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MAN Diesel & Turbo


MANAGUA
Order No.: 4500968861
Al Order No.: 84.6893.31
MAN Material: 11.63010-0244
Al Order No.: 84.6893.31
Order No.: 4500968861

MANAGUA
MAN Diesel & Turbo
S 946 Flex Separation Module
S 946 Flex Separation Module
System Manual - English

System Manual

English
2

Process Data Sheets 1

S and P Flex Separation Safety 2

System Description 3

Operating Instructions 4

Parameter List 5

Alarms and Fault


Finding
6

Installation System
Reference
7

Separator Manual
Marine & Diesel Equipment
With Spare Parts Catalogue
8

Anncillary Components
With Spare Parts Catalogue
9
Printed June 2008
Document No. 587876-02
Configuration No. 108918-25
ANNEX 10
MAN Diesel & Turbo
MANAGUA

Order No.: 4500968861


Al Order No. 84.6893.31

S 946 Flex Separation Module


3

MAN Diesel & Turbo SE


D-86224 Augsburg

Process data
Lubeoil Separator type S946
Delivery as Flex Modules
Order Managua
th
December 16 , 2014
4

General

ALCAPTM-System
ALCAPTM was specially developed for cleaning of heavy fuel oils
Max. density of the oils to be cleaned 1.010 kg/m at 15 C
Combination of purifier and clarifier within one machine, thus no more series arrangement of a
purifier followed by a clarifier necessary
Continuous supervision of changes in water content in the clean oil outlet
Measuring principle independent from the conductivity of the separated water

Separators of the S type 921 to 987 series


Self cleaning ALCAPTM separators
EPC 60 control unit with multilingual clear text messages (English, German, French, Spanish,
Portuguese, Finnish,)
Discharge without pressure pulse and remarkably reduced sludge tank load due to
CentriShootTM discharge system
Maintenance free and easy to handle CentriLockTM bowl lock function
5

Process conditions
treated Oil Lube Oil
viscosity 84 cSt/50C
density 895 kg /m3 at 15C
feed temperature min. 50C
separation temperature 95C at normal conditions
max. effective capacity 5.000 l/h
colour C3, RAL 9002

Separator
type S946
quantity 1
separation principle ALCAP
discharge system centrishoot
clean oil discharge pressure 3.0 bar
electric motor, IE2 11,0 kW
sludge production (without water and solids), 1h discharge 153

Pump
working principle screw pump
type ALP 0075
quantity 1 per separator
pump capacity 5.090 l/h,
suction height 4,4 m
delivery height approx. 2 bar
speed 1.700 1/min
electric motor, IE2 2,0 kW

Steam heater
type CBM 30-40
quantity 1 per separator
steam pressure, temperature of the system 9 bar / 175C
design steam pressure, temperature heater 6 bar / 164C
pressure drop steam, oil 0,03 bar / 0,36 bar
oil temperature 50 --> 95C
steam consumption 197 kg/h
duty margin 38%
max. operation pressure / temperature 16 bar, 225C

Enviromental conditions
ambient temperature max. 55C
humidity 95 RH
altitude max. 1.500m for 95C separation temperature
installation of equipment indoor
6

Electrical supply
voltage / frequency 440 V, 60 Hz
control voltage 230 V
valve operating voltage 24 V

Operating water
Hardness < 180 g Ca CO3, 10 dH
chloride ions <100 ppm NaCl
pH- value 6,5 - 9
suspended matter max 10 ppm
particle size max. 50 m
feed temperature between +5 and 55C
feed pressure between 2 and 8 bar
required capacity of water min. flowrate 11 l per minute
average water consumption per discharge 6,4 liter

Compressed air
feed pressure between 5 and 8 bar
average air consumption 1,01 Nm3/h

Adjustments and set points


01MJV22 CT960 temperature transmitter
01MJV22 CT960 temperature alarm low 90C
01MJV22 CT960 temperature alarm high 100C
01MJV22 CP980 pressure transmitter clean oil discharge
01MJV22 CP980 pressure clean oil discharge alarms high: 3,0 bar / low: 1,2 bar
7

ABB Motors Technical Data Sheet - DOL


and Generators
Project Location

Department/Author Customer name Customer ref. Item name


3GAA131315-KDEAL1
Our ref. Rev/Changed by Date of issue Saving ident Pages
A 31-10-2011
No. Definition Data Unit Remarks
1 Product TEFC, 3-phase, squirrel cage induction motor
2 Product code 3GAA131315-KDEAL1
3 Type/Frame M3AA 132 SMB 2
4 Mounting IM2111
5 Rated output PN 9,5 kW
6 Service factor 1
7 Type of duty S1(IEC) 100%
8 Rated voltage UN 460 VD 5 % (IEC 60034-1)
9 Rated frequency fN 60 Hz 2 % (IEC 60034-1)
10 Rated speed nN 3510 r/min
11 Rated current IN 17,5 A
12 No-load current 4,6 A
13 Starting current Is/IN 8,5 Fullfilled IEC 60034-12 des. N,H
14 Nominal torque TN 30 Nm
15 Locked rotor torque TS/TN 2,5
16 Maximum torque Tmax/TN 4
17 Minimum torque Tmin/TN 2,5
18 Speed at minimum torque 0 r/min
Load characteristics (IEC 60034-2-1:2007) Load % Current A Efficiency % Power factor
19 PLL determined from residual loss 100 17,0 90,9 / IE2 0,93
20 75 13,1 91,5 0,9
21 50 9,4 91,2 0,84
22 Start 145 0,5
23 Maximum starting time from hot 15 s
24 Maximum starting time from cold 27 s
25 Insulation class / Temperature class F/B
26 Ambient temperature 55 C
27 Altitude 1000 m.a.s.l.
28 Enclosure IP55
29 Cooling system IC411 self ventilated
30 Bearing DE/NDE 6308-2Z/C3 - 6208-2Z/C3
31 Type of Grease
32 Sound pressure level (LP dB(A) 1m) 68 dB(A) at load
33 Moment of inertia J = GD2 0,01865 kg-m2
34 Balancing
35 Vibration class
36 Position of terminal box Top
37 Terminal box entries; no, dimens.
38 Number of power terminals
39 Direction of rotation CW or CCW
40 Weight of rotor 13 kg
41 Total weight of motor 77 kg
42 Dimension drawing no.
43
44
45
Ex-motors
46
47
48
Option Variant Codes / Definition
49 Rating plate
50 V Hz kW RPM CosPh A
51 380-420D 50 9,5 2915 0,91 17,5
52 660-690Y 50 9,5 2915 0,91 10,1
53 440-480D 60 9,5 3510 0,91 17,5
54
55
Remarks:

Data based on situation 13-11-2010


All data subject to tolerances in accordance with IEC
Guaranteed values on request
8

ABB Motors Technical Data Sheet - DOL


and Generators
Project Location

Department/Author Customer name Customer ref. Item name


1,00001
Our ref. Rev/Changed by Date of issue Saving ident Pages
A 21.11.2012 untitled.xls 1(3)
No. Definition Data Unit Remarks
1 Product TEFC, 3-phase, squirrel cage induction motor
2 Product code 3GAA 102 213-BSE
3 Type/Frame M2AA 100 LC 4
4 Mounting IM3001, B5(flange)
5 Rated output PN 2,2 kW
6 Service factor 1
7 Type of duty S1(IEC) 100%
8 Rated voltage UN 460 VY 5 % (IEC 60034-1)
9 Rated frequency fN 60 Hz 2 % (IEC 60034-1)
10 Rated speed nN 1760 r/min
11 Rated current IN 4,2 A
12 No-load current 2,5 A
13 Starting current Is/IN 9,1 Fullfilled IEC 60034-12 design N,H
14 Nominal torque TN 11,9 Nm
15 Locked rotor torque TS/TN 3,4
16 Maximum torque Tmax/TN 4,5
17 Minimum torque Tmin/TN 3,4
18 Speed at minimum torque 0 r/min
Load characteristics (IEC 60034-2-1:2007) Load % Current A Efficiency % Power factor
19 PLL determined from residual loss 100 4,2 87,6 / IE2 0,75
20 75 3,5 87 0,67
21 50 3,0 84,3 0,54
22 Start 38 0,58
23 Maximum starting time from hot 15 s
24 Maximum starting time from cold 27 s
25 Insulation class / Temperature class F/B
26 Ambient temperature 40 C
27 Altitude 1000 m.a.s.l.
28 Enclosure IP55
29 Cooling system IC411 self ventilated
30 Bearing DE/NDE 6306-2Z/C3 - 6205-2Z/C3
31 Type of Grease
32 Sound pressure level (LP dB(A) 1m) 57 dB(A) at load
33 Moment of inertia J = GD2 0,009 kg-m2
34 Balancing
35 Vibration class
36 Position of terminal box Top
37 Terminal box entries; no, dimens.
38 Number of power terminals
39 Direction of rotation CW or CCW
40 Weight of rotor 8 kg
41 Total weight of motor 25 kg
42 Dimension drawing no.
43
44
45
Ex-motors
46
47
48
Option Variant Codes / Definition
49
50
51
52
53
54
55
Remarks:

Data based on situation 2012-04-10


All data subject to tolerances in accordance with IEC
Guaranteed values on request
9

Three-screw Pump Sizing


project no.: position no.:
Betriebsdaten 1 Betriebsdaten 2
performance data operating data 1 operating data 2

medium Lube Oil


series (3S / ALP) ALP ALP
size 75 75
suction pressure bar 0,0 0,0
total pressure bar 2,0 2,0
difference pressure bar 2,0 2,0
viscosity mm/s 1 84 1 54
revolution 1/min 1700 1700
temperature C 50 60
20
capacity l/h 5134,1 5096,2
m/h 5,13 5,10
power requirement kW 0,77 0,70
min. suction pressure (abs.) mWs / mWC 5,94 6,05
NPSH required mWs / mWC 2,25 2,14
noise level pump dB (A) 57,1 57,1
torque Nm 4,3 4
efficiency (total) % 37,1 40,2
efficiency (volumetric) % 97,1 96,4
axial velocity m/s 2,0 2,0
moment of inertia kgm2 0,0001645 0,0001645

power required starting torque


power requirement (kW)

1 5,0

0,8 4,0
torque (Nm)

0,6 3,0

0,4 2,0

0,2 1,0

0 0,0
0 0,5 1 1,5 2 2,5 0 500 1000 1500 2000

pressure (bar) revolution (1/min)

capacity
100
90
capcity (l/min)

80
70
60
50
40
30
20
10
0
0 0,5 1 1,5 2 2,5

pressure (bar) operating data 1 operating data 2

&ND&Field1051744:VI&Field1051745:Auslegung&Field64:20.09.2012&Field1051747:148414&Field1056706:0010&Field1:
subject to change (04/2013) Version: 14.4.1 COPY RIGHT by KRAL

Alfa Laval Kolding A/S, P O Box 802, 6000 Kolding, Denmark; Tel.: +45 79 32 22 00 17. Dezember 2014
www.alfalaval.com, E-mail: info.dk@alfalaval.com
10
S and P Flex Separation 11

Safety
Printed Feb 2008
Book No. 584610-02 V 1
12

Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by: Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
Copyright Alfa Laval Tumba AB 2008.
13
S AND P FLEX SEPARATION SAFETY 1 SAFETY INSTRUCTIONS

1 Safety Instructions

Important read this!

The centrifugal separator includes parts


that rotate at very high speeds, generating
huge forces. It is therefore essential for the
safe operation of this separator system that
you read and understand this manual,
including the warning signs and safety

P0 03 7 02 A
precautions presented in this manual.
Failure to do so may cause a fatal accident.

1.1 Key Factors for Safe


Operation
The separation system is designed and supplied
for a specific function (type of liquid, rotational
speed, temperature, density, etc.). The system

P00 3 62 3A
must be used for this function only, and strictly
within Alfa Lavals specifications.
Incorrect operation or maintenance may result
in a heavy unbalance, reduction of material
strength, etc. that could lead to serious
breakdown with fatal injury or damage to
property.
For safe operation, strictly follow the
instructions for installation, operation and
maintenance in this manual.

584610-02 1
14
1 SAFETY INSTRUCTIONS S AND P FLEX SEPARATION SAFETY

The following is compulsory for safe


operation:
1 Never start up a separator before the bowl is
completely assembled, and all fastenings
securely tightened.
2 Never discharge a vibrating separator. Always
stop with the emergency stop button.
3 Never begin to disassemble a separator
before it has come to a complete standstill.
4 Always set the discharge intervals according
to instructions in the instruction book.
5 Never ignore alarms. Always eliminate the
cause before resuming operation.
6 Never use the separator for other liquids than
those specified by Alfa Laval.
7 Never operate a separator with a different
power supply frequency than stated on the
machine plate.
8 Clean the operating system regularly to avoid
sludge discharge malfunction.
9 Ensure that personnel are fully trained and
competent in installation, operation,
maintenance, and emergency procedures.
10 Use only Alfa Laval genuine spare parts and
the special tools supplied.

2 584610-02
15
S AND P FLEX SEPARATION SAFETY 1 SAFETY INSTRUCTIONS

1.2 Warning Sign


Definitions
Below are definitions of the warning signs used.

Danger serious injury or death Example:

This type of safety sign or instruction


R
indicates an imminently hazardous
! DANGE
situation which, if not avoided, will result in
death or serious injury.
Entrapment hazard
Make sure that rotating parts have come to a
complete standstill before starting any
dismantling work.

Warning serious injury or death Example:

This type of safety sign or instruction indicates


ING
a potentially hazardous situation which, if not WARN
!
avoided, could result in death or serious injury.

Disintegration hazard
If unusually strong vibration occurs, press the
Emergency Stop button and leave the room.
Do not enter the room after an emergency stop
while the separator is still rotating.

Caution minor or moderate injury Example:

This type of safety sign or instruction indicates


ON
a situation which, if not avoided, could result in CAUTI
!
minor or moderate injury.

CAUTION used without the safety alert Burn hazard


symbol indicates a potentially hazardous Various machine surfaces can be hot and cause
situation which, if not avoided, could result in burns.
equipment damage.

584610-02 3
16
1 SAFETY INSTRUCTIONS S AND P FLEX SEPARATION SAFETY

1.3 Summary of Safety


Hazards
Below follows a selection of the warnings which
have been used in the text of this instruction
manual to ensure safe installation, start-up,
operation, stop, and maintenance. Further
warnings are to be found in the appropriate
places throughout the manual.

Start-up
Check that the separator is correctly assembled
and connected to power supply of correct voltage
and frequency. The control panel must be ON.
Be specially observant during start-up. If there
is any abnormal vibration, immediately stop the
separator and investigate the cause. Clean the
bowl if it contains sediment.

ING
WARN
!

Breakdown hazard
Assemble the separator completely before start. All
couplings, covers, and guards must be in place and
properly tightened. Failure to do so may lead to

X0 2 47 61 A
breakdown.

ING
WARN
!

Electrical hazard
Follow local regulations for electrical installation and
earthing (grounding).

ING
WARN 50 Hz?
!
60 Hz?

Breakdown hazard
P 00 36 06 A

Check that the power frequency is in agreement with


the machine plate. If incorrect, resulting overspeed
may cause breakdown.

4 584610-02
17
S AND P FLEX SEPARATION SAFETY 1 SAFETY INSTRUCTIONS

ING
WARN
!

Use the separation system for the purpose, and within


the limits, specified by Alfa Laval. Failure to do so
could cause a violent breakdown.

ON
CAUTI
!

If power cable polarity has been reversed, the


separator will rotate in reverse, and vital rotating
parts can loosen.

ON
CAUTI
!

Check the oil level before start. Top up when


necessary. Do not overfill.

584610-02 5
18
1 SAFETY INSTRUCTIONS S AND P FLEX SEPARATION SAFETY

Operation

ING
WARN
!

Excessive vibration
If vibration increases, or continues at full speed,
keep bowl filled and stop the separator.
The cause of the vibration must be determined and
corrected before starting again!
Excessive vibration may be due to incorrect
assembly or insufficient cleaning of the bowl.

ING
WARN
!

Breakdown hazard
If strong vibration occurs, press the emergency
stop button and evacuate the room.
Never discharge a vibrating separator. Vibration

P0 0 36 06 A
may then become violent and result in breakdown.

ING
WARN
!

Disintegration hazard
After an emergency stop, the cause of the fault
must be identified.
If all parts have been checked and the cause not
found, contact Alfa Laval for advice before
restarting the separator.

ING
WARN
!

Burning hazard
Lubricating oil and various machine surfaces can be
hot and cause burns.

ING
WARN
!

Noise hazard
Use ear protection if noise levels are high.

6 584610-02
19
S AND P FLEX SEPARATION SAFETY 1 SAFETY INSTRUCTIONS

ING
WARN
!

Breakdown hazard
Never reset an alarm without first finding and
remedying the cause.

ING
WARN
!

Disintegration hazard
Do not discharge a vibrating separator. Vibration
can increase if solidified sludge is only partially
discharged.

ON
CAUTI
!

X0 23 71 6A
Burn hazard
Avoid contact with hot surfaces. Process pipes,
various machine surfaces, and processed liquid
can be hot and cause burns.

ON
CAUTI
!

Slip hazard
Check all connections for leakage.
Oil leakage may make the floor slippery.

If speed or starting power is not correct:

ING
WARN
!

Stop and change the belt transmission to suit the


power supply frequency.

584610-02 7
20
1 SAFETY INSTRUCTIONS S AND P FLEX SEPARATION SAFETY

Stop

ON
CAUTI
!

Breakdown hazard
Stop the separator by means of the control unit, and
not by turning off the motor.

Never attempt to clean the bowl by manual discharge


in connection with stop.

Emergency stop

ING
WARN
!

Disintegration hazard
If unusually strong vibration occurs, press the

X02 4 57 9A
Emergency Stop button and leave the room
Do not enter the room after an emergency stop
while the separator is still rotating.

ING
WARN
!

Disintegration hazard
Do not start the separator after an emergency stop
without first remedying the cause of the
emergency.
Make sure that the bowl is clean before restart.

8 584610-02
21
S AND P FLEX SEPARATION SAFETY 1 SAFETY INSTRUCTIONS

After emergency stop

R
! DANGE

Entrapment hazard

X0 24 76 4 A
Make sure that rotating parts have come to a
complete standstill before starting any dismantling
work. The rotation indicator lamp, where applicable,
must be off.

ING
WARN
!

Entrapment hazard
To avoid accidental start, switch off and lock power
supply before starting any dismantling work.
Make sure that separator has come to a complete
standstill before starting any dismantling work

ING
WARN
!

Disintegration hazard
Do not start the separator after an emergency stop
without first remedying the cause of the emergency.
Make sure that the bowl is clean before restart.

Maintenance

R
! DANGE

Entrapment hazard
Make sure that rotating parts have come to a
complete standstill before starting any dismantling
work. The rotation indicator lamp, where applicable,
must be off.
X 02 47 64 A

584610-02 9
22
1 SAFETY INSTRUCTIONS S AND P FLEX SEPARATION SAFETY

ING
WARN
!

Disintegration Hazards
Separator parts that are either missing, worn
beyond their safe limits or incorrectly assembled,
may cause severe damage or fatal injury.

ON
CAUTI
!

Burn and Corrode Hazards


Escaping hot and/or corroding process material,
which can be hazardous, may still remain in the
separator after stop.

ING
WARN
!

Disintegration hazards
Use of imitation spare parts may cause severe
damage.

ING
WARN
!

Entrapment hazard
To avoid accidental start, switch off and lock power

I0 02 9 33 A
supply before starting any dismantling work.
Make sure that the separator has come to a
complete standstill before starting any dismantling
work.

ING
WARN
!

The nut must not be removed before the separator


has stopped.

ING
WARN
!

Crush hazard
The top disc can adhere to the bowl hood when
lifting. Be careful not to accidentally drop it.

10 584610-02
23
S AND P FLEX SEPARATION SAFETY 1 SAFETY INSTRUCTIONS

ING
WARN
!

Risk for eye injury from flying seal ring


parts
The seal ring breaks when removed from the bowl
hood.

ING
WARN
!

Crush hazard
The distributor and disc stack can adhere to the top
disc. Separate them from the top disc so that they
do not accidentally drop.

ON
CAUTI
!

Cut hazard
Sharp edges on the separator discs may cause cuts

ING
WARN
!

Crush hazard
The ring on the lifting tool must be pushed down
against the discharge slide, otherwise the discharge
slide may come loose from the tool.

ING
WARN
!

Crush hazard
Support the bowl body when turning to prevent it
from rolling.

ING
WARN
!

Crush hazard
The motor will come off if the screws are unscrewed.

584610-02 11
24
1 SAFETY INSTRUCTIONS S AND P FLEX SEPARATION SAFETY

ING
WARN
!

Crush hazard
Do not rotate the spindle assembly during lifting.
The spindle assembly may otherwise come loose
from the lifting tool.

ING
WARN
!

Risk for eye injury from flying snap ring


Use the correct pliers for dismantling of snap ring to
avoid accidental release.

ING
WARN
!

Crush hazard
If not supported, the motor with coupling will drop
when removing the screws.

ING
WARN
!

Electrical hazard
If the cables are not disconnected during lifting
procedures, they may become damaged.

ON
CAUTI
!

Inhalation hazard
When handling friction blocks/pads wear a mask to
avoid inhalation of dust.
DO NOT USE COMPRESSED AIR TO REMOVE
DUST. Remove dust using vacuum or a damp cloth.

ING
WARN
!

Crush hazard
The centrifugal clutch is heavy and can fall, causing
injury, when loosened from the motor shaft.

12 584610-02
25
S AND P FLEX SEPARATION SAFETY 1 SAFETY INSTRUCTIONS

ING
WARN
!

Electrical hazard
Never wash down a separator with a direct water
stream.
Never play a water jet on the motor. Totally enclosed
motors can be damaged by direct hosing to the
same extent as open motors, resulting in short-
circuit and internal corrosion.

Max. 0,2 mm
ING
WARN
!

G 0 20 52 4 1
Disintegration hazards
Always contact your Alfa Laval representative if
you suspect that the depth of the corrosion damage
exceeds 0.5 mm (0.2 mm for bowl body and bowl
hood) or if cracks have been found. Do not
continue to use the separator until it has been
inspected and given clearance for operation by Alfa
Laval.

ING
WARN
!

Disintegration hazard
Pits and spots forming a line may indicate cracks
beneath the surface.
All forms of cracks are a potential danger and are
totally unacceptable.
Replace any part where corrosion can be
suspected of affecting its strength or function.

ING
WARN
!

Disintegration hazard
All forms of cracks are potentially dangerous as
they reduce the strength and functional ability of
components.
Always replace a part if cracks are present.

584610-02 13
26
1 SAFETY INSTRUCTIONS S AND P FLEX SEPARATION SAFETY

ING
WARN
!

Disintegration hazard
Erosion damage weakens parts by reducing the
thickness of the material.
Pay special attention to the pillars between the
sludge ports in the bowl wall.
Replace parts if erosion is suspected of affecting
strength or function.

ING
WARN
!

Disintegration Hazard
If the belt pulley must be renewed, check that the
new pulley has the correct diameter. An incorrect
pulley will cause the separator bowl to run at either
an excessive or insufficient speed.

ING
WARN
!

Burn hazard
Use protective gloves when handling any heated
parts.

ING
WARN
!

Risk for eye injury from flying snap ring


Use the correct pliers for assembly of snap ring to
avoid accidental release.

ING
WARN
!

Cut hazard
Do not put fingers between the frame and air
deflector while lowering the assembly.

ON
CAUTI
!

Disintegration hazard
Impact marks may cause the separator to vibrate
while running.

14 584610-02
27
S AND P FLEX SEPARATION SAFETY 1 SAFETY INSTRUCTIONS

ING
WARN
!

Crush hazard
The ring on the lifting tool must be pushed home
against the discharge slide, otherwise it may come
loose from the tool.

ING
WARN
!

The number of discs may have to be increased to


adjust the disc stack pressure. Always check before
operating the separator.

ING
WARN
!

Crush hazards
A falling separator can cause accidents resulting in
serious injury and damage.
Never lift the separator by any other method than
described in this manual.

ING
WARN
!

Crush hazards
Use correct lifting tools and follow lifting
instructions.

ING
WARN
!

Disintegration hazard
I 0 02 93 5A

Separator parts that are either missing, worn


beyond their safe limits, or incorrectly assembled,
may cause severe damage or fatal injury.

ING
WARN
!
I 00 2 93 B A

Disintegration hazard
Do not weld nor heat parts that are subject to high-
speed rotation.

584610-02 15
28
1 SAFETY INSTRUCTIONS S AND P FLEX SEPARATION SAFETY

Separator reassembled

ING
WARN
!

Breakdown hazard
Assemble the separator completely before restart. All
couplings, covers, and guards must be in place and
properly tightened. Failure to do so may lead to

X0 2 47 61 A
breakdown.

Cleaning in place

ON
CAUTI
!

Health Risk
Do not forget to disconnect the CIP equipment and
re-connect connections.

ON
CAUTI
!

Use only Alfa Laval recommended CIP liquids.

16 584610-02
29
S AND P FLEX SEPARATION SAFETY 1 SAFETY INSTRUCTIONS

1.4 Optional Heaters

1.4.1 CBM heaters

ING
WARN
!

Burn Hazard
The heater must not be used without the insulated
protection cover. This shields the hot surfaces and
also acts as a safety cover in the unlikely event of
leakage.

ON
CAUTI
!

Burn Hazard
To prevent pressure or heat shocks in the system,
adjustment of the flow rate must be carried out
slowly. The heater can otherwise be damaged.

ING
WARN
!

Burn Hazard
Shut off the oil flow and the heating medium flow
before starting maintenance.

ING
WARN
!

Corrosion Hazard
Pay strict attention to the safety instructions for the
cleaning liquid used.

ING
WARN
!

Burn Hazard
Make sure that the relief valve outlet leads into a
collecting tank or below floor level.

584610-02 17
30
1 SAFETY INSTRUCTIONS S AND P FLEX SEPARATION SAFETY

1.4.2 Electric heaters

R
! DANGE

Electrocution Risk
Switch off the main power before opening the heater
junction box, or dismantling the heater.

ON
CAUTI
!

It is very important that the correct heater element is


installed.

18 584610-02
S Flex Separation 31

System Description
Printed Jul 2010
Book No. 584621-02 V3
32

Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by: Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
Copyright Alfa Laval Tumba AB 2010.
Original instructions
33

Contents

1 System Overview ...........................................................................................................................1


1.1 Oil Flow......................................................................................................................................... 1
1.2 System Layout .......................................................................................................................... 2
1.3 System Components ............................................................................................................... 4

2 The Process.......................................................................................................................................5
2.1 Principle ....................................................................................................................................... 5
2.2 Process Cycle Start.................................................................................................................. 6
2.3 Discharge ..................................................................................................................................... 8
2.4 Increased Water Content ....................................................................................................... 9

584621-02
34

584621-02
35
S FLEX SEPARATION SYSTEM DESCRIPTION 1 SYSTEM OVERVIEW

1 System Overview
The S-Type Separation System is designed for Cleaned oil leaves the separator through the oil
cleaning of fuel and lube oils for diesel engines, outlet while separated water and sludge
and fuel oil for gas turbine engines, in marine accumulate at the periphery of the rotating
and power applications. separator bowl.
Heated oil is fed through the separator to clean The control unit supervises the entire
the oil from solid particles and water. operation of the separation system, performing
monitoring, control, and alarm functions.
The basic separation unit comprises:
The process adapts automatically to certain
A separator.
changes in conditions, such as increased water
Ancillary equipment including control unit. content in the unprocessed oil, high or low oil
feed temperature, etc.
Optional equipment such as, butterfly valve,
vibration sensor, etc.

1.1 Oil Flow Settling tank Change-over Backpressure


regulating
valve
valve
The unprocessed oil is fed through a heater by a
feed pump, operating at a constant flow.
A change-over valve directs the oil to the
separator. The cleaned oil is pumped from the
separator to either the daily service tank (fuel
oil), or back to the engine (lube oil).
During separator start and stop procedures,
during alarm conditions, or if the oil
temperature is outside the preset range, the oil
is directed by the change-over valve to a return
line back to the engine sump or settling tank. Pump Heater Separator Daily
service tank

P 00 37 14 A

584621-02 1
36
1 SYSTEM OVERVIEW S FLEX SEPARATION SYSTEM DESCRIPTION

1.2 System Layout

Heater Temperature Pressure transmitter, Pneumatically controlled Separator


transmitter (TT1, oil (PT1) change-over valve (V1)
Heats unprocessed Cleans the oil by
oil to separation TT2) removing water
Measures the pressure Directs the unprocessed oil to
temperature. Measures the oil in the oil inlet, and the separator, or back to the and solid
temperature and signals the control unit. settling tank (recirculation particles.
signals the control fuel oil only).
unit.

Feed pump
Feeds
unprocessed oil to the
separator.

Unprocessed oil
inlet

Oil return
Conditioning water

Opening water
Water inlet
Closing water

Solenoid valve block, water Sludge outlet

Distributes separator opening/


Optional equipment not closing water, and conditioning water.
part of the basic S Flex
Separation System

2 584621-02
37
S FLEX SEPARATION SYSTEM DESCRIPTION 1 SYSTEM OVERVIEW

Control unit Pressure transmitter, oil Water transducer (MT60) Regulating valve (RV4)
(PT4) To manually regulate the
Supervises the separation Measures change in water
system. Measures the pressure in content in the cleaned oil, backpressure in the
the oil outlet, and signals the and signals the control clean oil outlet.
control unit. unit.

Pneumatically controlled
shut-off valve (V4)

EPC-60 Closes the clean oil outlet.

PT MT Clean oil outlet


to service tank

PT

Water drain

Pressure transmitter,
water (PT5)
Drain valve (V5)
Measures the pressure in
the water drain outlet, and Opens to drain separated water
signals the control unit. from the separator.

584621-02 3
38
1 SYSTEM OVERVIEW S FLEX SEPARATION SYSTEM DESCRIPTION

1.3 System Components

EPC 60 Control
unit and starter

Safety valve
SV10A
(Lube oil
only)
EPC 60 Control
unit Water
transducer Operating
(MT60) air
Operating
water
Change-over
valve (V1) Combined
regulating valve
(RV4) and shut-off
valve (V4)
Clean oil
outlet

Temperature
transmitter
(TT1,TT2) Pressure
transmitter, oil
outlet (PT4)

Oil inlet

Oil recirculation Pressure


transmitter,
water (PT5)

Pressure Oil in
transmitter, oil
inlet (PT1)
Drain valve
Oil out (V5)

Water
out

Sludge
outlet
P00 37 3 6E

4 584621-02
39
S FLEX SEPARATION SYSTEM DESCRIPTION 2 THE PROCESS

2 The Process
2.1 Principle
During the separation process, sludge and
water accumulate at the periphery of the
separator bowl. Oil

Sludge and
water

P 00 35 6B A
Sludge and water are discharged at preset time
intervals. During discharge, the oil inlet is
closed.

P 00 35 6C A
Excessive water can also be drained from the
separator bowl between discharges.

The cleaned oil leaving the separator is tested


for traces of water. Any increase in water is MT
detected by the water transducer. Disc stack
Water
transducer

Water
P0 03 56 DA

The signal from the water transducer is


continuously transmitted to the control unit, in Controller
which a reference value is stored. The control
unit compares the transducer signal with the
reference value. A significant deviation from MT
the reference value will cause draining of water.
P00 3 56 EC

584621-02 5
40
2 THE PROCESS S FLEX SEPARATION SYSTEM DESCRIPTION

2.2 Process Cycle Start

First the oil pump, separator, and heater are


started. Controller

The temperature transmitter (TT) and the


TT
speed transmitter (ST) signal the EPC-60
control unit continuously. When the correct
separator speed and the correct temperature
are reached, a sludge discharge is carried out to

P0 03 56 FC
ST
ensure the bowl is empty. The control unit then
starts the process cycle.

1 The change-over valve directs the oil to the


recirculation line. Conditioning water is Controller

added to the separator bowl until the


pressure sensor in the oil outlet senses PT
pressure and signals the control unit.

P0 03 56 G C
2 The control unit registers the time taken for
water addition. This water flow reference
value is later used to calculate the correct
amount of conditioning water and
displacement water to be added.

3 The separator discharges.


Controller

P 00 35 6 O C

6 584621-02
41
S FLEX SEPARATION SYSTEM DESCRIPTION 2 THE PROCESS

4 Using the flow rate calculated in paragraph 2


above, the control unit signals the solenoid Controller

valve to open so that the correct amount of


conditioning water is added to the separator
bowl.

P 00 35 6N C
5 The change-over valve opens so that oil is
directed to the separator bowl. When Controller

pressure in the oil outlet is sensed, the


pressure sensor (PT) signals the control unit. PT
The control unit calculates and stores the
time taken to add oil to the bowl.

P0 03 5 6M C
The cleaning process is now running.
Unprocessed oil is fed to the separator, and clean
oil is pumped from the separator.

584621-02 7
42
2 THE PROCESS S FLEX SEPARATION SYSTEM DESCRIPTION

2.3 Discharge
The separator discharges after a preset time has
elapsed. The following sequence takes place:

1 The change-over valve changes to oil


recirculation. Controller

2 Using the flow rate calculated in paragraph 2


under 2.2 Process Cycle Start, page 6, the
control unit signals the solenoid valve to
open so that displacement water is added to
push the oil towards the disc stack.

P0 0 35 6R C
3 After the calculated time for displacement
water addition has elapsed, the separator
discharges.

4 Conditioning water is then added, and a new

P 00 35 6J A
separation cycle begins.

8 584621-02
43
S FLEX SEPARATION SYSTEM DESCRIPTION 2 THE PROCESS

2.4 Increased Water


Content
If the water transducer senses increased water
content in the oil, the following takes place:

1 The water drain valve (V5) opens for a


number of seconds. Controller

MT

PT
2 The water drain valve closes again, and the
transducer signal is evaluated.

P 00 35 6K C
3 If there is still an increase in water content,
the drain valve opens again. If the water
content is still high after the drain valve has
opened five times, a discharge is initiated.

4 If the water content has decreased, the


separation cycle returns to normal.

584621-02 9
44
2 THE PROCESS S FLEX SEPARATION SYSTEM DESCRIPTION

10 584621-02
45

S and P Flex Separation

Operating instructions
Printed 03-2014
Book No. 584612-02, rev. 8
46

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden

Telephone: +46 8 530 650 00


Telefax: +46 8 530 310 40

Alfa Laval Tumba AB 03-2014


The original instructions are in English
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.
47

Contents
1 Operating 5
1.1 Before First Startup 5
1.2 Control Panel 8
1.3 Manual Start from Standstill 10
1.4 Automatic Start from Standstill 18
1.5 During Separation 19
1.6 Stop 22
1.7 Emergency Stop 24
1.8 After Emergency Stop 25
1.9 Separator Emergency Operation 27
1.10 Cleaning In Place 28
1.10.1 CIP Start 28
1.10.2 CIP Running 30
1.10.3 CIP Stop 31

1.11 Check if separator bowl is clogged 33


1.12 Intervals Between Sludge Discharges 34
1.12.1 Background 34
1.12.2 Recommended intervals between sludge
discharges 34
1.12.3 Fuel oil cleaning 35
1.12.4 Lubricating oil cleaning 35
1.12.5 Bowl inspection 37

1.13 Heater Control (optional) 38


1.13.1 Control of the electric heater (optional) 40
1.13.2 Control of the CBM heater (optional) 41
1.13.3 If heater not controlled or external 42
1.13.4 Heater shut down 42

1.14 Cross connection/serial operation 43


1.14.1 Set up communication 43
1.14.2 Configure parameters 43
1.14.3 Cross connection 44
1.14.4 Serial operation 44

1.15 Programmable Inputs and Outputs 45


1.15.1 Inputs 45
1.15.2 Outputs 45
1.15.3 Common alarm indication 46

1.16 I/O Test Function 47

3
48

1.17 Operation without all sensors


(Emergency operation) 51
1.17.1 System Without Speed Sensor 51
1.17.2 System Without Vibration Sensor 51
1.17.3 System Without Cover Switch 51
1.17.4 System With PT1 Disabled 52
1.17.5 System With PT4 Disabled 52
1.17.6 System With PT5 Disabled (S-separator only) 52
1.17.7 System With TT1/TT2 Disabled 53
1.17.8 Control of Sludge Pump, Level in Sludge Tank, and
Butterfly Valve 53
1.17.9 System Without Feed Pump 54
1.17.10 System Without Water Transducer (S-separator
only) 55
1.17.11 Purifier Operation (only valid for S 805 and S 815) 56

4
49

1 Operating

1.1 Before First Startup


The Control Panel must be configured to suit
the system components.

1. Check that the separator is correctly


assembled and connected to power supply
of correct voltage and frequency. The
control panel must be ON.

NG
WARNI
!
Breakdown hazard
Assemble the separator completely before start.
All couplings, covers and guards must be in
place and properly tightened. Failure to do so
may lead to breakdown.
X024761A

NG
WARNI
!
Electrical hazard
Follow local regulations for electrical installation
and earthing (grounding).

NOTE

Check that the Emergency Stop Box is properly


installed and functioning correctly.

NG
WARNI 50 Hz?
!
60 Hz?
Breakdown hazard
Check that the power frequency is in agreement
with the machine plate. If incorrect, resulting
overspeed may cause breakdown. P003606B

5
50
1 Operating

NG
WARNI
!
Use the separation system for the purpose, and
within the limits, specified by Alfa Laval. Failure
to do so could cause a violent breakdown.

2. Check the oil sump level. If necessary, top


up until oil starts to run from the oil-filling
hole.

NOTE

Too much or too little oil can damage the


separator bearings.

X024762A

Rotation Direction
Check the rotation of the bowl using the I/O test
function. See 1.16 I/O Test Function on page
47. The motor fan must rotate in a clockwise
direction.

ON
CAUTI
!
If power cable polarity has been reversed, the
separator will rotate in reverse, and vital rotating parts
can loosen.
X023719B

Operating Air Pressure


Check that the air supply is correct (500 800
kPa or 5 8 Bar).

6
51
1 Operating

Operating Water Pressure


Check that the operating water pressure is
sufficient (200 800 kPa or 2 8 Bar).

NOTE

The LEDs on the water block and connectors indicate


that the valve has power on. They do not indicate if the
valve is clogged (an alarm is given if this is the case).

Emergency Stop Push Box


Check that the Emergency Stop Box is located
close to the separator system and electrically
connected to the Control Panel

NOTE

If the Emergency Stop Box is not connected, the


system will not start.

7
52
1 Operating

1.2 Control Panel


To start the Control Panel, switch on the main
power switch on the control cabinet.

General
The Control Panel has three main lists.

Operation
Alarms
Setting

Operation List
To access the Operation List at any time during
the operation process press the Return button
repeatedly until the Operation List is reached. 7 8 9

The list gives information on the following where 4 5 6


installed: 1 2 3

. 0
Feed Flow
Time to discharge, min REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
Speed (SS), rpm FEED
PUMP
SLUDGE
PUMP
CLEANING
IN PLACE

Pressure (PT1, PT4, PT5)


X023912A

Temperature (TT1, TT2)


Vibration (VIB)
Transducer value

Press the arrow buttons to go up or down in


the list.
7 8 9

4 5 6
NOTE
1 2 3
During operation, the Operation list is active on the
. 0
display. The present stage of operation, for example
SEPARATION, shows on display together with REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

operating information such as present temperature.


CIP
Press the downward Arrow button to go down the list. FEED
PUMP
SLUDGE
PUMP
CLEANING
IN PLACE

X023914A

For further information regarding alarms, see


the Alarms and Fault Finding booklet.

For further information regarding parameters,


see the Parameter List booklet

8
53
1 Operating

At any time during operation, the operator can


initiate a STOP sequence by pressing the Stop
button. 7 8 9

4 5 6

1 2 3

. 0

REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
FEED SLUDGE CLEANING
PUMP PUMP IN PLACE

X023920A

NOTE

If control panel black screen appear.


See Alarms & Fault finding manual.

9
54
1 Operating

1.3 Manual Start from Standstill


Press the Start button. The operator can
select to start the system manually by setting
parameter P130 to stepwise. 7 8 9

4 5 6

NOTE 1 2 3

. 0
First start-up is always manual and not dependant on
P130 setting. REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

A rotation test must be carried out using the I/O test CIP
FEED SLUDGE CLEANING
function prior to first start-up. PUMP PUMP IN PLACE

NOTE

First start-up after power off should always be carried


out manually!

NOTE

If a butterfly valve is installed, it must be opened


manually before that the system can start.
X023911A

ON
CAUTI
!
If power cable polarity has been reversed, the
separator will rotate in reverse, and vital rotating parts
can loosen.

If speed sensor, vibration sensor, and frame


cover switch are installed (P113, P114, and
P115 = yes), the operator can select to start the
system automatically by setting parameter P130
to automatic.

10
55
1 Operating

If the power has been off and/or the separator


bowl cover has been removed a number of
questions which have to be answered before the
system can be started are shown on the display:

Has the bowl been dismantled? YES, NO


(S-type separator only)
7 8 9
Use the arrow buttons to move to the alternative
you want. 4 5 6

1 2 3

. 0

REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
FEED SLUDGE CLEANING
PUMP PUMP IN PLACE

X023914A

When the alternative you want is blinking, press


the Enter button.
1. If the bowl has been dismantled choose
YES Manual start only is possible.
If no work has been carried out on the bowl, 7 8 9
choose NO.
For S-type separators Proceed without 4 5 6
calibration appears on the display. 1 2 3
Stepwise/automatic start is possible (set
. 0
using parameter P 130).
For P-type separators the system then goes REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

to Standstill. CIP
FEED SLUDGE CLEANING
PUMP PUMP IN PLACE

NOTE X023913A

If this is the first start, answer YES.

Assembled according to manual? YES, NO

2. If the bowl has been dismantled and


assembled according to the instructions in
the Service Manual, choose YES.
(If NO is chosen, the system goes to
STANDSTILL).

Bowl cleaned? YES, NO


(S-type separator only)

3. If the bowl has been cleaned choose YES.


Proceed with calibration appears on the
display. Local manual start only possible.
If the bowl has not been cleaned, choose
NO. Proceed without calibration appears
on the display. Stepwise/automatic start is
possible (set using parameter P 130).

11
56
1 Operating

Start
1. The feed pump (if installed) starts.

The LED on the start button flashes, the 7 8 9


LED for the feed pump lights, and text
Starting feed pump shows on the display. 4 5 6

1 2 3
The start button LED shines steadily and
the display shows either To start heater, . 0
press start button, or To start separator, REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

press start button.


CIP
FEED SLUDGE CLEANING
PUMP PUMP IN PLACE

X023911A

12
57
1 Operating

2. Press the start button a second time.

The heater (if installed) starts. 7 8 9

The LED on the start button flashes, the 4 5 6


LED for the heater lights, and text Starting 1 2 3
heater shows on the display.
. 0
Wait for increasing temperature. REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
Cold Start Function FEED
PUMP
SLUDGE
PUMP
CLEANING
IN PLACE

If the viscosity of the oil is high (low


temperature), a smooth heater start-up is
preferred. The temperature up to which the
cold-start gain factor P126 is active is set in
parameter P125. Above this temperature
the normal P-constant P123 is used.

If the temperature has not reached the


value in parameters P184 (HFO/LO low
temperature limit) within the time specified
in parameter P169 (alarm delay), alarm
A24 Temperature increase too slow will X023911A

show on the display.

If the temperature feedback is correct


(reading on temperature sensor TT1 above
value in parameter P184), the start button
LED shines steadily and the display shows
To start separator, press start button.

13
58
1 Operating

3. Press the start button a third time.

The separator motor starts. 7 8 9

The LED on the start button flashes, the 4 5 6


LED for the separator lights, and text 1 2 3
Starting separator shows on the display.
. 0
Wait for speed feedback (if speed sensor REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

installed), or until the separator max. start


CIP
time (4 minutes) has elapsed. FEED
PUMP
SLUDGE
PUMP
CLEANING
IN PLACE

If the speed has not increased to over


90 rpm within 10 seconds after contactor
K2 response, alarm A96 Slow start
acceleration shows on the display.

If the low speed limit value in parameter


P180 has not been reached before the
separator max. start time has elapsed,
alarm A95 Separator motor run-up time
too long shows on the display.

If the separator is running above the low X023911A

speed limit, the start button LED shines


steadily, and the display shows the heading
RECIRCULATION and text To start
separation, press start button.

14
59
1 Operating

4. Press the start button a fourth time.

If the feed temperature is below the 7 8 9


value in P184, the controller stays in
RECIRCULATION mode. The LED on 4 5 6
the start button flashes, and text Waiting 1 2 3
in RECIRCULATION for separation
. 0
temperature shows on the display.
REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

If the correct feed temperature is reached,


CIP
the controller changes automatically FEED
PUMP
SLUDGE
PUMP
CLEANING
IN PLACE

to SEPARATION mode via a transition


sequence which is shown on the display.
The start button LED shines steadily,
and the display shows the heading
TRANSITION.

If speed sensor not installed (P113 = no)


or disabled (P148 = 0), change over to
RECIRCULATION/SEPARATION takes
place when the separator max. start time
has elapsed.

X023911A

NOTE

The time in RECIRCULATION is limited by timer


P178 to avoid overheating of the separator.

15
60
1 Operating

Start S-type separator start sequence

START
command

Has the bowl been No


dismantled?
Yes
Assembled according No
to manual? STANDSTILL

Yes
Bowl cleaned? No Proceed without calibration *
local or remote **, auto ** or stepwise
start possible
Yes
Proceed with
calibration * Change to
local stepwise SEPARATION
start only
Change to
SEPARATION
Transition * consists of: Transition *
Start discharge (step 4) consists of:
Displacement (step 1) Calibration Discharge (step 2)
discharge (step 5) Discharge with P244 instead of
(step 2) with P244 instead of P231
P231 Bowl leak/water transd. Bowl leak/water
test (step 3) transd. test (step 3)

SEPARATION

16
61
1 Operating

Start P-type separator start sequence

START
command

Assembled according to No
STANDSTILL
manual?
Yes
Proceed with start sequence
local start only

17
62
1 Operating

1.4 Automatic Start from Standstill


The operator can select to start the system
automatically by setting parameter P130 to
automatic.

The control panel automatically goes through


the same procedure as described under Manual
Start from Standstill.

If the bowl has not been dismantled or cleaned,


the previously calculated filling time (parameter
P233) is used, a discharge sequence and a
bowl leakage/water transducer test are run, and
the system goes into SEPARATION mode.

The following equipment must be installed for


automatic start:

Vibration monitor
Speed sensor
Frame cover switch

18
63
1 Operating

1.5 During Separation


Observe information on the control panel
display. The times in each sequence are shown
in the bottom left-hand corner of the display

NG
WARNI
!
Breakdown hazard
If strong vibration occurs, press the emergency stop
button and evacuate the room.
Never discharge a vibrating separator. Vibration may P003606A

then become violent and result in breakdown.

NG
WARNI
!
Noise hazard
Use ear protection if noise levels are high.

NG
WARNI
!
Breakdown hazard
Never reset an alarm without first finding and
remedying the cause.

ON
CAUTI
!
Burn hazard
Avoid contact with hot surfaces. Process pipes,
X023716A
various machine surfaces, and processed liquid can
be hot and cause burns.

ON
CAUTI
!
Slip hazard
Check all connections for leakage.
Oil leakage may make the floor slippery.

19
64
1 Operating

Discharge sequences run automatically at


preset intervals (timer P220).

Discharge sequence can also be run manually


by pressing the Discharge button.
7 8 9

4 5 6

1 2 3

. 0

REMOTE

i
HEATER SEPARATOR CONTROL

CIP
FEED CLEANING
PUMP IN PLACE

X023923A

20
65
1 Operating

The Sludge Pump runs during discharge or


when there is high level in the sludge tank, or
can be started manually by pressing the Sludge 7 8 9
Pump button on the control panel.
4 5 6

1 2 3
NOTE . 0

Do not run the sludge pump longer than necessary. If REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

the pump is run while dry it can be damaged. CIP


FEED CLEANING
PUMP IN PLACE

X023922A

In SEPARATION mode, the feed pump is


running, the feed has reached separation
temperature (the heater is working) and the
separator is running at full speed.

Feed valve V1 is open to the separator inlet.

21
66
1 Operating

1.6 Stop

ON
CAUTI
!
Breakdown hazard
Stop the separator by means of the control unit, and
not by turning off the power.

ON
CAUTI
!
Never attempt to clean the bowl by manual discharge
in connection with stop.

To stop the system:

The operator can stop the system when in the


START, RECIRCULATION, or SEPARATION
modes.

1. Stop the system by pushing the Stop


button on the control panel. The following
sequence takes place: 7 8 9

A stop discharge and flushing sequence 4 5 6


are initiated (does not apply to stop 1 2 3
from START).
. 0

NOTE REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
FEED SLUDGE CLEANING
Filling and flushing are not performed if the PUMP PUMP IN PLACE

discharge feedback has not been received

X023920A

22
67
1 Operating

The separator motor is turned off and


the stop timer starts running. At the
same time, the heater is turned off
(see 1.13.4 Heater shut down on page
42. The system waits for the feed
temperature and speed to decrease.
If the speed limit in P180 (low speed
limit) is not reached within 3 minutes,
alarm A94 Bowl speed high during
STOP is given.
When the bowl speed has reached
4000 rpm, closing water valve SV16 is
activated for 1 second in order to keep
the bowl closed.
If speed sensor not installed (P113
= no) or disabled (P148 = 0), SV16
opens for 1 second 5 minutes after the
separator motor has been turned off.
When 3 minutes has elapsed, the feed
pump is turned off.
The system waits for the speed sensor
(if installed) to indicate zero speed.
When the bowl has been still for 60
seconds, STAND STILL shows on the
display.
If speed sensor not installed (P113 =
no) or disabled (P148 = 0), STAND
STILL is shown when the stop timer
has elapsed.
The sludge pump runs for 10 seconds
after STAND STILL is reached if
stopped from SEPARATION mode or
RECIRCULATION mode.
All equipment except the sludge pump
(which can still be run manually) is now
deactivated.

NOTE

If the system is switched off, it can in most cases


be switched on again without waiting for the
separator to slow down. See 1.3 Manual Start
from Standstill on page 10, and the Alarms
and Fault Finding booklet.

NG
WARNI
!
Breakdown hazard
The system must not be restarted with the separator
rotating if high vibration alarm has been given.

23
68
1 Operating

1.7 Emergency Stop

NG
WARNI
!
Disintegration hazard
If an emergency situation or unusually strong vibration
occurs, press the Emergency Stop button and
evacuate the room.
X024579A
If oil spray, feed pump is stopped by emergency stop
button.
Do not enter the room after an emergency stop while
the separator is still rotating.

The following sequence occurs:

The power to heater pump and separator


motor is shut-down immediately.
Stop timer starts.
If a steam heater is installed, the steam
shutoff valve is forced to close.
Closing water valve SV16 opens for 15
seconds.
SV10 is open for 15 seconds if the speed is
supervised and the speed is over P255, or if
there is no speed supervision.
All other equipment is deactivated.

NOTE

In order to be able to restart, the system must be at


standstill.

24
69
1 Operating

1.8 After Emergency Stop


Separator standstill
Dismantling work must not be started before
all rotating parts have come to a complete
standstill.

NG
WARNI
!
Entrapment hazard
Make sure that rotating parts have come to a complete
standstill before starting any dismantling work.
The rotation indicator lamp, where applicable, must
be off. I00293CD

Avoid accidental start

NG
WARNI
!
Entrapment hazard
To avoid accidental start, switch off and lock power
supply before starting any dismantling work.
Make sure that separator has come to a complete
standstill before starting any dismantling work.

Remedy the cause


The cause of the emergency must be remedied
before attempting to restart the separator.
If the cause is not found, an overhaul must be
performed on the separator, and all moving
parts thoroughly checked.

NG
WARNI
!
Disintegration hazard
Do not start the separator after an emergency stop
without first remedying the cause of the emergency.
Make sure that the bowl is clean before restart.

25
70
1 Operating

Separator reassembled
The separator must be fully reassembled with
all covers and guards in place and tightened
before unlocking the power supply and starting
the system.

NG
WARNI
!
Breakdown hazard
Assemble the separator completely before restart.
All couplings, covers, and guards must be in place
and properly tightened. Failure to do so may lead to X023714B

breakdown.

NOTE

Check that the Emergency Stop Box is properly


installed and functioning correctly.

NOTE

Check that all ancillary equipment, in particular the


heater, is functioning correctly.

26
71
1 Operating

1.9 Separator Emergency Operation


If the Control System has a total failure, the
Separator and Feed Pump can be run manually.
Jumpers or pushbuttons can be connected
between terminals X1:113 - 114 (for separator)
and X1:115 - 116 (for feed pump).
Separator and Feed Pump will start immediately
when these terminals are bridged, but can be
stopped with the Emergency Stop pushbutton.

NOTE

- No supervision of the separator is performed, as the


Control System is deactivated.
- The system must be manually supervised by trained
operator when running.
- All actions must be performed by trained operator,
such as closing bowl, discharge, sludge pump running
and it is done on the manual actuators on the valves.

27
72
1 Operating

1.10 Cleaning In Place


The use of Cleaning In Place (CIP) equipment
is recommended for best separation results. For
further information on the CIP equipment, see
the CIP booklet, bookno. 1817261.

1.10.1 CIP Start


CIP can be selected from STAND STILL only,
and only from a local control panel.
7 8 9
Press the CIP button to select CIP.
4 5 6

1 2 3
NOTE
. 0
During CIP the separator is running at full speed, but REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

feed pump, heater, process valves, temperature and


CIP
pressure supervision and water transducer MT60 are FEED
PUMP
SLUDGE
PUMP

neither controlled nor supervised.

ON
CAUTI
!
Avoid accidental start of feed pump
To avoid accidental start, switch off and lock power
supply for feed pump.
Leakage of Hot oil may occur if feed pump is
accidentally started.

X023921A

28
73
1 Operating

Connect hoses for CIP liquid before pressing


start button.
7 8 9
With CIP selected from STAND STILL, press
the START button to start the separator motor. 4 5 6
The motor starts unless the system prevents 1 2 3
start, or alarms are active.
. 0
Wait for speed feedback. REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
Speed has to increase to above 90 rpm FEED
PUMP
SLUDGE
PUMP
CLEANING
IN PLACE

within 10 seconds after contactor K2


response, otherwise alarm A96 Slow start
acceleration will be shown on the display.
Speed limit in parameter P180 has to be
reached within 4 minutes, otherwise alarm
A95 Separator motor run-up time too long
will be shown on the display.
When the separator is running above low
speed limit (P180), or 4 minutes has elapsed
if speed sensor not installed (P113 = no)
or disabled (P148 = 0), a message to start
the cleaning liquid supply is given to the X023911A

operator.

29
74
1 Operating

1.10.2 CIP Running

NOTE

When the bowl has reached normal speed, a bowl


closing procedure will be performed.

While the CIP system is running, closing water


valve SV16 opens for 2 seconds and closes for
the time set in parameter P228 (pulse interval) 7 8 9
repeatedly. The sludge pump runs when there 4 5 6
is high level in the sludge tank or when activated
1 2 3
by pressing the SLUDGE PUMP button on the
control panel. . 0

REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
FEED CLEANING
PUMP IN PLACE

X023922A

A discharge can be activated manually during


the CIP process by pressing the DISCHARGE
button on the control panel. 7 8 9

4 5 6

1 2 3

. 0

REMOTE

i
HEATER SEPARATOR CONTROL

CIP
FEED CLEANING
PUMP IN PLACE

X023923A

30
75
1 Operating

1.10.3 CIP Stop


Stop the CIP process by pressing the Stop
button on the control panel. The CIP process
can be restarted. 7 8 9

The separator motor is turned off. Alarm 4 5 6


delay (3 minutes) starts, and stop timer 1 2 3
starts. If the speed limit in parameter P180
. 0
(alarm limit bowl speed low) is not reached
within 3 minutes, alarm A9 Bowl speed high REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

during STOP is given.


CIP
FEED SLUDGE CLEANING
PUMP

When the bowl speed has reached 4000 PUMP IN PLACE

rpm, closing water valve SV16 is activated


for 1 second in order to keep the bowl
closed.
If there is no speed sensor installed
(parameter P113 = no) or disabled
(parameter P148 = 0), SV16 opens for 1
second 5 minutes after the separator motor
has been turned off.
The system waits for the speed sensor (if
installed) to indicate zero speed. When the
bowl has been still for 60 seconds, STAND
STILL shows on the display.
If there is no speed sensor installed X023920A

(parameter P113 = no) or if speed sensor


disabled (parameter P148 = 0), STAND
STILL is shown when stop timer has
elapsed.
If the bowl speed has been above P180, or
the start timer has elapsed, the sludge pump
runs for 10 seconds after STANDSTILL.
Hold the CIP button pressed for 5 seconds
to leave CIP mode.

After cleaning:
1. Open the heater drain valve until the
flushing water has drained.

2. Close the drain valve.

3. Remove the CIP connections.

4. Return the turnable connections to their


former positions and re-tighten.

5. Re-open the valves before and after the


heater.

31
76
1 Operating

ON
CAUTI
!
Health Risk
Do not forget to disconnect the CIP equipment and
re-connect the process connections.

32
77
1 Operating

1.11 Check if separator bowl is clogged


Valid for Purifiers (not Alcap or Clarifiers)
Purifiers have no automatic indication if the bowl
is clogged or filled with too much solids.
Recommendation is to check each Bunker
analyze report and determine if there is any risk
for a higher than normal sludge production.
The time between each sludge discharge should
then be reduced accordingly.

From time to time , and especially when a new


Bunker is introduced ,it is advisable to do as
follows :

- Introduce water into the bowl by open


manually the SV10 solenoid valve , on the
Operating Water Block.
- Check that this water is coming out from the
bowl by unscrewing the Inspection Plug on
the sludge pipe.
Please however ,make sure that the
machine is not about to make a discharge!
Splash hazard.
X027007A

If water is seen flowing in the pipe, turn off SV10


and keep operating as before.
The bowl is not clogged.

If no water is seen , then the bowl is clogged.


Make a discharge.
If still the water is not seen in the Inspection
plug ,turn off SV 10 and shut down the Purifier
system.
Open and clean up the bowl.

NOTE

By opening the Inspection Plug without adding any


water , it can also be verified that no small oil leakage
is escaping from the bowl during operation.

33
78
1 Operating

1.13 Heater Control (optional)


The temperature in the feed inlet is normally
supervised via TT1, and can be controlled by
a heater via TT2. Supervision and control are
active even if one of the sensors is disabled.
TT2 can be used by the customer; no alarm is
given. TT2 is disabled in this case.

The heater is controlled according to


temperature setpoint P249 using a PI-regulator
with output:

Y(k) = Y(k+1) + P + l

where the proportional part

P = Kp *(e(k) - e(k-1) )

and integral part

l = Ki * e(k) / Ti

The error e = SetValue - ActualValue, is the


difference between the desired value (P249)
and the actual value (reading on TT) where
k = point of time

The tuning of the regulator is done by modifying


the amplification
Kp = Ki = 100/P123 (P123 is known as the
proportional band width) and integral time Ti =
P124.

Every second a new output Y is calculated, i.e.


the interval between each k is 1s.

With P119 it is possible to select heater control


mode:

no (no heater controlled)


electric (electric heater controlled, P120
active)
steam (steam heater controlled, P121
active)
external (start/stop request via
programmable output, heater not controlled)
Cold start function
If the viscosity of the oil is high (low
temperature), a faster start-up of the heater
might be favourable (a higher Kp). The
temperature, up to which the cold-start gain
factor P126 is active, is set in P125. Above this
temperature the normal P-band P123 is used.

38
79
1 Operating

Example: P123 = 30, P126 = 40 results in


a P-band of 0.40 x 30 = 12 as long as the
temperature is below P125.

39
80
1 Operating

1.13.1 Control of the electric


heater (optional)
P119 = electric. The following parameters
should not be displayed in the parameter list:
P121, P122.

Five outputs and one input are used to control


the electric heater:

three relay outputs to up to three fixed power


steps depending on the heater size (P120)
one variable load output
one output "heater on"
one input "heater fault" (see A05)
The total heater capacity (100%) is the sum of
the power available at the three fixed steps, plus
the power available via the variable load output
(always 16 kW nominal).

This means, if the output signal to the heater is


100%, all available power steps and the variable
load output have to be activated continuously.

Output signal 0% means that all outputs are


deactivated.

If the output signal is a value between 0 and


100%, the activation pattern of the outputs has
to be calculated using the table below.

Output power (in % of the total available power)


Heater size (kW Power step 1 Power step 2 Power step 3 Variable load
nominal, selected % % % output
with P120) %
7, 8 0 0 0 10 x 10
14, 16 0 0 0 10 x 10
22, 24 33,5 0 0 10 x 6,6
36, 40 20 40 0 10 x 4
50, 56 14,3 28,5 28,5 10 x 2,9
65, 72 11 22 45 10 x 2,2
100 14,3 28,5 28,5 10 x 2,9
130 11 22 45 10 x 2,2

For each value of P120 the contribution of each


power step to the total available heater capacity
is given in percent. First use the fixed power
steps to fill the power requirement as far as
possible, then use the variable load output to
fine adjust the output.

40
81
1 Operating

NOTE

It is important that the fixed power steps are working


continuously when activated. Use an established
method e.g. delay drop out.

As a new output signal is calculated every


second, the variable load output is activated for
parts (0.1) of a second.

0.1 s activates 1/10 of the available power on


the output = 1.6 kW.

0.5 s means 8 kW and so on.

Example 1: Heater size 72 kW and output signal


to the heater 50%. Activate step 3 (for 1s) and
activate variable. output for 0.2s.

Example 2: Heater size 16 kW and output signal


to the heater 88%. Activate variable output for
0.9s.

Example 3: Heater size 130 kW and output


signal to heater 88%. Activate steps 1, 2, and
3 (for 1s).

To prevent problems with too heavy momentary


load at start of the heater, only one output
can be activated per second during the first 6
seconds. After that time all outputs can be used
simultaneously.

1.13.2 Control of the CBM heater


(optional)
P119 = steam. In this case alarm A05 is not
supervised.

The steam heater is controlled using three relay


outputs:

increment steam valve


decrement steam valve
steam shut-off valve (hold signal)
The position of the valve is not supervised.

The transition time of the steam valve is set in


P121 (time from fully open to fully closed position
and vice versa). The controller function defines
if the valve should be opened (incremented) or
closed(decremented) in relation to its actual
position.

41
82
1 Operating

The signal to the steam valve is pulsed with


an on-time corresponding to the temperature
controller output. Example: output = +50%
means the increment steam valve output is
activated for 0.50 s/s.

When the heater is stopped, the decrement


steam valve signal is on for the time set in P121.
The hold signal is off if the start of the heater is
interlocked (e.g. on alarms A01, A20).

1.13.3 If heater not controlled or


external
It is possible to run the system without heater
control (P119 = no).

In this case alarms A05, A24 and A25 are not


supervised.

It is also possible to run the system with external


heater (P119 = external). The heater on signal
is given via a programmable output.

In this case alarm A05 is not supervised.

The description for the system with external


heater is also valid if one of the temperature
sensors is disabled or on sensor error
(A22/A30).

1.13.4 Heater shut down


The system waits for the feed temperature to
decrease (5 degrees or below P184). If the
time in P173 has elapsed and the temperature
feedback was not received, alarm A25
Temperature not decreasing is given.

When the temperature feedback has been


received, or P173 has elapsed, P256 is started.
When P256 has elapsed, the feed pump (if
running) is turned off. If the feedback signal
from the pump contactor is not received within
5 seconds, alarm A01 Pump starter failure is
given.

NOTE

Heater shutdown is also initiated at STOP request


during START if feed pump and heater are on but the
separator is not running.

42
83
1 Operating

1.14 Cross connection/serial operation


Valid for P-type separators

It might be desirable to cross-connect two


separator modules, or operate them in series.
For that purpose the EPC60:s must be able to
communicate via Ethernet.

1.14.1 Set up communication


The EPC60:s may communicate over any
customer defined network or be connected
directly to each other 1) .

The IP-addresses of the EPC60:s must be set


so there are no IP-conflict since all EPC60:s
are normally delivered with the same default
address, e.g. set one EPC60 to have address
192.168.0.1 and the other to have address
192.168.0.2.
1)Direct connection requires a crossover twisted
pair cable to be used since the EPC60 does not
have automatic MDI/MDI-X configuration.

1.14.2 Configure parameters


The parameter to select desired function is
P145.
The following values are possible:

disabled (default)
cross master
cross slave
serial master
serial slave
The adjustment of P145 is only possible, if both
systems are in STAND STILL.

The communication between the two control


systems is supervised. At communication error
an alarm (A136) is given and both systems will
go to STOP if running.

43
84
1 Operating

1.14.3 Cross connection


One separator module can use the feed pump
and heater of the other one.

P145 is set to cross master in the system


which separator is used. The heater/feed
pump of this system is automatically
disabled. The display shows CROSS
CONNECTION MASTER in STANDSTILL.
P145 is set to cross slave in the system
which heater/feed pump is used. The
separator of this system is automatically
disabled. The display shows CROSS
CONNECTION SLAVE.
After adjustment of P145, only stepwise local
start from resp. panel is possible.

The separator is started/stopped and the


separator system is supervised from the master
panel as if heater and feed pump were not
installed. Temperature readings from the master
are transferred to the slave panel.

Heater and feed pump are started/stopped and


controlled from the slave panel. Alarms for the
heater and feed pump are generated in the
slave panel.

1.14.4 Serial operation


This function is required when two separators
should operate in series, i.e. the oil coming from
the first separator (usually a purifier) is further
purified in the second one (usually a clarifier,
but may be a purifier).

P145 is set to serial master in the first


system. The display shows SERIAL
CONNECTION MASTER in STANDSTILL.
P145 is set to serial slave in the second
system. The display shows SERIAL
CONNECTION SLAVE in STAND STILL.
After adjustment of P145, both systems are
started individually. The discharge interval is
set with P220 in the master system. The slave's
automatic discharge initiation is disabled.
Instead the master initiates a discharge in the
slave system every (P262) time after the own
discharge has been completed.

44
85
1 Operating

1.15 Programmable Inputs and Outputs


An extra I/O kit is available as an option. This kit
contains two boards, one with six programmable
digital inputs and one with six progammable
relay outputs. The customer can select an
optional function for each of these inputs and
outputs from a list of alternatives (see below).

1.15.1 Inputs
See parameters 139 to 144

Alternative Comments
0 None default
1 Remote start enter automatic start, only if REMOTE selected on
operator panel (pushbutton) Closed (pulse) = start
2 Remote stop enter stop sequence, works with REMOTE button in
any position Closed (pulse) = stop
3 Remote start feed pump the same as first push at stepwise start.
Closed (pulse) = start
4 External alarm used for e.g. a level switch in a tank. See alarm
A123.
Closed = alarm
5 Remote recirculation Request Recirculation, only if REMOTE selected on
operator panel (pushbutton) Closed = recirculation
6 New temperature set point EPC 60 uses temperature set point P250 during
start when the separator is switched off

1.15.2 Outputs
See parameters P133 to P138.

altId Alternative Comments


0 None default
1 Indication heater on/ start external program request "heater function on"
heater Closed = heater on
2 Indication separator motor on program request "separator motor on"
Closed = motor on
3 Stand still indication when stand still flag on Closed = stand still
4 Indication alarm A20 if alarm "Oil feed temp. high" active Closed = alarm
5 Indication alarm A21 if alarm "Oil feed temp. low" active Closed = alarm
6 Indication alarm A51 if alarm "Oil backpressure PT4 low" active Closed
= alarm
7 Indication feed pump on program request "feed pump on" Closed = feed
pump on
8 Remote start allowed allowed to start the system Closed = start allowed

45
86
1 Operating

altId Alternative Comments


9 Remote enabled remote button activated Closed = remote activated
10 Valve in sludge outlet controlled if pneumatic valve, see P131 and
Activation diagram Closed = open or close valve
(set with P131)
11 Common alarm Alternative Common alarm, Closed = no alarm, also
see separate description
12 Indication V1 Position of valve V1, Closed = feed on to separator

1.15.3 Common alarm indication


There are two separate outputs for indicating
status of the alarms. One is standard and the
other is available through the programmable
outputs.

Standard output

When there is no alarm active the contact is


closed. When an alarm is triggered the contact
opens. If another alarm is triggered the contact
will close for 0.5s and then open again. When
all alarms have been acknowledged by the
operator the contact will close.

Programmable output

Programmable output When there is no alarm


active the contact is closed. When an alarm is
triggered the contact opens. When all alarms
have been acknowledged by the operator and
reset (the fault that triggered the alarm no longer
persists) the contact will close.

46
87
1 Operating

1.16 I/O Test Function


Activity Reference/Limits
If system has active alarms, check and take actions before
starting the I/O test.
Press button F-step backwards and related arrows up ( C ) Acc. to IB(s)
and down ( E ) for Log in into the I / O test.
Follow the list of I/Os (item 25-72) to check status of all el. Acc. to IB(s)
connections of the system including the operating function of
individual components.
OUTPUTS
K2 - Separator motor Valid for:
Check the operation and rotation of the separator motor. All S and P types
The output will only be activated for a short time.
Also check that the correct led is activated on the operating
panel.
If no operation, check jumpers according to electrical diagram.
K3 Feed pump Optional
Check the operation and rotation of the feed pump. Valid for:
Also check that the correct led is activated on the operating All S and P types
panel.
If no operation, check jumpers according to electrical diagram.
V1 3 way valve Valid for:
Verify the operation of the valve, see also that the green diode All S and P types
on the valve connector is lit.
V4 Oil outlet valve Valid for:
Verify the operation of the valve, see also that the green diode All S and P types
on the valve connector is lit.
Cabinet fan Valid for:
Verify the operation of the fan mounted inside the electrical All S and P types
cabinet.

NG
WARNI
!
Electrocution Hazard
This operation require tests to be made with cabinet door open and
with power on. Beware of live parts.
Steam shutoff valve Optional
Verify the operation of the valve, see also that the green diode Valid for:
on the valve connector is lit. All S and P types
V5 - Drain valve Valid for:
Verify the operation of the valve, see also that the green diode All S and P types
on the valve connector is lit.
Hold/reset vibration switch Optional
Ensure that the vibration switch is reset when this output is Valid for:
activated P605/615
SV10 Displacement water valve Valid for:
Verify the operation of the valve, see also that the green diode All S and P types
on the valve connector is lit.

47
88
1 Operating

SV15 Discharge valve Valid for:


Verify the operation of the valve, see also that the green diode All S and P types
on the valve connector is lit.
SV16 Closing water valve Valid for:
Verify the operation of the valve, see also that the green diode All S and P types
on the valve connector is lit.
Steam decrease Closing of steam valve Optional
Verify that the valve is moving towards closing position. Note Valid for:
that if the valve is already closed, an opening operation (see All S and P types
below) needs to be done prior to this test.
Steam increase Opening of steam valve Optional
Verify that the valve is moving towards opening position. Valid for:
All S and P types
Programmable output 1
Not to be tested
Programmable output 2
Not to be tested
Programmable output 3
Not to be tested
Programmable output 4
Not to be tested
Programmable output 5
Not to be tested
Programmable output 6
Not to be tested
Electric heater test Optional
Before the electric heater i/o-test, please ensure that the
electric power to the electric heater cabinet is turned OFF!
The operating voltage for the relays is supplied from control
cabinet.
Elheatvar Variable output Optional
Check that the diodes on the 2 triacs inside the electric heater Valid for:
cabinet are lit. All S and P types
Heater on signal Optional
Check that the relay KA11 (diode, see picture below) and Valid for:
K11 (mechanical indication) in the electric heater cabinet is All S and P types
activated.
Note, leave this output activated (indicating 1 on display) when
proceeding with the tests of the fixed power steps below!
ElheatPS1 Power step 1
Check that the relay KA12 (diode, see picture below) and
K12 (mechanical indication) in the electric heater cabinet is
activated. Optional Valid for: All S and P types
ElheatPS2 Power step 2 Optional
Check that the relay KA13 (diode, see picture below) and Valid for:
K13 (mechanical indication) in the electric heater cabinet is All S and P types
activated.
ElheatPS3 Power step 3 Optional
Check that the relay KA14 (diode, see picture below) and Valid for:
K14 (mechanical indication) in the electric heater cabinet is All S and P types
activated.

48
89
1 Operating

INPUTS
Heater fault signal Optional
Check that this input is 1 as long as the output Heater on is Valid for:
activated. If not ok, check settings of over temperature device All S and P types
Go back to Heater on Item no. 47 and deactivate (0 on
display), then go back to this section and verify that Heater
fault is 0.
Estop Emergency stop Valid for:
This input should be 1 when emergency stop button is not All S and P types
pushed.
Press emergency stop button and check that it goes to 0.
Feedback feedpump
Not to be tested
Feedback separator - Contactor feedback
Not to be tested
Sludge tank level switch Optional
If not installed, check that the input is 1, if not? check if Valid for:
jumper is installed according to electrical diagram. All S and P types
If installed, manually operate the level switch, the input
should be 0 when high level.
Cover switch on separator frame Optional
Manually operate the cover switch, the input should be 1 when Valid for:
switch (and cover) is closed All S and P types
Sludge valve interlock Optional
Manually operate the sludge valve, the input should be 1 when Valid for:
the valve is closed. All S and P types
Programmable input 1
Not to be tested
Programmable input 2
Not to be tested
Programmable input 3
Not to be tested
Programmable input 4
Not to be tested
Programmable input 5
Not to be tested
Programmable input 6
Not to be tested
ANALOGUE INPUTS
PT5 Water outlet pressure transmitter 4-20mA Input
Check that the indication shows approx 0 bar. Valid for:
Note that if pipes are connected to the system, pressure might All S types
not be 0 bar.
MT Water transducer, MT60 4-20mA Input
Check that the indication shows 30 pF 5. Valid for:
Note that this value is only correct when sensor is in air (no All S types
media in pipes).
PT1 Oil inlet pressure transmitter 4-20mA Input
Check that the indication shows approx 0 bar. Valid for:
Note that if pipes are connected to the system, pressure might All S and P types
not be 0 bar.

49
90
1 Operating

PT4 Oil outlet pressure transmitter 4-20mA Input


Check that the indication shows approx 0 bar. Valid for:
Note that if pipes are connected to the system, pressure might All S and P types
not be 0 bar.
TT1 Oil inlet temperature sensor 1 PT100 input
Check that the indication shows a relevant temperature. Valid for:
All S and P types
TT2 Oil inlet temperature sensor 2 PT100 input
Check that the indication shows a relevant temperature. Valid for:
Note that the temperature should not deviate from TT1 with All S and P types
more than 2 C
Speed sensor Namur input
In order to test this input, use the Separator motor, K2, sect Optional
1, I/O-test to start the separator (for a few seconds), then go Valid for:
back to this input and check the value, it shall be higher then All S and P625/626, P635/636
0 rpm. types
Vibration switch Optional
Check that this input goes to 0 when the switch is in tripped Valid for:
position P605/615 types
Vibration sensor 4-20mA Input
Check that the indication shows approx 3.5 mm. Optional
(Sensor should be installed with 3.5 mm from the axel) Valid for:
All S and P625/626, P635/636
types

50
91
1 Operating

1.17 Operation without all sensors (Emergency


operation)
If a sensor is malfunctioning it is possible to
disable it temporarily until it can be fixed or
replaced.

1.17.1 System Without Speed


Sensor
It is possible to run the system without speed
sensor (P113 = no).

In this case system control and supervision are


much more basic.

Alarms A90 A97 are not supervised.

Remote start is not allowed.

The separator is started within 4 minutes and


stopped with stop timer.

This also applies if the speed sensor is disabled


(P148 = 0) or on alarm A92, Bowl speed sensor
error.

1.17.2 System Without Vibration


Sensor
It is possible to run the system without vibration
sensor (P114 = no).

In this case alarms A100 A103 are not


supervised.

Remote start is not allowed.

This also applies if the vibration sensor is


disabled (P132 = yes) or on alarm A102,
Vibration sensor error

1.17.3 System Without Cover


Switch
It is possible to run the system without cover
switch (P115 = no).

In this case alarms A110 A111 are not


supervised.

51
92
1 Operating

Remote start is not allowed.

This also applies if the cover switch is disabled


(P116 = yes).

1.17.4 System With PT1 Disabled


It is possible to run the system with PT1 disabled
(P157 = 0).

In this case alarms A40 A42 and A44 are not


supervised.

This also applies on alarm A42, Feed pressure


sensor PT1 error.

1.17.5 System With PT4 Disabled


It is possible to run the system with PT4 disabled
(P153 = 0).

In this case alarms A50 A52 and A54 A59


are not supervised.

As a result, calibration of the water flow is


not possible. The old values are used for
displacement and conditioning water. Cold
start function is disabled. Bowl leakage test is
disabled.

This also applies on alarm A52, Oil pressure


sensor PT4 error.

1.17.6 System With PT5 Disabled


(S-separator only)
It is possible to run the system with PT5 disabled
(P155 = 0).

In this case alarms A70 A72 and A74 are not


supervised.

This also applies on alarm A72, Water pressure


sensor PT5 error.

52
93
1 Operating

1.17.7 System With TT1/TT2


Disabled
It is possible to disable one of the temperature
sensors TT1 or TT2 with parameter P146.
The readings normally taken from the disabled
sensor is then replaced with the readings from
the other sensor in all sequences.

When a temperature transmitter is disabled the


corresponding sensor error alarm, A22 or A31,
is blocked.

Alarms A20, A21, A24 & A25 that normally are


triggered by TT1 readings should be triggered
by TT2 when TT1 is disabled.

When the system has a Modbus connection


(P129=Modbus TCP or Modbus RTU) it is
possible to use Modbus registers to receive
temperature readings. Both TT1 and TT2
are then disabled and alarms A22, A23, A30
& A31 are blocked. This mode is activated
when P146=Modbus. It is not possible select
this mode if the system is controlling a heater
(P119=steam or electric).

If P146=TT2 custom then all alarm from TT2 is


blocked. It is intended for installations where
TT2 is permanently not connected to the
EPC60.

1.17.8 Control of Sludge Pump,


Level in Sludge Tank, and
Butterfly Valve
The sludge accumulated in the bowl can be
discharged into an optional small sludge tank
with level switch. At high level signal a sludge
pump (P118 = yes) is running until the signal
is normal + 10 seconds . Otherwise see alarm
A120.

The level switch can be disabled (P159 = 0). In


this case A120 is blocked and the sludge pump
is running for 30 seconds at discharge (instead
of P234, see below).

The sludge pump is also activated during


certain timers. These running times are always
terminated by an extra pump running time
(e.g. during P234, or 5 seconds as in the
drain sequence). Note that this extra time is
independent of the other timers which may be
running simultaneously.

53
94
1 Operating

See also the Sequence diagram for other


occasions when the sludge pump is activated,
if selected (Parameter List chapter 2.2
Discharge) .

The separator sludge outlet can contain a


manual butterfly valve which is used to close the
outlet when the separator is standing still.

Select with P131 (no, manual).

If P131 = no, alarm A122 is blocked.

1.17.9 System Without Feed Pump


It is possible to run the system without feed
pump (P127 = no).

In this case alarms A01 and A44 are not


supervised.

Remote start is not allowed.

54
95
1 Operating

1.17.10 System Without Water


Transducer (S-separator
only)
It is possible to run the system without water
transducer (P117 = no).

In this case alarms A80 - A85 and A74 are not


supervised.

There is no calibration of the water flow. In


separation, automatic discharges are initiated
every 15 minutes (overrides P220). SV10 is
never activated (this means no displacement
before discharge and no conditioning water).
Water draining from the bowl is not allowed.

This also applies if the water transducer is


disabled (P128 = standby) or on alarm A85,
MT60 fault.

55
96

S Flex Separation

Parameter List
Printed 10-2014
Book No. 584613-02 rev. 8
97

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden

Telephone: +46 8 530 650 00


Telefax: +46 8 530 310 40

Alfa Laval Tumba AB 10-2014


The original instructions are in English
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.
98

Contents
1 Parameter list 5
1.1 Setting List 5

2 Operation Modes 15
2.1 Change-over Sequence 15
2.1.1 Change-over without calibration 15
2.1.2 Calibration of the water flow via SV10 15

2.2 Discharge 17

3
99
100

1 Parameter list

1.1 Setting List


To access the Setting List at any time during
the operation process press the Return button
repeatedly until the Setting List is reached. 7 8 9

4 5 6

NOTE 1 2 3

. 0
Relevant parameters only are shown on the display.
REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
FEED SLUDGE CLEANING
PUMP PUMP IN PLACE

X023912A

Press the arrow buttons to go up or down in the


list. The list consists of the following:
7 8 9
1. Parameter menu List of all parameters.
Password protected. 4 5 6
To go directly to a parameter, enter the 1 2 3
parameter number.
. 0
2. Time settings For setting date, time, etc.
Password protected. REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

To go directly to a parameter, enter the FEED SLUDGE


CIP
CLEANING

parameter number. PUMP PUMP IN PLACE

3. Operation time Different counters and X023914A

timers can be read.


4. I/O Test Here it is possible to activate all
outputs and to read the status for all inputs,
for testing purposes.
5. Alarm history List of alarms which have
been rectified. The latest alarm shows at
the top of the list.
6. System info
7. IP settings
8. Password / Login
9. Set contrast

5
101
1 Parameter list

When in the Parameter Menu a list item is


blinking, you can press the Information button
for help and information. Press the Information 7 8 9
button again to return to your previous position.
4 5 6
You can also change this setting see below. 1 2 3

. 0

REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
FEED SLUDGE CLEANING
PUMP PUMP IN PLACE

X023915A

When a list item is blinking, its value can be


changed. Changes can be made either by using
the number buttons to write in a value, or by 7 8 9
choosing a value from the list. Save any change
by pressing the Enter button. 4 5 6

1 2 3

. 0
NOTE
REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

Certain parameters can only be changed by the factory, CIP


the chief engineer, or an Alfa Laval service engineer FEED
PUMP
SLUDGE
PUMP
CLEANING
IN PLACE

X023913A

Parameters are divided into three password


levels:

Level 0 No password needed.

Level 1 Possible to protect with password.

Level 2 Alfa Laval password protected.

@ = These configuration parameters can only


be adjusted while the system is in STAND STILL
(not visible on the HMI in all other modes).
The present configuration is displayed in menu
"System info".

6
102
1 Parameter list

Parameter Pass- Denomination Default Unit Min. Max.


word value value value
level
P100 0 Display language: English
English/ German/ Spanish/ French/
Italian/ Portuguese/ Finnish/
Swedish
P101 0 Selection of temp. presentation C
Celsius/Fahrenheit
P102 0 Selection of feed flow rate m3/h
presentation m3/h or USG/h
P103 0 Selection of pressure presentation bar
kPa, bar, psi
User password required for all following parameters if activated!

System configuration
P107 1 Flow correction factor. 1.00 0,00 2,00
If P107=0, the flow is not visible on
the HMI
P111 1@ Separator size 0 See Parameters
depending on the
setting of P111,
page 12.
P112 1 Oil type HF380 See Parameters
depending on the
setting of P112,
page 14.
P114 1@ Vibration sensor installed yes/no no Can be changed
in even in
STOP. See also
"System without
vibration sensor"
in the Operating
instructions manual.
P115 1@ Frame cover switch installed yes/no no Can be changed
in even in STOP.
See also "System
without frame
cover switch" in
the Operating
instructions manual.
P116 1 Frame cover switch disabled yes/no no See also "System
(if P115 = yes) without frame
cover switch" in
the Operating
instructions manual.
P117 Not used
P118 1@ Sludge pump installed yes/no no Can be changed in
even in STOP.

7
103
1 Parameter list

Parameter Pass- Denomination Default Unit Min. Max.


word value value value
level
P119 1@ Heater installed no/elec- no Can be changed
tric/steam/external in even in STOP.
See also "Control
of Heater" in
the Operating
instructions manual.
P120 1@
1 If P119 = electric: heater size 16 kW 7 130
P121 1 If P119 = steam: steam valve 120 s 0 999
transition time

Parame- Pass- Denomination De- Unit Min. Max.


ter word fault value value
level value
P122 1 Deadband heater 0.5 C 0 5
(P101)
P123 1 P-constant heater (if heater 75 10 500
controlled)
see also P125/P126 (cold start)
P124 1 I-constant heater (if heater 0.4 min 0.1 10.0
controlled)
P125 1 Breakpoint cold start (if heater 0 C 0 99
controlled) (P101)
P126 1 Gain factor cold start (if heater 40 1 100
controlled)
P127 1@ Feed pump controlled yes/no no Can be changed in
even in STOP.
P128 1 MT60 on/standby. Standby = on
MT60 disabled. Discharge every
15 min. (overrides P220). SV10
not activated. No drain sequence.
P129 1 Selection of remote control digital
method inputs
digital inputs
Modbus
P130 1 Selection of automatic or step- auto- step-
stepwise start wise matic wise
P131 1@ Valve in sludge outlet installed no Can be changed in
no, manual even in STOP.
P132 1 Vibration sensor disabled yes/no no

8
104
1 Parameter list

Parame- Pass- Denomination De- Unit Min. Max.


ter word fault value value
level value
P133 1 Optional output 1 (Relay) See also
P134 1 Optional output 2 (Relay) Programmable
in- and outputs
P135 1 Optional output 3 (Relay) in the Operating
P136 1 Optional output 4 (Relay) instructions
P137 1 Optional output 5 (Relay) manual for all
alternatives
P138 1 Optional output 6 (Relay)
P139 1 Optional input 1
P140 1 Optional input 2
P141 1 Optional input 3
P142 1 Optional input 4
P143 1 Optional input 5
P144 1 Optional input 6
P145 1 Cross connection/serial operation dis- see also Cross
abled connection/serial
operation
P146 1 Temperature sensor disabled no
no, TT1, TT2, TT2 custom
P148 1 Speed sensor disabled. no
P149 1 Level switch disabled. Run sludge no
pump 30 s at discharge (overrides
P234).

Parame- Pass- Denomination Default Unit Min. Max.


ter word value value value
level
Alarm related parameters: delays, limits etc.
P151 Not used
P152 1 Power failure alarm used yes/no yes
P153 1 High oil pressure limit (PT4), 0.0 = 3,0 bar 0,0 6,0
pressure sensor disabled
P154 1 Low oil pressure limit (PT4) 1,2 bar 0,0 6,0
P155 1 High water pressure limit (PT5), 0.0 5,5 bar 0,0 6,0
= water pressure sensor disabled
P156 1 Low water pressure limit (PT5) 0,2 bar 0,0 6,0
P157 1 Alarm limit high feed pressure 3,0 bar 0,0 6,0
(PT1), 0.0 = feed pressure sensor
disabled
P158 1 Alarm limit low feed pressure (PT1) 0,2 bar 0,0 6,0
P160 1 Alarm limit A131 Sludge in bowl 20 % 0 100
P161 1 Alarm limit "A97 Discharge 300 rpm 0 2000
feedback error"
P162 2 Alarm limit "A81 Transducer value 70 pF 0 320
low"

9
105
1 Parameter list

Parame- Pass- Denomination Default Unit Min. Max.


ter word value value value
level
P163 2 Alarm limit "A57 Oil leaking from 1,0 bar 0 4
bowl"
P164 2 High oil pressure limit (PT4) during 3,0 bar 0,0 6,0
leakage test
P165 2 Low oil pressure limit (PT4) during 1,0 bar 0,0 4,0
leakage test
P167 1 Not used
P169 1 Alarm delay "A24 Temperature 15 min 0 60
increase too slow"
P173 1 Alarm delay A25 Temperature not 5 min 0 30
decreasing
0 = no temperature supervision
P175 2 Alarm delay A59 PT4 pressure 5 s 0 60
high after cold start"
P177 1 Alarm limit "A32 Difference 10 C 0 30
TT1/TT2 too large" (P10
1)
P178 1 Time limit in RECIRCULATION 10 min 0 30
Setpoints
P220 1 Discharge interval 120 min 1 300
P222 1 V5 open time at drain sequence 25 s 0 250
P224 1 MT60 limit stop draining 70 % 0 100
P225 2 Test of MT60 signal frequency 5 0 40
(every xxx discharge), 0 = test
disabled
P226 2 MT60 low trigger limit at transducer 250 % 0 900
test
P227 2 Flush of drain outlet after 20 0 100
displacement (every xx discharge)
P228 1 SV16 pulse interval in 5 min 1 30
SEPARATION
P229 Not used

10
106
1 Parameter list

Parame- Pass- Denomination Default Unit Min. Max.


ter word value value value
level
P231 1 SV15 opening time 3,0 s 0,1 30,0
P232 1 Draining of operating water 15 s 0 30
P233 1 Filling time conditioning water s 0 120
(calculated during calibration)xxx
(120 initially)
P234 1 Sludge pump additional/manual 15 s 0 60
running time
P236 2 Water drain time during STOP 10 s 0 30
P237 1 Sludge pump running and V5 10 s 0 30
opening time before discharge
P238 2 Feed on after discharge and test of 60 s 0 90
water content in oil outlet
P239 2 Time for stabilization of the 60 s 0 300
transducer signal
P242 2 Test of calibration value, interval 60 0 100
(no. of discharges)
P256 1 Feed pump stop delay at normal 3 min 0 30
STOP

11
107
1 Parameter list

Parameters depending on the setting of P111


Separator size (P111, default 0)
S 811 S 820 S 400 S 500 S 600 S 700 S 800
S 816 S 825 S 840 S 850 S 860 S 870 S 880
S 200 S 300 S 841 S 851 S 861 S 871 S 881
S 821 S 830 S 845 S 855 S 865 S 875 S 885
S 826 S 831 S 846 S 856 S 866 S 876 S 886
S 921 S 835 S 946 S 956 S 966 S 976 S 986
S 926 S 836 S 947 S 957 S 967 S 977 S 987
S 927 S 936
S 937
Param- Pass- Description Min. Max. Unit
eter word value value
level
P180 2 Alarm limit bowl 83 90 90 89 82 82 81 0 100 % of
speed low max
speed
P181 2 Alarm limit 0,3 0,3 0,5 0,5 0,5 0,5 0,5 0,0 2,5 mm
high vibration
shutdown
P182 1 Alarm limit 0,2 0,2 0,3 0,3 0,3 0,3 0,3 0,0 2,5 mm
high vibration
warning
P240 1 Filling time 77 63 108 48 80 61 72 0 150 s
displacement
water, initial
value (calcu-
lated during
calibration, see
also P254)
SV10, constant 0,9 1,6 1,6 5,5 5,5 11,0 15,0 l/min
flow orifice
P243 1 SV16 open 15 s 15 s 15 s 15 s 25 s 25 s 60 s 0 120 s
after dis-charge
P244 1 SV15 open for 10 s 10 s 10 s 10 s 15 s 25 s 25 s 0,1 30,0 s
priming water
during start-up
P245 2 V4 closed 10 10 10 10 10 10 10 0 30 s
during bowl
leakage test
P247 1 V4 closing 2 2 4 6 8 10 10 0 15 s
delay at bowl
leakage test
P248 2 Delay of PT4 5 5 5 10 10 10 10 0 15 s
pressure
reference value
registration at
bowl leakage
test

12
108
1 Parameter list

NOTE

If P111 = 0 (default value), the operator is automatically


forced to go through a system configuration procedure
to setup the system.

13
109
1 Parameter list

Parameters depending on the setting of P112


Oil type (selected with P112)

Parame- Pass- Descrip- GO MDO IF30 HF180 LO TP LO CH Min. Max. Unit


ter word tion IF40 HF380 Trunk Cross value value
level IF60 HF460 head
IF100 HF600
HF700
P183 1 High tem- C
perature 40 105 100 100 0 115 (P101)
limit
P184 1 Low tem- C
perature 20 85 90 85 0 115 (P101)
limit
P249 1 Tempera- C
ture set- 30 98 95 90 0 110 (P101)
point
P187 2 Number of
drainings
before
alarm 5 2 0 20
A84 High
water
content
P251 MT60 trig- pF
ger fac-
tor (corre-
sponds to
100% in- 3,0 0,6 0,1 10,0
crease of
the trans-
ducer sig-
nal)
P252 1 MT60 %
trigger 100 100 100 0 250
limit
P189 2 Alarm pF
limit A80
Trans-
110 85 78 0 320
ducer
value
high"
P254 2 Reduction
of P240 if
DO
Calcul- 1,0 0,0 1,0
ated as
P240 *
P254

14
110

2 Operation Modes

2.1 Change-over Sequence


This sequence is run through when the
system changes operation mode from
RECIRCULATION to SEPARATION after start
(supervision similar as in RECIRCULATION).

This transition phase may include calibration


of the water flow via SV10, if the operator
answers yes to all three questions during
the start-sequence (see Manual Start from
Standstill in the Operating instructions manual).
If no to first or third question, the previously
calculated filling time (P233) is used.

2.1.1 Change-over without


calibration
A discharge sequence (step 2) and bowl
leakage/water transducer test (step 3) is run
through (see 2.2 Discharge, page XX).

The opening time of SV15 is in this case set


with P244 (not P231). Finally the system ends
up in SEPARATION.

2.1.2 Calibration of the water flow


via SV10
During 170 seconds, the oil outlet valve V4 is
closed and the bowl is filled with water through
SV10 until the pressure on PT4 has increased
by 0.2 bar.

The conditioning water flow rate is then


calculated as the known bowl volume divided by
the time needed to fill the bowl.

If the feedback signal from PT4 was not received


until 170 seconds has elapsed, the alarm A55
No PT4 pressure feedback at conditioning water
calibration is given. The bowl is emptied (P231,
P232, P243) and the calibration is repeated
when the alarm has been acknowledged.

15
111
2 Operation Modes

Test of calibration
The calibration is repeated at every (P242)
discharge. The measured time to fill the bowl
is then compared with the saved time used to
calculate the SV10 flow rate (the old value is
not changed).

If the time to fill the bowl has decreased


with the relative value in P160, the alarm A131
Sludge in bowl is given and the system goes to
STOP. Restart is not possible.

16
112
2 Operation Modes

2.2 Discharge
During discharge three different sequences are
run through:

displacement sequence (step 1)


discharge sequence (step 2)
bowl leakage/water transducer test (step 3)

The following diagram shows the equipment


which is activated during the sequences, the
activation pattern and the corresponding timers.

Sequence Diagram
If a combination of low PT4 pressure (P154) and low speed (P180) is detected when the feed is
on, the system will go to STOP immediately without waiting the time in P238. Alarm A57 Oil
leaking from bowl.

Vibration
supervision
blocked
SV15, P2
P23
discharge 31
2

P2
SV16, 43
closing water
SV10, P1 P2 P2
a)
conditioning, 72 40 33

displacement
V4, clean oil P2
outlet (NO) 45

V1, feed inlet P2 P2
(deactiv. = P17 38 39

recirculation) 1*
V5, water a)
drain (NC)
Sludge pump P2 P2
(optional) 37 34

Sep- Displacement sequence Discharge sequence Bowl Sep-
ara- (Step 1) (Step 2) leakage/water ara-
tion transducer test tion
(Step 3)
Discharge
initiation
= activated
= deacti- * Timer a) optional,
vated interrupted when frequency
feedback signal selected with
received. P227.

17
113

S Flex Separation

Alarms and Fault Finding


Printed 07-2014
Book No. 584614-02, rev. 6
114

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden

Telephone: +46 8 530 650 00


Telefax: +46 8 530 310 40

Alfa Laval Tumba AB 07-2014


The original instructions are in English
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.
115

Contents
1 Alarms 5
1.1 Alarms List 5
1.2 Alarm History List 8

2 Display Alarms and Actions 9

3 EPC 60 Control panel 21

3
116
117

1 Alarms

1.1 Alarms List


To access the Alarms List press the Alarm
Button.
7 8 9

4 5 6
NOTE
1 2 3
The latest 50 alarms are stored in the Alarm History
. 0
List. See below.
REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
FEED SLUDGE CLEANING
PUMP PUMP IN PLACE

X023912B

Press the arrow buttons to go up or down in


the list.
7 8 9

4 5 6

1 2 3

. 0

REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
FEED SLUDGE CLEANING
PUMP PUMP IN PLACE

X023914A

5
118
1 Alarms

For each item in the list you can press the


Information button for help and information.
Press the Information button again to return to 7 8 9
your previous position.
4 5 6
You can also acknowledge and/or reset this 1 2 3
alarm.
. 0

REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
FEED SLUDGE CLEANING
PUMP PUMP IN PLACE

X023915A

If the system has a fault, the alarm LED blinks.


Press the Alarm button once. The alarm shows
on the display.
Press the Alarm button again to acknowledge
the alarm.
To go through the alarm list, press the Arrow
buttons.

NOTE X023919A

After acknowledging an alarm, go through the


alarm list to make sure that there are no other
unacknowledged alarms!

If after all alarms have been acknowledged


fault(s) remain in the system, the alarm LED
stops blinking and remains on. An A appears
at the end of an alarm which has not been
rectified.
The alarms disappear automatically when the
fault is rectified.
When all the alarms have been rectified, the
alarm LED goes out.
For safety reasons, certain alarms must not only
be acknowledged, but also rectified before the
system can continue in operation, for example
alarm A122 Butterfly valve in sludge outlet
closed.
Also for safety reasons, some alarms will set the
system into recirculation or stop. These alarms
must be rectified before the operator can put the
system into operation.

6
119
1 Alarms

Press the Return button to leave the list.

7 8 9

4 5 6

1 2 3

. 0

REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
FEED SLUDGE CLEANING
PUMP PUMP IN PLACE

X023912A

7
120
1 Alarms

1.2 Alarm History List


To access the Alarm History List at any time
during the operation process press the Return
button repeatedly until the Alarm History List 7 8 9
is reached.
4 5 6

1 2 3
NOTE
. 0
Relevant parameters only are shown on the display REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

CIP
FEED SLUDGE CLEANING
PUMP PUMP IN PLACE

X023912A

Press the arrow buttons to go up or down in the


list. The list consists of the following:
7 8 9
1. Parameter menu List of all parameters.
Password protected. 4 5 6
To go directly to a parameter, enter the 1 2 3
parameter number.
. 0
2. Time settings For setting date, time, etc.
Password protected. REMOTE

i
HEATER DISCHARGE
SEPARATOR CONTROL

To go directly to a parameter, enter the FEED SLUDGE


CIP
CLEANING

parameter number. PUMP PUMP IN PLACE

3. Operation time Different counters and X023914A

timers can be read.


4. I/O Test Here it is possible to activate all
outputs and to read the status for all inputs,
for testing purposes.
5. Alarm history List of alarms which have
been rectified. The latest alarm shows at
the top of the list.
6. System info
7. IP settings
8. Password / Login
9. Set contrast

8
121

2 Display Alarms and Actions

A05 A20-A25 A30-A32 A40-A43 A50-A59 A80-A85


V1
V4
TT1 TT2 PT1 PT4 MT

A110-A111

A100-A103
V10

V15 SS
A70-A74

V16 YT PT5
ST

A90-A97
V5
A122

A120-A121
GS
A01 A15
A130 - A139
LS

X024968a

Alarm Alarm text Conditions Why? What to do


code
Feed pump (if P127 = yes)
A01 Pump starter failure Delayed by P168. Feedback signal from Check the contactor
contactor K3 missing. function.
Check input terminal
in the PLC.
A05 Heater fault (electric) Delayed 2 s. Power to heater Check the power
interrupted. supply to the heater.
High temp. switch Check temp. setpoint
released in the control unit.
Check the heater and
clean if necessary.
When the
temperature
decreases,
the switch is
automatically reset.

9
122
2 Display Alarms and Actions

Alarm Alarm text Conditions Why? What to do


code
Heater, electric (if P119 = electric)
A15 Separator starter Delayed 2s. Feedback signal from Check the contactor
failure contactor missing. function. Check input
terminal in the PLC
Temperatur transmitter feed inlet TT1
A20 Oil feed temperature Delayed by P150. Steam supply valve Investigate cause
high Limit in P183. faulty and remedy.
Faulty triac module(s)
in the power unit or
faulty controller in the
control unit. (electric
heater).
Broken wiring or
defective heater
resistance, or faulty
controller in the
control unit.
A21 Oil feed temperature Delayed by P150. Heater clogged Investigate cause
low Limit in P184 and remedy.
Steam supply Investigate cause
insufficient and remedy.
Steam trap faulty Investigate cause
and remedy.
Steam supply valve Investigate cause
insufficient and remedy.
Faulty fuses or burned Check and renew
contactors (electric broken fuses.
heater) Reset overcurrent
protection
(applicable for 8/7
- 24/22 kW power
unit).
Check wiring and
contactor coils.
Broken wiring or Check wiring and
defective heater heater resistance of
resistance (electric each block or heater
heater) element.
A22 Temperature alarm Delayed by P150 Short circuit / broken Disconnect cable
sensor error (TT1) sensor or cable. at sensor. Measure
resistance between
1-3. Resistance
shall be within
100-142 ohms =
0-110 C/32-230 F.
Replace sensor if
broken. If no spare
sensor available, set
parameter P146 =
TT1 to be able to run
the system.

10
123
2 Display Alarms and Actions

Alarm Alarm text Conditions Why? What to do


code
A23 Temperature alarm Reminder only, if P146
sensor disabled = TT1
A24 Temperature increase Delayed by P169. Insufficient heating Check heater
too slow Limit in P184. during start. function.
A25 Temperature not Delayed by P173. Heating on during Check heater
decreasing Limit in P184. Stop stop sequence. function.
sequence continues Recirculating oil not Reset alarm to
after alarm reset. cooling. continue.
Disabled if P173 = 0.
Temperatur transmitter heater control TT2
A30 Temperature control Delayed by P150. Short circuit / broken Disconnect cable
sensor error (TT2) sensor or cable. at sensor. Measure
resistance between
1-3. Resistance
shall be within
100-142 ohms =
0-110 C/32-230 F.
Replace sensor if
broken. If no spare
sensor available, set
parameter P146 =
TT2 to be able to run
the system
A31 Temperature control Reminder only, if P146
sensor disabled = TT2
A32 Difference TT1/TT2 Delayed by P176.
too large Alarm limit in P177.
Blocked if A22, A23,
A30, or A31
Pressure transmitter feed inlet PT1
A40 Feed pressure PT1 Delayed by P150. Pipe restricted. Check recirculation
high Limit in P157 for restriction.
A41 Feed pressure PT1 Delayed by P150. Pump not working Check pump.
low Limit in P158. Pressure in feed line Check feed line and
too low flow regulation.
Check heater for
fouling.
A42 Feed pressure sensor Delayed by P150. Sensor or cable Check cable
PT1 error damaged. connections.
Replace sensor. If
no spare sensor
available, set
parameter P157 =
0.
A43 PT1 disabled Reminder only, if P157
= 0.
Pressure transmitter oil outlet PT4
A50 Oil backpressure PT4 Delayed by P150. Increased throughput Check. Reduce
high Alarm limit in P153. backpressure.
Regulating valve too Adjust valve.
restricted

11
124
2 Display Alarms and Actions

Alarm Alarm text Conditions Why? What to do


code
A51 Oil backpressure PT4 Delayed by P150. Decreased Check feed pump
low Alarm limit in P154. throughput and adjust flow.
Regulating valve open Adjust back pressure
too much valve
Change over valve Check air pressure,
V1 in recirculation solenoid valve SV1
position and output from EPC
60.
Bowl opens
unintentionally during
operation because:
Strainer and piping in Clean the strainer
the operating water and check the
supply is clogged. whole system fore
limestone deposits.
Too little or no water Measure the water
in the operating water flow in the three
system. hoses from the water
block and compare
with correct values.
Hoses between Fit hoses correctly.
the supply valves
and separator are
incorrectly fitted.
Nozzle in bowl body Clean the nozzle.
clogged
Rectangular ring in Renew the
discharge slide is rectangular ring.
defective.
Valve plugs are Renew all plugs.
defective.
Supply valves SV15 Rectify the leak.
and SV 16 are
leaking.
A52 Oil pressure sensor Delayed by P150. Sensor or cable Check cable
PT4 error damaged. connections.
Replace sensor. If
no spare sensor
available, set
parameter P153 =
0.
A53 PT4 disabled Reminder only, if P153
= 0.
A54 Oil pressure PT4 high Delayed by P171. No decrease in oil Check function of
at discharge Alarm limit in P221. pressure at discharge. change-over valve
V1.
A55 No PT4 pressure Delayed by P170. No increase in Check supply of
feedback at Alarm limit in P221. oil pressure at displacement water
conditioning water calibration. (SV10).
calibration
A56 No PT4 pressure Delayed by P172. No increase in Check supply of
feedback at Alarm limit in P221. oil pressure at displacement water
displacement displacement. (SV10).

12
125
2 Display Alarms and Actions

Alarm Alarm text Conditions Why? What to do


code
A57 Oil leaking from bowl Delayed by P245. Bowl periphery Change seal ring
Alarm limit in P163. sealing damaged in bowl hood.
Check/change
rubber rings and
valve plugs.
Leakage somewhere Check for leakage.
in oil outlet
Closing water leaking Check/change
sealings and plugs.
A58 Leak test failure Limit in P164. No. of
attempts in P166.
A59 PT4 pressure high Delayed by P175.
during Transition Alarm limit in P154
Pressure transmitter water drain PT5
A70 Pressure in water Delayed by P150. Paring tube not Check that
outlet PT5 high Limit in P155. moving correctly. movement is not
impeded by friction.
A71 Pressure in water Delayed by P150. Paring tube not Check that
outlet PT5 low Limit in P156. moving correctly. movement is not
impeded by friction.
A72 Water pressure Delayed by P150. Sensor or cable Check cable
sensor PT5 error damaged. connections.
Replace sensor. If
no spare sensor
available, set
parameter P155 =
0.
A73 PT5 disabled Reminder only, if P155
= 0.
A74 Water outlet restricted Delayed 3s. V5 not opening or line Check V5 function.
restricted. Clean the outlet pipe.
Water transducer MT60
A80 Transducer value high Delayed by P150. Extremely high waterCheck where the
Limit in P189. content. water is coming
from.
Fouling in the MT60. Dismantle and clean
with detergent.
A81 Transducer value low Delayed by P150. Too much air in oil Check oil
Limit in P162. outlet. backpressure.
A82 MT60 in standby more Reminder only, if P128
than 24 hours = standby more than
24h.
A83 Transducer no Limit in P226. MT60 test failure. Check water supply.
response Check SV10.

13
126
2 Display Alarms and Actions

Alarm Alarm text Conditions Why? What to do


code
A84 High water content Number of drainings Too much water in Investigate cause and
in P187. Limit in P224. oil outlet. remedy.
Much water in the Check where the water
feed. is comimg from.
Paring tube not Check that movement
moving properly. is not impeded by
friction.
A85 MT60 fault Delayed by P150. Sensor or cable Check cable
damaged. connections.
Replace sensor. If
no spare sensor
available, set
parameter P128 =
standby.
Speed sensor separator (if P113 = yes)
A90 Bowl speed high Delayed 5 s. Limit in High power (net) Check power supply
P179. frequency. before restart.
Incorrect
transmission parts NG
WARNI
(50 Hz belt pulley !
and belt for 60 Hz
power supply). Disintegration hazard
Stop and change the belt
transmission to suit the
power supply frequency.
A91 Bowl speed low Delayed 5 s. Limit in Slipping belt Change belt.
P180. Worn coupling pads Check / change pads.
Bowl not properly Check closing water
closed supply (valve SV 16).
Check bowl operating
system for leakage.
Check nozzle.
Bowl not properly Check that the lock
assembled ring is in place.
Low power net Check power.
frequency
Motor failure Repair the motor.
Bearing(s) damaged Renew all bearings.
Incorrect
transmission parts NG
WARNI
(60 Hz belt pulley !
and belt for 50 Hz
power supply). Disintegration hazard
Stop and change the belt
transmission to suit the
power supply frequency.

14
127
2 Display Alarms and Actions

Alarm Alarm text Conditions Why? What to do


code
A92 Bowl speed sensor Delay 4s. Timer stop. Sensor or cable Replace sensor. If
error damaged. no spare sensor
available, set
parameter P179 =
0 to be able to run the
system.
A93 A93 Speed sensor Reminder only, if P148
disabled = yes.
A94 Bowl speed high Delayed by P174. Power still on to the Check reason and
during STOP Alarm limit in P180. motor remedy.
A95 Separator motor Delayed by P230. Separator friction Check the friction
run-up time too long Limit in P180. blocks slipping blocks.
Belt slipping Check the belt.
Height position Stop. Check and
of paring disc is adjust the height.
incorrect.
Motor failure Repair the motor.
Bearing(s) damaged Renew all bearings.
or worn in coupling or
spindle drive.
A96 Slow start Speed < 90 rpm 10s
acceleration after response from
motor contactor.
A97 Discharge feedback Alarm limit in P161. Strainer in the Clean the strainer.
error Test during P232, one operating water
extra discharge before supply is clogged.
alarm.
Water flow too low. Check opening water
flow (SV 15) into the
bowl.
Hoses between Fit hoses correctly.
the supply valves
and separator are
incorrectly fitted.
Rectangular ring in Replace the
the operating slide is rectangular ring.
defective.

15
128
2 Display Alarms and Actions

Alarm Alarm text Conditions Why? What to do


code
Vibration sensor separator (if P114 = yes)
A100 High vibration warning Delayed by P150. Sludge remaining in Dismantle, clean
Alarm limit in P182. part of the bowl and check the bowl
before restart.

NG
WARNI
!
Disintegration
hazard
The separator bowl must
be manually cleaned
before starting up again.
Bowl wrongly Check assembly.
mounted.
Disc stack Check assembly.
compression
incorrect.
Bowl assembled Check assembly.
with parts from other
separators.
Height position of Stop the separator,
paring disc is incorrect
measure and if
necessary adjust
the height.
Bowl spindle bent Renew the bowl
spindle
Bearing(s) damaged Renew all bearings.
or worn
The frame feet are Renew the frame
worn out. feet.
Spindle top bearing Renew all springs.
spring broken.

16
129
2 Display Alarms and Actions

Alarm Alarm text Conditions Why? What to do


code
A101 High vibration Delay 1s. Alarm limit Sludge remaining in Dismantle, clean
shutdown in P181. part of the bowl and check the bowl
before restart. See
Service Manual.

NG
WARNI
! WARNI
NG
!
Disintegration
hazard Disintegration hazard
If excessive The separator bowl
vibration occurs, must be manually
stop separator and cleaned before starting
keep bowl filled up again.
with liquid during
rundown. The cause
of the vibration must
be identified and
corrected before
the separator is
restarted.
Bowl wrongly Check assembly.
mounted
Disc stack Check assembly.
compression incorrect
Bowl assembled Check assembly.
with parts from other
separators
Height position Stop the separator,
of paring disc is measure and if
incorrect. necessary adjust
the height.
Bowl spindle bent. Renew the bowl
spindle.
Bearing(s) damaged Renew all bearings.
or worn.
The frame feet are Renew the frame feet.
worn out
Spindle top bearing Renew all springs.
spring broken.
A102 Vibration sensor error Delayed by P150. Sensor or cable Replace sensor. If
damaged no spare sensor
available, set
parameter P132 =
yes to be able to run
the system.
A103 Vibration sensor Reminder only. If P132
disabled = yes.

17
130
2 Display Alarms and Actions

Alarm code Alarm text Conditions Why? What to do


Frame cover switch separator (if P115 = yes)
A110 Frame cover open Delay 1s. Separator not Assemble
Start not possible. properly assembled the separator
according to
instructions.
Faulty frame cover Replace cover
switch switch. If no spare
switch available,
set parameter P116
= yes to be able to
run the system.
A111 Cover switch Reminder only, if
disabled P116 = yes.
Sludge handling
A120 Sludge tank level At high level: Start Pump has not Check the pump
high not possible. Sludge drained the tank function.
pump running until
level signal normal +
10s. Alarm delay and
max pump running
time 60s in all modes
without feed flow,
P159 in Separation.
Discharge blocked.
A121 Level switch Reminder only, if
disabled P149 = yes.
A122 Valve in sludge Delayed by P150. Valve closed. Open manual valve.
outlet closed
Discharge not
possible. Start not
possible.
A123 External alarm.
Delay 2 s
System
A130 Emergency stop Delay 1s. No restart. Emergency stop Check for the
button pushed button pushed cause. Reset
pushbutton.
A131 Sludge in bowl Alarm limit in P160. Too much sludge in This alarm is
bowl given if the bowl
is extremely dirty
and cannot be
acknowledged.
The separator
will be stopped.
Wait until STAND
STILL is indicated.
Investigate cause
and remedy.
A132 Power failure Disabled with P152 Black-out has Check plant
= no. occurred during conditions and
operation restart.
A133 Too long time in Delayed by P178. Time in
RECIRCULATION System goes to RECIRCULATION
STOP. expired.

18
131
2 Display Alarms and Actions

Alarm code Alarm text Conditions Why? What to do


A136 Communication
error
A137 Cabinet over Reminder only
temperature
A138 Too many start Contactor activated
attempts 5 times within last
60 minutes.
A139 EPC60 internal Delay 2 s IO-card status or Check IO cards
failure PLC status not OK have no red LEDs
PLC has detected Check if
an IO-configuration IO-configuration
that does not exist is right or verify
electrical drawings
A140 Too long time out of IO-card status Alarm is created Pre-lubricate
operation orPLC status not if the separator spindle bearings.
OK has been out of After service
operation for one always run
month or more. It is the separator
reset if the separator continuously for
has been running for at least 5 hours
at least 5 hours. to ensure proper
lubrication.
A141 Permanent variables Check the CPU is
have not been well mounted
correctly backed-up Check EMC
connections
A142 Restore the memory
A143 Permanent
variables have
been successfully
restored
A145 Panel communica- Check wiring
tion error
A149 Parameter is out of Enter a new
range parameter value
within the correct
range.
A150 Parameter level 3 The parameter will
has been changed. revert to its original
value.

19
132
2 Display Alarms and Actions
133

3 EPC 60 Control panel


Fault Remedy
Black screen Press and hold Enter button and adjust contrast with
up and down button.
This can be done regardless of which page is
currently displayed.

21
Separator Sizes S 976 - S987 134

Single Flex Module

Installation System Reference


Printed 02-2013

Book No. 9006452 - 02, rev. 0


135

Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.

Published by: Alfa Laval S.p.A


Marine & Diesel Equipment
20900 - Monza, MB
Italy
Copyright Alfa Laval Italy, Feb 2013.
136

Contents
1 Technical Data 7

1.1 Demand Specifications Water 7


1.2 Demand Specifications Air 8
1.3 System Data 9
1.3.1 Module Weights including optional
Sludge Removal Kit, kg 12

2 Mechanical Drawings 13
2.1 Single Module Flow Charts 14
2.1.1 Single Module S-separator, Full Options 14
2.1.2 Single Module S-separator with Optional
Feed Pump Block and Heating System Block 15
2.1.3 Single Module S-separator with Optional Feed
Pump Block and Flow Control Block 16
2.1.4 Single Module S-separator with Optional
Heating System Block 17
2.1.5 Single Module S-separator with Optional
Feed Pump Block 18
2.1.6 Single Module S-separator without Block Options 19
2.1.7 Single Module P-separator, Full Options 20
2.1.8 Single Module P-separator with Optional
Feed Pump Block and Heating System Block 21
2.1.9 Single Module P-separator with Optional
Feed Pump Block and Flow Control Blcok 22
2.1.10 Single Module P-separator with Optional
Heating System Block 23
2.1.11 Single Module P-separator with Optional
Feed Pump Block 24
2.1.12 Single Module P-separator without Block Options 25
2.2 Single Module Dimension Drawings 26
2.2.1 Single Module S / T / H Dimension Drawing 26
2.2.2 Single Module S /T / H Dimension Drawing 27
2.2.3 Single Module Electric Dimension Drawing 28
2.2.4 Single Module Electric Installation Drawing 29
2.2.5 Single Module Without Heater Dimension Drawing 30
2.2.6 Single Module without Heater Installation Drawing 31
2.2.7 Single Module Without Heater with pump
Dimension Drawing 32
2.2.8 Single ModuleWithout Heater With Pump
Installation Drawing 33

3
137

2.3 Control and Starter Cabinet Dimension Drawing 34

2.4 Control Cabinet Block Drawing 35

2.5 Control Cabinet Assembly Drawing 36

2.6 Change of EPC 60 Components 38

3 Electrical Drawings 41
3.1 Electrical System Layout S 936 - S 947 42
3.2 Electrical System Layout P 636 43
3.3 Control and Starter Electrical Diagrams 44
3.3.1 Starter cable list 44
3.3.2 Starter Interconnection Diagram 47
3.3.3 Starter Interconnection Diagram 51
3.3.4 Steam Regulating Valve (optional)
Interconnection Diagram 55
3.3.5 Speed Transmitter (optional) Interconnection
Diagram 56
3.3.6 Vibration Transmitter (optional) Interconnection
Diagram 57
3.3.7 Electric Heater (optional) Interconnection Diagram 58
3.3.8 I/O (optional) Interconnection Diagram 59
3.3.9 Heat Tracing (optional) Interconnection Diagram 61
3.3.10 Emergency Shutdown Interconnection Diagram 62
3.3.11 Separator Circuit Diagram 63
3.3.12 Separator Circuit Diagram 73
3.3.13 Steam Regulating Valve (optional) Circuit Diagram 83
3.3.14 Speed Transmitter (optional) Circuit Diagram 84
3.2.15 Vibration Transmitter (optional) Circuit Diagram 85
3.2.16 Electric Heater (optional) Circuit Diagram 86
3.3.17 I/O (optional) Circuit Diagram 88
3.3.18 Heat Tracing (optional) Circuit Diagram 90
3.3.19 Emergancy Shutdown Circuit Diagram 92

4 Specifications 93

4.1 Cables 94
4.2 Cable Routing 95
4.3 Oil, Water, Steam, and Condensate Piping 96
4.4 Ambient Temperature Limitation 97
4.5 Heat Tracing and Insulation of Fuel Oil, Sludge,
and Steam Pipes. 97
4
138

4.6 More than one Oil Tank 98


4.7 Sludge Removal Kit (Optional Equipment) 99
4.8 Sludge Tank 101
4.9 Sludge Piping 103

5 Single Module Lifting Instructions 105

5.1 Lifting Single Module with Steam/Hot Water/


Thermal Oil Heater. 105
5.2 Lifting Single Module with Electric Heater 106
5.3 Lifting Single Module without Heater 107

6 Commissioning and Initial Start 109


6.1 Completion Check List 109
6.2 Initial Start-up 110
6.2.1 Calculating Operating Pressure 113

7 Shut-down and Storage 115

7.1 Shut-down after Use 115


7.2 Protection and Storage 116
7.3 Reassembly and Start up 118

5
139

6
140

1 Technical Data

1.1 Demand Specifications Water


Alfa Laval ref. 574487 Rev. 1

Poor quality of the operating water may with time cause erosion, corrosion and/or operating problems.
The water shall be treated to meet certain demands.

The following requirements are important:


1. Turbidity-free water, solids content <0,001% by volume
Max. particle size 50 m.
Deposits shall not be allowed to form in certain areas in the system.
2. Total hardness less than 180 mg CaCO3 per litre, which corresponds to 10 dH or 12,5 E.
Hard water may with time form deposits in the operating mechanism. The precipitation rate is
accelerated with increased operating temperature and low discharge frequency. These effects
become more severe the harder the water is
3. Chloride content max. 1 00 ppm NaCl (equivalent to 60 mg Cl/l). Chloride ions contribute to
corrosion on surfaces in contact with the operating water. Corrosion is a process that is accelerated
by increased separating temperature, low pH, and high chloride ion concentration.
4. 6,5 < pH < 9
Bicarbonate content (HCO3) min. 70mg HCO3 per litre, which corresponds to 3,2 dKH.
5. Pressure 200 800 kPa (2 8 bar).


NOTE

Alfa Laval accepts no liability for consequences


arising from unsatisfactorily purified operating water
supplied by the customer.

7
141
1.2 Demand Specifications Air 1 Technical Data

1.2 Demand Specifications Air


Specific requirements regarding the quality of air
1. Pressure 500 800 kPa (5 8 bar).
2. Free from oil, and solid particles larger than 0.01 mm.
3. Dry, with dew point min. 10 C below ambient
temperature.

NOTE

Electrical interconnections must be made by qualified
electricians.
Mechanical interconnections must be made by
qualified mechanical technicians.

8
142
1 Technical Data 1.3 System Data

1.3 System Data


Application
Cleaning of fuel and lubricating oils
Min. density 820 kg/m3 at 15C
1010 Kg/m3 at 15C in ALCAP mode
Max. density
991 Kg/m3 at 15C in Purifier mode
Max. viscosity 55 cSt at 100C (700 CST at 50C)
Feed temperature 5C to 100C
Ambient temperature 5C to 55C
In accordance with the separator size capacity
Feed Capacity
table

Media inlet/outlet data at separator connections


Pressure
Oil inlet Max. 2 bar at separator inlet
Oil outlet Max. 2.5 bar
Sludge outlet from separator without pressure
Sludge outlet from sludge pump Max. 5 bar at 6 bar air pressure
Separated water Max. 4 bar (if not diverted into sludge outlet)
According to capacity table, depending on oil
Temperature
viscosity 2 C Max. 100 C

9
143
1.3 System Data 1 Technical Data

Sludge Removal kits (optional)


The systems can be equipped with their own
sludge tank for collecting the sludge discharge
from the separator.

Sludge Removal Kit tank volume: 46.5 Litres.


Auxiliary systems
Operating water
SV10: 1.6 l/m
- Operating water flow S 936, S 937, S 946, SV 15: 11.0 l/m
S 947 SV 16: 2.8 l/m
SV10: 15 l/m
- Operating water flow P 636 SV 15: 11.0 l/m
SV 16: 2.8 l/m
For further details see 1.1 Demand Specifications
Water
Quality
Pressure 2 - 8 bar
Temperature 5C - 55C (unheated water)
Air
Quality Instrument air
5 - 8 bar (an optional pressure reducer is available
Pressure for above 8 bar)
Consumption
Air operated valves 10 N l/h

1000 N l/h at max. 1l/s


Sludge pump (pneumatic) For further details see 1.2 Demand Specifications Air
Mechanical design part:
Oil and heating media piping
Design pressure Max. 6 bar (for steam / condensate Max. 9 bar)
Test pressure Max. 9 bar (for steam/condensate Max. 14 bar)
Design temperature 5 C - 180 C
Flange connections PN 16 DIN 2573/2633
Material ; ASTM A 106 gr. B seamless schedule 40
Pipe data thickness.
Sizes ; from upto 4
Auxiliary media - Operating water
Design pressure Max. 6 bar
Design temp. 5 C - 55 C
Auxiliary media - Air
Design pressure Max 10 bar
Nitrile rubber-steel braided hose or PTFE pipes
Material where possible
Drip tray volume Max. 19 litres
Drip tray Material Steel sheet laser cut and welded parts
Drip tray Drain connection size 2 x 1 G (internally threaded)
Frame Baseplate Material Steel sheet laser cut and welded parts
Electrical design

10
144
1 Technical Data 1.3 System Data

Auxiliary systems
Main supply
Voltage 460 /400V/
3x 230 V 440V / 480V / 575V / 690V 10 %
Frequency 50 / 60 Hz
In accordance with the separator size selected and
Separator el.motor related data sheet
Separator el motor power range From 7.5 kW up to 11 kW
In accordance with the pump size selected and
Feed Pump el. Motor related data sheet
Feed Pump el motor power range From 1.1 kW up to 4 kW
EPC
Voltage 24 V DC (internal)
Control voltage, operating supply 24 V AC ( from internal transformer )
Frequency 50 or 60 Hz 5 %
Control cabinet
Enclosure class IP 55
Material Steel sheet
Ambient temp. Max 55 C

11
145
1.3 System Data 1 Technical Data

1.3.1 Module Weights including optional Sludge Removal Kit, kg

Separator type (see


Without
Separator Module Type Steam Electric dimension drawings
Heater in chapter 2)
P 636 Single 790 865 585 a
S 936 - S 937 Single 790 865 585 a
946 - S 947
S 946 Single 865 935 660 b

Separation Module Planned Maintenance Kits (not including wear items)


Separator Module Sludge Feed Control El.
Hours Period pump pump cabinet heater CBM
1000
2000
4000 6 Inspection
months
12000 18 Overhaul Overhaul
months
24000 3 years Overhaul Overhaul Overhaul Overhaul
Repair
As necessary CIP (compo- Repair CIP
nents)
Inspection
With delivery Tools
Backup Support Support

NOTE

The lifespan of wear items, such as friction
blocks and main seal ring, depends on the
number of startups, as well as plant and feed
conditions. Check wear items regularly and
change when necessary.

12
146

2 Mechanical Drawings

13
147
148
149
150

MAN Managua: LO S946 Module, 4500968861-10 to -80,


Mat Nr 11.63010-0244
151
152
2.6 Change of EPC 60 Components 2 Mechanical Drawings

2.6 Change of EPC 60 Components

Operating Panel
Switch power off.
Remove the connections on the reverse side of
the panel.
Unscrew the four screws holding the panel and
remove the panel.
Mount the new panel and connect in reverse
order
I/O-Board
Switch power off.
Hold down the plastic clip on the top of the cable
terminal and pivot the cable terminal towards
you.

X025001A
X025002A

38
153
2 Mechanical Drawings 2.6 Change of EPC 60 Components

Pull away the cable terminal.

X025008A
Hold down the triangle on the top of the I/O board
and loosen the board.

X025003A
Pull the board straight out (otherwise it can fasten in
one of its guides)

Compare the part number of the new I/O board to


the old board to make sure it is correct.
If changing more than one board at a time,
check with the electrical diagram to ensure
X025004A
that the boards are mounted in the right places.

39
154
2.6 Change of EPC 60 Components 2 Mechanical Drawings

Mount the new I/O board by pressing it straight


into place. Make sure the board is firmly in place
otherwise it will be impossible to mount the cable
terminal.

X025005A
Remount the cable terminal. Make sure that the clip
on the bottom of the terminal fastens properly in
place on the axel on the bus holder.

X025007A
Pivot the terminal on the axel until the clip on the
terminal top fastens into place in the I/O board.

X025006A

40
155

3 Electrical Drawings

41
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190

4 Specifications

Only qualified personnel are allowed to work


with lifting of the module.
Use only the lifting lugs as shown in the
illustrations.
Slings or wires used for lifting the Module
must be adjusted so that the beam is located
above the centre of gravity.
Slings or wires used for lifting the Double
Module must be of the same length to avoid
instability.
Slings/wires must be dimensioned locally
depending on equipment used.
For information on how to lift the separator,
see the Separator Manual booklet.

ING
WARN
!
Crush hazard
When lifting the Module, use only the lifting
eyes specifically for this purpose. Always use
a lifting beam.

93
191
4.1 Cables 4 Specifications

4.1 Cables
Cable Identification
All cables are markes to simplify identification and
fault finding.
Specifications
The following specifications apply to cables connected
to and from Alfa Laval equipment. Follow the
instructions given in the cable list.Examples of cable
types that can be used.

Steel armoured cable.

G032224A
Copper armoured cable with a separate earth core.

G032244A

Steel armoured and sheilded single cable; pair


twisted or parallel.
G032214A

Sheilded single cable; pair twisted or parallel.


G032234A

94
192
4 Specifications 4.2 Cable Routing

4.2 Cable Routing


Recommendations
Power cables carry the power supply to motors,
heaters, etc.
Any distance between signal and power cables
reduces electrical noise transfer.

S002891A
Examples of recommended routing of various
cable types.
Power Signal
Power cables and signal cables routed on a Cables Cable
cable rack should be separated.
Sattbus cables should be routed away from

G 0 3 2 2 7 3A
power cables.

If the space is limited, cables can be routed in


tubes.

95
193
4.3 Oil, Water, Steam, and Condensate Piping 4 Specifications

4.3 Oil, Water, Steam, and Condensate Piping


For piping to and from Alfa Laval equipment, see
the specifications below.
Specifications
The correct pipe size must be used in the oil
system.
The number of bends in the oil pipes must be
minimized.
The suction height must be as low as possible.
The oil feed pump must be of positive
displacement type.
The pump must be positioned close to the oil
tank.
The heater must be installed close to the
separation module to maintain correct feed oil
temperature.
The recirculation line should be connected
either directly to the settling tank (HFO) or to
the oil outlet line from the separator (LO).
The oil outlet line from the separator must be
connected to the system tank for lube oil, or the
service tank for fuel oil.

96
194
4.5 Heat Tracing and Insulation of Fuel
4 Specifications oil, Sludge, and Steam Pipes

4.4 Ambient Temperature Limitation


Specifications
Leading classification societies state in their
regulations for engine room equipment that the
maximum ambient temperature permissible is
+55 C. To meet this regulation, it is essential that
electrical and electronic components have good
ventilation, and temperature control.

X024675A
4.5 Heat Tracing and Insulation of Fuel Oil, Sludge,
and Steam Pipes.
Alfa Laval can, on request, supply modules
which are heat traced and insulated, as optional
equipment.

97
195
4.6 More than one Oil Tank 4 Specifications

4.6 More than one Oil Tank


Recommendation
When one separator servres more than one oil
tank, both the suction and the outlet lines should be Unprocessed Clean oil
fitted with change-over valves. To avoid oil transfer oil
from one tank to another, these valves must be Change-
interlinked. over
valve

Change
-over
valve
Inter-
link

P000062A

98
196
4 Specifications 4.7 Sludge Removal Kit (optional Equipment)

4.7 Sludge Removal Kit (Optional Equipment)


If you have a Sludge Removal Kit, this mut be
connected to a ventilation pipe.

NOTE

The sludge removal pump must be set to the correct


speed circa 60 strokes/min, otherwise the lifetime
of the diaphragm, valve balls, and air motor will be
severely shortened.

ING
WARN
!
Health Risk
Oil mist and vaporized oil constituents from hot oily
sludge may be dangerous to health and must not be
inhaled.

A pipe or hose must be drawn from the flange


to the nearest oil tank ventilation pipe.
The pipe /hose must have the same diameter
as the flange opening.
The pipe/hose must be as straight as possible,
with a steady upward incline.
Oil tank ventilation
The connection to the oil tank ventilation pipe pipe
must point upwards as shown.

NOTE

For HFO separation, it is not recommended to


~ 5 mm
make the connection to the separator room
ventilation system.
P000063A

For LO separation, connection to the separator


room ventilation system should be made only if
the separator room ventilation is adequate. Use
the optional connection hose (part no. 568023-
80, -81, or -82) for this purpose. This hose is
designed to entrap oil drops in the vent hose,
and lead the oil back to the Sludge Removal Kit
tank.

99
197
4.7 Sludge Removal Kit (optional Equipment) 4 Specifications

Impurities gather in the Sludge Removal Kit tank.


Regularly check the tank and level switch. See
instructions below

Proceed as follows:
From the Control Panel, run the sludge pump
manually for a few seconds.
Undo the four screws connecting the sludge pump
to the sludge tank and remove the sludge pump.
If necessary, clean the level switch and the inside
of the tank using diesel oil.
Check the seals and gaskets, and change if
necessary.
Loosen the hose clip and check the inside of the
ventilation hose. Clean if necessary.
To avoid breakdown of the Sludge Removal system,
the sludge pump must be regularly overhauled as
follows using spare parts kit specified in the spare
parts catalogue.
Replace the diaphragms and the O-rings with
those delivered in the spare parts kit.
Perform a 4000 hour Inspection Service.
For Service and Overhaul intervals, see 1.3 System
Data on page 9.

100
198
4 Specifications 4.8 Sludge Tank

4.8 Sludge Tank


It is not necessary to have a sludge tank together with a
Separation Module with sludge removal kit (for lube oil).
If a sludge tank is required, follow the recommendations
below:

Recommendations
Ventilation pipe
Sludge tank volume per Separation Module should
cover approximately up to 2 days storage at a
Sludge pipe
discharge interval of 2 hours (for discharge volumes connection

see technical data).


A manhole should be installed for inspection and
cleaning.
The tank should be fitted with a sounding pipe. Sludge outlet
Min. height
400 mm
pump connection
The tank floor, or most of it, should have a slope (B)

G004273A
of minimum 15. Min. slope 15

The sludge outlet pump connection should be


positioned in the lowest part of the tank.
A high level alarm switch, connected to the sludge
pump, should be installed.
Bowl casing drain Manhole Water drain High level
A heating coil should be used to keep the sludge connection connection alarm
switch
warm and fluid while being pumped out.
Tank ventilation must follow the classification rules
for evacuation of gases. Heating
coil

There should be a ventilation pipe to fresh air.


The ventilation pipe should be straight. If this is not

G 0 0 4 2 7 0A
possible, any bends must be gradual.
The ventilation pipe must not extend below the tank
top.
A sludge tank with partition walls must have
ventilation pipes in all compartments, or cutouts in
the upper edge, to allow vapours to travel through
the tank.

In retrofit applications, where an Alfa Laval Separation


Module will share a common separator sludge tank
with existing separators, it is recommended to install a
Sludge Removal Kit.

101
199
4.8 Sludge Tank 4 Specifications

The number of ventilation pipes, and their


minimum dimension, depend on the size and
number of separators connected to the same
tank. See table below.

Type 1 module 2/3 modules modules


4 moudles
P 636 1 x 60 mm 1 x 90 mm 1 x 100 mm

Type 1 module 2/3 modules 4 modules


moudles
936 - S 947 1 x 60 mm
S 946 1 x 90 mm 1 x 115 mm

The Module generates almost no air during


operation. At any discharge, the maximum
volume of air produced is the same as the
bowl volume (see technical data).

102
200
4 Specifications 4.9 Sludge Piping

4.9 Sludge Piping


Specification
The sludge pipe from the separator to the
sludge tank should be vertical.
If a vertical pipe is not possible, the deviation (A)
from the vertical line must not exceed 30.

G004401A
The sludge pipe must not extend below the
tank top.

NOTE

An extended sludge pipe will obstruct


ventilation and create back pressure that could
cause separator problems.

Recommendation G004316A

In cases where sludge tank ventilation is not


adequate, and more than one separator is
connected to the same sludge tank, we recommend
that a butterfly valve is installed in each sludge
pipe.

NOTE

If a butterfly valve is not used, the bowl and the


operating system may be affected by corrosive
fumes and sludge from the sludge tank.
G004411A

If a butterfly valve is used, it should be equipped


with an interlocking switch (connected to the
separator starter) to prevent the separator
from being started when the valve is not fully
open.

103
201
5.2 Lifting Single Module with Electric Heater 4 Specifications

104
202

5 Single Module Lifting


Instructions

5.1 Lifting Single Module with Steam/Hot Water/


Thermal Oil Heater.
Weight = max. 790 kg A

Weight = max. 865 kg

X = 525
Y = 580 Centre of gravity
Z = 650

Secure the module to prevent tipping (A)

X024663b

Weight = max. 790 kg


Weight = max. 865 kg

X = 525
Y = 580 Centre of gravity
Z = 650

X024664b

105
203

6 Commissioning and Initial Start

6.1 Completion Check List


It is essential before starting up the separation system that
all modules are in good operating condition and that all
pipelines and control equipment are properly connected
to assure correct operation.

Use this check list as a guide for completing the system


installation:

ING
WARN
!
Breakdown hazard
Check that the power frequency is in agreement with
the machine plate. If incorrect, resulting overspeed
may cause breakdown.

1. Check that transport seals are removed from all pipes.


2. Use flushing filters to prevent pipe work debris from
being pumped into the separation module.

NOTE

The flushing filters must be removed after initial


flushing.
3. Check that all separators are in proper working
condition. Follow the manufacturers instructions.
4. Make sure that separators are lubricated in accordance
with instructions

NOTE

Make sure that the spindle bearings are prelubricated.


G08687T1

Drop some frame oil onto the bearings

109
204
6.2 Initial Start-up 6 Commissioning and Initilal Start

5. Separators are delivered without oil in the oil


sump. For information on oil filling and oil type,
see the Separator Manual booklet.

NOTE

Too much, or too little oil may result in damage to


separator bearings.
Neglecting an oil change may result in damage to
separator bearings.

6. Power on.
7. Check that the separator rotation direction
corresponds with the arrow on the frame by doing
a quick start/stop (12 seconds.) and looking at
the motor fan rotation.

ON
CAUTI
!
If power cables have been installed incorrectly, the
separator will rotate in reverse, and vital rotating
parts can unscrew.

8. Check the pump function and direction.


9. If a Sludge Removal Kit is used, check that the
sludge pump speed is set to circa 60 strokes/min.
If necessary, adjust the throttling valve (positioned
after solenoid valve SV 6).

6.2 Initial Start-up

NOTE

After every start the separator must always be run


continously for a minimum of 1 hour to ensure proper
lubrication.

Use this check list for initial system start up:


1. Check that there is oil in the feed oil tank.
2. Check water and air supply. See 1.3 System
Data.
3. Check power supplies to the control unit and
that the voltage is in accordance with data in
1.3 System Data.

110
205
6 Commissioning and Initilal Start 6.2 Initial Start-up

4. Check all parameter settings in the control unit.


See Installation Parameters in the Parameter
List booklet.
5. Check the separator.

NOTE

Always lubricate the bearings before start-up.

NOTE

The Separation module is supplied with standard


configuration parameters. You may have to make
some changes to suit your installation.

6. Start the separation system as described in the Operating


Instructions booklet.
7. Start up step by step, checking that the machine and module
function properly.
8. Establish system pressures.The delivery height pressure
is the pressure in the oil pipe work down stream from the
separation module, due to the pipe bends and the height
(head) to the cleaned oil tank. If the cleaned oil tank is below
the separation module the delivery height pressure may be
very low. The oil paring disc pressure will have to be greater
than the delivery height pressure for any oil to flow.
Proceed as follows:
Ensure the valves in the oil system are in the correct
positions.
The oil should be at separation temperature.
For S-type separators:
The paring tube should be able to move freely.
Ensure that V5 is closed.
Fully open the back pressure regulating valve RV4.
The shut off valve V4 should be open.
Open SV15 for 3 seconds to prime the operating slide.
Open SV16 for 15 seconds to close the bowl.
Open SV10 for 1 minute to put water into the bowl.
Feed oil to the separator at the normal flow rate by
opening SV1.

111
206
6.2 Initial Start-up 6 Commissioning and Initilal Start

Note the pressure in the oil outlet PT4, both on the


pressure gauge and in the EPC 60 display. This
pressure is P min.
Gradually close the back pressure regulating valve
RV4. The pressure on PT4 will increase. The water
pressure (PT5) decreases slightly as the paring tube
moves inwards. The water pressure will suddenly
drop when oil passes from the oil paring chamber
to the water paring chamber. Note the pressure of
PT4 both on the pressure gauge and in the EPC 60
display. This pressure is P max.
Open RV4.
Stop the oil feed to the separator and note the
pressure in the oil outlet. This is the delivery height
pressure P del.
Stop the heater.
Stop the separator.
Stop the feed pump when the heater has cooled
For P-type separators:
Fully open the back pressure regulating valve RV4.
Open SV15 for 5 seconds to prime the operating
slide.
Open SV16 for 15 seconds to close the bowl.
Open SV10 for 5 seconds to put water into the bowl.
Feed oil to the separator at the normal flow rate by
opening SV1.
Note the pressure in the oil outlet PT4, both on the
pressure gauge and in the EPC 60 display. This
pressure is P min.
Gradually close the back pressure regulating valve
RV4. The pressure on PT4 will increase. The oil
pressure will suddenly drop when oil passes over to
the water outlet. Note the pressure of PT4 both on
the pressure gauge and in the EPC 60 display. This
pressure is P max.
Open RV4.
Stop the oil feed to the separator and note the
pressure in the oil outlet. This is the delivery height
pressure P del.
Stop the heater.
Stop the separator.
Stop the feed pump when the heater has cooled

112
207
6 Commissioning and Initilal Start 6.2 Initial Start-up

6.2.1 Calculating Operating Pressure

Calculate the normal back pressure level


during operation as follows:
Pmin + Pmax
= Pnormal
2
Calculate the value for low pressure alarm
setting (Pr 11) as follows:

Pmin + Pnormal
= Plow press.
2
Calculate the value for high pressure alarm
setting (Pr 10) as follows:
Pnormal + Pmax
= Phigh press
2

Adjust the back pressure to Pnormal


Set P154 to give alarm at pressure decreasing
below the Plow press. value.
Set P153 to give alarm at pressure increasing
above the Phigh press. value.

113
208
6.2 Initial Start-up 6 Commissioning and Initilal Start

114
209

7 Shut-down and Storage


Storage before Installation
If the separation module is stored before installation,
the following safeguards must be taken:

Storage period 1 < 6 months > 6 months See


Action before storage
Protect from dust, dirt, X X This chapter
water, etc.
Protect with anti-rust oil X X This chapter
Action before
installation
Inspection service X Service manual
Overhaul service X Service manual

7.1 Shut-down after Use

If the separation system is going to be shut down for


a period of time, the following safeguards must be
taken
Shut-down period 1 < 6 months 6-18 >18 months See
(stand-by) months
Action before
storage
Remove bowl X X X Dismantling and
Assembly in the
Service Manual
Protect from dust, dirt, X X X This chapter
water, etc
Protect with anti-rust oil X X X This chapter

Inspection service X X Service manual


Overhaul service X Service manual

115
210
7.2 Protection and Storage 7 Shut-down and storage

7.2 Protection and Storage


All system equipment, both the separator and the
ancillary equipment, must be stored indoors at 5
55C, if not delivered in water-resistant box for outdoor
storage.
If there is a risk for condensation of water, the equipment
must be protected by ventilation and heating above
dew point.
The following protection products are recommended:
Anti-rust oil with long lasting effective treatment for
external surfaces. The oil should prevent corrosion
attacks and give a waxy surface.
Anti-rust oil (Dinitrol 40 or equivalent) thin and
lubricating for inside protection. It gives a lubricating
transparent oil film.
Solvent, e.g. white spirit, to remove the anti-rust oil
after the shut-down.
Moist remover to be packed together with separator
equipment.
If the storage time exceeds 12 months, the
equipment must be inspected every 6 months and,
if necessary, the protection be renewed.

Modules
Clean unpainted steel parts with solvent and treat
external surfaces with anti-rust oil (type 112).
If necessary, clean other equipment on the module
with solvent.
Treat the equipment with anti-rust oil by following
the description above accordingly.
Bolts, nuts and other external steel components
should be treated with anti-rust oil (type 112)

Rubber Parts
Gaskets, O-rings and other rubber parts should not
be stored for more than two years. After this time,
they should be replaced.

116
211
7 Shut-down and storage 7.2 Protection and Storage

Separator
Dismantle the separator bowl and take out the
O-rings. Clean the bowl with oil and reassemble
without the O-rings. Place in a plastic bag with silica
dessicant bags and seal the plastic bag.
Grease the spindle.

Valves, Pipes and Similar Equipment


Components such as valves need to be cleaned
with solvent and treated with anti-rust oil (type
112).
Water pipes should be drained and treated with
anti-rust oil (type 112).
Articles made of rubber or plastics (e.g. seals)
must not be treated with anti-rust oil.

Electric Heater
Fill the heater with a non-corrosive lubricating oil.
Place a number of bags of silica gel inside the
connection box to absorb humidity.

Pump
Clean the pump housing outside from oil and
grease with solvent.
Protect the pump by filling it with non-corrosive
lubricating oil.
Apply anti-rust oil on the pump housing outside.
Fill the pump screws with lubricating oil to prevent
rust.

117
212
7.3 Reassembly and Start up 7 Shut-down and storage

7.3 Reassembly and Start up

Clean away the anti-rust oil with white spirit.


Remove the silica gel bags from all modules.
Pre-lubricate the separator spindle bearings
If stored for 6 months or longer, perform an inspection
service (including change of oil in the separator sump).
Follow all relevant instructions in this booklet and in the
Separator Manual.
Before operating the heater:
-- Check by lifting the safety valve handle that it
functions correctly.
-- Follow the start-up check list for the heater in the
manufacturers instructions.
-- For plate heat exchangers: check the bolt
connections to ensure that all gaskets are tight.

NOTE

Always lubricate the bearings before start-up.

NOTE

After every start the separator must always be run


continously for a minimum of 1 hour to ensure proper
lubrication.

118
213

Separator Manual
High Speed Separator
S 946

Specification No. 881203-05-02/2


Book No. 9006919-02 rev. 3
214

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden

Telephone: +46 8 530 650 00


Telefax: +46 8 530 310 40

Alfa Laval Tumba AB 08-2014

The original instructions are in English

This publication or any part there of may not be


reproduced or transmitted by any process or
means without prior written permission of Alfa
Laval Tumba AB.
215

Contents
1 Read this first 9

2 Safety instructions 11
2.1 Warning signs in text 15
2.2 Environmental issues 16
2.3 Requirements of personnel 17
2.4 Remote start 17

3 Basic principles of separation 19


3.1 Introduction 19
3.2 Separation by gravity 19
3.3 Centrifugal separation 20
3.4 Separating temperatures 20

4 Design and function 21


4.1 Overview 22
4.2 Drive section 23
4.3 Process section 24
4.4 Sensors and indicators 26
4.5 Separating function 27
4.5.1 The liquid balance in the bowl 27
4.5.2 Liquid flow 28
4.5.3 Discharge of sludge and water (ALCAP concept) 29
4.5.4 Discharge of water through water outlet 30

5 Operating instructions 31
5.1 Before first start 31
5.1.1 Start after service 32

5.2 Normal operation 33


5.2.1 Before normal start 33
5.2.2 Start 34
5.2.3 Operating 36
5.2.4 Stop 38

5.3 Emergency stop 39

3
216

6 Service, dismantling, assembly 41


6.1 Periodic maintenance 41
6.1.1 Maintenance intervals 41
6.1.2 Maintenance procedure 43
6.1.3 Tightening of screws 44
6.1.4 Service kits 45
6.1.5 Cleaning 45

6.2 Maintenance logs 46


6.3 Dismantling 49
6.3.1 Introduction 49
6.3.2 Tools 49
6.3.3 Frame hood 51
6.3.4 Bowl 55
6.3.5 Driving device 72
6.3.6 Centrifugal clutch 91

6.4 Actions before assembly 99


6.4.1 Cleaning 99
6.4.2 Inspection for corrosion 101
6.4.3 Inspection for cracks 102
6.4.4 Inspection for erosion 103
6.4.5 Exchange of frame feet 105
6.4.6 Lubrication of bowl parts 106

6.5 Assembly 107


6.5.1 Centrifugal clutch 108
6.5.2 Driving device 115
6.5.3 Bowl 133
6.5.4 In and outlet device 151
6.5.5 Unbalance sensor (optional) 155
6.5.6 Speed sensor (optional) 157
6.5.7 Actions after assembly 158

6.6 Oil change 160


6.6.1 Lubricating oil 160
6.6.2 Check oil level 161
6.6.3 Oil change procedure 161
6.6.4 Lubrication chart 162
6.6.5 Recommended lubricants 164
6.6.6 Lubricating oils 168

6.7 Lifting instructions 170


6.7.1 Lifting the separator 170
6.7.2 Lifting the bowl 172

7 Fault finding 173


7.1 Mechanical functions 173
7.1.1 Separator vibration 173
7.1.2 Smell 174
7.1.3 Noise 174
7.1.4 Speed too low 174
7.1.5 Speed too high 174
7.1.6 Starting power too high 175
7.1.7 Starting power too low 175

4
217

7.1.8 Starting time too long 175

7.2 Separating functions 176


7.2.1 Bowl opens accidentally during operation 176
7.2.2 Bowl fails to open for sludge discharge 176
7.2.3 Unsatisfactory separation result 176
7.2.4 Bowl fails to close 177

8 Technical reference 179


8.1 Product description 179
8.1.1 Directives and standards 180

8.2 Technical data 182


8.3 Connection list 183
8.4 Interface description 185
8.4.1 Scope 185
8.4.2 References 185
8.4.3 Definitions 185
8.4.4 Goal 186
8.4.5 Description of separator modes 186
8.4.6 Remote start 188
8.4.7 Handling of connection interfaces 188

8.5 Demand specification water 194


8.6 Drawings 195
8.6.1 Basic size drawing 195
8.6.2 Foundation drawing 196
8.6.3 Interconnection diagram 197
8.6.4 PX sealing diagram 198
8.6.5 Electric motor 199

9 Installation 201
9.1 Introduction 201
9.2 Upon arrival at the storage area 202
9.2.1 Transport 202
9.2.2 Protection and storage of goods 203

9.3 Planning of installation 204


9.3.1 Important measurements 204
9.3.2 Maintenance service 205
9.3.3 Connections to surrounding equipment 206

9.4 Storage at out of operation 207


9.5 Before start-up 207

5
218
219

Study instruction manuals and observe the


warnings before installation, operation,
service and maintenance.

Not following the instructions can result


in serious accidents.

In order to make the information clear only


foreseeable conditions have been considered.
No warnings are given, therefore, for situations
arising from the unintended usage of the
machine and its tools.

7
220

!
221

1 Read this first

This manual is designed for operators,


maintenance personnel and service engineers
working with the Alfa Laval separator

If the separator has been delivered and installed


by Alfa Laval as a part of a processing system,
this manual should be viewed as part of the
System Documentation. Study carefully all
instructions in any System Documentation.

In addition to this Separator Manual a Spare


Parts Catalogue, SPC is supplied.

The Separator Manual consists of:

Safety instructions
Pay special attention to the safety instructions
for the separator. Accidents causing damage to
equipment and/or serious injury to persons or
personnel can result if the safety instructions
are not followed.

Basic principles of separation


This chapter describes the purpose of
separation and separation principles.

Design and function


This chapter contains a description of the
separator.

Operating instructions
This chapter contains operating instructions for
the separator only.

Service, dismantling, assembly


This chapter gives instructions for the
maintenance procedures. It also contains
step-by-step instructions for dismantling and
assembly of the separator for service and repair.

9
222
1 Read this first

Fault finding
Refer to this chapter if the separator functions
abnormally.

If the separator has been installed as a part


of a processing system, always refer to the
trouble-tracing instructions, in the System
Documentation.

Technical reference
This chapter contains technical data concerning
the separator and drawings.

Installation
This chapter contains specifications and
recommendations concerning separator
installation.

NOTE

A complete reading of this manual by personnel in


contact with the machine is essential to safety.
Do not allow personnel to clean, assemble, operate or
maintain the separator until they have read and fully
understood this manual.
Ensure that all personnel who operate and service
the separator are well-trained and knowledgeable
concerning the machine and the work to be carried out.

10
223

2 Safety instructions
!
The centrifuge includes parts that rotate at high
speed. This means that:

Kinetic energy is high


Great forces are generated
Stopping time is long

Manufacturing tolerances are extremely fine. G0010421

Rotating parts are carefully balanced to


reduce undesired vibrations that can cause
a breakdown. Material properties have been
considered carefully during design to withstand
stress and fatigue.

The separator is designed and supplied for a


specific separation duty (type of liquid, rotational
speed, temperature, density etc.) and must not
be used for any other purpose.

Incorrect operation and maintenance can result


in unbalance due to build-up of sediment,
reduction of material strength, etc., that
subsequently could lead to serious damage
and/or injury.

The following basic safety instructions therefore


apply:

Use the separator only for the purpose


and parameter range specified by Alfa
Laval. Applies not only to the process
but also to cleaning and service liquids.
Strictly follow the instructions for
installation, operation and maintenance.
Ensure that personnel are competent
and have sufficient knowledge of
maintenance and operation, especially
concerning emergency stopping
procedures.
Use only Alfa Laval genuine spare parts
and the special tools supplied.

11
224

!
2 Safety instructions

Disintegration hazards
When power cables are connected, always
check direction of motor rotation. If
incorrect, vital rotating parts could unscrew.

If excessive vibration occurs, stop separator


and keep bowl filled with liquid during
rundown.

Use the separator only for the purpose and kPa


3
m /h

parameter range specified by Alfa Laval. 3


kg/m o
C

r/min
Hz

Check that the gear/pulley ratio is correct


for power frequency used. If incorrect, 50Hz

subsequent overspeed may result in a 60Hz

serious break down.

Welding or heating of parts that rotate can


seriously affect material strength.

Inspect regularly for corrosion and erosion


damage. Inspect frequently if process or
cleaning liquid is corrosive or erosive.

Entrapment hazards
Make sure that rotating parts have come
to a complete standstill before accessing
parts inside the machine or starting any
dismantling work. If there is no braking
function the run down time can exceed two
hours.

To avoid accidental start, switch off and


lock power supply before starting any
dismantling work.
Assemble the machine completely before
start. All covers, connections and guards
must be in place.

12
225

!
2 Safety instructions

Electrical hazard
Follow local regulations for electrical
installation and earthing (grounding).

To avoid accidental start, switch off and


lock power supply before starting any
dismantling work.

Crush hazards
Use correct lifting tools and follow lifting
instructions.

Do not work under a hanging load.

Noise hazards
Use ear protection in noisy environments.

Burn hazards
Lubrication oil, machine parts and various
machine surfaces can be hot and cause
burns. Wear protective gloves.

Skin irritation hazards


When using chemical cleaning agents,
make sure you follow the general rules
and suppliers recommendation regarding
ventilation, personnel protection etc.

Use of lubricants in various situations.

Cut hazards
Sharp edges, especially on bowl discs and
threads, can cause cuts. Wear protective
gloves.

13
226

!
2 Safety instructions

Flying objects
Risk for accidental release of snap rings and
springs when dismantling and assembly.
Wear safety goggles.

Health hazards
Risk for unhealthy dust when handling
friction blocks/pads. Use a dust mask to
make sure not to inhale any dust

14
227

!
2 Safety instructions

2.1 Warning signs in text


Pay attention to the safety instructions in this
manual. Below are definitions of the three
grades of warning signs used in the text where
there is a risk for injury to personnel.

NGE R
! DA
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious
injury.

NG
WARNI
!
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.

ON
CAUTI
!
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.

NOTE

NOTE indicates a potentially hazardous situation


which, if not avoided, may result in property damage.

15
228

!
2 Safety instructions

2.2 Environmental issues


Unpacking
Packing material consists of wood, plastics,
cardboard boxes and in some cases metal
straps.

Wood and cardboard boxes can be reused,


recycled or used for energy recovery.

Plastics should be recycled or burnt at a


licensed waste incineration plant.

Metal straps should be sent for material


recycling.

Maintenance
During maintenance oil and wear parts in the
machine are replaced.

Oil must be taken care of in agreement with


local regulations.

Rubber and plastics should be burnt at a


licensed waste incineration plant. If not available
they should be disposed to a suitable licensed
land fill site.

Bearings and other metal parts should be sent


to a licensed handler for material recycling.

Seal rings and friction linings should be


disposed to a licensed land fill site. Check your
local regulations.

Worn out or defected electronic parts should be


sent to a licensed handler for material recycling.

16
229

!
2 Safety instructions

2.3 Requirements of personnel


Only skilled or instructed persons are allowed
to operate the machine, e.g. operating and
maintenance staff.

Skilled person: A person with technical


knowledge or sufficient experience to
enable him or her to perceive risks and to
avoid hazards which electricity/mechanics
can create.
Instructed person: A person adequately
advised or supervised by a skilled person
to enable him or her to perceive risks and to
avoid hazards which electricity/mechanics
can create.

In some cases special skilled personnel may


need to be hired, like electricians and others.
In some of these cases the personnel has to
be certified according to local regulations with
experience of similar types of work.

2.4 Remote start


If the separator is operated from a remote
position where the separator cannot be seen
or heard the power isolation device shall be
equipped with an interlock device to prevent that
a remote start command could result in liquid
being fed to the separator when it is shut down
for service.

The first start after the separator has been taken


apart or been standing still for a long time shall
always be manually supervised locally.

17
230

!
2 Safety instructions
231

3 Basic principles of separation

3.1 Introduction
The purpose of separation can be:

to free a liquid of solid particles,


to separate two mutually insoluble liquids
with different densities while removing any
solids presents at the same time,
to separate and concentrate solid particles
from a liquid.

3.2 Separation by gravity


A liquid mixture in a stationary bowl will clear
slowly as the heavy particles in the liquid mixture
sink to the bottom under the influence of gravity.

A lighter liquid rises while a heavier liquid and


solids sink.

G0870111

Continuous separation and sedimentation can


be achieved in a settling tank having inlet and
outlet arranged according to the illustration.

Heavier particles in the liquid mixture will settle C


and form a sediment layer on the tank bottom.

A
B
D
G0870221

A. Lighter liquid
B. Heavier liquid
C. Gravity
D. Sediment layer of heavier particles

19
232
3 Basic principles of separation

3.3 Centrifugal separation


In a rapidly rotating bowl, the force of gravity
is replaced by centrifugal force, which can be
thousands of times greater. A
B
Separation and sedimentation is continuous and
happens very quickly.

The centrifugal force in the separator bowl can


achieve in a few seconds what takes many
hours in a tank under influence of gravity.

The separation efficiency is influenced


by changes in the viscosity, separating
temperatures and in throughput. C
G0870321

A. Lighter liquid
B. Heavier liquid
C. Centrifugal force

3.4 Separating temperatures


For some types of process liquids a high
separating temperature will normally increase
the separation capacity. The temperature
influences viscosity and density and should be
kept constant throughout the separation.

Viscosity Density difference


Viscosity is a fluids resistance against movement. Density is mass per volume unit. The greater the
Low viscosity facilitates separation. Viscosity can density difference between the two liquids, the
be reduced by heating. easier the separation. The density difference can
be increased by heating.

A B A B

G10348k1 G10348j1

A. High viscosity A. High density (with low temperature)


B. Low viscosity B. Low density (with high temperature)

20
233

4 Design and function

1
7

5
3 4
G08707A1

1. Process section
The feed inlet and outlets are situated at the top of the separator. The liquid is cleaned in the
rotating separator bowl inside the frame hood.
2. Sensors
The separator is monitored by a speed sensor. An unbalance sensor and an interlocking
switch are optional.
3. Frame feet
The separator rests on vibration damping frame feet.
4. Lubrication system
Lubricates the bearings driven by the flat belt transmission.
5. Sludge outlet
Separated solids are discharged at preset intervals.
6. Drive section
The rotating separator bowl is driven by a flat belt transmission with friction coupling.
7. Electric motor
Rotating bowl is driven by the electric motor via a belt transmission.

21
234
4 Design and function

4.1 Overview
The separator comprises a process section and
a drive section powered by an electric motor.

The separator frame comprises a lower body


and a frame hood. The motor is attached to the
frame. The frame feet dampen vibration.

The bottom part of the separator contains a flat


belt transmission, a centrifugal clutch and a
vertical spindle. The lower body also contains
an oil sump for lubrication of spindle bearings.

The frame hood contains the processing parts


of the separator; the inlets, outlets and piping.

The process liquid is cleaned in the separator


bowl. The bowl is fitted on the upper part of a
vertical spindle and rotates at high speed inside
the frame hood. The bowl also contains the
discharge mechanism which empties the sludge
during operation.

A speed sensor, and the optional unbalance


sensor and lock switch, are parts of the
equipment for monitoring the separator
functions.

22
235
4 Design and function

4.2 Drive section


The separator bowl is driven by an electric
motor via a belt transmission. The belt pulley on
the motor shaft includes a centrifugal clutch.

The centrifugal clutch (2) with friction pads


ensures a gentle start and smooth acceleration,
and at the same time prevents overloading of
the belt and motor.

To reduce bearing wear and the transmission


of bowl vibrations to the frame and foundation,
the top bearing of the bowl spindle is mounted
in a spring dampened bearing seat (3). The
bearings on the spindle are lubricated by the
oil spray produced by an oil mist generator (4)
mounted on the lower end of the spindle.

The flat belt (1) transmission has a ratio


which increases the bowl speed several times
compared with the motor speed.

3 2
g08707B1

1. Flat belt
2. Centrifugal clutch
3. Spring dampened bearing seat
4. Oil mist generator

23
236
4 Design and function

4.3 Process section


The separation process takes place inside the
rotating separator bowl. The feed and outlet of
process liquid takes place in the in and outlet
unit on top of the separator frame hood.

Inlet and outlet


The inlet and outlet unit consists of the following 1
parts: 2

A connection house for pipe connections. 3


4
A pipe with a paring disc and a paring tube 5
is located inside the connection house. The
pipe has channels for incoming and outgoing 6
process liquid. 7
8

The paring disc and paring tube pump the


cleaned oil and water respectively out of the
9
bowl.

The paring tube can move radially. During


separation it surfs on the liquid surface. It is
balanced by a spring.

Under certain operating conditions, the paring


tube radial position can be locked in place by
two adjustable screws on the connection house.

The paring disc and tube are located inside and


at the top of the separator bowl.

The inlet and outlet device is held together


against the frame hood by a nut on the end of
the inlet pipe. G0886191

1. Inlet pipe
Height adjusting rings determine the height 2. Spring
position of the paring disc and paring tube 3. Uncleaned oil
relative to the bowl. 4. Cleaned oil
5. Separated water
6. Arm
7. Paring tube
8. Paring disc
9. Connecting housing

24
237
4 Design and function

Separator bowl
The separator bowl, with its sludge discharge
mechanism, is built-up as follows:

The bowl body and bowl hood are held together


by a lock ring (Centrilock). Inside the bowl are
the distributor and the disc stack. The disc
stack is kept compressed by the bowl hood.
The discharge slide forms a separate bottom
in the bowl body.
14
The upper space between the bowl hood and 13
the top disc forms the water paring chamber 1
and contains the paring tube, which pumps the 12 2
separated water out of the bowl. The oil paring 3
chamber, with its paring disc, is located inside 4
the top of the distributor. From here the cleaned
oil is pumped out of the bowl. 5
6
The sludge space is in the bowl periphery. The
bowl is kept closed by the discharge slide, which 7
seals against a seal ring in the bowl hood.

At fixed intervals, decided by the operator, the


discharge slide drops down to empty the bowl 8
11
of sludge.
10 9
The sludge discharge mechanism, which G08869a1

controls the movement of the discharge slide, 1. Top disc


is comprised of an operating slide and an 2. Oil paring chamber
operating water device. Passive parts are: 3. Disc stack
nozzle and valve plugs. The operating water 4. Lock ring
cover, beneath the bowl, supplies operating 5. Seal ring
water to the discharge mechanism via the 6. Discharge slide
operating water ring. 7. Operating slide
8. Sludge space
9. Operating water ring
10. Holder
11. Nozzle
12. Bowl body
13. Bowl hood
14. Water paring chamber

25
238
4 Design and function

4.4 Sensors and indicators


The separator is equipped with a speed sensor.
As options, an unbalance sensor and an
interlocking kit can be fitted.

Speed sensor (optional)

A speed sensor (3) indicates the speed of the 1


separator. The correct speed is needed to
achieve the best separating results and for
reasons of safety. Refer to type plate for speed
particulars.

Monitoring kit (optional)


2
For indication of any abnormal unbalance,
the separator can be equipped with a sensor
(2) monitoring the radial position of the bowl
spindle. 3

Cover interlocking kit (optional)

When the cover is closed the interlocking circuit


in the control system is closed (1) which makes
it possible to start the separator.

G08734F1

1. Cover interlocking switch


2. Unbalance sensor
3. Speed sensor

26
239
4 Design and function

4.5 Separating function


The separator separates water and solids from
the uncleaned oil. Water normally leaves the
separator through the water outlet. During
sludge discharge, solids (sludge) and water are
removed through the discharge ports.

4.5.1 The liquid balance in the


bowl
The liquid levels in the bowl depend on many 1
factors (bowl geometry, liquid densities, flow 2
rates etc.). To get a picture of how the liquids A 3
are distributed in the bowl, imagine that the bowl
is at standstill and turned 90 (only influenced
by gravity). The bowl can now be compared
with a settling tank: 7

6 5 4

1
2
B 3

G0886481

A. Separator bowl turned 90


B. Settling tank
1. Unseparated oil
2. Separated oil
3. Separated water
4. Top disc
5. Oil/water interface
6. Distributor
7. Gravity

27
240
4 Design and function

4.5.2 Liquid flow


Unseparated oil is fed into the bowl through the
inlet pipe and travels via the distributor towards
the periphery of the bowl.

When the oil reaches slots in the distributor, it


rises through the channels formed by the disc
stack, where it is evenly distributed.

The oil is continuously cleaned as it travels


towards the centre of the bowl. When the
cleaned oil leaves the disc stack, it flows through
a number of holes in the distributor and enters
the oil paring chamber. From here it is pumped
by the oil paring disc, and leaves the bowl
through the oil outlet. Separated water, sludge
and solid particles, which are heavier than the
oil, are forced towards the periphery of the bowl
and collect in the sludge space.

The space between the bowl hood and top disc,


as well as the water paring chamber, is filled
with oil, which is distributed over the entire
circumference via the grooves in the top disc.

During normal operation-, the water drain valve


in the water outlet is closed.

28
241
4 Design and function

4.5.3 Discharge of sludge and water (ALCAP concept)


As the sludge space fills up and water enters
the disc stack, traces of water will escape with
the cleaned oil. The increase of water content in
the cleaned oil is the sign of reduced separation
efficiency.

This condition is monitored by the process


control system, and water is removed from the
bowl when maximum levels are recorded.

The water is removed by either of two ways:


The water drain valve opens and the water
leaves the bowl through the water outlet.
Through the sludge ports at sludge
discharge.

Which way is decided by the process control


system.

29
242
4 Design and function

4.5.4 Discharge of water through water outlet

B
9
C
8
1
2
7
3
4

6 C
G08862b1

Discharge of water through water outlet

A. Unseparated oil
B. Separated oil
C. Water
1. Water paring tube
2. Water paring chamber
3. Holes in distributor
4. Top disc
5. Sludge space
6. Oil/Water interface
7. Oil paring chamber
8. Oil paring disc
9. Bowl hood

30
243

5 Operating instructions

These operating instructions describe routine


procedures to follow before and during the
start, running and stopping sequences of the
separator. If system documentation is available,
always follow the operating instructions therein.
If there is no system documentation, the
instructions below are to be followed.

5.1 Before first start


Technical demands for connections and
limitations for the separator are listed in
Technical reference.

- Technical data
- Connection list
- Interface description
- Operating water demands
- Basic size drawing
- Foundation drawing

G0868741

Before first start:


Ensure the machine is installed and
assembled correctly and that feed lines and
drains have been flushed clean.
Fill oil in the oil bath. See oil change
procedure in section Oil change on
page 160. For quality of oil, see section
Lubricating oils on page 168.

31
244
5 Operating instructions

Remove the oil pin and make sure that the


oil level is above the lower end of the pin,
see Oil change on page 160.

NOTE

Too much or too little oil can damage the


separator bearings.

NOTE

The separator should be level and at standstill


when oil is filled.

g08687h1

Make sure that the bearings on the spindle


are pre-lubricated.
Check the direction of rotation by doing
a quick start/stop. The motor fan should
rotate clockwise.

5.1.1 Start after service


Pay special attention to any unusual sounds or
vibrations when starting the separator after a
service. Different fault symptoms are listed in
chapter 7 Fault finding on page 173.

32
245
5 Operating instructions

5.2 Normal operation

5.2.1 Before normal start


To achieve the best separation results, the bowl
should be in a clean condition.

1. Check: 1
- that all couplings and connections
(1) are securely tightened to prevent
leakages. Leaking hot liquid can cause
burns.
- that the lock nut (2) is fully tightened.
Do not forget the washer.
- that all frame hood bolts (3) as well as
the belt cover are fully tightened.
- the direction of rotation by doing a
quick start/stop. The motor fan (4)
should rotate clockwise
- the oil bath level and top up if
necessary. 2

NOTE 4

The separator should be level and at standstill


when oil is filled. 3

ON
CAUTI
!
If power cable polarity has been reversed, the
separator will rotate in reverse, and vital rotating
parts can loosen.

ON
CAUTI
! G0871491

Disintegration hazard
After change of feed the sludge discharge
interval must be adjusted. Breakdown may result
if the intervals between discharges are too long.

33
246
5 Operating instructions

5.2.2 Start
1. Start of separator:

a. Open the water supply valve.

b. Start the separator by pushing the start


button at the starter unit.

NOTE

After every start the separator must always


be run continuously for a minimum of 5 hour
to ensure proper lubrication. Try to learn the
vibration characteristics during the critical
speeds.

O I
R

G08717c1

2. Check the separator for vibration.

NG
WARNI
!
Excessive vibration
If vibration increases, or continues at full speed,
keep bowl filled and stop the separator.

The cause of the vibration must be determined


and corrected before starting again! Excessive
vibration may be due to incorrect assembly or
insufficient cleaning of the bowl.
G0871881

NOTE

Normal vibration
Vibration may occur during start up when
passing critical speed. This is normal and should
pass without danger.

34
247
5 Operating instructions

3. Ensure that the separator is at full speed.

The time by full speed can be checked by


I
studying the ammeter. R O

- Current increases during start (1).


- When full speed has been reached, 1
the current decreases to a stable value
(2).

For normal length of the start-up period, 2


see 8.2 Technical data on page 182.
G0871931

4. Perform a discharge to fill up the operating


water system.

a. Add opening water until a discharge


sound is heard (10 seconds).

b. Wait 15 seconds.

c. Add closing water for 15 seconds.

5. Add some hot conditioning water.

6. Turn on the oil feed.

NOTE

Before turning on the feed make sure that the oil


has the correct temperature.

35
248
5 Operating instructions

5.2.3 Operating
1. Checkpoints during operation.

NG
WARNI
!
Burning hazard
Lubricating oil and various machine surfaces can
be hot and cause burns.

a. Check all connections for leakage.

b. Check that the feed has correct flow


and temperature.

c. Check the back pressure.

d. Check that the starter ammeter reading


(1) is the normal low and steady value.

e. Check for abnormal vibrations and


sounds.

NG
WARNI 1
!
1
Disintegration hazard R O

Do not discharge a vibrating separator.


Vibration can increase if solidified sludge is
only partially discharged.

G08715c1

36
249
5 Operating instructions

5.2.3.1 Sludge discharge

1. Turn off the oil feed.

2. Perform a displacement of the oil by adding


hot water (not more than bowl volume).

3. Perform a sludge discharge.

a. Add opening water until a discharge


sound is heard (max. 3 seconds).

b. Wait 15 seconds.

c. Add closing water for 15 seconds.

4. Turn on the oil feed.

NOTE

Before turning on the feed, make sure that the oil


has the correct temperature.

37
250
5 Operating instructions

5.2.4 Stop
Stopping the separator.

1. Turn off the oil feed.

2. Perform a displacement of the oil by adding


hot water (not more than bowl volume).
I
R O
3. Perform a sludge discharge.

a. Add opening water until a discharge


sound is heard (max. 3 seconds).

b. Wait 15 seconds.
G0872331

c. Add closing water for 15 seconds.

4. Fill the bowl up with water and stop the


separator.

NOTE

Keep the bowl filled during run-down to minimize


the vibrations.

5. Wait until the separator has stopped (after 1


about 35 minutes).

Check rotation of motor fan (1).

NG
WARNI
!
Entrapment hazard
Make sure that rotating parts have come
to a complete standstill before starting any
dismantling work.

G0872491

38
251
5 Operating instructions

5.3 Emergency stop


1. If the separator vibrates excessively push
the emergency stop button (1).

NOTE

Keep the bowl filled during run-down to minimize


the vibrations.
1

G0871281

2. Evacuate the room. EXIT

NG
WARNI
!
Disintegration hazard
Never discharge a vibrating separator.

NG
WARNI
!
Entrapment hazard
Make sure that rotating parts have come
to a complete standstill before starting any
dismantling work.

NG
WARNI
! G0871381

Disintegration hazard
After an emergency stop, the cause of the fault
must be identified.

If all parts have been checked and the cause


not found, contact Alfa Laval for advice before
restarting the separator.

39
252
5 Operating instructions
253

6 Service, dismantling,
assembly

6.1 Periodic maintenance


Periodic (preventive) maintenance reduces the
risk of unexpected stoppages and breakdowns.
Follow the maintenance log in this chapter in
order to facilitate the periodic maintenance.

6.1.1 Maintenance intervals


The following directions for periodic maintenance
give a brief description of parts to be cleaned,
checked and renewed at different maintenance
intervals. The maintenance log for each
maintenance interval, see page 46, gives a
detailed list of actions to be performed.

Inspection [i]
An Inspection consists of an overhaul of the
separator bowl, inlet/outlet and operating water
device at max. 6 months or 4000 operating
hours.
Seals in bowl and gaskets in inlet/outlet device
are renewed.

Overhaul [o]
An Overhaul consists of an overhaul of the
complete separator (including separator bowl,
inlet/outlet and operating device) at max. 18
months or 12000 operating hours. Seals,
bearings, friction blocks and flat belt in the
separator are renewed.

Oil change
The oil should be changed every 4000 hours,
or at least once every year if the total number of
operating hours is less than 4000 hours/year.

41
254
6 Service, dismantling, assembly

Electric motor
Motor service consists of an overhaul of the
motor at max. 36 months or 24000 operating
hours.
Bearings, fan, seals and washers for the motor
are renewed.

Ancillary
Verify correct flow at inspection service overhaul
water valveblock at least every 36 months.

42
255
6 Service, dismantling, assembly

6.1.2 Maintenance procedure


At each Inspection and/or Overhaul, take a copy
of the maintenance log and use it to make notes
during the service.

An inspection and overhaul should be carried


out as follows:

1. Dismantle the parts as described in 6.3


Dismantling on page 49.

Place the separator parts on clean, soft


surfaces such as pallets.
2. Inspect and clean the dismantled separator
parts according to the maintenance log and
description in 6.4 Actions before assembly
on page 99.
3. Fit all the parts delivered in the service
kit while assembling the separator as
described in 6.5 Assembly on page 107.
4. When the separator is assembled, make
final checks described in 6.5.7 Actions after
assembly on page 158.

NG
WARNI
!
Disintegration hazard
Separator parts that are either missing, worn beyond
their safe limits or incorrectly assembled, may cause
severe damage or fatal injury.

ON
CAUTI
!
Burn and corrode hazard
Escaping hot and/or corroding process material, which
can be hazardous, may still remain in the separator
after stop.

43
256
6 Service, dismantling, assembly

The use of service symbols in the


dismantling/assembly instructions
Parts that have to be renewed from the service
kits (see below) are marked [i] and/or [o] in the
assembly instructions.

Example
a. Fit the O-ring [i].

When dismantling and assembling between the


service periods, some procedures do not have
to be carried out. These procedures are marked
[i] and/or [o].

All symbols used in the instructions refer to


activities mentioned in the maintenance logs.

6.1.3 Tightening of screws


Tightening all screws with the correct torque
value is important.

These figures apply unless otherwise stated:

Torque
Metric Stainless steel Carbon steel
thread Nm kpm lb.ft Nm kpm Ib.ft
M4 1,7 0,17 1,2 2,25 0,25 1,8
M5 3,4 0,34 2,5 4,9 0,49 3,6
M6 7 0,7 5 8 0,8 5,9
M8 17 1,7 13 20 2 14,7
M10 33 3,4 24 39 3,9 28,7
M12 57 5,8 42 68 6,9 50
M16 140 14 100 155 15,8 114
M20 270 28 200 325 33 239
M24 470 48 340 570 58 420

The figures apply to lubricated screws tightened


with a torque wrench.

44
257
6 Service, dismantling, assembly

6.1.4 Service kits


Special service kits are available for Inspection,
Overhaul and Motor.

For other services, a Support kit is available.


Spare parts not included in the Support kit have
to be ordered separately.

Note that the parts for Inspection are included


in the Overhaul kit.

The contents of the kits are described in the


Spare Parts Catalogue.

NOTE

Always use Alfa Laval genuine parts as otherwise the


warranty may become invalid. Alfa Laval takes no
responsibility for the safe operation of the equipment
if non-genuine spare parts are used.

NG
WARNI
!
Disintegration hazard
Use of imitation spare parts may cause severe damage.

6.1.5 Cleaning
CIP (Cleaning In Place)
To prolong the intervals between manual
cleaning of the separator the use of CIP together
with repeated discharges can be used.

Some CIP liquids can be corrosive to brass-


and aluminium alloy parts which are included
in the separator.

ON
CAUTI
!
Use only Alfa Laval recommended CIP liquids.

45
258
6 Service, dismantling, assembly

6.2 Maintenance logs


Name of ship/plant: Local identification:
Separator: Manufacture No./Year:
Total running hours. Product No:
Date: Signature:

Part [i] [o] Check Action Page Note


In and outlet device
- All parts x x Clean 99
- All parts x x Check for corrosion 101
- All parts x x Check for cracks 102
- Connecting housing x x Check for erosion damages 103
x x Renew O-rings for hoses ---
- Frame hood x Renew O-ring 151
x Control measure of paring 151
disc height
x Check height adjusting rings 151
x Renew the spring 151
- Inlet pipe thread x x Lubricated 151
Bowl
- All parts x x Clean 99
- All parts x x Check for corrosion 101
- All parts x x Check for cracks 102
- All parts x x Check for erosion damages 103
- Bowl body x x Check for impact marks and 55
corrosion
x x Renew rectangular ring 55
x Renew guide ring 55
x x Renew O-rings 55
x x Renew holder screws and 55
washers
- Operating slide x x Renew rectangular ring 55
x x Renew valve plugs 55
- Discharge slide x x Renew rectangular ring 55
- In and outlet pipe x x Renew O-rings 55
x x Renew splash sealing 55
- Paring tube x x Renew O-rings and bearings 55

46
259
6 Service, dismantling, assembly

Part [i] [o] Check Action Page Note


- Lock ring x Check for deformations 55
x Check for impact marks 55
x Check pin not deformed or 55
loose
- Bowl hood x x Renew seal ring 55
x x Renew O-ring 55
- Operating water ring x x Renew seal ring and screws 55
Frame
- Frame feet Renew frame feet (including 115 Has to be
washers and screws) ordered
separately
- Drain and oil filling x x Renew washers 115
holes
- Oil pin x x Renew O-ring 115
Driving device
- All parts x Clean 99
- All parts x Check for corrosion 101
- All parts x Check for cracks 102
- Bottom bearing x Renew O-ring 115
housing
- Labyrinth ring holder x Renew labyrinth ring 115
x Renew O-ring 115
- Top bearing housing x Renew springs 115
- Flat belt x Renew flat belt 115
- Bowl spindle x Pre-lubricate and renew ball 115
bearing
x Pre-lubricate and renew 115
self-aligning roller bearing
x Lubricate the spindle 115
x Measure the radial wobble 115
- Neck bearing cover x Renew O-ring 115
- Deflector ring x Renew O-ring 115
- Water inlet pipe x Renew O-ring 115
- Operating water cover x Renew seal ring and O-ring 115
x Check that operating water 115
channel is free from blockage
- Fan x Renew O-ring 115
Coupling
- All parts x Clean 99
- All parts x Check for corrosion 101
- All parts x Check for cracks 102

47
260
6 Service, dismantling, assembly

Part [i] [o] Check Action Page Note


- Coupling hub x Renew single row ball 91
bearings
x Renew snap rings 91
- Friction block x Renew friction pads (if they 91
are worn) or clean the pads if
they are dirty
Electrical motor
- Bearings x* Renew bearings, fan, seals 41 *) Check
and washers maintenance
interval Electric
motor
Signs and on separator
- Machine plate x Check attachment an legibility 158
- Power supply x Check attachment an legibility 158
frequency
- Lifting instructions x Check attachment an legibility 158
- Safety labels x Check attachment an legibility 158
- Name plate x Check attachment an legibility 158
- Representative label x Check attachment an legibility 158

48
261
6 Service, dismantling, assembly

6.3 Dismantling

6.3.1 Introduction
The frame hood and heavy bowl parts must be
lifted by means of a hoist. Position the hoist
exactly above the bowl centre. Use a lifting sling
and lifting hooks with safety catches.

The parts must be handled carefully. Dont


place parts directly on the floor, but on a clean
rubber mat, fiberboard or a suitable pallet.

NOTE

For safety reasons, it is essential that all personnel


who work with the separator read this manual
thoroughly and completely. Do not allow personnel to
clean, assemble, operate or maintain the separator
until they have read and fully understood this manual.
Ensure that all personnel who operate and service
the separator are well-trained and knowledgeable
concerning the separator and the work to be carried
out.

6.3.2 Tools
Special tools from the tool kit must be used for
dismantling and assembly, as well as Standard
tools (not included). The special tools are
specified in the Spare Parts Catalogue and are
illustrated at the beginning of each dismantling
section.

NG
WARNI
!
Entrapment hazard
To avoid accidental start, switch off and lock-out
power supply before starting any dismantling work.

Make sure that machine has come to a complete


standstill before starting any dismantling work (takes
about 30 minutes from switch off).

49
262
6 Service, dismantling, assembly

Standard Tools

G0911691

1. Screwdriver
2. Torque wrench (capacity 0-200 Nm)
3. Drift ( 4 mm)
4. Dial indicator with magnetic base
5. Hexagon head keys, various sizes
6. Heating equipment for bearings
7. Sliding calliper
8. Hammers (standard and soft-faced)
9. Pliers for internal snap rings
10. Pliers for external snap rings
11. T-handle with extension rod,
sockets (13, 16, 17, 18, 19, 27, 30 mm)
12. Spanners (various sizes)
13. Adjustable spanner
14. Shackle

50
263
6 Service, dismantling, assembly

6.3.3 Frame hood

1
2
3
4
5

7
G0863331

1
8
G1019211

1. Hook spanner (for the lock nut) 9

10

11

G08634M1

1. Lock nut
2. Washer
3. Connecting housing
4. Spring
5. Screw
6. Arm
7. Screws
8. Frame hood
9. O-ring
10. Height adjusting rings
11. Support ring

51
264
6 Service, dismantling, assembly

1. Removing the connecting housing.

a. Remove connections before starting


dismantling.

b. Lubricate the inlet pipe thread

c. Remove the lock nut, using the hook


spanner, and the washer.
1

NG
WARNI
!
The nut must not be removed before the
separator has stopped.

d. Press the inlet pipe (1) down, with a


soft material, to loosen the connecting
housing.

e. Remove the connecting housing.

G08635c1

1. Inlet pipe

52
265
6 Service, dismantling, assembly

2. Removing the spring and arm.

B
C

G08636m1

A. Spring
B. Screw
C. Lock washer
D. Arm

a. Remove the spring (A) from the pin on


the hood.

b. Remove the screw (B) and lock washer


(C) from the arm.

c. Remove the arm (D) together with the


spring.

d. Turn the paring tube (1) so that the


frame hood can be removed upwards.

NOTE

To avoid the paring tube from being damaged


and preventing the inlet pipe from sticking to 1
the frame hood when lifting the hood, always
turn the paring tube towards the pipe before
lifting.

G08636J1

1. Paring tube

53
266
6 Service, dismantling, assembly

3. Removing the frame hood.

a. Remove the screws (A) holding the


frame hood. A

b. Loosen the hood by bending with a


screwdriver (B) in all grooves in the
hood.

c. Lift off the frame hood. B

NOTE

Do not place the hood upside down.


C

G08636I1

A. Screw
B. Screwdriver
C. Frame hood

54
267
6 Service, dismantling, assembly

6.3.4 Bowl

G0861621

1 2

3
6
4

7
8
9
10

G1019221

1. Compressing tool (lock ring)


2. Lifting eyes
3. Spanner for nut (nut/discharge slide)
4. Puller (discharge slide)
5. Lifting tool (distributor, spindle)
6. Puller (Bowl body)
7. Screw (lock ring) (M5)
8. Hexagon head key
9. Chisel (seal ring)
10. Pin (distributor/lifting tool)

55
268
6 Service, dismantling, assembly

2
3
4
5

6
7
8

10

11

12

13
14
15
16
17

18

19

20
21
22
26
23
24
25
27
28
29
31 30
G1029061

56
269
6 Service, dismantling, assembly

1. Lock ring
2. Bowl hood
3. Seal ring
4. O-ring
5. Top disc
6. O-rings
7. Inlet and outlet pipe
8. Paring tube
9. Splash sealing
10. Bowl disc (without caulks)
11. Bowl discs
12. Distributor
13. Cap nut
14. Nut
15. Discharge slide
16. Rectangular ring
17. O-ring
18. Bowl body
19. Guide ring
20. Rectangular ring
21. O-ring
22. Valve plugs
23. Nozzle
24. Rectangular ring
25. O-ring
26. Operating slide
27. Holder
28. Operating water ring
29. Screws
30. Seal ring
31. Screws & washers

57
270
6 Service, dismantling, assembly

1. Removing the lock ring.

a. Fit the compressing tool (A).


A
b. Fit the clamps (C) and the screws (B) D
to stop.
F
2
3

NOTE

Be sure not to cover the threaded holes for 4 1


the lock ring.
B
c. Compress the disc stack by alternately C
5
tightening the inner screws (F) on the 6
compressing tool in increments of 5 Nm
up to a maximum of 30 Nm.

NOTE
1
If the separator have been out of operation G
and the bowl is cold, a higher compression H
torque might be required due to oil residue
I
between bowl hood and bowl body. It these
cases a compression torque up to 60 Nm can
be used to open the bowl.

d. Fit the dismantling screws (D) to the E


bowl body and press out the lock ring
by tightening the screws successively
according to the numbering in the
illustration (1-6). Start with the screw
(1) nearest to the lock ring end (G), the
one without pin (I), and then continue
around until the other end (H) is
reached. The lock ring can be removed G08627B2

when it has passed the edge of the A. Compressing tool


groove. B. Screw
C. Clamp
e. Remove the lock ring (E) from the
D. Dismantling screw
groove. E. Lock ring
F. Compressing screw
G. Lock ring end without pin
NOTE H. Lock ring end with pin
I. Pin
Remove the dismantling screws.

58
271
6 Service, dismantling, assembly

2. Removing the bowl hood.

a. Remove the compressing screws (A). A


B
b. Loosen the screws (B) on the clamp
tool. Remove the tool. Remove the
lock ring.

NOTE

See removing the bowl hood with optional


hydraulic tool (if purchased) on next page.

c. Fit the compressing tool and the puller


screws (C). Pull the bowl hood off by
screwing the screws alternately (max.
1/2 turn) and gradually increase the
momentum evenly until the bowl hood C
come loose.

NOTE

The bowl hood must be pulled off straight


up, in order not to get stuck.

Recommendation: Take measurements with


a calliper around the bowl, between the
upper edge of the bowl body and the bowl
hood, to check that the bowl hood is being
pulled off straight up.

d. Remove the clamps and attach lifting


eyes (D) to the compressing tool and lift
off the bowl hood using slings and hoist. D

NG
WARNI
!
Crush hazard
The top disc can adhere to the bowl hood
when lifting. Be careful not to accidentally
drop it. G08628J1

A. Compressing screw
B. Screw
C. Puller screw
D. Lifting eye

59
272
6 Service, dismantling, assembly

3. Removing the bowl hood using the


hydraulic tool (optional).

NOTE

First remove the lock ring according to


instructions a -b, on previous page.

a. Fit the larger stud bolt (A) into the in- A F


and outlet pipe (must rest on the cap
nut).
E
b. Fit the nut (B) and the washer. Make B
sure that the nut is above the pipe.
D
c. Fit the stud bolts (C) into the
compressing tool (equal length). C

d. Fit the hydraulic piston (D) onto the bolt.

e. Fit the holder (E) and fasten with nuts.


Make sure that the holder is in a level
position (the bowl hood must be pulled
off straight up).

f. Attach the hose from the hand pump to


the hydraulic oil inlet (F).

Ease off the bowl hood by pumping the


handle on the pump.

NOTE

The bowl hood must be pulled off straight


up, in order not to get stuck.
G
g. Remove the hydraulic tool and clamps.
Fit lifting eyes (G) and lift off the bowl
hood using slings and hoist.

NG
WARNI
!
Crush hazard G08628K1

The top disc can adhere to the bowl hood


when lifting. Be careful not to accidentally
A. Larger stud bolt
drop it.
B. Nut and washer
C. Stud bolt
D. Hydraulic piston
E. Holder with nuts
F. Oil inlet
G. Lifting eye

60
273
6 Service, dismantling, assembly

4. Removing the seal ring.

a. Place the bowl hood on a support and


tap out a piece of the seal ring (A) using
a drift in the holes.

NG
WARNI
!
Risk for eye injury from flying seal A
ring parts or from splashing fluid
The seal ring breaks when removed from the
bowl hood and may cause trapped fluid to
splash. Wear safety goggles.
B
b. Turn the bowl hood upside down and
remove the seal ring by carefully knock
pieces of the seal ring out of the groove,
using the special chisel (B) tool.

NOTE
G08624A1
It is very important not to damage the bottom
of the groove! A. Seal ring
B. Chisel

5. Removing the inlet/outlet pipe and top disc.

a. Lift out the in- and outlet pipe together


with the top disc.
A

NG
WARNI
!
Crush hazard
The distributor and disc stack can adhere to
the top disc. Separate them from the top
disc so that they do not accidentally drop.

G08629c1

A. Inlet/outlet pipe

61
274
6 Service, dismantling, assembly

6. Removing the paring tube.

a. Remove the top disc (A) from the inlet


and outlet pipe. A

NOTE

To avoid damaging the paring tube, turn it


towards the centre of the pipe.

b. Remove the splash sealing (B).

c. Lift up and remove the paring tube (C).

NOTE
B
If the paring tube sticks, use a drift to
carefully tap it out from the pipe.

Be careful not to damage the paring tube.

Turn the paring tube (C) upwards.

G08630H1

A. Top disc
B. Splash sealing
C. Paring tube

62
275
6 Service, dismantling, assembly

7. Removing the disc stack and distributor.

A C

D
G08631C1

A. Lifting tool
B. Disc stack
C. Bowl discs
D. Pin

a. Assemble the lifting tool (A) with the


pin (D).

b. Fit the assembled tool into the


distributor and ease off the disc stack
using a spanner or wrench.

c. Carefully lift out the disc stack (B)


assembly.

ON
CAUTI
!
Cut hazard
Sharp edges on the bowl discs (C) may
cause cuts.

63
276
6 Service, dismantling, assembly

8. Removing the nut.

Before the nut can be loosened, the bowl


body must first be secured to prevent it
from rotating.

a. Fit a lifting sling on one of the


compressing tool clamps (A). Fit the B
clamp (A) to the bowl body.
C D
A

NOTE

Make sure that the screw on clamp (A) is


tightened and that clamp will not loosen.

b. Fit one of the frame hood screws (D) to


the frame.

E
NOTE G0923871

Make sure that the screw (D) in frame bottom A. Clamp


part is sufficiently tightened so as not to B. Spanner
loosen. C. Lifting sling
D. Screw
c. Fasten the other end of the lifting sling E. Nut
(C) on the screw (D). Make sure that
the lifting sling is fully tensed before
starting to uncrew the nut.

NOTE

Make sure that the lifting sling is positioned


below the head of the screw (D).

d. Use the spanner (B) to remove the


nut (E).

64
277
6 Service, dismantling, assembly

9. Removing the discharge slide.

a. Fit the lifting tool (A) by pressing the A


puller rods (E) towards each other and
position them into the two slots on the
B
bowl body (F).

Slide metal ring (D) down over bowl


nave. E

b. Ease off the discharge slide (C) by


turning the central screw (B).

NOTE

If discharge slide is difficult to remove, tap


lightly on outside edge with a soft faced D
E
hammer.
C
c. Lift out the discharge slide (C).
F

NG
WARNI
!
C
Crush hazard
The ring on the lifting tool must be pushed
down against the discharge slide, otherwise
the discharge slide may come loose from the
tool.

G0863291

A. Lifting tool
B. Screw
C. Discharge slide
D. Ring
E. Puller rod
F. Bowl body

65
278
6 Service, dismantling, assembly

10. Removing the cap nut.

a. Remove the cap nut (A).


A

NOTE

Left-hand thread!

G08606F1

A. Cap nut

11. Removing the bowl body.

G0860741

A. Lifting tool
B. Lifting eye

a. Fit the lifting tool (A) to the bowl body.

b. Raise the bowl body off the spindle


taper by turning the lifting eye (B)
clock-wise.

c. Lift off the bowl body using sling and


hoist.

66
279
6 Service, dismantling, assembly

12. Turn the bowl body upside down.

G0860841

NG
WARNI
!
Crush hazard
Support the bowl body when turning to prevent
it from rolling.

67
280
6 Service, dismantling, assembly

13. Removing the holder.


C

A
D

G0860951

A. Screw
B. Holder
C. Threaded hole
D. Washer

a. Remove and discard the screws (A) and


washers (D). New screws and washers
are included in the Inspection kit.

b. Remove the holder (B).

NOTE

If the ring sticks, use two M8 screws in


threaded holes (C) to raise the operating
slide holder up and away from the bowl body.

68
281
6 Service, dismantling, assembly

14. Removing the operating slide.

a. Lift off the operating slide. A

NOTE

If the ring sticks, use two M8 screws in


threaded holes to raise the operating slide
holder up and away from the bowl body.

G08610N1

A. Operating slide

15. Removing the valve plugs from the


operating slide.

a. Remove the valve plugs using a drift


(A). A

G0874891

A. Drift

69
282
6 Service, dismantling, assembly

16. Removing the guide ring. [O]

a. Gently pry loose the guide ring and


remove it from the bowl. Discard the
guide ring. A new guide ring is included
in the Overhaul kit.

NOTE

Do NOT remove the guide ring if only an


Inspection service [I] is performed.

G08610o1

A. Guide ring

70
283
6 Service, dismantling, assembly

17. Removing the operating water ring.


A

G0861141

A. Screw
B. Ring
C. Threaded hole

a. Remove and discard the screws


(A). New screws are included in the
Inspection kit.

b. Lift off the ring (B).

NOTE

If the ring sticks, use two M8 screws in


threaded holes (C) to raise the operating
slide holder up and away from the bowl body.

71
284
6 Service, dismantling, assembly

6.3.5 Driving device

G0857821

3 4 5

1 2 7 8
G08579G1

1. Puller (spindle pulley, ball bearing)


2. Tool (bearing housing)
3. Cover puller (neck bearing cover)
4. Lifting tool (spindle assembly)
5. Drift (bottom bearing)
6. Sleeve (ball bearing in top bearing seat)
7. Pin spanner (fan)
8. Crowfoot wrench head (oil mist generator)

72
285
6 Service, dismantling, assembly
286
6 Service, dismantling, assembly

1
23
2
3 24
5 4
6 9
7 25
8 10 26
11

12
27
13
28
14 29
15 30
31
32
16 33
34
35

17 36
18 37
19
20 38
21 39
22
G08580h1

74
287
6 Service, dismantling, assembly

1. Seal ring
2. Operating water cover
3. O-ring
4. O-rings
5. O-ring
6. Pipe
7. Elbow
8. Bushing
9. Deflector ring
10. Seal rings
11. Neck bearing cover
12. O-ring
13. O-rings
14. Fan
15. Snap ring
16. Bowl spindle
17. Ball bearing
18. Top bearing seat
19. Helical Spring
20. Composite spring
21. Plug
22. Top bearing housing
23. Screw
24. Air deflector
25. Spindle pulley
26. Belt
27. Self-aligning roller bearing
28. Oil mist generator
29. Nozzle
30. Screw
31. Labyrinth ring holder
32. O-ring
33. Labyrinth ring
34. Pipe
35. O-ring
36. Bottom bearing holder
37. Screw
38. O-ring
39. Strainer

75
288
6 Service, dismantling, assembly

1. Empty the oil sump.

Unscrew the oil plug (A) and empty the oil


sump.

A
G08685A1

A. Oil plug

2. Removing the belt cover.

a. Remove the screws (1).

b. Remove the belt cover (2).

2
G0858191

1. Screw
2. Belt cover

76
289
6 Service, dismantling, assembly

3. Loosen the flat belt, by tilting the motor.

a. Loosen, but do not remove, the screws


holding the motor. Start with the two
screws (4) at the bottom.
1 2
b. Remove the two upper screws so that
the motor can be tilted. Do not loosen
more than shown in the illustration. 3 4

NG
WARNI
!
Crush hazard
The motor will come off if the screws are
unscrewed.

c. Remove the flat belt from the motor


pulley.

5
G08588y2

1. Motor
2. Separator frame
3. Nut
4. Screw
5. Flat belt

77
290
6 Service, dismantling, assembly

4. Removing the operating water cover.

B
C

G0858951

A. Screw
B. Operating water cover
C. Threaded holes

a. Remove the screws (A).

b. Lift off the operating water cover (B).

NOTE

If the cover (B) sticks, fit two M10 screws to


the threaded holes (C) and tighten.

78
291
6 Service, dismantling, assembly

5. Removing the neck bearing cover and


deflector ring.

B
C

E D

G0859081

A. Tool
B. Mounting screw
C. Screw
D. Cover
E. Frame

a. Attach the tools (A).

b. Fasten the tool to the cover using


mounting screw (B).

c. Ease off the cover (D) by tightening the


screw (C).

d. Remove the neck bearing cover


together with the deflector ring.

79
292
6 Service, dismantling, assembly

6. Prepare for removal of spindle assembly.

a. To facilitate later removal of the plugs,


loosen (but do not remove) the plugs
(A) on the bearing housing.

b. Remove the screws (B)

NOTE

If the housing sticks, fit two M10 screws to


the threaded holes and tighten. B

G0859181

A. Plug
B. Screw

80
293
6 Service, dismantling, assembly

7. Lifting the spindle assembly from the frame.

a. Fit the lifting tool (1) to the spindle end.

b. Slowly raise and lift out the spindle


assembly using a hoist.

NG
WARNI
!
Crush hazard
Do not rotate the spindle assembly during
lifting. The spindle assembly may otherwise
come loose from the lifting tool.

NOTE

Take care not to damage the oil mist


generator (2).

NOTE

Protect the inside of the frame by covering


the hole.

g0907861

1. Lifting tool
2. Oil mist generator

81
294
6 Service, dismantling, assembly

8. Place the spindle assembly upside down


on a support.

Make a support (1) with a free space (A)


between the spindle top and the floor.

G08592c1

A=5 mm

NOTE

Always use a support as per this sketch when


overhaul service is performed on the spindle
assembly. It is very important that the top of the
spindle does not touch the ground.

82
295
6 Service, dismantling, assembly

9. Removing the air deflector.

a. Remove the screws (2) and the air


deflector (1).

G08592b1

1. Air deflector
2. Screw

83
296
6 Service, dismantling, assembly

10. Removing the fan.

a. Turn the spindle assembly the right way


up.

b. Place a spanner (or similar) on the 2


spindle pulley key-grip (1), as holder-up.
1
c. Fit the pin spanner and remove the
fan (2).

NOTE

Left-hand thread!

G0923981

1. Key-grip
2. Fan

84
297
6 Service, dismantling, assembly

11. Removing the oil mist generator.

a. Turn the spindle assembly up-side


down and remove the oil mist generator
1
(1) by using spanners.

b. Remove the two nozzles (2) using an


Allen key.

2
G1036811

1. Oil mist generator


2. Nozzle

12. Removing the bottom bearing assembly.

a. Pull off the belt pulley and the


self-aligning roller bearing using the
puller tool (1).
1

NOTE

Always discard a used bearing.

G1036821

1. Puller tool

85
298
6 Service, dismantling, assembly

13. Removing the top bearing housing.

a. Turn the spindle assembly over.

1 2

G0858251

1. Composite spring
2. Plug
3. Spindle
4. Axial springs

b. Remove the snap ring (5).

5
ON
CAUTI
!
Risk for eye injury from flying snap
ring
Use the correct pliers for dismantling of snap
ring to avoid accidental release. 6
c. Remove the plugs (2) and the
composite springs (1).

d. Carefully remove the spindle (3) and g08583A1

bearing seat from the top bearing


housing.

NOTE

Be careful not to damage the vibration


indicator (6).

e. Collect the axial springs (4).

86
299
6 Service, dismantling, assembly

14. Removing the ball bearing.

a. Fit the cap nut (1) on the spindle to


protect the threads.

b. Use the puller tool (2) to remove the top


bearing seat from the spindle. 1

2
NOTE

Take care not to damage the vibration


indicator (3) when separating the top bearing
seat from the spindle.
3

NOTE
4
Do not damage threads on spindle.

c. Place the top bearing seat (A) on


G0858381
a support to protect the vibration
indicator. Remove the bearing. Use a 1. Cap nut
drift in the two holes. 2. Puller tool
3. Vibration indicator
4. Piece of wood to protect the spindle.

G0858371

A. Top bearing seat

87
300
6 Service, dismantling, assembly

15. Removing the labyrinth ring holder.

a. Remove the screws (1).

NOTE

If the holder sticks, fit two screws M8 to the


threaded holes and tighten.

b. Remove the O-ring and labyrinth ring.

G08586G1

1. Screw

88
301
6 Service, dismantling, assembly

16. Removing the bottom bearing holder.

a. Fit the tool (4) into the bottom bearing


holder and attach the socket (3),
extension rod (2) and T-handle (1). 1

G08586J1

1. T-handle
2. Extension rod
3. Socket
4. Tool

b. Loosen the bottom bearing holder (A)


by turning it counter clockwise. Remove
it by hand.

G08586k1

A. Bottom bearing holder

89
302
6 Service, dismantling, assembly

17. Dismantling the bottom bearing holder


(when necessary).

a. Unscrew the screw (3).

b. Remove the pipe (1), O-rings (2), (4)


and strainer (5).

G1015731

1. Pipe
2. O-ring
3. Screw
4. O-ring
5. Strainer
6. Bottom bearing holder

90
303
6 Service, dismantling, assembly

6.3.6 Centrifugal clutch

G0864711

NG
WARNI
!
Entrapment hazard
To avoid accidental start, switch off and lock-out
power supply before starting any dismantling work.

Make sure that machine has come to a complete


standstill before starting any dismantling work (takes
about 30 minutes from switch off).

NOTE

50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks

The illustration shows 50 Hz G08651l1

1 2 1. Snap ring
2. Snap ring
3. Ball bearing
4. Spacing ring
5. Ball bearing
6. Belt pulley
7. Coupling hub
8. Parallel pin
9. Friction blocks (3=60 Hz)
G0865071 10. Cover
1. Mounting / dismantling tool (centrifugal clutch). 11. Snap ring
2. Mounting / dismantling tool (ball bearing).

91
304
6 Service, dismantling, assembly

NOTE

If belt cover and drive belt not has been removed


proceed with this before removing the motor. See
page 76

1. Removing the motor.

a. Disconnect the electrical cables.

NG
WARNI
!
Electrical hazard
To avoid electrical shock, switch off and lock
power supply before starting dismantling
work.

NOTE

If the cables are not disconnected during


lifting procedures, they may become
damaged.

b. Fit a sling to the motor using a shackle


on the upper part.

Weight of motor with coupling: approx.


84 kg.

c. Tense the lifting sling to support the


motor and remove the screws. Lift the G08646B1

motor while supported.

NG
WARNI
!
Crush hazard
If not supported, the motor with coupling will
drop when removing the screws.

d. Lower the motor onto a suitable pallet.

92
305
6 Service, dismantling, assembly

2. Removing the friction blocks.

a. Remove the snap ring (3), cover (2) and


friction blocks (1).

ON
CAUTI
!
Flying objects
Risk for accidental release of snap ring.
Wear safety goggles. G08652g1

1. Friction blocks (3=60 Hz)


2. Cover
ON 3. Snap ring
CAUTI
!
Inhalation hazard
When handling friction blocks/pads (1) wear
a mask to avoid inhalation of dust.

Do not use compressed air to remove dust.

Remove dust using vacuum or a damp cloth.

NOTE

50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks

93
306
6 Service, dismantling, assembly

3. Checking the condition of the friction


blocks. [o]

ON
CAUTI
!
Inhalation hazard
When handling friction blocks/pads wear a mask
to avoid inhalation of dust.

Do not use compressed air to remove dust.

Remove dust using vacuum or a damp cloth.

If the blocks are worn:

Fit new friction blocks.

NOTE

Replace all blocks, even if only one is worn.

NOTE

Be sure that the pins on the back of the blocks


project into the grooves in the clutch hub.

a. Clean the pins of coupling hub and


apply a thin film of lubricating paste to
the pins.

NOTE

Make sure that there is no oil on the pads.

b. If only friction block service is to be


done, proceed to fitting the friction
blocks on page 111.

G08653c1

1. Friction block

94
307
6 Service, dismantling, assembly

4. Removing the coupling from the motor


(complete dismantling of centrifugal clutch).

a. Attach a socket with extension rod and


handle (1) to the screw. 1
Place a piece of wood (2) according to
the illustration.
Push the handle to start the rotor
moving, when the handle hits the piece
of wood, the weight and movement of
the rotor loosens the screw.
Repeat until screw is loose.

Remove the screw (5), spring washer 2


(4) and washer (3).

b. Check that the brass plug (6) is


mounted on the puller tool (8). Fit the
tool to the friction clutch.
3 4
c. Ease off the friction coupling. 5

NG
WARNI
!
Crush hazard
The centrifugal clutch is heavy and can fall,
causing injury, when loosened from the
motor shaft.

NOTE
6 7 8
See dismantling with optional hydraulic
puller tool on page 96 (if purchased).

G08654y1

1. Socket with extension rod and handle


2. Piece of wood
3. Washer
4. Spring washer
5. Screw
6. Brass plug
7. Flat area for spanner
8. Puller tool

95
308
6 Service, dismantling, assembly

5. Removing the coupling from the motor


using the optional hydraulic tool.

NOTE

First remove the screw, spring washer and


washer according to instructions a -b, on
previous page.

1 2 3 4

7 5
6
G08654Q1

1. Sleeve
2. Nut
3. Hydraulic cylinder
4. Hydraulic oil inlet
5. Plate
6. Holder
7. Coupling nave
8. Motor shaft

a. Fit the sleeve (1) to the stud bolt.

Fit the stud bolt with sleeve to the motor


shaft (8).

b. Fit the holder (6) to the coupling


nave (7).

c. Fit nut (2) and sleeve to the stud bolt


as shown.

d. Fit hydraulic cylinder (3) as shown.

e. Fit the plate (5) and fasten with screws


through plate and holder.

96
309
6 Service, dismantling, assembly

f. Attach the hose from the hand pump to


the hydraulic oil inlet (4).

Ease off the friction coupling by


pumping the handle on the pump until
stop.

Release pressure on the hand pump


and adjust the nut on the stud bolt.

Repeat until coupling is loose.

NG
WARNI
!
Crush hazard
The centrifugal clutch is heavy and can fall,
causing injury, when loosened from the
motor shaft.

97
310
6 Service, dismantling, assembly

6. Dismantling of the coupling assembly.

a. Remove the snap rings (1).

ON
CAUTI 1
!
Flying objects
Risk for accidental release of snap ring.
Wear safety goggles.

b. Drive out the coupling hub (3).

c. Turn the coupling the other way round


and drive out the ball bearings (5) using
the mounting tool.
2
NOTE

Always discard used bearings.


3

5
G0865571

1. Snap ring
2. Wooden support
3. Coupling hub
4. Support
5. Ball bearing

98
311
6 Service, dismantling, assembly

6.4 Actions before assembly

6.4.1 Cleaning
[i], [o]

Clean the separator parts according to the


diagram below. Afterwards, protect all cleaned
carbon steel parts against corrosion by oiling.

NG
WARNI
!
Electrical hazard
Never wash down a separator with a direct water
stream. Never play a water jet on the motor. Totally
enclosed motors can be damaged by direct hosing
to the same extent as open motors, resulting in
short-circuit and internal corrosion.

ON
CAUTI
!
Cut hazard
Sharp edges on the separator discs may cause cuts.

99
312
6 Service, dismantling, assembly

Part Procedure Cleaning agents


Frame and motor The external cleaning of the frame and Water and de-greasing agent.
motor should be restricted to brushing,
sponging or wiping while the motor is
running or still is hot.

Clean the inside of the frame with a clean


cloth and remove visible particles.
Bowl Cleaning of bowl discs A chemical cleaning agent
Inlet/outlet Handle the bowl discs carefully in order must dissolve the deposits
to avoid damage to the surfaces during quickly without attacking the
cleaning material of the separator parts.

Remove the bowl discs from the Use Alfa Laval bowl disc
distributor and place them individually in the cleaning agent. Mix 1 part
cleaning agent. cleaning agent to 10 parts
water. The temperature should
Allow the discs to remain in the be 6080 C.
cleaning agent until the deposits have been
dissolved. This will normally take between Fuel oil sludge mainly consists
two and four hours. of complex organic substances
such as asphaltenes. The
Lastly, clean the discs with a soft brush. most important property of a
cleaning liquid for the removal
Cleaning of holder for operating slide, of fuel oil sludge is the ability to
operating water ring and operating slide dissolve these asphaltenes.
with nozzle.

Use 10% acetic acid solution to dissolve


lime deposits. The acid should be heated
to 80 C.

Clean the nozzle on the operating slide


using a soft iron wire or a similar object.
Driving device Use a sponge or a soft brush and clean White spirit, cleaning-grade
the oil mist generator and bearing holder kerosene or diesel oil.
thoroughly.
Centrifugal clutch Use a sponge or a soft brush. White spirit, cleaning-grade
kerosene or diesel oil.
Belt pulley Use a steel brush. Solvent

100
313
6 Service, dismantling, assembly

6.4.2 Inspection for corrosion


[i], [o]

Inspect the separator parts for corrosion.


Evidence of corrosion attacks should be looked
for and rectified each time the separator is
dismantled.

NG
WARNI
!
Disintegration hazards
Always contact your Alfa Laval representative if you
suspect that the depth of the corrosion damage G0205241

exceeds 0,2 mm for bowl body and bowl hood (0,5


for other parts) or if cracks have been found. Do
not continue to use the separator until it has been
inspected and given clearance for operation by Alfa
Laval.

Material Type of corrosive Appearance Measure


environment
Non-stainless steel and Water or dampness Rust If damage exceeds 0,5
cast iron parts mm, contact Alfa Laval.
Stainless steel Chlorides or acidic Acidic solutions cause Polish dark-coloured
solutions general corrosion. spots and other
Chloride corrosion corrosion marks with
begins as small dark a fine grain emery
spots that can be cloth. This may prevent
difficult to detect, further damage.
and goes on to local If damage exceeds 0,5
damage such as pitting, mm (0,2 mm for bowl
grooves or cracks. body and bowl hood)
contact Alfa Laval.
Other metal parts Aggressive Possible corrosion If damage exceeds 0,5
environment damage can be in the mm, contact Alfa Laval.
form of pits and/or
cracks.

NG
WARNI
!
Disintegration hazards
Pits and spots forming a line may indicate cracks
beneath the surface.

All forms of cracks are a potential danger and are


totally unacceptable.

Replace any part where corrosion can be suspected


of affecting its strength or function.

101
314
6 Service, dismantling, assembly

6.4.3 Inspection for cracks


[i], [o]

Check the separator parts for cracks. It is


particularly important to inspect for cracks in
rotating parts, and especially the pillars between
the sludge ports in the bowl wall.

NG
WARNI
!
Disintegration hazard
All forms of cracks are potentially dangerous as
they reduce the strength and functional ability of
components.

Always replace a part if cracks are present.

Cracks can occur from cyclic material stresses


and corrosion. Keeping the separator and its
parts clean and free from deposits will help to
prevent corrosion attacks.

NG
WARNI
!
Disintegration hazards
Always contact your Alfa Laval representative if you
suspect that the depth of the damage exceeds 0,2 mm
for bowl body and bowl hood (0,5 for other parts).

Do not continue to use the separator until it has been


inspected and given clearance for operation by Alfa
Laval.

102
315
6 Service, dismantling, assembly

6.4.4 Inspection for erosion


[i], [o]

Erosion may occur when particles suspended in


the process liquid slide along or strike against
a surface.

Erosion is characterised by:

a. Burnished traces in the material.


b. Dents and pits having a granular and shiny surface.

1. Inspect the bowl and inlet/outlet parts for


erosion damages.

NOTE

Always contact your Alfa Laval representative


if you suspect that the depth of the damage
exceeds 0,2 mm for bowl body and bowl hood
(0,5 for other parts). Do not continue to use the
separator until it has been inspected and cleared
for operation by Alfa Laval.

2. Inspect inside and outside of the frame


hood.

NOTE

Pay extra attention at the groove.

G1034011

3. Replace parts if erosion is suspected.

NG
WARNI
!
Disintegration hazard
Erosion damage weakens parts by reducing the
thickness of the material.
Pay special attention to the pillars between the
sludge ports in the bowl wall.
Replace parts if erosion is suspected of affecting
strength or function.

103
316
6 Service, dismantling, assembly

Surfaces particularly subjected to erosion are:

e
a f

c h g
d
G1033631

a. The sealing edge of the discharge slide.


b. Bowl body and holder.
c. Holder and operating slide.
d. The underside of the distributor in the vicinity of the distribution holes and wings.
e. Paring disc and paring tube.
f. Lock ring.
g. Pillars between the sludge ports in the bowl wall.
h. The sealing edge of the discharge slide for the seal ring in the bowl hood.
i. Groove in frame hood. (Inspect both the inside and outside of the frame hood.)

104
317
6 Service, dismantling, assembly

6.4.5 Exchange of frame feet


The frame feet have to be changed occasionally
due to rubber deterioration from age.

When replacing the frame feet, the separator


must be lifted. Follow the instructions in 6.7
Lifting instructions on page 170.
a. Loosen the central bolts (1) and prepare to
remove the separator frame

b. Remove the separator. See 6.7 Lifting


instructions on page 170.

c. Remove the existing screws (2), washers


and frame feet.

NOTE

Discard the old frame feet, screws and washers.

d. Fit the new feet, screws and washers.


e. Place the separator in its original position 1
and fasten the central mounting bolts (1).
Tightening torque: 160 Nm.

G0874481

105
318
6 Service, dismantling, assembly

6.4.6 Lubrication of bowl parts


Apply a thin layer of Molykote, or equivalent
lubrication, on all the contact surfaces shown
in the illustration.

G09117j1

A. Molykote 1000
1. Bowl hood
2. Bowl body
3. Discharge slide
4. Operating slide
5. Holder
6. Operating water ring
7. Screw
8. Nut

106
319
6 Service, dismantling, assembly

6.5 Assembly

NG
WARNI
!
Entrapment hazard
To avoid accidental start, switch off and lock power
supply before starting any assembly work.

107
320
6 Service, dismantling, assembly

6.5.1 Centrifugal clutch


1. Assembly of the coupling.

a. Slip the belt pulley (1) over the coupling


hub and place them on a firm and level
foundation.

NG
WARNI
!
Disintegration hazard
If the belt pulley must be renewed, check that
the new pulley has the correct diameter. An
incorrect pulley will cause the separator bowl
to run at either an excessive or insufficient
speed.

d=252 mm 50 Hz
d=210 mm 60 Hz

NOTE

Remove rust from the belt pulley using a


steel brush.

b. Apply a thin film of oil onto the external


and internal surfaces of the ball
bearings (2). [o]

c. Press the ball bearings (2) down one at


a time into the coupling hub, preferably
using a hydraulic press. Place the
spacing ring (4) between them.

NOTE

Never re-fit used ball bearings.


G08656a1

The ball bearings must not be heated as 1. Belt pulley


they are packed with grease and sealed with 2. Ball bearing
plastic membranes. 3. Mounting tool
4. Spacing ring
d. Fit the snap rings (5). [o] 5. Snap ring

108
321
6 Service, dismantling, assembly

2. Fitting the coupling to the motor.

NOTE

Make sure that the key (1) is in place on the motor


shaft. 1

2
NOTE 3
See mounting with optional hydraulic puller tool
(if purchased) on next page.

a. Clean the motor shaft and apply a thin


oil film.

b. Apply lubricating paste to the tool


threads (2). Keep the threads
lubricated. 4

NOTE

Left hand thread!


5 6 7
c. Remove the brass plug (3).

d. Fasten the sleeve of the tool to the


motor shaft with the screw (4) on the
tool.

e. Use a spanner to turn the nut on the 8


tool. This will press the centrifugal
clutch on to the shaft. Remove the tool.

f. Install and tighten the washer (5),


spring washer (6) and screw (7).

g. Attach a socket with extension rod and


9
handle (8) to the screw.
G08654Z1

h. Place a piece of wood (9) according to 1. Key


the illustration. 2. Threads
3. Brass plug
i. Push the handle to start the rotor 4. Screw
moving. When the handle hits the piece 5. Washer
of wood, the weight and movement of 6. Spring washer
the rotor tightens the screw. 7. Screw
8. Socket with extension rod, and handle
j. Repeat until screw is fastened. 9. Piece of wood

109
322
6 Service, dismantling, assembly

3. Fitting the coupling to the motor with


optional hydraulic tool.

NOTE 1

Make sure that the key (1) is in place on the motor 3 4 5


2
shaft.

a. Clean the motor shaft and apply a thin


oil film.

b. Fit the sleeve (7) to the stud bolt.

Fit the stud bolt (2) with sleeve to the 6 7


motor shaft (6).

c. Screw the holder (3) to the coupling


nave.
8 9
10
d. Fit hydraulic cylinder as shown.

e. Fit the sleeve and secure with the


nut (5).

f. Attach the hose from the hand pump to 11


the hydraulic oil inlet (4)

g. Fit the friction coupling by pumping the


handle on the pump until stop

h. Release pressure on the hand pump 12


and adjust the nut on the stud bolt G08654S1

1. Key
i. Repeat procedure until coupling is
2. Stud bolt
mounted. Note! The pressure on the
3. Holder
hand pump should not exceed 200 bar.
4. Hydraulic oil inlet
5. Nut
j. Remove the hydraulic tool.
6. Motor shaft
7. Sleeve
k. Install and tighten the washer (8),
8. Washer
spring washer (9) and screw (10).
9. Spring washer
l. Attach a socket with extension rod and 10. Screw
handle (11) to the screw. Place a piece 11. Socket with extension rod, and handle
of wood (12) according to the illustration 12. Piece of wood

m. Push the handle to start the rotor


moving. When the handle hits the piece
of wood, the weight and movement of
the rotor tightens the screw.

n. Repeat until screw is fastened.

110
323
6 Service, dismantling, assembly

4. Fitting the friction blocks.

a. Fit the friction blocks (2) onto the guide


pins (1).

NOTE

Be sure that the pins on the back of the


blocks project into the grooves in the clutch
hub.

NOTE

50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks

b. Place the cover (3) in position and


secure it with the snap ring (4).

ON
CAUTI
!
Flying objects
Risk for accidental release of snap ring.
G08654x1
Wear safety goggles.
1. Guide pin
2. Friction block
3. Cover
4. Snap ring

111
324
6 Service, dismantling, assembly

5. Fitting the motor.

a. Fit a lifting sling to the motor. Use a


shackle from the separator lifting tool.
Weight of motor with coupling: approx.
84 kg.

b. Lower the motor (while supported) on


to the separator frame. It will set on the
ledge.

NG
WARNI
!
Crush hazard
If not supported, the motor with coupling
may drop when lifted.

c. Fit the screws. Do not tighten until the


belt has been mounted.

d. Connect the electrical cables.

NG
WARNI
!
G08646b1

Electrical hazard
To avoid electrical shock, switch off and lock
power supply before starting assembly work.

NOTE

If carrying out change of friction blocks only,


continue with steps 6 to 7.

If carrying out a complete machine assembly,


continue with Driving device instructions on
page 115.

112
325
6 Service, dismantling, assembly

6. Fitting the flat belt.

NOTE

Clean the inside of the frame before fitting the flat


belt, and make sure that there is no oil on the belt.

a. Lift up the belt (1) to the middle (centre)


of the spindle pulley.

NOTE
1
For correct position, centre the belt on the
spindle pulley camber.

b. Fit the flat belt to the motor belt pulley.

c. Tighten the two upper screws (3).

d. Tighten all motor attachment screws


(3).

NOTE
2
Do not turn the spindle until the motor is
tightened properly to the frame.

G08588T1

1. Flat belt
2. Clearance
3. Screw

113
326
6 Service, dismantling, assembly

7. Fitting the belt cover.

a. Fit the belt cover.

b. Tighten the screws.

2
G08581A1

1. Screw
2. Belt cover

114
327
6 Service, dismantling, assembly

6.5.2 Driving device


1. Assembling the bottom bearing holder
(where necessary)

NOTE

Clean the pipe and strainer before fitting.

NOTE

Make sure to fit the pipe the right way up!

a. Fit the pipe (1), O-rings (2,4) and


strainer (5).

b. Secure the pipe (1) with the screw (6)


secured with Loctite 222.
G1015741

1. Pipe
2. O-ring
3. Bottom bearing holder
4. O-ring
5. Strainer
6. Screw

115
328
6 Service, dismantling, assembly

2. Fitting the bottom bearing holder.

a. To secure the bottom bearing holder


(3) into the frame, apply Loctite 222 on
the surfaces directly above the upper
O-ring.

b. Thread the bottom bearing holder (3)


into the frame and fit the tool into the
bottom bearing housing.

c. Tighten the holder to a torque of


200 Nm.

G10157051

1. Socket
2. Tool
3. Bottom bearing holder

116
329
6 Service, dismantling, assembly

3. Fitting the labyrinth ring holder.

1 2
G0866381

1. O-ring
2. Labyrinth-ring

a. Lubricate and fit the O-ring (1). [o]

b. Lubricate and fit the labyrinth ring (2).


[o]

c. Fit the labyrinth ring holder into the


frame. Apply Loctite 222 to screws (3).
Fit and tighten the screws.

G08663h1

3. Screw

117
330
6 Service, dismantling, assembly

4. Fitting the ball bearing to the top bearing


seat. [o]

a. Heat the top bearing seat (1) in oil


to minimum 110 C and maximum
125 C, either using hot clean oil or 1
induction heater (induction heater is
recommended).

NG
WARNI
!
Burn hazard
Use protective gloves when handling any
heated parts.

b. Drop some oil onto the bearing and


fit the bearing (2) into the top bearing
seat.

NOTE

Always fit a new bearing.


2
Pre-lubricate before fitting.

c. Fit the snap ring (3).

ON
CAUTI
!
Risk for eye injury from flying snap 3
ring
Use the correct pliers for assembly of snap
ring to avoid accidental release.

NOTE
G0984871

Make sure snap ring is correct fitted and


slides easily in the groove. 1. Top bearing seat
2. Ball bearing
3. Snap ring

118
331
6 Service, dismantling, assembly

5. Fitting the top bearing seat with bearing to


the spindle.

a. Heat the top bearing seat (1) and


bearing to minimum 110 C and 1
maximum 125 C, either using hot clean
oil or induction heater.

NG
WARNI
!
Burn hazard
Use protective gloves when handling any
heated parts.
2
b. Wipe off the spindle and fit the top
bearing seat to the spindle using the
sleeve (3) and puller (2).
3

NOTE

Make sure to fit the bearing seat correctly


or it might get stuck!

NOTE

Be careful not to damage the vibration


indicator

G0984881

1. Top bearing seat


2. Puller
3. Sleeve

119
332
6 Service, dismantling, assembly

6. Fitting the top bearing housing.

a. Fit the axial springs (2) to the top


bearing housing. [o] 1
b. Carefully lower the bowl spindle (1).
Make sure that the springs enter the
recesses on the top bearing seat.

c. Lubricate the threads (A) and both ends


of the composite springs (B) with oil
before assembly.
2
d. Fit the composite springs (B) and plugs
to the top bearing housing. Do not
tighten the plugs. Make sure that the
springs enter the recesses in the top
bearing seat. The plugs should be
tightened when the spindle assembly is
mounted into the frame. [o]

G0866661

1. Bowl spindle
2. Axial spring

G0866651

A. Threads
B. Composite spring

120
333
6 Service, dismantling, assembly

7. Fitting the spindle pulley.

a. Screw on the cap nut on the spindle.

b. Turn the spindle assembly upside down


and let the spindle rest on the cap nut.

1
NOTE

It is of utmost importance to use cap nut


and the support as the neck bearing may be
forced out of its position and damage the
2
neck bearing when the bottom bearing is
mounted otherwise.

The cartridge has to stand on the spindle top


with a clearance of minimum 1 mm (A in the
picture) between top bearing housing and
the support.

c. Wipe off the spindle pulley seat on the


spindle (1) and nave bore in the spindle
pulley (2) with a dry cloth.

d. Fit the spindle pulley firmly on the bowl


spindle.

A
G0866771

1. Spindle
2. Spindle pulley
3. Support
4. Cap nut
A. Minimum 1 mm

121
334
6 Service, dismantling, assembly

8. Fitting the self-aligning roller bearing. [o]

a. Lubricate the bearing with clean oil.

b. Heat the bearing (1) to minimum 30 C


and maximum 50 C.

NG
WARNI
!
Burn hazard
Use protective gloves when handling any
heated parts.

c. Lower the bearing onto the spindle


and press down onto the spindle pulley
using the special drift tool.

NOTE

Always fit a new bearing.


1

G08668B1

1. Bearing

122
335
6 Service, dismantling, assembly

9. Fitting the oil mist generator.

1 2 3 2

G08669f1

1. Nozzle
2. Oil mist generator
3. Threads

NOTE

Clean the oil mist generator and nozzles before


assembly.

a. Apply Loctite 222 and screw the two


nozzles (1) into the pump (2) so that
they lie level with the pump edge using
an Allen key.

b. Lubricate all threads (3) with a few


drops of oil before assembly.

c. Fit the oil mist generator. Use a spanner


and a crowfoot wrench head together
with a torque wrench handle. Tighten
to 150 Nm.
G08669g1

Crowfoot wrench head

123
336
6 Service, dismantling, assembly

10. Fitting the fan.

a. Turn the spindle assembly to up-right


position.

NOTE

Ensure that the spindle is seated against the


inner ring of the ball bearing.

b. Apply a thin layer of oil and fit the


O-rings (1) into the fan. [o]

NOTE

Make sure that the bearing is pre lubricated


1
before fitting the fan.

c. Place a spanner (or similar) on the


spindle pulley key-grip (3), as holder-up
and fit the fan. Tighten firmly, by hand, 2
with the pin spanner (2).

G09240L1

1. O-ring
2. Pin spanner
3. Key-grip

124
337
6 Service, dismantling, assembly

11. Fitting the air deflector.

a. Turn the spindle assembly up-side


down and fit the air deflector (1).

b. Tighten screws (2).


1

G08592A1

1. Air deflector
2. Screw

125
338
6 Service, dismantling, assembly

12. Lowering the spindle assembly into the


frame.

a. Turn the assembly and remove the cap


nut from the spindle. Fit the lifting tool
(1) to the spindle assembly and lift it.

NG
WARNI
!
Crush hazard
Do not rotate the spindle assembly during
1
lifting. The spindle assembly may otherwise
come loose from the lifting tool.

NOTE

Check that the hole at the bottom of the oil


mist generator (2) and nozzles are clean
before lowering the assembly down.
2
b. Position the flat belt (3) so that the
spindle assembly can pass through
when lowering. [o]

NOTE

When replacing the belt with new one, make


3
sure it has the right article number according
to SPC.

- Check the direction arrows on the belt and


the machine plate for correct position.
- Make sure that the belt does not get
smudged with oil or grease during handling.

c. Carefully lower the spindle assembly


and position the bolt holes over the 5
threaded frame holes. Make sure that 4
the bottom bearing, enters the bottom
bearing holder (4) correctly. Do not use
force.

NG
WARNI 6
!
G0867981

Cut hazard
1. Lifting tool
Do not put fingers between the frame and air
2. Oil mist generator
deflector while lowering the assembly.
3. Flat belt
d. Fit and tighten the screws (5). 4. Bottom bearing holder
5. Screw
e. Firmly tighten the plugs (6) crosswise. 6. Plug

126
339
6 Service, dismantling, assembly

13. Fitting the flat belt.

NOTE

Clean the inside of the frame before fitting the flat


belt, and make sure that the belt is clean.

a. Lift up the belt (1) to the middle (centre)


of the spindle pulley.

NOTE
1
For correct position, centre the belt on the
spindle pulley camber.

b. Fit the flat belt to the motor belt


pulley (4).

c. Tighten the two upper screws (3).

d. Tighten all motor attachment screws (3).

NOTE

Do not turn the spindle until the motor is 2


tightened properly to the frame.

4
G08588V1

1. Flat belt
2. Clearance
3. Screw
4. Belt pulley

127
340
6 Service, dismantling, assembly

14. Fitting the neck bearing cover and deflector


ring.

G08680T1

1. Seal ring
2. O-rings
3. Neck bearing cover
4. Deflector ring

a. Apply a thin layer of oil and fit the


O-rings (2) and seal rings (1). [o]

b. Fit the neck bearing cover (3).

NOTE

The guide pin on the cover should enter one


of the two holes in the bearing housing.

c. Push the deflector ring (4) down until


it stops.

128
341
6 Service, dismantling, assembly

15. Fitting the operating water cover.

a. Check that the operating water channel


(5) is not clogged. Clean if necessary. 1
[o] 2
3

NOTE

A blocked operating water channel can lead


to failure of the separator discharge function.

b. Lubricate with oil and fit the seal ring


(1) and O-ring (3) into the operating
water cover (2). [o]

Renew the O-ring (4). [o] 4


c. Fit the operating water cover. Fit
washers and tighten the screws. 5

NOTE
4
The water pipe in the frame should enter the
hole in the cover.

G08681T1

1. Seal ring
2. Operating water cover
3. O-ring
4. O-ring
5. Operating water channel

129
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6 Service, dismantling, assembly

16. Measuring the radial wobble of the bowl


spindle.

G0858721

A=max. 0,04 mm

a. Fit a dial indicator in a support and


fasten it in position as illustrated. Use
the flat belt to turn the spindle.

NOTE

Permissible radial wobble: max. 0,04 mm.


If the spindle wobble exceeds this value,
contact an Alfa Laval representative.

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6 Service, dismantling, assembly

17. Fitting the belt cover.

a. Fit the belt cover (2).

b. Tighten the screws (1).

2
G08581A1

1. Screw
2. Belt cover

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6 Service, dismantling, assembly

18. Fill oil in the oil sump.

NOTE

The separator should be level and at standstill


when oil is filled.

a. Remove the oil pin (1), plug (3) and


washer (4).

b. Fit new washer (6) and refit the drain


plug (5). [i]

c. Fill with new oil until oil flows out from


the filler hole. For correct oil volume see
Lubricating oil volume on page 182.

NOTE 6
4
2 3
For grade and quality of oil see 6.6.6 1 5
Lubricating oils on page 168.
G08687Z1

d. Fit new O-ring (2) onto the oil pin. [i] 1. Oil pin
2. O-ring
e. Refit the plug (3) with new washer 3. Plug
(4). [i] 4. Washer
5. Drain plug
f. Fit the oil pin (1). 6. Washer

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6 Service, dismantling, assembly

6.5.3 Bowl
1. Check for impact marks and corrosion in
bowl body nave and on spindle taper.[i], [o]

a. Remove any impact marks using a


scraper and/or a whetstone.

ON
CAUTI
!
Disintegration hazard
Impact marks may cause the separator to
vibrate while running.

b. Rust can be removed by using a


fine-grain emery cloth (e.g. No. 320).

c. Finish with polishing paper (e.g. No.


600).

d. Lubricate to prevent further corrosion.

G0874621

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6 Service, dismantling, assembly

2. Fitting new valve plugs on the operating


slide. [i]

a. Carefully tap in new valve plugs, using


a clean, soft-faced hammer.

NOTE

Make sure that the plugs are fitted as


described in the illustration.

G0874871

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6 Service, dismantling, assembly

3. Fitting the guide ring. [o]

a. Pointwise apply a small amount of


silicone grease in the groove on bowl
body (2) and mount the guide ring (1)
into the groove on bowl body. Secure
that the guide ring is fully inserted into
the groove and that it is secured in its
position by the silicone grease.

NG
WARNI
!
If too much silicon grease is applied to the
guide ring there is a risk that the silicone
grease will clog the nozzles on the operating
slide.

G08610p1

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6 Service, dismantling, assembly

4. Fitting the operating slide.

a. Apply a thin layer of silicone grease


and fit the rectangular ring (6) on the
operating slide and the rectangular ring
(8) and O-ring (7) on the bowl body (3).
[i],[o]

b. Fit the operating slide (2).

NOTE

The guide pin (4) in the bowl body (3) should


enter the hole (1) in the operating slide (this
hole is marked with a drill mark).

Nozzle (5) secured with Loctite 243

NOTE

Take special care to ensure that the guide


ring (9) is not pressed out of its position in
the groove during the fitting of operating
slide.

G0861261

1. Alignment hole
2. Operating slide
3. Bowl body
4. Guide pin
5. Nozzle
6. Rectangular ring
7. O-ring
8. Rectangular ring
9. Guide ring

136
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6 Service, dismantling, assembly

5. Fitting the operating slide holder.

a. Fit the holder (1) over the operating 3 2 1


slide.

b. Apply a thin layer of molykote grease


and fit and tighten new screws (2) and
washers (3) to a torque of 30 2 Nm.
[i], [o]

NOTE

It is very important NOT to refit used screws


and washers. Always fit new ones included
in the Inspection kit!

Every washer (3) consists of two parts which


must be correctly locked together.

G0861351

1. Holder
2. Screw
3. Washer

137
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6 Service, dismantling, assembly

6. Fitting the operating water ring.

a. Assemble the seal ring (5) into the


operating water ring (2). [i], [o]

1 5
NOTE

It is very important not to refit used 2 4


screws. Always fit new ones included in the
Inspection kit!
3
b. Apply a thin layer of silicone grease and
fit the O-ring (3). [i], [o]

c. Fit the ring (2) with screws (1) onto the


bowl body. [i], [o])

NOTE
G0861461

The drilled assembly mark (4) on the water


ring (2) should face the corresponding mark 1. Screw
on the bowl body. 2. Operating water ring
3. O-ring
d. Grease, fit and tighten the screws (1) to 4. Drill mark
a torque of 30 2 Nm. 5. Seal ring

138
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6 Service, dismantling, assembly

7. Lifting the bowl body onto the spindle taper.

a. Put a drop of oil on the spindle taper (1).

b. Wipe off the spindle taper (1) and nave


bore (2) with a dry cloth.

c. Turn the bowl body over. 1


2

NG
WARNI
!
Crush hazard
Support the bowl body when turning to
prevent it from rolling.

d. Fit the lifting tool (3) and lift the bowl


body using sling and hoist.

e. Carefully lower the bowl body (4) onto


the spindle taper.

f. Remove the lifting tool.

G0861741

1. Spindle taper
2. Nave bore
3. Lifting tool
4. Bowl body

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6 Service, dismantling, assembly

8. Fitting and tightening the cap nut.

a. To prevent the bowl body from rotating 3 4


2
when fitting the cap nut; Fit one of the 1
clamps (2) to the bowl body and one of
the screws (4) for the frame hood in the
frame. Fasten a sling (1) between the
clamp and the screw around the bowl
body.

b. Apply a thin layer of molykote grease.


Fit and tighten the cap nut (3) to a
torque of 100 Nm.

NOTE
G0861891

Left-hand thread!
1. Sling
2. Clamp
3. Cap nut
4. Screw

140
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6 Service, dismantling, assembly

9. Fitting the discharge slide.

a. Apply a thin layer of silicone grease and


fit the rectangular ring (1). [i], [o] 1

b. Apply a thin layer of silicone grease and


fit the O-ring (3). [i], [o]
2
c. Fit the lifting tool (2) and lower the
discharge slide into the bowl.

NG
WARNI
!
Crush hazard
The ring on the lifting tool must be pushed
down against the discharge slide, otherwise
it may come loose from the tool.

3
d. Remove the lifting tool.

e. Fit the nut (4). 4

f. Fit the spanner for nut (5) and tighten


the nut with a torque wrench to a torque
of min. 200 Nm.

g. Remove the spanner for nut.

G0861981

1. Rectangular ring
2. Lifting tool
3. O-ring
4. Nut
5. Spanner for nut

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6 Service, dismantling, assembly

10. Assembly of the disc stack.

a. Fit the discs (1) one by one onto the


distributor. The distributor has a guide
rib (4) for the correct positioning of the
bowl discs. Always end with the disc
without caulks.

NG
WARNI 1
!
The number of discs may have to be
increased to adjust the disc stack pressure.
Always check before operating the separator.
See Checking the disc stack pressure on
page 150.

ON
CAUTI
!
Cut hazard
Sharp edges (2) on the bowl discs may cause
cuts.

G0862081

1. Bowl disc
2. Sharp edge
3. Recess on bowl disc
4. Guide rib on distributor

142
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6 Service, dismantling, assembly

11. Fitting the disc stack assembly to the bowl


body.

a. Fit the lifting tool (1) into the distributor.


1
b. Lower the disc stack into the bowl using
sling and hoist.

NOTE

The guide pin (2) on the bowl body should


face the drill mark (3) on the distributor. The
guide ribs (4) inside the distributor will then
fit the recesses (5) on the bowl body nave
in the right way.

G08621D1

1. Lifting tool
2. Guide pin on bowl body
3. Drill mark on distributor
4. Guide ribs inside the distributor
5. Recesses on bowl body nave

143
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6 Service, dismantling, assembly

12. Assembling the paring tube. [i]

a. Apply a thin layer of silicone grease to


the O-rings (1). Fit the O-rings (1) and
bearings (2) to the paring tube. [i], [o]

G09849G1

1. O-ring
2. Bearing

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6 Service, dismantling, assembly

13. Mounting the paring tube and fitting the


inlet and outlet pipe.

a. Insert the paring tube (1) to the inlet


and outlet pipe.

b. Apply a thin layer of silicone grease and


mount the splash sealing (2). [i], [o]

c. Apply a thin layer of silicone grease and


fit the O-rings (3). [i], [o]

d. Carefully lower the inlet and outlet pipe


assembly into the top of the distributor.
2

1
3

G08622N1

1. Paring tube
2. Splash seal
3. O-ring
4. Inlet and outlet pipe

145
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6 Service, dismantling, assembly

14. Fitting the top disc.

a. Move the paring tube (1) to the centre.

NOTE
3
To avoid damaging the paring tube, turn it
towards the centre of the pipe.
2

b. Lower the top disc (2). The drill mark


(3) on the top disc should face the guide
pin on the bowl body.
4
The guide rib (4) on the distributor
should enter one of the two larger
recesses on the top disc. 1

G08623D1

1. Paring tube
2. Top disc
3. Drill mark
4. Guide rib

146
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6 Service, dismantling, assembly

15. Fitting the bowl hood.

a. Apply a thin layer of silicone grease and


fit the O-ring (1). [i], [o] 1

b. Fit the seal ring (2). Press the ring 2


down evenly into the groove all around.
[i], [o]

c. Gently tap down the seal ring crosswise


with a soft rubber mallet, until the entire
ring is fitted all the way around.

d. Fit the compressing tool (3) and attach


lifting eyes. Lower the bowl hood so
that its recess (4) fits into the guide pin
(5) in the bowl body.

e. Remove the compressing tool.

3 4

G08624D1

1. O-ring
2. Seal ring
3. Lifting tool
4. Recess in bowl hood
5. Guide pin on bowl body

147
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6 Service, dismantling, assembly

16. Fitting the lock ring.

a. Place the lock ring (1) on the bowl hood


(4) with its guide pin (5) close to the
corresponding hole (6) in the bowl body
1
(2).
5
2

NOTE
6
Make sure that the groove in the bowl body
which retains the lock ring is clean.

b. Fit the compressing tool and compress


the disc stack by tightening the screws
(3) alternately in increments of 5 Nm up
to a maximum of 20 Nm until the lock C
ring fits into the bowl body. Do not use
excessive force or any tool to knock the
lock ring into the groove. It must be
possible to fit by hand.
3
For correct disc stack pressure see
page 150.

c. Make sure that the lock ring is fully


engaged over its full length in the
groove and does not flex anywhere.
The lock ring ends must be facing each
other with a gap between them. The
lock ring ends must not be flush or
overlap each other. 1

NOTE
2
If there is not a gap between the lock ring
ends, the lock ring is damaged and must be
replaced with a new one immediately A B

G08625a1

1. Lock ring
2. Bowl body
3. Compressing tool screw
4. Bowl hood
5. Guide pin
6. Hole for guide pin
A. Before compressing
B. Lock ring in position
C. Gap

148
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6 Service, dismantling, assembly

d. Measure gap C of lock ring and make


sure it does not exceed 3 mm.

If the lock ring gap is greater than 3 mm,


the lock ring is damaged and must be
replaced with a new one immediately.

NG
WARNI
!
Health hazard
Welding of the lock ring is not allowed, as this
can seriously affect the material strength. If
the lock ring is either worn beyond the safety
limits or incorrectly assembled it may cause
severe damage or fatal injury.

NG
WARNI
!
Health hazard
Never remove any material from the lock
ring. This may cause severe damage or fatal
injury.

e. Release the pressure on the


compressing tool and remove it.

149
362
6 Service, dismantling, assembly

17. Checking the disc stack pressure. [i]

a. Remove bowl hood, top disc and inlet 2


and outlet pipe. 1

b. Add one disc (1) to the disc stack.

c. Refit the disc without caulks (2), the top


disc and bowl hood.

NOTE

Always refit the disc without caulks on top


of the disc stack!
4
d. Fit the lock ring (3) and fully compress
the disc stack with the compressing
tool (4).

NOTE

Tighten the screws alternately in increments


of 5 Nm up to a maximum of 20 Nm.

e. If the lock ring enters the groove (5),


repeat step a-d until the lock ring does
3
not enter the groove.

f. Dismantle the bowl and remove one


disc to get the correct disc stack
pressure.

g. Assemble the bowl with inlet and outlet 5


pipe.

G0874981

1. Bowl disc
2. Disc without caulks
3. Lock ring
4. Compressing tool
5. Groove

150
363
6 Service, dismantling, assembly

6.5.4 In and outlet device


1. Fitting the frame hood. [i], [o]

a. Turn the paring tube (1) so that the


frame hood (2) can pass the paring
tube.

b. Apply a thin layer of silicone grease and


fit the O-ring (3) onto the frame hood.
[i], [o]
1
c. Lower the frame hood.

5
NOTE

Make sure to fit the frame hood groove into


the projection of the pipe (5).

NOTE

Make sure that the frame hood is mounted in 2


its correct position according to the piping
arrangement.

d. Fit and tighten the screws (4).


3

G08637K1

1. Paring tube
2. Frame hood
3. O-ring
4. Screw
5. Frame hood groove / Projection of pipe

151
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6 Service, dismantling, assembly

2. Control measurement of paring disc height.


[o]

a. Remove the guide screw (A).

b. Measure the distance D through the


screw hole.

Assemble the correct number of height


adjusting rings (B) according to the list.

- 29 0,5 mm, 3 rings


- 28 0,5 mm, 2 rings
- 27 0,5 mm, 1 ring
c. Refit the guide screw (A)

B A

D
( 2)

G09115T1

A. Guide screw
B. Height adjusting rings

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6 Service, dismantling, assembly

3. Fitting the spring and arm. [o]

a. Fit the spring (2) on the arm (3) and fit


the arm to the top of the paring tube
end (4) with the screw (1).

b. Fit the spring to the pin (5) on the frame


hood and make sure that it is properly
attached on both ends.

1 2

5 4

G08637l1

1. Screw
2. Spring
3. Arm
4. Paring tube
5. Pin

G08637r1

A. Spring correctly fitted,


Spring hook opening facing towards paring tube.
B. Spring wrongly fitted,
Spring hook opening facing away from paring tube.

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6 Service, dismantling, assembly

4. Fitting the connecting housing.

a. Lubricate the inlet pipe thread.


2
b. Fit the connecting housing (1) over the
inlet/outlet pipe.

NOTE
1
Make sure that the screw, on top of the frame
hood, enters the guide hole at the underside 3
of the connecting housing.

c. Lubricate the lock nut threads.

d. Fit the washer (3) and the lock nut (2)


using the hook spanner.

NOTE

Fine threads on the pipe. Make sure that G0863981

the lock nut has entered the pipe threads


1. Connecting housing
correctly before tightening with the hook
2. Lock nut
spanner.
3. Washer

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6 Service, dismantling, assembly

6.5.5 Unbalance sensor


(optional)
1. Fitting the unbalance sensor holder.

a. Remove the cover (1).

b. Fit the O-ring (3) on the holder (2).


1
Fit the screw (4) into the holder and
mount the holder into the separator
frame (6).

NOTE 2

If removing the sensor holder; use a M10 screw


as a puller.

NOTE

See next page for fitting and correct adjustment


of the sensor.

6
4

5 3
G08734G1

1. Cover
2. Sensor holder
3. O-ring
4. Screw M8
5. Sensor arm
6. Frame
A. M10

155
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6 Service, dismantling, assembly

2. Adjusting the unbalance sensor

a. Fit the sensor (1) into the holder. Do


not forget the nut (2).

b. Adjust the sensor so that a value of 1,5


appears on the display.

c. When correct distance is achieved


tighten the nut against the holder. Fit
the cover (see previous page).

1 2

3
4 G 6
A
5

G08734H1

1. Sensor
2. Nut
3. + = brown or red
4. J = black or white
5. OV = blue
6. 24 V DC

156
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6 Service, dismantling, assembly

6.5.6 Speed sensor (optional)


1. Adjusting the speed sensor.

a. Adjust the speed sensor.


Distance A = 81 0,1 mm.

b. Fit the sensor to the frame, see 4.4


Sensors and indicators on page 26.

G08734E1

A. Speed sensor distance

NOTE

If the sensor does not work properly, check the


distance between the sensor and the spindle belt
pulley.

Adjust the sensor to achieve measure (B) shown


below.

G08588W1

1. Spindle belt pulley


B. Distance between sensor and pulley

NOTE

The distance (B) between the sensor and the


spindle belt pulley (1) must be 2,5 0,5 mm.

157
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6 Service, dismantling, assembly

6.5.7 Actions after assembly

6.5.7.1 Control of machine plates and


safety labels

1. Check that the following signs are


attached.[o].

5
1 2

XX XX
Xxxxxxxxxxxxxxxxxx. Xxxxxxxxxxxxxxxxxxxxxxxxx
xxxxxxxx.
XX
Xxxxxxxxxxxxxxxxxxxxxxxxx XX
xxxxxxxx. Xxxxxxxxxxxxxxx.

3 4
XX XX

! WARNING
Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxx. xxxxxxxxxxxxxxxx.

XX XX
Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxxxxxxx
xxxxxxxxxx. xxxxxxxxxxxxxxx.

XX XX
Xxxxxxxxxxxxxxxxxxxxxxxxx. Xxxxxxxxxxxxxxxxxxxxx.

XX XX
Xxxxxxxxxxxxxxxx. Xxxxxxxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxxxx.
XX
Xxxxxxxxxxxxxxxxxxxxxxxxx
xxxxxx.
XXXXXXXXXXXXXXXXXXXXX XXXX
XXXX XXXXXXXXXXXX XXX XXXXXXX
XXXXX XX XXXXX XXXXXXX XXX XXX X XXX XX XXXX XXXX XX X X
XXXXX XXX X XXX XXXX XXX XX XX X X
Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx
XXXXXXXXX. XX X XXXXX XX X XXXX XXX XXX X
XXX X XXX. XXXXXX XXX XXX XXX X XXXXX XXX X
XXXX .

XXXXX XXX XXXX XXX XXXXX XXXX X


XXXX XXX XX. XXXXX X XXXXX XX X XXX XX XXX XXX XX
X.
XXXXXXX/XX,X XX

6 50Hz

7
60Hz

1. Machine plate
2. Space for label indicating representative
3. Lifting instructions
4. Safety label
5. Space for additional label for numbering of separator and function
6. Indicating direction of rotation of horizontal driving device
7. Oil type plate
8. Checkpoint instructions

158
371
6 Service, dismantling, assembly

2. Check legibility.

Following texts should be read on the


labels.

Machine plate
Separator type
Serial No / Year
Product No
Main group no
Configuration no
Designation
Max. allowed speed (bowl)
Direction of rotation (bowl)
Speed motor shaft
El. current frequency
Recommended motor power
Max. density of feed
Max. density of sediment
Max. density of operating liquid
Process temperature min./max.
Inside diameter of bowl body
Manufacturer
Service enquiries: www.alfalaval.com

Safety label
Text on label: Warning

Read the instruction manuals before installation, operation


and maintenance. Consider inspection intervals.

Failure to strictly follow instructions can lead to fatal injury.

If excessive vibration occurs, stop separator and keep bowl


filled with liquid during rundown.

Out of balance vibration will become worse if bowl is not full.

Separator must stop rotating before any dismantling work


is started.

Lifting instructions
Text on label: Read instruction manual before lifting.

159
372
6 Service, dismantling, assembly

6.6 Oil change

NOTE

The separator should be level and at standstill when


oil is filled or the oil level is checked

6.6.1 Lubricating oil


Do not mix different oil brands.

Always use clean vessels when handling


lubricating oil.

Great attention must be paid not to contaminate


the lubricating oil. Of particular importance is to
avoid mixing of different types of oil. Even a few
drops of motor oil mixed into a synthetic oil may
result in severe foaming.

Any presence of black deposits in a mineral


type oil is an indication that the oil base has
deteriorated seriously or that some of the oil
additives have precipitated. Always investigate
why black deposits occurs.

If changing from one oil brand to another it is


recommended to do this in connection with an
overhaul of the separator. Clean the oil bath
housing and the spindle parts thoroughly and
remove all deposits before filling the new oil.

NOTE

Always clean and dry parts (also tools) before


lubricants are applied.

ON
CAUTI
!
Check the oil level before start. Top up when
necessary. For correct oil volume, see Lubricating
oil in the table on page 182.

It is of utmost importance to use the lubricants


recommended in our documentation.

160
373
6 Service, dismantling, assembly

This does not exclude, however, the use of other


brands, provided they have equivalently high
quality properties as the brands recommended.
The use of other oil brands and lubricants
than recommended, is done on the exclusive
responsibility of the user or oil supplier.

Applying, handling and storing of lubricants

Always be sure to follow lubricants


manufacturer's instructions.

6.6.2 Check oil level


1. Remove the oil pin and make sure that the
oil level is above the lower end of the pin.

6.6.3 Oil change procedure


1. Remove the oil pin, plug and washer (B).

2. Place a vessel under the drain plug (C).

3. Remove the drain plug.

ON
CAUTI
! A
Burn hazard B
The lubricating oil and various machine surfaces
can be sufficiently hot to cause burns.

4. Collect the oil in the vessel.


C
5. Fit and tighten the drain plug (C).

6. Fill with new oil until oil flows out of oil filler
hole (A). Max. Min.

NOTE

For grade and quality of oil, see 6.6.6


Lubricating oils on page 168.
G08687y1

For correct oil volume, see Lubricating oil in


A. Oil fill
the table on page 182.
B. Plug and washer
C. Oil drain plug
7. Fit the washer and the oil filling plug (B).
Tighten the plug.

8. Fit the oil pin.

161
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6 Service, dismantling, assembly

6.6.4 Lubrication chart


Alfa Laval ref. 567329-02 Rev. 1

3
4

6
2

5
1

G0875481

1. Bowl spindle bearings


2. Bowl spindle taper
3. Bowl
4. Rubber seal rings
5. Friction clutch bearings
6. Electric motor
7. Plug thread

Lubricating points Type of lubricant Interval


1 Bowl spindle bearings Bowl See 6.6.6 Lubricating oils on Oil change:
spindle bearings are lubricated page 168.
by oil mist from the oil bath. Volume: 8.2 Technical data on Continuous operation:
page 182. 4000 hours
Ambient temperature:
Between 0 to +55 C Seasonal operation:
before every operating period

Short periods operation:


12 months even if total
numbers of operating hours is
less than stated above
2 Bowl spindle taper Lubricating oil, only a few drops At assembly
for rust protection.
3 Bowl: Sliding contact surfaces, Pastes specified in 6.6.5 At assembly
thread of lock nut and cap nut. Recommended lubricants on
page 164.
4 Rubber seal rings. Grease as specified in 6.6.5 At assembly
Recommended lubricants on
page 164.

162
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6 Service, dismantling, assembly

Lubricating points Type of lubricant Interval


5 Friction clutch bearings The bearings are pre-lubricated No need for extra lubrication.
with grease.
6 Electric motor Follow the manufacturers Follow the manufacturers
instructions. instructions.
7 Plug thread Lubricating oil. At assembly
(neck bearing assembly)

NOTE

Check and pre-lubricate new spindle bearings and


those that have been out of service for one months
or longer.

If the ambient temperature is below 25 at start up,


the spindle bearings that have been out of service
for a shorter period than six months must also be
prelubricated.

The lubrication chart can be complemented with more


detailed charts, showing the lubricating points in
detail and what type of lubricants to use. Instructions
related to a specific design of the machine refer to
general assembly drawings.

Instructions related to a specific design of the machine


refer to general assembly drawings

If not otherwise specified, follow the suppliers


instructions about applying, handling and storing of
lubricants.

ON
CAUTI
!
Check the oil level before start.
Top up when necessary.
Do not overfill.
Do not check the oil level when separator is running.

163
376
6 Service, dismantling, assembly

6.6.5 Recommended lubricants

Lubricant recommendation for hygienic and non-hygienic applications


Alfa Laval ref. 553217 01 Rev. 13

Lubricants with an Alfa Laval part number are approved and recommended for use.

The data in the tables below is based on supplier information.

Trade names and designations might vary from country to country. Please contact your local
supplier for more information.

Paste for assembly of metallic parts,


non-hygienic applications

Part no Quantity Designation Manufacturer Remark


537086-02 1000 g Molykote 1000 Paste Dow Corning -
537086-03 100 g Molykote G-n plus Paste Dow Corning -
537086-06 50 g
537086-04 50 g Molykote G-rapid plus Dow Corning -
Paste
- - Gleitmo 705 Fuchs Lubritech -
- - Wolfracoat C Paste Klber -
- - Dry Moly Paste Rocol -
- - MTLM Rocol -

Bonded coating for assembly of metallic


parts, non-hygienic applications

Part no Quantity Designation Manufacturer Remark


535586-01 375 g Molykote D321R Spray Dow Corning -
- - Gleitmo 900 Fuchs Lubritech Varnish or spray

164
377
6 Service, dismantling, assembly

Paste for assembly of metallic parts,


hygienic applications (NSF registered H1 is
preferred)

Part no Quantity Designation Manufacturer Remark


- - Molykote D paste Dow Corning -
537086-07 50 g Molykote P-1900 Dow Corning NSF Registered H1 (22
Jan 2004)
- - Molykote TP 42 Dow Corning -
561764-01 50 g Geralyn 2 Fuchs Lubritech NSF Registered H1 (3
Sep 2004)
- - Geralyn F.L.A. Fuchs Lubritech NSF Registered H1 (2
April 2007). German
5 Absatz 1 LMBG
approved.
554336-01 55 g Gleitmo 1809 Fuchs Lubritech -
- - Gleitmo 805 Fuchs Lubritech DVGW (KTW) approval
for drinking water (TZW
prfzeugnis)
- - Klberpaste 46 MR 401 Klber White, contains no lead,
cadmium, nickel, sulphur
nor halogens.
- - Klberpaste UH1 Klber NSF Registered H1 (26
84-201 Aug 2005)
- - Klberpaste UH1 Klber NSF Registered H1 (25
96-402 Feb 2004)
252 OKS NSF Registered H1 (23
July 2004)
- - Foodlube Multi Paste Rocol NSF Registered H1 (13
April 2001)

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6 Service, dismantling, assembly

Silicone grease/oil for rubber rings, hygienic


and non-hygienic applications

Part no Quantity Designation Manufacturer Remark


- - No-Tox Food Grade Bel-Ray NSF Registered H1 (16
Silicone grease December 2011)
Dow Corning 360 Dow Corning Tested according to
Medical Fluid and complies with all
National Formulary
(NF) requirements
for Dimethicone
and European
Pharmacopeia (EP)
requirements for
Dimeticone or Silicone
Oil Used as a Lubricant,
depending on viscosity.
569415-01 50 g Molykote G 5032 Dow Corning NSF Registered H1 (3
June 2005)
- - Geralyn SG MD 2 Fuchs Lubritech NSF Registered H1 (30
March 2007)
- - Chemplex 750 Fuchs Lubritech DVGW approved
according to the German
KTW-recommendations
for drinking water.
- - Paraliq GTE 703 Klber NSF Registered H1 (25
Feb 2004). Approved
according to WRAS.
- - Unisilkon L 250 L Klber Complies with German
Environmental Agency
on hygiene requirements
for tap water. Certified
by DVGW-KTW, WRAS,
AS4020, ACS.
- - ALCO 220 MMCC NSF Registered H1 (25
March 2002)
- - Foodlube Hi-Temp Rocol NSF Registered H1 (18
April 2001)

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6 Service, dismantling, assembly

Always follow the lubrication recommendations of the bearing manufacturer.

Grease for ball and roller bearings in electric


motors

Part no Quantity Designation Manufacturer Remark


- - Energrease LS2 BP -
- - Energrease LS-EP2 BP -
- - Energrease MP-MG2 BP -
- - APS 2 Castrol -
- - Spheerol EPL 2 Castrol -
- - Multifak EP2 Chevron -
- - Multifak AFB 2 Chevron -
- - Molykote G-0101 Dow Corning -
- - Molykote Multilub Dow Corning -
- - Unirex N2 ExxonMobil -
- - Mobilith SHC 460 ExxonMobil -
- - Mobilux EP2 ExxonMobil -
- - Lagermeister EP2 Fuchs Lubritech -
- - Rembrandt EP2 Q8/Kuwait Petroleum -
- - Alvania EP2 Shell -
- - LGEP 2 SKF -
- - LGMT 2 SKF -
- - LGFP 2 SKF NSF Registered H1 (17
Aug 2007)
- - Multis EP2 Total -

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6 Service, dismantling, assembly

6.6.6 Lubricating oils


Alfa Laval ref. 567330 01 Rev. 5

Paraffinic mineral lubricating oil, category (ISO-L-) HM 68


Trade names and designations might vary from country to country. Please contact your local
supplier for more information.

Recommended oil brands General demands


Viscosity grade (ISO 3448/3104) VG 68 / Viscosity index (ISO 2909) VI>95

Part no Quantity Designation Manufacturer


567334-01 1litres Lubricating oil Alfa Laval
567334-02 4 litres
- - Bartran 68 BP
- - Hyspin AWS 68 Castrol
- - Hydraulic oil AW 68 Chevron
- - Rando HD 68 Chevron
- - Nuto H 68 ExxonMobil
- - Mobil DTE 26 (ISO VG 68) ExxonMobil
- - Haydn 68 Q8/Kuwait Petroleum
- - Tellus Oil S2 M 68 Shell
- - Tellus Oil S3 M 68 Shell
- - HydraWay HMA 68 Statoil
- - Azolla AF 68 Total
- - Azolla ZS 68 Total

Recommended oil brands General demands, oils for use at cold start
Viscosity grade (ISO 3448/3104) VG 68 / Viscosity index (ISO 2909) VI>95

These oils should be used at cold start, when the ambient temperature is below 20C. These oils
can also be used at ambient temperatures above 20C.

Part no Quantity Designation Manufacturer


- - Energol SHF-HV 68 BP
- - Hyspin AWH(-M) 68 Castrol
- - Rando HDZ 68 Chevron
- - Univis N 68 ExxonMobil
- - Mobil DTE 10 Excel 68 ExxonMobil
- - Handel 68 Q8/Kuwait Petroleum
- - Tellus Oil S2 V 68 Shell
- - HydraWay HVXA 68 Statoil
- - Equivis ZS 68 Total
- - Elf Lubmarine Visga 68 Total

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6 Service, dismantling, assembly

Recommended oil brands Special hygienic demands


Viscosity grade (ISO 3448/3104) VG 68 / Viscosity index (ISO 2909) VI>95

Conform to U.S. Food and Drug Administration (FDA) requirements of lubricants with incidental
food contact, Title CFR 21 178.3570, 178.3620 and/or those generally regarded as safe (US 21
CFR 182).

The hygienic oil on the list is in the online NSF White Book Listing at the time of the revision of
this document. For more information about the NSF registration and up to date H1 registration, see
www.nsf.org (http://www.nsf.org/business/nonfood_compounds/)

Part no Quantity Designation Manufacturer


- - No-Tox HD oil 68 Bel-Ray
- - Lubricating oil FM 68 Chevron
- - Cygnus Hydraulic Oil 68 Chevron
- - Mobil DTE FM 68 ExxonMobil
- - Lubriplate FMO AW 350 Fiske Brothers
- - (Keystone) Nevastane AW 68 Total

Standard requirements
Other oil brands may be used as long as they fulfill the standard requirements. Please contact your
local oil supplier for more information.

Standard Designation
ISO 11158 (International standard) ISO-L-HM 68
DIN 51524 part 2 (German standard) DIN 51524 HLP 68

Standard (oils for use at cold start) Designation


ISO 11158 (International standard) ISO-L-HV 68
DIN 51524 part 3 (German standard) DIN 51524 HVLP 68

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6 Service, dismantling, assembly

6.7 Lifting instructions


Alfa Laval ref. 562604 Rev. 2

6.7.1 Lifting the separator

G08684b1

A. Weight to lift: 350 kg


B. Sling length: Min. 750 mm
1. Bolts, Tightening torque 35-45 Nm

1. Disconnect all connections.

2. Remove the inlet and outlet device, the


frame hood and the bowl according to the
instructions in 6.3 Dismantling on page 49.

NOTE

Never lift or transport the separator with the bowl


still inside.

3. Fit the lifting tool (not included in set of


tools). All four bolts on the lifting tool must
be fastened to the frame.

4. Unscrew the foundation bolts.

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6 Service, dismantling, assembly

5. Use two lifting slings to lift the separator.


Total length of each loop: minimum 1,5
metres.

6. When lifting and moving the separator,


follow normal safety precautions for lifting
large heavy objects.

NG
WARNI
!
Crush hazard
A falling separator can cause accidents resulting
in serious injury and damage.

Never lift the separator by any other method than


described in this manual.

NOTE

When lifting parts without weight specifications,


always use lifting straps with the capacity of at
least 500 kg.

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6 Service, dismantling, assembly

6.7.2 Lifting the bowl


When lifting and moving an assembled bowl,
always follow these instructions.

1. Fit the lifting tool with lifting eyes to the


bowl assembly.
A
2. Check that the lock ring is mounted
correctly before lifting the complete bowl.

3. Lift the bowl using a sling with the proper


rating.

NOTE

Never try to lift the bowl while it is still in the


1
frame. The bowl body is fastened to the frame
with the cap nut.

2
G08684A1

A. Weight to lift: 80 kg
1. Lifting eye, Tightening torque 405 Nm
2. Lock ring (Make sure that lock ring is fitted.)

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385

7 Fault finding

These fault finding instructions are for the separator only. If a fault occurs, study the System
Documentation fault finding section (if applicable).

7.1 Mechanical functions

7.1.1 Separator vibration

NG
WARNI
!
Disintegration hazard
If excessive vibration occurs, stop separator and keep
bowl filled with liquid during rundown.
The cause of the vibration must be identified and
corrected before the separator is restarted.

NOTE

Some vibration is normal during the starting and


stopping sequences when the separator passes
through its critical speed.

Cause Corrective action


Bowl out of balance due to: Dismantle the separator and check the assembly
- poor cleaning and cleaning.
- incorrect assembly
- incorrect disc stack compression
- bowl assembled with parts from other
separators
Uneven sludge deposits in the sludge space. Dismantle and clean the separator bowl.
Height position of paring disc is incorrect. Stop the separator, measure, and if necessary,
adjust the height.
Bowl spindle bent. Renew the bowl spindle.
Bearing(s) damaged or worn. Renew all bearings.
The frame feet are worn out. Renew the frame feet.
Spindle top bearing spring broken. Renew all springs.

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7 Fault finding

7.1.2 Smell
Cause Corrective action
Normal occurrence during start while the friction None.
blocks are slipping. If smell continues when separator is at full speed,
stop the separator and replace friction blocks.
Oil level in oil sump too low. Check oil level and add oil if necessary.

7.1.3 Noise
Cause Corrective action
Height position of paring disc is incorrect. Stop the separator, measure and adjust the
height.
Bearing(s) damaged or worn. Renew all bearings.

7.1.4 Speed too low


Cause Corrective action
Friction blocks are oily or worn. Clean or renew friction blocks.
Bowl is not closed or leaking. Dismantle the bowl and check.
Motor failure. Repair the motor.
Bearing(s) damaged. Renew all bearings.
Incorrect transmission parts (60 Hz belt pulley
for 50 Hz power supply). NG
WARNI
!
Stop and change the belt transmission to suit the
power supply frequency.

7.1.5 Speed too high


Cause Corrective action
Incorrect transmission parts (50 Hz belt pulley
for 60 Hz power supply). NG
WARNI
!
Stop and change the belt transmission to suit the
power supply frequency.

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7 Fault finding

7.1.6 Starting power too high


Cause Corrective action
Incorrect transmission parts (60 Hz belt pulley
for 50 Hz power supply). NG
WARNI
!
Stop and change the belt transmission to suit the
power supply frequency.
Wrong direction of rotation. Change electrical phase connections to the
motor.

7.1.7 Starting power too low


Cause Corrective action
Incorrect transmission parts (50 Hz belt pulley
for 60 Hz power supply). NG
WARNI
!
Stop and change the belt transmission to suit the
power supply frequency.
Friction blocks are oily or worn. Clean or renew friction blocks.
Motor failure. Repair the motor.

7.1.8 Starting time too long


Cause Corrective action
Friction blocks are oily or worn. Renew or clean friction blocks.
Height position of paring disc is incorrect. Stop, check and adjust the height.
Motor failure. Repair the motor.
Bearing(s) damaged or worn. Renew all bearings.

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7 Fault finding

7.2 Separating functions

7.2.1 Bowl opens accidentally


during operation
Cause Corrective action
Strainer in the operating water supply is clogged. Clean the strainer.
No water in the operating water system. Check the operating water system and make
sure the valve(s) are open.
Hoses between the supply valves and separator Correct.
are incorrectly fitted.
Nozzle in operating slide clogged. Clean the nozzle.
Rectangular ring in discharge slide is defective. Renew the rectangular ring.
Valve plugs are defective. Renew all plugs.
Supply valve for opening water is leaking. Rectify the leak.

7.2.2 Bowl fails to open for


sludge discharge
Cause Corrective action
Strainer in the operating water supply is clogged. Clean the strainer.
Water flow too low. Check the water flow
Hoses between the supply valves and separator Correct.
are incorrectly fitted.
Nozzle in operating slide missing. Fit the nozzle.
Rectangular ring in the operating slide or bowl Renew the rectangular rings.
body is defective.

7.2.3 Unsatisfactory separation


result
Cause Corrective action
Incorrect separation temperature. Adjust.
Throughput too high. Adjust.
Disc stack is clogged. Clean disc stack.
Sludge space in bowl is filled. Clean and reduce the time between sludge
discharges.
Bowl speed too low. Examine the motor and power transmission
including the belt transmission (clutch).
Bowl rotates i wrong direction. Check the electrical connections to the motor.

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7 Fault finding

7.2.4 Bowl fails to close


Cause Corrective action
Nozzle in operating slide clogged. Clean nozzle.
Hoses reversed. Adjust.
Rectangular ring in discharge slide is defective Renew rectangular ring.
Valve plugs in operating slide missing or Renew valve plugs.
defective.
No water. Turn on water supply.

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7 Fault finding
391

8 Technical reference

8.1 Product description


Alfa Laval ref. 9006113 Rev. 2

NOTE

The separator is a component operating in an integrated system including a monitoring system. If the technical
data in the system description does not agree with the technical data in this instruction manual, the data in
the system description is the valid one.

Product specification: 881203 05 02

Commercial name: S946

Application: Cleaning of fuel oil and lubrication oil.


Technical Design: Intended for marine- and land installations.
Total discharge.
Centrilock lock ring.

Directives and standards: 8.1.1 Directives and standards on page 180.

Operational limits:
Feed temperature: 0 C to 100 C
Ambient temperature: 5 C to 55 C
Maximum allowed speed: 9340 r/min.
Discharge intervals: Min. 2 minutes, max. 4 hours.
Maximum allowed density of
operating liquid: 1000 kg/m3.

Viscosity max.: 700 cSt at 50 C.

Not to be used for liquids with flashpoint below 60 C.


Risk for corrosion and erosion have to be investigated in each case by the application centre.
Remote restart allowed under certain conditions, see Interface description.

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8 Technical reference

8.1.1 Directives and standards


Alfa Laval ref. 591985 Rev. 5

Supplier: ......................................................................................................................
Supplier address: ......................................................................................................................
Separator type: ................................................................................
Product specification: ................................................................................
Configuration number: ................................................................................
Serial number: ................................................................................

Declaration of Incorporation of Partly Completed Machinery


The machinery complies with the relevant, essential health and safety requirements of:

Designation Description
2006/42/EC Machinery Directive

To meet the requirements the following standards have been applied:

Designation Description
EN 60204-1 Safety of machinery - Electrical equipment of machines. Part 1: General
requirements
EN ISO 12100 Safety of machinery - General principles for design - Risk assessment
and risk reduction
ISO 3744 Acoustics - Determination of sound power levels of noise sources using
sound pressure

Declaration of Conformity
The machinery complies with the following Directives:

Designation Description
2004/108/EC Electromagnetic Compatibility Directive

To meet the requirements the following standards have been applied:

Designation Description
EN 60204-1 Safety of machinery - Electrical equipment of machines. Part 1: General
requirements
EN 61000-6-2 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards -
Immunity for industrial environments
EN 61000-6-4 Electromagnetic compatibility (EMC) - Part 6-4: Generic standards -
Emission standard for industrial environments
EN ISO 12100 Safety of machinery - General principles for design - Risk assessment
and risk reduction

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393
8 Technical reference

The technical construction file for the machinery is compiled and retained by the authorized
person Tomas Zetterling within the Product Centre for High Speed Separators, Alfa Laval Tumba
AB, SE-14780 Tumba Sweden. By reasoned request all relevant technical documentation will be
sent by post to national authorities.

This machinery is to be incorporated into other equipment and must not be put into service until
it has been completed with starting/stopping equipment, control equipment, auxiliary equipment.
e.g. valves, according to the instructions in the technical documentation, and after the completed
machinery has been declared in conformity with the directives mentioned above, in order to fulfill
the EU-requirements.

Location: ................................................................................
Date: ................................................................................

Signature: ................................................................................
Name: ................................................................................
Title: ................................................................................

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8 Technical reference

8.2 Technical data


Alfa Laval ref. 562576 Rev. 9

Subject Value Unit


General technical data:
Motor power: 9,5 / 11 kW 50Hz/60Hz
Jp reduced to motor 10 / 6,9 kgm2 50Hz/60Hz
Gear ratio: 50 Hz 252 / 82
Gear ratio: 60 Hz 210 / 82
Alarm levels for vibration monitor, 0,3 / 0,45 mm
connection 752, 1st/2nd:
Max. bowl inner diameter: 279 mm
Min./Max. discharge interval: 2 / 240 minutes
Max. density of operating liquid: 1000 kg/m
Max. density feed/sediment: 1100 / 2425 kg/m
Min./Max. feed temperature: 0 / 100 C
Max. running time without flow, bowl 60 / 60 minutes
empty/filled:
Bowl material: AL 111 2377-02
Operating data:
Bowl speed, synchronous: 50 Hz / 60 9220 / 9220 r/min
Hz
Motor speed, synchronous: 50 Hz / 60 3000 / 3600 r/min
Hz
Maximum allowed speed: r/min
Max. power consumption, start-up: 12 kW
Power consumption, idling/max. 3 / 7,5 kW
capacity:
Starting time min./max.: 1,5 / 2,5 minutes
Stopping time min./max.: 18 / 35 minutes
Stop time without brake, average: 27 minutes
Sound power: 9,1 Bel(A)
Sound pressure: 76 dB(A)
Max. vibration level, separator in use: 9,1 mm/second (r.m.s)
Volume and Capacity data:
Maximum hydraulic capacity, bowl: 12 m/h
Bowl liquid volume: 4,3 litres
Fixed discharge volume: 4 litres
Sludge volume, efficient/total: 0,65 / 1,8 litres
Lubricating oil volume: 2,7 litres
Weight information:
Motor drive weight: 84 kg
Bowl weight: 74 kg
Separator total: 445 kg

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8 Technical reference

8.3 Connection list


Alfa Laval ref. 562527 Rev. 4

Connection Description Requirements/limits


No.

201 Inlet for process liquid


- Max. Allowed density See 8.2 Technical data on page
182.
- Allowed flow Max. 9 m/h
- Allowed temperature Min. 0C Max. 100C

206 Inlet for conditioning and displacement Fresh water


Liquid
- Instantaneous flow 1,6 litres/min
220 Outlet for light phase, clarified liquid
- Counter pressure 0-250 kPa

221 Outlet for heavy phase


- Counter pressure No counter pressure
222 Outlet for solid phase The outlet from the cyclone must
always be arranged to prevent the
cyclone from being filled up with
sludge. Solids are discharged by
gravity.
- Small discharge
- Large discharge Total discharge
- Discharge frequency Max. 24 discharge/h

375 Inlet for discharge and make-up liquid


- Quality requirements See Demand specification water
- Max. density 1000 kg/m min.
- Pressure 150 kPa
Make-up liquid
- Flow (momentary) 2,8 litres/min
- Consumption 1,7 litres/h
- Interval 5 min
- Time 3 seconds
Discharge liquid
- Flow 11 litres/min
- Consumption 0,55 litres/discharge
- Time 3 seconds
Closing liquid
- Flow 2,8 litres/min
- Consumption 0,7 litres/discharge
- Time 15 seconds
Start up closing liquid
- Flow 11litres/min
- Time 5 seconds
462 Drain of frame top part, lower

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8 Technical reference

Connection Description Requirements/limits


No.

701 Motor for separator


- Allowed frequency variation 5%
(momentarily during 5 seconds) 10%
740 Speed sensor for bowl spindle See 8.4 Interface description on
page 185.
- Type Inductive proximity switch
- Supply voltage, nominal 8V
- With sensor activated (near metal) 1,2 mA
- With sensor not activated (far from metal) 2,1mA
- Number of pulses per revolution 1

752 Position transducer for bearing holder See interface description


- Type Inductive analogue sensor
- Supply voltage 15 to 30 V DC
- Operation range (mild steel) 3,5 mm 0,25 mm
- Output current analog 4 to 20 mA
- Load resistance, RL 1 kOhm max.
760 Cover interlocking switch
- Type Mechanical limit switch
- Switch rating, resestive load, max: 3 A (at 48 V DC)
1 A (at 220 V AC)

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8.4 Interface description


Alfa Laval ref. 564834 Rev. 3

8.4.1 Scope
This document gives information, requirements,
and recommendations about operational
procedures and signal processing for safe and
reliable operation of the separator. It is intended
to be used for designing auxiliary equipment
and control systems for the separator.

8.4.2 References
This Interface Description is one complementary
document to the separator. Other such
documents that contain necessary information
and are referred to here are:
Interconnection Diagram
Connection List
Technical Data

Standards referred to are:


EN 418 Safety of machinery - Emergency
stop equipment, functional aspects -
Principles of design
EN 1037 Safety of machinery - Prevention
of unexpected start-up
EN 954-1 Safety of machinery - Safety
related parts of control systems - Part 1
General principles for design.

8.4.3 Definitions
For the purpose of this document, the following
definitions apply:
Synchronous speed: The speed the
machine will attain when it is driven by a
three phase squirrel-cage induction motor
and there is no slip in the motor and the
drive system.
Full speed: The synchronous speed minus
normal slip.

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8 Technical reference

8.4.4 Goal
To eliminate situations that can cause harm,
i.e. injury, damage to health or property and
unsatisfactory process result are e.g.:

Situation Effect
Unbalance caused by uneven sediment Too high stress on bowl and bearing system
accumulation in the bowl. which might cause harm.
Too high bowl speed. Too high stress on bowl which might cause harm.
Access to moving parts. Can cause injury to person who accidentally
touches these parts.
Insufficient cleaning of separator. Unsatisfactory product quality.
Bowl leakage. Product losses.

Information and instructions given in this


document aim at preventing these situations.

Control and supervision can be more or less


comprehensive depending on the type of used
control equipment. When a simple control unit
is used it would be impossible or too expensive
to include many of the functions specified here
while these functions could be included at nearly
no extra cost when a more advanced control
unit is used. For this reasons functions that
are indispensable or needed for safety reasons
to protect the machine and/or personnel are
denoted with shall while other functions are
denoted with should.

8.4.5 Description of separator


modes
For control purposes the operation of the
separator should be divided into different
modes. The normally used modes are
described below but other modes might exist. It
is assumed that:
The separator is correctly assembled.
All connections are made according to
Connection List, Interconnection Diagram
and Interface Description.
The separator control system is activated.

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8 Technical reference

If above conditions are not fulfilled the separator


will be in SERVICE mode.

Stand still means:


The power to the separator motor is off
The bowl is not rotating.

Starting means:
The power to the separator motor is on.
The bowl is rotating and accelerating.

Running means:
The power to the separator motor is on.
The bowl is rotating at full speed.
RUNNING is a collective denomination for
a number of sub modes which e.g. can be:

- STAND BY: Separator is in a waiting


mode and not producing.
- PRODUCTION: Separator is fed with
product and producing.
- CLEANING: Separator is fed with
cleaning liquids with the intention to
clean the separator.
Stopping means:
The power to the separator motor is off.
The bowl is rotating and decelerating.
STOPPING is a collective denomination for
a number of sub modes which e.g. can be:

- NORMAL STOP: A manually or


automatically initiated stop.
- SAFETY STOP: An automatically
initiated stop at too high vibrations.
- EMERGENCY STOP: A manually
initiated stop at emergency situations.
This stop will be in effect until it is
manually reset.

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8 Technical reference

8.4.6 Remote start


This machine may be started from a remote
location under the following conditions;
First start after any kind of service or
manual cleaning must be supervised locally
in order to ensure that no mistakes has
been made during assembly.
The unbalance sensor is mandatory for
remote start.
The installation must include equipment
to prevent unintentional start-up from
remote location when the machine is
disassembled.
The installation must include equipment to
prevent unintentional start of process flow
from remote location when the machine is
not properly connected to the piping.

8.4.7 Handling of connection


interfaces
Electrical connections
701 Separator motor.

The separator is equipped with a 3-phase DOL


- (direct on line) started motor. The separator
can also be started by a Y/D starter, but then
the time in Y-position must be maximized to 5
seconds.

There shall be an emergency stop circuit


designed according to EN 418 and a power
isolation device according to EN 1037.

There shall be a start button close to the


separator that shall be used for first start after
assembly of the separator.

There should be a counter to count number of


running hours.

There should be a current transformer to give


an analogue signal to the control unit about the
motor current.

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8 Technical reference

740 Speed sensor

A proximity sensor of inductive type according


to Namur standard is giving a number of pulses
per revolution of the bowl (see Connection List).

Signal processing in STARTING:


The separator should be stopped
automatically according to NORMAL STOP
procedure and an alarm should be given
when the accumulated time for acceleration
is longer than the maximum time specified
in Technical Data. An abnormal start time
indicates some malfunction of the separator
equipment and should be investigated.
If the speed exceeds Bowl speed,
synchronous in Technical Data with more
than 5% the separator shall be stopped
automatically by NORMAL STOP and a
high speed alarm shall be given.
The speed monitoring system shall be
checked continuously (e.g. by checking
that pulses are coming). In case of failure
indication the separator shall be stopped
automatically by NORMAL STOP with a
timer controlled stop sequence and an
alarm for speed monitoring system failure
shall be given.
The acceleration should be supervised
to ensure that a certain speed (e.g. 250
r/min.) has been reached within a certain
time (e.g. 30 seconds).

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8 Technical reference

Signal processing in RUNNING:


If the speed exceeds Bowl speed,
synchronous in Technical Data with more
than 5% for a period longer than 1 minute
or momentarily during maximum 5 seconds
more than 10% the separator shall be
stopped automatically by NORMAL STOP
and a high speed alarm shall be given.
If the speed falls more than 10% below
the synchronous speed for a period longer
than 1 minute or 15% during more than
5 seconds a low speed alarm should
be given. Low speed indicates some
malfunction of the separator equipment and
shall be investigated.
The speed monitoring system shall be
checked continuously (e.g. by checking
that pulses are coming). In case of a failure
indication an alarm for speed monitoring
system failure shall be given. If there is a
risk of too high speed the separator shall
be stopped by NORMAL STOP.
The speed drop during DISCHARGE.
compared to the measured speed
immediately before, should be between
3-8% which will indicate a proper discharge.

Signal processing in STOPPING:


STAND STILL shall be indicated when no
pulses are detected within 30 seconds.
Stopping the separator when alarm for
speed monitoring system failure is active,
shall cause a timer controlled stop. (See
Stop time in 8.2 Technical data on page
182.)

752 Unbalance sensor (optional).

For indication of any abnormal unbalance


and to be able to perform appropriate
countermeasures, the separator has been
equipped with an inductive analogue sensor
monitoring the radial position of the Top bearing
seat on the separator frame. The signal from
the sensor shall be monitored and two alarm
levels according to the vibration alarm levels in
Technical data on page 182 should be set.

The vibration level shall be high for 3 seconds to


generate an alarm. The first level is only used to
generate an alarm while the second level shall
stop the machine.

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8 Technical reference

The vibration monitor shall include self check


function to be performed at least at initiation of
STARTING.

If vibrations exceed the second alarm level the


separator shall be stopped the quickest way
possible and it shall not been restarted until the
reasons for the unbalance have been found and
measures to remove them have been taken.

Signal processing in STARTING:

If vibrations exceed the second alarm level the


separator shall be stopped automatically by
SAFETY STOP.

If the self check system triggers, an alarm shall


be given and an automatic stop by NORMAL
STOP shall be initiated.

Signal processing in RUNNING:


If vibrations exceed the first alarm level
an alarm should be given. Vibrations of
this magnitude will reduce the expected life
time of the bearings and should therefore
be eliminated.
If vibrations exceed the second alarm
level the separator shall be stopped
automatically by SAFETY STOP.
If the self check system triggers, an alarm
shall be given.

Signal processing in STOPPING:


If the self check system triggers, an alarm
shall be given.

Signal processing in NORMAL STOP:


If vibrations exceed the second level the
system shall turn over automatically to
SAFETY STOP.

760 Cover interlocking switch (optional)


The separator is equipped with a interlocking
switch to detect if the cover is mounted.

Signal processing in STAND STILL:


The circuit is closed when the cover of the
separator is mounted.
The interlocking switch should be
connected in such a way that starting of
the motor is prevented when the separator
cover is not mounted.

191
404
8 Technical reference

Signal processing in STARTING, RUNNING and


CLEANING:
If the circuit is broken the separator should
be stopped automatically by NORMAL
STOP. This is to minimise the risk of having
access to moving parts.

Fluid connections
Complementary information is given in the
document Connection List.

201 Inlet

Processing in STAND STILL:


Shall be closed.

Processing in STARTING:
Should be closed. Bowl will be open and
empty or closed and filled depending on
if start is done from STAND STILL or
STOPPING.

Processing in RUNNING:
Could be closed or open.

Processing in CLEANING:
A sequence of cleaning liquids should be
fed to the separator. The flow rate should
be as high as possible and preferably not
less than the production flow rate.

Processing in NORMAL STOP or EMERGENCY


STOP:
Could be closed or open but the bowl
should be filled unless the stop is initiated
in STARTING.

Processing in SAFETY STOP:


Could be closed or open but the bowl
shall be filled unless the stop is initiated in
STARTING.

206 Inlet for conditioning and displacement


liquid
According to process

220, 221 and 222 Outlets

Processing in STAND STILL:


Could be closed or open.

Processing in other modes:


Shall be open.

192
405
8 Technical reference

375 Inlet for discharge and make-up liquid

Processing in all modes:


It is recommended to supervise the
supply pressure. If pressure is too low (see
Connection List), start should be interlocked
and if it happens in PRODUCTION or
CLEANING turn over to STAND BY should
take place.

Signal processing in STARTING:


Below 85 % of synchronous bowl speed no
water supply may be made.
When coming from PRODUCTION a
discharge shall be initiated to remove
sediment from bowl to avoid problems due
to solidification, see Connection List.

Signal processing in PRODUCTION:


Automatic discharges shall be initiated by
timer or ALCAP system.

Signal processing in CLEANING:


Automatic discharges shall be initiated by
timer or CIP-control system.

Signal processing in NORMAL STOP:


Discharges should not be made.

Signal processing in SAFETY STOP and


EMERGENCY STOP:
Discharges should not be made.

193
406
8 Technical reference

8.5 Demand specification water


Alfa Laval ref. 574487 Rev. 2

Operating water is used in the separator for


several different functions: e.g. to operate the
discharge mechanism, to lubricate and cool
mechanical seals.

Poor quality of the operating water may cause


erosion, corrosion and/or operating problem in
the separator and must therefore be treated to
meet certain demands.

NOTE

Alfa Laval accepts no liability for consequences


arising from unsatisfactorily purified operating water
supplied by the customer.

The following conditions must be fulfilled:


1. Turbidity free water, solids content <0.001%
by volume.
Deposits must not be allowed to form in
certain areas in the separator.
2. A maximum particle size of 50 m.
3. A total hardness of <180 mg CaCO3 per
litre, which corresponds to 10dH or 12.5E.
Hard water may with time form deposits in
the operating mechanism. The precipitation
rate is accelerated with increased operating
temperature and low discharge frequency.
These effects become more severe as the
hardness of the water increase.
4. A chloride content of maximum 100 ppm
NaCl (equivalent to 60 mg Cl/l).
A chloride concentration above 60 mg/l is
not recommended.
Chloride ions contribute to corrosion on
the separator surface in contact with the
operating water, including the spindle.
Corrosion is a process that is accelerated
by increased separating temperature, low
pH, and high chloride ion concentration.
5. 6.5 < pH < 9
Increased acidity (lower pH) increases the
risk for corrosion; this is accelerated by
increased temperature and high chloride
ion content.
6. A bicarbonate content (HCO3) of minimum
70 mg HCO3 per litre, which corresponds
to 3.2dKH.

194
407
8 Technical reference

8.6 Drawings

8.6.1 Basic size drawing


Alfa Laval ref. 562557 Rev. 3

G1028631

A. Tightening torque 160 Nm.


B. Maximum horizontal displacement at the inlet and outlet connections during operation 5 mm.
C. Maximum vertical displacement at the sludge connection during operation 2 mm.
D. M10, depth 30
E. 28, depth 45
F. 22, depth 45
G. M10, depth 30
H. 28, depth 45

Connection house, with connections 201, 220


and 221, turnable in 60 steps all around.

All connections to be installed non-loaded and


flexible.

All dimensions are nominal. Reservation for


individual deviations due to tolerances.

195
408
8 Technical reference

8.6.2 Foundation drawing


Alfa Laval ref. 562553 Rev. 2

F
E

I
J
K
L
G M

H N
C
A
B
G1028771

A. Centre of separator bowl.


B. Holes for foundation bolts (8x).
C. Centre of motor.
D. Min. lifting capacity required during service: 300 kg.
E. Max. height of largest component incl. lifting tool.
F. Service side.
G. Foundation bolts.
H. Installation according to stated foundation force.
I. Recommended free floor space for unloading when doing service.
J. No fixed installation within this area.
K. Centre of gravity (complete machine).
L. Dynamic forces (static force excluded) from separator do not exceed:
L. Force in any separator foot:
L. Vertical 12 kN
L. Horizontal 12 kN
M. Total foundation force (sum of all feet)
M. Vertical 12 kN
M. Horizontal12 kN
N. Total static load max. 4,5 kN

Total static load max 4,5kN.

196
409
8 Technical reference

8.6.3 Interconnection diagram


Alfa Laval ref. 561786 Rev. 5

760
BU

BK
BN
PU
RD

GN
YW
WT

752
BU
BN

1
2
3
4
5
6
7
8

740
BU
BN
BU
BK
BN
BK

RD
GN

1
DC
-
+

A B
N
J S

740 752 760

G1019311

A: Wiring without junction box Wiring of connector X: Wire colour codes:


B: Junction box RD=A BK=Black
740: Speed sensor BU=B BN=Brown
WT=C BU=Blue
752: Unbalance sensor, (position
YE=D RD=Red
trans. for bearing holder)
GN=E GN=Green
760: Interlocking switch (frame top BK=F PU=Purple
part) BN=G YE=Yellow
PU=H WT=White

Demand specification wire


Approval: UL 1007/1569
CSA TR-64
Area acc. to AWG 18
Items showed in this document are not included in all separators. See product specification.

197
410
8 Technical reference

8.6.4 PX sealing diagram


Alfa Laval ref. 562559 Rev. 2

2,4

A
2,2

1,8

1,6

1,4

1,2

B
1

0,8
C
0,6
0,6 0,8 1 1,2 1,4 1,6 1,8 f
G08697j1

A. No sealing
B. Operational envelope
C. Non physical

Separator bowl speed: 9220 r/min

Separator bowl number: 56190403

References density for Feed: 1100 kg/m3

References density for Wet solids: 2425 kg/m3

NOTE

Max. allowed operating liquid density: 1000 kg/m3

198
411
8 Technical reference

8.6.5 Electric motor


Alfa Laval ref. 599764 Rev. 1

G1039421

Manufacturer: ABB Type of mounting Degree of


protection
Type: M3AA132SMB2 IEC 34-7 IEC 34-5
Poles: 2
IM2111 IP 55
G0541421

Bearings D-end 63082Z/C3


N-end 62062Z/C3

NOTE

For complete information about motor variants, please contact your Alfa Laval representative.

199
412
8 Technical reference

Alfa Laval ref. 562534 Rev. 11

G10288b1

Manufacturer: ABB Motors Type of mounting Degree of


protection
Type: M2AA 132 SC2 IEC 34-7 IEC 34-5
Poles: 2
IM 2111 IP 55
G0541421

Bearings: D-end 6208-2Z/C3


N-end 6208-2Z/C3

NOTE

For complete information about motor variants, please contact your Alfa Laval representative.

200
413

9 Installation

9.1 Introduction
The installation instructions are specifications,
which are compulsory requirements.

Any specific requirements from classification


societies or other local authorities must be
followed.

NOTE

If the specifications are not followed, Alfa Laval can


not be held responsible for any malfunctions related
to the installation.

201
414
9 Installation

9.2 Upon arrival at the storage area


Ensure that the separator delivered is suitable
for the application.

9.2.1 Transport
1. When lifting the separator, make sure
that tools and lifting devices are fastened
securely. See 6.7.1 Lifting the separator
on page 170.

NG
WARNI
!
Crush hazard
Use correct lifting tools and follow lifting
instructions.

2. When lifting the bowl see 6.7.2 Lifting the


bowl on page 172.

3. During transport of the separator, the in-


and outlet device, frame hood and bowl
must always be removed.

G0873591

202
415
9 Installation

9.2.2 Protection and storage of


goods
1. The separator must be stored indoors at 5 -
55 C, if not delivered in a water-resistant
box, designated for outdoor storage.

G08736B1

2. If there is a risk for water condensation, the


equipment must stand well ventilated and
at a temperature above dew point.

3. If the storage time exceeds 12 months,


the equipment must be inspected every 6
months and, if necessary, the protection be
renewed.

The following protection products are recommended:


1. Anti-rust oil (Dinitrol 112 or equivalent) with long lasting effective
treatment for external surfaces. The oil should prevent corrosion
attacks and leaves a waxy surface.
2. Anti-rust oil (Dinitrol 40 or equivalent) is a thin lubricant for inside
protection. It gives a lubricating transparent oil film.
3. Solvent, e.g. white spirit, to remove the anti-rust oil after the
storage period.
4. Moist remover to be packed together with the separator
equipment.

203
416
9 Installation

9.3 Planning of installation

9.3.1 Important measurements

G0873711

Important measurements are:


- minimum lifting height for lifting bowl parts
- shortest distance between driving motor
and wall
- space for control and operation
- free passage for dismantling and assembly
- space for maintenance work
- space on floor for machine parts during
maintenance work

For more detailed information, see 8.6.1 Basic


size drawing on page 195 and 8.6.2 Foundation
drawing on page 196.

204
417
9 Installation

9.3.2 Maintenance service

G08738N1

A work bench should be installed in the


separator room.

Hot water, compressed air and diesel oil should


be available near the work bench to make
maintenance work easier.

An overhead hoist with capacity of 300 kg


is required for transport of bowl parts to the
working bench. Lifting point should be above
the centre of the separator.

NOTE

When two or more separators are installed, the lifting


height should be increased to enable bowl parts from
one separator to be lifted and moved over an adjoining
separator.

See 8.6.2 Foundation drawing on page 196.

205
418
9 Installation

9.3.3 Connections to
surrounding equipment
Local safety regulations
If the local safety regulations prescribe that the
installation has to be inspected and approved
by responsible authorities before the plant is put
into service, consult with such authorities before
installing the equipment and have the projected
plant design approved by them.

G0873911

Service media
Ensure that all service media (electric power,
operating and safety liquids etc.) required for the
separator have the correct quality and capacity.

G0874021

Sludge discharge tank


If the sediment from the separator is discharged
into a tank, this tank must be sufficiently
ventilated. The connection between the
separator and the tank must be of the size
and configuration specified. If the solids are
discharged from the separator bowl casing into
a closed system, ensure that this system cannot
be overfilled or closed in such a way that the
solids cannot leave the bowl casing. This could
cause a hazardous situation.

G0874311

206
419
9 Installation

9.4 Storage at out of operation


If the separator is out of operation for more than
1 month:

1. Lift out the bowl.

2. Protect the spindle taper from corrosion by


lubricating it with oil.

3. Keep the separator and bowl well stored,


dry and protected from mechanical
damage.

For details see 9.2.2 Protection and storage of


goods on page 203.

9.5 Before start-up


If the separator has been out of operation for:

1 months or longer

Pre-lubricate the spindle bearings if the


ambient temperature at start up is below
25C

6 months or longer

Perform an Inspection service [i] and make


sure to pre-lubricate the spindle bearings.
Change the oil before starting.

18 months or longer

Perform an Overhaul service [o] and make G0868741

sure to pre-lubricate the spindle bearings.


Change the oil before starting.

See 6.6.4 Lubrication chart on page 162.

207
420

S 946

Specification No. 881203-05-02/2


Book No. 9007138 02 Rev. 4
421
.S 946
Spare Parts Catalogue

Specification No. 881203-05-02/2


Book No. 9007138 02 Rev. 4

Spare parts catalogue Catalogo parti di ricambio


Reservdelskatalog Catalogo de pecas sobressalentes
Ersatzteilkatalog Varaosaluettelo
Catalogue de pices de
rechange
Catalogue de piezas de Reserveonderdelen-catalogus
recambio
Reservedelskatalog

422

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden

Telephone: +46 8 530 650 00


Telefax: +46 8 530 310 40

Alfa Laval Tumba AB 2013-09-12


Original instructions
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of
Alfa Laval Tumba AB.
423

Contents
1 Read this first 5
1.1 General information 6
1.2 Translation list 9

2 Machine bottom part 12


2.1 Driving device vertical 14
2.2 Monitoring kit, for speed 16

3 Separator bowl 18

4 Inlet and outlet device 20

5 Belt driving device 22


5.1 Centrifugal clutch 24

6 Set of plates 26

7 Monitoring kit, for vibration 28

8 Set of tools 30

9 Inspection kit 32

10 Overhaul kit 34

11 Lifting tool 36

12 Support kit 38

13 Cover interlocking kit 40

14 Hydraulic tool kit 42


14.1Hydraulic components 44

3
424

14.2Hydraulic tool 46

15 Motor service kit 48

16 Motor service kit 50

17 Cross reference list 52

4
425

1 Read this first

1 Read this first

Check the machine unit number on the name-plate before using this catalogue

Kontrollera maskinenhetens nummer p maskinskylten innan du anvnder katalogen

Das Typenschild - ein Hinweis zur korrekten Ersatzteilnummer

La plaque de la machine, un guide pour trouver le numro de pice de rechange correct

La placa-marca de la mquina - gua del nmero correcto del repuesto

La targhetta della macchina - guida al corretto numero dei ricambi

La placa do fabricante da mquina - um guia do nmero correto das partes sobressalentes

Konekilpi - opastin oikeaan varaosanumeroon

Het gegevensplaatje - een wegwijzer naar het juiste onderdeelnummer

Typeskiltet - en guide til det rette reservedelsnummer

5
426
S 946

1.1 General information

Safeguard your commitment to quality by always using genuine


Alfa Laval spare parts.
Remember, Alfa Laval cannot accept responsibility for the
failure of a separator equipped with non-original spare parts.
We guarantee the quality and reliability of our products.

Flj ditt kvalitetstnkande genom att endast anvnda Alfa Laval


originalreservdelar.
Kom ihg att Alfa Laval inte tar ngot ansvar fr fel p en
separator, som innehller icke-originaldelar. Vi garanterar
kvaliteten och driftskerheten endast hos vra egna produkter.

Aus Rcksicht auf Ihr Bestreben um beste Qualitt sollten Sie


nur Alfa Laval Originalersatzteile benutzen.
Vergessen Sie nicht, Alfa Laval kann keine Verantwortung fr
das Versagen eines Separators bernehmen, der nicht mit
Originalersatzteilen versehen ist. Wir garantieren Qualitt und
Zuverlssigkeit unserer Produkte.

Prservez la qualit de vos quipments en nemployant que des


pices de rechange Alfa Laval.
Noubliez pas qAlfa Laval dcline toute responsabilit en cas
de panne dun sparateur non quip de pices de rechange
dorigine. Nous garantissons la qualit et la fiabilit de nos
produits.

Mantenga su compromiso con la calidad, al usar siempre piezas


de repuesto Alfa Laval autnticas.
Recuerde que Alfa Laval no acepta responsabilidad por el
fallo de una separadora equipada con piezas de repuesto no
originales. Garantizamos la calidad y fiabilidad de nuestros
productos.

6
427

1.1 General information 1 Read this first


Alfa Laval.
, Alfa Laval
,
.
.

Salvaguardate la vostra garanzia di qualit facendo sempre uso


di parti di ricambio Alfa Laval autentiche.
Tenete presente che la Alfa Laval non pu accettare
responsabilit per avaria ad un separatore attrezzato con parti
di ricambio non originali. Noi garantiamo la qualit laffidabilit
dei nostri prodotti.

Proteja o seu cometimento a qualidade usando sempre peas


sobressalentes genuinas Alfa Laval.
No esquea que Alfa Laval no aceita responsabilidade por
falha de uma separadora equipada com peas sobressalentes
no genuinas. Ns garantimos a qualidade e a confiana dos
nossos produtos.

Varmistakaa vastuunne laadusta kyttmll aina alkuperisi


Alfa Laval varaosia.
Muistakaa, Alfa Laval ei voi hyvksy vastuuta ei-alkupersill
varaosilla varustetun separaattorin vaurioista. Me takaamme
tuotteidemme laadun ja kyttvarmuuden.


Alfa Laval.
Alfa Laval
,
.
.

7
428
S 946

Streef naar een zo hoog mogelijke kwaliteit en gebruik


uitsluitend originele Alfa Laval reserveonderdelen. Streef naar
een zo hoog mogelijke kwaliteit en gebruik uitsluitend originele
Alfa Laval reserveonderdelen.
Vergeet niet dat Alfa Laval niet verantwoordelijk is voor een
defecte separator die niet-originele onderdelen bevat. Wij
garanderen de kwaliteit en betrouwbaarheid van onze eigen
produkten.

Hold Dem til den kvalitet, De har valgt at satse p, ved altid at
anvende gte Alfa Laval reservedele.
Husk, at Alfa Laval ikke kan ptage sig noget ansvar for fejl
p en separator, som indeholder uoriginale dele. Vi kan kun
garantere kvalitet og driftsikkerhed p vore egne produkter.

8
429

1.2 Translation list 1 Read this first

1.2 Translation list

versttningslista
bersetzungsliste
Liste de traduction
Lista de traducciones

Part no. Reservdelsnummer Teil-Nr. Numro de pice Pieza No.

Qty Antal Anzahl Quantit Cantidad

Description Benmning Bezeichnung Dnomination Descripcin

Notes Anmrkningar Anmerkungen Remarques Notas

Machine type Maskintyp Maschinentyp Type de machine Tipo de mquina

Product no. Produktnr Produktnummer Numro de produit Nmero de producto

Machine unit description Maskinblocksbenmning Bezeichnung des Dnomination de partie Descripcin de seccin de
Maschinenblocks de machine la mquina

Machine unit no. Maskinblocksnr Maschinenblock Nr. Partie de machine n No. de seccin de
mquina

Subassembly description Undergruppsbenmning Bezeichung der Dnomination de Descripcin de


Untergruppe sous-ensemble subconjunto

Subassembly no. Undergruppsnr Untergruppe Nr. N de sous-ensemble Nmero de subconjunto

See page Se sidan Siehe Seite Vir page Vase la pgina

Fig. ref. Figurhnvisning Bildhinweise Rf. de fig. Referencia de figura

Product name Produktnamn Produktname Nom du produit Nombre del producto

Exchange necessitates Utbyte ndvndiggr Austausch erfordert Le remplacement El racmbio requiere el


rebalancing of bowl ombalansering av kulan Wiederauswuchtung der ncessite le rquilibrage reequilibrado del rotor
Trommel du bol
See separate spare parts Se separat reservdelslista Siehe separate Voir liste spare des Vase la lista de piezas
list Ersatzteilliste pices de rechange separada

Not delivered as spare Levereras ej som Nicht als Ersatzteil Non livr comme pice de No se entrega como pieza
part reservdel geliefert rechange de recambio

9
430
S 946


Lista traduzioni
Lista para traduo
Knnsluttelo

Part no. Nr. parte Numero de peca Varaosanumero

Qty Quantita Quantidade Lukumr

Description Descrizione Descricao Nimitys

Notes Note Notas Huomautuksia

Machine type Tipo macchina Tipo de maquina Konetyyppi

Product no. Nr.prodotto No. do produto Tuotteen no

Machine unit description Descrizione unita Descricao da unidade da Koneenosan nimitys


macchina maquina

Machine unit no. Nr. unita macchina Numero de unidade da Koneenosan no


maquina

Subassembly description Descrizione sottogruppo Descriao do subconjunto Alaryhmn nimitys

Subassembly no. Nr. sottogruppo Nmero de subconjunto Alaryhmn no

See page . Vedi pagina Vase la pgina Ks sivu

Fig. ref. Rif. fig. Referencia de figura Kuvaviite

Product name Nome prodotto Nombre del producto Tuotteen nimi

Exchange necessitates La sostituzione comporta El racmbio requiere el Vaihdettaessa kuula


rebalancing of bowl la equilibratura del reequilibrado del rotor tasapainoitettava
tamburo uudelleen
See separate spare parts . Vedi lista separata delle Vase la lista de piezas Katso erillist
list parti di ricambio separada varaosaluetteloa

Not delivered as spare Non fornito come parte di No se entrega como pieza Ei toimiteta varaosana
part ricambio de recambio

10
431

1.2 Translation list 1 Read this first

Vertaallijst
Oversttelseliste

Part no. Onderdeelnr. Reservedelsnummer

Qty Hoeveelheid Antal

Description Beschrijving Betegnelse

Notes Opmerkingen Bemaerkninger

Machine type Machinetype Maskintype

Product no. Produktnr. Produktnr.

Machine unit description Machineblokbenaming Maskinbetegnelse


Machine unit no. Machineblokbenamning Maskinnr.


Subassembly description Subgroepbenamning Undergruppsbetegnelse

Subassembly no. Subgroepnr. Undergruppenr.

See page Zie blz. Se side

Fig. ref. Afb. ref. Figurhenvisning

Product name Produktnaam Produktnavn

Exchange necessitates Vervangning vereist Udskriftning kraever


rebalancing of bowl herbalanceren van de kogel afbalcering af kuglen

See separate spare parts list Vervangning vereist van de Se spaat reservedelsliste
kogel

Not delivered as spare part Niet geleverd als Levereres ikke som reservedel
reserveonderdeel

11
432
S 946

2 Machine bottom part


Machine unit number or
Subassembly description
589650-
Ref Part No Description -01 Notes
Quantity
1 562962 80 Frame bottom part 1
1A 2522302 09 Square plug 2
2 560131 02 Frame support 4
3 70490 Washer 4
4 2210462 32 Screw 4
5 552766 07 Washer 2
6 526350 04 Plug 1
8 586732 01 Bottom bearing holder 1
9 2234121 38 O-ring 1
10 562091 01 Strainer 1
11 589704 01 Pipe 1
12 221706 03 Screw 1
13 2234121 40 O-ring 1
14 562094 01 Labyrinth ring holder 1
15 562095 02 Labyrinth ring 1
16 223412 23 O-ring 1
17 221716 23 Screw 2
18 589649 80 Driving device vertical 1 See page 14
19 221721 25 Screw 3
20 561950 80 Neck bearing cover 1
20A 221711 18 Screw 1
21 223412 48 O-ring 1
22 566788 01 Seal ring 2
23 565056 04 Deflector ring 1 Brass
23 598744 01 Deflector ring 1 SS.
24 223406 29 O-ring 2
25 560202 01 Pipe 1
26 223404 20 O-ring 1
27 539418 02 Elbow 1
28 526352 06 Bushing 1
29 564591 02 Operating water cover 1
30 41456 Washer 3
31 221040 46 Screw 3
32 566718 82 Monitoring kit, for speed 1 See page 16
34 221716 23 Screw 1
35 561773 03 Plug 1 Stainless Steel
35 561773 07 Plug 1 Brass
36 74067 O-ring 1
37 221716 23 Screw 1
38 579885 80 Front casing 1
38A 579884 02 Holder 1
38B 579885 01 Front casing 1
38C 221716 22 Screw 4
38D 221721 37 Screw 4
49 566788 06 Seal ring 1
51 223404 05 O-ring 1
52 565378 01 Plug 1
53 571743 80 Oil pin 1
54 223412 48 O-ring 1
55 221040 08 Screw 2
56 17812 Screw 2
57 221126 04 Screw 1
58 532333 03 Clamp 2
59 223101 94 Washer 1
60 221125 20 Screw 1

12
433

2 Machine bottom part

49 31
55 30
29
54
26
24
25 23
27 22
28 20
21
20A
19

18

17
14
16 A
15
11
13
8
12
9
10
5
52
53
51

35 5
6

36
37
4 57; 60
3 59
34
58
A
38B
1; 1A 56
38
2
2052S

32
38A
38C 38D

13
434
S 946

2.1 Driving device vertical


Machine unit number or
Subassembly description
589649-
Ref Part No Description -80 Notes
Quantity
1 561977 01 Bowl spindle 1
2 548747 10 Single row ball bearing 1
3 584150 80 Top bearing seat 1
4 223642 38 Snap ring 1
5 580044 02 Top bearing housing 1
6 562109 03 Helical spring 3
7 562110 02 Composite spring 6
8 560406 01 Plug 6
9 564149 01 Spindle pulley 1
10 548744 03 Self-align roller bearing 1
11 545869 03 Nozzle 1,5 mm 2
13 586513 01 Oil mist generator 1
14 565057 02 Fan 1 Brass
14 599092 01 Fan 1 Steel
15 580042 01 Air deflector 1
16 221716 22 Screw 3
17 223406 29 O-ring 2
99 9000794 01 Bearing Grease 0

14
435

2.1 Driving device vertical 2 Machine bottom part

17
14
4

2
3
6
7
8
5

16
15

10

13
11
2275B

15
436
S 946

2.2 Monitoring kit, for speed


Machine unit number or
Subassembly description
566718-
Ref Part No Description -82 Notes
Quantity
1 562902 81 Sensor with support 1
3 552870 41 Tube gland, angle 90 degr 1
5 556416 14 Protective tube 1
6 566692 80 Junction box 1

16
437

2.2 Monitoring kit, for speed 2 Machine bottom part

1
3

5
6
1904E

17
438
S 946

3 Separator bowl
Machine unit number or
Subassembly description
9006111-
Ref Part No Description -01 Notes
Quantity
1 597752 80 Bowl body 1
1A 597752 01 Bowl body 1
1B 560637 01 Guide lug 1
1C 68564 Cylindrical pin 1
2 560638 05 Rectangular ring 1
3 561831 01 Operating slide 1
4 545869 03 Nozzle 1,5 mm 1
5 560638 05 Rectangular ring 1
6 565308 01 Valve plug 3
7 576397 01 Holder 1
8 576173 05 Hexagon head screw 12
8.1 576279 01 Lock washer 6
9 68011 O-ring 1
10 579464 02 Operating water ring 1
11 546095 77 O-ring 1
12 574233 01 Discharge slide 1
13 565295 02 Rectangular ring 1
14 561897 01 Nut 1
15 586120 80 Distributor 1
15A 560652 02 Guide rib 1
15B 73103 Grooved pin 4
16 561804 80 Bowl disc 96
16.1 561804 80 Bowl disc 2
16.5 561804 80 Bowl disc 5
17 563114 02 Top disc 1
19 564405 01 Bowl hood 1
20 564406 01 Seal ring 1
21 546198 15 O-ring 1
22 561876 80 Lock ring 1
22A 560637 01 Guide lug 1
23 561724 01 Cap nut 1
24 566788 16 Seal ring 1
25 223403 63 O-ring 1
26 561804 01 Bowl disc 1
27 597777 05 Guide ring 1
98 594550 01 Slide Laquer Spray 0
99 596718 01 Locking liquid Medium 0

18
439

3 Separator bowl

22; 22A
19
20
21
17

26

16; 16.1; 16.5

15; 15A-B

23
14
12
13
11

1; 1A-C

27
2
9
6
3
4
5
25
7
10
8
8; 8.1 24
2593A

19
440
S 946

4 Inlet and outlet device


Machine unit number or
Subassembly description
563094-
Ref Part No Description -01 Notes
Quantity
1 563092 80 Inlet and outlet pipe wit 1
3 223403 59 O-ring 2
4 566618 80 Paring tube 1
4A 566618 02 Paring tube 1
4B 566408 03 Plain bearing bushing 2
4C 561386 01 Tolerance ring 1
5 561954 01 Axial support 1
6 260080 61 Hexagon socket set screw 1
7 563317 01 Splash sealing 1
8 566022 02 Support ring 1
9 561957 01 Height adjusting ring 3
10 567078 80 Frame hood 1
10A 567078 02 Frame hood 1
10B 561208 01 Spring holder 1
10C 561960 01 Support sleeve 1
10D 221711 13 Screw 1
10E 221716 09 Screw 1
11 221036 27 Screw 4
14 562844 80 Arm 1
15 566407 03 Spring 1
16 223406 30 O-ring 2
17 223406 20 O-ring 2
18 563457 80 Connection housing 1
19 561962 01 Washer 1
20 562343 02 Locking nut 1
24 561389 81 Purifier screw 1
25 260190 05 O-ring 1
26 223101 61 Washer 6
27 221041 01 Screw 6

20
441

4 Inlet and outlet device

20
19

18

24
B
10 D 15
11
C
E 14
A
27
26

25

8
C
A 4
17 B
3
16
6

5
7 1
2052T

21
442
S 946

5 Belt driving device


Machine unit number or
Subassembly description
562107-
Ref Part No Description -01 -02 Notes
Quantity
50 Hz
60 Hz
1 561114 01 Cover support 1 1
2 221721 37 Screw 4 4
3 564594 80 Centrifugal clutch 1 See page 24
3 564594 81 Centrifugal clutch 1 See page 24
4 221045 60 Screw 1 1
5 223107 35 Spring washer 1 1
6 547837 01 Washer 1 1
7 563468 01 Flat belt 1
7 563469 01 Flat belt 1
8 221040 58 Screw 4 4
9 41456 Washer 8 8
10 35120 Nut 4 4
11 579817 80 Clutch cover 1 1
12 221040 42 Screw 3 3
13 41456 Washer 3 3

22
443

5 Belt driving device

1524E

23
444
S 946

5.1 Centrifugal clutch


Machine unit number or
Subassembly description
564594-
Ref Part No Description -80 -81 Notes
Quantity
50 Hz
60 Hz
1 564589 02 Motor belt pulley, 60 Hz 1
1 564590 02 Motor belt pulley 1
2 548051 49 Ball bearing 2 2
3 547833 01 Spacing ring 1 1
4 66251 Snap ring 1 1
5 564102 80 Coupling hub 1
5 564103 80 Coupling hub 1
6 223641 18 Snap ring 1 1
8 564557 80 Friction block 5 3
9 549325 01 Cover 1 1
10 223641 20 Snap ring 1 1

24
445

5.1 Centrifugal clutch 5 Belt driving device

1523D

25
446
S 946

6 Set of plates
Machine unit number or
Subassembly description
9002941-
Ref Part No Description -04 Notes
Quantity
1 557714 01 Machine plate 1
2 66169 Drive screw 4
3 1270019 Set of safety labels 1
4 577803 01 Name sign 1
4 591263 01 Name sign 1 DNV approval, see order
5 66169 Drive screw 4
6 553171 01 Label 50 Hz 1
6 553272 01 Label 60 Hz 1
7 555529 01 Plate with arrow 1
8 1270001 Lifting instruction 1
9 554214 02 Cable tie 1
11 66169 Drive screw 4
12 9006227 Separator checkpoints 1

26
447

6 Set of plates

2161E

27
448
S 946

7 Monitoring kit, for vibration


Machine unit number or
Subassembly description
566727-
Ref Part No Description -03 Notes
Quantity
1 570142 01 Inductive analogue sensor 1
2 561773 04 Sensor holder 1 Stainless steel
2 561773 08 Sensor holder 1 Brass
4 552870 21 Tube gland, straight 1
6 556416 18 Protective tube 1

28
449

7 Monitoring kit, for vibration

1769F

29
450
S 946

8 Set of tools
Machine unit number or
Subassembly description
561614-
Ref Part No Description -15 Notes
Quantity
1 562237 82 Pin spanner 1 Fan
2 561584 81 Puller 1 Bowl body
3 565679 80 Lifting tool 1 Distributor/ Bowl spindle
4 562246 02 Spanner for nut 1 Nut/ Discharge slide
5 562239 80 Puller 1 Spindle pulley/ Neck bearing
5A 561829 02 Screw 1
6 548457 80 Tool for belt pulley 1 Motor/ Coupling
6A 223406 13 O-ring 1
7 589776 01 Key 1 Bottom bearing housing
8 561439 01 Drift 1 Bottom bearing
9 575135 81 Compressing tool 1 Disc stack
9A 575135 80 Compressing tool 1
9B 575139 02 Clamp 3
9C 575098 01 Screw 3
9D 221045 52 Screw 3
9E 561551 01 Screw 3
10 563084 80 Puller 2 Neck bearing cover
10A 221040 05 Screw 1
10B 221035 46 Screw 1
11 260154 01 Lifting eye bolt 2
12 561607 81 Puller 1 Discharge slide
12A 562249 01 Support ring 1
12B 221040 43 Screw 1
13 221706 05 Screw 6 Lock ring/ Bowl body
14 548043 01 Mounting tool 1 Coupling bearing
15 527395 11 Hook spanner 1 Nut/ Inlet and outlet pipe
16 565673 01 Pin 1 Distributor
16 565673 02 Pin 1 Distibutor
17 66414 Hexagon socket head key 1 Lock ring/ Bowl body
18 566441 01 Sleeve 1 Neck bearing
19 566606 01 Chisel 1 Seal ring
20 585810 01 Crowfoot wrench head 1 Oil pump
99 588054 Exploded view 1

30
451

8 Set of tools

1 2 3

4 5 A 6 A

7 8 9 D A

E
B

10 11 12 B
A B

13 14 15

16 17 18

19 20
2043D

31
452
S 946

9 Inspection kit
Machine unit number or
Subassembly description
9006114-
Ref Part No Description -01 Notes
Quantity
1 560638 05 Rectangular ring 1 Bowl body/ Operating slide
2 560638 05 Rectangular ring 1 Operating slide/ Holder
3 565308 01 Valve plug 3 Operating slide/ Bowl body
4 68011 O-ring 1 Bowl body/ Operating water ring
5 546095 77 O-ring 1 Bowl body/ Discharge slide
6 565295 02 Rectangular ring 1 Discharge slide/ Bowl body
7 564406 01 Seal ring 1 Bowl hood/ Discharge slide
8 546198 15 O-ring 1 Bowl hood/ Bowl body
9 223403 59 O-ring 2 Paring tube/ Inlet and outlet pipe
10 223406 30 O-ring 2 Inlet and outlet pipe/ Connecting housing
11 223406 20 O-ring 2 Inlet and outlet pipe/ Connecting housing
12 260190 05 O-ring 1 Frame hood/ Frame bottom part
13 552766 07 Washer 2 Frame bottom part/ Plug
15 9000764 02 Lubriaction Paste G-n Plu 1
16 223404 05 O-ring 1 Oil pin/ Plug
17 221706 05 Screw 6 Lock ring/ Bowl body
18 66414 Hexagon socket head key 1 Lock ring/ Bowl body
19 566408 03 Plain bearing bushing 2 Paring tube
20 563317 01 Splash sealing 1 Inlet pipe
21 566788 16 Seal ring 1 Operating water ring
22 223403 63 O-ring 1 Bowl body/ Holder
23 561386 01 Tolerance ring 1 Paring tube/ Arm
24 260104 22 O-ring 4 Oil pipe/ Connecting housing
25 223404 51 O-ring 2 Water pipe/ Connecting housing
26 576279 01 Lock washer 6 Bowl body/ Holder
27 576173 05 Hexagon head screw 12 Bowl body/ Holder operating water ring
29 566407 03 Spring 1 Arm
98 9006227 Separator checkpoints 1
99 572324 Exploded view 1

32
24
7
8

29
25
6
5
17
18
453

13
1
12
4 16
3
23
13
11 19
10 9 2
22
9

20 26
27
Inspection kit

33
27
21
2551D
454
S 946

10 Overhaul kit
Machine unit number or
Subassembly description
9006115-
Ref Part No Description -01 -02 Notes
Quantity
50 Hz
60 Hz
1 9006114 01 Inspection kit 1 1 See page 32
2 2234121 38 O-ring 1 1 Strainer/ Bottom bearing housing
3 2234121 40 O-ring 1 1 Bottom bearing housing
4 562095 02 Labyrinth ring 1 1 Labyrinth ring holder/ Spindle pulley
5 223412 23 O-ring 1 1 Labyrinth ring holder/ Frame bottom part
6 223412 48 O-ring 1 1 Neck bearing cover/ Frame bottom part
7 566788 01 Seal ring 2 2 Neck bearing cover/ Deflector ring
8 223406 29 O-ring 2 2 Deflector ring/ Bowl spindle
9 223404 20 O-ring 1 1 Pipe/ Operating water cover
11 74067 O-ring 1 1 Plug/ Frame bottom part
12 566788 06 Seal ring 1 1 Bowl spindle/ Operating water cover
13 548747 10 Single row ball bearing 1 1 Bowl spindle/ Top bearing seat
14 223642 38 Snap ring 1 1 Top bearing seat/ Ball bearing
15 562109 03 Helical spring 3 3 Top bearing seat/ Top bering housing
16 562110 02 Composite spring 6 6 Top bearing seat/ Plug
17 548744 03 Self-align roller bearing 1 1 Bowl spindle/ Bottom bearing housing
19 545869 03 Nozzle 1,5 mm 1 1 Operating slide
20 597777 05 Guide ring 1 1 Bowl body/Operating slide
22 548051 49 Ball bearing 2 2 Coupling hub/ Motor belt pulley
23 66251 Snap ring 1 1 Motor belt pulley/ Ball bearing
24 223641 18 Snap ring 1 1 Coupling hub/ Ball bearing
25 564557 80 Friction block 5 3 Coupling hub/ Motor belt pulley
26 223641 20 Snap ring 1 1 Coupling hub/ Cover
27 223107 35 Spring washer 1 1 Motor shaft/ Screw
28 563468 01 Flat belt 1 Motor belt pulley/ Spindle pulley
28 563469 01 Flat belt 1 Motor belt pulley/ Spindle pulley
29 596723 02 Locking liquid Low 1 1 Bottom bearing holder
30 223406 29 O-ring 2 2 Bowl spindle/ Fan
31 223412 48 O-ring 1 1 Frame bottom part
32 596718 02 Locking liquid Medium 1 1 Screws
99 9006312 Exploded view 1 1

34
29 30
9 31
8 14
1
7

6
24
23
22
20 22
13
5
4 18
15
16
455

2
25

26

28
11 12
17
10

19
27
Overhaul kit

35
2637A
456
S 946

11 Lifting tool

Separator

Machine unit number or


Subassembly description
563453-
Ref Part No Description -80 Notes
Quantity
2 563454 01 Lug 4
3 221035 53 Screw 4
5 27345 Nut, M8 4
6 260236 03 Shackle 2

36
457

11 Lifting tool

1686E

37
458
S 946

12 Support kit
Machine unit number or
Subassembly description
564922-
Ref Part No Description -02 Notes
Quantity
1 526350 04 Plug 1 Frame bottom part
2 221716 23 Screw 2 Labyrinth ring holder
3 221721 25 Screw 3 Top bearing housing/ Frame bottom part
4 221711 18 Screw 1 Neck bearing cover
5 565056 04 Deflector ring 1 (Brass) - Bowl spindle
5 598744 01 Deflector ring 1 (S.S.) Bowl spindle
6 41456 Washer 3 Screw/ Operating water cover
7 221040 04 Screw 3 Operating water cover
8 562902 80 Sensor with support 1 Frame bottom part
9 221716 23 Screw 1 Frame bottom part/ Sensor support
10 221716 23 Screw 1 Frame bottom part/ Plug
13 221040 41 Screw 3 Top bearing housing/ Air deflector
15 561876 80 Lock ring 1 Bowl body/ Bowl hood
15A 560637 01 Guide lug 1
16 561724 01 Cap nut 1 Bowl spindle/ Bowl body
19 561954 01 Axial support 1 Inlet and outlet device/ Pipe
20 260080 61 Hexagon socket set screw 1 Inlet and outlet device/ Axial support
21 561957 01 Height adjusting ring 3 Frame hood/ Height adjusting ring
22 561208 01 Spring holder 1 Frame hood
23 221036 27 Screw 4 Frame hood/ Height adjusting ring
24 562844 80 Arm 1 Frame hood/ Paring tube
25 561962 01 Washer 1 Inlet pipe/ Connecting housing
26 562343 02 Locking nut 1 Inlet pipe/ Connecting housing
27 223101 61 Washer 6 Frame hood/ Frame bottom part
28 221041 01 Screw 6 Frame hood/ Frame bottom part
29 547833 01 Spacing ring 1 Ball bearing/ Ball bearing
30 41456 Washer 8 Motor/ Frame bottom part
31 221040 58 Screw 4 Motor/ Frame bottom part
32 35120 Nut 4 Motor/ Frame bottom part
33 565378 01 Plug 1 Frame bottom part
34 571743 80 Oil pin 1 Frame bottom part/ Plug
35 545869 03 Nozzle 1,5 mm 2 Oil pump
36 562246 02 Spanner for nut 1 Nut/ Discharge slide

38
7
6
15
26
5 25

4
13 36
3 23
22
24
2 35 16
35 28
27
459

21

33 32
30 31
10
34 20
8B 8 1
8A 19 29
12

9
Support kit

39
2274D
460
S 946

13 Cover interlocking kit


Machine unit number or
Subassembly description
570819-
Ref Part No Description -03 Notes
Quantity
1 552870 21 Tube gland, straight 1
2 566054 01 Limit switch 1
3 556416 25 Protective tube 1
4 532333 03 Clamp 1
5 221125 20 Screw 1

40
461

13 Cover interlocking kit

2
3

1
1769E

41
462
S 946

14 Hydraulic tool kit


Machine unit number or
Subassembly description
574986-
Ref Part No Description -04 Notes
Quantity
1 574618 80 Hydraulic components 1 See page 44
2 574626 82 Hydraulic tool 1 See page 46

42
463

14 Hydraulic tool kit

3
1

2047D

43
464
S 946

14.1 Hydraulic components


Machine unit number or
Subassembly description
574618-
Ref Part No Description -80 Notes
Quantity
1 574618 01 Pump with hose 1
2 574618 02 Hydraulic cylinder 1

44
465

14.1 Hydraulic components 14 Hydraulic tool kit

2 2050A

45
466
S 946

14.2 Hydraulic tool


Machine unit number or
Subassembly description
574626-
Ref Part No Description -82 Notes
Quantity
1 571628 01 Stud bolt 1
2 574627 03 Sleeve 1
3 571627 01 Holder 1
4 221803 35 Nut, M20 1
5 574954 01 Sleeve 1
6 571620 01 Plate 1
7 571622 01 Screw 3

46
467

14.2 Hydraulic tool 14 Hydraulic tool kit

2047A

47
468
S 946

15 Motor service kit


Machine unit number or
Subassembly description
9007346-
Ref Part No Description -80 Notes
Quantity
1 548051 04 Ball bearing 1 D-end
2 548051 04 Ball bearing 1 ND-end
3 9001768 01 Fan 1
4 9007344 02 Spring washer 1
5 9001768 03 O-ring 1 D-end
6 9001768 03 O-ring 1 ND-end

48
469

15 Motor service kit

2585B

49
470
S 946

16 Motor service kit


Machine unit number or
Subassembly description
9001769-
Ref Part No Description -80 Notes
Quantity
1 548051 69 Ball bearing 1 D-end
2 548051 04 Ball bearing 1 ND-end
3 9001768 01 Fan 1
4 9001768 02 Spring washer 1
5 9001769 01 O-ring 1 D-end
6 9001768 03 O-ring 1 ND-end

50
471

16 Motor service kit

2585B

51
472
17 Cross reference list

17 Cross reference list

+ Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.

1270001 26 8 223403 59 32 9 526350 04 12 6


1270019 26 3 223403 63 18 25 526352 06 12 28
17812 12 56 223403 63 32 22 527395 11 30 15
221035 46 30 10B 223404 05 32 16 532333 03 40 4
221035 53 36 3 223404 05 12 51 532333 03 12 58
221036 27 20 11 223404 20 34 9 539418 02 12 27
221036 27 38 23 223404 20 12 26 545869 03 34 19
221040 04 38 7 223404 51 32 25 545869 03 38 35
221040 05 30 10A 223406 13 30 6A 545869 03 14 11
221040 08 12 55 223406 20 20 17 545869 03 18 4
221040 41 38 13 223406 20 32 11 546095 77 32 5
221040 42 22 12 223406 29 34 8 546095 77 18 11
221040 43 30 12B 223406 29 12 24 546198 15 18 21
221040 46 12 31 223406 29 34 30 546198 15 32 8
221040 58 22 8 223406 29 14 17 547833 01 24 3
221040 58 38 31 223406 30 20 16 547833 01 38 29
221041 01 20 27 223406 30 32 10 547837 01 22 6
221041 01 38 28 223412 23 12 16 548043 01 30 14
221045 52 30 9D 223412 23 34 5 548051 04 48 1
221045 60 22 4 223412 48 12 21 548051 04 48 2
2210462 32 12 4 223412 48 34 6 548051 04 50 2
221125 20 40 5 223412 48 34 31 548051 49 24 2
221125 20 12 60 223412 48 12 54 548051 49 34 22
221126 04 12 57 2234121 38 34 2 548051 69 50 1
221706 03 12 12 2234121 38 12 9 548457 80 30 6
221706 05 30 13 2234121 40 12 13 548744 03 34 17
221706 05 32 17 2234121 40 34 3 548744 03 14 10
221711 13 20 10D 223641 18 24 6 548747 10 34 13
221711 18 12 20A 223641 18 34 24 548747 10 14 2
221711 18 38 4 223641 20 24 10 549325 01 24 9
221716 09 20 10E 223641 20 34 26 552766 07 32 13
221716 22 12 38C 223642 38 34 14 552766 07 12 5
221716 22 14 16 223642 38 14 4 552870 21 28 4
221716 23 12 17 2522302 09 12 1A 552870 21 40 1
221716 23 38 2 260080 61 20 6 552870 41 16 3
221716 23 38 9 260080 61 38 20 553171 01 26 6
221716 23 38 10 260104 22 32 24 553272 01 26 6
221716 23 12 34 260154 01 30 11 554214 02 26 9
221716 23 12 37 260190 05 20 25 555529 01 26 7
221721 25 12 19 260190 05 32 12 556416 14 16 5
221721 25 38 3 260236 03 36 6 556416 18 28 6
221721 37 22 2 27345 36 5 556416 25 40 3
221721 37 12 38D 35120 22 10 557714 01 26 1
221803 35 46 4 35120 38 32 560131 02 12 2
223101 61 20 26 41456 22 9 560202 01 12 25
223101 61 38 27 41456 22 13 560406 01 14 8
223101 94 12 59 41456 38 6 560637 01 18 22A
223107 35 22 5 41456 38 30 560637 01 38 15A
223107 35 34 27 41456 12 30 560637 01 18 1B
223403 59 20 3 526350 04 38 1 560638 05 32 1

52
473

S 946

Part No. Page Ref. Part No. Page Ref. Part No. Page Ref.

560638 05 32 2 562249 01 30 12A 566441 01 30 18


560638 05 18 2 562343 02 20 20 566606 01 30 19
560638 05 18 5 562343 02 38 26 566618 02 20 4A
560652 02 18 15A 562844 80 20 14 566618 80 20 4
561114 01 22 1 562844 80 38 24 566692 80 16 6
561208 01 20 10B 562902 80 38 8 566718 82 12 32
561208 01 38 22 562902 81 16 1 566788 01 12 22
561386 01 20 4C 562962 80 12 1 566788 01 34 7
561386 01 32 23 563084 80 30 10 566788 06 34 12
561389 81 20 24 563092 80 20 1 566788 06 12 49
561439 01 30 8 563114 02 18 17 566788 16 18 24
561551 01 30 9E 563317 01 20 7 566788 16 32 21
561584 81 30 2 563317 01 32 20 567078 02 20 10A
561607 81 30 12 563454 01 36 2 567078 80 20 10
561724 01 18 23 563457 80 20 18 570142 01 28 1
561724 01 38 16 563468 01 22 7 571620 01 46 6
561773 03 12 35 563468 01 34 28 571622 01 46 7
561773 04 28 2 563469 01 22 7 571627 01 46 3
561773 07 12 35 563469 01 34 28 571628 01 46 1
561773 08 28 2 564102 80 24 5 571743 80 38 34
561804 01 18 26 564103 80 24 5 571743 80 12 53
561804 80 18 16.1 564149 01 14 9 572324 32 99
561804 80 18 16.5 564405 01 18 19 574233 01 18 12
561804 80 18 16 564406 01 18 20 574618 01 44 1
561829 02 30 5A 564406 01 32 7 574618 02 44 2
561831 01 18 3 564557 80 24 8 574618 80 42 1
561876 80 18 22 564557 80 34 25 574626 82 42 2
561876 80 38 15 564589 02 24 1 574627 03 46 2
561897 01 18 14 564590 02 24 1 574954 01 46 5
561950 80 12 20 564591 02 12 29 575098 01 30 9C
561954 01 20 5 564594 80 22 3 575135 80 30 9A
561954 01 38 19 564594 81 22 3 575135 81 30 9
561957 01 20 9 565056 04 12 23 575139 02 30 9B
561957 01 38 21 565056 04 38 5 576173 05 32 27
561960 01 20 10C 565057 02 14 14 576173 05 18 8
561962 01 20 19 565295 02 32 6 576279 01 32 26
561962 01 38 25 565295 02 18 13 576279 01 18 8.1
561977 01 14 1 565308 01 32 3 576397 01 18 7
562091 01 12 10 565308 01 18 6 577803 01 26 4
562094 01 12 14 565378 01 38 33 579464 02 18 10
562095 02 12 15 565378 01 12 52 579817 80 22 11
562095 02 34 4 565673 01 30 16 579884 02 12 38A
562109 03 34 15 565673 02 30 16 579885 01 12 38B
562109 03 14 6 565679 80 30 3 579885 80 12 38
562110 02 34 16 566022 02 20 8 580042 01 14 15
562110 02 14 7 566054 01 40 2 580044 02 14 5
562237 82 30 1 566407 03 20 15 584150 80 14 3
562239 80 30 5 566407 03 32 29 585810 01 30 20
562246 02 30 4 566408 03 20 4B 586120 80 18 15
562246 02 38 36 566408 03 32 19 586513 01 14 13

53
474
17 Cross reference list

Part No. Page Ref.

586732 01 12 8
588054 30 99
589649 80 12 18
589704 01 12 11
589776 01 30 7
591263 01 26 4
594550 01 18 98
596718 01 18 99
596718 02 34 32
596723 02 34 29
597752 01 18 1A
597752 80 18 1
597777 05 18 27
597777 05 34 20
598744 01 12 23
598744 01 38 5
599092 01 14 14
66169 26 2
66169 26 5
66169 26 11
66251 24 4
66251 34 23
66414 30 17
66414 32 18
68011 32 4
68011 18 9
68564 18 1C
70490 12 3
73103 18 15B
74067 34 11
74067 12 36
9000764 02 32 15
9000794 01 14 99
9001768 01 48 3
9001768 01 50 3
9001768 02 50 4
9001768 03 48 5
9001768 03 48 6
9001768 03 50 6
9001769 01 50 5
9006114 01 34 1
9006227 26 12
9006227 32 98
9006312 34 99
9007344 02 48 4

54
475

MAN Diesel & Turbo


Order no. 4500968861

Alfa Laval Order no. 84.6893.31


Configuration no. 108918-25
------------------------------------------------------------------------------------------------------------
Flex Module with Separator Type S 946

Main Power Supply: 460 V / 60 Hz


------------------------------------------------------------------------------------------------------------

Chapter 9, Optional Equipment


(Specification of equipment as delivered for the above mentioned order)

9.1 Feed Pump ALP 75

9.2 Heatpac CBM 30-40

9.3 Sludge Removal Kit


Component 476

Description

Oil Feed Pumps ALP 75


15-85

X02 7 35 1A

Product No.

Printed Feb 2014


Book No. 9006009-02 V5
Marine & Diesel Equipment
477

Alfa Laval reserve the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be gratefully
appreciated.
Copies of this publication can be ordered from your local Alfa Laval
company.
Published by: Alfa Laval Tumba AB
Marine & Diesel Equipment
S - 147 80 Tumba
Sweden
Copyright Alfa Laval Tumba AB 2014.
The original instructions are in English
478

Contents
1 EC Declaration of Conformity 7

2 Warning signs in text 9


2.1 Warning signs 9

3 Function Description 11
3.1 Application 11
3.1.1 Safety information 11

3.2 Design 12
3.2.1 Mechanical seal 12
3.2.2 Direction of Rotation 13
3.2.3 Pressure relief valve 13

3.3 Parts 14

4 Fault Finding 19
4.1 Possible faults 19
4.2 Troubleshooting 19

5 Maintenance 23
5.1 Safety instructions on maintenance and
repairs 23
5.2 Required maintenance 24
5.3 Mechanical seal 24
5.4 Ball bearing 24
5.5 Cleaning the leakage vent hole 25
5.6 Replacing the elastomer coupling 26
5.7 Replacing the mechanical seal and ball
bearing 29
5.7.1 Dismantling 29
5.7.2 Assembly 31

6 Technical Data 33
6.1 Operating limits 33
6.2 Required Net Positive Suction Height
(NPSH) values 33

3
479

6.3 Weights 34
6.4 Dimensions 35
6.4.1 Dimension drawing of ALP pump and pump unit 36

6.5 Capacity tables 37


6.5.1 Capacity at 50 Hz, delta = 4 bar 37
6.5.2 Capacity at 60 Hz, delta = 4 bar 38
6.5.3 Noise levels 39
6.5.4 Labelling 39

7 Installation 41
7.1 Installing the pump 41
7.2 Protect the pump against contamination 42
7.3 Piping 43
7.4 Strainer 43
7.5 Gauges 44
7.6 Commissioning 44
7.6.1 Cleaning the pipe system 44
7.6.2 Filling the pump 44
7.6.3 Checking the direction of rotation 45
7.6.4 Taking the pump out of operation 47
7.6.5 Recommissioning the pump 48

8 Transportation, storage and


disposal 49
8.1 Unpacking and checking the state of
delivery 49
8.2 Lifting the pump/pump unit 50
8.2.1 Pump 51
8.2.2 Pump unit 51

8.3 Storage 51
8.3.1 Preservation 52
8.3.2 Preserving the internal surfaces of the pump 52
8.3.3 Preserving the external surfaces of the pump 52
8.3.4 Removing the preservation 53

8.4 Disposing of the pump 53

9 Spare parts 55
9.1 Spare parts kit 55
9.1.1 Tightening torques 56
9.1.2 Required tools for maintenance work 56

4
480

Study instruction manuals and observe the


warnings before installation, operation,
service and maintenance.

Not following the instructions can result


in serious accidents.

In order to make the information clear only


foreseeable conditions have been considered.
No warnings are given, therefore, for situations
arising from the unintended usage of the
machine and its tools.

5
481

!
482

1 EC Declaration of Conformity

X027551A

The designating company

Alfa Laval Kolding A/S


Company name

Albuen 31, DK6000 Kolding, Denmark


Address

+45 79 32 22 00
Phone No.

hereby declares that

Denomination: Three-Screw Pump


Type: ALP
Date: 20130401

Is in conformity with

- Machinery Directive 2006/42/EC


and furthermore declares that if motorised the following applicable directives have been used

- Directive 2006/95/EC on low voltage


- EMC Directive 2004/108/EC
The technical construction file for this machinery has been drawn up. The signer of this declaration
is authorized to compile the technical file.

Manager, Product Center Fluid Handling Bjarne Sndergaard


Title Name

Alfa Laval Kolding A/S X027541A

Company Signature

7
483
1 EC Declaration of Conformity
484

2 Warning signs in text

2.1 Warning signs


Pay attention to the safety instructions in this
manual. Below are definitions of the three
grades of warning signs used in the text where
there is a risk for injury to personnel.

NGE R
! DA
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious
injury.

NG
WARNI
!
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.

ON
CAUTI
!
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.

NOTE

NOTE indicates a potentially hazardous situation


which, if not avoided, may result in property damage.

9
485
2 Warning signs in text
486

3 Function Description

The operating instructions form part of the pump


or of the pump unit and must be kept for future
reference. Furthermore please observe the
associated documents.

3.1 Application
Use the pump solely for transporting fuel or
lubricating oils that are chemically neutral and
that contain no gas or solid components.
Use the pump only within the performance
limitations specified on the machine plate and
in the "Technical data" section. In the case of
operating data that does not agree with the
specifications on the machine plate, please
contact the manufacturer.
The pump is specifically configured for the
operating pressure stated in chapter 5.

3.1.1 Safety information


The following general safety instructions must
be observed:

No liability is accepted for damage arising


through non-observance of the operating
instructions.
- Read the operating instructions carefully
and observe them.
- The operator-owner is responsible for the
observance of the operating instructions.
- Installation, removal and installation work
may only be carried out by authorised
personnel.
In order for the warranty to remain valid,
corrective maintenance carried out during
the warranty period requires the express
permission of the manufacturer.

11
487
3 Function Description

Observe the general regulations for the


prevention of accidents as well as the local
safety and operating instructions.
Observe the valid national and international
standards and specifications of the
installation location.
In case of systems with an increased
potential of danger to humans and/or
machines the failure of a pump may not lead
to injuries or damage to property.
- Always equip systems with an increased
potential of danger with alarm equipment.
- Maintain and check the protective/alarm
equipment regularly.
The pumped liquids can be dangerous
(e.g. hot, dangerous to health, poisonous,
combustible). Observe the safety regulations
for handling dangerous materials.
Pumped liquid can be subject to high
pressure and can cause damage and/or
personal injury should leaks occur.

3.2 Design
Screw pumps are rotating displacement pumps
whose displacement effect results from the
meshing of three rotating screws and the
enclosing housing. The radial support of the
screws is effected by the sliding contact in
the housing which requires lubrication by the
pumped liquid. Screw pumps are therefore not
suitable for dry running and can only be used up
to specific pressure and viscosity limits. Due to
the narrow tolerances, pumping of suspended
solids is not possible. Axial support of the
main screw is carried out by a deep-groove
ball bearing. An internal pressure relief valve
protects against excessive pressure that could
cause housing parts to burst.

3.2.1 Mechanical seal


The functionality of a mechanical seal is based
on the formation of a hydrodynamic film between
rotary seal ring and stationary seal ring of a
mechanical seal. The formation of this film
avoids solid body friction between both parts, the
stability of the film therefore is essential for the
functionality of the mechanical seal. However,
the formation of a fluid film also means that
the differential pressure on the seal will always

12
488
3 Function Description

move some fluid through the gap which is filled


by the film. Therefore a properly designed
mechanical seal will always show a certain
amount of leakage. The amount of leakage is
depending on various factors, dominated by
size, rotation speed and differential pressure. In
any case, a leakage of less than 10 drops per
hour (approx. 0.5 cm3/h) is considered to be
normal and gives no reason for a replacement
of the seal.The integrated leakage vent hole
allows draining of this leakage. The drainage
through these hole has to be kept free, see 5.5
Cleaning the leakage vent hole on page 25.
Dry running must be avoided at all costs, as the
seal will overheat and be destroyed in a matter
of minutes.

3.2.2 Direction of Rotation


Standard direction of rotation: clockwise, viewed
from the drive; marked on the housing by two
arrows, see 7.6.3 Checking the direction of
rotation on page 45. Flow direction: marked on
the housing by two arrows, see 7.6.3 Checking
the direction of rotation on page 45.

3.2.3 Pressure relief valve


The integrated pressure relief valve prevents
very high pressures which can result in housing
parts bursting. The valve is purely there as
a safety element and should not be used
for control or regulation such as maintaining
pressure. Circulation through the pressure relief
valve for too long heats the pump to excess.
This reduces viscosity and can ultimately lead
to pump failure. Setting: The valve spring is
pretensioned to an opening pressure of 6 bar
10 % for separator applications, or delta 10 bar
10 % for fuel conditioning applications.

13
489
3 Function Description

3.3 Parts
1 Pressure relief valve 10 Mechanical seal
2 Screw plug 11 Pump
3 Idle screw 12 adapter housing
4 End cover 13 Motor
5 Sealing sleeve 14 adapter housing foot
6 Ball bearing 15 Motor-side coupling half
7 Main screw 16 Coupling intermediate ring
8 Pump housing 17 Pump-side coupling half
9 Leakage vent hole

14
490
3 Function Description

X027101A

Fig. 1.Structure of ALP pump

X027111A

Fig. 2.Structure of ALP pump with elastomer coupling


and motor

15
491
3 Function Description

Pos. no. Denomination Pos. no. Denomination


001 Pump 501 Spring
043 Sealing sleeve 526 Bracket
052 Coupling 529 Motor
056(*) Supporting ring 661** Screw set
058 L-ring 739.1 O-ring
070 End cover 817 Ball bearing
131 Pump housing 859 Adapter sleeve
165.1 Screw plug 866 Feather key
165.2 Screw plug 894 Hexagon nut
180 Adapter housing 914.1 Socket screw
222 Flat gasket 914.2 Socket screw
305 Valve body 914.3 Socket screw
457 Mechanical seal 914.4 Socket screw
471 Circlip
472 Circlip

* Only for sizes 15 20.


** In case of wear of the screw set it is recommended to replace the pump.

16
492
3 Function Description

131

222
070
165.2
914.1 165.1

305 471
056*
501 859
866

056 472
8 817
043
457 739.1

661

X027151A

Fig. 1.ALP 1585

X027161A

Fig. 2.Completion elastomer coupling ALP 1585

17
493
3 Function Description
494

4 Fault Finding

4.1 Possible faults


Faults can have different causes. The following
tables list the symptoms of a fault, the possible
causes and measures for elimination.

Fault Cause/Remedy
No pump suction 1, 2, 3, 4, 5, 6, 7, 8, 30
Delivery rate too low 2, 3, 4, 9, 10, 11, 12, 13, 14, 15, 16
Pump runs noisily 2, 3, 4, 6, 10, 12, 14, 18, 19, 20, 21
Motor overload 9, 10, 13, 21, 22, 25
Uneven delivery rate 2, 3, 4, 6, 10, 12, 14, 15
Leaking shaft seal 17, 23, 24, 25
Pump has seized up 26, 27, 28, 29

4.2 Troubleshooting
No. Cause Remedy
1 Pump suction pipe closed Check shut-off devices in the suction pipe and
open them, if necessary.
2 Suction valve or pipe obstructed Check the suction valve and pipe for clear passage.
3 Suction pipe or shaft seal leaks Check suction pipe or shaft seal for leaks. Pay
particular attention to leakage at valves and
connection points. If necessary, replace parts.
4 Suction head too high Reinstall the pump at lower suctiion head level.
- or -
Reduce pipe length
- or -
Increase pipe diameter
- or -
Heat the liquid to reduce viscosity
- or -
Check that the strainer is not clogged, see 7.4
Strainer on page 43.
5 Level of liquid in the intake container
too low Top up the pumped liquid.
6 Dirty filter/strainer Clean the filter/strainer.
7 Pump suction capacity reduced by
inadequate wetting Fill pump with liquid.

19
495
4 Fault Finding

No. Cause Remedy


8 Incorrect pump direction of rotation Carry out the electrical connection so that the
direction of pump rotation matches that of the
arrow on the flange cover, see on page .
9 Differential pressure too high Check the system and reduce the differential
pressure.
10 Viscosity of the pumped liquid too Increase the temperature of the liquid
high
- or -
Reduce the rotation speed.
11 Viscosity of the pumped liquid too Decrease the temperature of the liquid
low
- or -
12 Airlock or gas in the liquid Increase the rotation speed.
Test the pipe system for ingress of air and replace
parts if necessary.
Reduce the suction head
- or -
Increase the inlet pressure.
13 Motor running at wrong voltage or Ensure that the motor voltage and frequency match
frequency the operating voltage.
Compare the speed of the motor with the pump
communication plate. If the data does not match,
adjust the speed of the motor.
14 Pressure relief valve opens during
normal operation Reduce operating pressure.
15 Pressure relief valve leaks Clean the pressure relief valve and reseat if
necessary.
16 Advanced wear of rotating pump Check screw set and housing and replace the
components pump if necessary.
Replace the seal and check the pumped liquid for
abrasive content.
17 Advanced wear of sealing surfaces Support the weight of the pipe system.
18 Pump distorted Loosen pipework connections and mount
stress-free, see 7.3 Piping on page 43.
19 Resonance in the system Provide a flexible bearing arrangement for the
pump unit
- or -
Make the connections with hoses.
20 Speed of flow in suction or pressure Set the flow speed in the suction pipe so that it
pipe too high does not exceed 1 m/s.
Set the flow speed in the pressure pipe so that it
does not exceed 3 m/s.
21 Ball bearing damaged Replace the ball bearing, see 5.7 Replacing the
mechanical seal and ball bearing on page 29.
22 Lack of lubrication or foreign bodies
have caused superficial damage to Check the screw set and the housing. If necessary
rotating pump components replace the pump with free shaft end.
23 Dry running has damaged the shaft Replace the shaft seal, see 5.7 Replacing the
seal mechanical seal and ball bearing on page 29.
When starting up the pump, pay attention to
venting.

20
496
4 Fault Finding

No. Cause Remedy


24 Thermal or chemical loading of Check the maximum operating temperature.
elastomer seals exceeded Check the resistance of the elastomers with regard
to the pumped liquid.
25 Cold start when delivering
high-viscosity liquids Preheat the pumped liquid.
26 Foreign bodies in the pump Dismantle the pump and clean it.
Smooth the superficial damage to the housing and
the rotating parts with an oilstone. If necessary,
replace the pump.
27 Differential pressure is too high and Dismantle the pump and clean it.
has overloaded the screws Smooth the superficial damage to the housing and
the rotating parts with an oilstone. If necessary,
replace the pump.
Reduce the differential pressure.
28 Viscosity is too low and has Dismantle the pump and clean it.
overloaded the screws Smooth the superficial damage to the housing and
the rotating parts with an oilstone. If necessary,
replace the pump.
Increase the viscosity, for example by reducing the
operating temperature.
29 Dry running has damaged the pump Dismantle the pump and clean it.
equipment Smooth the superficial damage to the housing and
the rotating parts with an oilstone. If necessary,
replace the pump.
When resuming operation, take action to prevent
dry running, see 7.6.5 Recommissioning the pump
on page 48.
30 Pump does not vent Vent the pressure pipe at the highest point.

21
497
4 Fault Finding
498

5 Maintenance

5.1 Safety instructions on maintenance and repairs


The following safety instructions must be
observed during all the repair work:

All the work may only be carried out by


authorized qualified personnel.

Wear protective clothing during all the work.

Switch off the motor and secure it against being


switched back on.

Before beginning the work let the pump/the


pump unit cool down to the ambient temperature
and remove it from the pipe system.

Ensure that the pump is depressurized.

Collect the emitted pumped liquid safely and


dispose of it in an environmentally compatible
manner.

Also observe the general drawings during all the


work, see Parts on page 14.

23
499
5 Maintenance

5.2 Required maintenance


The service life of the pump depends to a
great extent on the operating conditions. If the
operating limits are observed, see 6 Technical
Data on page 33, the pump has a service life
of many years. Signs of progressive wear of
individual pump elements:

Finding Cause Elimination


Incipient damage to
Increased running noises bearing Replace the bearing.
Increased leaking Incipient damage to seal Replace the shaft seal.
Deposits on the seal Non-volatile liquids Clean the seal.
Advanced wear of the
Increased play in the shaft coupling spider Replace the spider.
Reduction in the flow rate or pressure Advanced wear of screws
under constant operating conditions and housing Replace the pump.

Tab. 1 Check table for required maintenance

1. Check the pump visually and acoustically


every four weeks.

2. Check for signs of wear as listed in the


table above and eliminate the cause.

5.3 Mechanical seal


Mechanical seals are subject to a natural
wear that depends strongly on the respective
conditions of use. General statements about the
durability can therefore not be given. In case
of heavy pollution with solidified and/or sticky
leakage residues disassemble the mechanical
seal completely and carefully clean it, together
with the inner surfaces of the sealing sleeve,
see 5.7 Replacing the mechanical seal and
ball bearing on page 29. It is recommended
to replace the o-rings when reassembling the
mechanical seal.

5.4 Ball bearing


The ball bearings used are lifetime lubricated.
Maintenance is therefore not required. We
recommend renewing the ball bearings every
two years.

24
500
5 Maintenance

5.5 Cleaning the leakage vent hole


The regular small amounts of leakage can result
in deposits that can prevent free draining of
further leakage liquids after a longer operating
period. The leakage vent hole must therefore
be checked monthly and if necessary cleaned.

X027171A

Fig. 1 Cleaning the leakage vent hole

ON
CAUTI
!
Bearing damage due to insufficient drainage
of shaft seal leakage
Check permeability of leakage vent hole
regularly.

1. Remove any drainage line that is


connected.

2. Check the permeability of the drainage line:


Observe whether a small amount of added
liquid drains, or

Check visually, or

Insert an arbor made of a soft material


(wood, plastic, etc.), see Fig. 1.

3. Clean the line or leakage vent hole, if it is


not free.

4. Reconnect any drainage line that is


connected.

25
501
5 Maintenance

5.6 Replacing the elastomer coupling


Removing the coupling

X027181A

001 Pump 180 adapter housing 914.2 Socket screws


052.1 Pump-side coupling half 525 Coupling intermediate 914.3 Socket screws
ring
052.2 Motor-side coupling half 529 Motor

NG
WARNI
!
Risk of injury and/or damage to equipment
should the pump/pump unit fall
Lift large pumps/pump units using the crane.

Do not stand under raised loads.

1. Before dismantling close the suction and


pressure connection of the pump with
protective covers.
2. Loosen the connecting screws 914.3
between the motor 529 and adapter housing
180 and lift the pump with adapter housing
from the motor, see Fig. 2
3. Loosen the fixing screw on the motor-side
coupling half 052.2.
4. Remove the coupling intermediate ring 525
and pull off the coupling half 052.2 using a
suitable

26
502
5 Maintenance

5. Loosen the connecting screws 914.2


between the pump 001 and adapter housing
180 and remove the adapter housing, see
Fig. 3.
6. Loosen the fixing screw on the pump-side
coupling half 052.1 and remove the coupling
half using suitable mounting levers.
Installing the coupling

1. Slide the pump-side coupling half 052.1 onto


the shaft until it stops. Heating the coupling
to 80100 C facilitates mounting. Tighten
the fixing screw of the coupling half.
2. Place the adapter housing 180 on the pump
and tighten the connecting screws 914.2,
see Fig. 4.

X027201A

3. Measure and write down the distance X


between the face of the coupling and the
connecting surface of the adapter housing,
see Fig. 5.

X027211A

27
503
5 Maintenance

4. Mount the motor-side coupling half 052.2


on the shaft end of the motor, see Fig. 6.
Heating the coupling to 80100 C facilitates
mounting.

X027221A

5. Check the distance between the face of the


coupling teeth and the connecting surface
of motor flange. The distance has to be
adjusted to the value X - c, see table below.
6. Insert the coupling intermediate ring 525
and tighten the fixation screw at the coupling
half 052.2.
7. Place the pump with the adapter housing
on the motor.
8. Turn the pump slightly until the teeth of
the pump-side coupling half 052.1 mesh
correctly into the spaces of the coupling
intermediate ring 525.
spaces of the spider 052.3.
9. Tighten the connecting screws 914.3
between the motor and adapter housing
with torque, see 9.1.1 Tightening torques on
page 56.
Coupling diameter Linear offset c
[mm] min. [mm] max. [mm]
56 2.0 3.5
66 2.5 4.0

28
504
5 Maintenance

5.7 Replacing the mechanical seal and ball bearing

5.7.1 Dismantling
Aids:

Disassembly tool, see 9.1.2 Required tools for


maintenance work on page 56.

- Open-end wrench
- Extractor
1. Remove the circlip 472, screw plug 165.1
and feather key 866, see Fig. 7.

X027231A

2. Screw in the disassembly tool A by using


the open-end wrench B, see Fig. 8. The
main screw will be pressed out of the pump
housing. Remove the main screw from the
pump housing.

X027241A

3. Remove the circlip 471 and supporting ring


056, see Fig. 9.

X027251A

29
505
5 Maintenance

4. Pull the ball bearing 817 from the main


screw using a suitable extractor C, see Fig.
10.

X027261A

5. Remove L-ring 058, supporting ring 056*,


sealing sleeve 043 along with o-ring 739.1
and stationary seal ring of the mechanical
seal along with o-ring, see Fig. 11.
043 056* 8
457

739.1
Fig. 11
X027271A

6. Remove the remaining parts of the


mechanical seal 457 from the main screw,
see Fig. 11.

30
506
5 Maintenance

5.7.2 Assembly
Aids:

1. Clean the fitting surfaces and the main


screw. Grease the main screw and o-rings
slightly.
2. Press the stationary seal ring of the
mechanical seal along with o-ring manually
into the sealing sleeve 043, see Fig. 12.
Take the position of the clearance for the
adapter sleeve 859 into account.

X027281A

3. Slide the remaining parts of the mechanical


seal 457 onto the main screw, see Fig. 13.
457

Fig. 13
X027561A

4. Slide the new o-ring 739.1 onto the sealing


sleeve 043 and slide the sealing sleeve onto
the main screw, see Fig. 14. Mount the
supporting ring 056* and the L-ring 058.
8
043 056*

739.1
Fig. 14
X027301A

5. Press the ball bearing 817 onto the main


screw, see Fig. 15.

X027311A

31
507
5 Maintenance

6. Mount the supporting ring 056 and circlip


471. Slide the main screw with premounted
sealing sleeve into the pump housing until
the main screw engages into the idle screws,
see Fig. 16. In doing so turn the main screw
and take the position of the clearance for the
adapter sleeve into account.

X027321A

7. Mount the screw plug 165.1, circlip 472 and


feather key 866, see Fig. 17.

X027331A

32
508

6 Technical Data

6.1 Operating limits


Design pressure max. [bar] 16
Valve opening pressure [bar] 6 bar 10 %for separator systems
10 bar 10 % for fuel conditioning systems
Temperature max. [C] 180

Temperature min. [C] for pump materials -20

Viscosity min. max. [mm2/s] 1.4 10 000


Rotation speed [min-1]
at 50 Hz 2 900
at 60 Hz 3 500

6.2 Required Net Positive Suction Height (NPSH)


values
The following table lists the required NPSH
values during operation with a low-volatile
liquid such as lubricating oil or hydraulic liquid.
When liquids have a readily volatile component
content, the required NPSH values increase
notably when the pumped liquid contains water
(e.g. heavy fuel oil), the values in the table have
to be increased by the vapor pressure of the
water at the specified operating temperature.

33
509
6 Technical Data

The required NPSH values also need to be


increased if there are gas contents, regardless
of whether it is dissolved or not. In case of any
doubt, please contact the manufacturer.

Size Viscosity NPSH value [mWC] at Size Viscosity NPSH value [mWC] at
[mm2/s] Rotation speed [min-1] [mm2/s] Rotation speed [min-1]
1 450 1 750 2 900 3 500 1 450 1 750 2 900 3 500
ALP 6 2.0 ALP 6 2.0
15 55
37 2.0 37 2.0 2.7
152 2.0 2.2 152 2.1 2.8 3.3
380 2.0 2.7 3.0 380 2.5 2.7 3.5 4.0
ALP 6 2.0 ALP 6 2.0 2.6 3.0
20 75
37 2.0 37 2.0 2.9 3.4
152 2.0 2.4 2.7 152 2.3 2.5 3.3 4.1
380 2.2 2.4 3.2 3.8 380 2.7 3.0 4.4 5.0
ALP 6 2.0 ALP 6 2.0 2.8 3.4
30 85
37 2.0 37 2.0 3.1 3.8
152 2.0 2.3 2.6 152 2.4 2.6 3.8 4.6
380 2.2 2.4 3.1 3.7 380 2.8 3.1 4.6 5.8
ALP 6 2.0 2.3
40
37 2.0 2.1 2.6
152 2.0 2.8 3.5
380 2.5 2.7 4.0 4.8

6.3 Weights
ALP weights with elastomer coupling

Motor size Size 15 20 Size 30 40 Size 55 75 85 Weight of


bracket with
screws [kg]
Weight of pump with free shaft end [kg]
6.3 8.7 12.6
Weight of adapter housing with spider coupling and screws [kg]
80 1.1 1.1 1.0
90 1.5 1.5 1.0
100 2.1 2.1 2.0 1.8
112 2.1 2.1 2.0 1.8
132 3.2 2.7

34
510
6 Technical Data

6.4 Dimensions
Dimensions ALP pump

Size Pump Shaft end [mm]


[mm]
g B1 L1 L2 L3 L4 D1 D2 D3 S1 Z1 d l t u
15 20 73 15 50 12 60 60 128 103 80 9 4 14 30 16 5
30 40 73 12 50 12 68 75 135 103 80 9 4 14 30 16 5
55 85 83 15 50 15 75 85 160 125 100 11 4 19 35 21.5 6

Dimensions pump unit with elastomer coupling

Size Motor Pump unit [mm]


size
LP LL LM* LG* L5 L5.1 L6 L7 L8 L9 H1 H2 B2 B3 S4
*
15
20 80 157 110 * ** 60 90 21 89 12 112 210 180 11
90 157 118 * ** 60 90 19 99 12 112 210 180 11
100/112 157 128 * ** 185 230 106 109 15 155 250 215 14x24
30
40 80 208 110 * ** 60 90 21 97 12 112 210 180 11
90 208 118 * ** 60 90 19 107 12 112 210 180 11
100/112 208 128 * ** 185 230 106 117 15 155 250 215 14x24
55
85 90 226 118 * ** 60 90 19 114 12 112 210 180 11
100/112 226 128 * ** 185 230 106 124 15 155 250 215 14x24
132 226 150 * ** 225 270 130 130 18 185 300 265 14x24

* Depends on motor model.

** LG=LP+LL+LM

35
511
6 Technical Data

6.4.1 Dimension drawing of ALP


pump and pump unit

X027341A

36
512
6 Technical Data

6.5 Capacity tables

6.5.1 Capacity at 50 Hz, delta = 4


bar
Q [l/hour] at viscosity [mm/s] 50 Hz
Motor kW 13 30 40 60 100 180 380 460** 700**
ALP 15 0,75 1 625 1 678 1 693 1 712 1 731 1 747 1 762 1 765 1 771
0,55 727 780 796 814 833 850 865 868 873
0,37 407 459 475 494 513 529 544 547 553

ALP 20 1,1 2 138 2 208 2 228 2 253 2 278 2 299 2 319 2 323 2 330
0,55 957 1 026 1 047 1 072 1 096 1 118 1 138 1 142 1 149
0,37 535 604 625 650 674 696 716 720 727

ALP 30 1,5 3 456 3 537 3 561 3 590 3 619 3 644 3 667 3 672 3 680
1,1 1 597 1 678 1 702 1 731 1 760 1 785 1 808 1 813 1 821
0,75 934 1 014 1 038 1 067 1 096 1 121 1 144 1 149 1 158

ALP 40 2,2 4 606 4 713 4 746 4 784 4 822 4 856 4 887 4 893 4 905
1,1 2 129 2 236 2 268 2 307 2 345 2 379 2 409 2 416 2 427
0,75 1 244 1 351 1 384 1 422 1 460 1 494 1 525 1 531 1 543

ALP 55 3 6 326 6 464 6 505 6 555 6 604 6 647 6 687 6 695 6 710
2,2 2 939 3 077 3 118 3 168 3 217 3 260 3 300 3 308 3 323
1,5 1 729 1 867 1 909 1 958 2 008 2 051 2 090 2 098 2 113

ALP 75 3 8 184 8 346 8 394 8 452 8 510 8 561 8 607 8 616 8 634
2,2 3 829 3 991 4 040 4 098 4 156 4 206 4 252 4 262 4 279
1,5 2 274 2 436 2 485 2 542 2 600 2 651 2 697 2 707 2 724

ALP 85 4 9 135 9 302 9 352 9 412 9 471 9 524 9 571 9 581 9 599
2,2 4 296 4 463 4 514 4 573 4 633 4 685 4 733 4 743 4 761
1,5 2 568 2 735 2 786 2 845 2 905 2 957 3 005 3 015 3 033

37
513
6 Technical Data

6.5.2 Capacity at 60 Hz, delta = 4


bar
Q [l/hour] at viscosity [mm/s] 60 Hz
Motor kW 13 30 40 60 100 180 380 460** 700**
ALP 15 0,75 2 010 2 062 2 078 2 097 2 116 2 132 2 147 2 150 2 156
0,55 920 972 988 1 007 1 026 1 042 1 057 1 060 1 066
0,37 535 588 603 622 641 657 672 675 681

ALP 20 1,1 2 645 2 714 2 735 2 759 2 784 2 805 2 825 2 829 2 837
0,55 1 210 1 279 1 300 1 325 1 349 1 371 1 391 1 395 1 402
0,37 704 773 794 819 843 865 885 889 896

ALP 30 1,5 4 253 4 334 4 358 4 387 4 415 4 441 4 464 4 468 4 477
1,1 1 996 2 076 2 101 2 129 2 158 2 183 2 206 2 211 2 220
0,75 1 199 1 280 1 304 1 333 1 362 1 387 1 410 1 414 1 423

ALP 40 2,2 5 668 5 775 5 807 5 846 5 884 5 918 5 948 5 955 5 966
1,1 2 659 2 767 2 799 2 838 2 876 2 910 2 940 2 947 2 958
0,75 1 598 1 705 1 738 1 776 1 814 1 848 1 879 1 885 1 896

ALP 55 3 7 777 7 915 7 957 8 006 8 056 8 099 8 138 8 146 8 161
2,2 3 665 3 803 3 844 3 893 3 943 3 986 4 026 4 033 4 048
1,5 2 213 2 351 2 393 2 442 2 491 2 535 2 574 2 582 2 597

ALP 75 3 10 050 10 212 10 261 10 318 10 376 10 427 10 473 10 483 10 500
2,2 4 762 4 924 4 973 5 031 5 089 5 139 5 186 5 195 5 212
1,5 2 896 3 058 3 107 3 164 3 222 3 273 3 319 3 329 3 346

ALP 85 4 11 208 11 375 11 426 11 485 11 545 11 597 11 645 11 655 11 673
2,2 5 333 5 500 5 550 5 610 5 670 5 722 5 770 5 779 5 798
1,5 3 260 3 427 3 477 3 536 3 596 3 648 3 696 3 706 3 724

* Max. possible viscosity without cavitation with


a suction head of -4 mWC at sea level.

** Re-sizing of motor required.

38
514
6 Technical Data

6.5.3 Noise levels


Guide values at 1 m distance, 1450 min-1, 10
bar

Sound pressure level max. 3 [dB(A)]


Size 15 20 30 40 55 85
Pump 56 59 65

6.5.4 Labelling

6.5.4.1 Type code


2 4 6

ALP-0020-BAC090
1 3 5
X027421A

Pos. Designation Type


1 Model ALP
2 Size Corresponds to flow rate in [l/min] at 1 450 min-1
3 Shaft seal B: Mechanical seal of hard material
D: Magnetic coupling
4 Pressure stage A: 6 bar
overflow valve B: 10 bar
5 Completion A: Pump with free shaft end
B: With adaptor housing and coupling (flange mounted)
C: With adaptor housing, coupling and foot (foot mounted)
D: B with motor
E: C with Motor
6 Frame size 080
090
100
112
132
160
180

39
515
6 Technical Data
516

7 Installation

Observe the following instructions:

When selecting the location take the


operating limits, Net Positive Suction Head
(NPSH) values and ambient conditions into
account, see 6 Technical Data on page 33.
The function, safety and service life may
not be impaired by humidity, temperature
influences or explosive atmospheres.
During the installation ensure that all the
parts of the pump can be accessed easily
and that the maintenance work can be
carried out easily.
7.1 Installing the pump
The pump must be installed to meet the
following demands:

The pump must be mounted on a solid


foundation and on a drip tray or in a
cofferdam.
The pump can be operated vertically or
horizontally. However, if vertically mounted
the pump should not be mounted above the
motor since pumped liquid could enter the
motor should a leak occur.
The pump must be easily accessed for
inspection and service.
The pump must be installed so that the oil
is kept in the pump casing when the oil flow
is stopped.
The pump must be installed as close as
possible to the feed tank in order to avoid
suction losses.

41
517
7 Installation

X027351A

Model ALP vertical mounting Model ALP horizontal mounting

7.2 Protect the pump against contamination

ON
CAUTI
!
Avoid damage through impurities in the pipe
system.
1. During welding work attach protective
covers in front of the connecting flanges.
2. Ensure when welding that welding beads
and abrasive dust cannot get into the pipe
system and the pump.
3. After the connecting work clean the pipe
system thoroughly, see 7.6.1 Cleaning the
pipe system on page 44

42
518
7 Installation

7.3 Piping
The pipe installation must meet the following
demands:

The pipes must be installed and supported


with no support from the pump casing.
The pipe flanges must fit the pump flanges
so that they can be connected without using
any force. Check the clearance and the
angular, vertical and linear offset, adjusting
where necessary.
Before the pipes are connected to the pump
they must be cleaned from particles resulting
from, for example, welding and cutting.
Tighten the connecting screws crosswise X027361A

with torque, see 9.1.1 Tightening torques on


page 56.

In installations where the pump does not


retain the oil at stand still, the suction pipe
should be arranged so it forms a liquid trap
together with the pump. The liquid trap
should secure that the pump is kept at least
half filled with oil at stand still.
Shut-off valves must be installed on both
sides of the pump.
The suction line should be dimensioned for
an oil flow speed between 0.5 and 1.2 m/s,
and the pressure line for 1 to 3 m/s.
The suction line must be equipped with a X027513A

port near the pump, that allows filling the


pump with oil before the initial start.
The manometric suction head must not
exceed the NPSH values in 6.2 Required
Net Positive Suction Height (NPSH) values
on page 33

7.4 Strainer
An oil strainer of suitable size should be installed
to protect the pump against damage and wear
from coarse particles.

The pressure drop across the strainer should


not exceed 10 kPa (0.1 bar) at maximum flow
rate and normal viscosity.

43
519
7 Installation

7.5 Gauges
Pressure gauges on both the suction and
the pressure side must be connected by 1/2
sockets and ball valves.

7.6 Commissioning

7.6.1 Cleaning the pipe system


To protect the pump against soiling the complete
pipe system has to be cleaned carefully before
initial commissioning of the pump.

7.6.2 Filling the pump


The filling procedure must be followed when the
pump is taken into operation after installation
and whenever the pump casing has been
emptied of oil, for example, when the pump has
been dismantled.

NG
WARNI
!
Entrapment hazard
Do not start filling the pump unless the power is
switched off.

1. Remove the fan cover from the electric


motor.
2. Turn the pump shaft or the fan impeller of
the motor. This tests that the pump runs
smoothly. If the pump cannot be turned by
hand, remedy the fault before installing the
pump, see 4.2 Troubleshooting on page 19.
3. Open the port on the suction pipe near the
pump.

44
520
7 Installation

4. Open the shut-off valve on the pressure


side of the pump.

5. Vent the shaft seal compartment (3).

In installations with positive suction pressure:


After opening the inlet and outlet valves, simply
open the deaeration plug (3) a few turns until oil
sips out. Tighten the plug.

In installation with negative suction pressure:


After opening the inlet and outlet valves, remove
the deaeration plug (3) and fill the shaft seal
compartment with oil. Fit and tighten the plug. X027514A

8. Fill the pump with oil while rotating the


pump manually. The pump is rotated
by turning the motor fan in the direction
indicated by the rotation arrow on the motor
or connection flange. (There are arrows for
inlet and outlet directions on the pump. Do
not mix them up with the rotation arrow.)

9. When the pump is filled, close the filling port


and refit the fan cover.

10. Check that all valves necessary for


operation are open.

X027371A

1. Suction connection
2. Pressure connection
3. Vent hole

7.6.3 Checking the direction of


rotation
The direction of rotation and the flow direction
are indicated by arrows on the pump. The
direction of rotation of the motor gives the
direction of rotation of the pump. That is to say,
the fan impeller of the motor must rotate in the
direction in which the arrows on the pump are
pointing to indicate direction of rotation.

45
521
7 Installation

Standard direction of rotation: clockwise


(viewed from the drive)

X027381A

1. Arrow for flow direction


2. Arrow for direction of rotation

ON
CAUTI
!
Dry running can damage pump equipment.
Ensure that the pump is filled properly.

Switch the pump on for a maximum of 1 second and


then off again immediately.

ON
CAUTI
!
Dry running can damage pump equipment.
Ensure that the pump is filled properly.

If the pump does not deliver after 1015 seconds,


abort commissioning.

1. Ensure that the pump is filled. In case


of doubt prelubricate the pump and
mechanical seal by pouring in liquid via the
vent hole, see 5.5 Cleaning the leakage
vent hole on page 25.

2. Switch on the pump.


The pump will deliver when the pressure
on the pressure side of the pump rises or a
system-side flow indicator triggers.

46
522
7 Installation

3. If the pump does not deliver after


1015 seconds of operation, abort initial
commissioning, establish the cause of
the fault and only then continue the
commissioning procedure. Follow the
instructions in the fault table, see 4.2
Troubleshooting on page 19.

4. Run the pump for a few minutes to allow the


pipe system to vent fully. The pipe system
is fully vented when there is a smooth
operating noise and a pressure gauge on
the pressure side of the pump shows no
more fluctuations.

7.6.4 Taking the pump out of


operation

NG
WARNI
!
Risk of injury or poisoning through emitted
pumped liquid.
Wear protective clothing during all the work.

Collect the emitted pumped liquid safely and dispose


of it in an environmentally compatible manner.

Carry out the following measures during shutdowns:

Pump is Measure
shut down for longer period Depending on pumped liquid, see below..
Close the pressure-side and suction-side shut-off
drained devices.
Disconnect the motor from the power supply and secure
dismantled it against being switched back on.
Observe measures for storing and preservation, see
stored page 51.

Measures for operation interruption

Behavior of the pumped


liquid Duration of the shut down
Short Long
sediment solids Rinse the pump. Rinse the pump.
congealed/frozen Heat or drain the pump. Drain the pump.
no corrosive burden
congealed/frozen Heat or drain the pump. Drain the pump.
corrosive burden Preserve the pump.
remains liquid

47
523
7 Installation

no corrosive burden
remains liquid Drain the pump.
corrosive burden Preserve the pump.

Measures depending on behavior of the pumped


liquid

Drain the pump via the pressure and suction


line and vent screw.

7.6.5 Recommissioning the


pump
Carry out all the steps as for the commissioning
process, see 7.6 Commissioning on page 44.

48
524

8 Transportation, storage and


disposal

8.1 Unpacking and checking the state of delivery


1. Upon delivery unpack the pump/pump unit
and check for transport damage.

2. Report any transport damage immediately


to the manufacturer.

3. Dispose of packing materials in accordance


with the locally applicable regulations.

49
525
8 Transportation, storage and disposal

8.2 Lifting the pump/pump unit

X027411A

Fig. 1 Fig. 2

Prerequisites:

Sufficiently dimensioned hoisting equipment


The used hoisting equipment conforms to
the local regulations and health and safety
regulations

NGE R
! DA
Risk of injury and/or damage to equipment
should the pump/pump unit fall.
Use intact and correctly dimensioned hoisting
equipment suitable for the weight to be lifted.

Fasten the hoisting equipment in accordance


with figures 1 or 2.

50
526
8 Transportation, storage and disposal

Secure motors additionally against tilting.

Do not stand under raised loads.

8.2.1 Pump
Depending on the locally applicable
regulations, the pump can be transported
either manually or by using suitable hoisting
equipment.

8.2.2 Pump unit


1. Vertical mounting: Fasten the slings around
the adapter housing, see Fig. 1.

Horizontal mounting: Fasten the slings to


the pump unit at an appropriate angle, see
Fig. 2.

Ensure that the center of gravity of the


pump unit lies between and below the
attachment points. If this is not possible,
take other suitable measures to prevent the
pump unit from tilting.

2. Secure the slings against slipping, for


example with screwed-in eye bolts.

3. Attach the slings onto the crane hook and


lift the pump unit.

8.3 Storage
During the test run, the internal components of
the pump are wetted with test oil, which has
a preservative effect. The pipe connections
are fitted with protective covers. The external
components of the pump are preserved with
a single-coat PU-based two-component paint.
The preservative applied at the factory will
protect the pump for about six weeks, if it
is stored in a dry and clean location. The
manufacturer offers a long-term preservation for
storage times of up to 60 months. With longterm
conservation the pump is additionally packed in
hermetically sealing anti-corrosion paper.

51
527
8 Transportation, storage and disposal

8.3.1 Preservation
Preservation has to be carried out in the
following cases:

For standard delivery: For storage periods


exceeding six weeks and in case of adverse
storage conditions such as high humidity,
salty air, etc.
For delivery with long-term preservation:
If the packaging has been opened or
damaged.

8.3.2 Preserving the internal


surfaces of the pump
1. Close the suction connection of the pump
with a blind flange.

2. Pour non-corrosive, resin-free oil into the


pressure connection until it reaches approx.
2 cm under the pressure flange, while
slowly turning the main screw against the
direction of rotation.

3. Close the pressure connection of the pump


with a blind flange.

After about 6 months storage check the oil


level in the pump and top up if necessary.

8.3.3 Preserving the external


surfaces of the pump
Aids:

- Preservative (e.g. Castrol Rustilo DWX 33)


Paint or spray the preservative onto all plain and
unpainted parts.

At intervals of about six months, check the


preservative effect and if necessary repeat
preservation.

NOTE

Store the preserved pump in a cool and dry place and


do not expose it to direct sunlight.

52
528
8 Transportation, storage and disposal

8.3.4 Removing the preservation


Aids:

- Solvent
- Steam-jet cleaning device with
wax-dissolving additives

NG
WARNI
!
Risk of injury through emitted preservative
oil.
Wear protective clothing during all the work.

Remove the blind flange with caution to relieve any


pressure inside the pump.

Collect the emitted oil safely and dispose of it in an


environmentally compatible manner.

1. Clean the outside of the pump with


solvents, if necessary using a steam-jet
cleaning device.

2. Remove the blind flange on the pressure


side.

3. Drain the pump, collecting the preservative


oil in a suitable vessel.

4. Remove the blind flange on the suction


side.

5. To remove the residual oil, rinse the pump


with the pumped liquid.

8.4 Disposing of the pump


Aids:

- Solvents or industrial cleaners suitable for


the pumped liquid

53
529
8 Transportation, storage and disposal

NG
WARNI
!
Danger of poisoning and damage to the
environment from the pumped liquid.
Wear protective clothing during all the work.

Collect the discharging pumped liquid and oil and


dispose of it in accordance with the locally applicable
regulations.

Neutralize any residues of the pumped liquid.

1. Disassemble the pump.

2. Clean residues of the pumped liquid from


the individual parts.

3. Separate sealing elements made of


elastomers and ceramics (SiC) from the
pump and dispose of them in the residual
waste.

4. Recycle metal parts.

54
530

9 Spare parts

9.1 Spare parts kit


Pump size Kit type Part. no
ALP 15-20 Commissioning Kit 9007162-80
Overhaul Kit 9007162-81

ALP 30-40 Commissioning Kit 9007162-82


Overhaul Kit 9007162-83

ALP 55-85 Commissioning Kit 9007162-84


Overhaul Kit 9007162-85

Spare part kit Qty. Pos- Denomination


.no.
A: Commissioning kit
1 457.1 O-ring stationary seal
ring
1 457.2 O-ring rotary seal ring
1 472 Circlip
1 471 Circlip
1 056 Supporting ring
1* 056* Supporting ring
X027121A
1 058 L-ring
1 Disassembly tool
* Only for sizes 1520.
B: Overhaul kit
222 1 457 Mechanical seal
471 1 222 Flat gasket
056*
1 817 Ball bearing
1 739.1 O-ring
056 472 1 472 Circlip
8 817
1 471 Circlip
457 739.1
1 056 Supporting ring
X027516A
1* 056* Supporting ring
1 058 L-ring
1 Disassembly tool
* Only for sizes 1520.

55
531
9 Spare parts

9.1.1 Tightening torques


Tightening torque [Nm] for screws with metric threads + head contact With thread
surfaces measured in
inches
+ wedge lock Stainless steel Screw plugs
washers screws A2 and A4 with elastomer
seal
Thread 8.8 10.9 8.8 + 8.8 Rust-proof Property Property Thread Galva-
Alu* A4-70 class 70 class 80 nized +
stain-
less
steel
M3 1.5 1.2 1.5 1.1 G1/8" 13
M4 2.9 4.1 2.3 3 2 G1/4" 30
M5 6.0 8.0 4.8 6.0 3.9 3.5 4.7 G3/8" 60
M6 9.5 14 7.6 10.3 6.9 6 8 G1/2" 80
M8 23.1 34 18.,4 25 17 16 22 G3/4" 120
M10 46 68 36.8 47 33 32 43 G1" 200
M12 80 117 64 84 56 56 75 G1 1/4" 400
M14 127 186 101 133 89 G1 1/2" 450
M16 194 285 155 204 136 135 180 * reduced
M18 280 390 224 284 191 tightening
torque when
M20 392 558 313 399 267 280 370
screwing into
M24 675 960 540 687 460 455 605 aluminum

9.1.2 Required tools for


maintenance work
Disassembly tool

X027391A

Dimensions disassembly tool [mm]


Size d1 d2 l1 l2 s
G
15 85 1/4" 3 80 12 10

56
Component 532

Description

Heating System Kit


including Heatpac CBM Brazed
plate heat exchanger

P 00 32 61 A

Product No. 583382-11 to 20

Printed Apr 2014


Book No. 9007143-02 V5

Marine & Diesel Equipment


533

Alfa Laval reserve the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be gratefully
appreciated.
Copies of this publication can be ordered from your local Alfa Laval
company.
Published by: Alfa Laval Tumba AB
Marine & Diesel Equipment
S - 147 80 Tumba
Sweden
Copyright Alfa Laval Tumba AB Apr 2014.
The original instructions are in English
534

Contents

1 Function Description ........................................................................................... 7


1.1 Application ........................................................................................................... 7
1.2 Design .................................................................................................................... 8

2 Operation..................................................................................................................... 9
2.1 Start ........................................................................................................................ 9
2.2 Operation ............................................................................................................ 10
2.3 Stop....................................................................................................................... 10

3 Fault Finding .......................................................................................................... 11

4 Maintenance .......................................................................................................... 13
4.1 General information ........................................................................................ 13
4.2 Manual Cleaning ............................................................................................... 14
4.3 Cleaning with CIP............................................................................................. 15

5 Technical Data ..................................................................................................... 17


5.1 Specification...................................................................................................... 17
5.2 Dimensions CBM 30......................................................................................... 18
5.3 Dimensions CBM 110 ...................................................................................... 19

6 Installation .............................................................................................................. 21
6.1 System Design .................................................................................................. 21
6.2 Heater Mounting .............................................................................................. 22
6.3 Installation of Ancillary Components ........................................................ 23
6.4 Installation Drawings...................................................................................... 24
6.4.1 Heatpac CBM Heating Kit for Separator System ................................................ 24
6.4.2 Installation drawing, steam system ........................................................................ 25
6.4.3 Installation drawing, thermal oil/hot water system.................................................. 26
6.4.4 Heatpac CBM connection kit for CIP unit............................................................. 27

7 Spare Parts ............................................................................................................. 29

8 Ancillary Equipment ......................................................................................... 31


8.1 Steam Regulating Valve ................................................................................ 31
8.1.1 Application ............................................................................................................. 31
8.1.2 Design .................................................................................................................... 31
8.1.3 Motor Drive Assembly ............................................................................................ 32
8.1.4 Valve....................................................................................................................... 33
8.1.5 Motor Drive ............................................................................................................. 34
8.1.6 Valve Options ......................................................................................................... 34
8.1.7 Preventive Maintenance ......................................................................................... 34

9007143-02
535

8.1.8 Technical Data ........................................................................................................36


8.1.9 Dimensions ............................................................................................................37
8.1.10 Installation...............................................................................................................39
8.1.11 Spare parts .............................................................................................................46
8.2 Safety Valve .......................................................................................................48
8.2.1 Application..............................................................................................................48
8.2.2 Design ....................................................................................................................48
8.2.3 Working Principle ...................................................................................................48
8.2.4 Technical Data ........................................................................................................49
8.2.5 Dimensions ............................................................................................................49
8.3 Steam Shut-off Valve ......................................................................................50
8.3.1 Technical Data ........................................................................................................50
8.4 Steam Trap .........................................................................................................52
8.4.1 Technical Data ......................................................................................................52
8.5 Vacuum Breaker ...............................................................................................53
8.5.1 Technical Data .....................................................................................................53
8.6 Inlet Strainer ......................................................................................................54
8.6.1 Technical Data .....................................................................................................54

9007143-02
536

Study instruction manuals and observe the warnings before


Study instruction manuals and observe the
installation, operation, service and maintenance.
warnings before installation, operation,
service and maintenance.
Not following the instructions can result in serious accidents with
fatal injuries.
Not following the instructions can result in
serious accidents with fatal injuries.

In order to make the information clear only foreseeable conditions have P0 0 02 72 A

been considered. No warnings are given, therefore, for situations arising


from unintended usage of the machine and its tools.
A summary of the safety information is found in the Safety chapter under
divider 1.
537
538

1 Function Description

1.1 Application
The heating system is primarily for heating of
mineral oils. The heating medium can be
steam, hot water or thermal oil.
The main components in the heating system
are supplied separately.
The heating system is suitable for both
separator systems and fuel conditioning
systems.

9007143-02 7
539
HEATING SYSTEM KIT 1 FUNCTION DESCRIPTION

1.2 Design
The heater consists of a number of corrugated
stainless steel plates brazed together to form a
plate pack. The pack is designed so that the
mineral oil flows through every second space
between the plates, and the heating medium
through every second space. Highly efficient heat
transfer is generated by allowing the two liquids
to flow in opposite directions.

P0 0 35 31 A
Heat transfer priciple

The heater has a manufacturing plate, which


can be found behind the cover plate between the
connection flanges. When contacting Alfa Laval,
please state the heater type and manufacturing
number. 2007

30

X0 24 6 22 B

1. Manufacturer, manufacturing year


2. Manufacturing serial number
3. Type designation
4. Part number
5. Connection description
6. Dessign pressure, maximum
7. Design temperature
8. Volume, litres
9. Approval

8 9007143-02
540

2 Operation

Operation of the Heatpac CBM system will


depend on the actual heating system
configuration. Information regarding operation
is therefore mainly to be found in the relevant
instructions for the control equipment. General
start and stop procedures are described below.

2.1 Start

ING
WARN
!

Burn Hazard
The heater must not be used without the insulated
protection cover. This shields the hot surfaces and
also acts as a safety cover in the unlikely event of
leakage.

1 Make sure that all valves in the oil line are


fully open.
2 Start the oil feed pump.
3 If necessary vent air from the heater through
the safety valve.
4 Start the heater controller.
5 Open the heating media supply and outlet
valves.
6 Check that the correct oil outlet temperature
is reached. If the right temperature is not
reached, see the Fault finding chapter.

9007143-02 9
541
HEATING SYSTEM KIT 2 OPERATION

2.2 Operation

The Heatpac CBM does not require any


particular attention during normal operation.
However, regularly check the pressure indicators
(if installed) before and after the heater. The
pressure difference indicates the pressure drop
in the heater. If the pressure drop increases to
more than approx.
0.5 1 bar, the heater is starting to clog and
needs to be cleaned, see Maintenance.

ON
CAUTI

P0 03 48 1 A
!

Pressure drop checking


Burn Hazard 1. Inlet pressure
To prevent pressure or heat shocks in the system, 2. Outlet pressure
adjustment of the flow rate must be carried out
slowly. The heater can otherwise be damaged.

2.3 Stop
1 Stop the heater controller.
2 Close the heating medium supply and outlet
valves.
3 Wait until the oil outlet temperature starts to
drop.
4 Stop the oil feed pump.

10 9007143-02
542

3 Fault Finding

Fault Probable cause Remedy


High pressure Deposits inside the heater. Clean the heater, see the maintenance chapter.
drop.
High temperature. Set-point changed in the control unit. Adjust set-point.
Flow irregularities or abnormal input Check oil flow and inlet temperature. Adjust
conditions. process condition.
Regulating valve not functioning. Check fuse in the control unit or check for broken
wiring.
Check the regulating valve.
Safety valve Oil valves closed causing oil to overheat. Shut off heating medium. Open oil inlet and outlet
opens. valves.

Low temperature. Set-point changed in the control unit. Adjust set-point.


Flow irregularities or abnormal input Check oil flow and inlet temperature. Adjust
conditions. process condition.
Regulating valve not functioning. Check fuse in the control unit or check for broken
wiring.
Check the regulating valve.
Deposits inside the heater. Clean the heater, see the maintenance chapter.
Incorrect installation. Check if the heater is connected according to the
installation drawings, see Technical data.
Steam trap not functioning. By-pass the steam trap for a while to ensure that
the condensate line is not blocked or shut off. If the
flow of the condensate is in order, then check the
steam trap.
Leakage between Misalignment between flange and connection. Rearrange the pipe in order to eliminate stress and
flange and heater. to correct alignment.
Dislocated or damaged gasket. Relocate or replace damaged gaskets.
Foreign objects on the surfaces. Check and clean the surfaces. Fit new gaskets.
Mixing of media. Pipe connections mixed. Relocate the piping to the heater according to the
Installation chapter.

9007143-02 11
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HEATING SYSTEM KIT 3 FAULT FINDING

12 9007143-02
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4 Maintenance

4.1 General information


The plate corrugations are designed to create
high turbulence which, to a high degree, will
prevent the formation of deposits on the plate
surfaces. However, fouling cannot always be
eliminated and will cause pressure drop and
poor heat transfer, resulting in reduced
performance and increased energy
requirement. Therefore, never wait with
cleaning until the heater is choked-up.
Cleaning should be carried out every six
months or at other intervals based on
experience. If the heating medium is steam or
hot water, the heating cirquit must also be
cleaned.
Recommended cleaning agents:
For fuel oil heater:
Alfa Laval fuel oil liquid
(Art. No. 1763500-02).
For lube oil heater:
Alfa Laval lube oil liquid
(Art. No. 1762852-01).
The Alfa Laval cleaning liquids are specially
suitable for the materials used in the
Heatpac CBM. Liquids that are corrosive to
copper or stainless steel, for example
hydrochloric acid and nitric acid, must not be
used.

ING
WARN
!

Burn Hazard
Shut off the oil flow and the heating medium flow
before starting maintenance.

9007143-02 13
545
HEATING SYSTEM KIT 4 MAINTENANCE

ING
WARN
!

Corrosion Hazard
Pay strict attention to the safety instructions for the
cleaning liquid used.

NOTE

Only use cleaning liquids as specified. Other


cleaning agents may corrode the metal surfaces.

4.2 Manual Cleaning


Manual cleaning is carried out as follows:
1 Disconnect the heater.
2 Drain the heater.
3 Flush the heater through with fresh water.
4 Drain the heater from water.
5 Fill the heater with hot cleaning liquid (50-
70 C). Use the type and concentration
required for the deposits present.
6 Let the liquid stay in the heater for at least 60
minutes. If possible, let the cleaning liquid
circulate in the heater.
7 Drain the cleaning liquid.
8 Flush through with clean water.
9 Reconnect the CBM heater using new
gaskets.

14 9007143-02
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4 MAINTENANCE HEATING SYSTEM KIT

4.3 Cleaning with CIP

Alfa Laval CIP System type 10M (for in place


cleaning of separators) can be used for cleaning
the CBM heater (a CIP unit connection kit is
required). The cleaning procedure when using
the CIP unit is described below (see figure). See
also the CIP System Manual for information
regarding the operation of the CIP.
1 Disconnect the heater.
2 Connections suitable for either of the two CIP
hose dimensions are available in the CIP-CBM
connection kit. Use the appropriate

P0 0 35 01 A
connection to fit the CIP hoses to the CBM
heater oil inlet and outlet flanges, see
1. Return from the heater
drawings in Technical Data. 2. Outlet to the heater
3. Plugged connections
3 Connect a hose between the highest
connection on the CIP unit and the heat
exchanger oil outlet (2)
4 Connect a hose to the heat exchanger oil inlet
and put the free end into the CIP tank (1).
5 Plug the two remaining connections on the
CIP (3). Make sure that the bottom valve on
the CIP tank is closed. Close the valve in the
CIP tank also.
6 Fill the CIP with hot water (50-70 C) and
cleaning liquid at recommended
concentrations. Total volume should be 15-20
litres.
7 Start the CIP pump and run it for at least 60
minutes.
8 Stop the CIP pump.
9 Empty the CIP tank by opening the CIP drain
valve.
10 Close CIP tank drain valve.
11 Fill the CIP with fresh water, volume
15-20 litres.
12 Start the CIP pump and rinse the CBM heater
for 10 minutes.
13 Stop the CIP pump.

9007143-02 15
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HEATING SYSTEM KIT 4 MAINTENANCE

14 Empty the CIP tank by opening the CIP drain


valve.
15 Disconnect the CIP.
Reconnect the CBM heater using new gaskets.

NOTE

Take care not to reinstall the heater upside-down.

16 9007143-02
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5 Technical Data

5.1 Specification
Operating pressure, maximum 1.6 MPa (16 bar)
Test pressure 2.4 MPa (24 bar)
Operating temperature, maximum 200 C
Medium Mineral oil
Heating media Steam, hot water, thermal oil
The following shall apply to the heating media:
Steam:condensate pH 8.8 - 9.2
sodium in condensate < 0.01 mg/l
Water:pH value Shall be neutral to minimize corrosion risk
Thermal oil The thermal oil must be highly resistant to oxidation and
thermal desintegration. It must also have good corrosion
protection properties.
Materials:Plates and connections Stainless steel AISI 316
Brazing material Copper
Insulation Mineral wool (30 mm)
Cover Aluminium
Mounting style:for hot water or thermal oil Vertically or horizontally
for steam Vertically
Ref. 1764560-61 Rev. 3

9007143-02 17
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HEATING SYSTEM KIT 5 TECHNICAL DATA

5.2 Dimensions CBM 30

X0 0 65 63 A
Ref. 9007089 Rev. 0

A. Mounting brackets (2x) D.Mounting holes (4x)9


B. Identification plate E.For welding
C. Installation label F.Depth of heater (see table below)

Part No. Type Depth of heater Volume each side Weight


(mm)
583382-11 CBM 30 20 160 0.5 litres 10 kg
583382-12 CBM 30 40 160 1.0 litres 13 kg
583382-13 CBM 30 60 260 1.6 litres 15 kg
583382-14 CBM 30 80 260 2.1 litres 17 kg
583382-15 CBM 30 100 310 2.7 litres 19 kg

18 9007143-02
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5 TECHNICAL DATA HEATING SYSTEM KIT

5.3 Dimensions CBM 110

X00 65 5 2A
Ref. 9007096 Rev. 0

A. Mounting brackets (2x) D.Mounting holes (4x) 11


B. Identification plate E.For welding
C. Installation label F.Depth of heater (see table below)

Part No. Type Depth of heater Volume each side Weight


(mm)
583382-16 CBM 110 20 190 2.0 litres 27 kg
583382-17 CBM 110 40 190 4.0 litres 35 kg
583382-18 CBM 110 60 310 6.2 litres 44 kg
583382-19 CBM 110 80 310 8.2 litres 47 kg
583382-20 CBM 110 100 370 10.5 litres 55 kg

9007143-02 19
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HEATING SYSTEM KIT 5 TECHNICAL DATA

20 9007143-02
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6 Installation

6.1 System Design


Heatpac CBM is designed for use in an oil
preheating system for separator feed oil, or in a
fuel conditioning system for engine fuel oil.
Because of its small volume, the
Heatpac CBM is very sensitive to temperature
fluctuations in the various media. This must be
taken into consideration when designing the
control system.
Use a PI temperature controller.
Select a regulating valve with the fastest
possible reaction rate. It should also be
installed close to the steam inlet in order to
avoid condensate build up.
The temperature sensor, TT1/TT2 should be
placed as close to the oil outlet of the heater
as possible. This will give rapid reaction
even at low media flow.
The heating media inlet should be equipped
with a strainer to trap impurities in the
heating system.
Strainer mesh size should be:
For Steam and Hot Water - 500
For Thermal oil - 800
When using steam, a vacuum breaker
should be installed downstream the steam
regulating valve.
When using steam, a mechanical float type
steam trap must be used. Other types of
steam trap are not allowed.

9007143-02 21
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HEATING SYSTEM KIT 6 INSTALLATION

6.2 Heater Mounting


When installing the Heatpac CBM, the
following should be taken into consideration:
If steam is to be used, the heater must be
mounted vertically. If both media are liquids
the heater can be mounted either vertically
or horizontally.
Before connecting any piping to the heater,
make sure that all foreign objects have
been rinsed out of the system.
Vibrations or other forces from the
connected piping must be avoided.
When connecting the pipe system to the
heater make sure that no stress or strain is

P0 03 4 91 A
placed on the heater by the piping system.
Also remember that expansion of the piping
due to heat can result in high stress. 1. Heating medium inlet
2. heating medium outlet
3. Drip tray
4. Safety valve drain
5. Oil inlet pressure indicator
6. Oil inlet
7. Heated oil outlet
8. Oil outlet pressure indicator

The heater should be connected so that the


media flow in opposite directions.
The heating medium shall always be
connected to the upper and lower left
connections as seen from the front of the
Heatpac CBM. Make sure that the

X0 0 65 62 A
installation and identification labels are right
side up. Consequently the oil should be
connected to the right connections. A. Heating medium inlet
B. Heating medium outlet
Use the flange bolts supplied with the C. Oil inlet
heater as longer bolts may damage the D. Oil outlet
heater plates.
Install a drip tray under the heater for
collection of oil and heating medium when
the heater is disconnected for cleaning.

22 9007143-02
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6 INSTALLATION HEATING SYSTEM KIT

6.3 Installation of Ancillary Components

Specifications
A safety valve with provision for pressure relief
must be installed in the oil inlet line. See the
installation drawings

ING
WARN
!

Burn Hazard
Make sure that the safety valve outlet leads into a
collecting tank or below floor level.

All connections to the heater shall be fitted


with shut-off valves so that the heater can
be removed if necessary. The valves must
not be of the fast-closing type as these can
cause pressure shocks in the heater.
When using steam as heating medium, a
mechanical float type steam trap must be
installed at least 200 mm lower than the
outlet of the heater, providing a hydraulic
head above the steam trap.
The condensate collection should be
installed below the steam trap. Otherwise
there is a risk that the discharge pressure
becomes too high and the condensate can
not be drained off.
A vacuum breaker should be mounted on
the steam inlet side to facilitate condensate
P0 0 34 91 D
drainage. (Not used for Hot Water or
Thermal Oil.)
A. min. 200 mm

Recommendation
Pressure indicators should be installed on
the oil side before and after the heater in
order to detect pressure drops, which
indicate fouling of the heater.

9007143-02 23
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6 INSTALLATION HEATING SYSTEM KIT

6.4 Installation Drawings

6.4.1 Heatpac CBM Heating Kit for Separator System

Controller

D
B

A
E
F

X0 09 5 21 B
Ref. 1764576 Rev. 3

1. Heater , Heatpac CBM A.Oil inlet


2. Regulating valve B.To separator
3. Temperature sensor, 2x Pt100 C.Voltage supply
4. Temperature indicator D.Steam (Hot water or Thermal oil)
5. Steam trap (Steam heating only) E.Condensate
6. Shut-off valve F.Min. 200 mm
7. Safety valve
8. Temperature controller
9. Pressure indicator
10. Vacuum breaker (Steam heating only)
11. Non return valve
12. Strainer. Compulsory for good operation.
0,5 mm mesh for Steam and Hot Water
0,8 mm mesh for Thermal Oil
13. CIP connection
14. Draining point

All low points in the steam pipe should be drained.

Technical data:
Media: Mineral oil
Heating media: Steam, hot water, thermal oil
Max. working pressure: Oil-side: 0,6 MPa (6 bar)
Heating media-side: 1,6 MPa (16bar)
Max. media temperature: Oil 160C
Heating media: 225C

24 9007143-02
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6 INSTALLATION HEATING SYSTEM KIT

6.4.2 Installation drawing, steam system

X0 27 0 60 A
Ref. 9012390 Rev.0

1. CBM heater
2. Strainer (optional)
3. Vacuum breaker
5. Steam trap
6. Non-return valve (not Alfa Laval scope of supply)
7. Safety valve
8. Ball valve (not Alfa Laval scope of supply)
9. Heating shut-off kit (optional)

Connections
CBM30 A DN15/DN20/DN25
CBM110 A DN20/DN25/DN32
CBM30 A1 DN20
CBM110 A1 DN25
CBM30 B DN25
CBM110 B DN40
C G 1/2 Male
C1 G 1/2 Female
D G 1/4 Male
E G 3/4 Male

a. Vertical or horizontal installation e. Steam inlet


b. Oil outlet f. Alternative
c. Oil inlet g. Plugged, for drain
d. CIP connections h. Condensate outlet

9007143-02 25
557
6 INSTALLATION HEATING SYSTEM KIT

6.4.3 Installation drawing, thermal oil/hot water system

X0 27 0 61 A
Ref. 9012391 Rev.0

1. CBM heater
2. Strainer (optional)
3. Heating regulating valve
4. Thermal oil extension kit
5. Non-return valve (not Alfa Laval scope of supply)
6. Ball valve (not Alfa Laval scope of supply)
7. Safety valve
8. Heating shut-off kit

Connections
CBM30 A DN15/DN20/DN25
CBM110 A DN20/DN25/DN32
CBM30 B DN25
CBM110 B DN40
C G 1/2 Male
D G 1/4 Male
E G 3/4 Male

a.Vertical or horizontal installation e. Hot water/thermal oil inlet


b.Oil outlet f. Alternative
c. Oil inlet g. Plugged, for drain
d. CIP connections h. Hot water/thermal oil outlet
i. Extra extension (thermal oil only)

26 9007143-02
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6 INSTALLATION HEATING SYSTEM KIT

6.4.4 Heatpac CBM connection kit for CIP unit

X0 06 38 2A
Ref. 1764630 Rev. 2

1. Flange complete A.CIP Unit


2. Gasket B.To CIP tank
3. Couplings nut C.CBM heater
4. O-ring D.Oil outlet side
5. Caps E.Oil inlet side
6. Nut F.Lower (2x) connections on CIP unit blinded
G.For CIP connection R 1 1/2
Kit No.CBM26, CBM 30 1764630-80 H.For CIP connection R 1 1/4
CBM76, CBM 110 1764630-81

9007143-02 27
559
HEATING SYSTEM KIT 6 INSTALLATION

28 9007143-02
560

7 Spare Parts

G 0 52 89 1 A
Spare Parts for Heatpac CBM 30
Item Part No. Type Remarks Parts Recommended
included for 3 years
in operation
delivery
1 583382-11 Heater CBM 30 20 incl. insulation - -
583382-12 Heater CBM 30 40 incl. insulation - -
583382-13 Heater CBM 30 60 incl. insulation - -
583382-14 Heater CBM 30 80 incl. insulation - -
583382-15 Heater CBM 30 100 incl. insulation - -
2 1764629-01 Gasket for flange 4 24

9007143-02 29
561
HEATING SYSTEM KIT 7 SPARE PARTS

Spare Parts for Heatpac CBM 110


Item Part No. Type Remarks Parts Recommended
included for 3 years
in operation
delivery
1 583382-16 Heater CBM 110 20 incl. insulation - -
583382-17 Heater CBM 110 40 incl. insulation - -
583382-18 Heater CBM 110 60 incl. insulation - -
583382-19 Heater CBM 110 80 incl. insulation - -
583382-20 Heater CBM 110 100 incl. insulation - -
2 1764628-01 Gasket for flange 4 24

30 9007143-02
562

8 Ancillary Equipment

8.1 Steam Regulating


Valve

8.1.1 Application
The steam regulating valve is designed to
regulate the flow of steam, water of all
temperatures, or thermal oil.

8.1.2 Design

The valve has a two-way valve housing and a 24


V AC motor drive. The valve spindle is moved to
the open, closed, or any intermediate position by
the motor drive mounted on the valve housing.

X02 3 96 3A

9007143-02 31
563
HEATING SYSTEM KIT 8 ANCILLARY EQUIPMENT

8.1.3 Motor Drive Assembly

The motor drive is mounted on top of the valve


housing by two Allen screws and a clamp which
fasten the drive mounting rods to the valve neck.
LEDs
indicating
A spring-loaded circular grip on the drive Motor drive valve position

operating shaft is locked onto the valve spindle.


If the shaft and valve neck are not already
Crank handle
mounted together, before the regulating unit can
be used for the first time, wind the crank handle Drive operating shaft
Mounting
to lower the drive operating shaft until the rods
Spring-loaded circular grip
spring-loaded circular grip connects to the
spindle top.
Continue to wind the crank handle until the Clamp
valve is in the completely open position. Allen screws

Check that the level indicator disc is mounted

X02 39 6 4A
correctly, showing that the valve is in the open Valve neck

position. Otherwise if not already mounted, click


a level indicator into place.
Wind the crank handle back until the valve is in
the completely closed position.

Check that the level indicator disc is mounted


correctly, showing that the valve is in the closed
position. Otherwise if not already mounted, click
a level indicator into place.
Closed
When the valve is closed, fold the crank handle
Level indicator
back into its locked position. disc

The upper LED flashes green when the valve is


closing and the lower LED flashes green when
the valve is opening.
When one of the LEDs shines green steadily, the
drive is in a rest position and the last running Open
X0 2 39 64 A

direction is in accordance with the LED.


When one of the LEDs shines red steadily, an
end position is reached.

32 9007143-02
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8 ANCILLARY EQUIPMENT HEATING SYSTEM KIT

8.1.4 Valve
The upper part of the valve housing forms the
valve neck with inside threads for the stuffing
box and for mounting of the motor drive. The
stuffing box components provide a high
temperature seal for the spindle.
To improve sealing, teflon inserts are fitted in
recesses in the lower guide boss and the
stuffing box. A stuffing box gasket prevents
leakage through the thread.

LED display
The display consists of two dual-colour LEDs
(red / green).
Both LEDs flashing red: initialisation procedure
Upper LED lit red: upper limit stop or "CLOSED" position reached
Lower LED lit red: lower limit stop or "OPEN" position reached
Upper LED flashing green: drive running, moving towards "CLOSED" position
Upper LED lit green: drive stationary, last direction of running "CLOSED"
Lower LED flashing green: drive running, moving towards "OPEN" position
Lower LED lit green: drive stationary, last direction of running "OPEN"
Both LEDs are lit green: waiting time after switching on, or after emergency function
No LED lit: no voltage supply (terminal 2a or 2b)
Both LEDs flashing red and green: drive is in manual mode

NOTE

With 3-point control it will apppear as though the


LED flashes. This is because power is only
supplied when the valve moves.

9007143-02 33
565
HEATING SYSTEM KIT 8 ANCILLARY EQUIPMENT

8.1.5 Motor Drive

Power supply 24 V 50/60 Hz AC should be


supplied by a 4-core cable, providing common, 24 V AC

open and close signals.


Terminal 21 is only valid for drive with spring-
return.

NOTE

The extra supply to connection 21 goes to a solenoid that 24 V 2b 2a GND


holds the spring in place. If there is no voltage to Incr. Decr.
connection 21, the spring closes the valve.
RTM
*

Brown
Black

Blue
2b 2a 1
21 *

X 02 39 75 A
* Only with spring return

8.1.6 Valve Options


Eleven versions of the regulating valve are
available to cover the range of flow rates
required.
The valves have different plug and spindle
assemblies to obtain the different flow rates.
There are six different bore sizes with different
valve housings and bottom cover gaskets. The
remaining components (stuffing box and
options) are identical in all valves.

8.1.7 Preventive Maintenance


No preventive maintenance of the motor drive
is recommended.
The stuffing box seals should be periodically
checked, and the valve inspected for erosion
and cavitation damages. Any worn parts must
be replaced.

34 9007143-02
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8 ANCILLARY EQUIPMENT HEATING SYSTEM KIT

The frequency of valve maintenance necessary


to avoid breakdown can vary between every
three months and a number of years depending
on the working environment.

9007143-02 35
567
HEATING SYSTEM KIT 8 ANCILLARY EQUIPMENT

8.1.8 Technical Data

Actuator
Electric motor 24 V AC, 50/60 Hz
Power consumption 20 VA (while running)
Ambient temperature Max 60 C
Enclosure IP 66
Knock-out holes for cable glands M20x1.5 (2x)
M16x1.5 (1x)
Cover material Fire resistant plastic
Mounting position Upright or horizontal

Ref. 578787 Rev. 0

Valve
Media Steam, water or thermal oil
Maximum media temperature 240 C
Maximum working pressure 25 bar up to 120 C
20 bar up to 240 C
Permanent working temp. with teflon packing box -20 C 240 C for steam and water
Max. 230 C for thermal oil
Leakage 0.5 % of kvs value
Valve characteristic Equal percentage (logarithmic)
Valve plug with soft sealing (GF PTFE)
Material
Housing Ductile nodular cast iron
Packing box housing Brass
Spindle Stainless steel
Valve seat plug Stainless steel

Ref. 578787 Rev. 0

36 9007143-02
568
8 ANCILLARY EQUIPMENT HEATING SYSTEM KIT

8.1.9 Dimensions

X0 23 9 69 A
Ref. 578787 Rev. 0, Ref. 578788 Rev. 0

Part No. A B C D Kvs Size Notes


value
578787-11 126 415 230 60 40 DN50 Actuator without spring-return
578787-10 116 411 200 60 25 DN40 Actuator without spring-return
578787-09 110 417 180 60 16 D432 Actuator without spring-return
578787-08 97 398 160 60 10 DN25 Actuator without spring-return
578787-07 94 396 150 60 6.3 DN20 Actuator without spring-return
578787-06 84 402 130 60 4 DN15 Actuator without spring-return
578787-05 84 402 130 60 2.5 DN15/1 Actuator without spring-return
578787-04 84 402 130 60 1.6 DN15/2 Actuator without spring-return
578787-03 84 402 130 60 1 DN15/3 Actuator without spring-return
578787-02 84 402 130 60 0.63 DN15/4 Actuator without spring-return
578787-01 84 402 130 60 0.40 DN15/5 Actuator without spring-return

9007143-02 37
569
HEATING SYSTEM KIT 8 ANCILLARY EQUIPMENT

Part No. A B C D Kvs Size Notes


value
578788-11 126 415 230 73 40 DN50 Actuator with spring-return
578788-10 116 411 200 73 25 DN40 Actuator with spring-return
578788-09 110 417 180 73 16 D432 Actuator with spring-return
578788-08 97 398 160 73 10 DN25 Actuator with spring-return
578788-07 94 396 150 73 6.3 DN20 Actuator with spring-return
578788-06 84 402 130 73 4 DN15 Actuator with spring-return
578788-05 84 402 130 73 2.5 DN15/1 Actuator with spring-return
578788-04 84 402 130 73 1.6 DN15/2 Actuator with spring-return
578788-03 84 402 130 73 1 DN15/3 Actuator with spring-return
578788-02 84 402 130 73 0.63 DN15/4 Actuator with spring-return
578788-01 84 402 130 73 0.40 DN15/5 Actuator with spring-return

38 9007143-02
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8 ANCILLARY EQUIPMENT HEATING SYSTEM KIT

8.1.10 Installation

Specification

There must be enough free space to allow for


maintenance and repair.
The ambient temperature must be within the
range -5 to +55 C.
The valve must be installed to close against the
operating pressure.
The valve must not be installed with the motor
drive upside down.

X 02 39 66 A
Procedure

1 Fit the valve and motor assembly to the piping


system.
2 Remove the motor drive cover and the plastic
protection in the cable entry.
3 Slide the cable gland parts on to the cable.
4 Insert the cable and secure it by tightening the
gland nut. X0 2 47 39 A

9007143-02 39
571
HEATING SYSTEM KIT 8 ANCILLARY EQUIPMENT

5 Connect the cable leads to the Response


Time Module terminals:
Common Terminal GND (1)
Valve Close Terminal 2a
Valve Open Terminal 2b
Power supply Terminal 24 V
Solenoid for spring Terminal 21( with
spring return only)

X0 2 47 40 A
6 Fit the motor drive cover and run a system test
to check that the valve assembly is operating
properly.

40 9007143-02
572
8 ANCILLARY EQUIPMENT HEATING SYSTEM KIT

Extension kit, 240 C


Use an extenssion kit at temperatures above
180 C.

1 Unscrew the two Allen screws and remove the


clamp.

X 02 39 79 A
2 Release the spring loaded grip.

X0 2 39 81 A
click

3 Push the intermediate piece into the grip.

click

OK

X02 39 8 2A

9007143-02 41
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HEATING SYSTEM KIT 8 ANCILLARY EQUIPMENT

4 Fasten the mounting rod extensions and


mount the clamp.

X0 23 98 3 A

42 9007143-02
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8 ANCILLARY EQUIPMENT HEATING SYSTEM KIT

Potentiometer mounting
1 Switch off the power supply.
2 Remove the cover of the motor drive.
3 Adjust and hold the position of the crank
handle.

hold position!

X0 23 98 4A

9007143-02 43
575
HEATING SYSTEM KIT 8 ANCILLARY EQUIPMENT

4 Connect the terminals.

stroke = 14 mm stroke = 20 mm
stroke = s

connection terminal connection terminal


front side rear side

stroke connection connection adjustment


terminal side position

rear R

front F

Position

X0 23 9 85 A

44 9007143-02
576
8 ANCILLARY EQUIPMENT HEATING SYSTEM KIT

5 Mount the potentiometer.

front or rear side see step 3.

X023986A
6 Adjust the position.

adjustment position see step 3.

X023987A

9007143-02 45
577
HEATING SYSTEM KIT 8 ANCILLARY EQUIPMENT

8.1.11 Spare parts

Actuator

XO 2 39 70 C
Ref. 578785 Rev. 5

A B Part no. Description


578785-07 Response Time Module
578785-05 Adaptor kit
578785-04 Potentiometer kit
578785-03 Extension kit, 240 C
73 578785-02 Valve drive
60 578785-01 Valve drive
410 With extension kit 578785-03
350 Without extension kit

46 9007143-02
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8 ANCILLARY EQUIPMENT HEATING SYSTEM KIT

Regulating Valve

XO 23 96 7 B
Ref. 578784 Rev. 0

Pos. C A L Kvs Size Part no. Description


4 All 578784-61 Packing box
3 DN50 578784-51 Gasket
3 DN40 578784-50 Gasket
3 DN22 578784-49 Gasket
3 DN25 578784-48 Gasket
3 DN20 578784-47 Gasket
3 DN15 578784-46 Gasket
1 111,5 126 230 40 DN50 578784-11 Valve
1 107.5 116 200 25 DN40 578784-10 Valve
1 103.5 110 180 16 DN32 578784-09 Valve
1 94.5 97 160 I0 DN25 578784-08 Valve
1 92.5 94 150 6.3 DN20 57878407 Valve
1 98.5 84 130 4 DN15/0 578784-06 Valve
1 98.5 84 130 2.5 DN15/1 578784-05 Valve
1 98.5 84 130 1.6 DN15/2 578784-04 Valve
1 98.5 84 130 1 DN15/3 578784-03 Valve
1 98.5 84 130 0.63 DN15/4 578784-02 Valve
1 98.5 84 130 0.40 DN15/5 578784-01 Valve

9007143-02 47
579
HEATING SYSTEM KIT 8 ANCILLARY EQUIPMENT

8.2 Safety Valve

8.2.1 Application
The safety valve is for use in Alfa Laval
mineral oil systems.

8.2.2 Design

The relief valve consists of a housing with a


spring-loaded cone and spindle. A gasket ensures
efficient sealing between the cone and the
housing seat.

G003411A
8.2.3 Working Principle

The safety valve is delivered with preset opening


pressure. If the pressure in the system exceeds
the preset pressure, the spring-loaded cone is
affected, and the valve opens.
The cone movement can be tested by lifting the
spindle using the manual relief on the top of the
valve.
G003421A

48 9007143-02
580
8 ANCILLARY EQUIPMENT HEATING SYSTEM KIT

8.2.4 Technical Data

Specifications
Nominal pressure 1600 kPa (16 bar) (PN16)
Material:
Housing Brass
Cone and seat Stainless steel
Max. temperature 160 C
Weight 0.3 kg

8.2.5 Dimensions

X011561A

Part no. Preset at:


1761805-01 600 kPa (6 bar)
1761805-02 1500 kPa (15 bar)

9007143-02 49
581
HEATING SYSTEM KIT 8 ANCILLARY EQUIPMENT

8.3 Steam Shut-off Valve

8.3.1 Technical Data

Ball valve
Media Steam
Maximum media temperature 198 C
Material
Valve body steel
Ball SS
Sealing carbographite

Ref. 1766465 Rev. 3

Pneumatic actuator
Operating pressure 500 700 kPa (5 7 bar)
Max. pressure 1 MPa (10 bar)
Ambient temperature -20 C +85 C
Material aluminium-elax

Ref. 1766465 Rev. 3

Pilot ventil
Media air
Ambient temperature -20 C +60 C
Material aluminium-elax
Supply voltage 24 VAC, 50/60 Hz

Ref. 1766465 Rev. 3

50 9007143-02
582
8 ANCILLARY EQUIPMENT HEATING SYSTEM KIT

Dimensions

Air inlet
G 1/4

X024628A
Part no. DN A B C D E F G Actuator Air Total weight Ball valve
consumption kg item
1766465 01 15 168 213 173 90 35 M12 65 SR 52 0.126 Nl/ Conn.15 3.2 1765948 05
stroke
1766465 02 20 184 234 193 100 40 M12 75 SR 63 0.233 Nl/ Conn.20 4.5 1765948 01
stroke
1766465 03 25 188 243 196 110 46 M12 85 SR 63 0.233 Nl/ Conn.25 5.3 1765948 02
stroke
1766465 04 32 221 286 250 130 54 M16 100 SR 85 0.531 Nl/ Conn.32 7.6 1765948 09
stroke

Ref. 1766465 Rev. 3

9007143-02 51
583
HEATING SYSTEM KIT 8 ANCILLARY EQUIPMENT

8.4 Steam Trap

8.4.1 Technical Data


Working temp. max. 250 C
Working pressure max. 16 MPa (16 bar)
Valve seat 10 bar

Ref. 1766169 Rev. 1

Dimensions

X024629A

Ref. 1766169 Rev. 1

Part no. Conn A B C D Dh E Weight kg


1766169 01 DN 15 150 107 101 95 65 51 4.5
1766169 02 DN 20 150 107 101 105 75 55 5.0
1766169 03 DN 25 160 117 70 115 85 100 6.5

Ref. 1766169 Rev. 1

52 9007143-02
584
8 ANCILLARY EQUIPMENT HEATING SYSTEM KIT

8.5 Vacuum Breaker


8.5.1 Technical Data
Media Steam
Media temp. max. 260 C
Media pressure max. 16 bar
Material Brass

Ref. 1766607 Rev. 2

Dimensions

X024630B

Ref. 1766607 Rev. 2

Part no.
1766607-01

9007143-02 53
585
HEATING SYSTEM KIT 8 ANCILLARY EQUIPMENT

8.6 Inlet Strainer

X027590A
DN L Part no. MDO/ Part no. LO/ D Dh Ds B C
Steam (500) Thermal oil (800)
15 130 7060128-01 7060128-09 95 65 14 80 110
20 150 7060128-02 7060128-10 105 75 14 85 130
25 160 7060128-03 7060128-11 115 85 14 105 150
32 180 7060128-04 7060128-12 140 100 18 110 225

8.6.1 Technical Data


Media Steam/Thermal oil
Gasket Graphite
Flanges UNI PN 16/40 - DIN 2633
Material, body Cast steel GS C25
Strainer insert Stainless steel

Ref. 7060128 Rev. 1

54 9007143-02
Component 586

Description

Sludge Removal
Kit

Product No. 582522-01, -02


580258-01 to -12

Printed July 2011


Book No. 584692-02 V5

Marine & Diesel Equipment


587

Alfa Laval reserve the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local Alfa
Laval company.
Published by: Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
Copyright Alfa Laval Tumba AB 2011.
588

Contents

1 Sludge Removal Kit.............................................................................................. 3


1.1 Function ................................................................................................................ 3
1.2 Operation .............................................................................................................. 5
1.3 Installation .......................................................................................................... 5
1.4 Maintenance ....................................................................................................... 7
1.5 Technical Data ................................................................................................... 8
1.6 Dimension Drawings ........................................................................................ 9

2 Spare Parts ............................................................................................................. 12

584692-02
589

584692-02
590
SLUDGE REMOVAL KIT COMPONENT DESCRIPTION 1 SLUDGE REMOVAL KIT

1 Sludge Removal Kit


1.1 Function
The Sludge Removal Kit collects sludge
discharged from the separator in a small tank
positioned close to the separator. At pre-set
intervalls, the sludge pump is activated, and
the sludge is pumped away from the separation
system to a larger common sludge tank.
If the Sludge Removal Kit tank is filled
between the pre-set intervalls, a level switch
inside the tank is activated, and the the pump
empties the tank.
The Sludge Removal Kit makes positioning of
the separator much easier as it does not have
to be positioned directly over the common
sludge tank.

Ventilation outlet
(Optional, LO only)

Heating element
X024594A

(Optional, HFO only)


P 605/615, S 805/815 Sludge Removal Kit P 625/626, P 635/636, S 811 S 987 Sludge Removal Kit

584692-02 3
591
1 SLUDGE REMOVAL KIT SLUDGE REMOVAL KIT COMPONENT DESCRIPTION

Optional for HFO applications, the Sludge


Removal Kit is equipped with a heating
element positioned under the bottom plate of
the sludge tank. The heating element keeps
the oil, sludge, and water in the sludge tank at
a suitable temperature.
The heating element is activated automatically
when power to the Control Cabinet is switched
on. The temperature is regulated by a
termostat inside the heating element.

NOTE

If the separation system has not been run for a


longer period, the Sludge Removal Kit must be
started 1 hour before restart.

4 584692-02
592
SLUDGE REMOVAL KIT COMPONENT DESCRIPTION 1 SLUDGE REMOVAL KIT

1.2 Operation
The Sludge Removal Kit operates
automatically according to the separator
automation program. The sludge tank kit must
be inspected regularly and cleaned if necessary.
Time between inspections can vary depending
on the oil quality in the separation system. See
1.4 Maintenance, page 7.

1.3 Installation
The Sludge Removal Kit must be connected to
the ventilation pipe for the sludge outlet, the
separator sludge outlet, and the sludge pipe
system for the larger common sludge tank.

NOTE

The sludge removal pump must be set to the correct


speed circa 60 strokes/min, otherwise the lifetime
of the diaphragm, valve balls, and air motor will be
severely shortened.
Adjust the air quality to the sludge pump using the
sludge pump air regulating valve.

ING
WARN
!

Health Risk
Oil mist and vaporized oil constituents from hot oily
sludge may be dangerous to health and must not be
inhaled.

584692-02 5
593
1 SLUDGE REMOVAL KIT SLUDGE REMOVAL KIT COMPONENT DESCRIPTION

Sludge discharge
A sludge pipe with an inspection plug must be
connected from the tank to the separation
system.
Oil tank ventilation
pipe

Tank ventilation
A pipe or hose must be drawn from the flange
to the nearest oil tank ventilation pipe.
The pipe /hose must have the same diameter
as the flange opening. ~ 5 mm

The pipe/hose must be as straight as

P0 0 00 63 A
possible, with a steady upward incline.
The connection to the oil tank ventilation pipe
must point upwards as shown.

NOTE

For HFO separation, it is not recommended to make


the connection to the separator room ventilation
system.
For LO separation, connection to the separator room
ventilation system should be made only if the
separator room ventilation is adequate. Use the
optional connection hose (part no. 568023-80, -81, or
-82) for this purpose. This hose is designed to entrap
oil drops in the vent hose, and lead the oil back to the
Sludge Removal Kit tank.

Pipe to common sludge tank


A pipe must be drawn from the Sludge
Removal Kit tank to the larger common tank.
The pipe diameter must be size 1.
The pipe must have its own heat tracing and
insulation.

NOTE

The Sludge Removal Kit is equipped with its own


non-return valve on the sludge outlet flexible hose.

NOTE

The pipe from the Sludge Removal Kit must be as


straight as possible.

6 584692-02
594
SLUDGE REMOVAL KIT COMPONENT DESCRIPTION 1 SLUDGE REMOVAL KIT

1.4 Maintenance

NOTE

Impurities gather in the Sludge Removal Kit tank.


Regularly check the tank and level switch. See
instructions below.

Proceed as follows:
Undo the screws at the top of the sludge tank
and remove the sludge pipe kit.
Pour 2/3 litre diesel oil into the tank and start
the sludge pump manually. This is to clean the
inside of the tank and the complete sludge
discharge arrangement.

NOTE

To operate the sludge pump manually, use the screw


on the air solenoid valve.

Clean the level switch if necessary.


Check the seals and gaskets, and change if
necessary.
Loosen the hose clip and check the inside of
the ventilation hose. Clean if necessary.
To avoid breakdown of the Sludge Removal
system, the sludge pump must be regularly
overhauled as follows using spare parts kit
1766702-81.
Perform an overhaul on the sludge pump
every 18 months operation.
Replace the diaphragms and the o-rings with
those delivered in the spare parts kit.
Perform a 4000 hour Inspection Service.

584692-02 7
595
1 SLUDGE REMOVAL KIT SLUDGE REMOVAL KIT COMPONENT DESCRIPTION

1.5 Technical Data


Media oil, sludge, water
Media temperature max. 120 C
Flow max. 70 l/min. at 8 bar (water)
Delivery head 5 bar
Particle size max 4 mm
Air pressure 5 7 bar
Air consumption
normal 1m3 /h
max. 1 l/sec.

8 584692-02
596
SLUDGE REMOVAL KIT COMPONENT DESCRIPTION 1 SLUDGE REMOVAL KIT

1.6 Dimension Drawings

P 605/615, S 805/815

sludge outlet
Ventilation DN50 PN6

Separator

Separator vertical axis


Level switch

Air inlet G1/4 to MV6

Flexible hose

Sludge outlet G1

X024645A
Ref. 584126 Rev. 0

584692-02 9
597
1 SLUDGE REMOVAL KIT SLUDGE REMOVAL KIT COMPONENT DESCRIPTION

P 625/626 P 635/636, S 811 S 987

sludge outlet
Separator
Ventilation
Air inlet G1/4 to MV6

Separator vertical axis


Flexible hose

Sludge outlet G 1

Base plate
fixing

X024646A
Ref. 584128 Rev. 0

A B C D E F G H
S 811 S 927, P 625/626 465 350 350 DN50 PN6 618 210 463 180
S 831 S 937, P 635/636 503 350 350 DN50 PN6 618 210 463 180
S 841 S 947 513 340 350 DN50 PN6 618 210 463 180
S 851 S 957 595 490 390 DN65 PN6 798 270 643 240
S 861 S 967 595 490 390 DN65 PN6 798 270 643 240
S 871 S 977 750 530 446 DN80 PN6 868 300 713 240
S 881 S 987 750 530 446 DN80 PN6 868 300 713 240

10 584692-02
598
SLUDGE REMOVAL KIT COMPONENT DESCRIPTION 1 SLUDGE REMOVAL KIT

Floor level differences between SRK and separators

Separator
Customer supplied
Sludge Removal
Kit
S 811 S 947
P 605 P 636 80 mm
S 851 S 987 100 mm

X024650A

584692-02 11
599
2 SPARE PARTS SLUDGE REMOVAL KIT COMPONENT DESCRIPTION

2 Spare Parts

12 584692-02
600
.Sludge removal kit
Spare Parts Catalogue

Specification No. 582713-80/10


Book No. 595190 02 Rev. 2

Spare parts catalogue Catalogo parti di ricambio


Reservdelskatalog Catalogo de pecas sobressalentes
Ersatzteilkatalog Varaosaluettelo
Catalogue de pices de
rechange
Catalogue de piezas de Reserveonderdelen-catalogus
recambio
Reservedelskatalog

601

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden

Telephone: +46 8 530 650 00


Telefax: +46 8 530 310 40

Alfa Laval Tumba AB 2011-07-06


Original instructions
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of
Alfa Laval Tumba AB.
602

Contents
1 Read this first 5
1.1 General information 6
1.2 Translation list 9

2 Sludge removal kit 12

3 Sludge removal kit 14


3.1 Sludge outlet S 821- S 836 16
3.2 Sludge outlet S 881, S 886 18
3.3 Sludge outlet S 851, S 856 20
3.4 Sludge outlet S 861, S 866 22
3.5 Sludge outlet S 871, S 876 24

4 Sludge removal kit 26


4.1 Sludge outlet S 881, S 886 28
4.2 Sludge outlet S 881, S 886 30

5 Slugde pump T70 spare parts 32

6 Cross reference list 34

3
603

4
604

1 Read this first

1 Read this first

Check the machine unit number on the name-plate before using this catalogue

Kontrollera maskinenhetens nummer p maskinskylten innan du anvnder katalogen

Das Typenschild - ein Hinweis zur korrekten Ersatzteilnummer

La plaque de la machine, un guide pour trouver le numro de pice de rechange correct

La placa-marca de la mquina - gua del nmero correcto del repuesto

La targhetta della macchina - guida al corretto numero dei ricambi

La placa do fabricante da mquina - um guia do nmero correto das partes sobressalentes

Konekilpi - opastin oikeaan varaosanumeroon

Het gegevensplaatje - een wegwijzer naar het juiste onderdeelnummer

Typeskiltet - en guide til det rette reservedelsnummer

5
605
Sludge removal kit

1.1 General information

Safeguard your commitment to quality by always using genuine


Alfa Laval spare parts.
Remember, Alfa Laval cannot accept responsibility for the
failure of a separator equipped with non-original spare parts.
We guarantee the quality and reliability of our products.

Flj ditt kvalitetstnkande genom att endast anvnda Alfa Laval


originalreservdelar.
Kom ihg att Alfa Laval inte tar ngot ansvar fr fel p en
separator, som innehller icke-originaldelar. Vi garanterar
kvaliteten och driftskerheten endast hos vra egna produkter.

Aus Rcksicht auf Ihr Bestreben um beste Qualitt sollten Sie


nur Alfa Laval Originalersatzteile benutzen.
Vergessen Sie nicht, Alfa Laval kann keine Verantwortung fr
das Versagen eines Separators bernehmen, der nicht mit
Originalersatzteilen versehen ist. Wir garantieren Qualitt und
Zuverlssigkeit unserer Produkte.

Prservez la qualit de vos quipments en nemployant que des


pices de rechange Alfa Laval.
Noubliez pas qAlfa Laval dcline toute responsabilit en cas
de panne dun sparateur non quip de pices de rechange
dorigine. Nous garantissons la qualit et la fiabilit de nos
produits.

Mantenga su compromiso con la calidad, al usar siempre piezas


de repuesto Alfa Laval autnticas.
Recuerde que Alfa Laval no acepta responsabilidad por el
fallo de una separadora equipada con piezas de repuesto no
originales. Garantizamos la calidad y fiabilidad de nuestros
productos.

6
606

1.1 General information 1 Read this first


Alfa Laval.
, Alfa Laval
,
.
.

Salvaguardate la vostra garanzia di qualit facendo sempre uso


di parti di ricambio Alfa Laval autentiche.
Tenete presente che la Alfa Laval non pu accettare
responsabilit per avaria ad un separatore attrezzato con parti
di ricambio non originali. Noi garantiamo la qualit laffidabilit
dei nostri prodotti.

Proteja o seu cometimento a qualidade usando sempre peas


sobressalentes genuinas Alfa Laval.
No esquea que Alfa Laval no aceita responsabilidade por
falha de uma separadora equipada com peas sobressalentes
no genuinas. Ns garantimos a qualidade e a confiana dos
nossos produtos.

Varmistakaa vastuunne laadusta kyttmll aina alkuperisi


Alfa Laval varaosia.
Muistakaa, Alfa Laval ei voi hyvksy vastuuta ei-alkupersill
varaosilla varustetun separaattorin vaurioista. Me takaamme
tuotteidemme laadun ja kyttvarmuuden.


Alfa Laval.
Alfa Laval
,
.
.

7
607
Sludge removal kit

Streef naar een zo hoog mogelijke kwaliteit en gebruik


uitsluitend originele Alfa Laval reserveonderdelen. Streef naar
een zo hoog mogelijke kwaliteit en gebruik uitsluitend originele
Alfa Laval reserveonderdelen.
Vergeet niet dat Alfa Laval niet verantwoordelijk is voor een
defecte separator die niet-originele onderdelen bevat. Wij
garanderen de kwaliteit en betrouwbaarheid van onze eigen
produkten.

Hold Dem til den kvalitet, De har valgt at satse p, ved altid at
anvende gte Alfa Laval reservedele.
Husk, at Alfa Laval ikke kan ptage sig noget ansvar for fejl
p en separator, som indeholder uoriginale dele. Vi kan kun
garantere kvalitet og driftsikkerhed p vore egne produkter.

8
608

1.2 Translation list 1 Read this first

1.2 Translation list

versttningslista
bersetzungsliste
Liste de traduction
Lista de traducciones

Part no. Reservdelsnummer Teil-Nr. Numro de pice Pieza No.

Qty Antal Anzahl Quantit Cantidad

Description Benmning Bezeichnung Dnomination Descripcin

Notes Anmrkningar Anmerkungen Remarques Notas

Machine type Maskintyp Maschinentyp Type de machine Tipo de mquina

Product no. Produktnr Produktnummer Numro de produit Nmero de producto

Machine unit description Maskinblocksbenmning Bezeichnung des Dnomination de partie Descripcin de seccin de
Maschinenblocks de machine la mquina

Machine unit no. Maskinblocksnr Maschinenblock Nr. Partie de machine n No. de seccin de
mquina

Subassembly description Undergruppsbenmning Bezeichung der Dnomination de Descripcin de


Untergruppe sous-ensemble subconjunto

Subassembly no. Undergruppsnr Untergruppe Nr. N de sous-ensemble Nmero de subconjunto

See page Se sidan Siehe Seite Vir page Vase la pgina

Fig. ref. Figurhnvisning Bildhinweise Rf. de fig. Referencia de figura

Product name Produktnamn Produktname Nom du produit Nombre del producto

Exchange necessitates Utbyte ndvndiggr Austausch erfordert Le remplacement El racmbio requiere el


rebalancing of bowl ombalansering av kulan Wiederauswuchtung der ncessite le rquilibrage reequilibrado del rotor
Trommel du bol
See separate spare parts Se separat reservdelslista Siehe separate Voir liste spare des Vase la lista de piezas
list Ersatzteilliste pices de rechange separada

Not delivered as spare Levereras ej som Nicht als Ersatzteil Non livr comme pice de No se entrega como pieza
part reservdel geliefert rechange de recambio

9
609
Sludge removal kit


Lista traduzioni
Lista para traduo
Knnsluttelo

Part no. Nr. parte Numero de peca Varaosanumero

Qty Quantita Quantidade Lukumr

Description Descrizione Descricao Nimitys

Notes Note Notas Huomautuksia

Machine type Tipo macchina Tipo de maquina Konetyyppi

Product no. Nr.prodotto No. do produto Tuotteen no

Machine unit description Descrizione unita Descricao da unidade da Koneenosan nimitys


macchina maquina

Machine unit no. Nr. unita macchina Numero de unidade da Koneenosan no


maquina

Subassembly description Descrizione sottogruppo Descriao do subconjunto Alaryhmn nimitys

Subassembly no. Nr. sottogruppo Nmero de subconjunto Alaryhmn no

See page . Vedi pagina Vase la pgina Ks sivu

Fig. ref. Rif. fig. Referencia de figura Kuvaviite

Product name Nome prodotto Nombre del producto Tuotteen nimi

Exchange necessitates La sostituzione comporta El racmbio requiere el Vaihdettaessa kuula


rebalancing of bowl la equilibratura del reequilibrado del rotor tasapainoitettava
tamburo uudelleen
See separate spare parts . Vedi lista separata delle Vase la lista de piezas Katso erillist
list parti di ricambio separada varaosaluetteloa

Not delivered as spare Non fornito come parte di No se entrega como pieza Ei toimiteta varaosana
part ricambio de recambio

10
610

1.2 Translation list 1 Read this first

Vertaallijst
Oversttelseliste

Part no. Onderdeelnr. Reservedelsnummer

Qty Hoeveelheid Antal

Description Beschrijving Betegnelse

Notes Opmerkingen Bemaerkninger

Machine type Machinetype Maskintype

Product no. Produktnr. Produktnr.

Machine unit description Machineblokbenaming Maskinbetegnelse


Machine unit no. Machineblokbenamning Maskinnr.


Subassembly description Subgroepbenamning Undergruppsbetegnelse

Subassembly no. Subgroepnr. Undergruppenr.

See page Zie blz. Se side

Fig. ref. Afb. ref. Figurhenvisning

Product name Produktnaam Produktnavn

Exchange necessitates Vervangning vereist Udskriftning kraever


rebalancing of bowl herbalanceren van de kogel afbalcering af kuglen

See separate spare parts list Vervangning vereist van de Se spaat reservedelsliste
kogel

Not delivered as spare part Niet geleverd als Levereres ikke som reservedel
reserveonderdeel

11
611
Sludge removal kit

2 Sludge removal kit


Machine unit number or
Subassembly description
582522-
Ref Part No Description -01 -02 Notes
Quantity
2 1766699 01 Sludge pump T70 1 1
3 580753 01 Level switch 1 1
4 1767083 04 Rubber hose 1
4 1767084 04 Rubber hose 1
7 574351 04 Flexible hose L= 860 1 1
8 569763 02 Nipple G3/4-G3/4 2 2
9 1766002 01 Non-return valve 1 1
10 1765934 01 Flexible connection 2 2
11 1766893 01 Plug 1 1
13 1762017 12 Hose 1 1
15 569763 03 Nipple G1/2-G1/2 1 1
16 569763 08 Nipple G1-G3/4 1 1
17 572915 01 Solenoid valve 1 1
18 571395 01 Elbow coupling G1/4 1 1
19 1766081 02 Regulating valve 1 1

12
612

2 Sludge removal kit

2200H

13
613
Sludge removal kit

3 Sludge removal kit


Machine unit number or
Subassembly description
580258-
Ref Part No Description -01 -02 -03 -04 -05 Notes
Quantity
1 580259 80 Tank 1 1
1 583174 80 Tank 1 1
1 583381 80 Tank 1 S4
2 1766699 01 Sludge pump T70 1 1 1 1 1
3 580403 80 Sludge outlet S 821- S 836 1 See page 16
3 580407 80 Sludge outlet S 881, S 886 1 See page 18
3 583268 80 Sludge outlet S 861, S 866 1 See page 22
3 583361 80 Sludge outlet S 851, S 856 1 See page 20
3 583746 80 Sludge outlet S 871, S 876 1 See page 24
4 580753 01 Level switch 1 1 1 1 1
5 1766081 02 Regulating valve 1 1 1 1 1
6 572915 01 Solenoid valve 1 1 1 1 1
7 1766002 01 Non-return valve 1 1 1 1 1
8 574351 05 Flexible hose L= 400 1 1 1 1 1
9 580773 80 Pipe connection 1 1 1 1 1
10 1762672 03 Hexagon plug 1 1 1 1 1
11 1762672 01 Hexagon plug 1 1 1 1 1
12 580758 06 Push-In Fittings 2 2 2 2 2
13 580769 03 Flexible hose, air D.8 1 1 1 1 1
14 1763780 02 Nipple 4 4 4 4 4
15 221030 49 Screw 8 8 8 8 8
16 223101 47 Washer 12 12 12 12 12
17 2210293 27 Screw 2 2 2 2 2
18 223101 41 Washer 2 2 2 2 2
19 1763780 06 Nipple 1 1 1 1 1
20 572215 04 Adapter extension 1 1 1 1 1
21 583259 02 Hexagon Socket 1 1 1 1 1
22 583755 80 Ventilation pipe 1 1
22 583755 81 Ventilation pipe S3 1 1
22 583755 82 Ventilation pipe S4 1
23 546229 08 Rectangular ring 2 2 2 2 2
24 580759 06 Push-In Fittings 2 2 2 2 2
25 580318 01 Gasket 1 1
25 580318 02 Gasket 1 1 1
26 221030 07 Screw 4 4 4 4 4
27 1761834 03 Cu-washer 1 1 1 1 1
28 221035 07 Screw 4 4 4 4 4
29 70560 Washer 4 4 4 4 4
30 1761834 11 Cu washer 1 1 1 1 1

14
614

3 Sludge removal kit

2205M

15
615
Sludge removal kit

3.1 Sludge outlet S 821- S 836


Machine unit number or
Subassembly description
580403-
Ref Part No Description -80 Notes
Quantity
1 580303 80 Cover 1
2 580358 80 Sludge outlet 1
3 1762017 06 Hose 1
4 1766096 01 Plug 1
5 1762020 03 Hose clip 58 x 75 2

16
616

3.1 Sludge outlet S 821- S 836 3 Sludge removal kit

2219L

17
617
Sludge removal kit

3.2 Sludge outlet S 881, S 886


Machine unit number or
Subassembly description
580407-
Ref Part No Description -80 Notes
Quantity
1 580301 80 Cover 1
2 580374 80 Sludge outlet 1
3 1762017 07 Hose 1
4 1766096 01 Plug 1
5 2245101 01 Hose clip 2 83 x 93

18
618

3.2 Sludge outlet S 881, S 886 3 Sludge removal kit

2217E

19
619
Sludge removal kit

3.3 Sludge outlet S 851, S 856


Machine unit number or
Subassembly description
583361-
Ref Part No Description -80 Notes
Quantity
1 583362 80 Cover 1
2 583389 80 Sludge Outlet 1
3 1762017 09 Hose 1
4 1766096 01 Plug 1
5 2245102 02 Hose clip 2

20
620

3.3 Sludge outlet S 851, S 856 3 Sludge removal kit

2223K

21
621
Sludge removal kit

3.4 Sludge outlet S 861, S 866


Machine unit number or
Subassembly description
583268-
Ref Part No Description -80 Notes
Quantity
1 583304 80 Cover 1
2 583163 80 Sludge Outlet 1
3 1762017 08 Hose 1
4 1766096 01 Plug 1
5 2245102 02 Hose clip 2

22
622

3.4 Sludge outlet S 861, S 866 3 Sludge removal kit

2223L

23
623
Sludge removal kit

3.5 Sludge outlet S 871, S 876


Machine unit number or
Subassembly description
583746-
Ref Part No Description -80 Notes
Quantity
1 583747 80 Cover 1
2 583163 80 Sludge Outlet 1
3 1762017 10 Hose 1
4 1766096 01 Plug 1
5 2245102 02 Hose clip 2

24
624

3.5 Sludge outlet S 871, S 876 3 Sludge removal kit

2223N

25
625
Sludge removal kit

4 Sludge removal kit


Machine unit number or
Subassembly description
580258-
Ref Part No Description -06 -07 -08 -09 -10 -11 -12 Notes
Quantity
1 580259 80 Tank 1 1
1 583174 80 Tank 1 1
1 583381 80 Tank 1 1 1 S4
2 1766699 01 Sludge pump T70 1 1 1 1 1 1 1
3 580403 80 Sludge outlet S 821, S 831 1 See page 16
3 580407 80 Sludge outlet S 881, S 886 1 See page 30
3 583268 80 Sludge outlet S 861, S 866 1 See page 22
3 583361 80 Sludge outlet S 851, S 856 1 See page 20
3 583746 80 Sludge outlet S 871, S 876 1 See page 24
3 583750 80 Sludge outlet S 881, S 886 1 1 See page 28
4 580753 01 Level switch 1 1 1 1 1 1 1
5 1766081 02 Regulating valve 1 1 1 1 1 1 1
6 572915 01 Solenoid valve 1 1 1 1 1 1 1
7 1766002 01 Non-return valve 1 1 1 1 1 1 1
8 574351 05 Flexible hose L= 400 1 1 1 1 1 1 1
9 580773 80 Pipe connection 1 1 1 1 1 1 1
10 1762672 03 Hexagon plug 1 1 1 1 1 1 1
11 1762672 01 Hexagon plug 1 1 1 1 1 1 1
12 580758 06 Push-In Fittings 2 2 2 2 2 2 2
13 580769 03 Flexible hose, air D.8 1 1 1 1 1 1 1
14 1763780 02 Nipple