Alfa Laval ALS Series Instruction Manual


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Alfa Laval ALS Series Instruction Manual | Manualzz

Instruction Manual

Alfa Laval Agitator - ALS Shut Down Seal

4303-0128

100000047-EN1

Original manual

2018-09

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

4

2.

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

5

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

5

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

5

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

5

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

6

3.

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

7

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

7

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

9

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

10

3.4. Guidelines for welding procedure for flange (FSWF) . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

11

3.5. Mounting Agitator . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

12

3.6. Pre-use check . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

14

3.7. Recycling information .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

15

4.

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

16

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

16

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

17

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

18

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

18

5.

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

19

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

19

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

20

5.3. Replacement of shaft seal, type S3SD . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

26

5.4. Replacement of sealing parts, complete . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

30

6.

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

38

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

38

6.2. Tightening torques for bolt connections .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

39

6.3. Storage . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

39

7.

Parts lists and service kits . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

40

7.1. Main components . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

40

7.2. Lantern, complete . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

42

7.3. Shaft seal, type S3SD . . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

44

7.4. Tools . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

46

8.

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

48

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

48

3

1 EC Declaration of Conformity

The Designated Company

Alfa Laval Kolding A/S

Company Name

Albuen 31, DK-6000 Kolding, Denmark

Address

+45 79 32 22 00

Phone No.

hereby declare that

Agitator - EnSaFoil

Designation

ALS-ME-GP-50LF-S3SD-S700-P550D3G

ALS-ME-GP-50LF-S3SD-S700-P600D3G

ALS-ME-GP-50LF-S3SD-S700-P650D3G

ALS-ME-GP-50LF-S3SD-S700-P700D3G

ALS-ME-GP-50LF-S3SD-S700-P750D3G

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

Kolding

Place

2017-10-01

Date

10.000 - 100.000

Serial no(s)

Type variation

Lars Kruse Andersen

Name

Signature

4

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.

The English version of the instruction manual is the original manual. We make reservations in regard to possible mistranslations in language versions of the instruction manual. In case of doubt, the English version of the instruction manual applies.

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 nameplate and must be followed. Definitions on mounting angles can be seen

in section 6 Technical data.

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 nameplate and you will obtain the Alfa Laval quotation agreement.

5

6

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 section 6 Technical data).

Always follow installation instructions thoroughly (see section 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 section 6 Technical data).

Always read supplier instructions thoroughly (see section 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 section 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 section 6 Technical data).

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

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

Always study the parts list and assembly drawing carefully (see section 7 Parts lists 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.

!

!

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 below).

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 section 8 Appendix)

3 Installation

Step 3

Lifting instructions:

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

Locate Centre of gravity before moving the Agitator.

2

1

TD605-100

7

3 Installation

The instructions manual is part of the delivery.

Study the instructions carefully.

TD605-103

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

TD605-101

Do NOT use eye bolts on shroud (if any) to lift the Agitator. They are only for shroud removal.

TD605-172

8

3 Installation

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

Always check the Agitator before operation - see section 3.6 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

CAUTION!

Alfa Laval highly recommend NOT to use shaft as lifting point.

TD605-104

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.

3.2

Installation

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

Only install this Agitator in mounting angle according to the nameplate (see section 6 Technical data).

Always use lifting equipment when handling the Agitator (see Step 3 in section 3.1 Unpacking/delivery).

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.

9

3 Installation

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

Always check the Agitator before operation - see section 3.6 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Step 1

Ensure that the flange will accept forces applied by the drive unit.

Torque Mv, Bending torque Mb and Side thrust Fs.

The values are depending on the chosen configuration of impeller diameter, shaft length and the torque. The values can be calculated as follows:

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

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

D: Impeller diameter according to Agitator designation -Pxxx- in [mm]

Mv [Nm] = 23873 x P / n

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

Mb [Nm] = Fs x S / 1000

Step 2

Ensure sufficient rigidity of the tank.

Ensure that the max. bending angle (A), at loads from Step 1 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

3.3

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°

10

3 Installation

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

Always check the Agitator before operation - see section 3.6 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

3.4

Guidelines for welding procedure for flange (FSWF)

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.

11

3 Installation

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

Always check the Agitator before operation - see section 3.6 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

3.5

Mounting Agitator

CAUTION!

Always ensure that mounting is carried out according to description shown in section 6 Technical data.

Always refer to tightening torques in section 6.2 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 (II) is removed (see section 8.1 Drive unit instructions).

II

I

4303-0066

Step 2

Mount the Agitator onto the tank.

1) Standard vent plug

2) Transport securing device

12

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

Always check the Agitator before operation - see section 3.6 Pre-use check.

The Agitator is for permanent fastening.

Make sure that the motor correspond to the environment.

Step 3

Mount impeller device onto shaft.

3 Installation

4303-0062 4303-0063

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. -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.

Step 5

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

Further installation requirements regarding the position can

be found in section 6 Technical data to ensure optimum

performance.

TD605-147

NOTE!

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

>

100

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 3.6 Pre-use check).

NOTE!

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

13

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 6 Technical data

Check the rotation direction before operation.

3.6

Pre-use check

Never install the Agitator in environments which deviate from those given in section 6 Technical data.

Always ensure that all alignment specifications given in section 6 Technical data 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.

TD605-147

>

100

Step 5

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

Ensure that the seal never runs dry.

Ensure hole and plug are facing upwards (I).

Ensure end plug is installed in such way that air pockets are avoided (II).

I II

4303-0065

4303-0064

Step 6

When tank is filled for the first time with media - the end plug (aeration plug) must be opened to evacuate trapped air inside seal housing.

14

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 6 Technical data

Check the rotation direction before operation.

Step 7

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

Start and stop the Agitator momentarily.

Step 8

If frequency converter drive is used, 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 case of any doubt, please advise with Alfa Laval).

3.7

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.

15

4 Operation

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

section 3.6 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 section 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

Mechanical seal

- S3SD

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

Monthly x x x x x

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

Half-yearly

16

4 Operation

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

section 3.6 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 section 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

Sealing

- Obstructed

- Damaged

- Unbalanced impeller

- Damage to shaft seal

- Damaged

- Deviation from normal operation

- Increased / decreased temperature

- Defect

- Bearing gap

- Increased / decreased power

- No grease

- Wear sealing

- 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.

Remedy

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

Check power supply connection

Check voltage and frequency correspond with nameplate

Check frequency converter adjustment correspond to nameplate

Check Agitator can rotate freely without striking 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

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

Operation circumstances must be equal to those it was designed for

Operation circumstances must be equal to those it was designed for

1)

1)

Renovate or change the gear immediately

Replace sealing

Replace motor

Regulate frequency down

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

Check frequency connection

Inspect the Agitator carefully

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

17

4 Operation

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

section 3.6 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 section 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).

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.

18

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 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 section 8 Appendix.

Ensure totally clean surfaces during maintenance.

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

For lifting instruction, please refer to section 3 Installation.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Always disconnect the power supply when servicing the Agitator.

Always use proper tools.

Always replace sealing elements before reassembling.

Follow the dismantling and assembly instructions to the letter.

After maintenance, section 3.6 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.

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

Sealing

Mechanical seal

- S3SD X

Media perishability

Alfa Laval recommend to use the end plug (aeration plug) to get fresh media inside the seal housing while operating.

Loosen the plug and let the media drain down.

Refreshing is carried out as required and depends on the media inside the tank. The volume of the media inside the seal housing is approx. 0,1 L.

4303-0147 4303-0148

19

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

5.2

Replacement of drive unit

Step 1

Ensure motor is turned off.

Remove cover from gear.

4303-0145

Step 2

Remove guards from lantern.

Step 3

Loosen pointed screw (I).

CAUTION!

Label on the shaft indicate that the shut down device is open when the OPEN-label is aligned with the pointed screw (II).

I

4303-0068

OPEN

II

4303-0069

20

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Step 4

Activate shut-down device.

1. Place the tool, hook wrench with pin on the sleeve-device – and NOT on the pin-holes on the shaft (I)!

2. Hold or clamp the tool (II) to the lantern edge and rotate the shaft clockwise from the gear (III).

NOTE!

Rotate until it stops. The device is shut-down after approx. 5-6 rotations.

III

I

II

4303-0070

Step 5

The seal parts are isolated from the tank when the sleeve part is turned around until it stops.

NOTE!

Access to the tank is shut-down when the pointed-screw hole is aligned with the CLOSED-label.

CLOSED

4303-0071

Step 6

Loosen the special plug (1).

The items position number (1) refers to the part list in section 7.3

Shaft seal, type S3SD.

NOTE!

A small amount of media will drain out.

CAUTION!

If the media continues to drain, then the shut-down device is not activated, please repeat from step 4.

4303-0072

21

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Step 7

Loosen screws on the seal housing (8).

NOTE!

The media in the seal housing will drain down.

4303-0073

Step 8

Lift seal housing (7) and O-ring (11) carefully up.

4303-0074

Step 9

Insert the flat tool between the circlip (5) on the shaft and the lifted seal housing (7).

NOTE!

Even if the device is shut-down it may drain a small amount of media out because of the gap to the sealing point.

4303-0075

22

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Step 10

Mount the retainer tool.

CAUTION!

DO NOT remove the retainer tools throughout the service!

Step 11

Remove flat tool (I) and move the seal housing carefully back (II) on the retainer tools.

I

II

4303-0146

II

4303-0077

23

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Step 12

Loosen shaft from the gear motor.

1. Place the tool, hook wrench with pin, on the pin-holes on the shaft.

2. Lock the shaft by holding with hand or support the tool (I) to the lantern edge.

3. Turn the screw counter clockwise to loosen the shaft from the gear motor (II).

I

4303-0078

II

Step 13

Dismantle lantern and gear motor.

1. Locate centre of gravity between lantern and gear motor.

2. Loosen cap nuts.

CAUTION!

Always use the correct lifting equipment.

4303-0079

Step 14

Lift up the lantern and gear motor and pull it carefully away.

4303-0080

24

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Step 15

Remove seal housing (7) carefully, avoiding contact.

Remove O-ring (11).

CAUTION!

DO NOT remove the retainer tools throughout the service!

Clean all surfaces.

4303-0081

Step 16

Remove rotary seal part (3d) and spring (3c) carefully.

CAUTION!

*DO NOT remove the retainer tools throughout the service!

Clean all surfaces.

*

4303-0082

25

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

5.3

Replacement of shaft seal, type S3SD

Step 1

Dismantle Agitator as described in section 5.2 Replacement of drive unit.

Step 2

Carefully remove the stationary seal ring (3b) and the O-ring (3a) in the seal housing (7) and replace with new.

NOTE!

Ensure all seal surfaces are totally clean, using alcohol.

4303-0086

Step 3

Mount the new rotary seal (3c, 3d, 3e) part carefully on the shaft, avoiding contact.

NOTE!

Ensure all seal surfaces are totally clean, using alcohol.

*DO NOT remove the retainer tools throughout the service!

*

4303-0084

Step 4

Place new O-ring (11) and seal housing (7) carefully on the shaft.

CAUTION!

Ensure air vent hole is facing upward.

CAUTION!

DO NOT remove the retainer tools throughout the service.

!

4303-0085

Step 5

Replace lantern and gear motor.

Mount cap nuts

Loosen the gear motor from the lifting equipment.

Tool: Wrench key 19mm

26

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Step 6

Lock the shaft with the hook wrench (I) while mounting the fastening element and screw (II).

I

4303-0088

II

Step 7

Lift seal housing (7) and insert the flat tool on the shaft.

4303-0075

27

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Step 8

Dismount the retainer tools.

Step 9

Ensure new O-ring (11) is in the groove.

Remove the flat tool and move seal housing (7) carefully back.

Mount the seal housing (7).

NOTE!

Ensure air vent hole is facing upward.

Step 10

Place the O-ring (2) and the end plug (1) - but do not fasten it!

4303-0089

4303-0076

4303-0125

28

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

I Step 11

Opening the shut-down device

Place the hook wrench tool on the sleeve device (I) and rotate the shaft (II).

CAUTION!

Media from the tank is flowing into the seal housing. Ensure seal housing is filled with media - avoid air pockets before completely mounting the end plug.

Continue to rotate till stop (until the device is fully open).

NOTE!

The device is fully open after approx. 5-6 full rotations.

4303-0087

II

Step 12

Mount pointed screw (6) (I).

NOTE!

Hole for pointed screw should be aligned with the marking “OPEN”

(II).

I

OPEN

II

4303-0069

Step 13

Clean all surfaces.

Start the motor.

Mount the guards on lantern.

Mount cover on gear motor.

29

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

5.4

Replacement of sealing parts, complete

Step 1

Dismantle Agitator as described in section 5.2 Replacement of drive unit.

4303-0091

Step 2

Dismantle Agitator from welding flange.

4303-0092

Step 3

Lift up Agitator from welding flange and place it off-center from hole.

NOTE!

Protect the shaft against edge of tank.

4303-0093

Step 4

Dismantle impeller device from shaft.

Step 5

Remove Agitator from tank.

30

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Step 6

Remove screws and dismantle the mounting flange.

4303-0094

Step 7

Remove retainer tools and dismantle supporting flange.

4303-0095

Step 8

Remove circlip (5) carefully. Use suited pliers.

31

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Step 9

Loosen sleeve inner (4) part.

Step 10

Push the sleeve outer part (17) down.

Remove the pins (14).

Step 11

Move the sleeve outer part (17) along the shaft.

4303-0098

32

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

NOTE!

Ensure totally clean surfaces during seal replacement.

Lubricate the O-rings with FDA approved grease.

Step 12

Replace O-rings (15, 16, 18).

Step 13

Move sleeve outer part (17) below the holes for pins.

Place the pins (14) in the holes.

Step 14

Pull sleeve outer part up so the pins are in the grooves.

CAUTION!

Groove and pin must be aligned. The pins must be located in grooves.

4303-0098

4303-0102

33

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Step 15

Lubricate inner surface and thread with grease (*) on sleeve inner part (4).

Move sleeve inner part (4) along shaft and screw it down into the sleeve outer part (17) while pulling it (17) upwards against (4) ensuring that the pins stays inside the grooves.

4303-0103

Step 16

Measure check - ensure pins are inside the grooves.

40

Step 17

Replace carefully circlip (5).

Use suited pliers.

34

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Step 18

Mount pointed screw (6).

NOTE!

Pointed screw should be aligned with the marking “OPEN”.

4303-0106

Step 19

Mount rotary seal part (3c, 3d, 3e) on sleeve part (4).

NOTE!

Ensure seal surface is totally clean, using alcohol.

Step 20

Mount stationary seal part (3a, 3b) in seal housing (7).

Place O-ring (2).

NOTE!

Ensure seal surface is totally clean, using alcohol.

4303-0108

35

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Step 21

Replace O-rings (9, 11, 12).

Mount supporting flange (13) on mounting flange.

4303-0109

Step 22

Replace shaft parts into flange parts.

Step 23

Mount seal housing.

CAUTION!

Place seal housing according to section 3.6 Pre-use check (step

5) / section 5.3 Replacement of shaft seal, type S3SD (step 4).

4303-0111

36

5 Maintenance

Read the instructions carefully. The items refer to the parts lists in section 7.3 and service kit section.

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

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

Always refer to tightening torques in section 6.2 Tightening torques for bolt connections.

Step 24

Mount lantern and gear motor onto mounting flange.

CAUTION!

Mount lantern and gear motor according to section 3 Installation

step 1.

Step 25

Pull the shaft up and fasten into the gear motor.

Lock the shaft with the hook wrench (I) while fastening the screw securing the shaft in the gear motor (II).

Step 26

Assemble Agitator onto the tank as described in section 3.5 Mounting Agitator.

I

4303-0088

II

37

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 nameplate as shown on the illustration.

Mounting angle for side mounting Agitator type ALS-SD:

Agitator mounting angle between 90-135°.

To ensure optimal agitation the side mounted Agitator must be installed in the mounting angle specified on the nameplate as shown on the illustration.

ALS

135°

90°

Angle

180

0

43050001

38

6 Technical data

All dimensions in mm unless otherwise stated.

6.2

Tightening torques for bolt connections

CAUTION!

Use Loctite ® before fastening.

Do NOT use air powered tools.

M4 M5 M6 M8 M10 M12 M14 M16* M18 M20 M22 M24

3Nm 6Nm 11Nm 26Nm 51Nm 88Nm 141Nm

*Maximum tightening torque for shaft, M16 using hook wrench tool 100 Nm.

218Nm 308Nm 439Nm 582Nm 724Nm

6.3

Storage

Store the Agitator in dry and clean environments.

Rotate shaft every second week to ensure seal not seizing up.

39

7 Parts lists and service kits

Main components

7.1

Main components

40

4303-0113

7 Parts lists and service kits

Main components

Parts list

Pos.

7

8

9

5

6

3

4

1

2

Qty

1

1

1

1

1

1

1

1

1

Denomination

GP Gear motor

Lantern, complete

Parallel key

Shaft seal, type S3SD

Flange, mounting

O-ring (for flange)

Shaft

O-ring (for shaft)

Impeller device, EnSaFoil

Article numbers are to be found in the Spare part manual 1000000046, available from the online Alfa Laval product catalogue

Anytime or the Close at hand spare part catalogue.

41

7 Parts lists and service kits

Lantern, complete

7.2

Lantern, complete

42

Lantern, complete

Parts list

Pos.

1

2

3

4

5

6

Qty

1

6

2

8

8

8

Denomination

Lantern, ext.

Screw

Guard, ext.

Nut, cap

Screw

Stud

7 Parts lists and service kits

43

7 Parts lists and service kits

Shaft seal, type S3SD

7.3

Shaft seal, type S3SD

4303-0115

44

Shaft seal, type S3SD

Parts list

Pos.

6

7

1

2  ♦

3  ♦

4

5

8

9 ♦

10

11  ♦

12 ♦

13

14

15 ♦

16 ♦

17

18 ♦

19

20

Service kits

Qty

2

1

1

1

1

1

1

2

1

1

1

1

1

1

4

1

4

1

1

1

Denomination

End Plug

O-ring

S3SD Seal

Sleeve, inner

Circlip

Screw, pointed

Seal housing

Screw

O-ring (for flange, mounting)

Screw

O-ring

O-ring

Flange, support

Locking pin

O-ring

O-ring

Sleeve, outer

O-ring

Screw

Plate, retainer S3SD

Denomination Item no.

Seal Kits for shaft seal, type S3SD

 Seal Kit, In-place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9615364501

Seal Kit, Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9615364601

7 Parts lists and service kits

45

7 Parts lists and service kits

Tools

7.4

Tools

46

4303-0116

Tools

Parts list

Pos.

1 ♦

2 ♦

3 ♦

Service kits

Qty

1

1

2

4

Denomination

Hook wrench with pin

Tool, flat

Tool, retainer

Screw

Denomination Item no.

Seal kit, Tools

Seal kit, Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9615364701

7 Parts lists and service kits

47

8 Appendix

Tools

8.1

Drive unit instructions

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

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

48

49

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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