Alfalaval ALTB-SB-30 User manual

ESE03057-EN5 2018-08
Original manual
Instruction Manual
ALTB-SB-30

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. Requirement for installation, personnel ......................................................... 8
3.3. Installation (with cutting/machining and welding required) ..................................... 8
3.4. Installation (assembling) .......................................................................... 12
3.5. Installation, electrically ............................................................................ 25
3.6. Recycling information ............................................................................. 25
4. Operation ............................................................................................... 26
4.1. Operation .......................................................................................... 26
4.2. Inspection ......................................................................................... 26
4.3. Troubleshooting ................................................................................... 26
4.4. Cleaning ........................................................................................... 27
5. Maintenance ........................................................................................... 28
5.1. General Maintenance ............................................................................. 28
5.2. Disassembling of agitator ........................................................................ 28
5.3. Replacement of gear motor ..................................................................... 28
5.4. Replacement of seals ............................................................................ 28
5.5. Replacement of Bearing for bottom console ................................................... 28
6. Technical Data ......................................................................................... 29
7. Parts list / Service Kits ............................................................................... 30
7.1. ALTB-SB-AE (with aeration) ..................................................................... 30
7.2. ALTB-SB (without aeration) ...................................................................... 32
7.3. ALTB-SB (with and without aeration) ........................................................... 34
7.4. Mounting Tools .................................................................................... 43
7.5. Installation Drawings .............................................................................. 44
8. Appendix ............................................................................................... 47
8.1. Declaration of Compliance ....................................................................... 47
8.2. Order specific “Tank With Agitator” drawing, example ........................................ 48
8.3. WPS ................................................................................................ 49
8.4. Drive unit lubrication .............................................................................. 50
8.5. Drive unit instruction .............................................................................. 55
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
ALTB-SB
Designation
30
Type
is in conformity with the following directives with amendments:
Machinery Directive 2006/42/EC
FDA 21CFR§177
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 2017-03-01
Place Date Signature
(This Declaration of Conformity replaces Declaration of Conformity dated 2015-06-02)
4

2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
2.1 Important information
Always read the manual before using the agitator!
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:
Caustic agents:
Dangerous electric voltage:
2.3 Intended use
- The Agitator in 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.
5

2Safety
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 valve are avoided.
2.4 Safety precautions
2.4.1 Installation:
Always read the technical data thoroughly (see 6 Technical Data).
Always follow installation instructions thoroughly (see 3 Installation).
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 1000 m above sea level.
Only use authorized personnel when electrically equipment is connected.
2.4.2 Operation:
Always read the technical data thoroughly (see 6 Technical Data).
Never start Agitator in the wrong direction of rotation.
Beware of Agitator in operation can produce sound levels in excess of 85dB(A).
Always handle lye and acid with great care.
Always rinse well with clean water after cleaning.
Never run the agitator for a longer time (seconds) without product, water or cleaning liquid in the tank.
2.4.3 Maintenance:
Always follow the maintenance instruction thoroughly (see 5 Maintenance.)
Always follow the maintenance instruction for gear motor thoroughly (see 8.5 “Drive unit instruction”).
Always study the parts list and assembly drawing carefully (see 7 Parts list / 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 propeller before startup and after any maintains there might have impact on
the direction.
Never service the agitator or tank with product or cleaning liquid in the tank.
2.4.4 Transportation:
Alwaystransport 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 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.
3.1 Unpacking/delivery
Always use lifting equipment when handling the agitator.
Alfa Laval cannot be held responsible for incorrect unpacking.
Step 1
3.1.1 Inspect the delivery for visible transportation damage (crates and packaging) - all issues should be reported to carrier.
Step 2
3.1.2 Check that deliveries are according to delivery notes.
Complete Agitators can be delivered in more than one shipment.
Agitators can be delivered as one of the following:
1. Agitator parts and instruction manual required for tank builder to install shafts and propellers.
2. Agitator parts and instruction manual required for tank builder to install drive unit (gear motor) and sealing system.
3. As 1) and 2) in one shipment.
Step 3
3.1.3 Inspect Agitator parts for visible transport damage.
Step 4
3.1.4DoNOTuse eye bolts on gear motor to lift the Agitator. They are only for gear motor removal.
Step 5
3.1.5 During lifting:
- Always support the shaft adequately to protect shaft and bearings.
- Be carefully not to damage shaft-end with treads.
- Never expose the Agitator to undue vibrations or shocks.
- Control for oil leakage on gears – leave vent plug in gear until gear is installed and in correct position.
Figure 1, un-activated vent plug
7

3 Installation
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.
3.2 Requirement for installation, personnel
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 carried out safe for personnel
and property.
Erectors:
Experience from similar types of installation.
Proven skills in reading installation guidelines and drawings ensuring that the installation is carried out safe 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 carried out safe for personnel
and property.
3.3 Installation (with cutting/machining and welding required)
3.3.1 Requirement for installation
This work should be carried out by at least two persons and for safety reasons a platform or a scaffold should be
established around the tank top.
During installation ensure to use sufficient lightning.
The tank top must be horizontally during installation – if that is not the case, a laser must be used to ensure that the
right position for the “Bottom Console” can be found.
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 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 to the Agitator.
8

3 Installation
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.
All position numbers and item numbers refer to the drawings show and specified in 7 Parts list / Service Kits
Step 1
3.3.2
See illustration in 7.5. page 44.
A. The three “Adjustable Leg For Bottom Console” pos. 70 are fastened to the “Bottom Console for Agitator” pos. 74 using
the three “Screw” pos. 77.
B. The assembled “Bottom Console”, “Screw” pos. 89, “Washer” pos. 84, “Tool – Mounting Shaft Welded” pos. 87, “Propeller,
Lower” pos. 73, “Agitator Shaft” pos. 71 (if delivered), “Propeller, Upper” pos. 72 (if delivered), “Agitator Shaft” pos. 75 are
lowered into the tank and assembled. In some cases all the parts can be assembled outside the tank and lowered into the
tank assembled. All threads must be greased to ensure not to damage the threads.
C. According to the order specific drawing "Agitator with Tank" that comes with the manual (not in the manual) the correct
Agitator position is selected (0/125/175 mm off center) which specify which position of holes to be used (data in this
manual are not to be used – find order specific drawing).
Example of an order specific drawing "Order specific ‘Tank With Agitator’ drawing, example" are to be found in 8.2, page 48.
D. Mount the “Tool Guide Plate” pos. 80 on the “Tank mounting flange” pos. 99 letting the shaft pos. 75 entering the correct
hole in pos. 80. The “Tool Guide Plate” must be fastened to the tank top using two diagonally located holes in the tank top.
E. Mount the “Tool – Top Guide” pos. 82 to the “Tool Guide Plate” pos. 80 using the four “Screw” pos. 88.
F. The “Screw” pos. 90 is used to fasten the shaft in vertical direction during adjustment of the “Bottom Console” pos. 74.
9

3 Installation
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.
Step 2
3.3.3 See illustration in 7.5.1. page 44.
A. If the tank top is horizontally within 0,5° the gravity can be used
as guideline for position of the “Bottom Console” – if it is not
possible to adjust the tank top to horizontally position (within
the tolerance) a laser pointer must be used to ensure that the
right position for the “Bottom Console” is found.
B. The Agitator is lifted to the correct position as shown on the
order specific drawing "Tank with Agitator" that comes with
the manual (not in the manual).
Example of an order specific drawing "Order specific ‘Tank With
Agitator"drawing,example’aretobefoundin8.2page,48.
The "Screw" pos. 90 is tightened (not more than sufficient) to
fasten the shafts in vertical position.
C. When the agitator shaft is in correct position the three
“Adjustable Leg For Bottom Console” pos. 70 are
adjusted/rotated facing the tank bottom and the three “Screws”
pos. 77 are fastened. If the legs on “Bottom Console for
Agitator”pos. 74aretoolongtheyarecuttotherequired
length.
D. Tag weld the three “Adjustable Leg For Bottom Console” pos.
70 to the tank bottom using TIG welding.
E. Untighten the “Screw” pos. 90 ensure that the shaft can rotate
freely.
F. Tighten the two screws again and finish the welding.
G. Remove one “Screw” pos. 77 and fill the thread hole with
welding, continue one by one with the two other screws.
H. Remove the “Screw” and “Washer” pos. 84, 89, 90.
I. Verify that the shaft can rotate freely.
J. Grind the welded seams to the required finish.
Figure 2, Height of Bottom Console
Figure 3, Tightening screws
Figure 4, Welding Bottom Console
10

3 Installation
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.
Step 3
3.3.4 See illustration and Parts List in 7.5.1 and 7.5.3.
A. Using a permanent pen do a marking line at position ∆1as
shown on 7.5.1. page 44 on the shaft pos. 75.
B. Verify that the line is at the same vertical position as the
upper surface of the tank top flange (welding flange) pos.
99.
C. Remove the “Tool” parts pos. 88, 82, 80.
D. Using the equation: X1 = “Thickness of Gasket, pos. 101” +
“Thickness of Top Plate, pos. 100”, mark the cutting line ∆2.
e.g:
Thickness of Gasket = 5 mm
Thickness of Top Plate = 20 mm
X1=5+20=25m
if an O-ring is used as gasket the “Thickness of Gasket” = 0
E. The “Agitator Shaft” is delivered longer than needed and
should be shortened to no more than 350 mm. If it must be
shortened more, the outside diameter must be machined
to fit the “Shaft Male Connection” pos. 76 inner diameter
within a 0,1 mm tolerance.
F. Cut the “Agitator Shaft” pos. 75 at the cutting line ∆2.
G. Press the “Shaft Male Connection” pos. 76 onto the
“Agitator Shaft” pos. 75 firmly and ensure that it is aligned
with the shaft.
H. Weld it as shown on 7.5.1. page 44 and in WPS in 8.3.
I. Grind the welded seams to the required finish.
Figure 5, Marking of pos.∆1
Step 4
3.3.5
A. Unscrew and disassembly the shafts and propeller unit – label all the parts carefully with item number and tank number.
B. Arrange careful transportation of the tank and the agitator parts to the destination.
11

3 Installation
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.
3.4 Installation (assembling)
3.4.1 Mounting of O-Rings in general
A. Apply some food-approved grease to the O-ring
Figure 6, Greasing O-ring
B. Press the O-ring into the appropriated groove at position 0°
and 180°
Figure 7, Inserting O-ring
C. Press the O-ring into the appropriated groove at position 90°
and 270°
Figure 8, Inserting O-ring
12

3 Installation
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.
Step 5
3.4.2 See illustrations, 7.1, 7.2, and 7.5.3.
A. Mount the “Bearing For Bottom Console” pos. 32 into the “Bottom Console” pos. 74.
B. Clean all shaft, propeller and Guide Spindel (pos. 9) threads for grease.
C. Assemble the shaft and propeller unit inside the tank with gaskets, o-rings and Loctite®: pos. 3, 9, 30, 33, 34, 35, 36,
71, 72, 73, 75, 76.
D. Tighten all threads to 100-300 Nm.
E. Press the “Spray Ball Bearing” pos. 31 onto the “Gear Shaft”, pos. 3.
F. Avoid hard bumping against the bottom console bearing.
G. In some cases all the parts can be assembled outside the tank and lowered into the tank assembled.
13

3 Installation
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.
Step 6
3.4.3 See illustrations, 7.1, 7.2, and 7.5.3.
A. Mount the “Gasket” pos. 101 and the “Top Flange” pos. 100 – tight with a couple of screws.
B. Insert the “O-ring” pos. 37 (see also illustration in 3.4.4 Step 7) into the “Tube, CIP for Spray Ball” pos. 8.
C. Position the “Tube, CIP for Spray Ball” pos. 8 onto the “Top Flange” pos. 100.
14

3 Installation
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.
Step 7
3.4.4 See illustrations, 7.1, 7.2, and 7.5.3.
A. Press in the two “Guide Pin” pos. 14 into the “Console For Agitator”, pos. 7.
B. Pressinthetwo“O-ring”pos. 38intopos. 7.
C. Mount the “Console For Agitator”, pos. 7 on the “Tube, CIP for Spray Ball” pos. 8.
15

3 Installation
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.
Step 8
3.4.5 See illustrations, 7.1, 7.2, and 7.5.3.
A. Apply some food approved grease to the shaft and to the inside of the rotating part of the “Single Mechanical Seal” pos. 29.
B. Remove the PTFE sliding part of the rotating part of the seal and slide the rotating part of pos. 29 along the shaft to
the shoulder on the shaft.
Figure 9, PTFE sliding part of
rotating part of seal
16

3 Installation
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.
A. “Tool – Top Guide” pos. 82 can also be used to press the rotating part of the seal pos. 29 along the shaft.
B. Mount again the PTFE sliding part of the rotating part of the seal pos. 29.
Figure 10, Pressing down the seal
17

3 Installation
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.
Step 9
3.4.6 See illustrations, 7.1, 7.2, and 7.5.3.
A. Press in the “O-ring” pos. 38 into pos. 6.
B. Apply some food-approved grease to the “O-ring” mounted on the stationary part of the seal pos. 29.
Figure 11, O-ring for stationary part of seal
C. Mount the “O-ring” onto the stationary part of the seal pos. 29 and press in gently both parts into the “Intermedia coupling”
pos. 6.
D. Clean both sliding surfaces on the seal pos. 29 with some alcohol.
18

3 Installation
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.
E. Mount the “Gasket Support” pos. 11 into the “Intermedia coupling” pos. 6 – use some food approved grease to “glue” it in.
Figure 13, Gasket support Figure 12, Gasket support in place
F. Ensure that the two holes in pos. 6 and pos. 7 for the “Guide Pin” pos. 12 are aligned and positioned in a way that still
enables access to the four threads in the pos. 7.
G. Mount the pos. 6 onto the pos. 7.
H. Press / hammer down the two “Guide Pin” pos. 12.
19

3 Installation
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.
Step 10 (only for ALTB-SB-AE, Agitators with aeration)
3.4.7 See illustrations, 7.1 and 7.5.3.
A. Mount the circlip pos. 15 onto the shaft pos. 3.
B. Apply some food-approved grease to the shaft and to the inside of the rotating part of the “Single Mechanical Seal” pos. 29.
C. Remove the PTFE sliding part of the rotating part of the seal and slide the rotating part of pos. 29 along the shaft until
circlip pos. 15.
D. Mount again the PTFE sliding part of the rotating part of the seal pos. 29.
E. Press in the “O-Ring” pos. 38 into pos. 10.
F. Apply some food approved grease to the “O-ring” mounted on the stationary part of the seal pos. 29.
G. Mount the “O-ring” onto the stationary part of the seal pos. 29 and press in gently both parts into the gear console pos. 10.
H. Clean both sliding surfaces on the seal pos. 29 with some alcohol.
I. Position the gear console pos. 10 in a way that still enables access to the four threads in the pos. 7.
J. Press / hammer down the two “Guide Pin” pos. 13.
20