Alfalaval ALTB-SB-35 User manual

Classified by Alfa Laval as: Business
s
Instruction Manual
ALTB-SB-35
Original manual
100006450EN 2022-04

0 Table of contents
Page 2
Classified by Alfa Laval as: Business

0 Table of contents
Page 3
0 Table of contents
0Table of contents ..............................................................................................................3
1EC Declaration of Conformity ...........................................................................................4
2Safety................................................................................................................................5
2.1 Important information........................................................................................................5
2.2 Warning signs ...................................................................................................................5
2.3 Intended use .....................................................................................................................5
2.4 Safety precautions............................................................................................................6
3Installation.........................................................................................................................7
3.1 Unpacking / Delivery.........................................................................................................7
3.2 Requirement for installation, personnel............................................................................9
3.3 Installation in an accessible tank with crane / hoist above tank .......................................10
3.4 Installation in a none-accessible tank (no manhole) with no crane / hoist above tank.....16
3.5 Installation in a none-accessible tank (no manhole) with crane / hoist above tank..........27
3.6 Installation, electrical.........................................................................................................29
3.7 Pre-use check...................................................................................................................30
4Operation ..........................................................................................................................31
4.1 General information ..........................................................................................................31
4.2 Aeration.............................................................................................................................31
4.3 Inspection..........................................................................................................................32
4.4 Troubleshooting ................................................................................................................32
4.5 Cleaning............................................................................................................................33
5Maintenance .....................................................................................................................35
5.1 General maintenance........................................................................................................35
5.2 Disassembly of Agitator....................................................................................................35
5.3 Replacement of gear motor ..............................................................................................35
5.4 Replacement of seals .......................................................................................................35
5.5 Replacement of busing pos. 38 in bottom console...........................................................35
6Technical Data..................................................................................................................36
6.1 ALTB-SB-35, With Aeration (item number 8010010025) .................................................36
6.2 ALTB-SB-35, Without Aeration (item number 8010010024): ...........................................37
7Parts list / Service kits.......................................................................................................38
7.1 ALTB-SB-35, With Aeration (item number 8010010025) .................................................39
7.2 ALTB-SB-35, Without Aeration (item number 8010010024) ............................................41
7.3 ALTB-SB-35, (With and Without Aeration) .......................................................................43
7.4 Accessories.......................................................................................................................47
8Appendix...........................................................................................................................49
8.1 Declaration of Compliance................................................................................................49
8.2 Agitator Drive Unit lubrication ...........................................................................................50
8.3 Agitator Drive Unit Instructions .........................................................................................56

1 EC Declaration of Conformity
Page 4
Classified by Alfa Laval as: Business
1 EC Declaration of Conformity
The Designation company:
Hereby declare that:
Is in conformity with the following directives:
- Machine Directive 2006/42/EC
- FDA 21CFR§177
- Regulation (EC) 1935/2004
The person authorized to compile the technical file is the signer of this document.
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
ALTB-SB
Denomination
35
Type
Global Product Quality Manager, Pumps, Valves, Fittings and Tank Equipment
Title
2022-01-01
Date
Kolding
Place
Lars Kruse Andersen
Name
Signature

2 Safety
Page 5
2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
All warnings in the manual are summarised on this page.
Pay special attention to the instructions below so that serious personal injury and/or damage to the Agitator
are avoided.
The instruction manual is part of delivery. Study the instructions carefully.
The Agitator is for permanent fastening.
Make sure the motor corresponds to the environment.
Check the direction of rotation before operation.
2.1 Important information
Always read the manual before using the Agitator!
WARNING
Indicates that special procedures must be followed to avoid severe personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the Agitator.
NOTE
Indicates important information to simplify or clarify practices.
2.2 Warning signs
General warning:
Caustic agents:
Dangerous electric voltage:
2.3 Intended use
- The Agitator is only for mixing / conditioning / stirring of liquids in a tank.
- The Agitator is only made for top mounting position on the top plate / welding flange on the tank.

2 Safety
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Classified by Alfa Laval as: Business
2.4 Safety precautions
2.4.1 Installation:
- Always read the technical data thoroughly (see chapter 6).
- Always follow installation instructions thoroughly (see chapter 3).
- Never expose the Agitator to undue vibrations or shocks.
- Never start the Agitator in the wrong direction of rotation.
- 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 1.000 m above sea level.
- Only use authorized personnel when electrical equipment is connected.
2.4.2 Operation:
- Always read the technical data thoroughly (see chapter 6).
- Never start Agitator in the wrong direction of rotation.
- Beware of Agitator in operation can produce sound levels higher than 85dB(A).
- Always handle lye and acid with great care.
- Always rinse well with clean water after cleaning.
- Never run the agitator without product, water or cleaning liquid in the tank.
2.4.3 Maintenance:
- Always follow the maintenance instruction thoroughly (see chapter 5).
- Always follow the maintenance instruction for gear motor thoroughly (see section 8.3).
- Always study the parts list and assembly drawing carefully (see chapter 7).
- 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 propeller before start-up and after any maintenance.
- Never service the agitator or tank with product or cleaning liquid in the tank.
2.4.4 Transportation
- Always transport the Agitator in original packaging.
- Never transport the Agitator mounted in a tank.
- Always support the shaft adequately, to protect shaft and bearings.
- Never expose the Agitator to undue vibrations or shocks.
- Ensure control for oil leakage on gears with vent screw.
Ensure correct rotation direction of impeller before start-up and after any maintenance.

3 Installation
Page 7
3 Installation
The instruction manual is part of the delivery –study the instructions carefully.
The Agitator is for permanent fastening.
Make sure the motor corresponds to the environment.
Check the direction of rotation before operation.
All position numbers and item numbers refer to the drawings shown and specified in chapter 7.
The installation can be done in many ways depending on tank type, equipment and working space around
the tank. Three possible installations methods are described in below sections:
3.3 Installation in an accessible tank with crane / hoist above tank (see page 10):
•Installation of agitator in a tank that is accessible for a person through manhole in tank top or tank
side or through cone in bottom of tank –installation with crane / hoist and sufficient head room
above tank top which makes handling of the complete Agitator Drive Unit possible.
3.4 Installation in a none-accessible tank (no manhole) with no crane / hoist above tank (see page 16):
•Installation of agitator in a tank that is only accessible through tank top when the agitator is not
installed –installation with no crane / hoist and with limited head room above tank top.
3.5 Installation in a none-accessible tank (no manhole) with crane / hoist above tank (see page 27):
•Installation of agitator in a tank that is only accessible through tank top when the agitator is not
installed –installation with crane / hoist and sufficient head room above tank top which makes
handling of the complete Agitator Drive Unit possible.
This work should be carried out by at least two persons. For safety reasons a platform or a scaffolding
should be established around the tank top.
During installation ensure to use sufficient lighting.
The tank top must be horizontal during installation.
Ensure that the tank does not contain neither dangerous liquid nor gasses and that good ventilation
is established.
Always have safety elements removed by authorized personnel.
Never cover or remove nameplates.
Always use approved lifting equipment when handling heavy parts of the Agitator.
Never connect to power during installation.
Always have the Agitator connected to power supply by authorized personnel.
Note:
Alfa Laval highly recommends installing motor protection guard and a soft starter, or a frequency converter,
with a ramp up and down time about 2-7 sec. to the Agitator.
3.1 Unpacking / Delivery
Always use approved lifting equipment when handling the Agitator.
Alfa Laval cannot be held responsible for incorrect unpacking.
3.1.1 Step 1
Inspect the delivery for visible transportation damages (crates and packaging) - all issues to be reported to
carrier.

3 Installation
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Classified by Alfa Laval as: Business
3.1.2 Step 2
Check that deliveries are according to delivery notes.
Complete Agitators can be delivered in more than one shipment.
3.1.3 Step 3
Inspect Agitator parts for visible transport damage.
3.1.4 Step 4
Do NOT use eye bolts on gear motor to lift the Agitator. They are only for gear motor removal.
3.1.5 Step 5
During lifting:
- Always support the shaft adequately to protect shaft and bearings.
- Be careful not to damage shaft-end with treads.
- Never expose the Agitator to undue vibrations or shocks.
- Control gearbox for oil leaks –leave vent plug un-activated on gear until gear is installed and in
correct position (see Figure 1).
Figure 1, un-activated vent plug

3 Installation
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3.2 Requirement for installation, personnel
Erectors:
- Experience from similar types of installation.
- Proven skills in reading installation guidelines and drawings ensuring that the installation is
safely carried out for personnel and property.
Electrician:
- Certified according to local regulations and experience from similar types of installation.
- Proven skills in reading installation guidelines and drawings ensuring that the installation is
safely carried out for personnel and property.
Welder:
- Experience from similar types of installation, covering TIG, MIG and MAG welding
procedures in stainless steel thin-walled material.
- Proven skills in reading installation guidelines and drawings ensuring that the installation is safely
carried out for personnel and property.

3 Installation
Page 10
Classified by Alfa Laval as: Business
3.3 Installation in an accessible tank with crane / hoist above tank
All position numbers and item numbers refer to the drawings shown and specified in chapter 7.
When the inside of the tank is accessible with the agitator mounted to the top plate the agitator can be
installed in different ways depending on tank type, equipment and working space around the tank and tank
top.
The below described procedure can be used, if suitable crane or hoist facilities above the tank top can lift the
complete Agitator Drive Unit (which includes the gear motor) about 1.300 mm above the tank top, –if that is
not the case, please see section 3.3.3
3.3.1 Step 1
1. Weld the welding flange pos. 60 (if used) into the top plate pos. 100 (the welding flange pos. 60 is
normally integrated into the AL top plate pos. 100).
2. Clean shaft and propeller threads.
3. Add some food approved grease to the threads to prevent them from galling.
4. Assemble the shafts, propellers, gaskets and O-rings: pos. 1, 2, 3, 32 and 33.
5. The propellers and shafts can be assembled outside the tank, if the size of the counter flange pos.
99 and the head room above the tank is sufficient –otherwise the shaft and propeller unit must be
assembled one by one inside the tank. The shaft and propeller unit can consist of one or two shafts
and one or two propellers –see order confirmation.
6. Mount the top plate pos. 100 onto the counter flange pos. 99.
7. Final tightening (between 100 Nm and 300 Nm) of all shaft connections can be postponed until the
complete agitator is assembled and mounted on the tank top.
8. Screw the lifting eye tool pos. 51 onto the upper shaft part pos. 1 and lift the shaft and propeller unit
using a hoist.
9. Ensure that the studs pos. 61 are screwed into the welding flange pos. 60.
10. Temporarily place the complete shaft and propeller unit in the mounting tool pos. 50.
11. Unscrew the lifting eye tool pos. 51 and store it.

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3.3.2 Step 2
1. Clean the connection threads in pos. 1 and pos. 5.
2. Add some food approved grease to the threads to prevent them from galling.
3. Mount the gasket and O-ring pos. 32 and 33 into the shaft pos. 1.
4. Ensure that the O-ring pos. 34 is installed in flange on pos. 10.
5. Lift the complete Agitator Drive Unit using a hoist (do not use the lifting eye on the gear motor) and
screw on the shaft pos. 1 into the thread in pos. 5.
6. Lift the complete agitator a little further enabling the mounting tool pos. 50 to be removed and stored.
7. Position the complete agitator onto the welding flange pos. 60.
8. Mount the washers pos. 18 and nuts pos. 17 to the studs pos. 61 and tighten them sequentially to
150 Nm to 200 Nm.

3 Installation
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Classified by Alfa Laval as: Business
3.3.3 Alternative to 3.3.1 and 3.3.2 (if reduced headroom above tank –tank with manhole)
1. If manhole in tank is too small for propellers use hole in counter flange pos. 99 to place propellers
inside tank.
2. Weld the welding flange pos. 60 (if used) into the top plate pos. 100.
3. Mount the top plate pos. 100 onto the counter flange pos. 99.
4. Ensure that the studs pos. 61 are screwed into the welding flange pos. 60.
5. Ensure that the O-ring pos. 34 is installed in flange in pos. 10.
6. Lift the complete Agitator Drive Unit using a hoist (do not use the lifting eye on the gear motor) onto
the top of the tank and slide the shaft with pos. 5 through the hole of the welding flange pos. 60.
7. Position the complete agitator onto the welding flange pos. 60.
8. Mount the washers pos. 18 and nuts pos. 17 to the studs pos. 61 and tighten them sequentially to
150 Nm to 200 Nm.
9. Clean all shaft and propeller threads in pos. 1, 2, 3 and 5.
10. Add some food approved grease to the threads to prevent them from galling.
11. Equip the tank with sufficient scaffolding ensuring safe working conditions inside the tank.
12. Insert O-ring and gasket pos. 32 and 33 in the upper shaft pos. 1 and screw it onto the Agitator Drive
Unit pos. 5.
13. Insert O-ring and gasket pos. 32 and 33 in the upper propeller pos. 2 and screw it onto the upper
shaft pos. 1.
14. Repeat step 12 and step 13 for lower shaft pos. 1 and propeller pos. 3 installation.

3 Installation
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3.3.4 Step 3
1. Equip the tank with sufficient scaffolding ensuring safe working conditions inside the tank.
2. Enter the tank and tighten the lower propeller pos. 3 between 100 Nm and 300 Nm ensuring that all
shaft and propeller connections are tightened.
3. Slide on the mounting tool pos. 70 onto the propeller pos. 3.
4. Fasten the mounting tool pos. 70 with the screw pos. 28 (1-2 Nm) enable the mounting tool pos. 70
to rotate freely.
5. Rotate the mounting tool pos. 70 until the legs are pointing in the direction and position of where the
legs of the bottom bearing stand pos. 29 are required to touch the tank bottom.
6. Fix the mounting tool pos. 70 by tightening screw pos. 28 (5-10 Nm).

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Classified by Alfa Laval as: Business
3.3.5 Step 4
1. Note that each leg of mounting tool pos. 70 is numbered 1, 2 and 3 (which has the same geometry
as the upper part of the bottom steady bearing pos. 29 and the bushing pos. 38).
2. Carefully measure the distance X1 in mm from the end of leg number 1 to the surface of the tank
bottom, where leg number 1 would touch if it was extended.
3. Do the same measurement for leg number 2 and leg number 3 and note the distance X2 and X3 for
the other legs. Mark the three touching points in the tank bottom.
4. Dismantle the mounting tool pos. 70 and store it.

3 Installation
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3.3.6 Step 5
1. Below figure shows the correct vertical and horizontal position of the bottom bearing support pos. 29
which guides the bushing pos. 38.
2. To calculate the length Z1, that must be cut of the bottom bearing support leg number 1, the
following equation is used:
Leg length of new bottom bearing support pos. 29 (use actual length if it differs):
Z1 + X1 + Y1 = 523 mm
Leg length of mounting tool pos. 70 (use actual length if it differs):
Y1 = 82 mm
Merging the two equations into one:
Z1 = 523 mm –Y1 –X1 = 523 mm –82 mm –X1 = 441 mm –X1
The cut-of length for each leg Z1, Z2 and Z3 are therefore calculated as (use actual length if it
differs):
Z1 = 441 –X1
Z2 = 441 –X2
Z3 = 441 –X3
3. Shorten the legs of the bottom bearing stand support pos. 29 as calculated in step 2 and adjust
angle at leg ends to fit tank bottom. If the legs of the bottom-bearing-stand-support are too short, the
legs can be extended by welding a stainless-steel rod of the same diameter and material to the
current leg. The agitator may optionally be delivered with an extra leg.
4. Place the bottom bearing stand pos. 29 inside the tank.
5. Gently pull the shaft to one side to allow the bottom bearing stand to be positioned around the
tap-end (the lower part of propeller pos. 3 that is used for bushing pos. 38. If that is not possible due
to tank geometry, the complete agitator must be lifted a little by use of a hoist.
6. Position the legs at the marked points in tank bottom as when the measuring with the mounting tool
pos. 70 was done (in section 3.3.4-5).
7. Temporary mount the bushing pos. 38.
8. Measure the distance A1 and A2 and verify that they are the same within ±10 mm and that the top of
the bottom bearing stand are horizontal within ±1,5°. If that is not the case the legs of the bottom
bearing stand must be modified.
9. Weld in the three legs to the tank bottom and grind the surfaces as required.
10. Mount the bushing pos. 38 together with the two O-rings pos. 36, 37 using the screw pos. 28 and
tighten it to 15 Nm.

3 Installation
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Classified by Alfa Laval as: Business
3.4 Installation in a none-accessible tank (no manhole) with no crane / hoist above tank
All position numbers and item numbers refer to the drawings shown and specified in chapter 7.
When the inside of the tank is not accessible with the agitator mounted on the top plate, the agitator can be
installed as described below.
The purpose of this description is to position the agitator shafts and propellers in the precise same vertical
position (as when it is mounted on the top plate) without the top plate pos. 100 (see section 3.3). To do that
the mounting tool pos. 80 or 81 and 90 must be available.
Before installation can be done the Agitator Drive Unit must be disassembled as described in section 3.4.6 to
3.4.9 but read and done in reverse order.

3 Installation
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3.4.1 Step 1
When the horizontal groove in shaft pos. 5 is in the slot in the mounting tool pos. 90, which is positioned on
top of the mounting tool pos. 80 or pos. 81, the shaft pos. 5 is in the same vertical position as when the
complete agitator is mounted on the welding flange pos. 60 –see Figure 2 and Figure 3 (and figure in
section 3.4.5).
If the thickness of the top plate pos. 100 is different than the thickness of the mounting tool pos. 80, the
vertical position of the mounting tool pos. 90 holding the shaft pos. 5 in place must be adjusted (illustrated
below with top plate pos. 100 and tool pos. 80 both being 20 mm in thickness).
Figure 2, Agitator mounted on tank top
Figure 3, Shaft positioned with mounting tool pos. 80 or 81 and 90

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Classified by Alfa Laval as: Business
3.4.2 Step 2
1. Clean shaft and propeller threads.
2. Add some food approved grease to the threads to prevent them from galling.
3. The propellers and shafts can be assembled outside the tank, if the size of the counter flange pos.
99 and the head room above the tank is sufficient –otherwise the shaft and propeller unit must be
assembled one by one inside the tank. The shaft and propeller unit can consist of one or two shafts
and one or two propellers –see order confirmation.
4. Assemble the shafts, propellers, gaskets and O-rings: pos. 1, 2, 3, 32 and 33
5. Tighten all shaft and propeller connections between 100 Nm and 300 Nm –can be done by tighten
the lower propeller pos. 3 between 100 Nm and 300 Nm when the shaft pos. 5 is fixed and secured.
6. Equip the tank with sufficient scaffolding ensuring safe working conditions inside the tank.
7. Enter the tank and slide on the mounting tool pos. 70 onto the propeller pos. 3.
8. Loosely install mounting tool pos. 70 loose with the screw pos. 28 (1-2 Nm). Mounting tool must be
able to rotate freely.
9. Rotate the mounting tool pos. 70 until the legs is pointing in the direction and position of where the
legs of the bottom bearing stand pos. 29 are required to touch the tank bottom.
10. Tighten the screw pos. 28 (5-10 Nm).

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3.4.3 Step 3
1. Continue as described in section 3.3.5
3.4.4 Step 4
1. Continue as described in section 3.3.6

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Classified by Alfa Laval as: Business
3.4.5 Step 5
1. Lift the complete shaft and impeller unit pos. 5 vertical (2-5 mm) and remove the mounting tool pos.
90.
2. Lower the complete shaft and impeller unit pos. 5 slowly and let it rest on top of the bottom bearing
stand pos. 29 –secure the shaft pos. 5 in horizontal direction.
3. Remove the mounting tool pos. 80.
4. Mount the top plate pos. 100 on the counter flange pos. 99.
5. Ensure that the O-ring pos. 34 is mounted in the flange in pos. 10.
6. Install spray ball bearing pos. 31 on tube pos. 10.
7. Lift the complete shaft and impeller unit pos. 5 vertical until the mounting tool pos. 90 can be slid into
the horizontal slot again in the shaft in pos. 5.