1.4.7 Standard Instruction Manual (O M) PDF

1.4.
7 Standard Instruction Manual (O&M)

Orange County Sanitation District (OCSD) -
DEWATERING AND THICKENING OPERATIONS
Project: T-113D / P1-101
Rev: 0 Date: 24.04.2013
GEA Mechanical Equipment / GEA Westfalia Separator
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Instruction manual
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Designation Clarifying decanter (thickener)
Type CA 1036-50-33
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No. 8399-9001-804
Edition 17.08.2011
GEA Mechanical Equipment / GEA Westfalia Separator Group

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ORIGINAL INSTRUCTION MANUAL

Subject to modification!
The authors are always grateful for comments and suggestions for improving
the documentation. They can be addressed to:
GEA Mechanical Equipment

GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1, 59302 Oelde (Germany)
Phone +49 2522 77-0, Fax +49 2522 77-2488
ws.info@geagroup.com, www.westfalia-separator.com
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59302 Oelde, Germany
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Model Serial-No.
Built in
Max. admissible rated bowl speed in min-1
Max. permissible density in kg/dm3 of product
Heavy liquid kg/dm3 IN Solids kg/dm3
min/max temp. of product in °C
min/max housing pressure in bar

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This page must be filled in by the operator.
Please transfer the data from the decanter nameplate.
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For your safety
• Warning in case of danger to machine parts. Strictly adhere to

instructions marked with this symbol.
This avoids damage or destruction of the decanter and other equip-
ment.
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• Take special care when carrying out operations marked with this
symbol –
otherwise danger to life.
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• Observe accident prevention regulations.
The local safety and accident prevention regulations apply uncondi-
tionally to the operation of the decanter.
• Refer to the instruction manual.

Follow only the instructions given in this manual.
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• Operate the decanter only in accordance with agreed process and
operating parameters.
• Maintain the decanter as specified in this instruction manual.

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• Carry out safety checks on the decanter,
as described in the chapter "Safety precautions" in this manual.
• Liability for the function of the machine passes to the owner.

Liability for the function of the machine passes unconditionally to the
owner or operator irrespective of existing warranty periods in so far as
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the machine is improperly maintained or serviced by persons other

than Westfalia Separator personnel or if the machine is not applied in
accordance with the intended use.
Westfalia Separator AG shall not be liable for damage which occurs as
a result of non-compliance with the above. Warranty and liability con-
ditions in the Conditions of Sale and Delivery of Westfalia Separator
AG are not extended by the above.
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1 Safety precautions 9
1.1 Correct usage ........................................................................................ 10

1.2 Incorrect usage ...................................................................................... 10
1.3 Safety markings on the decanter ........................................................... 11
1.4 Demands relating to service personnel and spare parts ....................... 12
1.5 Operations on the decanter ................................................................... 12
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1.5.1 Before start-up ....................................................................................... 13
1.5.2 Operation ............................................................................................... 14
1.5.3 Voltage cut-off during operation ............................................................ 16
1.5.4 Shut-down and “Emergency Stop” ........................................................ 16
1.5.5 Maintenance and servicing .................................................................... 17
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1.6 Corrosion ............................................................................................... 20
1.7 Erosion ................................................................................................... 20
2 Machine description 21
2.1 Schematic .............................................................................................. 22

2.2 Main components of the decanter ......................................................... 23
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2.2.1 Bowl and Varipond E ®.......................................................................... 23
2.2.2 Housing .................................................................................................. 23
2.2.3 Drive unit ................................................................................................ 24
2.2.4 Motor control .......................................................................................... 25
2.3 Operating principles of the decanter ...................................................... 26
2.4 Throughput capacity .............................................................................. 26
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2.5 Lubrication ............................................................................................. 28
2.5.1 Lubricating oil unit .................................................................................. 28
2.5.2 Bowl bearing and gearbox lubrication (schematic) ................................ 30
2.6 Dimensioned drawing ............................................................................ 32
3 Operation 37
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3.1 What must be kept in mind when using third-party controls? ................ 38
3.2 Start-up preparations ............................................................................. 38
3.2.1 Drive motors and motor control units ..................................................... 38
3.2.2 Checklist ................................................................................................ 39
3.3 Program for start-up, operation and shut-down ..................................... 40
3.3.1 Pre-lubrication ........................................................................................ 40
3.3.2 Run-up ................................................................................................... 40
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3.3.3 Production .............................................................................................. 40

3.3.4 Interruption ............................................................................................. 40
3.3.5 Shut-down .............................................................................................. 40
3.3.6 Relubrication .......................................................................................... 40
3.4 Operation ............................................................................................... 41
3.4.1 Vibration monitoring ............................................................................... 41
3.5 Emergency Stop .................................................................................... 42
3.6 Shut-down and cleaning ........................................................................ 42
3.7 Long-term shut-down ............................................................................. 42
3.8 Troubleshooting ..................................................................................... 43
3.8.1 Start-up difficulties ................................................................................. 43
3.8.2 Bearing temperature or oil return temperature too high ........................ 43
3.8.3 Oil level in oil tank too low ..................................................................... 44
3.8.4 Condensation water in the lube oil ........................................................ 44
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3.8.5 Oil pump doesn't start ............................................................................ 44

3.8.6 No oil return flow .................................................................................... 44
3.8.7 Oil leakage at bowl bearing ................................................................... 44
3.8.8 Vibrations too high ................................................................................. 44
4 Maintenance 45
4.1 Avoiding accidents during maintenance work ....................................... 46

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4.3 Service and maintenance contract with Westfalia Separator ................ 47
4.4 Storing wearing parts and operating media ........................................... 48
4.4.1 Gaskets and V-belts .............................................................................. 48
4.4.2 Roller bearings ....................................................................................... 49
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4.4.3 Lubricants .............................................................................................. 49
4.5 Maintenance schedule (machine in operation or in readiness) ............. 51
4.5.1 Maintenance schedule (machine shut-down medium term) .................. 55
4.6 Lubricants .............................................................................................. 57
4.6.1 Synthetic oil based special grease ........................................................ 57
4.6.2 Industrial gear oil CLP HC 68 ................................................................ 57
4.7 Screw tightening torques ....................................................................... 58
4.7.1 Screw tightening torques in inch-pound (inlb) ....................................... 59
4.8 Checking screw tightening torques ........................................................ 60
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4.9 Checking the decanter for leakage. ....................................................... 62
4.10 Checking the vibration isolators ............................................................. 63
4.10.1 Vibration isolators for the drive unit ....................................................... 63
4.10.2 Vibration isolators on the decanter housing .......................................... 63
4.11 Checking the gearbox for leakage ......................................................... 64
4.12 Drive belts .............................................................................................. 67
4.12.1 Checking the belt tension (bowl drive) ................................................... 67
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4.12.2 Checking the belt tension (scroll drive) .................................................. 71
4.12.3 Replacing the drive belts (bowl and scroll drive) ................................... 73
4.12.4 Adjusting the proximity sensors ............................................................. 76
4.13 Oil lubrication system ............................................................................. 77
4.13.1 Checking the oil level / topping up oil .................................................... 77
4.13.2 Replacing the oil filter ............................................................................ 78
4.13.3 Replacing the filter element of the cooling water feed ........................... 78
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4.13.4 Filling in new oil ..................................................................................... 78

4.13.5 Cleaning the oil tank. ............................................................................. 79
4.13.6 Touching up damaged paintwork .......................................................... 79
4.13.7 Checking for tightness ........................................................................... 79
4.13.8 Checking/draining condensation water .................................................. 79
4.14 Relubricating / cleaning the motor ......................................................... 80
4.15 Scroll ...................................................................................................... 81
4.15.1 Relubricating the scroll bearings ........................................................... 81
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4.16 Relubricating the bearings on the rotating feed tube ............................. 81
5 Long-term storage 83
5.1 Important instructions on long-term storage .......................................... 84

5.2 Decommissioning the decanter ............................................................. 84
5.3 Preparing the decanter for long-term storage........................................ 85
5.3.1 Requirements for the storage room ....................................................... 85
5.3.2 lacquered parts ...................................................................................... 85
5.3.3 Unpainted areas and galvanized parts .................................................. 85
5.3.4 Gearbox / replacement gearboxes ........................................................ 86
5.3.5 Drive motors........................................................................................... 86
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5.4 Maintenance schedule (machine shut-down long-term)........................ 89

5.5.2 Roller bearings ....................................................................................... 92
5.5.3 Lubricants .............................................................................................. 92
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Notes
Notizen
Anotaciones
Notizen
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Notes
Note
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1 Safety precautions
1.1
1.2
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Correct usage ........................................................................................ 10
Incorrect usage ...................................................................................... 10
1.3 Safety markings on the decanter ........................................................... 11
1.5 Operations on the decanter ................................................................... 12
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1.5.1 Before start-up ....................................................................................... 13
1.5.2 Operation ............................................................................................... 14
1.5.3 Voltage cut-off during operation ............................................................ 16
1.5.4 Shut-down and “Emergency Stop” ........................................................ 16
1.5.5 Maintenance and servicing .................................................................... 17
1.6 Corrosion ............................................................................................... 20
1.7 Erosion ................................................................................................... 20
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1.1 Correct usage

Decanters are used for the separation of liquid mixtures or for the separation of
solids out of liquids or liquid mixtures.
The following parameters were taken into consideration when designing the de-
canter:
• The chemical and physical properties of the product to be processed (density
etc.).
• The temperatures, pressures and throughput capacities encountered during
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processing.
• The admissible operating materials (cleaning agents, lubricants etc.)
The decanter may only be operated in accordance with the contractually agreed
provisions.
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1.2 Incorrect usage
In the view of Westfalia Separator, misuse of the decanter would involve one or
more of the following points:
• The product fed does not conform to the specifications on the nameplate.
– The density of the product is too high.
– The temperature of the product is too high.
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• The maximum admissible bowl speed is exceeded as a result of manipulating
the drive.
• The decanter is operated when not completely and properly assembled.
– The required supervisory equipment is not activated.
– The required protective covers are not installed.
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• The decanter is operated by persons who have not been adequately trained.
• The decanter is operated with spare parts that do not originate from Westfalia
Separator.
Each point listed represent incorrect usage and can result in severe dam-
age to property and personal injury.
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Prior to any intended deviation from the agreed operating mode, it is therefore
imperative to obtain the consent of Westfalia Separator.
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1.3 Safety markings on the decanter

The following safety markings must be attached to the machine as self-adhesive
stickers. The stickers must always be in perfect condition.
• Clean dirty stickers.
• Replace damaged stickers. The part number is situated at the bottom right on
each sticker.
This multi-sticker is attached to every

decanter. It is available in several lan-
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a c d
guage combinations.
Meaning of the stickers:

• Pay attention to the instruction man-
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ual (a).
b • Disconnect the power to the decant-
er before carrying out maintenance
work (b).
• Never loosen parts before the de-
canter has come to a standstill (c).
• Shut down the decanter immediately
when severe vibrations occur (d).
Fig. 1
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tective equipment in accordance
with EN 294.
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Fig. 2
• Warning against hot surfaces.

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Fig. 3
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• Never manipulate the frequency

converter to exceed the permissible
bowl speed (see nameplate).
Is used only with frequency convert-
er operation.
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Fig. 4
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1.4 Demands relating to service personnel and spare parts
• Use only genuine spare parts from Westfalia

Separator.
The use of non-genuine parts leads to:
– Safety risks
– Lower durability and availability
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If a safety risk arises, this may have legal
consequences for the responsible persons. In
Fig. 5 this case, Westfalia Separator shall assume no
liability or warranty.
• Deploy only well trained personnel for maintenance work, e.g. the service
personnel from Westfalia Separator or personnel trained by Westfalia
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Separator.
An incorrectly maintained/assembled machine poses a safety risk for the op-
erators.
1.5 Operations on the decanter
The decanter works reliably, provided

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that it is operated and looked after in

accordance with our operating instruc-
tions.
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Fig. 6
Special attention must be given to:

• Start-up
• Operation
• Shut-down
• Maintenance and servicing
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1.5.1 Before start-up
• The bowl must rotate in counter-

clockwise direction when looked at
from the drive side (see arrow on
housing or protective hood).
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Fig. 7
• The decanter may only be operated

with protection devices conforming
to EN 294.
– Equip solid and liquid discharges
accordingly.
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Fig. 8
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• Check that the lubrication and cool-
ing systems are serviceable.
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Fig. 9
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• Check that the product paths are set

to operation.
• Regularly check hose pipes for signs
of ageing.
• Check sight glasses for mechanical
damage.
• Damaged parts must be replaced
immediately by new or reconditioned
parts.
Fig. 10
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1.5.2 Operation
• Refer to chapter »Operation«.
• Note nameplate. The following val-
ues are maximum values and must
not be exceeded.
– Bowl speed
– Density of the feed product
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Fig. 11
• Wear ear protection.

• Wear personal protective gear in
accordance with the local regula-
tions.
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Fig. 12
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In case of frequency converter op-
eration:
• The machine may only be operated
with an independent device for
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speed limitation.
Fig. 13
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• Do not feed product which is catego-

rised as explosive.
• Inert gas blanketing is not possible.
Fig. 14
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• When processing products harmful

to persons, observe the pertinent
safety regulations.
– Refer to the safety data sheet of
the product.
– Wear protective clothing.
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Fig. 15
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• Some plant components can get
very hot.
– pipes and hoses
– collectors
– lubricating oil system
– oil cooler
If the hot surfaces are readily acces-
sible, warning signs must be at-
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sonnel.
Fig. 16
• Shut down the decanter immediately

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when unusual noises, vibrations or
overheating occur.
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Fig. 17
• The bowl is not allowed to run with-

out liquid supply for more than 30
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minutes, as otherwise it would result

in overheating of the bowl material.
Fig. 18
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1.5.3 Voltage cut-off during operation
If the voltage is interrupted for more

than one second during operation,
“Emergency Stop” is activated:
The main motor and any auxiliary units
are switched off directly.
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Fig. 19
Do not start maintenance work on the decanter until the following conditions are
met:
• The main switch is kept in position “OFF” by means of a locking mechanism.
• The decanter is at standstill.
1.5.4 Shut-down and “Emergency Stop”

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• In an emergency situation, press

one of the red push buttons with the
yellow background.
By this means, the main motor and
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any auxiliary units are switched off
directly.
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Fig. 20
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1.5.5 Maintenance and servicing

Unfavourable operating conditions may require shorter maintenance intervals.
The factors listed below are unfavourable because they either attack the de-
canter material directly or impair the lubrication/cooling system.
• aggressive product (chemical or physical)
• high product temperature
• product with grease decaying properties
• environment: temperature, dust, vapours
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• chlorine ions in the product or environment
Particularly highly stressed parts of the
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decanter such as bearing hub, bowl
hub and other bowl parts with a large
outer diameter must be checked on a
regular basis to ensure safe and effi-
cient operation.
Fig. 21
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Timely maintenance and replacement of worn or damaged machine parts are
essential for safe operation of the decanter.
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Maintenance work may only be carried out by the customer to the extent de-
scribed in this instruction manual.
Always clean the machine thoroughly. Uneven solids deposits in the bowl or on
the scroll cause serious imbalance.
Maintenance or repair work not described in this manual may only be carried
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out by the manufacturer or by "central repair shops" authorized by the manufac-

turer.
We recommend having your decanter serviced by Westfalia Separator Service
at regular intervals. Such inspections will help keep your decanter working relia-
bly and prevent undesirable shut-downs.
Before maintenance and servicing:

• Switch off all electrical apparatus via
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the main switch.

• Secure the installation against unin-
tended restarting with locking devic-
es.
Fig. 22
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• Do not loosen any part before the

bowl has come to a standstill.
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Fig. 23
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• Do not climb onto or stand on the
machine or parts of the machine.
Fig. 24
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• Place dismantled machine parts on
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a suitable base, e.g. a rubber mat.
• Take steps to prevent machine parts
from overturning and rolling away.
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Fig. 25
• Do not heat bowl parts with a na-

ked flame.
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• Bowl parts must never be welded.

• Even during cleaning the bowl parts
the temperature must not exceed
100 °C.
Fig. 26
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• Collect dripping oil to prevent danger

of slipping and product infection.
• When handling waste oils note:
– They can be injurious to health
depending on their chemical com-
position.
– Waste oil must be disposed of in
accordance with local regulations.
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Fig. 27
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• Load carrying equipment such as
lifting devices for
– bowl or scroll
– gear etc.
may only be used for work routines
as described in this manual.
• Do not use damaged or incomplete
load carrying equipment.
Fig. 28
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1.6 Corrosion
Corrosion can also affect bowl parts made of stainless steel. This corrosion can
be flat-shaped, pittings or crack-shaped.
Since corrosion endangers the operating safety of the decanter, Westfalia Sepa-
rator urgently recommends shutting down the decanter when signs of corrosion
are detected.
The machine must be checked by Westfalia Separator Service before putting it
back into operation.
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1.7 Erosion
Erosion is caused by solid particles in the process liquid. These solid particles
grind marks into the surfaces with which they come into contact.
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The following factors favour the occurrence of erosion:
• hard solid particles
• high throughput capacities
The first signs of erosion should be carefully observed and documented. Ero-
sion can deepen rapidly, thereby weakening the bowl material.
Contact your nearest Westfalia Separator Service for a thorough examination.
Information on the nature of the damage can be provided by photos, plaster
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casts or lead molds.
The surfaces most susceptible to ero-

sion are:
1) Solids ejection ports
2) Bowl shell
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3) Scroll flights
4) Scroll distributor
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Fig. 29
Signs of erosion which you should

immediately report to your nearest
Westfalia Separator Service:
• The bottom of the erosion mark has
a radius smaller than 1 mm (large
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notch effect).
• The depth of erosion mark exceeds
1 mm at the deepest point.
Fig. 30
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2 Machine description
2.1
2.2
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Schematic .............................................................................................. 22
Main components of the decanter ......................................................... 23
2.2.1 Bowl and Varipond E ®.......................................................................... 23
2.2.2 Housing .................................................................................................. 23
2.2.3 Drive unit ................................................................................................ 24
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2.2.4 Motor control .......................................................................................... 25
2.3 Operating principles of the decanter ...................................................... 26
2.4 Throughput capacity .............................................................................. 26
2.5 Lubrication ............................................................................................. 28
2.5.1 Lubricating oil unit .................................................................................. 28
2.5.2 Bowl bearing and gearbox lubrication (schematic) ................................ 30
2.6 Dimensioned drawing ............................................................................ 32
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2.1 Schematic
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Fig. 31
A Dewatering zone
B Clarifying zone
1 Main drive motor

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2 V-belts (bowl drive)

3 Gearbox
4 Main bowl bearings
5 Scroll bearings
6 Scroll
7 Distributor area
8 Separation chamber
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9 Bowl
10 Throttle; Varipond-E ®
11 Feed
12 Gravity discharge of the clarified liquid
13 Housing
14 Solids discharge
15 V-belts (scroll drive)
16 Back drive motor
17 Drive frame
18 Hood
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2.2 Main components of the decanter
2.2.1 Bowl and Varipond E ®

The bowl is of cylindrical-conical design. Clarification and separation of the liq-
uid phases takes place in the cylindrical section of the bowl, dewatering of the
separated solids takes place in the conical section of the bowl.
Axially arranged ribs in the bowl shell enhance trouble-free conveyance of the
solids.
Existing or possible wear and corrosion protection:
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• All bowl and scroll parts coming in contact with the product are made of
CrNiMo steel.
• Exchangeable wearing bushes in the solids ejection ports of the bowl.
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• Hard-faced scroll flights for products with erosive properties.
The clarifying and dewatering efficiency can be changed and hence adapted to
the respective process.
With the aid of Varipond E®, the gap between regulating plate and throttle disk
can be adjusted during operation.
The throttle disk is moved steplessly by 3 electric motors. The liquid level in the
bowl and consequently splitting up of the discharging solids and liquid volume
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are influenced.
2.2.2 Housing
The housing consists of:
a steel frame with lower part of catcher,
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a protective hood (upper part of catcher) and
catchers for the product discharges.
Vibration dampers between housing and foundation largely prevent the transfer
of machine vibrations.
The housing parts are coated with a caustic-, acid- and impact-resistant paint.
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2.2.3 Drive unit
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Fig. 32
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The drive motors are mounted in a vibration-damping arrangement on a de-
tached drive frame.
a) Function of the 2-motor drive (variable differential speed)
The bowl F is driven by the primary motor A via belts C.
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The scroll G is driven by the differential motor B via belts E and a rotating gear-
box D.
The bowl and differential speeds are infinitely variable within a preset range via
the frequency converter.
Attention !
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• The machine may only be operated
with an independent device for
speed limitation.
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Fig. 33
The bowl speed is the command variable for the scroll speed. The differential
speed as consequential variable remains constant when the bowl speed chang-
es.
The efficiency of the differential motor is proportional to the torque produced at
the scroll. The measured value is processed for process technical regulations.
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b) Function of the 2-motor drive (constant differential speed)

The bowl F is driven by the primary motor A via belts C.
The scroll G is driven by the differential motor B via belts E and a rotating gear-
box D.
The differential motor B is operated with a fixed frequency and produces a con-
stant differential speed.
The efficiency of the differential motor is proportional to the torque produced at
the scroll.
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2.2.4 Motor control
A motor control unit capable of performing the following functions is necessary.
• Automatic start-up of the drive motors after the pre-lubrication time has
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elapsed. Direct start via frequency converter.
• Automatic opening and closing of the water supply to the heat exchanger for
the oil circulation lubrication system via solenoid valve.
• Automatic pre- and post running of the oil circulation system for lubricating
bearings and gear.
• Motor protection for gear pump units and, where appropriate, the air cooler.
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• Motor protection for the drive motors and phase failure monitoring.
• Bowl speed monitoring and indication during operation.
• Start-up time monitoring.
• Switching off the drive unit and shutting off the feed in case of
– gear overload
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– speed drop (approx. 100 min below rated speed)
– too high a bearing temperature
– malfunctions in the oil supply.
• Bearing temperature indication.
• Indication of the current consumption.
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• Indication of the operating hours.

• Indication of operating faults (e.g. overheating of the motors).
• Supply of flush liquid possible if the gear is overloaded and when the decanter
is shut down.
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2.3 Operating principles of the decanter

The decanter is a horizontal scroll centrifuge with cylindrico-conical solid-wall
bowl for the continuous separation of solids from suspensions.
The process liquid enters the decanter through the centrally arranged feed tube
and flows into the inlet chamber of the scroll from where it flows through ports
into the separation space of the bowl where it is accelerated to operating speed.
The solid particles settle against the bowl wall in the shortest space of time due
to the action of centrifugal force.
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The scroll, rotating at a slightly higher speed than the bowl shell, continuously
conveys the separated solids to the narrow bowl end.
Due to the conical shape of the bowl, the solids are lifted out of the liquid in the
dewatering zone and freed of adhering liquid due to the action of the centrifugal
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force.
At the end of the bowl, the solids are discharged into the catch chamber of the
housing.
The liquid flows between the scroll flights to the cylindrical bowl end.
The specifically light impurities still present in the liquid are centrifugally re-
moved on their path through the clarifying zone and are conveyed by the scroll
to the solids discharge.
2.4
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The clarified liquid leaves the separation chamber via adjustable/exchangeable
regulating plates and is discharged under gravity.
Throughput capacity
The effective throughput capacity of the decanter depends on
• the separability or clarifiability of the product,
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• the solids loading in the product,
• the required residual moisture content in the discharged solids,
• the maximum admissible solids content in the clarified liquids.
The decanter can be adapted to meet a wide range of conditions and require-
ments.
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IN Note
Notes
Notizen
Anotaciones
Notizen
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Notes
Note
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2.5 Lubrication
The following parts are continuously lubricated by two electrically operated oil
circulation lubrication systems:
• Main bowl bearings
• Gearbox
• The scroll bearing on the solids side
The liquid-side scroll bearing is packed with grease. Re-lubrication is possible
when the bowl is at a standstill.
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2.5.1 Lubricating oil unit
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IN
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Fig. 34
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Pos. Designation Qty. Remarks

10 Strainer insert
20 Vent, complete.
30 Magnetic switch Oil level monitoring
40 Strainer Oil filling connection
50 Indicator Oil return
Condensate water collects in the
oil return chamber.
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60 Oil level indicator with Oil feed
thermometer During operation, the oil level
must be between the min. and
max. marks.
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70 Clutch
80 Oil return block 2
90 Electronic probe 2 Flow detector in oil return
100 Gear pump unit
110 Seal 2.2 m
120 Water detector
130 Seal
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140 Pressure gauge 0-10 bar
150 Terminal box, complete
Oil pressure switch
160 Feedback sensor Triggers an alarm when the oil

filter is fouled.
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190 Gasket
200 Oil discharge
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2.5.2 Bowl bearing and gearbox lubrication (schematic)
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Fig. 35
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Pos. Designation Function
1 Gear pump conveys oil

approx. 1,000 l/h
2 Motor drives gear pump
3 Pressure relief valve limits the oil pressure to 10 bar
4 Oil filter with differential pressure cleans the oil and sends a signal to the control system when the filter
switch is fouled
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5 Heat exchanger cools the oil
Required water quantity approx. 1200 l/h
G2 or filtered G3 (particle size max.
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Required water quality:
100 μm)
at water feed temperature 33 °C
6 Distributor distributes oil
7 Drain screws drain
7.1 waste oil
7.2 condensate and waste oil
8.2 Oil return

IN
8 Oil level window with thermometer enables checking of: oil level, oil temperature, condensate
8.1 Oil feed during operation the oil level must be above the minimum mark
shows condensate water level:
Drain any visible condensate water immediately.
9 Charge hole filling in / topping up oil
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10 Level monitoring – monitors the level
– triggers an alarm when there is a lack of oil
11 Vent hole prevents vacuum formation in the system
13 Water detector triggers an alarm when the water content in the oil exceeds the limit
value
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14 Flow indicator triggers an alarm when there is no oil flow.

17 Pressure gauge monitors the oil pressure in the oil feed
solids side liquid side
A Pressure oil connection Main bowl bearings Main bowl bearings

Ca. 432 ± l/h
50
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B Pressure oil connection Main bowl bearings Main bowl bearings

Ca. 384 ± l/h
50
C Pressure oil connection Gearbox (an orifice plate ∅ 2.3 mm N.A.

approx. 200 ± l/h
25
is fitted in the connection piece).
D Oil return Main bowl bearings and gear box Main bowl bearings
E Oil return Main bowl bearings Main bowl bearings
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2.6 Dimensioned drawing

For information only, do not use as a planning document! Subject to modification.
Y
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IN
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Fig. 36 (8399-4100-070)
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IN
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Fig. 37
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IN
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Fig. 38
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Fig. 39
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A Frame height approx. 353 mm when the machine is resting on the isola-
tors
B Product feed,
connection 4 inch ASA 150 LBS
D Flush water connection possible
E Connection for PVC tube DIN 19534-DN250A
F Solids discharge, connecting flange is supplied,
vent required, min. Ø 300 mm
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G Electric trolley hoist
Minimum lifting capacity:
– 15,000 kg for assembling the rotor
– 12,000 kg for frame complete
– 9,000 kg for assembling the scroll
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– 1,200 kg for assembling the scroll
K Pump unit for oil circulation lubrication system
L Centre of gravity of the decanter without drive
M Direction of rotation, see instruction manual
N Carry out voltage equalization according to VDE 0100-410, Jan. 1997
O Terminal box
R Oil cooler
IN
Q Clarified liquid, gravity discharged
U Vibration isolators, Part-No. 0021-3241-000

V Rubber-metal cushions shore hardness 80, Part-No. 0021-3152-760
Z Safety system
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• Depending on the customer installation, assembly aids like working plat-
forms may be necessary.
• When carrying out the electrical installation, pay attention to the circuit dia-
gram of the respective motor control unit.
• Note the planning instructions when designing the feed and discharge con-
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nections.
• When the supporting structure is loaded by the decanter, the inherent fre-
quencies of this structure and adjacent parts must not be in the range of the
decanter's operating speed.
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3 Operation
3.1
3.2
IN
What must be kept in mind when using third-party controls? ................ 38
Start-up preparations ............................................................................. 38
3.2.1 Drive motors and motor control units ..................................................... 38
3.2.2 Checklist ................................................................................................ 39
3.3 Program for start-up, operation and shut-down ..................................... 40
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3.3.1 Pre-lubrication ........................................................................................ 40
3.3.2 Run-up ................................................................................................... 40
3.3.3 Production .............................................................................................. 40
3.3.4 Interruption ............................................................................................. 40
3.3.5 Shut-down .............................................................................................. 40
3.3.6 Relubrication .......................................................................................... 40
3.4 Operation ............................................................................................... 41
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3.4.1 Vibration monitoring ............................................................................... 41

3.5 Emergency Stop .................................................................................... 42
3.6 Shut-down and cleaning ........................................................................ 42
3.7 Long-term shut-down ............................................................................. 42
3.8 Troubleshooting ..................................................................................... 43
3.8.1 Start-up difficulties ................................................................................. 43
3.8.2 Bearing temperature or oil return temperature too high ........................ 43
3.8.3 Oil level in oil tank too low ..................................................................... 44
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3.8.4 Condensation water in the lube oil ........................................................ 44

3.8.5 Oil pump doesn't start ............................................................................ 44
3.8.6 No oil return flow .................................................................................... 44
3.8.7 Oil leakage at bowl bearing ................................................................... 44
3.8.8 Vibrations too high ................................................................................. 44
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3.1 What must be kept in mind when using third-party controls?

The decanter is normally operated with controls from Westfalia Separator. The-
se control systems ensure safe operation and protect the decanter from damage
due to overload.
This instruction manual assumes in the sections “Machine description” and “Op-
eration” that the decanter control has been delivered by Westfalia Separator.
If the decanter control has not been delivered by Westfalia Separator, a number
of requirements must be met by the control system to guarantee to guarantee at
least an adequate standard of safety.
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The following list is not complete since the complete working process including
all relevant parameters and limits must be taken into account to ensure safe and
optimum operation of the decanter.
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• The maximum bowl speed must not be exceeded under any circum-
stances (see nameplate).
In the case of non-compliance, there is a risk of damage to persons and
property.
• Applies only for decanters with adjustable scroll drive.

The variable speed motor may only transfer the maximum admissible torque
for the scroll drive. This can in individual cases mean that the torque is signifi-
cantly below the possible torque of the variable-speed motor.
IN
– The control system must limit the torque of the variable-speed motor (sec-
ondary drive) as otherwise the scroll drive will get damaged.
– The admissible speed ranges must be observed.
– The admissible torque is project-specific and can be inquired from the re-
sponsible business unit.
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3.2 Start-up preparations
Please pay attention to:
• "Safety precautions" (chapter 1)
• Decanter monitoring unit manual
• Manuals for other auxiliary equipment
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3.2.1 Drive motors and motor control units

• Check the direction of rotation of the drive motors. The direction of rotation
may only be checked when the drive belts are not mounted.
– The fan of the primary motor must run counter-clockwise.
– The fan of the back drive motor must run clockwise.
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• To avoid damage to the gearbox, the variable-speed motor must not be

-1
switched on until the bowl has reached a speed of 150 min .
When shutting down the decanter, the variable-speed motor must be
-1.
switched off when the bowl speed drops below 150 min
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3.2.2 Checklist
Decanter Has the decanter been installed completely and fail-safe ?
In particular, the covers for the following components must be
mounted:
• Bowl
• Drive belts
• Belt pulleys
Is the supervisory equipment complete and functional ?
Are the oil tanks for the oil circulation lubrication filled ?
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Is the torque factor (decanter factor) on the decanter
monitoring unit set correctly ?
The setting is specified in the datasheet furnished with the
decanter according to EN 12547.
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An incorrect setting will result in damage to the gearbox.
Cooling and flush water Are the cooling water lines to the oil circulation lubrication
systems connnected and open ?
Is the cooling water line to the slide-ring packing at the feed
tube connected and open ?
Is the water pressure in the cooling system limited to max. 10
bar (145 psi) ?IN
Are the flush water lines connected and ready for operation ?
• Bowl
• Housing
• Discharge chutes
Product paths Is the product feed ready ?
• Idling of the decanter is admissible for only max. 30 minutes
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as otherwise the decanter would overheat.
• Note nameplate. Do not feed product that does not conform
to the specifications on the nameplate.
Are feed lines for additives etc. ready (e.g. dispersing agentsl)
?
Is the discharge of the solids ensured ?
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Is the discharge of the liquid phase ensured ?

Are the vents ready for operation ?
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3.3 Program for start-up, operation and shut-down

The decanter is operated via a program adapted to the specific product. The re-
spective product may necessitate deviations from the procedure described.
The optimum program will be prepared for each product in cooperation with the
customer.
3.3.1 Pre-lubrication Press "decanter start" button. At first, only the oil lubrication system
starts.
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Check during the pre-lubrication time Approx. 10 minutes
• Is the oil cooler supplied with cool-
ing water?
• Is the slide-ring packing at the feed
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tube supplied with cooling water ?
3.3.2 Run-up The main motor starts after the pre-
lubrication time has elapsed. The
decanter bowl is accelerated.
-1
Bowl speed = 150 min .
The back drive motor starts.
The bowl is accelerated to the pre-set
IN
bowl speed.
3.3.3 Production Increase the product feed step by
step until the nominal feed rate is
reached.
3.3.4 Interruption If the product feed is interrupted, the To resume production, “flushing” must
bowl speed is reduced to approx. be carried out again.
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–1
1200 min and the decanter switches
to no-load operation.
3.3.5 Shut-down Press "decanter stop" button.
The product feed is closed.
The bowl speed is run down to
–1
1200 min .
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The decanter is flushed with approx.

10 m³/h for about 15 minutes.
3.3.6 Relubrication The bowl speed drops towards 0. Approx. 30 minutes
-1
• Bowl speed = 150 min .
The back drive motor is stopped.
-1
• Bowl speed = 0 min . The cleaning program can now be
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started to clean out the bowl as thor-

oughly as possible.
This program will be compiled by
Westfalia Separator in cooperation with
the customer.
After the post-lubrication time has
elapsed, the liquid discharge valve is
closed.
All water connections are closed au-
tomatically.
The shut-down procedure is com-
plete.
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3.4 Operation
The machine is monitored to a large extent by the decanter control unit.
When faults occur (power loss, gear overload etc.), the product feed must be
automatically cut off and the flush water line opened.
Operations to be carried out regularly:
• Adhere to the "Maintenance schedule" !
• Repairing the scroll
If the operating efficiency of the decanter is impaired due to increased residu-
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al moisture in the discharged solids, the scroll must be checked for wear.
If the wear is extensive, the scroll must be reconditioned or replaced. In this
connection, consult Westfalia Separator Service.
• Wear check
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If the erosive effect of the product is unknown, we recommend checking for
wear every 500 operating hours. Concentrate especially on
– scroll,
– scrapers in the solids discharge,
– bushes in the solids discharge,
– catch chamber.
• Servicing IN
We recommend having your decanter serviced by Westfalia Separator Ser-
vice at regular intervals. These inspections help to
– maintain the operating reliability of the decanter and
– to avoid unwanted downtime.
Note: A deterioration in the processing efficiency of the decanter can also
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be caused by changes in the product.
3.4.1 Vibration monitoring

The decanter is equipped with a vibration monitoring system.
This system determines the effective vibration velocity (RMS as per ISO 2372)
thereby ensuring objective monitoring of the vibration behaviour of the decanter.
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The table below shows the evaluation of the determined vibration characteris-
tics.
Effective vibration velocity

Evaluation as per ISO 2372
RMS peak to peak*
0 -10 mm/s 0 -28.3 mm/s good
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10 -20 mm/s 28.3 -56.6 mm/s acceptable

20 -25 mm/s 56.6 -70.7 mm/s still acceptable
above 25 mm/s above 70.7 mm/s not acceptable
* The conversion factor from RMS to "peak to peak" is 2.828.
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3.5 Emergency Stop

An automatic “Emergency Stop" is triggered by the decanter control when a crit-
ical operating status is reached. Causes can be:
• Gearbox overloaded
• Machine vibrations too high
• Bearing temperatures too high
• Failure of the lubrication oil supply
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An “Emergency Stop” can be triggered
by hand at the following points:
• Direct on the decanter
• On the decanter control
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3.6
Fig. 40
IN
Shut-down and cleaning
Westfalia Separator will compile an optimum shut-down program in cooperation
with the customer.
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3.7 Long-term shut-down
When the machine is shut down for longer than one year, special measures are
required to avoid the machine getting damaged during standstill, see chapter 5.
The required preservation measures will be worked out together with Westfalia
Separator Service.
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3.8 Troubleshooting
Operating faults Possible cause Remedy
3.8.1 Start-up difficulties No electrical energy for control and Switch on power.
motors.
Plant components interlinked with the Make the plant components ready for
machine are not ready for operation. operation.
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Fault in the lube oil supply Check lubrication system.
Fault in the cooling water supply for oil Check cooling water supply.
cooler or slide-ring packing.
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Main motor rotates, bowl remains sta- Clean gaps, check solids discharge.
tionary.
Machine started with high vibration Product residues in the bowl. Activate
levels. the cleaning program.
3.8.2 Bearing temperature Cooling water volume for oil cooler too Check cooling water volume.
or oil return low.
temperature too high – Cooling water line sealed off or bro- Clean/replace the filter element.
IN
ken.
– Opening valves mechanically or elec-
trically defective
– Filter element blocked
Feed temperature of cooling water too Lower the feed temperature.

high.
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Heat exchanger is soiled on the water Have heat exchanger cleaned by
side. Westfalia Separator Service.
Lube oil throughput too low Check the oil lines for damage.
– Line break in the lube oil line Check the oil level in the oil tank.
– Oil level in oil tank too low Renew oil filter.
– Oil filter soiled Check the oil pump.
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– Oil pump pressure too low
Oil pump drive motor does not run or Check the electrical connection.
runs in the wrong direction. Check the times for pre-lubrication and
post-lubrication (decanter control).
Lube oil doesn’t meet the specifications. Change the oil.

– Incorrect oil quality.
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– Change interval exceeded.
Temperature probe defective. Determine the temperature with a

manual device.
Re-calibrate or replace the tempera-
ture probes.
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3.8 Troubleshooting
Operating faults Possible cause Remedy
3.8.3 Oil level in oil tank Leakage Check the oil unit, oil lines and decant-
too low er bearings for leakage.
The lube oil feed and return lines are Top up just enough lube oil that the
too long. min. mark is exceeded.
The increased volume in the oil lines When shutting down the decanter,
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can result in inadmissible emptying of make sure that the oil tank does not
the oil tank. overflow due to the returning oil.
The oil unit may have to be placed
nearer to the decanter to be able to
shorten the feed and return lines.
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3.8.4 Condensation water Extreme temperature differences – Drain condensate water.
in the lube oil Check the oil level and top up if nec-
High air humidity essary.
– Change the oil.
If large condensation water volumes

occur regularly, contact Westfalia Sep-
IN arator Service to eliminate the fault.
Even small amounts of condensation
water in the oil can lead to bearing
damage.
3.8.5 Oil pump doesn't Motor is incorrectly connected. Check the electrical connection.
start
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The pre-lubrication and post-lubrication Check the times for pre-lubrication and
times are incorrectly set. post-lubrication (decanter control).
3.8.6 No oil return flow Oil feed too low Check oil feed.
Oil level in oil tank too low. Check oil level.

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Oil return lines are damaged. Check oil return lines.
Probes in the oil return are soiled. Clean the glass bodies of the probes.
3.8.7 Oil leakage at bowl Oil return is impeded. – Oil return lines must have sufficient
bearing slope.
– Immersed areas (siphon) are not
admissible.
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– Check/clean vent of oil tank.
3.8.8 Vibrations too high One-sided product deposits Activate the cleaning program.
Bearing damage Replace roller bearings.
Solids discharge is blocked. Clear out the solids discharge.
Product deposits in the housing. Clean the housing.
Vibration isolators are defective. Replace vibration isolators.
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4 Maintenance
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4.1 Avoiding accidents during maintenance work ....................................... 46
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4.3 Service and maintenance contract with Westfalia Separator ................ 47
4.4.2 Roller bearings ....................................................................................... 49
4.4.3 Lubricants .............................................................................................. 49
4.5 Maintenance schedule (machine in operation or in readiness) ............. 51
4.5.1 Maintenance schedule (machine shut-down medium term) .................. 55
4.6 Lubricants .............................................................................................. 57
4.6.1 Synthetic oil based special grease ........................................................ 57
IN
4.6.2 Industrial gear oil CLP HC 68 ................................................................ 57
4.7 Screw tightening torques ....................................................................... 58
4.7.1 Screw tightening torques in inch-pound (inlb) ....................................... 59
4.8 Checking screw tightening torques ........................................................ 60
4.9 Checking the decanter for leakage. ....................................................... 62
4.10 Checking the vibration isolators ............................................................. 63
4.10.1 Vibration isolators for the drive unit ....................................................... 63
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4.10.2 Vibration isolators on the decanter housing .......................................... 63
4.11 Checking the gearbox for leakage ......................................................... 64
4.12 Drive belts .............................................................................................. 67
4.12.1 Checking the belt tension (bowl drive) ................................................... 67
4.12.2 Checking the belt tension (scroll drive) .................................................. 71
4.12.3 Replacing the drive belts (bowl and scroll drive) ................................... 73
4.12.4 Adjusting the proximity sensors ............................................................. 76
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4.13 Oil lubrication system ............................................................................. 77

4.13.1 Checking the oil level / topping up oil .................................................... 77
4.13.2 Replacing the oil filter ............................................................................ 78
4.13.3 Replacing the filter element of the cooling water feed ........................... 78
4.13.4 Filling in new oil ..................................................................................... 78
4.13.5 Cleaning the oil tank. ............................................................................. 79
4.13.6 Touching up damaged paintwork .......................................................... 79
4.13.7 Checking for tightness ........................................................................... 79
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4.13.8 Checking/draining condensation water .................................................. 79

4.14 Relubricating / cleaning the motor ......................................................... 80
4.15 Scroll ...................................................................................................... 81
4.15.1 Relubricating the scroll bearings ........................................................... 81
4.16 Relubricating the bearings on the rotating feed tube ............................. 81
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4.1 Avoiding accidents during maintenance work

Only routine maintenance work is described in the following. Maintenance and
repair work extending beyond this scope may only be carried out by Westfalia
Separator service.
Observe the local occupational health and ac-

cident prevention regulations. Use protective
equipment.
• Protective helmet
• Ear protection
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• Protective goggles
• Safety shoes
• Safety gloves
Fig. 41
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Before all maintnance work:
• Shut down the decanter in a controlled manner
via „Decanter Off“.
• Switch off all electrical apparatus via the main
switch.
• Secure the installation against unintended re-
starting with locking devices.
Fig. 42
IN Shut off all supply lines. In the case of lines under
pressure, ensure that the pressure is relieved.
• Product feed
• Flush water feed
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• Cooling water feed
• Polymer feed
• Oil feed lines
Fig. 43
Attention: Danger to life through high-speed

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rotating machine parts !

• Do not loosen any part of the machine before
the decanter bowl has come to a standstill.
The run-down time of the decanter bowl is
approx. 60 minutes.
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Fig. 44
Attention: Danger of injury due to hot surfaces.

• Do not start maintenance work until all machine
parts have adequately cooled down. This can
take up to 3 hours depending on the processed
product and machine size.
Fig. 45
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Attention: Danger of injury through falling ma-

chine parts.
• Load-carrying equipment must only be used for
the intended purpose, i.e. for work steps
described in this manual.
• Do not use damaged or incomplete load carry-
ing equipment.
Fig. 46
Y
• Collect dripping oil to avoid the danger of
slipping and environmental pollution.
• When handling waste oils note:
– They can be injurious to health depending on
AR
their chemical composition.
– Waste oil must be disposed of in accordance
with the local regulations.
Fig. 47
4.2 Demands relating to service personnel and spare parts
IN • Use only genuine spare parts from Westfalia

Separator.
The use of non-genuine parts leads to:
– Safety risks
– Lower durability and availability
– Increased maintenance requirement
If a safety risk arises, this may have legal
IM
consequences for the responsible persons. In
Fig. 48 this case, Westfalia Separator shall assume no
liability or warranty.
• Deploy only well trained personnel for maintenance work, e.g. the service
personnel from Westfalia Separator or personnel trained by Westfalia
Separator.
An incorrectly maintained/assembled machine poses a safety risk for the op-
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erators.
4.3 Service and maintenance contract with Westfalia Separator

When a service and maintenance contract is concluded with Westfalia Separa-
tor, the maintenance work is optimally adapted to the production process. This
can substantially lower maintenance costs.
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4.4 Storing wearing parts and operating media

When storing wearing parts and operating media please note the following.
4.4.1 Gaskets and V-belts

The physical properties of rubber and caoutchouc products change under unfa-
vourable storage conditions. The consequence is
• reduced life time
• defective condition.
Y
Gaskets and V-belts are capable of keeping their physical properties for several
years, provided they are stored in accordance with the following instructions.
Required storage room:
AR
• cool (+ 15° up to max. + 25°C)
• dry ( < 65 % humidity)
• dust-free
• dark, no direct sunlight or artificial light (if possible, paint windows red or or-
ange)
• moderate, draught-free ventilation (if necessary, wrap or pack parts in foil or
bags of paper, polyethylene or polyamide).
Surroundings:
Do not store
IN
• in the vicinity of sources of heat,
• together with solvents, fuels, lubricants, acids, disinfectants, etc.
IM
Storage:
• Without strain, i. e. without tension, pressure or change in dimensions.
• Avoid contact with different materials.
• Avoid direct contact with metals (especially copper and manganese have a
damaging effect on rubber products).
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• V-belts are preferably hung up on so-called "saddles" or pipes of large diame-

ters. The diameter should be 10 times the height of the V-belt section.
• To save space, V-belts of greater length can be piled one on top of the other,
provided they are put together properly.
• V-belts of smaller length may be stored in shelves. The piles of belts should
not be higher than 300 mm, in order to avoid deformation of the belts.
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• Hooks and nails are not suitable for hanging the belts on.
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4.4.2 Roller bearings

The roller bearings should be stored in their original packing. It should not be
removed until the bearing is installed. Otherwise there is the risk that the bear-
ings get dirty and rust.
Larger bearings which have rings with relatively thin walls should not be stored
in upright position. They must be stored lying, supported over their whole length.
Roller bearings are immersed in slushing oil before being packed. This oil does
not harden and resinify and does not affect other commercially available roller
bearing greases. The original packing gives the roller bearings protection
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against attack from the outside.
This protection lasts only for a longer period, if the packed bearings are stored
in a dry (humidity max. 60 %) and frost-free room.
AR
Aggressive chemicals such as acids, ammonia or chlorinated lime are not al-
lowed to be stored in this room.
4.4.3 Lubricants
Always keep lubricant containers tightly closed and store them in closed rooms.
Avoid large temperature fluctuations as they cause respiration of the containers.
As a result, moisture penetrates into the containers.
Clean the lubricant containers before opening them to prevent contaminants
IN
from getting into the lubricant. Even the smallest foreign matter in the lubricant
can drastically reduce the life of the roller bearings.
IM
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IN
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PR
Fig. 49
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Westfalia Separator
8399-9001-804 / 17.08.2011 51
4.5 Maintenance schedule (machine in operation or in readiness)
Important instructions
• Take special care when carrying out maintenance and lubrication work!
Carefully executed lubrication and maintenance improves operating times and
the service life of the decanter.
• Clean lubricating points prior to lubrication.
Y
After operating hours
AR
Machine status
Pos. inFig. 49
After months
No.
Machine part / assembly Operation / remark
1 170 2 running 5 Complete decanter Check installation for leakage, refer to

page 62
2 170 2 running
IN
16 Oil circulation lubrication sys- Check oil fill quantity
tem Check condensation water level
Refer to page 77.
Lubricant oil Öl CLP HC 68,
Specification on page 57.
IM
3 2 running 5 Complete decanter Check paint finish. Touch up damage
immediately using the repair kit of the
paint manufacturer.
4 1450 stand- 2 Feed tube bearing Westfalia Separator Service:

still
Re-grease roller bearings.
EL
4 Scroll bearing (liquid side) Lubricant: special grease, specification

on page 57.
5 1450 stand- 3 Bowl bearings (liquid side) Westfalia Separator Service:

still
Carry out vibration analysis to assess
10 Bowl bearings (solids side) the bearing condition.
Evaluate and record the data.
PR
6 2900 running 12 Drive motors Re-grease roller bearings.

See nameplate on motor.
7 4350 stand- 6 Bowl and scroll Check wear.

still
In the case of wear, damage or
corrosion on load-bearing bowl parts,
contact Westfalia Separator service.
Shorter intervals may be necessary.
8 4350 stand- 7 Protective ring and bushes at Check for wear and replace if
still
solids discharge necessary.
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Machine status
Pos. inFig. 49
After months
No.
9 4350 stand- 8 Catcher and hood Clean product-contacting parts and
Y
still
check for damage and wear.
10 4350 stand- 15 Oil circulation lubrication sys- Renew oil filter.
AR
still
tem Refer to page 78.
11 4350 6 stand- 13 V-belts Check belt tension and wear.

still
Refer to page 67.
12 4350 6 running 5 Complete decanter Check the functionality of the vibration

monitoring system.
Carry out a comparison measurement
with a portable vibration measuring
IN device.
13 8750 stand- 16 Oil circulation lubrication sys- Renew the oil filling (2 x 60 litres).
still
tem Clean the oil tanl.
Lubricant: oil CLP HC 68, specification
on page 57.
IM
14 8750 12 stand- 1 Feed tube Check the condition of the slide-ring
still
packing.
15 8750 12 stand- 13 V-belts Replace V-belts.

still
Refer to page 67.
EL
16 8750 12 stand- 14 Vibration isolators / frame Westfalia Separator service:

still
Check whether
– the bellows are damaged
– liquid (damper medium) is discharg-
ing
– impurities have penetrated the sys-
tem
PR
17 8750 12 stand- 11 Vibration isolators / drive Check condition.

still
Replace the vibration isolators when
one-sided dents or discolouration are
detected.
18 17 500 stand- 2 Feed tube Westfalia Separator service:

still
Replace roller bearings.
Renew grease filling
Lubricant: special grease, specification
on page 57.
®
Westfalia Separator
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Machine status
Pos. inFig. 49
After months
No.
19 17 500 stand- 4 Scroll bearings / liquid side Westfalia Separator service:
Y
still
Renew grease filling.
Lubricant: special grease, specification
on page 57.
AR
20 17 500 30 stand- 3 Bowl bearings (liquid side) Westfalia Separator Service:
still
The roller bearings can remain longer

in service (max. 35,000 operating hours
or 60 months).
10 Bowl bearings (solids side)
The pre-condition is that the bearing
IN condition is checked regularly(see no. 5
of this maintenance schedule).
21 20 000 50 stand- 9 Gearbox Westfalia Separator service:

still
Inspection of the gearbox.
22 42 000 60 stand- 11 Vibration isolators / drive Westfalia Separator service:

IM
still
Replace vibration isolators.
EL
PR
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Y
AR
IN
IM
EL
PR
Fig. 50
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8399-9001-804 / 17.08.2011 55
4.5.1 Maintenance schedule (machine shut-down medium term)

The following table applies for machines which are shut down for max. 1 year.
The machines must be operational upon short notice.
Shut-down
For a standstill up to one year, the decanter must be prepared as follows after
shut-down:
• Clean hood and catcher.
Y
• Seal off all feed and discharge lines of the machine to prevent contamination
of the machine.
– Product feed
AR
– Solids discharge
– Liquid discharge
– Water supply for slide-ring packing and oil cooler
– Polymer feed
Maintenance work once a month

IN
Pos. in Fig. 50
Machine component
Operations Remarks
Assembly
IM
Open water supply for
slide-ring packing and oil
cooler.
Start the decanter for 20 minutes; refer also to
5 Complete decanter The product and polymer
sections 3.1 to 3.2.
feed remain closed.
The product discharges
must be opened.
EL
Maintenance work 6 times a year

Pos. in Fig. 50
Machine component
Operations Remarks
Assembly
PR
16 Oil lubrication system Check condensation water level. See page 77.
Check paint finish. Touch up damage immedi- The work can be carried
5 Complete decanter ately using the repair kit of the paint manufac- out while the machine is
turer. running.
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Maintenance work before resuming operation

Pos. in Fig. 50
Machine component
Operations Remarks
Assembly
2 Feed tube bearing Re-lubricate roller bearing. The required work will be
Y
Scroll bearings / carried out by Westfalia
4 Re-lubricate roller bearings. Separator Service
Liquid side
When wear, damage or
AR
corrosion is detected on
6 Bowl and scroll Check wear. load-bearing bowl parts,
contact Westfalia Separa-
tor Service.
The required work will be
Guard ring and bushes/
7 Check wear and replace when necessary: carried out by Westfalia
solids discharge
Separator Service.
13 V-belts Check belt tension and wear.
IN See page 67.
1 Feed tube Check the condition of the slide-ring packing. carried out by Westfalia
Separator Service.
Check whether
Vibration isolators / – the bellows are damaged
14
Housing – liquid (damper medium) is discharging
IM
impurities have penetrated the system
Renew oil fill quantity. The required work will be
CLP HC 2x carried out by Westfalia
16 Oil lubrication system Clean oil tank.
68 60 litres Separator Service
Renew oil filter.
Vibration isolators /
11 Check condition.
Drive frame
EL
3
Bowl bearings Check torques of the fastening screws. See page 60.
10
While machine is running: Pay attention to motor

12 Drive motor
Re-lubricate the motor bearings. plate.
PR
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4.6 Lubricants
Selection of a suitable lubricant is essential for correct functioning of the de-
canter. Wear is minimised. The service life and operating safety of the decanter
is increased.
For this reason, we recommend the lubricant filled in at the factory. Westfalia
Separator carries out continuous quality checks only for this product.
Notes on storage: The possible storage time when stored carefully in dry rooms
and with closed original containers is at least 24 months.
Y
4.6.1 Synthetic oil based special grease
AR
Designation Manufacturer WS - Part-No /drum. Key data
Synthetic 0015-0128-010 (0.4 kg) car-

substance tridge according to DIN 1284
Polycarbamide grease
based spe-
cial grease 0015-0128-000 (1.0 kg)
IN
4.6.2 Industrial gear oil CLP HC 68
Designation as
Designation Manufacturer WS - Part-No /drum. Specification
per DIN 51502
IM
Industrial
CLP HC 0015-0020-200 Kinematic viscosity
gear oil ±6,8 2
68 (20 litres) 68 mm /s bei 40 °C
CLP HC 68
EL
PR
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4.7 Screw tightening torques

The torques apply to:
• metric screws with coarse-pitch thread.
– hex head screws according to DIN EN ISO 4014
– Allen screws according to DIN EN ISO 4762
• through holes according to DIN ISO 20273 (medium).
• greased screws (coefficient of friction = 0.10).
Y
• torque wrench with a scatter (tolerance) of ±10 %.
• the material combination steel - steel or stainless steel.
Screws whose torque deviates from this table are marked with the required
AR
torque in the manual.
Extract from the works standard WSN 19-0019-00

A2–70
Property class 8.8 10.9 12.9
A4–70
Yield strength/ 640/ 450/
2 940 1100
proof stress [N/mm ] 660 IN 250
Pitch Thread size Torques [Nm]
0.70 M4 2.6 3.9 4.5 1.9 M4
0.80 M5 5.2 7.6 8.9 3.6 M5
1.00 M6 9.0 13.2 15.4 6.3 M6
IM
1.25 M8 21.6 31.8 37.2 15.2 M8
1.50 M 10 43.0 63.0 73.0 30.0 M 10
1.75 M 12 73.0 108.0 126.0 52.0 M 12
2.00 M 16 180.0 264.0 309.0 126.0 M 16
2.50 M 20 363.0 517.0 605.0 248.0 M 20
EL
3.00 M 24 625.0 890.0 1041.0 237.0 M 24

3.50 M 30 1246.0 1795.0 2077.0 472.0 M 30
4.00 M 36 2164.0 3082.0 3607.0 - M 36
PR
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4.7.1 Screw tightening torques in inch-pound (inlb)

The following formula is used to convert the torques (Ma) from “Nm“ to “inlb“:
Mainlb = MaNm x 8.85
Example:
Y
Mainlb = Wanted (screw tightening torques in “inch-pound”)
MaNm = 50 (screw tightening torques in “Newtonmeter“)
Mainlb =
AR
50 Nm x 8.85
Mainlb = 442.5 inlb
Extract from the works standard WSN 19-0019-00

A2–70
Property class 8.8 10.9 12.9
A4–70
Yield strength/ 640/ IN 450/
2 940 1100
proof stress [N/mm ] 660 250
Pitch Thread size Torques [inlb]
0.70 M4 23.0 34.5 39.8 16.8 M4
0.80 M5 46.0 67.3 78.8 31.9 M5
IM
1.00 M6 79.7 116.8 136.3 55.8 M6
1.25 M8 191.2 281.5 329.3 134.5 M8
1.50 M 10 380.6 557.6 646.1 265.5 M 10
1.75 M 12 646.1 955.9 1115.2 460.3 M 12
2.00 M 16 1593.2 2336.7 2735.0 1115.2 M 16
EL
2.50 M 20 3212.9 4576.0 5354.9 2195.0 M 20

3.00 M 24 5531.9 7877.4 9213.9 2097.7 M 24
3.50 M 30 11028.3 15887.5 18383.5 4177.7 M 30
4.00 M 36 19153.6 27278.8 31925.6 - M 36
PR
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4.8 Checking screw tightening torques

Due to settling processes particularly during the initial 100 operating hours, the
screw pre-tension may decrease.
The correct torques are given in the table on page Fehler! Textmarke nicht
definiert..
For screws larger than M 24, the force amplifier from the “Set of tools“ must be
used to produce the required torque.
When using the force amplifiers, it must be kept in mind that the torque M1 to be
Y
set on the torque wrench must be calculated.
Example for hex head screws M 30 (8.8)
Ma
AR
M1 =
i
Required torque from table on page Fehler!
Ma = 1246 Nm Textmarke nicht definiert..
Translation ratio of the force amplifier (10.8,

i = 10,8 corresponds to the type STW 392 N)
1246 Nm
IN
M1 =
10,8
M1 = 115 Nm Torque to be set on the torque wrench.

IM
The following screwed unions must be checked and re-tightened if neces-
sary since loosening of the screws represents a high safety risk.
Liquid side
• Check fastening screws M20 on the

bearing cover.
EL
– 8x M20x320, material 8.8

– Required torque (greased
screws): 363 Nm

bearing assembly.
To do this, the protective ring 1 and
vibration pick-up 2 must be disman-
PR
tled.
screws): 1246 Nm
– Use a power assist tool. Calculate
Fig. 51
and adjust the torque on the
torque wrench, see 60 .
®
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Solids side

bearing cover.
screws): 363 Nm

bearing assembly.
Y
To do this, vibration pick-up 2 must
be dismantled.
screws): 1246 Nm
AR
– Use a power assist tool. Calculate
and adjust the required torque on
Fig. 52
the torque wrench, see page 60 .
After checking the scroll torques, it is essential to refit all machine parts that had
to be dismantled for better access to the screws.
IN
IM
EL
PR
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4.9 Checking the decanter for leakage.

To ensure safe operation, the complete decanter installation must be regularly
checked for leakage.
Leakage fouls the installation. Leakage can endanger the environment, the op-
erating personnel and the operating safety of the decanter.
Component What discharges Remark / remedy
Pipes and hoses Product • Seal leaky pipes.
Y
Water • Shut down the decanter.
Polymer • Have the leakage remedied by Westfalia Separator
Service.
• Dispose of the leakage residue properly and correctly.
AR
Observe the local regulations.
Hood seals, Product • Have the leakage remedied by Westfalia Separator

discharge chutes etc. Service.
• Dispose of the leakage residue properly and correctly.
Observe the local regulations.
Leakage at the liquid side. Product If leakage occurs at this point, the seal of the cooling
Water IN chamber of the slide ring packing may leak or the slide
ring packing itself may be leaky.
• Shut down the decanter; otherwise the bearing may
get damaged.
• Have the leakage remedied by Westfalia Separator
Service.
Lube oil system Lube oil • Shut down the decanter, in case of major leakage.
IM
• Oil units • Have the leakage remedied by Westfalia Separator
• Oil lines Service.
• Decanter bearings • Collect the lube oil and dispose of it in accordance
with the local regulations. Lube oil and lube oil resi-
dues may not enter the environment, in particular the
ground water.
EL
Vibration isolators Damping medium • Shut down the decanter immediately.

(Visco compound) • Have the damage checked and remedied by Westfalia
Separator Service.
PR
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4.10 Checking the vibration isolators

Vibration isolators are designed to isolate the decanter as far as possible from
environmental influences.
The effect of the isolators can deteriorate due to damage, aging and other envi-
ronmental influences.
4.10.1 Vibration isolators for the drive unit

Rubber elements are fitted between the drive frame and the foundation. The
rubber elements must be visually checked on a regular basis. Pay attention to
Y
the following:
• Cracks
• Deformations
AR
• Discoloration
When changes are detected, the decanter must be shut down and Westfalia
Service called in.
4.10.2 Vibration isolators on the decanter housing

Vibration isolators with springs and a Visco-damper are fitted between the de-
canter housing and foundation.
IN
The vibration isolators must be visually checked on a regular basis. Pay atten-
tion to the following:
• Damage to the rubber seals
• Damage to the fastening tapes on the rubber seals
• Discharge of Visco compound from the isolation elements
IM
In the case of damage or discharging Visco compound, the decanter must be
shut down immediately.
Westfalia Separator Service must be called in to check and assess the damage.
Important note
When cleaning in the vicinity of the vibration isolators, be sure not to directly
EL
spray the vibration isolators.

Penetrating water or detergent could change the properties of the isolator.
PR
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4.11 Checking the gearbox for leakage

If oil leakage occurs at the gearbox, it can become damaged through a lack of
oil. Discharging lube oil can additionally cause pollution.
To avoid this, the gearboxes must be regularly checked for oil leakage.
• Shut down the decanter. Observe the safety precautions, see page 46.
• Dismantle the protection covers on

the liquid-side bearing assembly. To
do this, unscrew 7 screws M12x60.
Y
AR
Fig. 53
IN • Remove the screws for fastening the
hood.
– On each long side 20 screws
IM
M16x60
– On each front side 4 screws
M16x80.
• Lift the hood off the housing with a
suitable hoist. Ensure that the hood
remains in horizontal position.
• Set the hood down on a suitable
EL
surface to avoid damage. The sup-

port must be level and soft, i.e. a
rubber mat.
Fig. 54
PR
• Inspect the gearbox and environment including hood and catcher area. Watch
out for an oily coating on the gearbox surface, particularly in the area of the
plugs.
If lube oil leakage is detected, the machine must be assessed by Westfalia
Separator Service to avoid gear damage.
• Following inspection, clean the hood and catcher.
– Use wooden scrapers, brushes and suitable detergent.
– Do not use metal tools because this could damage the surfaces of hood
and catcher. Such damage facilitates product caking and can form a start-
ing point for corrosion.
– Likewise clean the rubber seals between hood and catcher. Replace dam-
aged seals.
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• Mount the hood again. Note:

– The heads of 2 Allen screws M10
adjust the position of hood and
catcher relative to each other.
– Be careful not to damage the gas-
kets.
– Screw in all fastening screws M16
and tighten to the required torque.
Y
AR
Fig. 55
• Mount the protection covers. Screw

in all fastening screws and tighten to
the required torque.
IN
IM
Fig. 56
EL
Note on putting back into operation

Exercise special care when putting the decanter back into operation. In this way,
consequential damage after defects in assembling can be minimised.
-1
• Accelerate the decanter to a bowl speed of just 100 min and immediately
switch it off again.
PR
– Pay attention to grinding noises or other irregularities when running up the

decanter.
– In the event of irregularities, call in Westfalia Separator Service.
• If nothing unusual is observed or heard, the decanter can be accelerated to
operating speed.
– First only feed water to the decanter.
– Check the hood and catcher for leakage.
– If leakage is found the decanter must be shut down. Westfalia Separator
Service must then be called in.
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• If no leakage occurs, the decanter can be fed with product.

– Check the hood and catcher for leakage.
– If leakage is found the decanter must be shut down. Westfalia Separator
Service must then be called in.
• If no leakage occurs now, the machine can be operated in normal mode.
Y
AR
IN
IM
EL
PR
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4.12 Drive belts

Check the condition and position of the drive belts at regular intervals. The in-
spection and replacement intervals are given in the "Maintenance schedule".
Signs of insufficient belt tension or worn belts can be:
• Increased noise level due to flapping belts.
• Excessive speed drop under load (bowl or differential speed).
When tensioning and replacing the V-belts, bear in mind the following:
Y
Danger to life through high-speed rotating parts !
• Do not loosen any part of the machine before the decanter bowl has come to
a standstill.
– The run-down time for the decanter bowl is approx. 60 minutes.
AR
– Wait for at least 3 hours after switching off the machine before beginning
with maintenance work. Only after this time have all machine parts cooled
down to the extent that there is no danger of injury due to hot surfaces.
• Use the belts specified in the parts list. Only then is it assured that the belts
meet the high requirements.
4.12.1 Checking the belt tension (bowl drive)

IN • Undo screws 1. Remove the wear
insert.
IM
EL
Fig. 57
PR
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• Unscrew fastening screws 2 and 3.
Y
AR
Fig. 58
• Suspend guard parts 4 and 5 into a

hoist and remove them.
IN
IM
Fig. 59
EL
• Use the measuring instrument from

the “Set of tools” to measure the
drive belt tension.
The measuring instrument consists
of:
– 1 Indicating arm
PR
– 2 Pressure surface
– 3 Pressure spring
Fig. 60
®
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Function:
• Push the indicating arm to the end of
the scale.
Y
AR
Fig. 61
• Place the measuring instrument in

the centre between the two belt pul-
leys on one of the belts.
IN • Press gently against the pressure
surface. The indicating arm will de-
flect on the scale span.
• Stop pressing when you feel or hear
a click
• Carefully lift off the measuring in-
strument without moving the indicat-
ing arm.
IM
Fig. 62
EL
• Read off the value at the point of

intersection between the upper edge
of the indicating arm and the scale
span.
• The setpoint for optimally tensioned
belts is:
– new belts: 1150 ± 50 N
PR
(258.5 ± 11,2 lbf)

– used belts: 950 ± 50 N
(213.6 ± 11,2 lbf)
Fig. 63
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• The belt tension is increased by

raising the motor bracket.
– Undo lock nuts 3 on both sides of
the motor.
– Raise the motor by turning nuts 2.
Pay attention to uniform and even
adjustment on all 4 bolts.
– On all 4 bolts the clearance be-
tween motor bracket and drive
frame must be equal.
– Tighten lock nuts 3.
Y
• Re-fit the belt guard.
AR
Fig. 64
IN
IM
EL
PR
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4.12.2 Checking the belt tension (scroll drive)

• Remove the covers as required.
Y
AR
Fig. 65
IN • Place the measuring instrument in

the centre between the two belt pul-
leys on one of the belts.
• Press gently against the pressure
surface. The indicating arm will de-
flect on the scale span.
• Stop pressing when you feel or hear
IM
a click
• Carefully lift off the measuring in-
strument without moving the indicat-
ing arm.
EL
Fig. 66
PR
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• Read off the value at the point of

intersection between the upper edge
of the indicating arm and the scale
span.
• The setpoint for optimally tensioned
belts is:
– new belts: 1150 ± 50 N
(258.5 ± 11,2 lbf)
– used belts: 950 ± 50 N
(213.6 ± 11,2 lbf)
Y
AR
Fig. 67
• The belt tension is increased by

lowering the motor bracket.
– Undo lock nuts 2 and 3 on both
sides of the motor.
– Lower the motor by turning nuts 1.
IN Pay attention to uniform and even
adjustment on all 4 bolts.
– On all 4 bolts the clearance be-
tween motor bracket and drive
frame must be equal.
– Tighten all nuts.
IM
• Mount covers.
Fig. 68
EL
PR
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4.12.3 Replacing the drive belts (bowl and scroll drive)

• Always replace the complete set (bowl or scroll drive).
This makes sure that the belts are the same length. Equal length is necessary
for uniform tension and smooth running.
• Use only genuine spare parts from Westfalia Separator.
• Dismantle the belt guard, see page 67.
Y
• Remove the covers for the scroll
drive.
AR
IN
Fig. 69
IM
• Remove the lube oil hose for the oil
supply to the gear.
EL
PR
Fig. 70
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• Dismantle the holder for the proximi-

ty sensor.
Y
AR
Fig. 71
• Raise the motor. To do this, turn

nuts 2 on both sides evenly up-
wards.
IN • Remove drive belts.
IM
Fig. 72
EL
• Lower the main motor. To do this,

turn nuts 2 on both sides down-
wards.
• Remove and replace drive belts.
• Raise the main motor. To do this,
turn nuts 2 on both sides upwards.
Adjust the belt tension, see page 67.
PR
• Tighten nuts 3.
Fig. 73
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• Mount the new drive belt for the

scroll drive.
Adjust the belt tension, see page 67.
Y
AR
Fig. 74
• Mount the holder for the proximity

sensor.
• Adjust the proximity sensor.
The axial distance between proximi-
IN ty sensor and belt pulley must be 4-
6 mm.
IM
Fig. 75
EL
• Connect the lube oil line for the oil

supply to the gear.
PR
Fig. 76
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• Mount the covers for the scroll drive.

• Suspend guard 1 in a hoist and fit.
Y
AR
Fig. 77
4.12.4 Adjusting the proximity sensors
• Align the bowl proximity sensors as

IN illustrated.
– Required gap width: 4 – 6 mm
– Check the gap width on both
pulse transmitters.
IM
EL
Fig. 78
• Align the differential proximity sen-

sor as illustrated.
– Required gap width: 4 – 6 mm
PR
Fig. 79
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4.13 Oil lubrication system

The two oil lubrication systems must be regularly maintained so that the ma-
chine bearings do not wear prematurely and fail as a result of dirt particles or an
inadequate lubrication effect of the oil.
The decanter must be shut down for maintenance. The safety precautions
must be observed, see page 46.
• The required maintenance intervals are given in the "Maintenance schedule".

When supervisory equipment responds, maintenance may be necessary be-
Y
fore the actual maintenance interval has elapsed, e.g.
– Filter change in the case of alarm by the differential pressure switch
– Drain condensation water in the case of an alarm by the water detector
AR
• Suitable lubricants are listed in the "table of lubricants", see page 57. The first
oil filling is supplied with the machine.
• The lube oil can be treated. Westfalia Separator is a specialist for professional
lube oil treatment.
4.13.1 Checking the oil level / topping up oil

An insufficient oil level can lead to increased bearing temperatures, failure of
and damage to the decanter.
IN
The oil level is monitored via level switches and flow detectors as a safety pre-
caution. Nevertheless, a visual check should be carried out regularly to track the
development of the oil level. Oil can then be topped up before one of the moni-
toring systems triggers an alarm or the decanter shuts down.
Oil level in operating mode:

IM
During operation the oil level must be
between the min. and max. marks
Oil level at machine standstill

After a prolonged standstill, the oil
level will be somewhere around the
max. mark because of backflowing oil.
EL
Fig. 80
Topping up oil
PR
• Shut down the decanter and wait until the oil has flowed back into the oil tank
from the return lines.
• Open filling cap 40 and clean the strainer.
• Fill in new or treated oil until the max. mark is reached.
Use only the lube oil specified in the “Table of lubricants”. The required oil
quantity is specified in the “Lubrication and maintenance schedule”.
• Close filling cap 40.
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4.13.2 Replacing the oil filter

• Check availability of genuine spare part from Westfalia Separator.
• Place a suitable collecting vessel underneath.
• Unscrew oil filter 10; use a tool if

necessary.
• Lightly oil the gasket of the new oil
filter and screw on the oil filter tightly
Y
by hand.
AR
Fig. 81
4.13.3 Replacing the filter element of the cooling water feed

In order to ensure an adequate supply of cooling water to the oil lubrication, the
IN
filter element in the cooling water feed to the plate heat exchanger must be reg-
ularly checked and replaced when necessary.
4.13.4 Filling in new oil

• Check whether sufficient lube oil is present in the required quality. Use only
the lube oil specified in the chapter “Lubricants”. The required oil quantity is
IM
specified in the “Maintenance schedule”.
– Approx. 60 litres flow out of the feed chamber (drain screw next to the long
sight glass).
EL
– Approx. 10 litres flow out of the return chamber (drain screw next to the
short sight glass).
• Unscrew filling cap 40.

• Unscrew oil drain screws 200 and
completely drain the oil.
• Renew gasket 190.
• Clean oil drain screws 200 and re-
PR
tighten with new gasket.

• Clean the strainer in filling cap 40.
• Fill in new or treated oil until the
max. mark is reached.
• Close filling cap 40.
Fig. 82
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4.13.5 Cleaning the oil tank.

During every second oil change the oil tank must be thoroughly cleaned. West-
falia Separator Service must then be called in.
4.13.6 Touching up damaged paintwork

Even in the case of a minor spot in the paintwork, it must be repaired immedi-
ately.
• Clean the damaged spot with a grease-dissolving detergent.
Y
• Apply a thin coat of the original paint using the manufacturer’s repair kit and
let it dry.
4.13.7 Checking for tightness
AR
In the case of unexplained oil losses, the tightness of the oil circulation lubrica-
tion must be checked. Pay special attention to the following points:
• Hose and pipe connections
• Feed and return hoses
• Consult Westfalia Separator Service
4.13.8 Checking/draining condensation water

IN
Condensation water in the lube oil drastically impairs the lubrication properties
of the oil. Even small amounts of condensation water in the oil can therefore
lead to bearing damage.
A water detector monitors the oil for inadmissible condensation water concentra-
tions. Nevertheless, a visual check should be carried out regularly to track the
development of the condensation water level. In this way, problems can be de-
IM
tected at an early stage.
Sight glass 50 is connected to the settling chamber of the oil tank. When con-
densation water is present in the lube oil, it is visible in sight glass 50.
If large condensation water volumes occur regularly, contact Westfalia Separa-
tor Service to eliminate the fault.
EL
Draining condensation water.

• Unscrew filling cap 40.

• Unscrew oil drain screw 200 and
drain the condensation water.
PR
• Screw in the oil drain screw with a

new gasket.
• Replenish the oil loss until the max.
mark is reached.
Fig. 83
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4.14 Relubricating / cleaning the motor
The roller bearings of the drive motors

must be re-lubricated on a regular
basis according to the instructions of
the manufacturer indicated on the
motor plate.
The motors of the lube oil units are
Y
maintenance-free.
AR
Fig. 84
When relubricating, note the following:

IN
• Relubrication should take place during operation to protect the roller bearings
from overheating due to overlubrication.
• Observe the local industrial safety regulations.

Use protective gear.
– Helmet
– Ear protection
IM
– Protective goggles
– Safety shoes
– Safety gloves
Fig. 85
• Danger of injury due to hot surfaces.

EL
PR
Fig. 86
• Do not climb onto or stand on the machine or parts of the machine.

• Grease quality, grease quantity and relubricating intervals are specified on the
nameplate of the motor manufacturer. The nameplates are located near the
lubricating nipples.
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Required work steps:

• Remove the protective cap of the lubricating nipple and clean the lubricating
nipple. Clean the grease gun and check its functionality.
• Relubricate on both sides (fan and shaft side) as per the specifications on the
nameplate.
Spent and surplus grease is spun out into the discharge chamber. Open the
discharge flap several times and remove the spent grease. Dispose of it in
accordance with local regulations.
• Re-attach the protective flaps of the lubricating nipples.
Y
• Check the cooling ribs and suction holes of the fan hood for soiling.
– Remove slight impurities immediately.
– Remove heavier soiling only when the machine is at standstill.
AR
In the case of heavy soiling, there is a risk of overheating of the motor
which can lead to shut down of the decanter.
4.15 Scroll
The scroll must be checked for wear at regular intervals. The maintenance in-
tervals are given in the "Maintenance schedule" , see page 51.
In case of extensive wear to the scroll flights, the operating efficiency of the de-
canter is impaired. This is indicated by
IN
• high residual moisture content in the discharged solids
• vibrations caused by imbalance.
The required work will be carried out by Westfalia Separator Service
4.15.1 Relubricating the scroll bearings

IM
Lubrication intervals, grease quality and quantity are specified in the "Mainte-
nance schedule", see page 51.
4.16 Relubricating the bearings on the rotating feed tube

Lubrication intervals, grease quality and quantity are specified in the "Mainte-
EL
nance schedule", see page 51.

PR
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AR
IN Note
Notes
Notizen
Anotaciones
Notizen
IM
Notes
Note
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AR
5 Long-term storage
5.1
5.2
IN
Important instructions on long-term storage .......................................... 84
Decommissioning the decanter ............................................................. 84
5.3 Preparing the decanter for long-term storage........................................ 85
5.3.1 Requirements for the storage room ....................................................... 85
5.3.2 lacquered parts ...................................................................................... 85
IM
5.3.3 Unpainted areas and galvanized parts .................................................. 85
5.3.4 Gearbox / replacement gearboxes ........................................................ 86
5.3.5 Drive motors........................................................................................... 86
5.4 Maintenance schedule (machine shut-down long-term)........................ 89
5.5.2 Roller bearings ....................................................................................... 92
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5.5.3 Lubricants .............................................................................................. 92

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5.1 Important instructions on long-term storage

The decanter will get damaged if it is not operated for a prolonged period and no
adequate preserving measures are taken. This likewise applies to the time be-
fore commissioning.
When the machine is shut down for longer than 12 months, special measures
are required to prevent the machine from getting damaged during standstill.
If these measures are not taken, the roller bearings of the machine on particular
will get damaged through corrosion and one-sided loading. This bearing dam-
age results in high consequential costs.
Y
The required preserving measures should be monitored by Westfalia Separator
Service.
AR
5.2 Decommissioning the decanter
For a long-term storage (standstill longer than one year), the decanter must be
prepared as follows after shut-down:
• Clean hood and catcher.
• Dismantle all feed and discharge lines of the machine and seal the openings.
– Product feed
– Solids discharge
IN
– Liquid discharge
– Water supply for slide-ring packing and oil cooler
– Polymer feed
• Slacken and remove the flat belts.
IM
• Drain the oil from the oil lubrication system.
• Fill in preserving oil.
• Drain the water from the oil coolers and seal all openings.
EL
PR
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5.3 Preparing the decanter for long-term storage
5.3.1 Requirements for the storage room

The storage room must meet the following requirements:
• cool, 15 – 25 °C
• dry, approx. 65 % relative atmospheric humidity (formation of condensation
water must be prevented)
Y
• dark (avoid direct sunlight and ultraviolet radiation)
• dust-free
• moderately ventilated
AR
• free from aggressive media (e.g. salts, acids, caustics, solvents)
5.3.2 lacquered parts

An intact paint coat provides adequate corrosion protection. Painted parts there-
fore only have to be checked for damage and changes once per month.
Touch up the damage in accordance with the instructions of the paint manufac-
turer.
IN
5.3.3 Unpainted areas and galvanized parts
Unpainted parts and galvanized parts must be treated as follows.
• Carefully clean the area or part.
IM
• Spray on anti-corrosive wax (WS Part-No. 6969-0022-010)
• Check and, if necessary, touch up the corrosion protection once per month.
EL
PR
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5.3.4 Gearbox / replacement gearboxes
Y
AR
Fig. 87
IN
The gearbox and replacement gearboxes must be prepared as follows for long-
term storage:
• Completely drain the lubricating oil from the preliminary and main stages.
• Seal opening A. Use threaded plug M16x1.5, DIN 908 and gasket
IM
A17x21x1.5, DIN 7603 (WS Part-No’s 0019-8920-030 and 0007-1797-550).
• Seal openings B. Use 2 threaded plugs G1/8 in, DIN 910 and gaskets
A10x13.5x1, DIN 7603 (WS Part-No’s 0019-9114-3000 and 0007-1920-550).
• Fill in 0.5 litres of preserving oil into both the preliminary and main stage.
Use preserving oil “Anticorit VCI UNI 0-40, WS Part-No. 6969-0005-010.
• Carefully clean the gearboxes.
EL

For transporting the gearbox for inspection by the manufacturer, the
gearbox must likewise be prepared as described above.
PR
5.3.5 Drive motors

The drive motors must be prepared as follows for long-term storage.
• Connect the trace heating of the motor winding. This applies in particular
when there is high atmospheric humidity in the environment.
• Carefully clean the motor.
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Y
AR
IN Note
Notes
Notizen
Anotaciones
Notizen
IM
Notes
Note
EL
PR
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AR
IN
IM
EL
PR
Fig. 88
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5.4 Maintenance schedule (machine shut-down long-term)

Machines that are shut down for longer than one year still require regular care to
remain serviceable.
Maintenance work once a month

Pos. in Fig. 88
Y
Machine component
Operations Remarks
Assembly
AR
Touch up damage immedi-
Check paint work. ately using the repair kit of
the paint manufacturer.
5 Decanter housing
If necessary, spray on cor-
Check corrosion protection. rosion protection wax (WS
Part-No. 6969-0022-010)
Touch up damage immedi-
Check paint finish.
IN ately using the repair kit of
the paint manufacturer.
17 Drive frame
If necessary, spray on cor-
Check corrosion protection. rosion protection wax (WS
Part-No. 6969-0022-010)
Do not stop the bowl in the
6 Bowl Rotate the bowl (minimum 10 revolutions)
same position.
IM
9a Gearbox, input Rotate the gearbox (minimum 10 revolutions)
Rotate the motor shaft (minimum 10 revolu-
12 Drive motors
tions)
EL
Maintenance work once a year

Pos. in Fig. 88
Machine component
Operations Remarks
Assembly
PR
Spray on corrosion protec-

5 Decanter housing Renew the corrosion protection. tion wax (WS Part-No.
6969-0022-010)
Spray on corrosion protec-
17 Drive frame Renew the corrosion protection. tion wax (WS Part-No.
6969-0022-010)
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Maintenance work before resuming operation

Pos. in Fig. 88
Machine component
Operations Remarks
Assembly
2 Feed tube bearing Re-lubricate roller bearing. The required work will be
Y
Scroll bearings / carried out by Westfalia
4 Re-lubricate roller bearings. Separator Service
Liquid side
When wear, damage or
corrosion is detected on
AR
6 Bowl and scroll Check wear. load-bearing bowl parts,
contact Westfalia Separa-
tor Service.
Protective ring and The required work will be
7 bushes / solids dis- Check wear and replace when necessary. carried out by Westfalia
charge Separator Service
13 V-belts Mount belts. See page 67
1 Feed tube
IN
Check the condition of the slide-ring packing.
Check whether
carried out by Westfalia
Separator Service
Consult Westfalia Separa-

Vibration isolators / – the bellows are damaged
14 tor Service if defects are
Housing – liquid (damper medium) is discharging
detected.
IM
impurities have penetrated the system
Drain the preserving oil.
Clean oil tank. CLP HC 2x
16 Oil lubrication system carried out by Westfalia
Renew oil filter. 68 60 litres
Separator Service
Fill in lubricating oil.
Vibration isolators /
11 Check condition.
EL
Drive frame
3
Bowl bearings Check torques of the fastening screws. See page 60
10
While the machine is running: Pay attention to motor

12 Drive motor
Re-lubricate the motor bearings. plate.
PR
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5.5 Storing wearing parts and operating media

When storing wearing parts and operating media please note the following.
5.5.1 Gaskets and V-belts

The physical properties of rubber and caoutchouc products change under unfa-
vourable storage conditions. The consequence is
• reduced life time
• defective condition.
Y
Gaskets and V-belts are capable of keeping their physical properties for several
years, provided they are stored in accordance with the following instructions.
Required storage room:
AR
• cool (+ 15° up to max. + 25°C)
• dry ( < 65 % humidity)
• dust-free
• dark, no direct sunlight or artificial light (if possible, paint windows red or or-
ange)
• moderate, draught-free ventilation (if necessary, wrap or pack parts in foil or
bags of paper, polyethylene or polyamide).
Surroundings:
Do not store
IN
• in the vicinity of sources of heat,
• together with solvents, fuels, lubricants, acids, disinfectants, etc.
IM
Storage:
• Without strain, i. e. without tension, pressure or change in dimensions.
• Avoid contact with different materials.
• Avoid direct contact with metals (especially copper and manganese have a
damaging effect on rubber products).
EL
• V-belts are preferably hung up on so-called "saddles" or pipes of large diame-

ters. The diameter should be 10 times the height of the V-belt section.
• To save space, V-belts of greater length can be piled one on top of the other,
provided they are put together properly.
• V-belts of smaller length may be stored in shelves. The piles of belts should
not be higher than 300 mm, in order to avoid deformation of the belts.
PR
• Hooks and nails are not suitable for hanging the belts on.
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5.5.2 Roller bearings

The roller bearings should be stored in their original packing. It should not be
removed until the bearing is installed. Otherwise there is the risk that the bear-
ings get dirty and rust.
Larger bearings which have rings with relatively thin walls should not be stored
in upright position. They must be stored lying, supported over their whole length.
Roller bearings are immersed in slushing oil before being packed. This oil does
not harden and resinify and does not affect other commercially available roller
bearing greases. The original packing gives the roller bearings protection
Y
against attack from the outside.
This protection lasts only for a longer period, if the packed bearings are stored
in a dry (humidity max. 60 %) and frost-free room.
AR
Aggressive chemicals such as acids, ammonia or chlorinated lime are not al-
lowed to be stored in this room.
5.5.3 Lubricants
Always keep lubricant containers tightly closed and store them in closed rooms.
Avoid large temperature fluctuations as they cause respiration of the containers.
As a result, moisture penetrates into the containers.
Clean the lubricant containers before opening them to prevent contaminants
IN
from getting into the lubricant. Even the smallest foreign matter in the lubricant
can drastically reduce the life of the roller bearings.
IM
EL
PR
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AR
IN
IM
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Westfalia Separator
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IN
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GEA Mechanical Equipment

Werner-Habig-Str. 1, 59302 Oelde (Germany)
Phone +49 2522 77-0, Fax +49 2522 77-2488
ws.info@geagroup.com, www.westfalia-separator.com

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1.4.

7 Standard Instruction Manual (O&M)

GEA Mechanical Equipment / GEA Westfalia Separator

Designation Clarifying decanter (thickener)

GEA Mechanical Equipment / GEA Westfalia Separator Group

ORIGINAL INSTRUCTION MANUAL

GEA Mechanical Equipment

Max. admissible rated bowl speed in min-1

Max. permissible density in kg/dm3 of product

Heavy liquid kg/dm3 IN Solids kg/dm3

min/max temp. of product in °C

min/max housing pressure in bar

For your safety

• Warning in case of danger to machine parts. Strictly adhere to

• Refer to the instruction manual.

• Maintain the decanter as specified in this instruction manual.

• Liability for the function of the machine passes to the owner.

the machine is improperly maintained or serviced by persons other

1.1 Correct usage ........................................................................................ 10

2.1 Schematic .............................................................................................. 22

3.3.3 Production .............................................................................................. 40

3.8.5 Oil pump doesn't start ............................................................................ 44

4.1 Avoiding accidents during maintenance work ....................................... 46

4.13.4 Filling in new oil ..................................................................................... 78

4.16 Relubricating the bearings on the rotating feed tube ............................. 81

5.1 Important instructions on long-term storage .......................................... 84

5.4 Maintenance schedule (machine shut-down long-term)........................ 89

1.1 Correct usage

1.3 Safety markings on the decanter

This multi-sticker is attached to every

Meaning of the stickers:

• Warning against hot surfaces.

• Never manipulate the frequency

• Use only genuine spare parts from Westfalia

1.5 Operations on the decanter

The decanter works reliably, provided

that it is operated and looked after in

Special attention must be given to:

1.5.1 Before start-up

• The bowl must rotate in counter-

• The decanter may only be operated

• Check that the product paths are set

• Wear ear protection.

• Do not feed product which is catego-

• When processing products harmful

• Shut down the decanter immediately

• The bowl is not allowed to run with-

minutes, as otherwise it would result

1.5.3 Voltage cut-off during operation

If the voltage is interrupted for more

1.5.4 Shut-down and “Emergency Stop”

• In an emergency situation, press

1.5.5 Maintenance and servicing

Particularly highly stressed parts of the

out by the manufacturer or by "central repair shops" authorized by the manufac-

Before maintenance and servicing:

the main switch.

• Do not loosen any part before the

• Do not heat bowl parts with a na-

• Bowl parts must never be welded.

• Collect dripping oil to prevent danger

The surfaces most susceptible to ero-

Signs of erosion which you should