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, .

Maintenance and Adjustment


LOPX 707/ -09/ -1 0
Separation Systems
for
Lube-Oil

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~r;: : :I.- - = =~KDJj: : : :;1 ~--
I
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I
NOTE!
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I
Th.is manual should be used together
I wIth the SUPPLEMENT.

So~e parts of the information have been


revIsed. See the "Table of Contents" in the
SUPPLEMENT for parts that are affected.

CXll156-H

Product No.: 1763482-01 to -04


1763483-01 to -04
1763484-01 to -04
1763742-01 to -04
1763743-01 to-04
1763744-01 to -04
Book No.: SO 11388E

b.! Alfa Laval


Alfa Laval Marine & Power L-OOOl6-1-1

(190-MA-E-02-000-01 )
Whilst every effort has been made to ensure that the information
tained in this publication is correct and fully up-to-date, Alfa-Lave
serve the right to make changes at any time without prior notice.

Any comments regarding possible errors and omissions or sug-


gestions for improvement of this publication would be gratefully c
preciated.

Copies of this publication can be ordered from your local Alta-La


company.
Published by: Alta-Laval Separation AS
Technical Publications & Training
Department SLP
S -14780 Tumba
Sweden
Edition: 1

Printed: June 1994


© Copyright Alta-Laval Separation AS 1991. Printed in Sweden.
TABLE OF CONTENTS
1.0 GENERAL INFORMATION ••••.•..•••..••..••••. 1
1.1 SAFETY INSTRUCTIONS •••••.•••.•..•••••.•... 1
1.2 SAFETY PRECAUTIONS AND INSTRUCTIONS •••. 2
1.3 WARNING SIGNS AND LABELS ...•••..••••••••• 3
1.4 SYMBOLS .•..••.••..••••••.••.•.•.•.•••.•.••• 4
1.5 READ THIS FIRST! ..•.••••....•.•••..••.••••••• 5
1.6 THE INFORMATION MATERIAL ••••.•••••.•.•.•• 5

2.0 SYSTEM DESCRIPTION •••.•.••••••••••.•••.••• 7


2.1 SEPARATION SYSTEM •••••.••••••..•••.••.•••• 7
2.1.1 Application.. • • . • . • • • • • • • . . • • • . • . • . • • • . 7
2.2 SYSTEM LAYOUT ••••••.•••••••.•••.••.•••••.• 8
2.2.1 Desig n ..•...•...•....•................ 8
2.2.2 Configuration ••••••.•••••••..•••••••••• 9
2.2.3 Pumping ............•.......•......•.. 9
2.2.4 Temperature and preheater monitoring •.• 9

3.0 MAINTENANCE, SCHEDULE ••••••.•••.•..••.•• 11


3.1 MAINTENANCE SCHEDULE .•.••.•••••..•..•.. 11
3.2 SPARE PARTS KITS .••••....•••....••.•..•••• 13
3.3 LUBRICATION ....•••••...•••..•••••••••••••• 14
3.3.1 Lubricants •••.....••.•...••..•..••••• 14
3.3.2 Oil change intervals .•..•.•..••••.••••. 15
3.3.3 List of commercial oil brands •.•••.••••• 16
3.3.4 Comments •.•....••......•...•.•.•••. 17
3.4 MISCELLANEOUS MAINTENANCE •••••..••.••. 18
3.4.1 Vibration analysis .•..•••.•••.•.••.••.• 18
3.4.2 Oiling •.••.•••..•...••................ 18
3.4.3 Shut-downs ....•..••••••..••••.•..•.• 18
3.5 CLEANING •................................. 19
3.5.1 Cleaning agent ••...••••.••.••.•..•••• 19
3.5.2 Cleaning of bowl discs .•..•.•..••••.•.. 19

4.0 MAINTENANCE, PROCEDURES •...•..••••.•..• 21


4.1 GENERAL INFORMATION ..•.••.•....•.•..•.•. 21
4.2 DISMANTLING OF SEPARATOR .....•.......•.. 22
4.2.1 Inlet/outlet, frame hood ..•..•.•..•...•• 22
4.2.2 Bowl hood, disc stack, sliding bowl bottom 25
4.2.3 Bowl body and discharge mechanism ••. 29
4.2.4 Control paring-disc device •.•.....•.•.. 33
4.2.5 Bowl spindle .•••.......•....•..•..••• 35
4.2.6 Worm wheel shaft, coupling ••..•.....•. 41
4.3 ASSEMBLY OF SEPARATOR ...•....••.•.•..•. 46
4.3.1 Worm-wheel shaft, coupling; assembly .• 46
4.3.2 Bowl spindle; assembly ...............• 51
4.3.3 Control paring-disc device; assembly ... 55
4.3.4 Bowl body and discharge mechanism; as-
sembly ....•.•...•.•................•..••.• 58
4.3.5 Bowl hood, disc stack, sliding bowl
bottom; assembly ...........•......•.•..... 63
4.3.6 Oil paring disc, inlet and outlet; assembly 69
4.4 EXCHANGE OF THE FRICTION-PADS OF THE
COUPLING •.......•............••.•........••..• 72
4.5 BRAKE ...............•.....•.......•..•...•• 73
4.6 EXCHANGE OF FRAME FEET •.•••...•.. '••..••• 75
4.7 OIL SUMP .............•..•..•....•...•..•... 76
4.7.1 Oil change ...........•....•..••...••. 76
5.0 CHECK POINTS .............................. 77
5.1 CORROSION ................................. 77
5.1.1 Non-stainless steel and cast iron parts •. 77
5.1.2 Stainless steel and non-ferrous metal parts 77
5.1.3 Other metal parts •••....•..•...•...... 78
5.2 EROSiON.. ................................... 79
5.3 WORM WHEEL AND WORM. .. ................. 81
5.4 GUIDING SURFACES ......................... 82
5.4.1 Repair of galling on guiding surfaces. . .. 83
5.5 SPINDLE TOP AND BOWL BODY NAVE ......... 85
5.6 DISCHARGE MECHANISM .••.....••...•...•.•• 86
5.6.1 Dosing ring .......................... 86
5.6.2 Operating slide springs .•........•..... 86
5.6.3 Operating slide ....................... 86
5.6.4 Valve plugs .......................... 86
5.7 BOWL SEA LINGS ............................ 87
5.7.1 Bowl hood seal ring ................... 87
5.7.2 Seal ring of sliding bowl bottom ........ 88
5.8 THREADS OF LOCK RING AND BOWL HOOD .... 89
5.9 THREADS OF INLET PIPE, THREADS OF OIL PAR-
ING DISC ........................................ 91
5.10 ELASTIC COUPLING ....•....••....•...•..... 92
5.11 RADIAL WOBBLE OF BOWL SPINDLE •..•....• 93
5.12 TOP BEARING SPRINGS AND BALL BEARING
HOUSING ....................................... 94
5.12.1 Top bearing springs .......•...•••.••• 94
5.12.2 Ball bearing housing ................. 94
5.13 WEAR OF DRIVER AND OF GROOVE IN WORM • 95
5.14 HEIGHT POSITION OF SPINDLE ...•..•••..•... 96
5.15 HEIGHT POSITION OF CONTROL PARING DISC. 98
5.16 PRIMING OF LARGE LOCK RING ...•......... 100
5.17 DISC STACK PRESSURE .................... 102
5.18 HEIGHT POSITION OF OIL PARING DISC .....• 103

6.0 MAINTENANCE, COMPONENTS ....•.......... 105


6.1 EPC-400 CONTROL UNIT .........•.•.••.•.... 105
6.1.1 Maintenance ........................ 105
6.1.2 Replacing the control module ......... 106
6.2 WATER TRANSDUCER, WT 200 ••............. 107
6.2.1 Replacing of oscillator unit ••.......••. 107
6.2.2 Checking of transducer resistance •..•. 107
6.2.3 Cleaning of water transducer. . ........ 108
6.3 FLOW SWITCH, TYPE FS ......•.............. 109
6.3.1 Preventive Maintenance ......••...... 109
6.3.2 Removing the flow switch insert ....... 109
6.4 FLOW INDICATOR ...................••.•.... 110
6.4.1 Maintenance ........................ 110
6.5 SOLENOID VALVE BLOCK (WATER) ........... 111
6.5.1 Dismantling and cleaning ............. 111

7.0 ADJUSTMENT .............................. 113


7.1 EPC-400 CONTROL UNIT ..................... 113
7.1.1 Fuses and related functions ........... 114
7.1.2 Information during operation •......... 115
7.2 EPC-400 PARAMETER FUNCTIONS ............ 116
7.2.1 Parameter Adjustment .............•.. 116
7.2.2 Process parameter list ..........•...•• 118
7.2.3 Installation parameter list •.•........•. 119
7.2.4 Explanation and recommendation of pa-
rameter settings ..•..••...•••••.••.•••••.•• 123
7.2.5 Installation parameters, P20 - P99 •.•.•• 126
7.3 EPC-400 ALARM FUNCTIONS ••••••••••....••• 131
7.3.1 Alarm identification ••••••••.••••••••• 132
7.3.2 Alarm reset •.•.•••.•••.••••••••.••••. 133
7.4 ALARM TEST ............................... 133
GENERAL INFORMATION

1.1 SAFETY INSTRUCTIONS

Pay attention to the safety instructions in this booklet.

• Below three different types of instruction used in the text, are dis-
played.

DANGER:

This type of safety instruction is used where there


is grave danger of injury to persons and/or seri-
ous damage to the equipment or the environment.

WARNING:

This type of safety instruction is used where there


is a danger of injury to persons and/or damage to
the equipment or the environment.

,•
CAUTION:

This type of safety instruction is used where dan-


ger, of injury to persons and/or damage to equip-
ment or the environment, may occur if the
instruction is not followed.

• On the following pages you will find:

- Warning signs and labels. The illustration shows where to find


them on the equipment.

- Safety precautions and instructions which contain important


information concerning safety.

NOT FOLLOWING THE SAFETY INSTRUCTIONS CAN


CAUSE ACCIDENTS RESULTING IN SERIOUS INJURY
TO PERSONS AND DAMAGE TO EQUIPMENT

1
19O-MA-E-02-101-01
GENERAL INFORMATION

1.2 SAFETY PRECAUTIONS AND INSTRUCTIONS

The bowl in a separator rotates at a very high speed and great forces
are generated. Heat and electric power are incorporated as well.

Incorrect installation, operation and maintenance, or use of non-origi-


nal parts, can cause a breakdown of the equipment. Serious injury or
damages owing to thrown-off machine parts, dangerous
liquids/gases, steam, electricity etc. may occur.

Personnel installing, operating or performing service must have


G-00104+1 proper knownledge and skill for their task. It is essential to read, un-
derstand and follow the instructions in this manual.

• Always follow safety regulations, local or general, concerning


lifting devices, electrical equipment, pressure vessels, inflamma-
ble, toxic or corrosive process media etc.

• Always follow Alfa Lavals specification about checking and main-


tenance intervals.

8-00087-1-1
• Always follow stated values for process parameters.
Too long intervals between the discharges may cause a machine
breakdown.

• Always use ear-protection when working in noisy environment.

• Be careful when working near pipes, valves, heater or motor.


If you get in contact with hot liquids, hot surfaces or steam you
may experience grave burns.

• Never use the separator for separating other liquids or liquids with
other caracteristics than originally specified. If your needs
change, always consult your Alfa Laval representative before any
changes are made.

• A separator has maximum and minimum safe operating limits


concerning e.g. temperature, pressure, flow etc. (see Technical
Data and Drawings). Operating above or below these limits may
be potentially dangerus.

• Never neglect alarms. They indicate a faulty condition. Cause of


the alarm must be found and corrected before restart.

It you are uncertain about any points,


contact your Alta Laval
representative

Alfa Laval representatives are listed in the


folder "Service Network for Marine Equipment".

2
190-MA-E-02-102-01
GENERAL INFORMATION

1.3 WARNING SIGNS AND LABELS

J, Warning sign placed on


the frame hood.

WARNING WARNING WARNING

------~~~

&OOO9CH-l

f- Safety precautions
sign.
To be placed on the
wall near the separa-
tor.
NwllcpIt"'hlftlIe,,"t\lflJn11ll1) et...:\.I .... ~I...... fllr.np
_.,111,,,,,,. 011 dI . . . _.
tJ...c.,,_.~y"""'IIO'/I'CIItI""ChII
tIW ..
,.. .. UlI .. tI.....
_,_~
"'''I eI'III

....' ......... I!trMO,. .... .


~III
1II'~'G .....II""",ALI... _!ItII_
.. _"'JllCitl IMler ....... If ..

"""P~'"t,._ ",_,C-",..Al",_ItIfttI .

• 1wIt$.., ... dbe..... 1I\t,.....hoPfIr1vth~ • A ....11W ...... b.w-I • I GIl","", .n. 0. nit
..... .. __-"I\f._
""'1"''''''4.~.'''' . ....... ~~ . . . . , . ~'IS of. IIoIw' Whh 1110_ of .. ,
• ~_ ... U......,... _ ....
not,,"n .r h• • II..., ~"""'. ~......"'IWOI
. . . _ • • If I" ,lIIIi" ... I"~ ...f.,
wIIIdt rI!a
b_
ftO,.. ••."' ......
ot.'"*'*-...-If It. 1M .... ."..II1II11:1 ......
-afy.
. , . . . . . .my h1lttladoow corc"~~I"""
",.d'\InI .... b_fIUIl"'-d or ...rDIIIl4 , , _ ..... l!'IIII .........n.... Mfll. hMf.
..........'._wlily...' ... l,.,........ lIIII'Ii.~_ ..fnIneM. . inllf.mI_...... .

- ()(lII.l"'t.t,VII' , ,,,, • • • "",,,.. _

S-00089-H

3
1~MA-E-02-1 03-01
GENERAL INFORMATION

1.4 SYMBOLS

Alarm and front panel symbols

I
G.()OII4-1-2

fS] $-00002-1-1
Preheater fault fS] S-00002-1-1
Start/stop preheater

® 8-00012-1-1
High!low oil temperature
1f S'{)OOS~I-1
Start separation

@) Emergency stop/vibration
~ Stop separation

e
8-0001H-l S-OOOSH-l

High oil pressure -()-


.. Sludge discharge

e
8-0018~H S.{)0052-1-1

Low oil pressure }-M- Sludge discharge failure


8-0018H-l S'{)OOOI-1-1

fj S.{)0054-1-1
Main alarm and alarm reset

Programming symbols
Mode selector

~ s'()o071-H
R=Remote mode
L=Local mode
P=Programming mode
,.,.., Increase of va-
S.{)0027-Hlue e)
S-00031-H
Time

S'{)0028-H
Decrease of va-
lue i Temperature
setpoint

e
S-00036-1-1

Parameter
No.1
8-00029-1-1

8-6 e) -6 9H~ -G-


S'{)0030-1-1
Sludge dis-
charge
81
9 O=<!>
G'{)OII6-1-3

4
190-MA-E-02-104-01
GENERAL INFORMATION

1.5 READ THIS FIRST!

This handbook is intended for all personnel who operates the equip-
ment described. It is of utmost importance to read and understand the
contents of this booklet.

Non-compliance may cause serious accidents.

1.6 THE INFORMATION MATERIAL

The complete information material includes a number of booklets,


each concerning one special area. All booklets are listed below.

Booklet Contents
FO Description of the functions of a specific sys-
Function Descriptions tem and/or component.
Personnel who deal with maintenance and
service must have a thorough knowledge of
this booklet.
01 Routine operation.
Operating Instructions Brief description of main components.
ATT Alarm identification.
Alarms and Trouble Tracing Faults, causes and remedies for the system
and/or anCillary equipment.
MA Detailed information on routine maintenance,
Maintenance and Adjustments adjustments and corrective service.
Intended for skilled/trained personnel.
SPC Complete spare parts catalogue for the sys-
Spare Parts Catalogue tem.
Order routine.
TOO Technical data.
Technical Data and Drawings Dimensioned, mounting, and installation
drawings.
Interconnection and circuit diagrams.
ISR General information on installation planning.
Installation SpeCifications and Instructions for the installation of the separator
Recommendations and the oil, water, air and electrical systems.

5
19O-MA-E-02-1 05-01
SYSTEM DESCRIPTION

2.1 SEPARATION SYSTEM

2.1.1 Application
The LOPX separation system is specifically designed for cleaning of
lubrication oil for diesel engines. The LOPX separator basically oper-
ates as a clarifier and is capable of handling the water in lubricating
oil.

The LOPX separation system is operated, in accordance with preset


parameters, from the EPC-400 control unit, except for starting the se-
parator and the oil feed pump.

WARNING:

Never use the LOPX Separation System for sepa-


rating any other oils or liquids than those stated in
the instructions.
Serious injuries and damaged equipment may oc-
cur.

7
190-MA-E-02-201-01
SYSTEM DESCRIPTION

2.2 SYSTEM LAYOUT

2.2.1 Design
The equipment described in this book, shown in the picture below, in-
cludes the LOPX separator and ancillary components.

16--t-

~1003+2

Schematic installation layout of LOPX separation system

1. Oil feed pump 11. Water tranducer


2. Flow switch 12. Flexible connections
3. Preheater 13. LOPX separator
4. Temperature sensor 14. Emergency stop push button
5. Pneumatic 3-way valve 15. Solenoid valve block, water
6. Regulating valve 16. Operating water tank
7. Pressure indicator 17. Starter
8. Low pressure switch 18. EPC-400 control unit
9. High pressure switch 19. Solenoid valve block, air
10. Flow indicator

8
190-MA-E-02-202-01
SYSTEM DESCRIPTION

2.2.2 Configuration
The basic concept is single operation with one EPC-400 control unit
and preheater.

2.2.3 Pumping
The oil is fed to the separator by a separate pump with a constant
feed. The pump is not controlled from the EPC-400 control unit.

2.2.4 Temperature and preheater monitoring


Oil that is fed to the separator must be maintained at a correct and
constant separating temperature. This is achieved in the heater, which
is installed between the oil feed pump and the separator.

190-MA-E-02-202-01
9
MAINTENANCE, SCHEDULE

3.1 MAINTENANCE SCHEDULE

Maximum intervals
More in-
Part Action 2000h 8000h Every form a-
1000h or3 or 1 4 tion
month year years
Anm: Corrosion and erosion - To be checked every time the separator is dismantled. See 5.1.
EPC control unit Alarm test X 7.4

Oil sump Oil change 1) X 2)


4.7

Inlet/outlet Cleaning and inspection X 4.3.6

Bowl body Cleaning and inspection X 4.3.4

a-rings, seal rings Inspection/exchange X

Guiding surfaces Cleaning and inspection X 5.4

Frame hood Cleaning and inspection X 4.3.5


Threads of inlet pipe and oil
Inspection X 5.9
paring disc
Discs Cleaning and inspection X 4.3.5

Disc stack pressure Checking X 5.17


Lock ring and bowl body
Cleaning and inspection X 5.8
threads
Sliding bowl bottom Cleaning and inspection X 4.3.5

Discharge mechanism Cleaning and inspection X 4.3.4,5.6

Valve plugs Cleaning and inspection X 5.6.4

Springs Inspection X 5.6.2

Nozzles Cleaning and inspection X 4.3.4,5.6

Spindle top Cleaning and inspection X 5.5

1) NOTE! In a new installation or after replacement of gear, change the oil after 200 operating hours.
2) If a Group D gear oil is used (see 3.3), oil change interval can be increased to 2000 hours.

Always remedy faults immediately

11
190-MA-E-02-301-01
MAINTENANCE, SCHEDULE

Maximum intervals
More in-
Part Action 2000h 8000h Every forma-
Monthly or3 or 1 4 tion
months year years
Bowl body nave Inspection and cleaning X 5.5

Worm gear Inspection X 5.3,5.13


Height position of oil paring Checking and adjust-
X 5.18
disc ment
Height position of control Checking and adjust- 5.15
paring disc ment
X
Checking and adjust- 5.14
Height position of spindle
ment
X

Bowl spindle Inspection and cleaning X 5.5,4.3.2

Bowl spindle radial wobble Checking X 5.11

Frame top and bottom part Inspection and cleaning X

Worm wheel shaft Inspection and cleaning X 4.3.1


\

Friction coupling Inspection and cleaning X 4.3.1

Brake Inspection and cleaning X 4.5

Bearings Exchange X

Ball bearing housings Inspection X

Frame feet Exchange X 4.6

Solenoid valve block, water Cleaning X 6.5

Flow switch, type FS Cleaning X 6.3


See separate instruc-
Preheater
tion book \

See manufacturer's in-


Electric motor
structions

Always remedy faults immediately

12
190-MA-E-02-301-01
MAINTENANCE, SCHEDULE

3.2 SPARE PARTS KITS

Kits of spares are available for the periodic maintenance.

These kits are:

• IS (intermediate service kit) every 2000h or 3 months .

• MS (major service kit) every 8000h or 1 year.

Each kit contains spares intended for the respective service.

Spare parts kits for LOPX 707, 709, 710

Article
Name Remarks
no.
Movable gaskets in bowl, 0-
IS -Intermediate ser-
548149-01 rings for inlet pipe, Molykote
vice kit
paste, oil
Non movable gaskets, ball
548153-01 MS - Major service kit
bearings, friction pads, Loctite
Service kit for frame
548542-01
feet

13
190-MA-E-02-302-01
MAINTENANCE, SCHEDULE

3.3 LUBRICATION

3.3.1 Lubricants
The following recommendations are applicable for a separating tem-
perature of +15 - +98 °C and an ambient temperature range of +10 -
+55°C.

Lubricating Points Lubricant


Bowl spindle ball bearings and buffers, worm gear Lubricating oil specified in
and ball bearings on worm wheel shaft are lubri- LIST OF COMMERCIAL OIL BRANDS
cated by splash and oil mist lubrication from an oil
bath in the worm gear housing.
Bowl spindle taper and bearing seats at assembly Lube oil (only to counteract corrosion)
Bowl, guiding surfaces Pastes:
Screw threads Dow Corning Molykote 1000.
Tools Molybdan Gleitmo 805.
Pressure loaded surfaces KIOber Wolfracot C.
Lubricating sp'ray:
Molykote 321 R
O-rings, rubber seal rings Silicone grease:
Dow Corning Molycote 111 compound
KIOber Unisilkon L250L
Wacker Silicon P
Ball bearings at friction coupling Ball bearings grease 1)
Electric motor Follow manufacturer's instructions or 1)
1)

Use a lithium-soap complex ball bearing grease according


to NLGI class 2 or 3, recommended up to 110°C

Examples of ball bearing grease:


Mobil Mobilith SHC 460
BP Energrease MMEP2 Mobilux EP2
(Energrease LS 2) Q8/ Kuwait Rembrandt EP2
Castrol (Spheerol SW2 EP) Shell (Calithia EP Grease T2)
Spheerol EPL2 Alvania EP Grease 2
Chevron Duralith grease EP2 SKF LGEP2
Exxon Beacon EP2 Texaco Multifak AF B2,
Gulf (Gulflex MP 2) (Multifak premium 2, 3)
( ) Available only in a few countries

14
19C>-MA·E-02·303·01
MAINTENANCE, SCHEDULE

3.3.2 Oil change intervals


Change oil after every period of 1000 operating hours.

Exceptions:

• In a new separator, or after replacement of worm gear, change the


oil after 200 operating hours.

• When using a group D oil, see next page, time of operation be-
tween oil changes can be extended from the normal 1000 to 2000
hours.

• When the separator is running for short periods, lubricating oil


must be changed every 12 months even if the total number of op-
erating hours is less than 1000 (2000 hours for group D oil).

• In seasonal operation change before every operating period.

Top up when necessary (oil level to upper half of oil gauge glass).

15
190-MA-E-02-303-01
MAINTENANCE, SCHEDULE

3.3.3 List of commercial oil brands


These recommendations specifically concern the choice of lubricants for
separators LOPX 707, 709 and 710, which clean lubricating oil.

Designation Supplier
Oil type Lube- Visco Visco Esso!
Alfa- Final
011 grade Index
Laval
BP Castro I Chevron Exxon!
Petrofina
group VG 1) V1 2) Statoll
Paraffin A 220 >95 --- (Bartran AlphaZN -- Teresso --
base 220) 220 220
mineral 011 (Terrestic
withAW- 220)
and A 320 >95 Article No (Bartran AlphaZN - (Nuto 320) -
stabilizing 546099 320) 320 Teresso
Inhibitors (dark 320
green) (Terrestic
320)
High tem- D 220 >130 -- Enersyn AlphaSyn - (ESL 812) ---
perature 011, HTX 220 T220
usually a
synthetic 011
D 320 >130 Article No -- AlphaSyn - --- -
542690- T320
of 84-87
poly-alpha
olefine type
with inhibi-
tors

Designation Supplier
Vlsc.
Oil type Lube- Vlsc. Lub- Q8!
grade 9ptimol Texaco!
011 Index marine! Mobil Kuwaiti Shell
br. V1 2) Olwerke Nippon
group VG 1) ELF Gulf

Paraffin A 220 >95 Polytelis DTEoil Ultra 220 (Gulf Har- Tellus Regal
base 220 BB monyAW C220 R&0220
mineral 011 220) Vitrea220 (Paper
with AW- (Tellus Machine
and 220) oilHD
stabilizing 220)
inhibitors A 320 >95 Polytelis DTEoil Ultra 320 (Gulf Har- Tellus Regal
320 AA monyAW C320 R&O 32(
320) Vitrea 320 (Paper
(Tellus Machine
320) oil HD
320)
High tem- D 220 >130 EponaSA SHC630 -- Schu- (Delima (ETL
perature 011, 220 mann 220 HT 220)3) 4226)
usually a
synthetic 011
D 320 >130 (Epona SHC632 -- Schu- (Delima (ETL
SA 320) mann 320 HT 320)3) 4227)
of
poly-alpha-
olefine type
with inhibi-
tors

1)
According to ISO 3448/3104 Technical data or product not available
2)
According to ISO 2909 () Available only in a few countries
3)
Not to be used if the maximum ambient
temperature exceeds 50°C.

16
190-MA-E-02-303-01
MAINTENANCE, SCHEDULE

3.3.4 Comments

• Overheating of oils may lead to the formation of hard deposits.


The mineral oil base 'is carbonized and/or additives are precipi-
tated.

These deposits, which are abrasive and accelerate bearing wear,


may cause a complete bearing breakdown. This happens if suffi-
ciently large particles enter the bearing and are squeezed be-
tween a ball and the race thus breaking the relative rotation.

Presence of black deposits on spindle parts or on worm


wheel is an indication that the oil has deteriorated seriously.

• Great attention must be paid not to contaminate the gear oil.


Of particular importance is to avoid mixing of different types
of oil. Even a few drops of motor oil mixed into synthetic oil
may result in severe foaming.
Therefore always use clean cans.

• Before filling a new brand of Oil, it is of great importance to


remove all deposits on surfaces both in gear casing and on
rotating parts.

• If oils VG 320 (viscosity class ISO VG 320) are unavailable,


oils VG 220 of group 0 (synthetic) may be used instead.

NOTE!

If viscosity VG 220 instead of recommended VG 320 of


group A (mineral oil) is used, worm wheel wear may ac-
celerate.

If you have any further questions or doubt please read the main bu 1-
letin in this matter (300-MS8-01-001), or contact your Alfa Laval rep-
resentative.

1go.MA·E·~·303-o1
17
MAINTENANCE, SCHEDULE

3.4 MISCELLANEOUS MAINTENANCE

3.4.1 Vibration analysis


Abnormal vibration or noise indicates that something is wrong. Stop
the separator and look for the cause.

If vibration analyzing equipment is available, use this equipment to


periodically check and record the magnitude of vibration.

G'()0752-1-1

3.4.2 Oiling
Protect cleaned carbon steel parts against corrosion by oiling. Sepa-
rator parts that are not mounted after cleaning should be wiped and
protected against dust and dirt.

3.4.3 Shut-downs
G-00753-1·1 If the separator is shut down for some time, the parts in contact with
liquid should be oiled. The O-rings should be removed.

,

CAUTION:

The bowl must not be left on the spindle for a


shut-down period.
Vibrations in the foundation could be transmitted
to the bowl and produce one-sided loading of the
bearings. The resultant indentations in the ball
bearing races could cause bearing failure.

18
190-MA·E·02-304·01
MAINTENANCE, SCHEDULE

3.5 CLEANING

3.5.1 Clean ing agent


When using chemical cleaning agents, please make sure to observe
general rules and supplier's recommendations as to ventilation, pro-
tection of personnel etc.

For separator bowl, inlet and outlet


~f"·l"""L

-...
. ~f~~II'IG UQUIC
-~- ..
A chemical cleaning agent should dissolve the deposits quickly with-
out attacking the material of the separator parts.

• For cleaning of LUBE OIL SEPARATORS the most important


function of the cleaning agent is to be a good solvent for the gyp-
sum in the sludge. It should also act as a dispersant and emulsifier
for oil. It is recommended to use the Alfa Laval Cleaning Liquid
for lube oil separators 1), which has the above mentioned quali-
ties. Note that carbon steel parts (e.g. lock rings) may be affected
by the agent if submerged a long time.
~65-1-1

For discharge mechanism

Use 10% acetic acid solution to dissolve lime deposits. The acid
should be heated to 80° C.

For parts of the driving devices

Use white spirit, cleaning kerosene or diesel oil.

3.5.2 Cleaning of bowl discs


Handle the bowl discs carefully so as to avoid damage on the surfaces
during cleaning. Mechanical cleaning is likely to scratch the disc sur-
faces, causing deposits to form more quickly and adhere more firmly.
An indulgent chemical cleaning is therefore preferred to mechanical
cleaning.

Cleaning procedure

Remove the bowl discs from the distributor and put them down, ONE
BY ONE, in the cleaning agent. Let the discs remain in the cleaning
agent until the deposits have been dissolved. This will normally take
between two and four hours. Finally clean the discs with a SOFT
brush.

G-0065&-1-1

1) Alfa Laval cleaning liquid for lube oil separators is available in 25-litres plastiC con-
tainers. Part No.1762852-01.

19
190-MA-E-Q2-3Q5-01
MAINTENANCE, PROCEDURES

4.1 GENERAL INFORMATION


The separator bowl is to be dismantled regularly for .cleaning and in-
spection.
The recommended intervals can be found in chapter 3.

Step by step instructions of how to dismantle and assemble the sep-


arator are given in this chapter.

DANGER:

Never start dismantling before the separator bowl


has come to a complete standstill.

Tools needed for dismantling and assembly but not included in tool
kit:

• Screw spanner
• Adjustable spanner for pressing off
(for example 8ahco No. 75 or 86)
• Thrust washer
• Puller
• Socket
• Screw driver (2)
• Pliers for internal snap ring
• Pliers for external snap ring
• Tube for driving off ball bearings
• Tube for driving on ball bearings

The heavy bowl parts must be lifted by means of a hoist. Position the
hoist very exactly. Use a lifting hook with catch.

The parts must be handled carefully.


Do not place parts directly on the floor, but on a clean rubber mat, fi-
breboard or a suitable pallet.

21
190-MA-E-02-401-01
MAINTENANCE, PROCEDURES

4.2 DISMANTLING OF SEPARATOR

4.2.1 Inlet/outlet, frame hood

~----B
">----c

+-----D

A Hose liner / water inlet


B Rectangular ring
CO-ring
o Inlet pipe
E Support / oil inlet
F Connecting housing / oil outlet
G Paring chamber cover
-r----E H Paring disc

\~~---B

cr~---C

).---H

22
190-MA-E-02-402-01
MAINTENANCE, PROCEDURES

1. Disconnect and remove the hose liner.

G'()1250-1-1

2. Unscrew the inlet pipe clock-wise (left-hand


thread). Lift it out carefully.

G'()1252-1-1

3. Undo the coupling nuts of inlet and outlet piping


at the pipe support.
4. Lift off the support, that is the inlet connection·
housing, and turn it aside.

G'()1254-1-1

5. Loosen the fastening bolts of the outlet con-


nection housing.

6. Disconnect the pipe (take care of the washer)


and turn it aside.
~
~
7. Remove the outlet connection housing.

\~
\
.I
G.()1248-H

190-MA-E-02-402-01
23
MAINTENANCE, PROCEDURES

8. Undo the fastening screws of the frame hood.

Fit the eye bolts.

Lift off the frame hood.

-,.
~ G-01247·1·1

24
190-MA·E-02-402-01
MAINTENANCE, PROCEDURES

4.2.2 Bowl hood, disc stack, sliding


bowl bottom

n------<~---(IS)
K---+
O------<I:l:>----(IS)

M (IS)

N
IS)
IS)

G'()3791-1-1

F----f

A Paring chamber cover


B Paring disc
C Large lock ring
D Bowl hood
E Seal ring
F Top disc
G Bowldiscs
H Wing insert
I Bowldiscs
J Distributor
K Distributing cone
L Sliding bowl bottom
M Rectangular ring
N Bowl body
a a-rings
IS Included in Intermediate Service Kit

Left-hand thread
8-00006-1-1

G-03790-1-1

25
1~MA-E-02-402-01
MAINTENANCE, PROCEDURES

1. Remove the paring chamber cover by using the


special tool, left-hand tread.

2. Remove the paring disc.

G-Ol~l·l

= 3. Removing large lock ring (a-f):

Before the large lock ring is loosened the disc


stack pressure may be neutralized by means
of a compressing tool. The latter has a certain
adapter and should be used together with a
lifting ring and a thimble.

,

CAUTION:

Use only the original compress-


ing tool.
G-Ol259+1
Other tools may damage the
discs.

a. Fit the lifting ring and the thimble.


b. Fit the compressing tool.

Turn the switch into upright position.

Tighten the compressing tool to the distrib-


utor.

G-01373+1

c. Switch over to position for compression.

Pump until full pressure is obtained. The


compressing tool is equipped with a relief
valve.

G-01374-H

26
19()'MA·E-02-402-o1
MAINTENANCE, PROCEDURES

d. Fit the large lock ring spanner.

Unscrew the large lock ring by hitting with


the lead hammer as shown, left-hand
thread.

~124&-1-1

e. Turn the switch into upright position.

Unscrew and remove the compressing


tool. Do not remove the lifting ring and the
paring chamber cover.

~1375-1-1

f. Remove the large lock ring by using a hoist


and the two eye-bolts.
Be careful not to damage the contact sur-
face.

G'()1261-1-1
,

CAUTION:

The large lock ring should be kept


lying horizontal or hanging in an
overhead hoist. It may not, on any
occasion, be kept edgeways.

4. Fit the lifting tool for the bowl hood. The cap has
left-hand threads.

Screw down the central screw, right-hand


thread, to release the distributor and the top
disc from the hood.

Ease off and lift out the bowl hood by means of


lifting tool. Be careful not to scratch the bowl
hood seal ring.

~1262-1-1

,•
CAUTION:

When the bowl hood is lifted in


any other way than as described
above, the top disc and even the
disc stack and distributor may
stick to the bowl hood and be
dropped during the lifting proce-
dure.

190-MA-E-02-402-01
27
MAINTENANCE, PROCEDURES

5. Lift out the distributor with bowl discs and wing


insert.
Use the special lifting tool and hoist.

Cleaning of bowl discs, see chapter 3.

G-OI264-H

6. Lift out the distributing cone by means of the


special tool.

-
'"
G-OI266-1-1

Lift out the sliding bowl bottom by hoist. Take


care not to scratch the sealing edge.

Exchange seal ring, see Bowl sealing, 5.7.

G-OI267-1-1

28 190-MA-E-02-402-01
MAINTENANCE, PROCEDURES

4.2.3 Bowl body and discharge


mechanism

..uJ.t------A

J---:7C (IS)
A Cap nut

b;E~~d--E(IS)
B Bowlbody
CO-rings
D Operating slide
o E Valve plugs
F Springs and spring support
G Nozzles
H Dosing ring
(IS) Included in Intermediate Service Kit

Left-hand thread
lHXIOO6-1-1
H

~792-H

190-MA-E-02-402-01
29
MAINTENANCE, PROCEDURES

1. Unscrew the cap nut.

~126S-1-1

2. Unscrew the three screws from the bowl body.

G-01324-1-1

3. Ease off the bowl body from the spindle top by


means of the central screw of the lifting tool. If
necessary, knock on the spanner handle.

When the bowl body has come loose turn the


central screw of the tool another two turns in
order to avoid damaging the control paring disc
when lifting the bowl body.

Lift out the bowl body by means of a hoist.

G-01263-1-1

4. To take apart the discharge mechanism:

Put a strap through a sludge port. Lift the bowl


and turn it over.

G-01351-1-1

30
19~MA-E-02-402-01
MAINTENANCE, PROCEDURES

5. Loosen the screws for the spring support suc-


cessively a little at a time. Remove the screws.

Remove spring support· and springs.

G-03766-1·1

6. Undo the screws of the dosing ring.

G-03767·H

7. Dismantle the dosing ring by means of its puller


ring in the following way:
a. Screw the nuts against the head of the
screws on the puller ring.
b. Place the puller on the operating slide and
screw down the screws in the dosing ring
to stop.
c. Force off the dosing ring by tightening the
nuts two by two. The screws are to be
locked when tightening the nuts.

G-03766·1·1

8. Fit eye bolts and lift the dosing ring off the op-
erating slide

G-02800·1·1

31
190-MA·E·02-402-o1
MAINTENANCE, PROCEDURES

9. Fit the eye bolts and lift the operating slide by


hoist.

Place the operating slide with the valve plugs


facing upwards not to scratch the sealing sur-
face of the plugs.
a. Clean all parts thoroughly in a suitable cle-
aning agent, see Cleaning, 3.5.
~821·1-1 b. Clean the nozzles of the dosing ring and
the inlets fot operating water, in the bowl
body.
Use compressed air or a soft iron wire.
c. Check for damage, corrosion and erosion,
see 5.1 and 5.2.
d. Replace O-rings if required.

G-02794+1
,

CAUTION:

Dirt and lime deposits in the


sludge discharge mechanism
may cause bad discharge func-
tion or none at all.

32
190-MA·E·02-402-01
MAINTENANCE, PROCEDURES

4.2.4 Control paring-disc device


Prior to dismantling the paring disc device, the
inlet and the outlet, the framehood and the bowl
must be removed, see previous pages.

A O-ring
B Distributing ring
C Control paring disc
DO-ring
E Cover
F Gasket
G Distributing cover
(IS) Included in Intermediate Service Kit

~130H·l

1. Slacken the screws of the control paring-disc


device by a hexagon wrench and unscrew with
a suitable screw driver.

~792·1·1

2. Lift out the paring disc device

G.()1273·1·1

33
1~MA·E..()2-402-01
MAINTENANCE, PROCEDURES

3. To dismantle the device:


Turn it upside down and remove the Screws.

G-01274+1

4. Remove operating water inlet tubes.

G-01275-H

5. Lift out the distributing cover.

G-0127&-1-1

6. Clean all dismantled parts thoroughly. Pay


special attention to the channels.

Check for damage and corrosion.

Remove any lime deposits with steel wool. If


necessary use 10% acetic solution to dissolve
the deposits. The solution should be heated to
ao°c.

G-02807-1-1

34
190-MA-E-02-402-01
MAINTENANCE, PROCEDURES

4.2.5 Bowl spindle

~~--A
CT:>f-----B
@~----C

+----0

E
F
..--+-w
G
~-l--B

6--H
G-03794-1-1
I-----J

A Protecting plate
K B O-ring
C Protecting collar
0 Guard
E Spring casing
F Buffer
G Spring
H Screw plug
I Oil fan
J Ball bearing
K Bowl spindle
L Stop sleeve
M Worm
N Conveyor
0 Spacing washer
P Washer
Q Ball
R Support plug
L S Height adjusting ring
T Spacing sleeve
U Slotted pin
V Bottom bearing housing
W Gasket
G.o:l793-1-1

35
190-MA-E-02-402-01
MAINTENANCE, PROCEDURES
Before the bowl spindle is dismantled the inlet and
the outlet, the frame hood, the bowl and the control
paring disc device must be removed_

In the case of 8000 hours service:

• Check the height position. See 5.14, I1Height


position of spindlel1 •

• Check the radial wobble. See 5.11, I1Radial


wobble of bowl spindle".

G-OI363-1-1

1 Thrust washer
2 Puller
3 Screw spanner for top bearing screw
plugs

66mm

G-OI31S-1-1

1. Remove the hood above the top bearing.


2. Remove protecting plate, O-ring and protecting
collar.

G-OI32()'1-1

36
190-MA-E-02-402-Q1
MAINTENANCE, PROCEDURES

3. Remove top bearing hood.

~1321-1-1

4. Loosen buffer plugs using a spanner and a


hammer.

~1322-1-1

5. Remove plugs and springs. Move spindle top a


few turns in a circle while pressing outwards.
This will disengage the buffers from the ball
bearing housing.

~12n-l-l

6. Remove buffers.

37
190-MA-E-02-402-01
MAINTENANCE, PROCEDURES

7. Unscrew the screws of spring casing.

G-01324-1·1

8. Remove spring casing with gasket and ball


bearing housing.

<>-01325+1

9. Drain the worm gear housing of oil.

<>-01163-1-1

10. Remove the revolution counter cap.

G-01279-1-1

38
MAINTENANCE, PROCEDURES

11. Force out the taper pin of the worm-wheel stop


ring.

~12eo-1-1

12. Push the worm wheel aside before lifting spin-


dle. If the wheel is stuck, loosen it by using a
piece of wood and a mallet according to illus-
tration.

G-41281-1-1

13. Lift out spindle.

G-41282-H

p 14. Pull off bearing (Q) together with spacing


washer (R) and the upper ball race of thrust ball
bearing (8).

Remove driver (P) and pull off worm.

Q R s
G-412S3-1-1

39
190-MA-E-02-402-01
MAINTENANCE, PROCEDURES

15. Remove ball bearings and of worm by pro-


ceeding as illustrated. Use a thrust washer (a)
as a support for the jack screw of the puller.

G-01284-1-1

D 16. Detach top ball bearing by supporting the bowl


spindle on a soft base (wooden or similar) and
knock on the inner ball race with the drive-off
tool.

17. Lift out thrust ball bearing and bottom sleeve (Y)
with parts, using the special tool.

The lower ball race of the thrust ball bearing is


detached by means of a drift through the holes.
The upper ball race is shrunk on spindle.

G-0136&+1

If the height position of the bowl spindle


must be adjusted, or in the case of 8000
hours (4 years) service, see 5.14, Height
position of spindle.

40
MAINTENANCE, PROCEDURES

4.2.6 Worm wheel shaft, coupling

(MS) (MS)

~ G-03797-1-1

A Round nut
B Lock washer
~~ . C Bearing shield
r----------------------*~. o Ball bearing
E Taper pin
F Stop ring
G Worm wheel
H Ball bearing
I Lip seal ring
J Sealing washer
K Worm-wheel shaft
- - - -.N M L with coupling drum

L Nave
M Friction block
N Friction pad
(MS)(MS) a Holding bracket

r-
P Ball bearing
Q Spacing sleeve
R Ball bearing
S Lock washer
T Round nut
v u Q U Coupling disc
G-0379&-I-l V Elastic plate

(MS) Included in
Major Service Kit

41
19().MA-E-02-402-01
MAINTENANCE, PROCEDURES

1. Drain off the oil from the worm gear housing.

G-01163+1

2. Remove the revolution counter cap.

G-01279-1-1

3. Force out taper pin of stop ring.

G-01260-1-1

4. Remove the protecting cover and its gasket.

G-01269-1-1

42
190-MA-E-02-402-01
MAINTENANCE, PROCEDURES

5. Remove bearing shield.

G.ol290·1·1

6. Remove round nut and lock washer.

G.ol291·1·1

7. Remove ball bearing.

G.ol292·1·1

8. Remove stop ring and worm wheel with ball


bearing.

G.o1293-1·1

43
19().MA·E-02-402..Q1
MAINTENANCE, PROCEDURES

9. Lift out the motor.

G-OI294-1-1

10. Remove coupling disc.

G-Ol~I-1

11. Lift out worm wheel shaft.

G-0129&-1-1

12. To dismantle nave: unscrew round nut and re-


move lock washer.

G-01297-1-1

44
190-MA-E-02-402-01
MAINTENANCE, PROCEDURES

13. Ease off the nave and remove friction blocks.

~1298+1

14. Remove sealing washer using two screws with


threads 1/4" - 20 UNC.

G-05148-H

15. Remove lip seal ring by using a drift.

Clean all dismantled parts thoroughly.


Use a degreasing agent for the coupling drum.

Check for damage.

Replace parts supplied in the Major service kit


(MS).

~1300-1-1

45
190-MA-E-02-402~1
MAINTENANCE, PROCEDURES

4.3 ASSEMBLY OF SEPARATOR

4.3.1 Worm-wheel shaft, coupling;


assembly

(MS) (MS) (MS)


.:
.... - ,
f/ "....
! .!

B
~797-1-1

A Round nut
B Lock washer
C Bearing shield
o Ball bearing
E Taperpin
F Stop ring
G Worm wheel
H Ball bearing
I Lip seal ring
J Sealing washer
K Worm-wheel shaft
with coupling drum
L Nave
M Friction block
N Friction pad
o Holding bracket
P Ball bearing
(MS)(MS) (MS) Q Spacing sleeve
R Ball bearing
S Lock washer

I
T Round nut
U Coupling disc
V Elastic plate
(MS) Included in Major Service Kit
u T S R Q P
~3798-H

46
190-MA-E-02-403-01
MAINTENANCE, PROCEDURES

1. Fit sealing washer in the frame. Check that lip


seal ring is turned the right way.

Lubricate with silicone grease.

G.()5148·1·1

2. Fit friction blocks with pads. Lock the blocks


with holding brackets

Apply ball bearing grease on bearings. Note


that no grease must be packed in the nave
proper, as superfluous grease might ooze out
of the nave and adhere to the friction blocks.

Fit the bearings and spacing sleeve. Use the


drive-on sleeve of the tool set to force the
bearings into their seats.
G~837+1

3. Tighten round nut and secure it with lock


washer.

G.Q1297+1

4. Fit worm-wheel shaft.

G.Q1296+1

47
190-MA·E·02-403-01
MAINTENANCE, PROCEDURES

5. Fit worm wheel with ball bearing. Fit stop ring.

G-0129a.l-1

6. Fit ball bearing.

G-01292-1-1

7. Use the drive-on sleeve of the tool set to force


the bearing into its seat.

[], ,,,,
,,
,
"

G-01328-1-1

8. Screw on round nut and secure it with lock


washer.

G-OI291-1-1

48
19Q.MA-E-02-403-01
MAINTENANCE, PROCEDURES

9. Fit bearing shield.

~121lO-1·1

10. Force taper pin of stop ring in place.

G-Q1260-1·1

11. Fit protecting cover with gasket.

~1289·1-1

12. Pour oil into the worm gear housing. Level


slightly above middle of sight glass. Fit the rev-
olution counter.

~1279·1-1

49
19D-MA·E-02-403-01
MAINTENANCE, PROCEDURES

13. Fasten coupling disc with gasket. Check axial


play of elastic plate.
Fit the brake.

G-Ol330+1

14. Fasten the motor. Connect the motor to the


mains so that the bowl will rotate clockwise,
as seen from above.

50
19O-MA-E-02-403-o1
MAINTENANCE, PROCEDURES

4.3.2 Bowl spindle; assembly

~Sh.------A
CT~----B
@.~----C

G-03794-H
1

~ \ K
A Protecting plate
B a-ring
C Protecting collar
0 Guard
E Spring casing
F Buffer
G Spring
H Screw plug
I ai/fan
J Ball bearing
K Bowl spindle
L Stop sleeve
M Worm
N Conveyor
a Spacing washer
P Washer
L Q Ball
R Support p/uger
S Height adjusting ring
T Spacing sleeve
U Slotted pin
G.()3793-H V Bottom bearing housing
W Gasket

51
190-MA-E-02-403-01
MAINTENANCE, PROCEDURES

1. First fit bottom sleeve with its parts and then


thrust ball bearing, but without the upper ball
race. Use the special tool.

y s --.-.-------~
G-Ol331-H

2. Heat the bowl spindle bearings, the worm spin-


dle and the upper ball race of the thrust ball
bearing in oil to facilitate fitting.

Fit the bearings, the upper ball race and oil fan.

G-Ol332-1-1

3. Carefully lower the spindle into the frame.

Guide the bearings into bottom bearing hous-


ing. If they do not completely enter their seats,
tap the spindle top with a tin hammer.

G-Ol333-1-1

4. In the case of 8000 h service, check the top


bearing springs and the ball bearing housing.

Fit spring casing with gasket and ball bearing


housing.

Take care to bring the flats of the ball bearing


housing right in front of the buffer holes.

G-0132S-H

52
190-MA-E-02-403-01
MAINTENANCE, PROCEDURES

5. Tighten the screws of the spring casing.

G~1324-1-1

6. Fit buffers, springs and screw plugs.

~1323·1·1

7. Tighten the buffer plugs.

See 5.14, "Height position of spindle".

~1322·1·1

8. Fit top-bearing hood.

G~1321·1·1

53
MAINTENANCE, PROCEDURES

9. Fit collar, the O-ring and protecting shield.

G-01320+1

10. Fit the hood above the top bearing.

In the case of 8000 hours service or if the spin-


dle has been dismantled due to a rough bowl
run check the radial wobble. See 5.11, Radial
wobble of bowl spindle".

G-01319-1-1

54
190-MA-E-ll2-403-01
MAINTENANCE, PROCEDURES

4.3.3 Control paring-disc device;


assembly

A. O-ring
B. Distributing ring
C. Control paring disc
D. O-ring
E. Cover
F. Gasket·
G. Distributing cover
(IS) Included in Intermediate Service Kit

G'()1301-1-1

1. Put the distributing cover in place. Do not


tighten the screws yet (this will make it easier
to fit the operating water inlet tubes).

G'()1276-1-1

2. Fit the operating water inlet tubes.

G-01275-H

190-MA-E-02-403-01 55 ~
\~
MAINTENANCE, PROCEDURES

3. Fasten the distributing cover.

G-Ol335-1·1

4. Assemble the paring-disc device. Do not forget


the gasket on its underside.

(;,01336+1

5. Align the three holes (1) of the paring disc with


the three holes (2) of the distributing cover.

, ,
. -.! -.~ -.... -. -... --_ . . ,---.. . . . . . . -_ . --_ . . ~ ..... .

G-O:l772+1

6. Fit the paring-disc device in its place.

(;'01273-H

56
190-MA·E-02-403-01
MAINTENANCE, PROCEDURES

7. Tighten the screws of the paring disc.

Check the height position as described in


Check point.

G-02792·'·'

57
190-MA·E·02-403-01
MAINTENANCE, PROCEDURES

4.3.4 Bowl body and discharge


mechanism; assembly
AOk------A

A Cap nut
B Bowl body
C(IS) C O-rings
D Operating slide
E Valve plugs
E(IS) F Springs and spring support
G Nozzles
D H Dosing ring
(IS) Included in Intermediate Service Kit

F ~ Left-hand thread
$000006-1-1

G-03792-1-1

58
19D-MA-E-02-403-01
MAINTENANCE, PROCEDURES

Bowl body and discharge mechanism


The separator bowl is assembled in reverse se-
quence to dismantling.

• Observe check pOints to be carried out when


assembling the separator bowl.

WARNING:

Only use original parts for the


bowl. The bowl was balanced
as a complete unit before de-
livery.
Never interchange parts be-
tween separators.

1. New valve plugs, in the operating slide, should


be knocked in with a rubber mallet to avoid
damaging of the sealing surface.

~&11+1

2. Clean the guiding surfaces of bowl body, oper-


ating slide and dosing ring.

Lubricate with Molykote 1000 Universal Paste.

Lubricate the O-rings with silicone grease.


3. Clean the nozzles of the dosing ring and the
inlets for operating water, in the bowl body.
Use compressed air or a soft iron wire.
4. Check for damage, corrosion (see 5.1) and
erosion (see 5.2).

190-MA-E-02-403-01
59
MAINTENANCE, PROCEDURES

5. Fit the operating slide.

Notice the guide pin.

G-0281)().1·1

6. Fit the dosing ring.

Notice the guide pin and the drill mark.

G-0282101·1

7. Apply a.thin film of lubricating paste Molykote


1000 Universal to the screws before tightening
the dosing ring screws.
If too much paste is provided, the surplus will
collect between operating slide and bowl body
with risk of operating trouble as a result.
It is absolutely necessary to use a torque
20 Nm wrench when tightening the dosing ring screws.
G-O 1349-101 First tighten diametrically, then all around.
Tightening torque 20 Nm.

8. Apply lubricating paste on the guiding surface


of the spring support. Fit springs and spring
support.

Tighten the screws of the support successively


a little at a time. Finally tighten firmly (by hand).

G-03789-101

60 19D-MA·E-02-403-01
MAINTENANCE, PROCEDURES

9. Wipe off the spindle top.


Apply oil onto the tapered end of the spindle.
Use a few drops of oil only to prevent from cor-
rosion. Smear it over the surface and wipe it off
with a clean cloth.

Check the distance from paring disc device to


spindle top. Chapter 5.15.

G4.!850-H

10. Wipe off the nave bore in the bowl body.

Turn the bowl body over.

G-0135H-l

11. Fit the bowl body on the spindle. Proceed as


follows:

• Fit the lifting tool and screw the lifting eye


home.

• Lift the bowl body by hoist.

• Lower the bowl body until the central screw


is supported on the spindle top.

G-Ol263-1-2 • Now unscrew the lifting eye so that the


bowl body sinks down on the spindle cone.

• Rotate the bowl body slowly and align the


screw holes in the bottom exactly above
the holes in the distributing ring (of the
paring disc device).

• Apply lubricating paste on the bowl body


screws and tighten firmly.

G-03788-1-1

61
190-MA-E-02-4~1
MAINTENANCE, PROCEDURES

12. Lubricate the cap nut threads with Molykote


1000 Universal Paste.

Screw the cap nut counter-clockwise on the


spindle (left-hand thread). Tighten firmly.

G-01266+2

62
190-MA-E-02-403-Ql·
MAINTENANCE, PROCEDURES

4.3.5 Bowl hood, disc stack, sliding


bowl bottom; assembly

K---f
ol-----<:n>----(IS)

M (IS)

G'{)3791-H

F----f

A Paring chamber cover


B Paring disc
C Large lock ring
D Bowl hood
E Seal ring
F Top disc
G Bowldiscs
H Wing insert
I Bowldiscs
J Distributor
K Distributing cone
L Sliding bowl bottom
M Rectangular ring
J------,fln N Bowl body
o O-rings
IS Included in Intermediate Service Kit
G-03790+1

Left-hand thread
S-OClOO&-l-l

63
190-MA-E-02-403-01
MAINTENANCE, PROCEDURES

1. Before fitting the sliding bowl bottom:


Degrease the locating face and lubricate it with

\ I Molykote 1000 Paste.


Lubricate the O-ring and the seal ring with sili-
cone grease and check that they lie properly in
their grooves.
At each Major Service only: spray Molykote 321
R on the guiding surfaces common to bowl
body nave and sliding bowl bottom.

G-03787-1-1

1=e=1 2. Fit the lifting tool and lift the sliding bowl bottom
into the bowl body by hoist.

Take care to position the <p mark of the sliding


bowl bottom right in front of the guiding lug. This
will ensure that the sliding bowl bottom drops
into correct position.

G-01267-1-1

IbT'1 3. Fit the distributing cone.


Correct position:
The bore mark on the edge of the distributing
cone faces the <p mark of the sliding bowl bot-
tom. The guide pins on the underside of the
distributing cone will then enter the recesses in
the sliding bowl bottom.

-
..-
G-O 1296-1-1

64.
190-MA-E-02-403-01
MAINTENANCE, PROCEDURES

4. Assemble the discs one by one on the distribu-


tor. The distributor has three guide ribs for the
correct positioning of the discs.
f!i.I!fIlI!--B

Number of discs: A B
LOPX707: 43 46
LOPX709: 45 49
LOPX 710: 58 62

The number of bowl discs above the wing inset


may have to be adjusted to achieve the right
:,l1li--- A disc stack pressure when the large lock ring is
tightened. See chapter 5.18.

~857·1-1

c )
5. Lubricate the O-ring of the top disc with silicone
grease and fit the top disc.

6. Lift the disc stack into the bowl body by hoist.

Position the guide rib of the distributor right in


front of the bore mark on the bowl body. The
guide pins of the distributing cone will then fit
into the corresponding recesses in the distribu-
tor bottom.

G-01264+1

65
190-MA·E-02-403-01
MAINTENANCE, PROCEDURES

7. Fit the lifting tool on the bowl hood.


When the bowl hood is lowered into position the
guide lug in the bowl body has to enter the re-
cess in the hood.

,

CAUTION:

If the bowl hood is not positioned


correctly at once, it must be re-
positioned.
G-Ol356-1-1

When the bowl hood is lifted


again the top disc is likely to stick
in the hood. The top disc must be
knocked out and be fitted on the
disc stack again before the bowl
hood is repositioned.

8. Degrease the large lock ring threads, the con-


tact surfaces and the guiding surfaces (see ar-
rows). Apply Molykote 1000 Universal Paste to
the threads and surfaces. Brush on the paste
according to the manufacturer's directions.

G-05149-1-1

66
190-MA-E-02-403-01
MAINTENANCE, PROCEDURES

9. Lift the large lock ring into its place.

Fit the large lock ring tool and tighten the ring
counter-clockwise (left-hand thread). Use the
tin hammer.
If the lock ring can be tightened without resist-
ance until the <I> marks on the lock ring and the
~1246+2
bowl body are facing each other, an extra disc
must be added to the disc stack to achieve the
correct pressure.

,

CAUTION:

Lifting of bowl hood, see above!

Re-check the disc-stack pressure if a disc has


been added. See chapter 5.18.

~1358-1-1 In a new bowl the <I> marks will be in line with


each other when the large lock ring has been
tightened as far as possible.

DANGER:

The <p mark of the large lock ring


must never pass the <p mark of the
bowl hood by more than
25° without remedy.

If so, call your Alfa-Laval repre-


sentative.

M
Mounting of the large lock ring by means of the
compressing tool, see a-g below:
a. Degrease and lubricate as described above.
b. Fit the large lock ring and tighten as far as pos-
sible without using force. Left-hand thread.

~1259-1-1

67
190-MA-E-02-403-01
MAINTENANCE, PROCEDURES

c. Fit the lifting ring to the bowl hood cover. Fit the
thimble.

d. Fit the compressing tool.


Turn the switch into upright position.
Tighten the compressing tool to the top disc.

G-01373-1-1

e. Switch to position for compression. Pump until


full pressure is obtained. The compressing tool
is equipped with a relief valve.

G-01374-1-1

f. Fit the large lock ring spanner.


Give the spanner handle a few blows with the
lead hammer. The <l> marks on the lock ring and
the bowl body should now face each other.

,

CAUTION:

If the marks are not facing each


other, see above!
G-OI358-1-1

g. Turn the switch into upright pOSition. Unscrew


and remove the compressing tool, the thimble,
the lifting tool and the paring-chamber cover.

Check the disc stack pressure, see chapter


5.17.

G-01375-1-1

68
190-MA-E-<l2-403-01
MAINTENANCE, PROCEDURES

4.3.6 Oil paring disc, inlet and


outlet; assembly

«!»----B
~----C

+-----0

A Hose liner
B Rectangular ring
CO-ring
o Inlet pipe
E Support
F Connection housing
G Paring chamber cover
H Paring disc

-r---E

.g~----iB

r1~----C

~--H

190-MA-E-02-403-01
69
MAINTENANCE, PROCEDURES

1. Check the threads inside the paring disc.


Lubricate the O-ring with silicone grease.
Lubricate the threads of the bowl hood top with
Molykote 1000 Universal Paste.
2. Fit the paring disc.
t
3. Screw on the paring-chamber cover. Left-hand
~
c~ thread! .
Fit the tool and tighten the paring-chamber
cover to the bowl hood by giving the tool some
slight taps with a lead hammer.

G-OI260-1-1

4. Lift the frame hood into its place and clamp it


with the hinged bolts.
5. Check the height of the paring disc.
Adjust with height adjusting rings and secure
with the metal ring.

G-OI247-1-1

6. Fit the outlet connection housing on the top of


the paring disc. Don't tighten the fastening
screws yet!
7. Fit the cap nut, the supporting washer and the
(lubricated) O-ring on the outlet pipe.
~
-~
Join the pipe and the outlet connection hous-
ing.

\~ Tighten the fastening screws of the outlet con-


\ nection housing.
I I
G-OI20-1-1

70
190-MA-E-Q2C403-o1
MAINTENANCE, PROCEDURES

8. Lubricate the rectangular ring between the inlet


support and outlet connection housing.

Put the inlet support, connected to the oil inlet


piping, on top of the outlet connection housing.
9. Lubricate the O-ring of the inlet pipe.

Insert the inlet pipe till the threads find the


threads of the paring disc.

Tighten the pipe firmly by means of an adjusta-


ble wrench. This will lift the paring disc and the
rotating paring chamber will run free. Left-hand
thread.

10. Tighten the pipes at the pipe support.

~1254-1-1

11. Fit the hose liner for displacement water.

Connect the displacement water pipe.

~1250-1-2

12. Fill oil into the worm gear housing.

See 3.3, Lubrication.

~1359-1-1

71
190-MA-E-02-403-01
MAINTENANCE, PROCEDURES

4.4 EXCHANGE OF THE


FRICTION-PADS OF THE
COUPLING
If the separator does not attain full speed within
about 10 minutes the friction pads of the coupling
may be worn or oily.
The friction pads must then be renewed or properly
cleaned from oil.

G-01316-1·1

• Remove the brake cap. Undo the screws of the


holding brackets.

G-01336-1·1

• Remove holding brackets and friction blocks.

• If the pads are worn:


Remove the screws and exchange the pads.

NOTE!

The screws are slotted in both ends.


G-01339-H

Replace all pads even if only one is


worn.

• If pads are oily only:


Clean the pads and the inside of the coupling
drum with a suitable degreasing agent.
Roughen friction surfaces of pads with a coarse
file.

72
190-MA·E·02-404·01
MAINTENANCE, PROCEDURES

4.5 BRAKE
A worn or oily lining will lengthen the braking
period.

• Remove the brake cap .

Exchange of brake lining:

If the lining is worn:

Remove the screws and exchange the lining.

NOTE!
\, The screws are slotted in both ends.
G-01341·1·1

If oiliness is the fault:

- Clean the lining and the coupling drum with a


suitable degreasing agent.

Roughen the friction surface of the lining with a


coarse file.

G-01342·1·1

73
MAINTENANCE, PROCEDURES

Checking of spring and brake shoe:

Formation of rust on the brake parts may cause the


brake to jam.

Remove any rust from the surface (1) of the


brake shoe and the corresponding guiding sur-
face in the cap (2).

Rub the surfaces for instance with Molykote


G-01343-1-1 Paste. '

Replace the spring (3) if it has lost its stiffness.

Oil the spring when assembling.

74
19D-MA-E-02-405-01
MAINTENANCE, PROCEDURES

4.6 EXCHANGE OF FRAME FEET


When replacing the frame feet the separator
must be lifted.

NOTE!

Always remove the bowl before lifting the


separator.

Follow stated procedure,


see 4.2 Dismantling of separator (4.2).

1. Tighten the frame hood.


2. Use two endless slings, each capable of lifting
1 ton (2,200 Ibs).

Length of each sling: minimum 2 m.

Exchange of rubber cushions:


1. First place the frame (1) without cushions in
position.
2. Check that the bolts do not press against the
edges of the holes, otherwise the resilient
mounting of the frame would be impeded.
3. If it was found necessary to use adjusting
washers when the separator originally was in-
stalled, fit these washers. Check that the frame
is horizontal and that all feet rest on the foun-
G~"64·'·2
dation.
4. Lift the frame, fit the vibration dampers in the
order illustrated, lower, and check that the bolts
do not press against the edges of the holes.
5. Tighten the nuts till they touch the cup covers
and tighten a further half-turn.
6. Hold the nuts firmly and secure with lock nuts.

19().MA·E-02-4~1
75
MAINTENANCE, PROCEDURES

4.7 OIL SUMP

c
1---1---1

~=----2 1 Oil filling plug


2 Sight glass
3 Oil drain
'--_~~==-- 3

<>-01344-1-1

4.7.1 Oil change

1. Place a collecting tray under the drain hole, re-


move the screw and drain off the oil.

G-Ol16a-l-l

2. Fillnew oil into the worm gear housing. Oil level


. slightly above middle of sight glass.
See Lubrication, chapter 3.3.

,

CAUTION:

The separator is delivered with-


out oil in the worm gear housing.
Therefore, it is necessary to sup-
ply oil to the worm gear housing
before the first start of the sepa-
G-OI345-H rator.

76
190-MA-E-Q2-407-01
CHECK POINTS

5.1 CORROSION
Corrosive attacks on bowl parts and particularly
bowl body, bowl hood and lock ring should be
watched with utmost care.

5.1.1 Non-stainless steel and cast


iron parts
Corrosion (rusting) occurs on unprotected com-
ponents of non-stainless steel and cast iron
which are forming parts of the bowl, bowl spindle
and frame when the parts are exposed to the
process liquid or aggressive atmosphere.

5.1.2 Stainless steel and


non-ferrous metal parts
In certain circumstances corrosion can form on
stainless bowl parts. The risk of attack increases
when the surface is isolated from surroundings
by a layer of dirt.

Corrosion attacks on stainless steel are not ea-


sily detected. This applies for instance to attacks
made by chlorides. Such attacks may begin as
small dark spots.

• Polish dark spots and corrosion spots with a


fine-grain abrasive cloth. This may prevent fur-
ther attacks.

• Under special conditions corrosion on stainless


steel can result in deeper attacks, known as
S~I-1
pits.

• Always watch for all kinds of attacks from cor-


rosion and record the obervations carefully.

77
190-MA·E·02-501-01
CHECK POINTS

,

CAUTION:

Replace the part if the corrosion


could effect the strenght or func-
tion of it.

Pits and spots forming a pattern


like a line may indicate cracking
beneath the surface.

5.1.3 Other metal parts


Under unfavourable circumstances components
of copper alloy, light metal etc. may be corroded.
Check for corrosive attacks when the separator
is dismantled.

78
190-MA-E-02-501-01
CHECK POINTS

5.2 EROSION
Erosion can occur when particles suspended in
the process liquid slide along or strike against a
surface while passing through the bowl.
Erosion is intensified at some locations by locally
high flow rates.

Erosion is characterized by:

• Burnished traces in the material

• Dents and pits with a granular and shiny


surface.

Surfaces subjected to erosion are:


1. The underside of the distributor around the dis-
tributing holes and the wings.
2. The sealing edge of the sliding bowl bottom,
and the seal ring in the bowl hood.
3. The surface of the sliding bowl bottom that
faces the conical part of the distributor.
4. The bowl wall area ("pillars") between the
sludge ports in the bowl body.

,

CAUTION:

Always carefully observe any


signs of erosion damage.

Pay special attention to the


bowl wall pillars between the
sludge ports.

Erosion damage may deepen


rapidly and weaken the bowl
parts by reducing the metal
thickness.

79
190-MA-E-02-502-01
CHECK POINTS

If one or more of the following observations are


made always consult your ALFA-LAVAL repre-
sentative. .

Radius <1 mm • The bottom radius of the erosion trace is less


then 1 mm in the narrowest place or that coarse
Max. 1 mm scratches are present.

• The largest depth of the trace exceeds


1 mm.

G-02052-1-1 • The bowl wall area between the sludge ports


have defects presumably caused by corrosion.

Valuable information on the nature of the damage


can be given by photos, plaster impressions or
hammered-in lead.

80
190-MA-E-02-602-01
CHECK POINTS

5.3 WORM WHEEL AND WORM.

Check at each oil change.


Check the teeth of worm wheel and worm for wear.

Examine the contact surfaces and compare the


tooth profiles.
The gear may work satisfactorily even when worn
to some degree.

• Replace worm wheel and worm at the same


time, even if only one of the parts is worn.

• To avoid damaging the teeth when lifting the


bowl spindle, first push the worm wheel aside.
Put the spindle in place before mounting the
worm wheel.
1 Worm
2 Worm wheel

NOTE!

Counting the number of teeth:

When replacing the gear, always make


sure that the new worm wheel and worm
have the same number of teeth as the
old ones.

,

CAUTION:

Presence of metal chips in the


oil bath is an indication that the
gear is wearing abnormally.

81
190-MA-E-02-503-01
CHECK POINTS

5.4 GUIDING SURFACES

Check at each dismantling

• Check surfaces indicated A for burrs .


Remedy when necessary.

• Check surfaces indicated Band C for galling .


Repair if necessary.

• Prime surfaces indicated Band C with lubricat-


ing spray Molykote 321 R. Proceed in the same
way as for the large lock ring.

• Lubricate surfaces indicated Band C with Mo-


Iycote 1000 Paste after priming.

1. Sliding bow/ bottom


2 Bow/body
3. Operating slide
4. Dosing ring

G-03762-1-1

82
190-MA-E-02-604-o1
CHECK POINTS

5.4.1 Repair of galling on guiding


surfaces.
Galling (friction marks) may appear on guiding sur-
faces of the bowl discharge mechanism, the bowl
body and the sliding bowl bottom. Surfaces sub-
jected to repairs are indicated by an arrow.

The example below describes the repair of the


lower guiding surface of the bowl body nave.

G-Q2055·1·1

Recommended tools for correction of galling:

Emery cloth, 240 grade.


Hand drilling machine
Degreasing agent.
Fibre brush, 0 25 mm.
Fibre brush, 050 mm.
Very fine single-cut file~

1. Clean the surface thoroughly with a degreasing


agent, i.e. white spirit. This is important.

G-{)2056+1

2. If the galling is excessive, first use a fine sin-


gle-cut file. The file should be used with caution
so that the damage is not made worse.

Remove the high spots on the surface. Do not


use rotating files or similar. Remove the high
spots only - not the undamaged material.

G-02057·1·1

3. A fine grain emery cloth of 240 grade should be


used to smooth the edges and to remove the
burnt-in foreign matter.

G.{)2058-1·1

83
190-MA·E-02·504-01
CHECK POINTS

4. Finish off by polishing the damaged spot with


the fibre brushes and brush wax. It is recom-
mended that the whole area where galling may
occur should be polished. Polishing will help
smoothen the whole of the damaged area,
even in the deepest parts.

<702059+1

5. Prime the repaired area with lubricating spray


Molykote 321 R. Read the correct procedure
under Check Point "Priming of large lock ring".
Apply Molykote 1000 Paste onto the surface
after priming.

84
19Q-MA-E-{)2-504-01
CHECK POINTS

5.5 SPINDLE TOP AND BOWL BODY


NAVE

Check every 2000 operating hours or 3


months
Impact marks on the spindle cone and/or in the
nave may cause bad bowl run.
The bowl spindle and the nave should be checked
if the bowl spindle has been dismantled or if the
bowl runs roughly.

• Remove any impact marks with a scraper


and/or whetstone.
Rust can be removed by using a fine-grain em-
ery cloth (e.g. No 320).
Finish with polishing paper (e.g. No 600).

,

CAUTION:

Always use the scraper with great


care. The conicity must not be
marred.

G-02060-H

190-MA-E-02-505-01
85
CHECK POINTS

5.6 DISCHARGE MECHANISM

Check every 2000 operating hours or 3


months
Dirt and lime deposits in the sludge discharge
mechanism may cause bad discharge function
or none at all.

5.6.1 Dosing ring

• Exchange the nozzles. Polish the surface (1)


with steel wool. .

• Inspect the surface (2) in contact with the op-


erating slide. Remove any marks with whet-
stone (grain size 240).
Defectiv or broken springs as well as poor sealing
between the valve plugs of the operating slide and
the bowl body may prevent complete closing of the
G.03784-1-1 bowl.

5.6.2 Operating slide springs

• Replace springs which differ from the other


ones in regard to length or which seem to be
defective in other respects.

<'; Ala 5.6.3 Operating slide

~ • Examine the three sealing surfaces (1) of the


bowl body which are in contact with the valve
plugs. Remove any marks and lime deposits
with a very fine-grain emery cloth.

• Inspect the guiding surface (2) in contact with


the dosing ring. Remove any marks with whet-
stone (grain size 240).

5.6.4 Valve plugs

• Exchange the valve plugs.


Tap in the new plugs with a rubber mallet.

86
19G-MA-E-Q2-506-01
CHECK POINTS

5.7 BOWL SEA LINGS

Check every 2000 operating hours or 3


months

5.7.1 Bowl hood seal ring


Poor sealing between the bowl hood seal ring and
the sealing edge of the sliding bowl bottom will .
cause a leakage of process liquid from the bowl.

Replace the bowl hood seal ring at each intermedi-


ate service (IS) if the ring is damaged or indented
more than 1 mm.

~062·1·1

If the seal ring in the lower edge of the bowl hood


needs replacement, force out the ring by means of
a pin, inserting it in the holes intended for this pur-
pose.

~063·1·1

Fit the new ring as follows:


Press the ring into the groove with a straight board
(1" x 4"), placed across the ring.

NOTE!

If a new ring is too narrow, put it into hot


water, 70-80 °C for about 5 min.
~·1·1
If it is too wide it will recover after drying
in 80-90 °C for about 24 hours.

87
1~MA·E-02-507-01
CHECK POINTS

5.7.2 Seal ring of sliding bowl


bottom
Min 1.5 mm Check the sealing edge of the sliding bowl bottom
for damage, corrosion or erosion.

Maximum permitted reduction of the original profile


height: 0.5 mm.

If the seal ring of the sliding bowl bottom is to be


replaced and compressed air is available, turn the
sliding bowl bottom upside down and inject com-
pressed air through the hole on the underside. This
will press the ring outwards far enough to be easily
gripped.

G-02075-1-1

88 190-MA·E..()2-507-Q1
CHECK POINTS

5.8 THREADS OF LOCK RING AND


BOWL HOOD

Check every 2000 operating hours or 3


months.

Excessive wear or impact marks on threads and


guiding surfaces of the lock ring, bowl hood or
bowl body may cause hazardous seizure dam-
age.

• Check the thread condition by tightening the


bowl hood after removing the disc stack with
top disc from the bowl and the O-ring from the
bowl hood.

• In a new bowl the alignment marks on the lock


ring and the bowl body should be aligned.

~t358·t·t

If thread wear is observed, mark the bowl body at


the new position by punching a new alignment
mark. If the mark on the lock ring passes the corre-
sponding mark on the bowl by more than 25°, an
Alfa Laval representative must be contacted imme-
diately.

If the marks are not legible, an Alta Laval repre-


sentative should be contacted tor determination
and punching of new alignment marks.

190-MA·E·02-5O&-01
89
CHECK POINTS

Damage
Position of threads, contact and guiding surfaces
are indicated by arrows in the illustration.

• Check for burrs and protrusions caused by im-


pact.
Watch your fingers for sharp edges!

• If damage is established, rectify using by a


G-0190!H-l whetstone or fine emery cloth. Recommended
grain size 240.

• If the damage is considerable use a fine single


cut file, followed by a whetstone.

G-02077-1-1

90
190-MA-E-02-508-01
CHECK POINTS

5.9 THREADS OF INLET PIPE,


THREADS OF OIL PARING DISC

Check every 2000 operating hours or 3


months.

Damage to the threads of the inlet pipe or the inter-


nal threads of the oil paring disc may causeincor-
rect positioning of the oil paring disc in the paring
chamber, even though the height adjustment of the
paring disc has been made correctly.

• Check the threads for damage and rectify if re-


quired.

G-03774-1.1

91
190-MA·E.()2·50~1
CHECK POINTS

5.10 ELASTIC COUPLING

Check every 8000 operating hours or 1 year

The axial play (A) of the elastic plate should be 2


mm (approx.).

G-02874-1-1

/ Check playas follows:


1. Measure the distance, X, from frame ring to
coupling disc of the separator.

<>-02872-1-1

2. Measure the distance, V, from motor coupling


disc to motor frame ring.
3. X mm - Y mm =2 mm.

If required, adjust the postition of the motor


coupling disc.

G-02873-1-1

92
190-MA-E-02-610-01
CHECK POINTS

5.11 RADIAL WOBBLE OF BOWL


SPINDLE

Check every 8000 operating hours or 1 year

The bowl spindle wobble should also be checked if


the bowl spindle has been dismantled or if rough
bowl run (vibration) occurs.

WARNING:

Spindle wobble may cause rough


bowl run, leading to dangerous
vibration.
~1-1

Check the wobble before dismounting the spindle.

Before measuring make sure the buffer plugs are


properly tightened.

- Fit a dial indicator in a support and fasten it to


the frame, as illustrated.

- Measure the wobble at the top of the tapered


end of the spindle.
Maximum permissible radial wobble: 0.04 mm.

- Remove the brake cover to get access to the


coupling drum. Use the coupling drum to re-
volve the spindle manually.

Max. 0,04 mm - I f wobble is too large: replace ball bearings in


top and bottom bearings.
G.()1915-1-1
Measure wobble after assembly. If it is still ex-
cessive, the spindle is probably damaged and
must be replaced.

190-MA-E-02-511-01
93
CHECK POINTS

5.12 TOP BEARING SPRINGS AND


BALL BEARING HOUSING

Check every 8000 operating hours or 1 year


Weakened or broken buffer springs 1 as well as
defective contact surfaces 2 for the buffers on the
ball bearing housing may cause vibration (rough
bowl run).

G.02634-1-1

5.12.1 Top bearing springs

• In case of a sudden spring fracture, the com-


plete set should be replaced, even if only one
spring is broken.

G-02635-1-1

A Ball bearing housing


B Radial buffer
C Buffer spring
D Screw plug

5.12.2 Ball bearing housing

• Examine the contact surface for the buffers on


the ball bearing housing. In case of defects, in-
dentions deeper than 0.5 mm, replace the
housing as well as buffers and springs.

_~ ~~·~Max.O.5mm
_ _ _ __

1\. G-02636-1-1

94
190-MA-E-02-612-01
CHECK POINTS

5.13 WEAR OF DRIVER AND OF


GROOVE IN WORM

Check every 8000 operating hours or 1 year.

Replace the driver when wear exceeds 2 mm.

Max. 2 mm The wear of the groove a in the worm, which re-


ceives the driver, should not exceed 7-8 mm .

......_ _ a

G~7n-l-l

190-MA-E-02-513-01
95
CHECK POINTS

5.14 HEIGHT POSITION OF SPINDLE

Check every 8000 operating hours or 1 year

The height position should also be checked if the bowl spindle has
been removed.

Incorrect spindle height could make the subsequent paring disc posi-
tioning impossible.

The spindle height is measured to the top edge of the frame ring:

• Remove seal ring from the frame ring .

• Place a steel ruler across the frame ring. Push


the narrow tongue of the templet (2), marked
MIN (10 mm), between the ruler and the spindle
top. There should now be a small gap between
the templet and the ruler, however not so large
that the wide templet tongue marked MAX (12
mm) can be inserted.

~
G-03776-1·1

NOTE!

Before measuring, tap the spindle top a few times with a


tin hammer. It might be that the bottom bearing of the
spindle is not properly seated in the bottom bearing
housing.

96
190-MA·E-02-6 14-01
CHECK POINTS

If the height of the bowl spindle must be ad-


justed, or in the case of 8000 hours (4 years)
service:

w y • Force the slotted pin (X) into spacing sleeve


(W) and remove the spacing sleeve.

• Unscrew supporting plug (U) using two screws


(a) with threads 1/4"-20 UNC to make height
adjustin rings (V) accessible.

~@]). Clean all dismantled parts thoroughly.

• Check for damage and for severe corrosion on


G'()1365+1
spindle top.
Presence of black deposits on the spindle parts
may indicate, that another lubricating oil must
be used, chapter 3.3, Lubrication.

• Replace parts supplied in the Major Service Kit


(MS).

97
190-MA-E-02-514-01
CHECK POINTS

5.15 HEIGHT POSITION OF


CONTROL PARING DISC

Check every 8000 operating hour or 1 year


The height position should also be checked if the
bowl spindle has been dismantled.

,

CAUTION:

Incorrect height position can


cause the paring disc to scrape
against the paring chamber
housing.

G.01301+1

I;i~ l il!lj~
• Support the templet on the spindle top with the
measurement indication 177.3 facing the
spindle: Now there should be a small gap be-
tween the lower end of the templet and the up-
per side of the paring disc, otherwise the paring

:.I!~: :~
. ....... 1'1'iI11i:,·,I!I.,)
disc position is too high.

tn\it~Hi:
,·...•:.:•..,··::.:·.::·i:.::••:.,.·. • ..:::,:.:.:,:,.::. . •:,. ::.:.:• .:••.. :,. .:•. ..:•.•:.:1,
. :.•..:.•,.•.: :.,.: .·:.:,
. :.. •:::
. •.::.•..:;.·

G-0377()'1·1

• Turn the templet so that the measurement indi-


cation 178.3 faces the spindle and the templet
lower end supports on the paring disc.

There should now be a small gap between the


templet tongue and the spindle top, otherwise
the paring disc position is too low.

G-03771+1

98
190-MA·E-02-61S-01
CHECK POINTS

• Adjust the height position by adding or by re-


moving height adjusting rings (H) under the
distibuting cover.

• After adjustment, rotate the spindle. If a


scraping noise is heard, re-adjust.

99
190-MA-E-02-515-01
CHECK POINTS

5.16 PRIMING OF LARGE LOCK


RING

To be performed every8000 operating hours


or 1 year

The arrows indicate positions of threads, guid-


ing and contact surfaces to be primed.

NOTE!

The procedure of priming also applies to


the discharge mechanism.

GoO 1909-1-1

Recommended agents for priming


procedure:

Degreasing agent
Lubricating spray Molycote 321 R
Hand drilling machine
2 fibre brushes

1. Clean the lock ring thoroughly with a degreas-


ing agent and wipe it.

G-02069-1-1

Spray the threads, guiding and contact sur-


faces with lubricating spray Molycote 321 R
and let the ring dry for approx. 15 minutes.

G-0207()-1·1

100
190-MA·E-02-51 &-01
CHECK POINTS

3. Use a fibre
Thbrush to polish the M
surface
ished bl"aCk~~laCk spray WilllOO::lr~ote
into the
formed . oe cream when p roperly per-pol-
i e well

4. for
Spray the lock
approx. rinm.g a second time and Iet It' dry
15 m-

G-02072-1-1

which now caX~~~~~~oau~lack shining surface


5. Polish the Mol
one year.

NOTE!

~ever use the sam


VIOUS operat'Ion. e brush as in th e pre-

slidin~~0~'16 th:~Ui~~:;
Proceed
the b I in the sarne way 'th
G-02073-1-1 and with threads of
and dosing r"mg.
attorn, bowl body' 0 peratmg
9 surfaces of
slide

101
19O-MA-E-02-S1 &01
CHECK POINTS

5.17 DISC STACK PRESSURE

Check every 8000 operating hours or 1 year

,

CAUTION:

Insufficient pressure in the disc


stack may affect the bowl bal-
ance. which in turn will cause
abnormal vibration of the sep-
arator.

The lock ring (1) should press the bowl hood (2)
firmly against the bowl body (3), the hood in turn
should excert a pressure on the disc stack (4),
1 clamping it in place. .

4
G-02833-1-1

1 Lock ring
2 Bow/hood
3 Bow/body
4 Disc stack

Correct pressure is obtained when it is possible to


tighten the lock ring so far by hand that the 0 mark
on the lock ring is positioned 60° - 90° before the
mark on the bowl body. To achieve this, add an ap-
propriate number of discs to the top of the disc stack
beneath the top disc.
Then advance the ring by giving the spanner handle
some light blows till the 0 marks are aligned.

G-Ol358-1-1

102
1SQ-MA-E-02-5 17-01
CHECK POINTS

5.18 HEIGHT POSITION OF OIL


PARING DISC

Check every 8000 operating hours or 1 year

The height position should also be checked if the


bowl spindle has been dismantled or the bowl
has been replaced.

,

CAUTION:

Incorrect height position can


cause the paring disc to
scrape against the top disc or
the paring chamber cover.

The height position of the oil paring disc is checked


when the bowl has been completely assembled and
I the frame hood has been fixed in its place with the
hinged bolts.
I
I • Measure the distance between the oil paring
disc and the metal ring on the frame hood top
I according to adjacent pictures.
Correct distance is 19.5 cm ± 0.5 mm.
I
I • Adjust the distance by adding or removing
height adjusting rings under the metal ring.
I.
!um~~ • When the distance is correct proceed with the
assembly of inlet and outlet parts.
I
I • When the inlet and outlet parts have been fitted
revolve the bowl by pushing the coupling drum
I by hand. If it turns heavily or if a scraping noise
I is heard, wrong height adjustment or wrong fit-
G-00775-1-1 ting of the inlet pipe may be the cause.
Pay attention of such scraping noises at the
start up.
A Meta/ring
B Height adjusting ring
C Oil paring disc

103
19().MA-E-02-518-01
MAINTENANCE, COMPONENTS

6.1 EPC-400 CONTROL UNIT

6.1.1 Maintenance
No regular preventive maintenance is required.

NOTE!

If a persistant fault is found in the control modul it must not


be repaired onboard but replaced. The faulty modul must
be submitted to Alfa Laval representatives for repair.
Enclose return note with a description of the observed
fault.

105
190-MA-E-02-601-01
MAINTENANCE, COMPONENTS

6.1.2 Replacing the control module


Before starting to replace the control module
check that actual parameter settings are noticed.

1~r . ! OIl
2 1. Switch off the power to the control unit EPC-
400 by the main switch on the starter.

~~~b
2. Open the panel door.

3. Pull out the wire terminal sockets by hand and


remove terminal XC and XD using a screw dri-
ver.
Both terminals and sockets are marked with
terminal numbers.

4. Remove the two screws holding the module by


means of a screw driver and hinge the control
module outwards. Disconnect the two cable
plugs at the rear cirquit board.

5 6 5. Lift off the control module from the cabinet and


replace·it with a spare module.

6. Fit the spare module in reverse order.

7. Switch on the power again.

8. Reset the parameters to original.

G-00929-H
9. When replacement is completed shut the door.

10. Fill in the return note and place it with the old
module in the return package.

106
19D-MA-E-02-601-01
MAINTENANCE, COMPONENTS

6.2 WATER TRANSDUCER, WT 200

6.2.1 Replacing of oscillator unit


In case of transducer fault owing to faulty oscillator or test circuit
board, the entire oscillator unit must be replaced.
1. Disconnect the wires from the oscillator terminals.
2. Loosen the screw and lift off the complete unit.
DO NOT replace the circuit board only.
3. Assemble the complete oscillator unit spare kit and reconnect the
wires on the terminals.

NOTE!

Fill in the report form and return it with the faulty oscillator
unit to Alfa Laval.

6.2.2 Checking of transducer resistance


If a short circuit is suspected in the transducer pipe, the resistance
between the electrode and the transducer housing can be measured
by means of an ohmmeter.

Prior to measuring, the oscillator with the circuit board must be re-
moved. Measurement is performed between the electrode and one of
the earth connections in the oscillator box.

• High resistance indicates that the fault is lo-


cated in the oscillator unit or in the cables.

•. Low resistance indicates a short circuit. The


transducer should then be removed from the
pipe system and checked for solids or other
matter causing the short circuit between the
two concentric pipes.

~13n·l·l

107
190-MA-E.()2·602-01
MAINTENANCE, COMPONENTS

6.2.3 Cleaning of water transducer.


In the case of transducer fault owing to low resistance, the water
transducer must be removed and cleaned.
The water transducer need not to be electrically disconnected for cle-
aning.

1. Remove the water transducer from the pipe


system.

G-013711-1-1

2. Apply suitable detergent to the transducer


electrode and housing.

G-01379-1-1

3. Rinse, by using pressure freshwater.

G-01313O-1-1

4. Before remounting the transducer, check that


no solids or other matter that can cause short
circuit is stuck between the transducer elec-
trode and housing.

108
190-MA-E-02-602-01
MAINTENANCE, COMPONENTS

6.3 FLOW SWITCH, TYPE FS


Only in connection with Heatpac preheater.

6.3.1 Preventive Maintenance


Periodical cleaning of the insert is necessary.
Recommended interval: every 8000 hours or 1
year.

6.3.2 Removing the flow switch


insert

--=+----1 1. Remove the cover of the junction box (1) and


disconnect the wires.
2. Remove nut (2).

2 3. Pull off the junction box.


4. Remove nut (9) from the housing.
5. Remove the insert (8).
6. Clean the insert in diesel oil, kerosene or
equivalent and blow dry by means of com-
9
pressed air.
6*
7. Replace gasket (10) and O-ring (6), if neces-
sary.
B*

NOTE!

The flow switch is adjusted in the factory


prior to delivery and needs no further
adjustment.
?"'(!r:>-:=--10* Do not dismantle the insert.

1 Cover
2 Adjusting nut
9 Nut
6 O-ring
B Insert
~1-1 10 Gasket

109
190-MA-E-02-603-01
MAINTENANCE, COMPONENTS

6.4 FLOW INDICATOR


No preventive maintenance is required to the
flow indicator.

6.4.1 Maintenance

• To replace the protection glass, remove the


lock spring using a pair of pliers.

G-01382· 1·1

• To dismantle the flow indicator turn the gauge


dial counter-clockwise to remove the spring
wire inside the housing. The entire indicator will
then come loose.

110
190-MA·E-Q2-604·01
MAINTENANCE, COMPONENTS

6.5 SOLENOID VALVE BLOCK


(WATER)

Periodical cleaning, recommended interval: ev-


ery 2000 operating hours or 3 month, of the
valve block strainer and solenoid valves is nec-
essary. Occasionally the flow of water has to be
checked, considering worn flow valves.

6.5.1 Dismantling and cleaning

WARNING:

Switch off electrical power and


depressurize valve before dis-
mantling.

• Clean the strainer regularly in order to obtain


trouble-free operation.

• Prior to disassembly ensure the manual open-


ing mechanism in the valve bonnet is in normal
position, as so the diaphragm hanger spring is
not damaged.

G-OI376·1·1 • Do not loose the core spring when removing


the core/diaphragm sub-assembly.

• Place core spring with wide end in core first


when assembling the solenoid. Closed end
protrudes from top of core.

• Make sure O-rings are properly placed in their


grooves prior to assembly.

• Lubricate all dismantled threads with Silicone


grease.

IMPORTANT:

When fitting a flow valve;


1. Lubricate the O-rings with Silicone-grease,
2. Place the flow valve in the housing without the
use of any tool,
3. Screw on the hose nipple by hand until the flow
valve fits in place. Then tighten the hose nipple
lightly by using a tool.

111
190-MA· E·Q2·605·01
ADJUSTMENT

7.1 EPC-400 CONTROL UNIT


The EPC-400 control unit is designed and programmed to handle all
necessary functions of the cleaning system, in accordance with preset
parameters.

The display on the control panel is used for indication of parameter


numbers and values which can be visualized on request.

Normally the remaining time to next sludge discharge is displayed.


Information on how to check the process values is found in chapter
7.1.2

1 2 3 4 5 6

16 15 14 13 12 11
G-01243-2-1

10. Alarm reset


1. Fuse main switch ON/OFF 11. Function symbols
2. LEOs for alarm inputs (red) 12. LED for main alarm (red)
3. Alarm input diagram 13. LED for discharge failure (red)
4. LED for stop sequence running (yellow) 14. Display
5. LED for control program running (green) 15. System output diagram
6. LED for external preheater on (green) 16. LEOs for system output (green)
7. External preheater ON/OFF push-button 17. Door lock
8. Control program ON/OFF push-button
9. Sludge discharge push-button

113
190-MA-E-02-701-01
ADJUSTMENT

7.1.1 Fuses and related functions

Board Fuse Functions influenced Alarm

EPC- F1 10 V AC supply to the board Remote alarm


400 Display black
front (A4 when new fuse)
board A F2 20 V AC supply to the board A 1-4
1 Analog/digital conversion A2-6
Pt-100 inputs C/F EEE
F3 All outputs PS42

EPC- F2 10 V AC supply to the board A 1-4


400 rear
board A F3 Internal communications A 1-4
2 At restart with new fuse, switch power
ON - OFF - ON

a
o ~ 0

f13~:!::::l
F'12 Q
l:,I~xz ;,
Idec • CONTROL MODULE BcIok ald •

EMm
F12.F"13 '" 1.I5A Ilow
A1

A1,F1 a 2.SA .Iow


Al:F2 - 600mA alow
Al:F3 - SA IIow
A2:F2 = 1.611 .Iow
A2:F3 - 260mA 1110.

G.oo747+3

114
19O-MA-E-02-701 -01
ADJUSTMENT

7.1.2 Information during operation


The red 2+3 digit display (14) can show various
information:
During normal operation, remaining time to the next

1m I]~~I -8- cg sludge discharge is continuously displayed:

• The display shows 1_3


The remaining time is one hour and 30 - 39 mi-
O@) nutes_

o fi\ cg • The display shows 32


The remaining time is 32 minutes_

G-00648-1-1
• The display shows 0.32
The point before the number indicates seconds
and the remaining time is, in this example, 32
seconds.

By pushing the alarm reset button (10), the follow-

[~~~~~~]~i
ing operation condition readings can be obtained in
the following order:

1. Push the button once and the display shows

I[E][~~I
the oil temperature's actual value in degrees
Celsius or Farenheit, if optional PT 100 alarm
temperature sensor is fitted;

I~~I
2. Push the button the second time and the dis-
play shows the oil temperature's actual value in
degrees Celsius or Farenheit, if optional PT
100 control temperature sensor is fitted;

Imlm~1 3. Push the button the third time and the display
shows the accumulated operating time in hours
x 1000

IffiJ l?1~~1 0.72 on display = 720 hours.


Maximum indication is 99.9 x 1000 hours;
G.00647-2-1
4. Actual transducer value.
5. Number of water pulses at last discharge;

6. Functions not used are indicated by (- - -).


Push the button until the display again shows
the basic information, that is the remaining tillie
to next sludge discharge.

115
190-MA-E-{)2-701-{)1
ADJUSTMENT

7.2 EPC-400 PARAMETER FUNCTIONS

Selecting activities and parameter values is done inside the control


unit cabinet. Before any parameter setting or supervision of parame-
ters is possible, the mode selector must be set in I1pl1 position.

Parameter numbers and values are selected by means of the four


pushbuttons. The two upper ones are used for parameter selection
and the two lower ones for setting the values.

The parameters are divided in:

• process parameters (C1): P1 - P19

• installation parameters (C2): P20 - P99

When setting paramaters at start up set the installation parameters


first and then proceed with the process parameters.
, 2

7 6 5 4 J
CMOl39-1-1

1. Parameter number - increase


2. Parameter number - decrease
3. Parameter value - increase
4. Parameter value - decrease
5. Mode selector
6. Parameter value indication
7. Parameter number indication

7.2.1 Parameter Adjustment


How to reach the

1. Process parameters, C-1 (P1 - P19)


2. Installation parameters, C-2 (P20 - P99)

a. Open the front panel door.

G-00186-1-1

116
190-MA-E-02-702-Q1
ADJUSTMENT

'1/
111ij=lor-
/ 1 ,
b. Change the mode selector to "P" position.

~t87-t-t • "Pro" intermittently displayed.

c. Step to the process parameter code "C1" by pushing the upper


button once.
You can read "C 1-1" on the display . To reach "C2" keep the upper
III
G-OOt 88- t - t button pushed until you can read "C2-2".

lei ~11I4 d. Set the parameter code C1-1/ C2-2, to C1-12/C2-12, by using the

rmrrn G.QOt89-t-t
parameter value push-buttons, the two lower ones.
When C1-12/C2-12 is flashing, confim the value by pushing the
upper push-button.

• Unless the parameter code is set to 12 the C1 parameter val-


ues can not be adjusted, but only stepped through.
The C2 parameters do not show up.

I'I II 1'1 1 ~~
e. Select appropriate activities from the parameters displayed in nu-
1

.
B merical order, using the parameter selection push-buttons, (two

, •
I I /
III

~,o:
upper ones) .

Adjust the value of the selected parameter, using the parameter


-1'11I1/~I-
, value push-buttons, the two lower ones.

~
/ I I
G-OOt 90- t - t
• - New value lit intermittently.

~1J~B f. Confirm the new value by pushing the upper push-button.


14 1/ I/~I B '<'
IZI
• - New value lit steadily.
G-OOt9t-t-t

Proceed until all parameters are appropriately adjusted.

1111111 ~C>
p
g. When all parameters are adjusted change the mode selector back
to "L", (local) or "R" (remote) if applicable.
G-OOt93-t-t

h. Close the front panel door.

~t94-t-t

117
190-MA-E-ll2-702-Q1
ADJUSTMENT

7.2.2 Process parameter list


-1 (1)
LOPX Process Parameter List

PROM-version (front circuit board): 31830-5853-1.0


PROM-version (rear circuit board): 31830-5854-1.0
Factory Plant
Parameter Designation/Unit Range set va- set
lue value
P1 Time between sludge Minutes 0-999 30 .....
discharge

P2 ) Clarifier mode C C .....


'
P3 Not in use _. -
P4 Not in use ---
P52) High temperature alarm °C/oF O.115°C/O.255°F 0 .....
P6 Low temperature alarm °C/oF 0-115°C/0-255°F . -. .....
P7 Temperature set-point °C/oF 0-110°C/0-240°F --- .....
PS3) P - Constant % 10-500 --- .....

P9 3) 1- Constant Minutes 0.1-10.0 --- .....


P104) Standby/On mode O=standby 0-1 1 .....
1=on

P11 Not in use 0

P12 Conditioning water Pulses 0-999 5, see .....


table be-
low

P13 Displacement water Pulses 0-999 10 .....


P14 Minimum number of Pulses 0-999 2 .....
separate pulses

P15 Not in use ---


to
P18

P19 Factory test constant 0-1 0 .....

1)
Cannot be changed for LOPX.
2)
If P5 = 0; No Pt1 00 temperature sensor connected. Then P6 = P7 = - - -.
3)
If 37 = 1 or 2 then P8 is automatically preset to 40and P9 is automatically preset to 1.2.
4)
P10=0, must only be used during testoperation

LOPX705 LOPX707· LOPX713


710
P 12 5 5 5
P70 6 10 15
P 53 and P 78 30 50 75
= P12xP70

List No 3183()'5855-6
MO No 19()'PL·E·01-(lO()'OI

118
19()'MA·E·02·702·01
ADJUSTMENT

7.2.3 Installation parameter list

- 2(4)
LOPX Installation Parameter List

PROM-version (front circuit board): 31830-5853-1.0


PROM-version (rear circuit board): 31830-5854-1.0
Factory Plant
Parameter Designation/Unit Range set va- set
lue value

P20 Separator type 5.1=LOPX 4.1-5.2 4.1 5.1

P21 Power supply fre- Hz 50/60 50


quency
,
P22 Not in use ---
P23 EPC-400 address 1 = EPC-400 1-8 1 1

P24 Not in use ---


to
P32

P33 Type of vibration switch O=Emergency stop only 0-1 0 .....


1=Mechanic

P33 Not in use 0

P34 Alarm delay time Seconds 1-30 15 .....

P35 Delay of temperature Seconds 1-999 15 .....


alarm after changing of
MV1

P36 Remote control o = No remote control 0, 1, 2, 3, 10, 11, 0 .....


1 = Remote switches 12, 13
2 = Remote computer
3 = Remote control unit
10= No remote control and alarm A4
cancelled
11 = Remote switch and alarm A4 can-
celled
12= = Remote computer and alarm A4
cancelled
13= Remote control unit and alarm A4
cancelled

P37 Heater type O=Non or common heater with separate 0-2 0 .....
controller
1=HEATPAC EHS-62 controlled by
EPC-400
2=Heater with control valve, controlled
by EPC-400

List No 31830-5855-6
MO No 190-PI-E-01-OO0-01

119
190-MA-E-02-702-01
ADJUSTMENT

. - 2(4)
LOPX Installation Parameter List

PROM-version (front circuit board): 31830-5853-1.0


PROM-version (rear circuit board): 31830-5854-1.0
Factory Plant
Designation/Unit Range set va- set
Parameter
lue value

P381) Size of HEATPAC pre- kW 0,7,8,14,16,22, --- .....


heater 24,36, 40, 50, 56,
65, 72

P392) Run time of steam Seconds 0-999 --- .....


valve

P40 3) Temperature reading C=oC C,F C .....


F=oF

P41 Maximum start time for Minutes 0-999 15 .....


heater

P42 Not in use --- .....

P43 Extra alarm function O=Alarm indication on display. No action 0-1 0 .....
1=Alarm indication on display. Oil feed
off during separation sequence

P44 Number of times the 0-999 4 .....


displacement water is
increased by two
pulses before alarm

P45 Not in use ---


to
P49

STARTING
SEQUENCE:
P50 Bowl closing water Seconds 0-999 15 .....

P51 Not in use ---


P52 Reference time, oil feed Seconds 0-999 120 .....
on

P53 Bowl conditioning wa- Seconds 0-999 30 .....


ter, automatically set

P54 Not in use ---


to
P59

1)
If P37=1 then P38 is automatically preset to 16
2) If P37=2 then P39 is automatically preset to 120
3)
P5, P6 and P7 have to be set according to °C or OF

List No 31830-5855-6
MO No 190-PL-E-01-000-01

120 190-MA-E-02-702-01
ADJUSTMENT

- 3(4)
LOPX Installation Parameter List

PROM-version (front circuit board): 31830-5853-1.0


PROM-version (rear circuit board): 31830-5854-1.0
Factory Plant
Parameter Designation/Unit Range set va- set
lue value

SEPARATION
SEQUENCE:
P60 5) Time to first discharge Minutes 0-999 10 .....
after startup (for cali-
bration)

P61 5) Max time between Minutes 0-999 20 .....


sludge discharges
=P1=P60+P61

P62 Pre dischage interval Seconds 0-999 60 .....


P63
to
Not in use ---
P69
P706) Bowl displacement wa- Seconds 0-999 6, se ta- .....
ter. ble be-
low

P71 Pause between pulses Pulses 30

P72 Sludge discharge Seconds 0-99.9 3.0 .....


P73 Not in use ---
to
P75

P76 Reference time Seconds 0-999 60 .....


P77 Not in use ---
P78 Bowl conditioning water Seconds 0-999 30,see .....
(automatically set) table be-
=P12xP70 low

P79 Not in use - --


5)
Bowl closing water intermittently supplied
6)
Interrupted when trigger signal obtained

LOPX705 LOPX707- LOPX713


710
P 12 5 5 5
P70 6 10 15
P 53 and P 78 30 50 75
= P12xP70

List No 31830-585fHl
MO No 19D-PL-E-Ol-0()(}'Ol

121
190-MA-E-02-702-01
ADJUSTMENT

- 4(4)
LOPX Installation Parameter List

PROM-version (front circuit board): 31830-5853-1.0


PROM-version (rear circuit board): 31830-5854-1.0
Factory Plant
Parameter Designation/Unit Range set va- set
lue value

STOPPING
SEQUENCE:
P80
to
Not in use ---
P83

P84 Bowl displacement wa- Seconds 0-999 70 .....


ter
Oil teed off

P85 Not in use ---


P8S Separator motor off Seconds 0-999 180 .....
Bowl closing water off

P87
to
Not in use ---
P89

P907) Service mode o= No service mode (FO) values 0-1 0 .....


1 = Timer P50 - P89 count-down

P91
to
Not in use ---
P99

7)
From range 2 and on to be used when inquired by Alta Laval or by Alfa Laval representatives.

List No 31830-5855-6
MO No 1go.PL-E-01-000-01

122
190-MA-E-02-702-01
ADJUSTMENT

7.2.4 Explanation and recommendation of parameter


settings
P1 Time between discharge

Factory set value: 30 minutes.

Too long intervals between sludge discharge may cause accumu-


lation and compaction of sludge. The sludge may then break-up une-
venly on discharge and this cause hazardous unbalance of the bowl,
with risk of serious separator damage and injury to personnel.

When the bowl is opened, for any reason, the sludge space should be
inspected. The interval between discharges shall, if neccessary, be
changed accordingly.

NOTE!

The responibility for correct time setting lies with the per-
son who makes the time settings, according to his ober-
servations and judgements.

Lubricating oil cleaning

In a new lubricating oil system the oil is initially clean but as it gets
dirtier, the interval between discharges will have to be shortened until
a "steady state" is reached.

The interval between discharges must be shortened if the separator


has been out of service for 24 hours or longer while the engine has
been running. See table below.

Main lubricating oil system

Time to first
Initial dis-
bowl
charge
inspection
Recommended intervals
1 hour 1 week
for Crosshead engines
Recommended intervals
0.5 hour 2 days
for Trunk engines

123
190-MA-E-02-702-01
ADJUSTMENT

P2 Purifier/Clarifier mode

Factory set value: C. .


The LOPX separator is to be regarded as an clarifier which can handle
water.

P3 - P4 - --

P5 High temperature alarm

Factory set value: O.

• To be set according to plant application sufficiently above the


temperature (P7) set point.
Note: If no Pt1 00 temperature sensor connected, P5 = O. Then P6 =
P7 =---.

P6 Low temperature alarm

Factory set value: - - -


To be set according to plant application sufficiently below the temper-
ature (P7) setpoint.

P7 Temperature setpoint

Factory set value: - - -


To be set according to plant application.

P8 P-Constant

Factory set value:


Plant-dependent P-function.
If P37 = 1 or 2 then P8 is automatically preset to 40.

P9 I-Constant

Factory set value:


Plant-dependent I function.
If P37 = 1 or 2, then pg is automatically preset to 1.2.

P10 Standby / On mode

Factory set value: 1.


P10 = 0, must only be used during testoperation.

124
19D-MA-E-Q2-702-01
ADJUSTMENT
P11---

P12 Conditioning water


Factory set value: 5.
Number of water pulses.

P13 Displacement water


Factory set value: 10.
Number of water pulses.

P14 Minimum number of separate pulses


Factory set value: 2.
Number of water pulses.

P15-P1S ---

Pig Factory test constant.


Factory set value: 0

125
19().MA·E·02-702-01
ADJUSTMENT
7.2.5 Installation parameters, P20 • P99

P20 Separator type

Factory set value: 4.1; LOPX =5.1.

P21 Power supply frequency

Factory set value: 50 Hz


To be set according to power supply.
50 = 50 Hz
60 = 60 Hz

P22 - --

P23 EPC-400 address

Factory set value: 1

P24 - P32 - --

P33 Type of switch

Factory set value: O.


To be set according to type of vibration switch (optional).
o = Emergency stop
1 = Mechanical vibration switch

P34 Alarm delay time

Factory set value: 15 seconds


Activation of alarm functions can be delayed up to 30 seconds.
Except Emergency/vibration alarm
High temperature alarm
Transducer alarm

Which has a fixed delay time of 2 seconds.

P3S Delay of temperature alarm after changing of MV1

Factory set value: 15 seconds.


When the 3-way oil feed valve changes position the flow rate and thus
the oil temperature may be influenced. By delaying the temperature
alarm a false alarm is avoided as the temperature stabilizes.

• To be set according to plant application. If delay time above 120


seconds is necessary, check the heating system and the installa-
. tion layout.

126
190-MA-E-02-702-01
ADJUSTMENT

P36 Remote control

Factory set value: O.


Remote control can be applied in form of external switches, an ex-
ternal computer or an external EPC-400 control unit.

o= No remote control
1 = Remote switches
2 = Remote computer
3 = Remote control unit
10 = No remote control and alarm A 4-1 cancelled
11 = Remote switches and alarm A 4-1 cancelled
12 = Remote computer and alarm A 4-1 cancelled
13 = Remote control unit and alarm A 4-1 cancelled

P37 Heater type

Factory set value: O.


The EPC-400 control unit is designed for control of HEATPAC
EHS-62, HEATPAC SHS-64 or any steam/hot oil heater.

If a steam/hot oil heating system is connected to the EPC-400, and if


the system is equiped with an optional shut-off valve, and provided
P37 =0 or 2 does the valve opens when the heater is started. The valve
is shut when the heater is stopped, at high temperature alarm or
power failure and at EPC stand-by mode.

NOTE! If a different electrical type of heater is installed only start/stop


signal is available from the EPC-400 control unit.

o= No or common heater with separate controller


1 = HEATPAC EHS-62 controlled by EPC-400
2 = Heater with control valve EPC-400

P38 Size of HEATPAC EHS-62 preheater

Factory set value: - --


Range: 0, 7,8,14, 16,22,24, 36,40,50, 56, 65, or 72kVV.

Applies only if HEATPAC EHS-62 preheater installed.

Note: If P38 = - - -, then P37 is not set for HEATPAC EHS-62 pre-
heater.

P39 Run time for steam valve

Factory set value: - --


The time, in seconds, it takes to change the steam control valve from
closed to open position or vice versa.
Note! If P39 = - - -, then P37 is not set for heater with ,control valve.

127
190-MA-E-02-702-01
ADJUSTMENT
P40 Temperature reading

Factory set value: C. . .


Degrees Celsius (0C) or Fahrenheit (OF) temperature readings avail-
able.

P41 Maximum start time for heater

Factory set value: 15 minutes.


Minimum temperature limit (P6) must be reached within this time.

P42 - --

P43 Extra alarm function

Factory set value: 0


o= No actions at alarm.
1 = Oil feed off during separation sequence, at alarm.

P44 Displacement water pulses

Factory set value: 4


Number of times the displacement water is increased by two pulses
before alarm (A7-11).

P45 - P49 - --

STARTING SEQUENCE:

P50 Bowl closing water

Factory set value: 15 seconds


To be set for proper closing of the separator bowl during start-up se-
quence. If more than 60 sec. needed, it may indicate abnormal func-
tion.

P51 - --

P52 Reference time, oil feed on

Factory set value: 120 seconds.


Time for transducer to collect a reference value, during starting se-
quence. The reference value is stored when the time has elapsed. Oil
feed on.

P53 Bowl conditioning water

Factory set value: 30 seconds.


Automatically set according to: P53 and P78 = P12 x P70

128
190-MA-E-02-702-01
ADJUSTMENT

Addition of water to separator bowl during starting sequence. The


water is used for conditioning of sludge collected in the space of the
bowl.

P54 - P59 - --

SEPARATION SEQUENCE:

P60 Time to first discharge after startup

Factory set value: 10 minutes.

P61 Maximum time between sludge discharges

Factory set value: 20 minutes.


P1 = P60 + P61

P62 Pre discharge interval

Factory set value: 60 seconds.

P63 - P69 - --

SLUDGE DISCHARGE SEQUENCE:

P70 Pulse length

Factory set value: 6


Pulse length during filling of displacement and conditioning water.
Interrupted when trigger signal obtained.
LOPX705 6 seconds
LOPX 707 - -10 10 seconds
LOPX713 15 seconds

P71 Pause between pulses

Factory set value: 30

P72 Sludge discharge

Factory set value: 3.0 seconds.


Sludge discharge initiated by MV15 admitting water to the bowl oper-
ating system.

129
190-MA-E-02-702-01
ADJUSTMENT
P73 - P75 - --

P76 Reference time

Factory set value: 60 seconds


See also P52.

P77 ---

P78 Conditioning water

Automatically set according to: P53 and P78 = P12 x P70

P79 - --

STOPPING SEQUENCE:

P80 - P83 - --

P84 Bowl displacement water. Oil feed off

Factory set value: 70 seconds.

P85 - --

P86 Separator motor off.

Factory set value: 180 seconds.


The separator motor is automatically switched off. Restarting is
blocked for 3 minutes.

P87 - P89 - --

P90 Service mode

Factory set value: 0


o= No service mode (FO) values
1 = Timer P50 - P 89 count down of clock funtion
From range 2 and on, only to be used when inquired by Alfa Laval or
by Alfa Laval representatives.

P91 - P99 - --

130
190-MA-E-02-702-01
ADJUSTMENT

7.3 EPC-400 ALARM FUNCTIONS


The alarm system is designed to ensure that the separation system
always arrives at a safe status in an alarm situation.

• Sensor-related alarm functions

Sensor-related alarm functions are indicated by LEOs and by the


common main alarm LED. When an alarm function is activated the
appropriate LED and the common main alarm LED starts flashing.

To avoid false alarms some alarm functions have been pro-


grammed with a "self-cure" strategy. In the case an alarm signal
is received the control unit automatically repeats the operation of
the faulty function. Only if unsuccessful will the alarm function be
activated.

• Other alarm functions

Other alarm functions are indicated on the display.


When any of the displayed alarm functions are activated the left
hand digits start flashing and the right hand digits are steadily lit.

131
190-MA-E-02-703-01
ADJUSTMENT

7.3.1 Alarm identification


An activated alarm condition is identified either by a red light emitting
diode (LED) or alarm codes on the display.
If there is more than one alarm at the same time, the EPC-400 control
unit will show the most important first, when acknowledged the control
unit will show the next alarm, and so on.

• At alarm the activated alarm LE D or the alarm code will be flashing


together with the main alarm LED.

Alarm indication Alarm Indication Alarm function


Alarm function by display
byLEDs

e High oil pressure

e@
8-0018()'1-1

Low oil pressure [rae Communication error


s-00181-1-1 8-00015-1-1

8-00026-1-1
Water transducer fault W- 8-000 16-1-1
Processor fault

fH[ Programming mode too long


8-00017-1-1

@) Vibration (Vibration switch op-


tional)
8-00011-1-1

@ Emergency stop ~ 8-OOOUH-l


Power failure
s.oo391-1-1

@)
~
Excessive deviation between
High/low oil temperature 1)

rc
8-00012-1-1
sensor signals TT1 and TT2
(Temperature sensor optional). (Temperature sensor optional)
8-00019-1-1

8-00014-1-1

lie E~EI) Broken or short circuited tem-


perature sensors1) (Temper- IIR7 - ALCAP alarms
8-00013-1-1
ature alarm sensor optional) 8-00021-1-1

IRM] I] Extra alarm

).~. Sludge discharge failure


s-00154-1-1

8-00001-1-1
IR91J 21 PS 42 faulty at start

8-00155-1-1

~
Further alarm functions are pro-
Heater fault vided as sub~alarms to A 1-, A2-
S-OOOO2-1-1
and A7-, visually indicated in the
display window.

1) To find appropriate value 1C or 2C, press the alarm reset pushbutton stepwise (1C=TI1, 2C= TI2)

132
190-MA-E-()2-703-01
ADJUSTMENT

7.3.2 Alarm reset

• Acknowledge the alarm signal by pressing the alarm pushbutton.


The flashing light then changes to steady.

• Remedy the fault.

• Reset the alarm function by pressing the alarm pushbutton a


second time.
The LED will turn off.

NOTE!

It is possible to reset the system without repairing the


fault.
If the alarm was not false the alarm signal will then be re-
peated.

WARNING:

Never return to the EPC control unit to acknowl-


edge or reset an alarm if it by any means can be
hazardous.

7.4 ALARM TEST


A test can be performed by activating an alarm function. However
certain alarm functions can not be tested by simple means but have
to be disconnected prior to testing.

• By testing one of the alarm loops the corresponding logical func-


tions are tested simultaneously.

• If alarm functions are to be disconnected in the control unit, make


sure POWER is switched OFF.

133
190-MA-E-02-703-01
ADJUSTMENT

Guide for how to test alarm functions (a and b alternative actions).

Alarm symbol Alarm function Sensor Actions' alternatives

e High oil pressure PS41 Increase back pressure

e
S-oOl80-1-1

a_ Stop oil feed pump


Low oil pressure PS42 b_ Change V1 position by reducing
air pressure

e
S-00181-1-1

1. Disconnect hose for opening wa-


ter
Sludge discharge failure PS42
2_ Initiate a sludge discharge

e
S-00181-1-1

Disconnect cable to XE:4 (test signal to


Transducer fault MT4
MT-4)
S-00026-1-1

IRI71 I III
S-oOl86-1-1
Transducer value >max (400) MT4
Put your finger on the central screw in
MT 4 connection box.

IRI71 I 1c?1
S-()()186-1-1
Transducer value <min (100) MT4 Disconnect cable to XE:3

IRI71 I lsi
S-00187-1-1
Triggering 5 times MT4
Add displacement water, manually, un-
til triggering_ Repeat 5 times in a row_

Insufficient amount of displacement Close displacement water supply, at


IRI71 I1I1I
S-oOl8f>-1-1
water
MT4
the 1O:th discharge after start

@ Vibration XS 1
Knock on the vibration switch, 3 times
within one sec.
S-oOOll-1-1

@ S-00391-1-1
Emergency stop XS2 Press Emergency stop push-button

IS] S-oOOO2-1-1
Preheater fault -
1_

2_
Start the heater

Disconnect cable to X9:3

a. Remove sensor from pipe and put

@) High or low oil temperature TT 1 b.


into hot/cool liquid

Change alarm limit parameters


S'()()()12-1-1 (P5 max temp/P6 min temp) in re-
lation to actual temperature_

134
190-MA-E-02-703-o1
ADJUSTMENT

Guide, how to test alarm functions (a and b alternative actions).

Alarm symbol Alarm function Sensor Actions· alternatives

fR6 s-c0019-H
Excessive deviation between tem-
perature sensor signals TT1 and
TT2
TT1-TT2
Remove one sensor from pipe to cool
off or be heated up (temp diff
>30°C/86°F)

llBL S-00015-1-1
Communication error Remove fuse F2

l1R2~ Processor fault Remove fuse F2


-Alarm A2-6
S-00016-1-1

[ff[ Programming mode too long - Leave the mode selector switch in po-
sition P20 for 30 minutes
S-00017-H

IRllIl I I'IS.ool92-H
Power failure - Switch power off-on when EPC is in
operation

~Sl] 'I Extra alarm -


a_

b_
Activate appropriate sensor

Disconnect cable X7:1


S.ool54-H

IRsl] ~ PS 42 Faulty at start PS42


With the EPC in OFF-mode put a jum-
per between X7:4-XC and push the
start button_
S-OOlSS-H

135
190-MA-E-02-703-01
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