Alfalaval ALS Series User manual

4303-0128
100000047-EN1 2018-09
Original manual
Instruction Manual
Alfa Laval Agitator - ALS Shut Down Seal

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
[phone]
Phone No.
hereby declare that
Agitator - EnSaFoil 10.000 - 100.000
Designation Serial no(s)
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 Type variation
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 Lars Kruse Andersen
Title Name
Kolding 2017-10-01
Place Date 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 agreement1) 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

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.
6

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 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)
4303-0006
Step 3
Lifting instructions:
Always use the correct lifting equipment (see Agitator weight on nameplate).
Locate Centre of gravity before moving the Agitator.
TD605-100
1
2
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 powersupplybyauthorizedpersonnel.
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:Powerofthemotorin[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
TD605-028
Mv
Mb
Fs
Fs
Mb
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: <100 >100
A° (max bending angle at applied loads): 0.1 0.05
A
TD605-213
Mb
Fs
Fs
Mb
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°
45°
TD605-023
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
A
B
C
D
TD605-007
Step 2
Spot weld from outside.
TD605-010
A
C
D
B
Adjust alignment!
A
C
D
B
TD605-011
Step 3
Weld the following sections first from outside then from inside, and cool
with air between each section.
1
A
B
C
D
4
2
3
TD605-014
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.
4303-0022
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)ispointingdownwards.
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).
4303-0066
I
II
1) Standard vent plug
2) Transport securing device
Step 2
Mount the Agitator onto the tank.
12

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 3
Mount impeller device onto shaft.
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.
NOTE!
In special cases clearence can be reduce to 20mm+actual
deflection, please advice with Alfa Laval.
>
100
TD605-147
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.
>
100
TD605-147
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).
4303-0064
I
4303-0065
II
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.
TD605-029 TD605-030
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

4Operation
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
Inspect / Clean / Lubricate
Supplier
instruction
Weekly Monthly Half-yearly
Drive unit
Motor x
- Clean surfaces - to avoid overheating x
Gear x
- Clean vent screw (if any) x
- Check for oil leakage x
Flange
Clean drain x
Sealing
Mechanical seal
-S3SD x
Impeller device
Sticky media
- Clean impeller device x
Abrasive media
- Check blade thickness* x
- Check fastening of pointed set screws x
* If any suspicion of reduction in blade thickness, contact Alfa Laval and inform serial no. stated on the nameplate.
16

4Operation
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
Cause/result Remedy
- Defect Dismantle drive unit, check for correct rotation. Replace drive unit
- Fault at power supply Check power supply connection
Check voltage and frequency correspond with nameplate
Drive unit
Check frequency converter adjustment correspond to nameplate
Agitator - Obstructed Check Agitator can rotate freely without striking anything
Vibrations - Damaged Contact Alfa Laval
- Unbalanced impeller Clean impeller device
Impeller device
- Damage to shaft seal Replace sealing
Shaft - Damaged Contact Alfa Laval
- Deviation from normal operation Operation circumstances must equal to those it was designed for 1)
Other - Increased / decreased temperature
Unusual noise - Defect Replace drive unit
- Bearing gap Renovate or change the drive unit immediately
- Increased / decreased power Switch of power supply
Drive unit
- No grease Replace drive unit
- Wear sealing Replace sealing
Sealing - Seal surfaces stick together Separate surfaces carefully and clean them - ensure that seals are
sufficient cleaned before still stand
- Deviation from normal operation Operation circumstances must be equal to those it was designed for 1)
Other - Circuit overload Operation circumstances must be equal to those it was designed for 1)
Leakage
Gear - Oil leakage Renovate or change the gear immediately
Sealing - CIP fluid or other Replace sealing
Continuously breakdown - Defect Replace motorDrive unit - Too high frequency Regulate frequency down
Other - Deviation from normal operation Operation circumstances must be equal to those it was designed for 1)
Performance
Drive unit - Wrong frequency Check frequency connection
Agitator - Reverse direction Inspect the Agitator carefully
Other - Deviation from normal operation Operation circumstances must be equal to those it was designed for 1)
1) See section 2.3 Intended use.
17

4Operation
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.
Replace every:
500 hour or
yearly
1000 hour or
yearly
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.
4303-0068
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).
OPEN
4303-0069
I
II
20