Alfalaval ALS-ME-GR-30 40LF-S3 Series User manual

4303-0151
100000818-EN2 2020-02
Original manual
Instruction Manual
Alfa Laval Agitator - ALS / ALB ATEX

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC/EU Declaration of Conformity .................................................................. 4
2. Safety .................................................................................................... 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 ......................................................................................... 10
3.3. Pre-use check ..................................................................................... 21
3.4. Recycling information ............................................................................. 23
4. Operation ............................................................................................... 24
4.1. Operation/Control ................................................................................. 24
4.2. Troubleshooting ................................................................................... 25
4.3. Cleaning - recommendations .................................................................... 26
4.4. Temperature limits ................................................................................ 26
5. Maintenance ........................................................................................... 27
5.1. General maintenance ............................................................................. 27
5.2. Replacement of drive unit ........................................................................ 28
5.3. Replacement of shaft seal, type S3 ............................................................. 29
6. Technical data ......................................................................................... 31
6.1. Technical data ..................................................................................... 31
6.2. Mounting angle for side mounted Agitator type ALS .......................................... 31
6.3. Mounting angle for bottom mounted Agitator type ALB ...................................... 32
6.4. Specific conditions for safe use ................................................................. 33
6.5. Tightening torques for bolt connections ........................................................ 34
6.6. Shaft alignment ................................................................................... 34
6.7. Use of frequency converter drive (VLT) ......................................................... 36
6.8. Storage ............................................................................................ 37
7. Parts list and drawing & service kits ............................................................... 38
7.1. Agitator - ALS / ALB ATEX ....................................................................... 38
8. Appendix ............................................................................................... 40
8.1. Drive unit instructions ............................................................................. 40
3

1 EC/EU Declaration of Conformity
Revision of Declaration of Conformity: 2018-11-01
The Designated Company
Alfa Laval Kolding A/S Albuen 31, DK-6000 Kolding, Denmark [phone]
Company name Address Phone no.
hereby declare that
Agitator - EnSaFoil
Designation
ALS-ME-GR-30_40LF-S3-…
ALS-ME-GP-30_40LF-S3-…
ALB-ME-GR-30_40LF-S3-…
ALB-ME-GP-30_40LF-S3-…
Serial number from AAC000000001
to AAC999999999
Serial number from 100700000001
to 100799999999
Type Agitator marking options Serial nos.
is in conformity with Machinery Directive 2006/42/EC and the following harmonized standard is used:
DS/EN ISO 12100:2011 Safety of Machinery - Risk Assessment
is in conformity with (Ex/ATEX) Directive 2014/34/EU
The following harmonised standards and regulations have been applied for non-electrical equipment for ATEX:
- EN ISO 80079-36: 2016 Basic method and requirements
- EN ISO 80079-37: 2016 Protection by constructional safety ’c’ and control of ignition source ’b’
The Agitator technical file is stored with: Teknologisk Institut, Kongsvang Allé 29, 8000 Aarhus C, Denmark
Certification body no.: 0396. Archive no.: Archive no.: 2018-1-0292A
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 2020-02-01
Place Date (YYYY-MM-DD) 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.
2.2 Warning signs
General warning:
!
Dangerous electrical voltage:
2.3 Intended use
- The Alfa Laval Agitator is only for mixing/stirring of liquids in a tank.
- The Agitator is only for mounting positions as specified on the nameplate by the first group of letters of the type designation.
ALT(B)- is for top mounting, ALS- is for side mounting and ALB- is for bottom mounting.
The exact mounting angle is specified on the Name Plate and must be followed. Definitions on mounting angles can be
seen in section 6.2 Mounting angle for side mounted Agitator type ALS and section 6.3 Mounting angle for bottom mounted
Agitator type ALB.
- 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 Name Plate 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 chapter 6.1 Technical data).
Always follow installation instructions thoroughly (see chapter 3 Installation).
Never expose the Agitator to undue vibrations or shocks.
Never start Agitator in the wrong rotation direction.
Always follow drive unit installation instruction thoroughly (see chapter 8 Appendix).
Ensure that the tank media is not corrosive to the Agitator.
Only install the Agitator in environments within temperature limit: -20°C and +40°C.
Only install the Agitator in altitudes less than 1000 m above sea level.
Always ensure that the Agitator has sufficient cooling around the lantern, may not be wrapped with isolating materials.
!
Ensure that installation is in accordance with EN 60079-14.
Beware of ignition temperature can be decreased when enclosed by the equipment/tank (see EN 14522).
Never touch the moving parts while the Agitator is connected to the power supply.
Operation:
Always read the technical data thoroughly (see chapter 6.1 Technical data).
Always read supplier instructions thoroughly (see chapter 8 Appendix).
Always make sure that the Agitator corresponds to the category marked on the name plate:
Gas atmosphere:
Never start Agitator in the wrong rotation direction.
Never use the Agitator for hybrid mixture.
Always rinse well with clean water after cleaning.
Beware of temperature limitations.
Beware of Agitator in operation can produce sound levels in excess of 85dB(A).
Never operate continuously within 20% of critical oscillation speed (see chapter 6.1 Technical data).
!
Beware of static electricity risk when the media conductivity is below 1000pS/m. (Recommendations: CLC/TR
50404 or IEC/TS60079-32).
Never touch the moving parts while the Agitator is connected to the power supply.
Maintenance:
Always read the technical data thoroughly (see chapter 6.1 Technical data
Always follow the maintenance instruction thoroughly (see chapter 5 Maintenance).
Always follow the maintenance instruction from drive unit supplier (see chapter 8 Appendix).
Always study the parts list and assembly drawing carefully (see chapter 7 Parts list and drawing & service kits).
Never replace ATEX Agitator with other type of Alfa Laval Agitator.
Ensure that maintenance is in accordance with relevant standards EN 60079-17 and EN 60079-19.
!
Never touch the moving parts while the Agitator is connected to the power supply.
Always disconnect the power supply while servicing the Agitator.
Transportation:
Always transport the Agitator in original packaging.
Always support the shaft adequately, to protect shaft and bearings.
Never expose the Agitator to undue vibrations or shocks.
Control for oil leakage on gears with vent screw.
Ensure correct rotation direction of impeller before startup and after any maintains there might have impact on the direction.
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).
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Alfa Laval cannot be held responsible for incorrect unpacking.
Step 1
Inspect the delivery for visible transportation damages - all issues to be reported to carrier.
Step 2
Check the delivery for:
1. Complete Agitator
2. Nameplate designations
3. Delivery note
4. Separate instruction manuals from suppliers (see chapter 8 Appendix).
4303-0020
Step 3
Lifting instructions:
Always use the correct lifting equipment (see Agitator weight on name plate).
Locate Centre of gravity before moving the Agitator.
4303-0051
7

3 Installation
The instructions manual is part of the delivery.
Study the instructions carefully
TD605-103
WARNING
Do NOT use eye bolts on gear motor to lift the Agitator. They are only for gear motor removal.
TD605-101
WARNING
Do NOT use eye bolts on shroud (if any) to lift the Agitator.
They are only for shroud removal.
4303-0052
8

3 Installation
The instructions manual is part of the delivery.
Study the instructions carefully
CAUTION
Alfa Laval recommends NOT to use shaft as lifting point but long shafts must be supported adequately during lifting to
protect shaft, bearings and seals arrangements.
Gear motor / motor may be used for lifting the assembled Agitator.
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.
9

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see chapter 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
3.2 Installation
Always read the technical data thoroughly (see chapter 6.1 Technical data).
Only install this Agitator in mounting angle according to the name plate (see chapter 6.1 Technical data).
Always use lifting equipment when handling the Agitator (see Step 2).
Always have safety elements removed by authorized personnel.
Never coverorr
emove 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.
Welding flange:
CAUTION
Only authorized personnel to weld in flanges.
Alfa Laval cannot be held responsible for incorrect installation.
TD605-096
Step 1
Dismantle the welding flange if fitted onto the Agitator.
2
1
TD605-004
10

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see chapter 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Step 2
Ensure that the tank, where the welding flange are to be welded in,
can handle the forces applied by the Agitator: Torque Mv, Bending
torque Mb and Side thrust Fs.
The values are depending on the Agitator configuration. The
following information is required to calculate the forces:
P: Power of the motor in [kW]
n: Speed of Agitator shaft [RPM]
S: Shaft length according to Agitator type designation -Sxxxx-
in [mm]
D: Largest impeller diameter according to Agitator designation
-Pxxx- in [mm]
The values can be calculated as follows:
Type ALS/ALB:
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 3
During the design phase of the tank, ensure sufficiently rigidity
of the tank.
Ensure that the max. bending angle (A), at loads from Step 2 does
not exceed according to below scheme
RPM: <100 >100
A° (max bending angle at applied loads): 0.1 0.05
A
TD605-213
Mb
Fs
Fs
Mb
11

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see chapter 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Guidelines for installing Flat Shaped Welding Flange (FSWF), ALS Agitator:
(for mounting flange without nose)
CAUTION
Alfa Laval recommend that all other welding tasks on the tank are finished before installing welding flange in tank.
ALS Agitator must be installed in the tank as shown in chapter 6.2 Mounting angle for side mounted Agitator type ALS which can
be achieved as shown on the illustration below.
1. Tank wall
2. Cone for welding flange
3. Welding flange 1
2
3
4305-0004
1
2
3
4305-0005
12

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see chapter 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Guidelines for installing Flat Shaped Welding Flange (FSWF), ALB Agitator:
(for mounting flange with nose)
CAUTION
Alfa Laval recommend that all other welding tasks on the tank are finished before installing welding flange in tank.
ALB Agitator must be installed in the tank as shown in chapter 6.3 Mounting angle for bottom mounted Agitator type ALB
which can be achieved as shown on the illustration below.
In case of installation of Welding Flange parallel to tank bottom surface (shaft perpendicular to tank bottom surface) it is always
recommended to use a bead/cone. This is to ensure that tank bottom stresses / forces are not transmitted directly to the
Welding Flange increasing the risk of leakages.
1. Tank bottom
2. Cone for welding flange
3. Welding flange
1
2
3
4305-0007
1. Tank bottom
2. Cone for welding flange
3. Welding flange
4. Weldings
1
2
3
2
3
*
4
4305-0008
CAUTION
Ensure that no weldings are applied to the outside surface of the welding flange* as the Agitators mounting flange has the same
size as the welding flange. If weldings by mistake are applied to the surface of the welding flange it must be removed by grinding,
or the like, to ensure a correct fit and installation of the mounting flange.
13

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see chapter 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Welding procedure FSWF, ALS Agitator:
(for mounting flange without nose)
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
14

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see chapter 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
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
15

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see chapter 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Welding procedure FSWF, ALB Agitator:
(for mounting flange with nose)
NOTE
Alfa Laval recommend a welding tool with, if possible, build in cooling by flowing water, to be made and fixed to the FSWF to
ensure shape and form of the FSWF during welding and installation.
In general Alfa Laval recommend to weld the welding flange onto a bended rim of the tank bottom plate – this is to secure
adequate flexibility at high loads, e.g. when the tank is filled. If a bended rim is impossible to obtain due to a high plate
thickness, Alfa Laval recommend to weld the welding flange onto a cone shaped plate section.
If not following the above recommendations there will be a risk that the flange can deform, especially at high tank fillings, which
can cause a leakage between the welding flange and the Agitator mounting flange.
Step 1
Position the flange correctly.
Always allow flange to cool to ambient temperature after each section has been welded.
Step 2
Spot weld from outside.
4303-0153
A
C
Adjust alignment!
4303-0154
B D
Step 3
Spot weld from inside
TD605-216
5
12
7
1
11
3
10
2
6
4
8
9
16

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see chapter 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Step 4
Weld the following sections first from inside then from outside and cool to ambient temperature after each section has been
welded
Step 1 Step 2 Step 3
TD605-217
A
B
C
D
E
F G
H
1
2
3
TD605-218
4
5
A
B
C
D
E
F
G
H
TD605-219
A
B
C
D
E
F G
H
8
6
7
Cool with air! Cool with air! Cool with air!
Step 5
Remove the welding tool.
Ensure that the surface flatness tolerance equals ±0.1mm.
Grind and polish the welding flange.
17

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see chapter 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Mounting Agitator:
CAUTION
Always ensure that mounting is carried out according to description shown in chapter 6.2 Mounting angle for side mounted
Agitator type ALS and chapter 6.3 Mounting angle for bottom mounted Agitator type ALB.
Always refer to tightening torques in chapter 6.5 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 (III) is removed (see chapter 8.1 Drive unit
instructions).
III
I
4303-0053
1) Standard vent plug
2) Transport securing device
Step 2
Mount the Agitator onto the tank.
18

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see chapter 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Step 3
Mount impeller device(s) onto shaft.
Hub diameter [mm] a - dimension [mm]
Ø30 1,1
Ø40 1,8
Ø55, Ø80, Ø120 2,8
TD605-037
3 x
3 x
TD605-038
aa
All-weld propeller to shaft with one welding seam at
a time, cool with air and continue with one welding
until welding is according to illustration. Use welding
procedures which introduce as less heat, tension
and bending to the shaft as possible.
TD605-035
x 4 x 1
TD605-036
TD605-031
TD605-032
TD605-033
TD605-034
19

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see chapter 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Step 4
Ensure the impeller device orientation is correct according to the direction of the desired flow. The direction is determined by the
letter "D" or "U" in the last part of the Agitator type description. E.g. -E400D3P has the letter "D" which means the flow direction
is away from the drive unit. -E400U3P has the letter "U" which means the flow direction is towards the drive unit.
Step 5
Ensure the impeller is positioned, keeping minimum radial
distance to the tank.
Further installation requirements regarding the position can
be found in chapter 6.2 Mounting angle for side mounted
Agitator type ALS and chapter 6.3 Mounting angle for
bottom mounted Agitator type ALB to ensure optimum
performance.
Clearance > S/15
and
Clearance > 20mm
4303-0144
Step 6
If propellers has been all-welded to the shaft (not if it has been all-welded to the shaft-end) it can be necessary to align the shaft,
using heat and or bending forces according to specifications and instructions in chapter 6.6 Shaft alignment.
WARNING
Step 7
CAUTION
Do NOT connect the power supply until installation is completed.
Follow instructions in chapter 8.1 Drive unit instructions.
Ensure that the rotation direction is according to nameplate.
Always perform pre-use check before operation (see chapter 3.3 Pre-use check).
NOTE
On closed tanks, Alfa Laval recommends installing a manhole circuit breaker, cutting power supply if hatch is open.
20