Professional Documents
Culture Documents
578150-02
6.3.2 Tools............................................................................... 56
6.3.3 Frame hood ................................................................... 58
6.3.4 Bowl ............................................................................... 61
6.3.5 Driving device................................................................ 71
6.3.6 Centrifugal clutch .......................................................... 83
6.4 Actions Before Assembly ..................................... 89
6.4.1 Cleaning ...................................................................... 89
6.4.2 Inspection for corrosion ............................................... 91
6.4.3 Inspection for cracks ................................................... 92
6.4.4 Inspection for erosion .................................................. 93
6.4.5 Exchange of frame feet ................................................. 94
6.4.6 Lubrication of bowl parts ............................................... 95
6.4.7 How to lubricate bowl parts with slide laquer................ 96
6.4.8 Check for galling on operating slide and bowl body ... 97
6.5 Assembly .................................................................... 98
6.5.1 Centrifugal clutch .......................................................... 98
6.5.2 Driving device ............................................................. 104
6.5.3 Bowl ............................................................................. 116
6.5.4 Frame hood ................................................................. 130
6.5.5 Unbalance sensor (optional) ....................................... 133
6.5.6 Speed sensor (optional) .............................................. 134
6.6 Actions After Assembly....................................... 135
6.6.1 Control of machine plates and safety labels .............. 135
6.7 Oil Change ............................................................... 137
6.7.1 Lubricating oil .............................................................. 137
6.7.2 Check oil level ............................................................. 138
6.7.3 Oil change procedure.................................................. 138
6.7.4 Lubrication chart.......................................................... 139
6.7.5 Lubricants.................................................................... 140
6.7.6 Lubricating oils ............................................................ 144
6.8 Lifting instructions ............................................... 146
6.8.1 Lifting the separator..................................................... 146
6.8.2 Lifting the bowl ............................................................ 147
578150-02
7.2.2 Bowl fails to open for sludge discharge153
7.2.3 Unsatisfactory separation result153
7.2.4 Bowl fails to close154
8 Technical Reference.155
8.1 Product description155
8.2 Technical Data156
8.3 Connection List157
8.4 Interface Description159
8.4.1 Scope159
8.4.2 References159
8.4.3 Definitions160
8.4.4 Goal160
8.4.5 Description of separator modes161
8.4.6 Remote start162
8.4.7 Handling of connection interfaces163
8.5 Demand Specification Water169
8.6 Drawings170
8.6.1 Basic size drawing170
8.6.2 Foundation drawing171
8.6.3 Interconnection diagram172
8.6.4 Counter pressure173
8.6.5 Power consumption174
8.6.6 Operating water interface178
8.6.7 Electric motor180
9 Installation.181
9.1 Introduction181
9.2 Upon Arrival At The Storage Area182
9.2.1 Transport182
9.2.2 Protection and storage of goods
183
9.3 Planning of Installation184
9.3.1 Important measurements184
9.3.2 Maintenance service185
9.3.3 Connections to surrounding equipment186
9.4 Storage187
9.5 Before start-up187
578150-02
SEPARATOR MANUAL
6
578150-02
SEPARATOR MANUAL 1 READ THIS FIRST
Safety Instructions
Pay special attention to the safety instructions
for the separator. Accidents causing damage to
equipment and/or serious injury to persons or
personnel can result if the safety instructions
are not followed.
Operating Instructions
This chapter contains operating instructions for
the separator only.
578150-02 7
SEPARATOR MANUAL 1 READ THIS FIRST
Fault Finding
Refer to this chapter if the separator functions
abnormally.
If the separator has been installed as a part of a
processing system, always refer to the trouble-
tracing instructions, in the System
Documentation.
Technical Reference
This chapter contains technical data
concerning the separator and drawings.
Installation
This chapter contains specifications and
recommendations concerning separator
installation.
NOTE
8
578150-02
2 Safety Instructions
G0010421
x Stopping time is long
9
2 Safety Instructions
Disintegration hazards
S01512F1
x If excessive vibration occurs, stop
separator and keep bowl filled with
liquid during rundown.
S01512N1
x Use the separator only for the purpose
and parameter range specified by
Alfa Laval.
S01512P1
x Check that the gear ratio is correct for
power frequency used. If incorrect,
subsequent overspeed may result in a
serious break down.
S01512L1
x Welding or heating of parts that rotate
can seriously affect material strength.
S0151241
10
2 Safety Instructions
Entrapment hazards
S01512O1
S0151261
Assemble the machine completely
before start. All covers and guards must
be in place.
Electrical hazard
S0151271
lock power supply before starting any
dismantling work.
Crush hazards
Do not work under a hanging load.
S01512Y1
11
2 Safety Instructions
Noise hazards
S0151291
Burn hazards
S01512A1
Skin irritation hazards
S01512D1
protection etc.
x Use of lubricants in various situations.
12
2 Safety Instructions
Cut hazards
S01512B1
Flying objects
S01512C1
Health hazard
S01512V1
13
2 Safety Instructions
R
! DANGE
ING
WARN
!
ON
CAUTI
!
NOTE
14
2 Safety Instructions
Unpacking
Packing material consists of wood, plastics,
cardboard boxes and in some cases metal straps.
Wood and cardboard boxes can be reused,
recycled or used for energy recovery.
Plastics should be recycled or burnt at a licensed
waste incineration plant.
Metal straps should be sent for material recycling.
Maintenance
During maintenance oil and wear parts in the
machine are replaced.
Oil must be taken care of in agreement with local
regulations.
Rubber and plastics should be burnt at a licensed
waste incineration plant. If not available they
should be disposed to a suitable licensed land fill
site.
Bearings and other metal parts should be sent to
a licensed handler for material recycling.
Seal rings and friction linings should be disposed
to a licensed land fill site. Check your local
regulations.
Worn out or defected electronic parts should be
sent to a licensed handler for material recycling.
15
2 Safety Instructions
2.3 Requirements of
personnel
Only skilled or instructed persons are allowed to
operate the machine, e.g. operating and
maintenance staff.
x Skilled person: A person with technical
knowledge or sufficient experience to enable
him or her to perceive risks and to avoid
hazards which electricity/mechanics can
create.
x Instructed person: A person adequately
advised or supervised by a skilled person to
enable him or her to perceive risks and to
avoid hazards which electricity/mechanics
can create.
In some cases special skilled personnel may
need to be hired, like electricians and others. In
some of these cases the personnel has to be
certified according to local regulations with
experience of similar types of work.
16
SEPARATOR MANUAL 3 BASIC PRINCIPLES OF SEPARATION
G 08 70 11 1
Continuous separation and sedimentation can be
achieved in a settling tank having outlets
arranged according to the difference in density of
the liquids.
Heavier particles in the liquid mixture will settle Gravity
and form a sediment layer on the tank bottom.
Lighter
liquid
Heavier
liquid Sediment layer of
heavier particles
G 0 87 02 1 1
578150-02 17
SEPARATOR MANUAL 3 BASIC PRINCIPLES OF SEPARATION
G 0 87 03 1 1
Centrifugal force
3.3 Temperatures
For some types of process liquids (e.g.
mineral oils) a high separating temperature
will normally increase the separation
capacity. The temperature influences oil
viscosity and density and should be kept
constant throughout the separation.
G 0 88 6 01 1
G 08 85 91 1
18
578150-02
SEPARATOR MANUAL 4 DESIGN
4 Design
Process section
The feed inlet and outlets
are situated at the top of Electric motor
the separator. The rotating bowl is driven
by the electric motor via a
The liquid is cleaned in the belt transmission.
rotating separator bowl
inside the frame hood.
Sensors (optional)
Drive section
The separator can be
monitored by a speed The rotating separator
sensor, an unbalance bowl is driven by a flat
sensor and an interlocking belt transmission.
switch.
Frame feet
Sludge outlet
The separator rests
on vibration damping Separated solids are discharged at
frame feet. preset intervals.
G 0 8 70 68 1
4.1 Overview The inlet and outlet device contains the
processing parts of the separator; the inlets,
The separator comprises a process section and outlets and piping.
a drive section powered by an electric motor.
The process liquid is cleaned in the separator
The separator frame comprises a lower body bowl. The bowl is fitted on the upper part of a
and a frame hood. The motor is attached to the vertical spindle and rotates at high speed
frame. The frame feet dampen vibration. inside the frame hood. The bowl also contains
the discharge mechanism which empties the
The bottom part of the separator contains a flat
sludge during operation.
belt transmission, a centrifugal clutch and a
vertical spindle. The lower body also contains A speed sensor (option) and an unbalance
an oil sump for lubrication of spindle bearings. sensor (option) are part of the equipment for
monitoring the separator functions.
578150-02 19
SEPARATOR MANUAL 4 DESIGN
Flat belt
The flat belt transmission has a
ratio which increases the bowl
speed several times compared
with the motor speed.
20
578150-02
4 DESIGN SEPARATOR MANUAL
21
578150-02
SEPARATOR MANUAL 4 DESIGN
Paring disc
Connecting housing
G 08 8 61 81
22
578150-02
4 DESIGN SEPARATOR MANUAL
23
578150-02
SEPARATOR MANUAL 4 DESIGN
Bowl hood
Gravity disc
Top disc
Level ring Oil paring chamber
Disc stack
Bowl body Lock ring
Seal ring
Discharge
slide
Operating slide
Sludge space
Distributor support
G 08 86 9 91
Nozzle
Holder Distributor
24
578150-02
4 DESIGN SEPARATOR MANUAL
Purifier bowl
The illustration shows the characteristic part of 0
G 0 6 85 5A 1
Position of interface
An interface (1) is formed between the oil and
water in the bowl. In order to achieve optimum
separation of the oil, the interface must be
maintained in the correct position, which is
between the disc stack and the outer edge of
the top disc. If the interface moves outside the
outer edge of the top disc the water seal will
break and oil will be discharged with the water.
An interface positioned inside the disc stack
G 0 0 47 03 1
will cause bad separation results.
The position of the interface is adjusted by
altering the pressure balance of the liquid
phases oil and water inside the separator,
which is done by exchanging the gravity disc.
For this purpose a number of gravity discs with
various hole diameters are delivered with the
separator.
25
578150-02
SEPARATOR MANUAL 4 DESIGN
G 00 11 72 1
C. Wrong interface position - bad separation
26
578150-02
4 DESIGN SEPARATOR MANUAL
G 0 01 18 2 1
A. High viscosity/density/ B. Low viscosity/density/
throughput throughput
2 Gravity disc
To compensate for the above factors the
interface is adjusted to a correct position by
altering the outlet for the water, i.e. exchanging
the gravity disc. Changing to a gravity disc
with a larger hole diameter will move the
interface towards the bowl periphery, whereas,
a disc with a smaller hole diameter will move
the interface closer to the bowl centre.
G 0 0 11 92 1
A. Gravity disc with large B. Gravity disc with small
hole diameter hole diameter
27
578150-02
SEPARATOR MANUAL 4 DESIGN
Clarifier bowl
The illustration shows the characteristic part of 0
G 0 6 85 5B 1
28
578150-02
4 DESIGN SEPARATOR MANUAL
discs.
Clarification
When running the separator as a clarifier,
select the gravity disc with the smallest hole
diameter, the so-called clarifier disc. Use the
biggest level ring for clarification. See the
Spare Parts Catalogue for correct hole
diameter.
G 0 68 55 A 1
Purification
A number of gravity discs are delivered for
operating the separator as a purifier. The
diameter of a gravity disc sets the position of
the oil-water interface in the separator. The
separation efficiency can be optimized by
selection of the correct diameter for each
process.
When selecting a gravity disc the general rule
is to use the disc having the largest possible
hole without causing a break of the water seal.
The heavier or more viscous the light phase
(oil) and the larger the liquid feed the smaller
the diameter should be.
To remove more of the light phase (oil) from the
heavy phase (water), the interface should be
placed nearer the bowl centre, however not
inside the outer edge of the discs (too small
gravity disc), as this would prevent the liquid
flow.
For a more detailed description of the interface
position, see ‘‘ Purifier bowl” on page 25.
Some gravity discs have four small holes drilled
outside the large hole. You must pay regard to
these holes when measure the hole diameter Ø,
see the illustration. Measure between the
G 0 73 2 92 1
29
578150-02
SEPARATOR MANUAL 4 DESIGN
30
578150-02
4 DESIGN SEPARATOR MANUAL
66,5
0,90 0,90
70,3
Density Ratio
900
75
0,85 0,85
81
850
0,80 0,80 88
800
0,75 0,75
15 25 35 45 55 65 75 85 95 105 0 1 2 3 4 5 6 7 8
3
t, °C m /h
G 0 8 69 7A 1
NOTE
31
578150-02
SEPARATOR MANUAL 4 DESIGN
Example I in nomogram
Reference in graph:_________________
Oil density:945 kg/m3 at 15 °C
Separating temperature:75 °C
Throughput:3 m3/h
The nomogram indicates that a gravity disc
with a hole diameter of 66,5 mm should be
tried.
r = Density of oil in kg/m3 at 15 °C
Q = Throughput in m3/h
T = Separating temperature in °C or °F
D = Density ratio
Example II in nomogram
Reference in graph:_ _ _ _ _ _ _ _ _ _
Oil density:845 kg/m3 at 15 °C
Separating temperature:55 °C
Throughput:6 m3/h
The nomogram indicates that a gravity disc
with a hole diameter of 81 mm should be tried.
32
578150-02
4 DESIGN SEPARATOR MANUAL
Unbalance sensor
Speed sensor
G 08 73 47 1
33
578150-02
SEPARATOR MANUAL 4 DESIGN
Level ring
Unseparated oil
Separated oil
G Water
R
Top disc
A Distributor
V
I Oil/water interface
T
Unseparated oil
G 08 86 4 71
Y
Separated oil
Water
SETTLING TANK
34
578150-02
4 DESIGN SEPARATOR MANUAL
35
578150-02
SEPARATOR MANUAL 4 DESIGN
Unseparated oil
Water
Separated oil
Water chamber
Bowl hood
Top disc
Oil paring chamber
Sludge
space
Oil/water interface
Uncleaned oil
Cleaned oil
G 0 8 86 28 1
36
578150-02
SEPARATOR MANUAL 5 OPERATING INSTRUCTIONS
5 Operating Instructions
These operating instructions describe routine
procedures to be followed before and during
the start sequence, during the running and
stopping sequence of the separator.
578150-02 37
SEPARATOR MANUAL 5 OPERATING INSTRUCTIONS
ING
WARN
!
Breakdown hazard
Assemble the separator completely before start. All
couplings, covers, and guards must be in place and properly
tightened. Non compliance may lead to breakdown.
ING
WARN
!
Electrical hazard
Follow local regulations for electrical installation and
earthing (grounding).
G 08 70 6B 1
ING
WARN
!
Breakdown hazard
Check that the power frequency is in agreement with the
machine plate. If incorrect, resulting overspeed may cause 50 Hz?
breakdown. 60 Hz?
P0 0 39 92 A
ING
WARN
!
Use the separation system for the purpose, and within the
limits, specified by Alfa Laval. Failure to do so could cause a
violent breakdown.
38
578150-02
5 OPERATING INSTRUCTIONS SEPARATOR MANUAL
x Remove the oil pin and make sure that the oil
level is above the lower end of the pin see
‘‘6.7.2 Check oil level” on page 138.
NOTE
NOTE
G 08 68 7K 1
39
578150-02
SEPARATOR MANUAL 5 OPERATING INSTRUCTIONS
5.3 Start
1 Make sure that the bowl is clean and that the separator is properly assembled and check..
G 0 87 06 B 1
... the oil sump level.
Top up if necessary
ON
CAUTI
!
Disintegration hazards
After change of feed the sludge discharge interval
must be adjusted.
Breakdown may result if the intervals between
discharges are too long.
40
578150-02
5 OPERATING INSTRUCTIONS SEPARATOR MANUAL
1 Start of separator
G 0 8 71 78 1
41
578150-02
SEPARATOR MANUAL 5 OPERATING INSTRUCTIONS
NOTE
Normal vibration
Note the normal occurrence of critical speed periods.
Some vibrations occur for short periods during the
starting cycle, when the separator passes through its
critical speeds. This is normal and passes without
danger. Try to learn the vibration characteristics of
the critical speed pattern.
ING
WARN
!
Excessive vibration
If vibration increases, or
continues at full speed, keep
bowl filled and stop the
separator.
The cause of the vibration must
G 0 8 71 87 1
be determined and corrected
before starting again!
Excessive vibration may be due
to incorrect assembly or
insufficient cleaning of the bowl.
NOTE
42
578150-02
5 OPERATING INSTRUCTIONS SEPARATOR MANUAL
3 Ensure that the separator is at full speed (after about 190 - 210 seconds).
G 08 71 9 21
see ‘‘8.2 Technical Data” on page 156
4 For purification:
Supply water to form the water-seal. The
water should have the same temperature as
the process liquid.
a. Close the water feed when water flows
out through the water outlet.
b. Start the oil feed slowly to avoid
breaking the water seal.
5 For clarification:
a. Start the oil feed with full flow.
43
578150-02
SEPARATOR MANUAL 5 OPERATING INSTRUCTIONS
5.4 Operating
1 Checkpoints during operation:
ING ING
WARN WARN
! !
44
578150-02
5 OPERATING INSTRUCTIONS SEPARATOR MANUAL
1 Performing a discharge
G08 7 06 C1
NOTE
45
578150-02
SEPARATOR MANUAL 5 OPERATING INSTRUCTIONS
G0 87 0 6C1
ING
WARN
!
Entrapment hazard
Make sure that rotating parts have come
to a complete standstill before starting
any dismantling work.
46
578150-02
5 OPERATING INSTRUCTIONS SEPARATOR MANUAL
G 08 71 27 1
NOTE
ING
WARN
!
Disintegration hazard
Never discharge a vibrating
separator.
G 08 7 13 71
ING
WARN
!
ING
WARN Entrapment hazard
!
Make sure that rotating parts
have come to a complete
Disintegration hazard standstill before starting any
After an emergency stop, the cause of the fault must be dismantling work.
identified.
If all parts have been checked and the cause not found,
contact Alfa Laval for advice before restarting the
separator.
47
578150-02
SEPARATOR MANUAL 5 OPERATING INSTRUCTIONS
Separator standstill
ING
WARN
!
Entrapment hazard
Make sure that rotating parts have come to a
complete standstill before starting any dismantling
work.
ING
WARN
!
Entrapment hazard
To avoid accidental start, switch off and lock power
supply before starting any dismantling work.
ING
WARN
!
Disintegration hazard
Do not start the separator after a emergency stop
without first remedying the cause of the emergency.
Make sure that the bowl is clean before restart.
48
578150-02
5 OPERATING INSTRUCTIONS SEPARATOR MANUAL
Separator reassembled
ING
WARN
!
Breakdown hazard
All couplings, covers, and guards must be in place
and properly tightened.
If not, a breakdown may result!
G 08 7 06 B1
49
578150-02
SEPARATOR MANUAL 5 OPERATING INSTRUCTIONS
50
578150-02
SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
The following directions for periodic Place the separator parts on clean, soft
maintenance give a brief description of parts to surfaces such as pallets.
be cleaned, checked and renewed at different 2 Inspect and clean the dismantled separator
maintenance intervals. parts according to the maintenance log and
The maintenance log for each maintenance description in ‘‘6.4 Actions Before
interval on page 53 gives a detailed list of Assembly” on page 89.
actions to be performed. 3 Fit all the parts delivered in the service kit
while assembling the separator as
described in chapter ‘‘6.5 Assembly” on
Inspection i i page 98.
An Inspection consists of an overhaul of the
4 When the separator is assembled, make
separator bowl, inlet/outlet and operating
final checks described in ‘‘6.6 Actions After
water device every 6 months or 4000 operating
Assembly” on page 135.
hours.
Seals in bowl and gaskets in inlet/outlet device
are renewed.
ING
WARN
!
Overhaul o
Disintegration Hazards
An Overhaul consists of an overhaul of the Separator parts that are either missing, worn
complete separator (including separator bowl, beyond their safe limits or incorrectly
assembled, may cause severe damage or fatal
inlet/outlet and operating device) every 18
injury.
months or 12000 operating hours. Seals,
bearings, friction blocks and flat belt in the
separator are renewed.
ON
CAUTI
Oil change !
578150-02 51
6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
M8 17 1,7 13 20 2 14,7
52 578150-02
6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Date: Signature:
Inspection
Overhaul
Check
53
578150-02
SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
Inspection
Overhaul
Check
Part i o Action Page Note
Frame
- Frame feet Renew frame feet (including washers 94 Has to be ordered
and screws) separately
- Drain and oil filling holes x x Renew washers 115
- Oil pin x x Renew O-ring 115
Driving device
- All parts x Clean 89
- All parts x Check for corrosion 91
- All parts x Check for cracks 92
- Bottom bearing housing x Renew O-ring 104
- Labyrinth ring holder x Renew labyrinth ring 105
x Renew O-ring 105
- Top bearing housing x Renew springs 107
- Flat belt x Renew flat belt 111
- Bowl spindle x Pre-lubricate and renew ball bearing 106
x Pre-lubricate and renew self-aligning
roller bearing 108
x Lubricate the spindle
x Measure the radial wobble 114
- Lubricating oil orifice x Renew O-ring 109
- Neck bearing cover x Renew O-ring 113
- Deflector ring x Renew O-ring 113
- Water inlet pipe x Renew O-ring 114
- Operating water cover x Renew seal ring and O-ring 114
- Fan x Renew the O-ring 110
Coupling
- All parts x Clean 89
- All parts x Check for corrosion 91
- All parts x Check for cracks 92
- Coupling hub x Renew single row ball bearings 98
x Renew snap rings 98
- Friction blocks x Renew friction pads (if they are worn) 98
or clean the pads if they are oily
Electrical motor
- Electrical motor x Lubricate if nipples are fitted. See sign ---
on motor
54
578150-02
6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Inspection
Overhaul
Check
Part i o Action Page Note
Signs and labels on separator
- Machine plate x Check attachment and legibility 135
- Power supply frequency x Check attachment and legibility 135
- Lifting instructions x Check attachment and legibility 135
- Safety labels x Check attachment and legibility 135
- Name plate x Check attachment and legibility 135
- Representative label x Check attachment and legibility 135
55
578150-02
SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
6.3 Dismantling
6.3.1 Introduction
The frame hood and heavy bowl parts must
be lifted by means of a hoist. Position the
hoist exactly above the bowl centre. Use a
lifting sling and lifting hooks with safety
catches.
NOTE
6.3.2 Tools
Special tools from the tool kit must be used
for dismantling and assembly, as well as
Standard tools (not included). The special
tools are specified in the Spare Parts Catalogue
and are illustrated at the beginning of each
dismantling section.
ING
WARN
!
Entrapment hazard
To avoid accidental start, switch off and lock-
out power supply before starting any
dismantling work.
56
578150-02
6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Standard Tools
3 4
1 2 6
7 12
9 11
10
8
13
14
G 09 11 6 61
1 Screwdriver
2 Torque wrench (capacity 0-200 Nm)
3 Drift ( Ø 4 mm)
4 Dial indicator with magnetic base
5 Hexagon head keys, various sizes
6 Heating equipment for bearings
7 Sliding calliper
8 Hammers (standard and soft-faced)
(not lead)
9 Pliers for internal snap rings
10 Pliers for external snap rings
11 T-handle with extension rod, sockets
(various sizes)
12 Spanners (various sizes)
13 Adjustable spanner
14 Shackle
57
578150-02
SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
Screw
Connecting housing
O-ring
G 0 8 63 3B 1
Screws
Support ring
G 0 86 05 M
Frame hood
1 Spanner (nut)
ING
WARN
!
G 0 8 63 4B 1
Entrapment hazard
To avoid accidental start, switch off and lock- O-ring
out the power supply before starting any
dismantling work.
58
578150-02
6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
ON
CAUTI
!
NOTE
59
578150-02
SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
Do not place
the hood
upside down.
G 08 6 36 F1
b Loosen the hood
by bending with
a screwdriver in
all grooves in the
hood.
60
578150-02
6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Bowl hood
Seal ring
O-ring
Gravity disc
O-rings
Top disc
Level ring
G 0 8 61 66 1
O-ring
O-rings
O-ring
Distributor
5
O-ring
Distributor support
3
Cap nut
4 Screw
6
Nut
Discharge slide
7
Rectangular ring
8 O-ring
9 Bowl body
10
G 0 86 05 I1
Rectangular ring
O-ring
1 Compressing tool (lock ring) Valve plugs
2 Lifting eyes
3 Spanner for nut (nut/discharge slide) Operating slide
4 Puller (discharge slide) Nozzle
5 Lifting tool (distributor, spindle) Rectangular ring
6 Puller (Bowl body)
7 Screw (lock ring) (M5) O-ring
8 Hexagon head key Holder
9 Chisel (seal ring)
Operating water ring
G 0 8 62 6P 1
61
578150-02
SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
4
1
Screw
NOTE
G 0 86 27 A 1
62
578150-02
6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
NOTE
Recommendation: Take
measurements with a calliper around
the bowl, between the upper edge of
the bowl body and the bowl hood, to
check that the bowl hood is being
pulled off straight up.
ING
WARN
!
Crush hazard
The top disc can adhere to the
bowl hood when lifting. Be
careful not to accidentally drop
G 08 6 28 I1
it.
63
578150-02
SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
3 Removing the top disc, level ring, and inlet and outlet pipe.
a Carefully tap out the top b Carefully prise off the level
disc, together with the ring.
gravity disc, and lift up the
bowl hood.
G 08 62 9 B1
4 Removing the seal ring.
a Place the bowl hood on a support b Turn the bowl hood upside down
and tap out a piece of the seal ring and remove the seal ring by
using a drift in the holes. carefully knocking pieces of the
seal ring out of the groove, using
the special tool: chisel.
NOTE
Seal ring
ING
WARN
!
hood.
Wear eye protection!
64
578150-02
6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
ON
CAUTI
!
Cut hazard
Sharp edges on the bowl
discs may cause cuts
G 0 86 31 A 1
6 Removing the distributor and distributor support.
Distributor support
G 0 8 62 6Q 1
65
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Nut Sling
Screw
G 09 23 86 1
for the frame hood in the frame. Fasten
a sling between the clamp and the
screw around the bowl body.
Clamp
66
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
NOTE
If discharge slide is
difficult to remove,
tap lightly on outside
edge with a soft
faced hammer.
Ring on tool
Puller rod
Discharge slide
Bowl body
ING
WARN
!
Crush hazard
The ring on the lifting tool must be
pushed down against the discharge
slide, otherwise the discharge slide
G 0 86 32 7 1
67
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
Left-hand thread!
G 08 60 6 71
10 Removing the bowl body
68
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
ING
WARN
!
G 0 86 08 21
Crush hazard
Support the bowl body when turning to prevent it from rolling.
NOTE
69
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
G 0 86 10 21
14 Removing the operating water ring.
a Remove and discard the screws.
New screws are included in the Inspection kit.
NOTE
70
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
G 0 85 79 7 1
G 08 57 85 1
7
1 Puller (spindle pulley, 4 Lifting tool
ball bearing). (spindle assembly)
2 Tool (bearing housing). 5 Drift (bottom bearing).
3 Cover puller 6 Sleeve (ball bearing in
(neck bearing cover). top bearing seat
7 Pin spanner (oil fan).
Seal ring
Air deflector
Operating water cover
O-ring
O-rings Spindle pulley
Deflector ring
Seal ring
Neck bearing cover Belt
O-ring
O-ring
Self-aligning roller
Fan bearing
Lubrication oil orifice
Snap ring
O-ring
Oil pump
Bowl spindle
O-ring
Plugs
G 08 58 07 1
Strainer
71
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G 0 85 8 13 1
2 Empty the oil sump.
72
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Screw
ING
WARN
!
Crush hazard
c Remove the flat belt from the motor pulley. The motor will come off if the screws
G 08 58 8A 1
are unscrewed.
73
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
G 0 85 89 3 1
5 Removing the neck bearing cover and deflector ring.
Cover
Frame
74
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
NOTE
NOTE
G 0 85 91 51
75
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
ING
WARN
!
Crush hazard
Do not rotate the spindle assembly
during lifting. The spindle
assembly may otherwise come
loose from the lifting tool.
G 09 07 8 31
76
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Make a support
~185 mm
~120 mm
~6,5 mm
free space
G 0 85 9 21 1
9 Removing the air deflector.
08 59 24 1
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE Key-grip
Left-hand
thread!
G 09 23 9 21
11 Removing the bottom bearing assembly.
NOTE
Lubrication oil orifice c Cover the the oil orifice and blow compressed
air through the bottom hole of the oil pump and
slowly ease out the lubrication oil orifice.
G 08 6 59 81
Compressed air
78
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
G 08 5 82 21
79
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
ING
WARN
!
NOTE
Vibration indicator
Piece of wood to
protect the spindle
threads.
NOTE
G 0 85 83 5 1
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
NOTE
G 0 85 8 6C 1
81
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
a Fit the tool into the bottom bearing holder and attach the
socket, extension rod and T-handle.
T-handle
Extension rod
Socket
Tool
82
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Ball bearings
Spacing ring
G 08 64 78 1
Belt pulley
Coupling
ING hub
WARN
!
Parallel pin
Entrapment hazard
To avoid accidental start, switch off and lock-
out power supply before starting any
dismantling work. Friction blocks
(3=60 Hz)
Make sure that machine has come to a complete Cover
standstill before starting any dismantling work
(takes about 22 minutes from switch off).
Snap ring
G 08 65 1 B1
NOTE
50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks
1
G 0 86 5 04 1
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
G 0 85 81 3 1
2 Loosen the flat belt, by tilting the motor.
Screw
ING
WARN
!
Crush hazard
G 0 8 58 8A 1
c Remove the flat belt from the motor pulley. The motor will come off if the screws
are unscrewed.
84
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
ING
WARN
!
Electrical hazard
If the cables are not disconnected during lifting
procedures, they may become damaged.
b Fit a sling to the c Tense the lifting sling to support the motor and
motor using a remove the screws. Lift the motor while supported.
shackle on the upper
part.
Weight of motor with
ING
coupling: approx. WARN
!
60 kg.
Crush hazard
If not supported, the motor with
coupling will drop when removing the
screws.
G 0 86 46 A 1
d Lower the motor onto a suitable pallet.
Friction blocks
(3=60 Hz)
Cover
Snap ring
NOTE
50 Hz = 5 Friction blocks
G 0 86 52 3 1
60 Hz = 3 Friction blocks
85
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
G 08 65 3 31
86
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Washer
Spring washer
Screw
Piece of wood
Puller tool
ING
WARN
!
87
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
Wooden support
Support
NOTE
88
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
6.4.1 Cleaning i o
Clean the separator parts according to the
diagram below. Afterwards, protect all cleaned
carbon steel parts against corrosion by oiling.
Frame and The external cleaning of the frame and motor should be Water and de-greasing agent.
motor restricted to brushing, sponging or wiping while the motor is
running or still is hot.
ING
WARN
!
Electrical hazard
Never wash down a separator with a direct
water stream.
Never play a water jet on the motor. Totally
enclosed motors can be damaged by direct
hosing to the same extent as open motors,
resulting in short-circuit and internal corrosion.
Clean the inside of the frame with a clean cloth and remove
visible particles.
89
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
ON
Cleaning of holder for operating slide, operating water CAUTI
ring and operating slide with nozzle. !
Use 10% acetic acid solution to dissolve lime deposits. The
acid should be heated to 80 °C. Cut hazard
Clean the nozzle on the operating slide using a soft iron wire Sharp edges on the separator
discs may cause cuts.
or a similar object.
Driving device Use a sponge or a soft brush and clean the oil orifice, bearing White spirit, cleaning-grade kerosene
holder and oil pump thoroughly. or diesel oil.
90
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Max. 0,2 mm
ING
WARN
!
G 0 2 05 24 1
Disintegration hazards
Always contact your Alfa Laval representative if
you suspect that the depth of the corrosion
damage exceeds 0,2 mm for bowl body and
bowl hood (0,5 for other parts) or if cracks have
been found. Do not continue to use the
separator until it has been inspected and given
clearance for operation by Alfa Laval.
Non-stainless steel Water or dampness Rust If damage exceeds 0,5 mm, contact
and cast iron parts Alfa Laval.
Stainless steel Chlorides or acidic Acidic solutions cause general Polish dark-coloured spots and
solutions corrosion. other corrosion marks with a fine
Chloride corrosion begins as small grain emery cloth. This may prevent
dark spots that can be difficult to further damage.
detect, and goes on to local damage If damage exceeds 0,5 mm (0,2 mm
such as pitting, grooves or cracks. for bowl body and bowl hood)
contact Alfa Laval.
Other metal parts “Aggressive” Possible corrosion damage can be If damage exceeds 0,5 mm, contact
environment in the form of pits and/or cracks. Alfa Laval.
ING
WARN
!
Disintegration hazard
Pits and spots forming a line may indicate
cracks beneath the surface.
All forms of cracks are a potential danger and
are totally unacceptable.
Replace any part where corrosion can be
suspected of affecting its strength or function.
91
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
ING
WARN
!
Disintegration hazard
All forms of cracks are potentially dangerous as
they reduce the strength and functional ability
of components.
Always replace a part if cracks are present.
ING
WARN
!
Disintegration hazards
Always contact your Alfa Laval representative if
you suspect that the depth of the damage
exceeds 0,2 mm for bowl body and bowl hood
(0,5 for other parts).
Do not continue to use the separator until it
has been inspected and given clearance for
operation by Alfa Laval.
92
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Lock ring
Bowl body and holder.
G 09 11 8 H1
distribution holes and wings
1 Inspect the bowl and inlet/outlet parts for 2 Replace parts if erosion is suspected.
erosion damages.
ING
NOTE WARN
!
Always contact your Alfa Laval representative if
you suspect that the depth of the damage Disintegration hazard
exceeds 0,2 mm for bowl body and bowl hood Erosion damage weakens parts by reducing
(0,5 for other parts). Do not continue to use the the thickness of the material.
separator until it has been inspected and Pay special attention to the pillars between
cleared for operation by Alfa Laval. the sludge ports in the bowl wall.
Replace parts if erosion is suspected of
affecting strength or function.
93 578150-02
SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
94
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
= Molykote 1000
Bowl hood
(apply D321)
Bowl body
(also apply D321 on guide pin)
Discharge slide
Operating slide
(apply D321)
Screw
Holder
G09 11 7 D1
95
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
1
1
NOTE
96
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
1
1
NOTE
b Using an emery cloth (e.g. No. 320) to smooth the
To avoid the risk of galling,
metal edges. the guiding surface of the
operating slide should be
primed with a slide laquer at
c Finish by polishing the damaged spots with polishing
every inspection service.
paper (e.g No. 600).
97
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
6.5 Assembly
a Slip the belt pulley over the coupling hub and place them on a firm and level
foundation.
ING
WARN
!
Disintegration Hazard
If the belt pulley must be renewed, check that the new pulley has
the correct diameter. An incorrect pulley will cause the
separator bowl to run at either an excessive or insufficient
speed. NOTE
d=283 mm 50 Hz
d=235 mm 60 Hz Remove rust from the
belt pulley using a steel
brush.
Mounting tool
c Press the ball bearings down one at a time into the coupling
hub, preferably using a hydraulic press. Place the spacing
ring between them.
NOTE
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
NOTE
Piece of wood
99
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
Guide pin
NOTE
NOTE
50 Hz = 5 Friction blocks
Be sure that the pins on the
60 Hz = 3 Friction blocks
back of the blocks project into
the grooves in the clutch hub.
Snap ring
Cover
G 0 86 54 51
100
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
ING
WARN
b Lower the motor (while !
supported) on to the
separator frame.
It will set on the ledge.
Crush hazard
If not supported, the motor
with coupling may drop
when lifted.
G 0 86 46 A 1
d Connect the electrical cables.
NOTE
101
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
NOTE
For correct
position, centre
the belt on the
spindle pulley
Clearance camber.
NOTE
102
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
G 0 85 8 14 1
103
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
Socket
Tool
104
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Frame
a Lubricate and fit the
labyrinth ring o .
G 0 86 63 7 1
105
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
3 Fitting the ball bearing and top bearing seat o to the spindle.
a Heat the top bearing seat in oil to b Fit the ball bearing.
maximum 125 °C.
ING
WARN NOTE
!
Always fit a new bearing.
Burn hazard Pre-lubricate before fitting.
Use protective
gloves when
handling any
heated parts.
ING
WARN
!
NOTE
106
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Axial springs
b Carefully lower the bowl spindle.
Make sure that the springs enter the
recesses on the top bearing seat.
~2 mm
107
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
G 0 86 67 31
6 Fitting the self-aligning roller bearing o .
ING
WARN
!
Burn hazard
Use protective gloves when
handling the heated bearing.
G 0 86 68 41
108
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
a Fit O-ring o onto lubrication oil orifice. Spread oil c Lubricate all threads before
film on O-ring. assembly.
b Push lubrication oil orifice into oil pump. Be sure to
line up tabs on orifice with slots in pump.
NOTE
G 08 6 69 61
109
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
NOTE
G 0 92 4 03 1
9 Fitting the air deflector.
G 0 85 92 41
110
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
ING
WARN
!
Crush hazard
Do not rotate the spindle assembly during lifting. The spindle
assembly may otherwise come loose from the lifting tool.
NOTE
Check that the hole at the bottom of the oil pump is clean
before lowering the assembly down.
ING
WARN
! Space
Cut hazard
Do not put fingers between the frame
and air deflector while lowering the
assembly.
NOTE
111
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
For correct
position, centre
the belt on the
spindle pulley
Clearance camber.
NOTE
G 0 85 8 8B 1
112
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
G 08 68 05 1
113
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
O-ring
NOTE
G 08 68 14 1
14 Measuring the radial wobble of the bowl spindle.
Max. 0,04 mm
G 0 85 87 1 1
114
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
G 08 58 1 41
a Fit the clutch cover.
NOTE
G 0 8 68 7G 1
c Fill with new oil until oil flows out from
the filler hole.
For correct oil volume see ‘‘Technical
Data” on page 156.
NOTE
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
6.5.3 Bowl
Disintegration hazard
Impact marks may cause the separator
to vibrate while running.
G 08 74 6 11
2 Fitting new valve plugs on the operating slide i i .
a Remove the valve plugs using b Carefully tap in new valve plugs, using a
a drift. clean, soft-faced hammer.
Drift NOTE
116
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Alignment hole
Operating slide
Bowl body
Guide pin
G 0 86 12 41
4 Fitting the operating slide holder.
G 0 8 61 34 1
NOTE
117
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
a Fit the ring and screws i o .
It is very important not to refit used screws.
Always fit new ones included in the
Inspection kit!
NOTE
G 08 61 44 1
30 Nm + 2 Nm.
118
578150-02
6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
ING
WARN
!
Crush hazard
Support the bowl body when turning to
prevent it from rolling.
119
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
Left-hand thread!
Sling Screw
Clamp
G 0 86 18 7 1
Cap nut
120
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
O-ring
ING
WARN
!
c Fit the lifting tool and
lower the discharge
slide into the bowl. Crush hazard
The ring on the lifting tool must be
pushed home against the discharge
slide, otherwise it may come loose
from the tool.
d Remove the lifting tool.
e Fit the nut.
121
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
All parts have drill marks to b Fit the O-ring to the distributor support
be mounted in line with i .
each other.
G 08 62 6 R1
d Fit the distributor.
122
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
ON
CAUTI
!
Cut hazard
Sharp edges on the bowl discs may cause
cuts.
123
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
Guide rib on
distributor
124
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
G 0 86 2 2J 1
125
578150-02
SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
Gravity disc
Drill mark
Top disc
Guide lug
G 0 86 23 C1
126
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
127
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
c Release the
pressure on the
compressing
NOTE tool and
remove it.
Never remove
any material Lock ring
from the lock
ring. A
hazardous Bowl hood
situation could
result.
Bowl body
8 62 57 1
128
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
a Remove bowl hood, top disc and inlet and outlet pipe.
NOTE
Always refit the disc
without caulks on top
of the disc stack!
129
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
G 0 86 3 7J 1
NOTE
130
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
NOTE
G 09 11 5 P 1
131
578150-02
SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
NOTE
NOTE
Fit connections.
G 0 8 63 5B 1
132
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Sensor holder.
Sensor
holder
O-ring NOTE
NOTE
133
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
a Fit the sensor into the holder. Do not forget the nut.
Nut
Sensor
Nut.
+ = brown or red
J = black or white G 24 V DC
A
0V = blue
c When correct distance is achieved tighten the nut Adjustment value for the sensor is; 12 mA ± 1mA.
For more details see ‘‘8.3 Connection List” on page 157
against the holder. and ‘‘ 752 Unbalance sensor (option).” on page 165.
Fit the cover (see previous page).
G 0 87 3 4A 1
6.5.6 Speed sensor (optional)
page 33.
81 + 0,1 mm
134
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Machine plate
Safety label.
Lifting instructions
Space for
additional label as
specified.
S00 50 1 F1
135
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
Separator
Manufacturing serial No. / Year
Product No.
Inlet and outlet device
Bowl
Machine bottom part
Bowl speed synchronous
WARNING
! WA R N I N G
Read the instruction manuals before installation, operation and maintenance.
Consider inspection intervals.
XXXXXXXXXXXXXXXXX
XXXX XXXX XXXX
XXXXXXXXXXXX XXX
XXXXXXX XXXXX XX
XXXXX XXXXXXX
XXX XXX X XXX XX XXXX
XXXX XX X X XXXXX XXX
X XXX XXXX XXX XX XX X
XX X XXXXX XX X XXXX
XXX XXX X XXXXXX
Failure to strictly follow instructions can lead to fatal injury.
XXXXXXXXX. X XXX X XXX. XXX XXX XXX X XXXXX
XXX X XXXX .
XXXXX XXX XXXX XXX
XXXXX XXXX X XXXX XXX XXXXX X XXXXX XX X
XX. XXX XX XXX XXX XX X.
If excessive vibration occurs, stop separator and keep bowl filled with liquid
XXXXXXX/XX,X XX
during rundown.
Out of balance vibration will become worse if bowl is not full.
Separator must stop rotating before any dismantling work is started.
136
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
NOTE
Always clean and dry parts (also tools) before lubricants are applied.
ON
CAUTI
!
137
578150-02
SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
ON Oil fill
CAUTI
!
Plug and washer
Burn hazard
The lubricating oil and various machine
surfaces can be sufficiently hot to cause burns.
6 Fill with new oil until oil flows out of oil filler
hole.
G 0 8 68 7K 1
NOTE
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Plugs (7)
G 0 87 54 71
Lubricating points Type of lubricant Interval
1 The oil bath. Bowl spindle bearings See ‘‘6.7.1 Lubricating oil” on page Oil change:
are lubricated by oil mist from the oil 137 Volume: ‘‘8.2 Technical Data” on 1. Continous operation: 4000 hours
bath. page 156 2. Seasonal operation:
Ambient temperature 0 to +55°C before every operating period
3. Short periods operation:
12 months even if total numbers of
operating hours is less than stated
above
2 Bowl spindle taper. Lubricating oil, only a few drops for At assembly
rust protection.
3 Bowl: Sliding contact surfaces, thread Pastes specified in ‘‘6.7.5 Lubricants” At assembly.
of lock nut and cap nut. on page 140
4 Rubber seal rings. Grease as specified in ‘‘6.7.5 At assembly
Lubricants” on page 140
5 Friction clutch bearings. The bearings are pre-lubricated with No need for extra lubrication.
grease.
6 Electric motor. Follow the manufacturer’s instructions. Follow the manufacturer’s instructions.
7 Plug thread Lubricating oil At assembly
(neck bearing assembly)
NOTE ON
CAUTI
!
Check and pre lubricate new spindle bearings
and those that have been out of service for one
month or longer. Check the oil level before start and
If not otherwise specified, follow the suppliers top up if necessary.
instructions about applying, handling and Do not overfill.
storing of lubricants.
139
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
6.7.5 Lubricants
Alfa Laval ref. 553217-01 rev. 10
NOTE
Bonded coatings:
140
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
141
578150-02
SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
142
578150-02
6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
NOTE
BP Energrease MP-MG2
Energrease LS2
Energrease LS-EP2
Castrol APS 2
Spheerol EPL 2
Shell Alvania EP 2
Albida EP2
SKF LGEP 2
LGMT 2
143
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
Standard Designation
Manufacturer Designation
BP Bartran 68
Bartran HV 68*
144
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
Manufacturer Designation
The list of recommended oil brands is not complete. Other oil brands may
be used as long as the follow the above standards and have equivalent
high quality as the brands recommended. The use of oil brands and other
lubricants other than recommended, is done at the full responsibility of
the user or oil supplier.
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
G 08 6 84 51
1 Remove the inlet and outlet device, the
frame hood and the bowl according to the
instructions in ‘‘6.3 Dismantling” on page 56.
NOTE
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6 SERVICE, DISMANTLING, ASSEMBLY SEPARATOR MANUAL
ING
WARN
!
Crush hazards
A falling separator can cause accidents
resulting in serious injury and damage.
Never lift the separator by any other method
other than described in this manual.
NOTE
Weight to lift 50 kg
1 Fit the lifting tool with lifting eyes to the bowl
assembly.
2 Check that the lock ring is mounted correctly
before lifting the complete bowl.
3 Lift the bowl using a sling with the proper
rating.
Tightening torque 35 - 45 Nm
NOTE
147
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SEPARATOR MANUAL 6 SERVICE, DISMANTLING, ASSEMBLY
148
578150-02
SEPARATOR MANUAL 7 FAULT FINDING
7 Fault Finding
These fault finding instructions are for the
separator only.
ING
WARN
!
- incorrect assembly
- incorrect disc stack compression
- bowl assembled with parts from other separators
Uneven sludge deposits in the sludge space. Dismantle and clean the separator bowl.
Height position of paring disc is incorrect. Stop the separator, measure, and if necessary,
adjust the height.
Bowl spindle bent. Renew the bowl spindle.
Bearing(s) damaged or worn. Renew all bearings.
The frame feet are worn out. Renew the frame feet.
Spindle top bearing spring broken. Renew all springs.
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7.1.2 Smell
Cause Corrective action
Normal occurrence during start while the friction None.
blocks are slipping. If smell continues when separator is at full speed,
stop the separator and replace friction blocks.
Oil level in oil sump too low. Check oil level and add oil if necessary.
7.1.3 Noise
Cause Corrective action
Height position of paring disc is incorrect. Stop the separator, measure and adjust the height.
Bearing(s) damaged or worn. Renew all bearings.
ING
WARN
!
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ING
WARN
!
ING
WARN
!
ING
WARN
!
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8 Technical Reference
8.1 Product description
Alfa Laval ref. 576624, rev. 0
NOTE
Operational limits:
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NOTE
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375 Inlet for discharge and make-up liquid See ‘‘Operating water interface” on page 178.
x Discharge water flow, set value 9,9 - 12,1 litres/minute
x Make-up water flow, set value 2,52 - 3,08 litres/minute
x Quality requirements See ‘‘Demand Specification Water” on page 169.
x Temperature < 80 oC
462 Drain of frame top part, lower Should be possible to drain liquids by gravity.
752 Position transducer for bearing holder (unbalance sensor) See page 159.
x Type Inductive analogue sensor
x Supply voltage 15 to 30 V DC
x Operation range (mild steel) 2 to 5 mm
x Output current analogue 4 to 20 mA
x Load resistance, RL Max. 1 k:
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8.4.1 Scope
This document gives information, requirements,
and recommendations about operational
procedures and signal processing for safe and
reliable operation of the separator. It is intended
to be used for designing auxiliary equipment and
control systems for the separator.
8.4.2 References
This Interface Description is one complementary
document to the separator. Other such documents
that contain necessary information and are referred
to here are:
x Interconnection diagram
x Connection List
x Technical Data
x Operating water interface
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8.4.3 Definitions
For the purpose of this document, the following
definitions apply:
x Synchronous speed: The speed the machine
will attain when it is driven by a three phase
squirrel-cage induction motor and there is no
slip in the motor and the drive system.
x Full speed: The synchronous speed minus
normal slip.
8.4.4 Goal
To eliminate situations that can cause harm,
i.e. injury, damage to health or property and
unsatisfactory process result are e.g.:
Situation Effect
Unbalance caused by uneven sediment Too high stress on bowl and bearing
accumulation in the bowl. system which might cause harm.
Too high bowl speed. Too high stress on bowl which might
cause harm.
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Starting means:
x The power to the separator motor is on.
x The bowl is rotating and accelerating
Running means:
x The power to the separator motor is on.
x The bowl is rotating at full speed.
x RUNNING is a collective denomination for a
number of sub modes which e.g. can be:
– STAND BY: Separator is in a waiting mode
and not producing.
– PRODUCTION: Separator is fed with
product and producing.
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Stopping means:
x The power to the separator motor is off.
x The bowl is rotating and decelerating.
x STOPPING is a collective denomination for a
number of sub modes which e.g. can be:
– NORMAL STOP: A manually or
automatically initiated stop.
– SAFETY STOP: An automatically initiated
stop at too high vibrations.
– EMERGENCY STOP: A manually initiated
stop at emergency situations. This stop
will be in effect until it is manually reset.
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Electrical connections
701 Separator motor.
The separator is equipped with a 3-phase DOL
- (direct on line) started motor. The separator
can also be started by a Y/D starter, but then
the time in Y-position must be maximised to 5
seconds.
There shall be an emergency stop circuit
designed according to EN 418 and a power
isolation device according to EN 1037.
There shall be a start button close to the
separator that shall be used for first start after
assembly of the separator.
There should be a counter to count number of
running hours.
There should be a current transformer to give
an analogue signal to the control unit about the
motor current.
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Fluid connections
Complementary information is given in the
document Connection List.
201 Inlet
Processing in STAND STILL:
x Shall be closed.
Processing in STARTING:
x Should be closed. Bowl will be open and empty or
closed and filled depending on if start is done from
STAND STILL or STOPPING.
Processing in RUNNING:
x Could be closed or open (see Operating Water
Interface).
206 Inlet for liquid seal and displacement liquid
x See "Operating Water Interface
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x Shall be open.
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Poor quality of the operating water may with time cause erosion,
corrosion and/or operating problems. The water shall be treated
to meet certain demands.
NOTE
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8.6 Drawings
A B
X0 23 81 6 A
Connection house, with connections 201, 220 and 221, turnable in 60° steps all around.
All connections to be installed non-loaded and flexible
All dimensions are nominal. Reservation for individual deviations due to tolerances.
Data for connection, see ‘‘8.3 Connection List” on page 157.
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E
F
I
J
G L
M
H
A N
C
X0 23 8 17 A
B
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Junction box
Wiring without
junction box
Wiring of connector “X”: Wire colour codes:
RD=A BK=Black
BU=B BN=Brown
GN=C BU=Blue
YW=D RD=Red
WT=E GN=Green
BK=F PU=Purple
BN=G YW=Yellow
PU=H WT=White
G 0 86 75 61
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600
500
400
[ kPa ]
300
200
100
0
0 1 2 3 4 5 6 7 8
3
[ m /h ]
10 cSt
15 cSt
G 0 96 5 98 1
36 cSt
48 cSt
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5
[kW]
0
0 1 2 3 4 5 6 7 8
3
[ m /h ]
Min
150 kPa
G 09 6 59 91
300 kPa
Max
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5
[kW]
0
0 1 2 3 4 5 6 7 8
3
[ m /h ]
Min
150 kPa
G 0 96 5 9A 1
300 kPa
Max
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5
[kW]
0
0 1 2 3 4 5 6 7 8
3
[ m /h ]
Min
150 kPa
G 0 96 5 9B 1
300 kPa
Max
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5
[kW]
0
0 1 2 3 4 5 6 7 8
3
[ m /h ]
Min
150 kPa
G 0 96 5 9C 1
300 kPa
Max
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1 Close the operating slide valves by supplying discharge water (connection 372) for 5 seconds.
2 Pause for 15 seconds.
3 Close the bowl by supplying make-up water (connection 376) for 15 seconds.
4 Apply liquid seal by opening connection 206 for 9 seconds.
5 Open the feed (connection 201).
376
372
206
201
G 08 69 7B 1
0 5 10 15 20 25 30 35 40 45 50 55 60 65
Performing a discharge:
1 Close the feed (connection 201).
2 Perform a displacement (of the interface) by opening connection 206 for 10 seconds.
3 Initiate a discharge by supplying discharge water (connection 372) for 3 seconds.
4 Pause for 15 seconds.
5 Close the bowl by supplying make up water (connection 376) for 15 seconds.
6 Apply liquid seal by opening connection 206 for 9 seconds.
7 Open the feed (connection 201).
376
372
206
201
G 08 69 7 C1
-5 0 5 10 15 20 25 30 35 40 45 50 55 60
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Knockout openings
for M25 + M20 cable
glands on both sides. 4 holes M10x18
External earthing bolt
acc. to variant code 067
j6
G 09 38 2 91
point for IM2111 mounting Metal fan cover acc.
position. to variant code 053
Weight 42 kg
Note!
Poles 2
High output design (Genelec +1)
Insulation class F Cast iron bearing shield at N-end
Bearings D-end 6208-2Z/C3
N-end 6206-2Z/C3 NOTE
Method of cooling IC 411 (IEC 34-6) For complete information about motor variants,
please contact your Alfa Laval representative.
Spec. Totally enclosed three-phase
motor for marine service
Motor with feet and small flange.
180 578150-02
SEPARATOR MANUAL 9 INSTALLATION
9 Installation
9.1 Introduction
These installation specifications are valid for
the P 635 separator.
NOTE
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9.2.1 Transport
a When lifting the separator, make sure that tools and lifting
devices are fastened securely. See chapter ‘‘6.8.1 Lifting
the separator” on page 146.
ING
WARN
!
Crush hazards
Use correct lifting tools and follow lifting
instructions.
b When lifting the bowl see ‘‘6.8.2 Lifting the bowl” on page
147.
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The following protection products are b If there is a risk for water condensation, the
recommended: equipment must stand well ventilated and at
1 Anti-rust oil (Dinitrol 112 or equivalent) with long a temperature above dew point.
lasting effective treatment for external surfaces.
The oil should prevent corrosion attacks and
leaves a waxy surface.
2 Anti-rust oil (Dinitrol 40 or equivalent) is a thin
lubricant for inside protection. It gives a
lubricating transparent oil film.
3 Solvent, e.g. white spirit, to remove the anti-rust c If the storage time exceeds 12 months, the
oil after the storage period. equipment must be inspected every 6
4 Moisture remover to be packed together with months and, if necessary, the protection be
the separator equipment. renewed. G 08 73 65 1
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9.3 Planning of
Installation
G 08 7 37 41
Important measurements are:
- minimum lifting height for lifting bowl parts
- shortest distance between driving motor and wall
- space for control and operation
- free passage for dismantling and assembly
- space for maintenance work
- space on floor for machine parts during maintenance
work
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NOTE
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G 0 8 73 91 1
plant design approved by them.
Service media
Ensure that all service media (electric power,
operating and safety liquids etc.) required for the
separator have the correct quality and capacity.
G 0 8 74 02 1
Sludge discharge tank
If the sediment from the separator is discharged
into a tank, this tank must be sufficiently
ventilated. The connection between the
separator and the tank must be of the size and
configuration specified.
If the solids are discharged from the separator
bowl casing into a closed system, ensure that
this system cannot be overfilled or closed in such
a way that the solids cannot leave the bowl
casing. This could cause a hazardous situation.
G 0 87 4 31 1
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9.4 Storage
If the separator is out of operation for more
than 1 month:
1 Lift out the bowl.
2 Protect the spindle taper from corrosion by
lubricating it with oil.
3 Keep the separator and bowl well stored, dry
and protected from mechanical damage.
For details see ‘‘9.2.2 Protection and storage of
goods” on page 183
1 month or longer
x Pre-lubricate the spindle neck bearing.
6 months or longer
x Perform an Inspection service i i and make
sure to pre-lubricate the spindle bearings.
x Change the oil before starting.
G 08 68 7 L1
18 months or longer
x Perform an Overhaul service o and make
sure to pre-lubricate the spindle bearings.
x Change the oil before starting.
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