

Always perform pre-use check before operation (see section 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 section 2.3 Intended use, 6.2 Mounting angle for top mounting agitator type ALT and 6.3 Mounting angle for top mounting agitator type ALTB. Check the rotation direction before operation.

3.3

Pre-use check

Never install the Agitator in environments which deviate from those given in section 2.3 Intended use and 6.1 Technical data.

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

Always make sure that the motor corresponds to the environment.

Step 1

Go through section 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*sin(V)

NOTE

In special cases clearance can be reduced to 20mm+actual deflection, please advise with Alfa Laval.

S

V

Clearence

TD605-026

Step 5

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

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 section 2.3 Intended use, 6.2 Mounting angle for top mounting agitator type ALT and 6.3 Mounting angle for top mounting agitator type ALTB. Check the rotation direction before operation.

Step 6

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

Step 7

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 section 8.1 Drive unit instructions and mounting instructions in Step 1 on page 18.

III

4303-0053

I

Step 8

(Only for agitators with bearing frame)

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

TD605-180

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 section 2.3 Intended use, 6.2 Mounting angle for top mounting agitator type ALT and 6.3 Mounting angle for top mounting agitator type ALTB. Check the rotation direction before operation.

Step 9

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

Step 10

If frequency converter drive is used, it must be ensured NOT to operate continuously within +/-20% of critical oscillation speed (see section 2.3 Intended use and 6.1 Technical data).

Step 11

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.

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.

24

4 Operation

Study the instructions carefully and pay special attention to warnings! Always check the Agitator before operation (see section 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 section 2.3 Intended use, immediately switch off the Agitator and find the cause of failure (see section 4.2 Troubleshooting).

The Agitator is designed to max 5 starts per hour.

The Agitator is normally constructed for use with the lower impeller adequately submerged in the liquid. However, the Agitator can be dimensioned for use while emptying the tank completely (see section 2.3 Intended use).

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

Shaft seal

- Radial seal: R

- Gab seal: G

- V-ring seal: V

Mechanical seal

- NOT flushed: S, S3

- Flushed: DC, D

Bearing frame

Clean PreVent screw

Check spider clearance

Check gaskets

Lubricate radial seals

Guidance

Shaft rotation - radial movement < 5mm

- Bushing: BS3

- Bushing: MS2

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 x

Monthly x x 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 x

25

4 Operation

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

- Obstructed

Shaft

- Damaged

- Unbalanced impeller

- Damage to shaft seal

- Damaged

- Large deflection

Other

Unusual noise

Bearing frame

Drive unit

Sealing

- 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 2)

- Seal surfaces stick together

Bottom support - Regular knocking sound from the support

- Irregular knocking sound from the support

Other

Leakage

Gear

Sealing

Continuously breakdown

Drive unit

Other

Performance

Drive unit

Agitator

Other

- Deviation from normal operation

- Circuit overload

- Oil leakage

- CIP fluid or other

- Defect

- Too high frequency

- Deviation from normal operation

- Wrong frequency

- Reverse direction

- Deviation from normal operation

1)

2)

See section 2.3 Intended use.

Type S and S3 are designed for dry running.

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 stricking anything

Ensure that retainer bolt has been removed

Contact Alfa Laval

Clean impeller device

Replace sealing

Contact Alfa Laval

Check angle of bottom support type BS3

Check shaft alignment

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 2)

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

Check shaft alignment.

A small movement of the shaft is to be expected in normal operation.

This is due to increased clearance for better hygienic and installation properties

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)

26

4 Operation

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

For applications with bottom support:

The bottom support is designed for a continuous operating temperature up to 121°C with O-rings material EPDM and 150°C with O-rings material FPM. The temperature for the O-rings material EPDM may go as high as 150°C for a short period of time, but the increased temperature reduces the flexibility of the O-rings and ages them over time. In these cases it is recommended, due to sanitary reasons, regularly to inspect the O-rings for eventually leakage by disassembling the bushing from the shaft.

27

4 Operation

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

-R-

-G-

-V-

-S-

-S3-

-D-

-DC-

Tank pressure [barg]

Min.

Atm.

Max.

Atm.

Atm.

Atm.

-1.0

-0.5

-1.0

-1.0

Atm.

Atm.

6.0

1.5

4.5

6.0

Designation

Radial seal, non-mechanical shaft seal

Gab seal, no sliding seal faces

Lip seal, non-mechanical shaft seal for direct drive only

Single mechanical shaft seal, High pressure and medium speed

Single mechanical shaft seal, Medium pressure and low speed

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

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

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.

28

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 section 6.6 Tightening torques for bolt connections.

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.

Otherwise it is recommended to purchase a shaft retainer tool (see section 7.15 Tools).

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 section 2.3 Intended use and chapter 6.1 Technical data.

Always refer to tightening torques in section 6.6 Tightening torques for bolt connections.

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, section 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.

3000 hour or yearly

3000 hour or every 3rd year

Replace every:

6000 hour or every 3rd year

10000 hour or every 3rd year

Sealing

Shaft seal

- Radial seal: R

- Gab seal: G

- V-ring seal: V

Mechanical seal

-NOT flushed: S, S3

-Flushed: DC, D

Bearing frame

Spider type coupling (if any)

Static seals

Radial seals

Bearings, rpm < 700

Bearings, rpm > 700

Guidance

Bushing: BS3

Bushing: MS2

Bushing: MS2 x x x x x x x

Replace if temperature > 100°C x x x x x

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 section 6.6 Tightening torques for bolt connections.

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

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 section 6.6 Tightening torques for bolt connections.

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 section 6.8 Spider coupling.

Step 7

Replace spider if necessary.

Use Loctite® 243 before fastening screws.

Always refer to tightening torques in section 6.1 Technical data when tightening bolts.

Step 8

Mount drive unit reverse as dismantling.

XX

TD605-072

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 section 6.6 Tightening torques for bolt connections.

5.3

Replacement of drive unit

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

Support shaft using shaft retainer tool.

NOTE

Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilograms and a shaft diameter between Ø30 and Ø60 (see section 7.15 Tools).

Step 4

Before dismantling drive unit, please see instructions in 5.10 Replacement of shaft seal, type D to 5.13 Replacement of shaft seal, type S3, depending on seal type.

Step 5

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

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 section 6.6 Tightening torques for bolt connections.

Step 6

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

TD605-050

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.

Step 7

Lift up the drive unit and pull it away.

2

TD605-043

1

Step 8

Replacement drive unit.

Step 9

Use Loctite® 243 before fastening screws.

Always refer to tightening torques in section 6.6 Tightening torques for bolt connections.

Step 10

Mount drive unit reverse as dismantling.

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 section 6.6 Tightening torques for bolt connections.

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 section 6.6 Tightening torques for bolt connections.

Step 7

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 section 6.6 Tightening torques for bolt connections.

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

Step 2

Support shaft using shaft retainer tool.

NOTE

Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilograms and a shaft diameter between Ø30 and Ø60 (see section 7.15 Tools).

1 Step 3

1. Dismantle drive unit as described in section 5.2 Replacement of drive unit with bearing frame.

2. Remove PreVent valve.

TD605-047

Step 4

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

TD605-048

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 section 6.6 Tightening torques for bolt connections.

Step 5

1. Mount retainer bolt tool for shaft locking.

2. Remove centre bolt.

NOTE

Extra retainer bolt tool can be acquired if needed (see section 7.15

Tools) or Spare Part Manual.

1

2

TD605-049

Step 6

Remove spider and coupling part.

2

1

43030007

Step 7

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 section

7.15 Tools or Spare Part Manual).

Step 8

Mount shaft reverse as dismantling

CAUTION

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

2

TD605-051

1

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 section 6.6 Tightening torques for bolt connections.

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

2. Remove retainer bolt in step 5 in section 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

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 section 6.6 Tightening torques for bolt connections.

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.

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 section 6.6 Tightening torques for bolt connections.

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 section 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

Step 5

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

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

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 section 6.6 Tightening torques for bolt connections.

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

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 section 6.6 Tightening torques for bolt connections.

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 section 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

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 section 6.6 Tightening torques for bolt connections.

8b Step 5

1. Pull out drive shaft (4) including bearings (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

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 section 6.6 Tightening torques for bolt connections.

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 section 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

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 section 6.6 Tightening torques for bolt connections.

Step 5

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

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

4

9

11

8

12

7

2

1

TD605-065

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

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

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 section 6.6 Tightening torques for bolt connections.

5.10

Replacement of shaft seal, type D

21

22

23

TD605-165

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

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

Support shaft using shaft retainer tool.

NOTE

Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilograms and a shaft diameter between Ø30 and Ø60 (see section 7.15 Tools).

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 section 6.6 Tightening torques for bolt connections.

Step 3

1. Remove flush connections (21).

2. Remove guards from lantern.

3

1

3

2

1

TD605-084

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. 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 6

Dismantle drive unit as described in section 5.2 Replacement of drive unit with bearing frame.

Step 7

1. Dismantle shaft as described in section 5.3 Replacement of drive unit 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.

CAUTION

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

TD605-112

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 section 6.6 Tightening torques for bolt connections.

Step 8

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

2. Remove stationary seal housing.

1

2

Step 9

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

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 section 6.6 Tightening torques for bolt connections.

5.11

Replacement of shaft seal, type DC

17

16 15

TD605-163 1

2

14

10

9

8

7

6

5

4

3

13

12

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

Support shaft using shaft retainer tool.

NOTE

Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilograms and a shaft diameter between Ø30 and Ø60 (see section 7.15 Tools).

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 section 6.6 Tightening torques for bolt connections.

Step 3

1. Remove flush connections (17).

2. Remove guards from lantern.

3

1

3

2

1

TD605-084

Step 4

1. Rotate distance pieces as shown in Step 10.

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 5

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

2

1

3

2

3

1

TD605-087

Step 6

1. Remove cap nuts, securing mounting flange.

1

2

Step 7

Dismantle shaft, as described in section 5.3 Replacement of drive unit or 5.5 Dismantling and mounting shaft (with bearing frame except BC160) depending on agitator type and carefully remove lantern.

Step 8

Lift lantern and drive unit flange.

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 section 6.6 Tightening torques for bolt connections.

Step 9

Remove DC seal.

Step 10

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

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 section 6.6 Tightening torques for bolt connections.

5.12

Replacement of shaft seal, type S (and type S with dust trap)

TD605-162

8

7

6

5

4

3

2

1

11

12

10

9

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

Seal is designed for dry running, so a whining noise during operation is quite normal.

Change seal!

Disassembled seal

NOTE

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

New seal after mounting

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 section 6.6 Tightening torques for bolt connections.

Step 1

1. Dismantle Agitator from welding flange.

2. Lift up Agitator.

1

2

TD605-075

Step 2

Support shaft using shaft retainer tool.

NOTE

Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilogram and a shaft diameter between Ø30 and Ø60 (see section 7.15 Tools).

Step 3

1. Remove guards from lantern.

2. Loosen screws, securing the rotating seal part onto the shaft.

3. Move the rotating seal part carefully along the shaft.

1

1

1

Step 4

1. Remove cap nuts.

2. Move the mounting flange, including stationary seal part, by pulling it carefully along the shaft, avoiding contact.

2

2

3

1

TD605-145

2 TD605-146

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 section 6.6 Tightening torques for bolt connections.

Step 5

5a

1. Remove screws (9).

2. Move retainer ring (3).

3. Move stationary seal part (1) and o-ring (2) from mounting flange.

1

2

3

TD605-093

5b (only for dust trap option)

1. Remove screws.

2. Move retainer ring.

3. Move stationary seal part and o-ring from mounting flange.

4. Move dust trap and o-ring from mounting flange.

1

2

4

3

4

4303-0158

Step 6

If necessary, dismantle drive unit as described in section 5.2 Replacement of drive unit with bearing frame or 5.3 Replacement of drive unit depending on agitator type.

Step 7

If necessary, dismantle shaft as described in section 5.3 Replacement of drive unit or 5.5 Dismantling and mounting shaft (with bearing frame except BC160) depending on agitator type and remove lantern with bearing frame.

Step 8

Remove oil trap ring, if any.

2

1

2

3

1

3

TD605-087

Step 9

Remove rotary seal part (4, 5, 6, 7, 8, 10, 11), by pulling it carefully along the shaft.

Step 10

1. Replace all seal parts and o-rings (2, 6, 7).

2. Assemble the new rotary seal part on the shaft, by using plenty of detergent.

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 section 6.6 Tightening torques for bolt connections.

Step 11

Assemble oil trap ring, if any.

Step 12

CAUTION

Assemble the stationary seal into the mounting flange by following instructions to the letter.

1. Ensure that pins fit onto the groove in the seal.

2. Carefully press down the stationary seal part (1, 2) and retainer ring (3) into the mounting flange.

3. Use first: DIN7984 or DIN912 M5x12 screws during assembly and afterwards: DIN7984 M5x10, DIN7984 or DIN912 M5x10 screws during assembly – The procedure is used to ensure that the retainer ring (3) is ALWAYS parallel to the mounting flange

4. Remove the M5x10 screws and assemble with original fitted screws.

Step 13

Assemble mounting flange, shaft and drive unit, following the reverse procedure of dismantling.

Step 14

Move the rotating seal part towards the stationary seal part.

1. Tighten the screws (8) securing the seal onto the shaft.

CAUTION!

The new seal must be adjusted to the “NEW SET” line.

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 section 6.6 Tightening torques for bolt connections.

5.13

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 section 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

Step 2

Support shaft using shaft retainer tool.

NOTE

Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilograms and a shaft diameter between Ø30 and Ø60 (see section 7.15 Tools).

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 section 6.6 Tightening torques for bolt connections.

Step 3

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.

TD605-127

1

2

Step 4

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 5

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

3 TD605-092

2

1

3

2

3

1

TD605-087

Step 6

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

TD605-148

Step 7

Remove all seal parts from shaft.

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 section 6.6 Tightening torques for bolt connections.

Step 8

1. Replace all seal parts.

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

Shaft size:

Ø30-Ø35, x=37.5

Ø40-Ø45, x=40.0

Ø50-Ø55, x=42.5

Ø60-Ø65, x=47.5

Ø70-Ø75, x=55.0

Ø80, x=54.0

Ø90, x=59.0

4303-0172

8

7

6

5

4

3

2

1

9

57

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 section 6.6 Tightening torques for bolt connections.

5.14

Replacement of shaft seal, type R or G

TD605-150

1

Shaft seal type R

1

Shaft seal type G

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.

2

1

TD605-075

58

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 section 6.6 Tightening torques for bolt connections.

Step 2

Support shaft using shaft retainer tool.

NOTE

Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilogram and a shaft diameter between Ø30 and Ø60 (see section 7.15 Tools).

Step 3

1. Remove guards from lantern, if any.

2. Remove cap nut from lantern or mounting flange depending on actual configuration.

3. Move the mounting flange including seal carefully along the shaft.

2

1

1

1

2

4303-0054

3

Step 4

If necessary, dismantle drive unit as described in section 5.2 Replacement of drive unit with bearing frame or 5.3 Replacement of drive unit and if required dismantle shaft as described in section 5.3 Replacement of drive unit or 5.5 Dismantling and mounting shaft (with bearing frame except BC160) depending on actual configuration.

Step 5

Remove oil trap ring, if any.

2

1

2

3

1

3

TD605-087

Step 6

Push R/G seal (1) out of the mounting flange.

TD605-082

59

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 section 6.6 Tightening torques for bolt connections.

Step 7

1. Replace R/G seal (1) by pressing it evenly into mounting flange, using a proper tool.

NOTE!

Assure correct sealing orientation.

TD605-081

Step 8

Apply some grease around the shaft at the position of the seal.

Step 9

Assemble Agitator reverse as dismantling.

TD605-080

60

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 section 6.6 Tightening torques for bolt connections.

5.15

Replacement of shaft seal, type V

1

TD605-167

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.

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

2

1

TD605-075

Step 2

Support shaft using shaft retainer tool.

NOTE

Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilograms and a shaft diameter between Ø30 and Ø60 (see section 7.15 Tools).

Step 3

1. Dismantle impeller device.

2. Pull V seal (1) along the shaft.

61

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 section 6.6 Tightening torques for bolt connections.

Step 4

1. Replace seal.

2. Assemble Agitator reverse as dismantling.

62

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 section 6.6 Tightening torques for bolt connections.

5.16

Replacement of wear bushing in intermediate bearing support

Step 1

Remove screw(s).

Remove cap nuts.

TD605-133

Step 2

1. Remove o-rings.

2. Remove wear bushings.

3. Remove o-rings.

3

2

1

TD605-134

Step 3

1. Replace wear bushing and O-rings (for MS2 type, position bushings according to shaft diameter).

2. Assemble reverse as dismantling.

TD605-137

63

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 section 6.6 Tightening torques for bolt connections.

5.17

Replacement of wear bushing in bottom support

Step 1

1. Remove screw and lower o-ring.

2. Replace o-ring.

2

1

4303-0163

Step 2

1. Remove wear bushing and upper o-ring.

2. Replace wear bushing and o-ring.

3. Assemble reverse as dismantling.

2

1

4303-0163

NOTE

Screw tightening torque max. 15Nm.

64

6 Technical Data

All dimensions 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.

65

6 Technical Data

All dimensions in mm unless otherwise stated.

6.2

Mounting angle for top mounting agitator type ALT

To ensure optimal agitation the top mounted agitator must be installed in the mounting angle specified on the name plate as shown on the illustration and in the off center position required from the Alfa Laval quotation agreement.

S: is the length of the agitator shaft including the impeller.

Y-dim: is the distance from the welding flange face surface and to the tank bottom where the center line of the agitator intersects with the tank bottom line.

66

All dimensions in mm unless otherwise stated.

6 Technical Data

67

6 Technical Data

All dimensions in mm unless otherwise stated.

6.3

Mounting angle for top mounting agitator type ALTB

To ensure optimal agitation the top mounted agitator must be installed in the mounting angle specified on the name plate as shown on the illustration and in the off center position required from the Alfa Laval quotation agreement.

P1min: is a distance to position the lower impeller to ensure agitation to the lowest fluid level as possible / required for actual application.

Y-dim: is the distance from the welding flange face surface and to the tank bottom where the center line of the agitator intersects with the tank bottom line.

43030027 43030028

43030030

43030029

68

6 Technical Data

All dimensions 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 due to the atmosphere in the tank will push the flush media out of the primary seal faces.

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

69

6 Technical Data

All dimensions 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.

70

6 Technical Data

All dimensions 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 due to the atmosphere in the tank will push the flush media out of the primary seal faces.

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

71

72

6 Technical Data

All dimensions 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

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.

6 Technical Data

All dimensions 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

73

6 Technical Data

All dimensions 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, ALT)

U (max radial tolerance, ALTB)

50

0.4

2.0

100

0.3

1.5

500

0.2

1.0

1000

0.1

2800

0.05

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.

74

6 Technical Data

All dimensions 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.

75

6 Technical Data

All dimensions 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

76

6 Technical Data

All dimensions in mm unless otherwise stated.

6.9

Bottom support alignment

Shaft alignment (radial and angle misalignment) must be according to values shown in table below.

Shaft length,

[mm]

Z, [mm], (max)

α

, [°], (+/- 1.5°)

500-1000

4

12

2000

8

12

3000

10

12

4000

12

12

5000

15

12

6000

22

12

7000

30

12

7001-15000

40

12

α

4303

-016

4

Z

77

6 Technical Data

All dimensions in mm unless otherwise stated.

6.10

Bottom support positioning

Shaft diameter, [mm]

X, Bushing height

Ø30-Ø65

65

Ø70-Ø90

75

Ensure that bushing can be removed after position and welding-in steady bearing stand: Y>X (also depending on tank bottom angle).

The distance Lx can be found in the Alfa Laval quotation agreement.

4303-0165

78

All dimensions in mm unless otherwise stated.

6.11

Storage

Store the Agitator in dry and clean environments.

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

6 Technical Data

79

7 Part lists, part drawings and service kits

Agitator type ALT / ALTB, main components - Drive end

7.1

Agitator Main Components, Drive end

80

Agitator type ALT / ALTB, main components - Drive end

7 Part lists, part drawings and service kits

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

X

1

1

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 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.

81

7 Part lists, part drawings and service kits

Agitator type ALT / ALTB, main components - Wet end

7.2

Agitator Main Components, Wet end

82

4303-0139

Agitator type ALT / ALTB, main components - Wet end

7 Part lists, part drawings and service kits

31 

40 ♦

41

42 

43 

44 

45 

46 

47 ♦

48 ♦

Parts list

Pos.

12 ♦

14 

15 

16 

28 

29 

30 

Qty

X

1

1

1

1

1-10

1-10

1

X

X

1

1

X

X

X

Denomination

O-ring

Shaft

Parrallel key

Screw

Impeller device, EnSaFoil (ESF or

ESFL), w. thread

Impeller device, EnSaFoil, (ESF or

ESFL), w. screws or welded

Impeller device, EnSaFerm,

(ESFm), w. screws or welded

Impeller device, Low level, (LLI), w. screws or welded

Shaft and coupling unit

O-ring

Welded shaft coupling

Sleeve for welded shaft coupling

Sleeve coupling

Parrallel key for sleeve coupling

Screw

Intermediate support

Bottom support, type 3

¬ 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 available from the on-line Alfa Laval product catalogue Anytime or the

Close at hand spare part catalogue.

83

7 Part lists, part drawings and service kits

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

84

7 Part lists, part drawings and service kits

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

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

Close at hand spare part catalogue.

85

7 Part lists, part drawings and service kits

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

86

7 Part lists, part drawings and service kits

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

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

Close at hand spare part catalogue.

87

7 Part lists, part drawings and service kits

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

7.4

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

88

4303-0059

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

7 Part lists, part drawings and service kits

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

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

Close at hand spare part catalogue.

89

7 Part lists, part drawings and service kits

Shaft seal, type S

7.5

Shaft seal, type S

90

7 Part lists, part drawings and service kits

Shaft seal, type S

Parts list

Pos.

4

5

1 

2

3  ♦

Service kits

Qty

2

1

1

1

1

4

Denomination

S seal

S seal

Oil trap

O-ring

Ring, retainer

Screw

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

Seal Kits

 Seal kit, S, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000040 TE2613000041 TE2613000042 TE2613000043

Seal kit, S, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000031 TE2613000032 TE2613000033 TE2613000034

Parts list

Pos.

4

5

1 

2

3  ♦

Service kits

Qty

2

1

1

1

1

4

Denomination

S seal

S seal

Oil trap

O-ring

Ring, retainer

Screw

Denomination size: Ø50 size: Ø60 size: Ø70 size: Ø80

Seal Kits

 Seal kit, S, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000045 TE2613000046 TE2613000047 TE2613000038

Seal kit, S, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000035 TE2613000036 TE2613000037 TE2613000048

Parts list

Pos.

1 

2

3  ♦

4

5

Service kits

Qty

1

4

1

1

1

2

Denomination

S seal

S seal

Oil trap

O-ring

Ring, retainer

Screw

Denomination size: Ø90

Seal Kits

 Seal kit, S, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000049

Seal kit, S, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000039

91

7 Part lists, part drawings and service kits

Shaft seal, type S with dust trap

7.6

Shaft seal, type S with dust trap

92

7 Part lists, part drawings and service kits

Shaft seal, type S with dust trap

Parts list

Pos.

5

6

7

8

1 

2

3  ♦

4

Service kits

Qty

2

1

1

1

1

4

1

1

1

Denomination

S seal

S seal

Oil trap

O-ring

Ring, retainer

Screw

Dust trap

Spacer ring

O-ring

Denomination size: Ø30 size: Ø40 size: Ø50

Seal Kits

 Seal kit, S, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000040 TE2613000042 TE2613000045

Seal kit, S, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000031 TE2613000033 TE2613000035

93

7 Part lists, part drawings and service kits

Shaft seal, type S3

7.7

Shaft seal, type S3

94

7 Part lists, part drawings and service kits

Shaft seal, type S3

Parts list

Pos.

4

5

6

1 

2

3  ♦

Service kits

Qty

2

1

1

1

1

1

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 TE2613000076 TE2613000091 TE2613000093

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

Parts list

Pos.

4

5

6

1 

2

3  ♦

Service kits

Qty

1

1

1

1

1

1

2

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

95

7 Part lists, part drawings and service kits

Shaft seal, type S3

96

7 Part lists, part drawings and service kits

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

97

7 Part lists, part drawings and service kits

Shaft seal, type D

7.8

Shaft seal, type D

98

7 Part lists, part drawings and service kits

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

1

1

2

4

4

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

99

7 Part lists, part drawings and service kits

Shaft seal, type DC

7.9

Shaft seal, type DC

100

7 Part lists, part drawings and service kits

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

1

1

1

1

2

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

101

7 Part lists, part drawings and service kits

Shaft seal, type DC

102

7 Part lists, part drawings and service kits

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: Ø80 size: Ø90

Seal kits

 Seal Kit, DC, C/SiC-C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9615479001 9615479401

Seal Kit, DC, C/SiC-C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9615479101 9615479501

 Seal Kit, DC, SiC/SiC-C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . 9615479201 9615479601

 Seal Kit, DC, SiC/SiC-C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9615479301 9615479701

103

7 Part lists, part drawings and service kits

Shaft seal, type R

7.10

Shaft seal, type R

104

7 Part lists, part drawings and service kits

Shaft seal, type R

Parts list

Pos.

1 

2

3  ♦

Service kits

Qty

1

1

1

2

Denomination

Radial seal

Radial seal

Oil trap

O-ring, FPM

Denomination size: Ø20 size: Ø25 size: Ø30 size: Ø35

Seal kits

 Seal Kit, Radial, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000001 TE2613000002 TE2613000003 TE2613000004

Seal Kit, Radial, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TE2613000190

Parts list

Pos.

1 

2

3  ♦

Service kits

Qty

1

1

1

2

Denomination

Radial seal

Radial seal

Oil trap

O-ring

Denomination size: Ø40 size: Ø45 size: Ø50 size: Ø55

Seal kits

 Seal Kit, Radial, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000005 TE2613000006 TE2613000194 TE2613000008

Seal Kit, Radial, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000192 TE2613000193 TE2613000007

105

7 Part lists, part drawings and service kits

Shaft seal, type R

106

7 Part lists, part drawings and service kits

Shaft seal, type R

Parts list

Pos.

1 

2

3 

Service kits

Qty

1

1

2

Denomination

Radial seal

Oil trap

O-ring

Denomination size: Ø60 size: Ø65 size: Ø70 size: Ø75

Seal kits

 Seal Kit, Radial, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000009 TE2613000010 TE2613000011 TE2613000012

Parts list

Pos.

1 

2

3 

Service kits

Qty

1

1

2

Denomination

Radial seal

Oil trap

O-ring

Denomination size: Ø80 size: Ø90

Seal kits

 Seal Kit, Radial, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000013 TE2613000014

107

7 Part lists, part drawings and service kits

Shaft seal, type G

7.11

Shaft seal, type G

108

7 Part lists, part drawings and service kits

Shaft seal, type G

Parts list

Pos.

1 

2

3  ♦

Service kits

Qty

1

1

1

2

Denomination

Gab seal

Gab seal

Oil trap

O-ring

Denomination size: Ø20 size: Ø25 size: Ø30 size: Ø35

Seal kits

 Seal Kit, Gap, PTFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000015 TE2613000016 TE2613000017 TE2613000018

Seal Kit, Gap, PTFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TE2613000195

Parts list

Pos.

1 

2

3  ♦

Service kits

Qty

1

1

1

2

Denomination

Gab seal

Gab seal

Oil trap

O-ring

Denomination size: Ø40 size: Ø45 size: Ø50 size: Ø55

Seal kits

 Seal Kit, Gap, PTFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000019 TE2613000020 TE2613000198 TE2613000022

Seal Kit, Gap, PTFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000196 TE2613000197 TE2613000021

109

7 Part lists, part drawings and service kits

Shaft seal, type G

110

7 Part lists, part drawings and service kits

Shaft seal, type G

Parts list

Pos.

1 

2

3 

Service kits

Qty

1

1

2

Denomination

Gab seal

Oil trap

O-ring

Denomination size: Ø60 size: Ø65 size: Ø70 size: Ø75

Seal kits

 Seal Kit, Gap, PTFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000023 TE2613000024 TE2613000025 TE2613000026

Parts list

Pos.

1 

2

3 

Service kits

Qty

1

1

2

Denomination

Gab seal, PTFE

Oil trap

O-ring, FPM

Denomination size: Ø80 size: Ø90

Seal kits

 Seal Kit, Gap, PTFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000027 TE2613000028

111

7 Part lists, part drawings and service kits

Shaft seal, type V

7.12

Shaft seal, type V

112

7 Part lists, part drawings and service kits

Shaft seal, type V

Parts list

Pos.

1

Service kits

Qty

1

Denomination

Lib seal (V)

Denomination size: Ø20 size: Ø25 size: Ø35

Service kits a Lip seal (V), FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2601000229 TE2601000229 TE2601000363

113

7 Part lists, part drawings and service kits

Intermediate support

7.13

Intermediate support

114

7 Part lists, part drawings and service kits

Intermediate support

Parts list

Pos.

1

2 

3 

4 

5

Service kits

Qty

1

3

3

3

3

Denomination

Intermediate steady support

Bushing

O-ring

O-ring

Nut

Denomination size:

Ø35/Ø40/Ø50 size:

Ø55/Ø65/Ø75 size:

Ø60/Ø70/Ø80

Spare part kits

 Spare part kit, ISB, EPDM/FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613079680 TE2613222920 TE2613222930

115

7 Part lists, part drawings and service kits

Bottom support, type 3

7.14

Bottom support, type 3

1

2

3

4

5

4303-0166

116

7 Part lists, part drawings and service kits

Bottom support, type 3

Parts list

Pos.

1

2  ♦

3 

4 

5

Service kits

Qty

1

1

1

1

1

1

1

Denomination

Bottom support

Bushing

O-ring

O-ring

O-ring

O-ring

Screw

Denomination size:

Ø30/Ø35/

Ø40Ø45 size:

Ø50/Ø55/

Ø60/Ø65 size:

Ø70/Ø75/

Ø80/Ø90

Spare part kit, BS3, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9615411604 9615411605 9615411606

Spare part kit, BS3, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9615411601 9615411602 9615411603

117

7 Part lists, part drawings and service kits

Tools

7.15

Tools

To assist installation and maintenance of the Agitator, an original Alfa Laval Shaft Retainer is available. Once the bolts are tightened the shaft is retained by a well-defined torque leaving no doubt about safety. The amterial used protects the polished surface against scratching.

A very useful tool during maintenance of the Agitator.

Designed to support Agitator at a weight up to 500 kilogram.

Description

Shaft diameter between Ø30 and Ø60

Item no.

TE2608084880

TD605-173

TD605-039

Shaft retainer - mounting instructions:

WARNING

Ensure no personnel inside tank.

TD605-176

CAUTION

Ensure weight of Agitator is no higher than 500 kilogram.

Step 1

Dismantle back plate by loosen both screws on the shaft retainer.

1

1

TD605-177

118

TD605-174

2

Tools

Step 2

1. Dismantle Agitator from welding flange.

2. Lift up Agitator.

Step 3

Tighten both of the screws on the shaft retainer tool equal.

CAUTION

Ensure that the springs are completely compressed.

7 Part lists, part drawings and service kits

2

1

TD605-075

TD605-175

1

2

TD605-040

119

8 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/manuals.jsp

and select document "Gear Units and Geared Motor B1000".

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

120

121

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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