Alfalaval ALT User manual

4303-0143
ESE03504-EN9 2020-10
Original manual
Instruction Manual
Alfa Laval Agitator - ALT / ALTB

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 ....................................................................... 5
2. Safety .................................................................................................... 6
2.1. Important information ............................................................................. 6
2.2. Warning signs ..................................................................................... 6
2.3. Intended use ...................................................................................... 6
2.4. Safety precautions ................................................................................ 7
3. Installation .............................................................................................. 8
3.1. Unpacking/delivery ............................................................................... 8
3.2. Installation ......................................................................................... 11
3.3. Pre-use check ..................................................................................... 22
3.4. Recycling information ............................................................................. 24
4. Operation ............................................................................................... 25
4.1. Operation/Control ................................................................................. 25
4.2. Troubleshooting ................................................................................... 26
4.3. Cleaning - recommendations .................................................................... 27
4.4. Temperature limits ................................................................................ 27
4.5. Pressure limits ..................................................................................... 28
5. Maintenance ........................................................................................... 29
5.1. General Maintenance ............................................................................. 29
5.2. Replacement of drive unit with bearing frame ................................................. 30
5.3. Replacement of drive unit ........................................................................ 32
5.4. Replacement of drive unit (Motor and shaft unit) .............................................. 34
5.5. Dismantling and mounting shaft (with bearing frame except BC160) ....................... 35
5.6. Replacement of bearings, type B20, B25, B25/30, B35, B35/40, B45, B45/50, B55,
B55/60 ............................................................................................. 37
5.7. Replacement of bearings, type BC160DH ..................................................... 39
5.8. Replacement of bearing, type BC160D ........................................................ 41
5.9. Replacement of bearings type BC160 .......................................................... 43
5.10.Replacement of shaft seal, type D .............................................................. 45
5.11.Replacement of shaft seal, type DC ............................................................ 48
5.12.Replacement of shaft seal, type S (and type S with dust trap) ............................... 51
5.13.Replacement of shaft seal, type S3 ............................................................. 55
5.14.Replacement of shaft seal, type R or G ........................................................ 58
5.15.Replacement of shaft seal, type V .............................................................. 61
5.16.Replacement of wear bushing in intermediate bearing support .............................. 63
5.17.Replacement of wear bushing in bottom support ............................................. 64
6. Technical Data ......................................................................................... 65
6.1. Technical data ..................................................................................... 65
6.2. Mounting angle for top mounting agitator type ALT ........................................... 66
6.3. Mounting angle for top mounting agitator type ALTB ......................................... 68
6.4. Connecting flush – Seal type D .................................................................. 69
6.5. Connecting flush – Seal type DC ................................................................ 71
6.6. Tightening torques for bolt connections ........................................................ 73
6.7. Shaft alignment ................................................................................... 74
6.8. Spider coupling ................................................................................... 76
6.9. Bottom support alignment ....................................................................... 77
6.10.Bottom support positioning ...................................................................... 78
3

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
6.11.Storage ............................................................................................ 79
7. Part lists, part drawings and service kits ......................................................... 80
7.1. Agitator Main Components, Drive end .......................................................... 80
7.2. Agitator Main Components, Wet end ........................................................... 82
7.3. Bearing frame, B20, B25, B25/30, B35, B35/40, B45, B45/50, B55, B55/60 ............. 84
7.4. Bearing frame BC160/35, BC160D/30, BC160DH/30 ....................................... 88
7.5. Shaft seal, type S ................................................................................. 90
7.6. Shaft seal, type S with dust trap ................................................................ 92
7.7. Shaft seal, type S3 ................................................................................ 94
7.8. Shaft seal, type D ................................................................................. 98
7.9. Shaft seal, type DC ............................................................................... 100
7.10.Shaft seal, type R ................................................................................. 104
7.11.Shaft seal, type G ................................................................................. 108
7.12.Shaft seal, type V ................................................................................. 112
7.13.Intermediate support ............................................................................. 114
7.14.Bottom support, type 3 .......................................................................... 116
7.15.Tools ............................................................................................... 118
8. Appendix ............................................................................................... 120
8.1. Drive unit instructions ............................................................................. 120
4

1 EC Declaration of Conformity
Revision of Declaration of Conformity: 2018-02-01
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 / EnSaFerm
Serial number from AAC000000001 to AAC999999999
Serial number from 10.000 to 100.000
Serial number from 100700000001 to 100799999999
Designation Serial no(s)
GX = GC, GR or GP
BXX/XX = B20, B25, B25/30, B35, B35/40,
B45, B45/50, B55, B55/60
ALT(B)-ME-(GX)-BC160D(H)/30(L)F-SX-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) SX = S, S3
ALT(B)-ME-(GX)-BC160/35(L)F-SX-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) SH = S500-S15000
ALT(B)-ME-(GX)-BXX/XX(L)F-SX-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) PXXXX E125, E150, E175, E200, E225, E250, E300
ALT(B)-ME-(GX)-BC160D(H)/30(L)F-D(C)-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) E350, E400, E450, E500, E550, E600, E650
ALT(B)-ME-(GX)-BC160/35(L)F-D(C)-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) E700, E750, E800, E900, E1000, E1100
ALT(B)-ME-(GX)-BXX/XX(L)F-D(C)-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) E1300, E1500, E1700, E1900
ALT(B)-ME-(GX)-BC160D(H)/30(L)F-R-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) F450, F500, F550, F600, F650, F700, F750,
ALT(B)-ME-(GX)-BC160/35(L)F-R-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) F800, F900, F1000, F1100, F1300, F1500
ALT(B)-ME-(GX)-BXX/XX(L)F-R-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) F1700, F1900
ALT(B)-ME-(GX)-BC160D(H)/30(L)F-G-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) LXXXX = L600, L800, L900, L1100, L1300,
ALT(B)-ME-(GX)-BC160/35(L)F-G-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) L1500, L1700
ALT(B)-ME-(GX)-BXX/XX(L)F-G-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) DY = D2, D3
ALT(B)-ME-(GX)-ZZ(L)F-SX-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) Y = P, G
ALT(B)-ME-(GX)-ZZ(L)F-D(C)-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) BSXX BS3P, BS3G
ALT(B)-ME-(GX)-ZZ(L)F-R-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) MSXX = MS2P, MS2G
ALT(B)-ME-(GX)-ZZ(L)F-G-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) ZZ = 20, 25, 30, 35, 40, 45, 50, 55, 60, 65,
ALT-ME-ZZF-V-SH-PXXXXDYY 70, 75, 80, 90
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 2020-02-01
Place Date (YYYY-MM-DD) Signature
5

2Safety
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 problemandisNOTadrawingofthecurrentAgitator!
2.1 Important information
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the agitator!
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
!
Dangerous electrical voltage:
2.3 Intended use
- The Alfa Laval Agitator is only for mixing/stirring of liquids in a tank.
- The Agitator is only for mounting positions as specified on the nameplate by the first group of letters of the type designation.
ALT(B)- is for top mounting, ALS- is for side mounting and ALB- is for bottom mounting.
The exact mounting angle is specified on the Name Plate and must be followed. Definitions on mounting angles can be seen in
section 6.2 Mounting angle for top mounting agitator type ALT.
- The different duties and operation data like pressure, speed and media temperature, which the Agitator is designed for, can
be found in the Alfa Laval quotation 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.
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 chapter 6 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.
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 altitudeslessthan1000mabovesealevel.
!
Never touch the moving parts while the Agitator is connected to the power supply.
Operation:
Always read the technical data thoroughly (see chapter 6 Technical Data).
Always read supplier instructions thoroughly (see chapter 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 chapter 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 chapter 6 Technical Data).
Always follow the maintenance instruction thoroughly (see chapter 5 Maintenance).
Always follow the maintenance instruction from drive unit supplier (see chapter 8 Appendix).
Always study the parts list and assembly drawing carefully (see chapter 7 Part lists, part drawings and service kits).
!
Never 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.
7

3 Installation
The instructions manual is part of the delivery.
Study the instructions carefully.
3.1 Unpacking/delivery
Always use lifting equipment when handling the Agitator (see step 3).
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Step 1
Inspect the delivery for visible transportation damages - all issues to be reported to carrier.
Step 2
Check the delivery for:
1. Complete Agitator
2. Nameplate designations
3. Delivery note
4. Separate instruction manuals from suppliers (see chapter 8 Appendix).
4303-0006
Step 3
Lifting instructions:
Always use the correct lifting equipment (see Agitator weight on name plate).
Locate Centre of gravity before moving the Agitator.
4303-0051
8

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
9

3 Installation
The instructions manual is part of the delivery.
Study the instructions carefully.
CAUTION
Alfa Laval recommends NOT to use shaft as lifting point but long shafts must be supported adequately during lifting to protect
shaft, bearings and seals arrangements.
Gear motor / motor may be used for lifting the assembled agitator.
NOTE
If possible, lift the Agitator in horizontal position, andintwopoints.
Step 4
During transportation
1. Alwayssupport the shaft adequately, to protect shaft and bearings.
2. Neverexpose the Agitator to undue vibrations or shocks.
3. Control for oil leakage on gears with vent screw.
10

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see section 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
3.2 Installation
Always read the technical data thoroughly (see chapter 6 Technical Data).
Only install this Agitator in mounting angle according to the name plate (see chapter 6 Technical Data).
Always use lifting equipment when handling the Agitator (see Step 2).
Always have safety elements removed by authorized personnel.
Never cover or remove the nameplate.
Never connect to power supply during installation or service.
Always have the Agitator connected to power supply by authorized personnel.
NOTE
Alfa Laval highly recommend to install motor protection guard to protect the motor from overloading.
NeverinstallanoneAlfaLavalshroudontheagitatoras it can lead to overheat and a breakdown of the motor.
Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilogram and a
shaft diameter between Ø30 and Ø60 (see section 7.15 Tools).
Welding flange - Flat Shaped Welding Flange (FSWF):
CAUTION
Only authorized personnel to weld in flanges.
Alfa Laval cannot be held responsible for incorrect installation.
TD605-096
Step 1
Dismantle the FSWF if fitted onto the Agitator.
2
1
TD605-004
11

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see section 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Step 2
Ensure that the tank, where the welding flange are to be welded in,
can handle the forces applied by the agitator: Torque Mv, Bending
torque Mb and Side thrust Fs.
The values are depending on the Agitator configuration. The
following information is required to calculate the forces:
P: Power of the motor in [kW]
n: Speed of Agitator shaft [RPM]
S: Shaft length according to Agitator type designation -Sxxxx-
in [mm]
D: Largest impeller diameter according to Agitator designation
-Pxxx- in [mm]
The values can be calculated as follows:
Type ALT / ALTB:
Mv [Nm] = 23873 x P / n
Fs [N] = 4.5 x Mv x 1000 / D
Type ALT:
Mb [Nm] = Fs x S / 1000
Type ALTB:
Mb [Nm] = Fs x S / 5333
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
12

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see section 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Guidelines for cutting hole in tank for Flat Shaped Welding Flange (FSWF)
CAUTION
Alfa Laval recommend that all other welding tasks on the tank are finished before cutting the hole for the flange.
Chamfer inner and outer hole edge 45°.
45°
45°
TD605-023
13

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see section 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Welding procedure, flange (FSWF) without nose:
Step 1
Always allow flange to cool to ambient temperature after each section has been welded
Position the flange correctly
TD605-006
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
14

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see section 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Welding procedure, flange (FSWF) with nose:
NOTE
Alfa Laval recommend a welding tool with, if possible, build in cooling by flowing water, to be made and fixed to the FSWF to
ensure shape and form of the FSWF during welding and installation.
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.
Ifnotfollowingtheaboverecommendationstherewillbeariskthat 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.
TD605-214
A
C
Adjust alignment!
TD605-215
B D
Step 3
Spot weld from inside
TD605-216
5
12
7
1
11
3
10
2
6
4
8
9
15

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see section 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Step 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.
16

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see section 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Welding procedure for divided shaft with thread connection:
NOTE
Only relevant for divided shafts prepared for welding.
Step 1
Ensure that shaft ends are screwed completely together.
Step 2
Spot weld and cool with air.
Step 3
All-weld shaft connections with one welding seam at a time, cool
with air and continue with one welding until welding is according
to illustration. Use welding procedures which introduce as less
tension and bending to the shaft as possible.
Step 4
If shaft sleeve is used weld as described in step 3.
Step 5
Align the shaft, using heat and or bending forces according to specifications in section 6.7 Shaft alignment.
17

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see section 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Mounting Agitator:
CAUTION
Always ensure that mounting is carried out according to description shown in section 6.2 Mounting angle for top mounting
agitator type ALT and 6.3 Mounting angle for top mounting agitator type ALTB.
Always refer to tightening torques in section 6.6 Tightening torques for bolt connections when tightening bolts.
Step 1
Place impeller device(s) in the tank.
Ensure that tank and Agitator surfaces are clean.
Ensure that drain (I) is pointing downwards.
For gears with vent screw, ensure the vent is pointing upwards and the rubber plug (III) is removed (see section 8.1 Drive unit
instructions).
III
I
4303-0053
1) Standard vent plug
2) Transport securing device
Step 2
Mount the Agitator onto the tank.
NOTE
Alfa Laval recommends using shaft retainer tool during mounting and dismantling (see section 7.15 Tools).
Step 3
(Only for ALTB machines with Intermediate steady bearing)
- Mount the intermediate steady bearing onto the shaft.
- Ensure before welding that the intermediate steady bearing is
perpendicular to the mounting flange.
- Position wear bushings according to shaft diameter.
TD605-137
18

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see section 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Step 4
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
Step 5
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.
19

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Always check the Agitator before operation - see section 3.3 Pre-use check.
The Agitator is for permanent fastening.
Make sure that the motor correspond to the environment.
Step 6
Ensure the impeller is positioned, keeping minimum radial
distance to the tank.
Further installation requirements regarding the position can
be found in 6.2 Mounting angle for top mounting agitator
typeALTand6.3Mountinganglefortopmountingagitator
type ALTB to ensure optimum performance.
Clearance > S/15xsin(V)
NOTE
In special cases clearance can be reduce to 20mm+actual
deflection, please advice with Alfa Laval.
S
15
TD605-026
S
>
__
V
Clearence
Step 7
(Only when shaft is divided)
Assembleallshaftpartsasshownonthefigure.
Step 8
Align the shaft, using heat and or bending forces according to
specifications and instructions in section 6.7 Shaft alignment.
20