Alfa Laval ALT Instructions


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Alfa Laval ALT Instructions | Manualzz

Instruction Manual

Alfa Laval Agitator ALT - ATEX

100000068-EN5

Original manual

2020-02

4303-0119

Table of contents

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

1.

EC/EU Declaration of Conformity . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

4

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

21

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

22

4.

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

23

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

23

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

24

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

25

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

25

5.

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

26

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

26

5.2. Replacement of drive unit .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

27

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

29

6.

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

32

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

32

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

33

6.3. Specific conditions for safe use . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

34

6.4. Tightening torques for bolt connections .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

37

6.5. Shaft alignment .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

37

6.6. Support bearing alignment . . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

39

6.7. Use of frequency converter drive (VLT) . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

40

6.8. Storage . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

41

7.

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

42

7.1. Agitator ALT ATEX, marking II 1/2G... or II 1/2D...

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

42

7.2. Agitator ALT ATEX, marking II 2G... or II 2D...

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

46

7.3. Agitator ALT ATEX, shaft divided, marking II 1/2G... or II 1/2D...

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

50

7.4. Agitator ALT ATEX, shaft divided, marking II 2G... or II 2D...

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

54

7.5. Tools . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

58

8.

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

60

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

60

3

1 EC/EU Declaration of Conformity

Revision of Declaration of Conformity: 2019-10-01

The Designated Company

Alfa Laval Kolding A/S

Company name hereby declare that

Agitator - EnSaFoil / EnSaFerm

Designation

ALT-ME-GR-30_50LLF-S-SD...

ALT-ME-GP-30_50LLF-S-SD...

ALT-ME-GR-30_90LLF-S-...

ALT-ME-GP-30_90LLF-S-...

Type

Albuen 31, DK-6000 Kolding, Denmark

Address

II 1/2G

Ex h IIB T4 Ga/Gb

II 1/2D

Ex h IIIB T1 35 °C Da/Db

Agitator marking options

+45 79 32 22 00

Phone no.

Serial number from AAC000000001 to AAC999999999

Serial number from 100700000001 to 100799999999

Serial nos.

is in conformity with Machinery Directive 2006/42/EC and the following harmonized standard is used:

DS/EN ISO 12100:2011 Safety of Machinery - Risk Assessment is in conformity with (Ex/ATEX) Directive 2014/34/EU

The following harmonised standards and regulations have been applied for non-electrical equipment for ATEX:

- EN ISO 80079-36: 2016 Basic method and requirements

- EN ISO 80079-37: 2016 Protection by constructional safety ’c’ and control of ignition source ’b’

ATEX directive 2014/34/EU conformity for the gear motor unit and the mechanical shaft seal is covered by the relevant EU Type examination and declaration supplied by the manufacturer.

The QAN (Quality Assurance Notification) is carried out by SGS Fimko Oy, Särkiniementie 3, Helsinki 00211, Finland. Notified Body no. 0598.

EU Type Examination Certificate no. DTI18ATEX0096X_Rev.01.

EU Type Examination Certification is carried out by Teknologisk Institut, Kongsvang Allé 29, 8000 Aahus C, Denmark. Certification Body no. 0396.

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

Kolding

Place

2020-02-01

Date (YYYY-MM-DD)

Lars Kruse Andersen

Name

Signature

4

1 EC/EU Declaration of Conformity

Revision of Declaration of Conformity: 2019-10-01

The Designated Company

Alfa Laval Kolding A/S

Company name hereby declare that

Agitator - EnSaFoil / EnSaFerm

Designation

ALT-ME-GR-30_50LLF-S-SD...

ALT-ME-GP-30_50LLF-S-SD...

ALT-ME-GR-30_90LF-S-...

ALT-ME-GP-30_90LF-S-...

Type

Albuen 31, DK-6000 Kolding, Denmark

Address

II 2G

Ex h IIB T4 Gb

II 2D

Ex h IIIB T1 35°C Db

Agitator marking options

+45 79 32 22 00

Phone no.

Serial number from AAC000000001 to AAC999999999

Serial number from 100700000001 to 100799999999

Serial nos.

is in conformity with Machinery Directive 2006/42/EC and the following harmonized standard is used:

DS/EN ISO 12100:2011 Safety of Machinery - Risk Assessment is in conformity with (Ex/ATEX) Directive 2014/34/EU

The following harmonised standards and regulations have been applied for non-electrical equipment for ATEX:

- EN ISO 80079-36: 2016 Basic method and requirements

- EN ISO 80079-37: 2016 Protection by constructional safety ’c’ and control of ignition source ’b’

ATEX directive 2014/34/EU conformity for the gear motor unit and the mechanical shaft seal is covered by the relevant EU Type examination and declaration supplied by the manufacturer.

The Agitator technical file is stored with: Teknologisk Institut, Kongsvang Allé 29, 8000 Aarhus C, Denmark

Certification body no.: 0396. Archive no.: 2018-2-0291A

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

Kolding

Place

2020-02-01

Date (YYYY-MM-DD)

Lars Kruse Andersen

Name

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 6.1 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.

Always follow drive unit installation instruction thoroughly (see chapter 8 Appendix).

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.

Always ensure that the Agitator has sufficient cooling around the lantern, may not be wrapped with isolating materials.

Ensure that installation is in accordance with EN 60079-14.

Beware of ignition temperature can be decreased when enclosed by the equipment/tank (see EN 14522).

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

!

OPERATION:

Always read the technical data thoroughly (see chapter 6.1 Technical data).

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

Always make sure that the Agitator corresponds to the category marked on the name plate:

Gas atmosphere:

Dust atmosphere:

II 1/2G

Ex h IIB T4 Ga/Gb or

II 1/2D

Ex h IIIB T1 35 °C Da/Db or

II 2G

Ex h IIB T4 Gb

II 2D

Ex h IIIB T1 35°C Db

Never start Agitator in the wrong rotation direction.

Never use the Agitator for hybrid mixture.

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 6.1 Technical data).

Beware of static electricity risk when the media conductivity is below 1000pS/m. (Recommendations: CLC/TR

50404 or IEC/TS60079-32).

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

!

MAINTENANCE:

Always read the technical data thoroughly (see chapter 6.1 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 replace ATEX Agitator with other type of Alfa Laval Agitator.

Ensure that maintenance is in accordance with relevant standards EN 60079-17 and EN 60079-19.

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

Always disconnect the power supply while servicing the Agitator.

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.

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

!

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 6.1 Technical data).

Only install this Agitator in mounting angle according to the name plate (see chapter 6.1 Technical data for illustration).

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 7.5 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 3 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

1

2

C

4

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.

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 11 5

3 1

7 9

TD605-216

10 8

2 4

6 12

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

2

C

Cool with air!

5

C

Cool with air!

C

Cool with air!

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 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 6.5 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.

Always refer to tightening torques in section 6.4 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 7.5 Tools).

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 3

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.

TD60

5-036

TD605-0

35

TD605-031 x 4 x 1

TD605-03

2

TD605-033

TD605-034

Step 4

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

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 5

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 to ensure optimum performance.

Clearence > S/15xsin(V)

Clearence

V

NOTE!

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

TD605-026

Step 6

Align the shaft, using heat and or bending forces according to specifications and instructions in section 6.5 Shaft alignment.

Step 7

NOTE! Only relevant when shaft is divided with a threaded coupling.

Ensure that the two screws are screwed in tightly. Maximum torque 11Nm.

4303-0159

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.

20

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. Check the rotation direction before operation.

3.3

Pre-use check

Always make sure that the ATEX category stated on the Agitator name plate corresponds with the environment it is installed in.

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 6.5 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.

Clearence > S/15*sin(V)

NOTE!

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

S

Clearence

V

TD605-026

Step 5

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 section 3.2 Installation).

Position (II) refers to power cord entry location.

III

4303-0053

I

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. Check the rotation direction before operation.

Step 6

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

Step 7

If frequency converter drive is used the speed must be monitored according to section 6.7 Use of frequency converter drive

(VLT). It must be ensured NOT to operate continuously within +/- 20% of critical oscillation speed.

(The critical oscillation speed can be found in the supplied Alfa Laval quotation agreement. In any doubt please advise with Alfa

Laval).

Step 8

Check forces FR2, FA2 and XR2 applied to the gear box are higher or equal to the value listed in the supplied ATEX addendum.

NOTE!

Please pay special attention to the stated maintenance interval

(MI) of the gear box.

The gear can have a shorter live time than the agitator.

The axial force FA2 is depended on the density of the media and must therefore not be higher than the density stated in the ATEX addendum.

If frequency converter drive is used please pay special attention to the maximum motor speed n1 stated on the gear box.

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.

22

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

Inspect / Clean / Lubricate

Drive unit

Motor

- Clean surfaces - to avoid overheating

Gear

- Clean vent screw (if any)

- Check for oil leakage

- Check temperature sticker

Flange

Clean drain

Sealing

Mechanical seal

- NOT flushed: S

Impeller device

Sticky media

- Clean impeller device

Abrasive media

- Check blade thickness*

Check fastening of pointed set screws

Bearing

- Check bearing aligment (Only when Zone

0 or 20)

Supplier instruction x x

Weekly x x x x x

Monthly 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

23

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

Vibrations

Impeller device

Shaft

Other

Unusual noise

Drive unit

- Obstructed

- Damaged

- Unbalanced impeller

- Damage to shaft seal

- Damaged

- Deviation from normal operation

- Increased / decreased temperature

Sealing

- Defect

- Bearing gap

- Increased / decreased power

- No grease

- Wear sealing

- Seal are not flushed 2)

- Seal surfaces stick together

Other - Deviation from normal operation

- Circuit overload

Leakage

Gear

Sealing

Continuously breakdown

Drive unit

- Oil leakage

- CIP fluid or other

- Defect

- Too high frequency

- Deviation from normal operation Other

Performance

Drive unit

Agitator

Other

- Wrong frequency

- Reverse direction

- Deviation from normal operation

1) See section 2.3 Intended use.

2) 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

Contact Alfa Laval

Clean impeller device

Replace sealing

Contact Alfa Laval

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

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

Operation circumstances must be equal to those it was designed for

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

Check frequency connection

Inspect the Agitator carefully

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

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).

4.3

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.

Ensure that the mechanical seal are regular cleaned for dust as described in section 6.3 Specific conditions for safe use.

Ensure that the clearance between the support bearing and the shaft are regular cleaned for dust to prevent unnecessary action

on the support bearing as described in section 6.6 Support bearing alignment.

4.4

Temperature limits

The media temperature can be reduced depending on the operating condition and must not exceed the limits described in

section 6.3 Specific conditions for safe use.

The highest allowable ambient temperature is 40°C.

25

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6.1

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always

refer to tightening torques in section 6.4 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.

Ensure nonexplosive atmosphere 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 7.5 Tools).

For lifting instruction, please refer to chapter 3 Installation.

Always read the technical data thoroughly (see chapter 6.1 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 6.4 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.

Sealing

Mechanical seal

-NOT flushed: S

Drive unit

Gear box

500 hour or yearly

1000 hour or yearly

Replace every:

3000 hour or yearly

3000 hour or every 3rd year

6000 hour or every 3rd year x

According to gear box name plate

26

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6.1

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always

refer to tightening torques in section 6.4 Tightening torques for bolt connections.

5.2

Replacement of drive unit

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 7.5 Tools).

Step 3

Before dismantling drive unit, please see instructions in 5.3 Replacement of shaft seal, type S (and type S with dust trap).

Step 4

Loosen cap nuts.

CAUTION!

If dismantling motor from gear:

Follow supplier instructions

Ensure that the gear oil is contained

A cog wheel may be mounted onto the motor shaft.

1

TD605-042

2

Step 5

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

TD605-050

27

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6.1

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always

refer to tightening torques in section 6.4 Tightening torques for bolt connections.

Step 6

Lift up the drive unit and pull it away.

2

1

TD605-043

Step 7

Replacement drive unit.

Step 8

Use Loctite® 243 before fastening screws.

Always refer to tightening torques in section 6.4 Tightening torques for bolt connections.

Step 9

Mount drive unit reverse as dismantling.

28

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6.1

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always

refer to tightening torques in section 6.4 Tightening torques for bolt connections.

5.3

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.

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

Step 1

1. Dismantle Agitator from welding flange.

2. Lift up Agitator.

New seal after mounting

1

2

TD605-075

29

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6.1

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always

refer to tightening torques in section 6.4 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 7.5 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

Step 5

1. Remove screws.

2. Move retainer ring.

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

Step 6

If necessary, dismantle drive unit as described in section 5.2 Replacement of drive unit.

2

1

TD605-146

2

3

TD605-093

30

5 Maintenance

For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6.1

Technical data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always

refer to tightening torques in section 6.4 Tightening torques for bolt connections.

Step 7

Remove oil trap ring, if any.

2

1

3

2

3

1

TD605-087

Step 8

Remove rotary seal part, by pulling it carefully along the shaft.

Step 9

1. Replace all seal parts and o-rings.

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

Step 10

Assemble oil trap ring, if any.

Step 11

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 and retainer ring 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 is ALWAYS parallel to the mounting flange

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

Step 12

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

Step 13

Move the rotating seal part towards the stationary seal part.

1. Tighten the screws securing the seal onto the shaft.

CAUTION!

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

31

6 Technical data

All dimenstions in mm unless otherwise stated.

6.1

Technical data

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

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

32

6 Technical data

All dimenstions 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.

33

6 Technical data

All dimenstions in mm unless otherwise stated.

6.3

Specific conditions for safe use

- The mechanical shaft seal operating limits is pressure and temperature depended according to below table and must not be exceeded.

Table 1. Maximum speed for marking: II 1/2G Ex h IIB T4 Ga/Gb and II 1/2D Ex h IIIB T135°C Da/Db

Øshaft

Ø30

Ø40

Ø50

Ø60

Ø70

Ø80

Ø90

80

420

420

300

300

240

240

195

0,5

90

350

350

250

250

200

200

165

45

300

300

240

240

180

180

150

60

200

200

160

160

120

120

100

6,0

80

150

150

120

120

90

90

75

90

125

125

100

100

75

75

60

Pressure max. [Barg]

Media temp. max. [°C]

Max. speed [rpm]

Table 2. Maximum speed for marking: II 2G Ex h IIB T4 Gb and II 2D Ex h IIIB T135°C Db

Øshaft

Ø30

Ø40

Ø50

Ø60

Ø70

Ø80

Ø90

80

560

560

400

400

320

320

260

0,5

90

490

490

350

350

280

280

225

80

300

300

240

240

180

180

150

6,0

90

250

250

200

200

150

150

125

Pressure max. [Barg]

Media temp. max. [°C]

Max. speed [rpm]

34

6 Technical data

All dimenstions in mm unless otherwise stated.

NOTE

Regular cleaning of the mechanical seal is required when a dust atmosphere is present.

It must be ensured that the seal face pos. 4 can move freely to ensure correct alignment between the seal faces (pos. 4 and pos. 1).

High dust accumulation on the thrust ring pos. 12 can prevent the seal face pos. 4 to move freely which then can lead to an ignition source. Regular cleaning with pressurized air or vacuum must therefore be ensured. The interval of cleaning is depended on the operating environment and must be tested and defined by the user before commissioning.

8

7

6

5

4

3

2

1

11

12

10

9

TD605-162

The gear box ATEX validation is depended on the forces applied to it and must therefore have values for FR2, FA2 and XR2 stated on the gear box name plate that are higher or equal to the values from the supplied ATEX addendum. See picture example of the gear box name plate below.

NOTE

The axial force FA2 is depended on the density of the media and must therefore not be higher than the density stated in the ATEX addendum.

The position of the impellers (S1-S10) have great impact on the critical oscillation speed and must therefore be according to the supplied ATEX addendum.

If the lowest impeller is mounted with a threaded hub the maximum distance to the tank bottom Hmax from the ATEX addendum must not be exceeded. If Hmax = N/A then the impeller must be welded to the shaft or mounted with 4 pointed set screws. This is to ensure the single impact energy level don’t reach a level of 10J where a potential ignition source can become effective.

Operating with variable speed please pay special attention to section 6.7 Use of frequency converter drive (VLT).

35

6 Technical data

All dimenstions in mm unless otherwise stated.

36

4303-0123

6 Technical data

All dimenstions in mm unless otherwise stated.

6.4

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

6.5

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

37

6 Technical data

All dimenstions in mm unless otherwise stated.

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.

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.

38

6 Technical data

6.6

Support bearing alignment

The inner ring and the outer ring of the bearing MUST be aligned at all times during operation. This is checked by the alignment of the red line

(1) marked on the bearing inside the lantern.

The Agitator must NOT resume operation if the bearing is out of alignment, before the cause of misalignment has been established and corrected.

Before re-commissioning, the support bearing must be checked for grease loss and must be able to turn freely. Sign of grease loss could indicate that the rubber seals in the bearing are warn out and the bearing must be replaced.

In doubt cases Alfa Laval recommends to replace the bearing.

The support bearing must be replaced if it has run in the state "out of alignment" for more than 600h. If the running period is less than 500h the support bearing can be reset and continue operation.

CAUTION!

The cause of misalignment in the support bearing can be due to worn out bearings in the gearbox. If this is the case, the Agitator cannot be re-commissioned before the gearbox has been replaced.

Dust accumulation can also cause misalignment. All dust must therefore be removed during the inspection before resuming operation.

4303-0122

39

6 Technical data

6.7

Use of frequency converter drive (VLT)

CAUTION!

The speed of the agitator must be monitored if frequency converter drive (VLT) is installed to regulate the speed.

When the motor is controlled by a frequency converter, the manual from the motor manufacturer and the information in the certificate for the motor shall be followed. Temperature monitoring devices must meet the requirements in the directive

2014/34/EU and EN1127-1.

In additional for the speed of agitator EnSaFoil, the operating limits “Critical speed” according to the ATEX addendum must not be exceeded.

NOTE!

The build in function in the frequency converter cannot be used for that.

If the operating limits is to be exceeded it can lead to an ignition source coming affective, either by large deflection of the shaft, resulting in mechanical contact to the tank wall, or by heat buildup in the mechanical shaft seal, resulting in exceeding the assigned temperature class of the product.

Equipment protective level / safety devices

The Equipment protective level (EPL) has to be realized and integrated completely in the ignition protection system according to the Directives 2014/34/EU, EN ISO 80079-37, §6 and EN ISO 80079-36. The system shall be evaluated and may marked “b2” according to EN ISO 80079-37, §6.

The functions of these ignition protective systems have to be checked before start-up according to the manual from the manufacturer of the system.

The Equipment protection level (EPL) for the monitoring have to meet the demands of EN ISO 80079-37, §6. The functions of these systems have to be checked regularly by the user, according to the manual from the manufacturer of the system.

The reaction time of the ignition protection system must not exceed 2 seconds.

- The reaction time is the period between reaching the shut-down value and until the power is shut-off of the machine.

Required measures of the end user to eliminate ignition hazards:

With a zone 0/20 inside the tank and zone 1/21 outside, the speed of the agitator has to be monitored with an EPL, corresponding to b2 or two b1 according to EN ISO 80079-37, §6.

With a zone 1/21 inside and outside the tank the speed of the agitator has to be monitored with an EPL, corresponding to b1 according to EN ISO 80079-37, §6.

With a zone 2/22 inside and outside the tank no further measures needs to be taken.

If the agitator is supplied with an incremental encoder attached to the motor shaft, it may be used as one of the two independent control measure devices b1. In regard to b2 a second control measure device must be applied and the complete EPL must be assessed acc. to the Directives 2014/34/EU, EN ISO 80079-37, §6 and EN ISO 80079-36.

40

6.8

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

41

7 Part lists, part drawings and service kits

Agitator ALT ATEX, marking II 1/2G... or II 1/2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

7.1

Agitator ALT ATEX, marking II 1/2G... or II 1/2D...

4303-0149

42

7 Part lists, part drawings and service kits

Agitator ALT ATEX, marking II 1/2G... or II 1/2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

Parts list

Pos.

Imp1

Imp2-Imp10

37

38

39

40

41

22

23

24

25

36

4

5

6

12

13

14

109

125

126

127

128

130

142

58

85  ♦ ▲

86

87

90

91

108

155

156

157

158

159

160

161

162

163

164

143

146

147

153

154

Service kits

Qty Denomination

4

16

16

1

1

1

1

1

1

8

1

1

1

1

1

4

4

4

4

2

Impeller device, EnSaFoil

(E125-E1900, D2(L), D3(L)) or

Low Level (L600-L1700) or

EnSaFerm (F450-F1900)

Impeller device, EnSaFoil

(E250-E1900, D2, D3) or

EnSaFerm (F450-F1900)

GR gear motor, hollow shaft

GP gear motor, hollow shaft

Shaft

Drive unit flange

8

8

4

4

1

1

1

1

4

1

2

1

Screw

Disc spacer

Cap nut

Washer

Stud

Screw

Lantern, complete

Stud

Stud

Stud

Cap nut

O-ring

Mounting flange

S seal

Ring, retainer

Screw

Oil trap

O-ring

O-ring

4/Imp Screw

1 Name plate

4

1

4

1

1

1

1

Rivet

Name plate

Rivet

Parallel key

Welding flange (Ø134)

Welding flange

1

1

1

Fixing element

Screw

Circlip, inner

Bearing

Flange, collision protection 1

8

1

Stud

Spring, ring

Guard

Screw

Cap nut

O-ring

Sleeve

Drive ring, stationary

O-ring

Denomination size: Ø30 size: Ø40 size: Ø50 size: Ø60

Seal kits

 Seal kit, S, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000114 TE2613000073 TE2613000119 TE2613000184

Seal kit, S, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000176 TE2613000097 TE2613000089 TE2613000088

▲ Seal kit, S, C/SiC, FFKM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000302 TE2613000314 9615453801 9615453901

43

7 Part lists, part drawings and service kits

Agitator ALT ATEX, marking II 1/2G... or II 1/2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

Service kits

Denomination size: Ø70 size: Ø80 size: Ø90

Seal kits

 Seal kit, S, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000206 TE2613000094 TE2613000092

Seal kit, S, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000207 TE2613000182 TE2613000211

▲ Seal kit, S, C/SiC, FFKM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9615454001 9615454101 9615454201

Parts marked with  ♦ ▲ are included in the service kits.

44

7 Part lists, part drawings and service kits

Agitator ALT ATEX, marking II 1/2G... or II 1/2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

This page is intentionally left blank

45

7 Part lists, part drawings and service kits

Agitator ALT ATEX, marking II 2G... or II 2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

7.2

Agitator ALT ATEX, marking II 2G... or II 2D...

4303-0150

46

7 Part lists, part drawings and service kits

Agitator ALT ATEX, marking II 2G... or II 2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

Parts list

Pos.

Imp1

143

146

147

157

158

159

160

109

125

126

127

128

130

142

58

85  ♦ ▲

86

87

90

91

108

37

38

39

40

41

22

23

24

25

36

4

5

6

12

13

14

163

164

Imp2-Imp10

Qty Denomination

1

1

8

1

1

1

1

1

4

4

4

4

2

Impeller device, EnSaFoil

(E125-E1900, D2(L), D3(L)) or

Low Level (L600-L1700) or

EnSaFerm (F450-F1900)

Impeller device, EnSaFoil

(E250-E1900, D2, D3) or

EnSaFerm (F450-F1900)

GR gear motor, hollow shaft

GP gear motor, hollow shaft

Shaft

Drive unit flange

8

8

4

4

1

1

1

1

4

1

2

1

Screw

Disc spacer

Cap nut

Washer

Stud

Screw

Lantern, complete

Stud

Stud

Stud

Cap nut

O-ring

Mounting flange

S seal

Ring, retainer

Screw

Oil trap

O-ring

O-ring

2

8

8

1

1

4/Imp Screw

1 Name plate

4

1

4

1

1

1

1

Rivet

Name plate

Rivet

Parallel key

Welding flange (Ø134)

Welding flange

Fixing element

Screw

Spring, ring

Guard

Screw

Cap nut

12

1

1

Cap nut

Drive ring, stationary

O-ring

47

7 Part lists, part drawings and service kits

Agitator ALT ATEX, marking II 2G... or II 2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

Service kits

Denomination size: Ø30 size: Ø40 size: Ø50 size: Ø60

Seal kits

 Seal kit, S, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000114 TE2613000073 TE2613000119 TE2613000184

Seal kit, S, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000176 TE2613000097 TE2613000089 TE2613000088

▲ Seal kit, S, C/SiC, FFKM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000302 TE2613000314 9615453801 9615453901

Service kits

Denomination size: Ø70 size: Ø80 size: Ø90

Seal kits

 Seal kit, S, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000206 TE2613000094 TE2613000092

Seal kit, S, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000207 TE2613000182 TE2613000211

▲ Seal kit, S, C/SiC, FFKM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9615454001 9615454101 9615454201

48

7 Part lists, part drawings and service kits

Agitator ALT ATEX, marking II 2G... or II 2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

This page is intentionally left blank

49

7 Part lists, part drawings and service kits

Agitator ALT ATEX, shaft divided, marking II 1/2G... or II 1/2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

7.3

Agitator ALT ATEX, shaft divided, marking II 1/2G... or II 1/2D...

4303-0160

50

7 Part lists, part drawings and service kits

Agitator ALT ATEX, shaft divided, marking II 1/2G... or II 1/2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

Parts list

Pos.

Imp1

37

38

39

40

41

22

23

24

25

36

4

5

6

12

13

14

109

125

126

127

128

130

142

58

85  ♦ ▲

86

87

90

91

108

155

156

157

158

159

160

161

162

163

143

146

147

153

154

164

166

167

168

Imp2-Imp10

Qty Denomination

1

1

1

1

4

1

2

1

8

8

4

4

1

1

8

1

1

1

1

1

4

4

4

4

2

Impeller device, EnSaFoil

(E125-E1900, D2(L), D3(L)) or

Low Level (L600-L1700) or

EnSaFerm (F450-F1900)

Impeller device, EnSaFoil

(E250-E1900, D2, D3) or

EnSaFerm (F450-F1900)

GR gear motor, hollow shaft

GP gear motor, hollow shaft

Shaft divided

Drive unit flange

Screw

Disc spacer

Cap nut

Washer

Stud

Screw

Lantern, complete

Stud

Stud

Stud

Cap nut

O-ring

Mounting flange

S seal

Ring, retainer

Screw

Oil trap

O-ring

O-ring

4

16

16

1

1

1

4/Imp Screw

1 Name plate

4

1

4

1

1

1

1

Rivet

Name plate

Rivet

Parallel key

Welding flange (Ø134)

Welding flange

1

1

1

Fixing element

Screw

Circlip, inner

Bearing

Flange, collision protection 1

8

1

Stud

Spring, ring

Guard

Screw

Cap nut

O-ring

Sleeve

Drive ring, stationary

2

2

1

1

O-ring

O-ring

O-ring

Screw

51

7 Part lists, part drawings and service kits

Agitator ALT ATEX, shaft divided, marking II 1/2G... or II 1/2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

Service kits

Denomination size: Ø30 size: Ø40 size: Ø50

Seal kits

 Seal kit, S, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000114 TE2613000073 TE2613000119

Seal kit, S, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000176 TE2613000097 TE2613000089

▲ Seal kit, S, C/SiC, FFKM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000302 TE2613000314 9615453801

52

7 Part lists, part drawings and service kits

Agitator ALT ATEX, shaft divided, marking II 1/2G... or II 1/2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

This page is intentionally left blank

53

7 Part lists, part drawings and service kits

Agitator ALT ATEX, shaft divided, marking II 2G... or II 2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

7.4

Agitator ALT ATEX, shaft divided, marking II 2G... or II 2D...

4303-0161

54

7 Part lists, part drawings and service kits

Agitator ALT ATEX, shaft divided, marking II 2G... or II 2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

Parts list

Pos.

Imp1

163

164

166

167

168

143

146

147

157

158

159

160

109

125

126

127

128

130

142

58

85  ♦ ▲

86

87

90

91

108

37

38

39

40

41

22

23

24

25

36

4

5

6

12

13

14

Imp2-Imp10

Qty Denomination

12

1

1

1

2

2

1

1

8

1

1

1

1

1

4

4

4

4

2

Impeller device, EnSaFoil

(E125-E1900, D2(L), D3(L)) or

Low Level (L600-L1700) or

EnSaFerm (F450-F1900)

Impeller device, EnSaFoil

(E250-E1900, D2, D3) or

EnSaFerm (F450-F1900)

GR gear motor, hollow shaft

GP gear motor, hollow shaft

Shaft divided

Drive unit flange

8

8

4

4

1

1

1

1

4

1

2

1

Screw

Disc spacer

Cap nut

Washer

Stud

Screw

Lantern, complete

Stud

Stud

Stud

Cap nut

O-ring

Mounting flange

S seal

Ring, retainer

Screw

Oil trap

O-ring

O-ring

2

8

8

1

1

4/Imp Screw

1 Name plate

4

1

4

1

1

1

1

Rivet

Name plate

Rivet

Parallel key

Welding flange (Ø134)

Welding flange

Fixing element

Screw

Spring, ring

Guard

Screw

Cap nut

Cap nut

Drive ring, stationary

O-ring

O-ring

O-ring

Screw

55

7 Part lists, part drawings and service kits

Agitator ALT ATEX, shaft divided, marking II 2G... or II 2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

Service kits

Denomination size: Ø30 size: Ø40 size: Ø50

Seal kits

 Seal kit, S, C/SiC, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000114 TE2613000073 TE2613000119

Seal kit, S, C/SiC, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000176 TE2613000097 TE2613000089

▲ Seal kit, S, C/SiC, FFKM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TE2613000302 TE2613000314 9615453801

56

7 Part lists, part drawings and service kits

Agitator ALT ATEX, shaft divided, marking II 2G... or II 2D...

Note: For information on item numbers, please refer to the spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

This page is intentionally left blank

57

7 Part lists, part drawings and service kits

7.5

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

58

TD605-174

2

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

59

8 Appendix

8.1

Drive unit instructions

The drive unit instruction is supplied together with the Agitator in a separate supplier instruction manual. Important requirements for installation, operation and service is to be found in this separate instruction manual and must be follow very carefully.

The supplier instruction manual can be downloaded from www.alfalaval.com.

(http://ebusiness.alfalaval.org/alweb/view/category/1E4DC4E7-D4BB-45A2-99CF-107263F60FFB).

60

61

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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