SU 840 - Service Manual - 2003

Separation Unit 840
Service Manual
Printed Jan 2003
Book No. 1810828-02 V 1
Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by: Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2003.
Contents
1 Separator Design ................................. 1 3.4 Actions Before Assembly ............74
1.1 Overview .............................................1 3.4.1 Cleaning .............................................74
1.2 The Drive Section.............................3 3.4.2 Inspection for corrosion ......................76
1.3 The Process Section .......................4 3.4.3 Inspection for cracks ..........................77
1.4 Sensors................................................8 3.4.4 Inspection for erosion .........................78
1.5 Separating Function ........................9 3.4.5 Exchange of frame feet ........................80
1.5.1 The liquid balance in the bowl ...............9 3.4.6 Lubrication of bowl parts ......................81
1.5.2 Liquid flow ............................................10 3.4.7 How to lubricate bowl parts with slide
laquer....................................................82
1.5.3 Discharge of sludge and water ............10
3.4.8 Check for galling on operating slide
1.5.4 ALCAPTM concept................................11
and bowl body .....................................83
2 Technical Reference ...................... 13 3.5 Assembly...........................................84
2.1 Technical Data ................................13 3.5.1 Centrifugal clutch .................................84
2.2 Connection List...............................15 3.5.2 Driving device.......................................90
2.3 Interface Description ....................17 3.5.3 Bowl ....................................................102
2.3.1 Scope ...................................................17 3.5.4 Frame hood ........................................115
2.3.2 References ...........................................17 3.5.5 Unbalance sensor (option) .................119
2.3.3 Definitions .............................................18 3.5.6 Speed sensor .....................................120
2.3.4 Goal ......................................................18 3.6 Actions After Assembly..............121
2.3.5 Description of separator modes ...........19 3.6.1 Control of machine plates and safety
labels .................................................121
2.3.6 Remote start .........................................20
3.7 Oil Change ......................................123
2.3.7 Handling of connection interfaces .......20
3.7.1 Lubricating oil .....................................123
2.4 Drawings ...........................................27
3.7.2 Check oil level ....................................124
2.4.1 Basic size drawing ...............................27
3.7.3 Oil change procedure.........................124
2.4.2 Foundation drawing..............................28
3.7.4 Lubrication chart.................................125
2.4.3 Interconnection diagram ......................29
3.7.5 Lubricants...........................................126
2.4.4 Electric motor .......................................30
3.7.6 Lubricating oils ...................................128
2.5 Nomogram paring tube.................32
3.8 Lifting instructions ......................129
3 Separator Service, 3.8.1 Lifting the separator............................129
Dismantling, Assembly ................. 35 3.8.2 Lifting the bowl ...................................131
3.1 Periodic Maintenance ...................35
4 Change of Circuit Board ............ 132
3.1.1 Maintenance intervals ..........................35
4.1 Circuit Board Temperatures .....134
3.1.2 Maintenance procedures .....................36
3.1.3 Tightening of screws ............................37 5 Cleaning in Place ........................... 135
3.1.4 Service kits ...........................................37 5.1 Cleaning in Place, Separator....135
3.1.5 Cleaning ...............................................38 5.2 Cleaning in Place, Heatpac®
3.2 Maintenance Log ............................39 CBM Heater ....................................136
3.3 Dismantling ......................................41 5.3 Cleaning in Place, Separator
3.3.1 Introduction...........................................41 and Heater ......................................138
3.3.2 Tools .....................................................42
6 Heatpac® CBM Heater
3.3.3 Frame hood ..........................................44
(Optional) ............................................. 139
3.3.4 Bowl......................................................46
6.1 Technical Data .............................139
3.3.5 Driving device ......................................56
6.1.1 Manual Cleaning.................................139
3.3.6 Centrifugal clutch .................................68
1810828-02
7 Heatpac® EHM Electric
Heater (Optional) ........................... 141
7.1 Technical Data ............................ 141
7.2 Dismantling and Cleaning......... 142
7.2.1 Replacing Heater Element................. 143
7.2.2 Insulation Resistance Megger Test ... 144
7.2.3 Measuring of Heater Block
Resistance ........................................ 146
8 Heatpac® Power Unit

(Optional) ............................................. 149
8.1 Technical Data ............................ 149
8.2 Working principle ........................ 150
8.3 Electric Heater Function ......... 150
8.4 Heating Performance
Principle ........................................ 151
8.5 Load Control and Functions..... 152
8.5.1 Variable Part Load ............................ 152
8.5.2 Fixed Part Load ................................ 152
8.5.3 External Safety Stop ......................... 153
8.5.4 Start and Reset Functions ................ 153
1810828-02
SEPARATION UNIT 840 SERVICE MANUAL 1 SEPARATOR DESIGN
1 Separator 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
Drive section
The separator is
monitored by a speed The rotating separator
sensor. An unbalance bowl is driven by a flat
sensor is optional. belt transmission.
Frame feet
Sludge outlet
The separator rests
on vibration damping Separated solids are discharged at
frame feet. preset intervals.
G0870641
1.1 Overview
The separator comprises a process section and a
drive section powered by an electric motor.
The separator frame comprises a lower body and
a frame hood. The motor is attached to the
frame. The frame feet dampen vibration.
The bottom part of the separator contains a flat
belt transmission, a centrifugal clutch and a
vertical spindle. The lower body also contains an
oil bath for lubrication of spindle bearings.
1810828-02 1
1 SEPARATOR DESIGN SEPARATION UNIT 840 SERVICE MANUAL
The frame hood contains the processing parts of

the separator; the inlets, outlets and piping.
The process liquid is cleaned in the separator
bowl. The bowl is fitted on the upper part of a
vertical spindle and rotates at high speed inside
the frame hood. The bowl also contains the
discharge mechanism which empties the sludge
during operation.
A speed sensor and an unbalance sensor (option)
are part of the equipment for monitoring the
separator functions.
2 1810828-02
1.2 The Drive Section

The separator bowl is driven by an electric
motor via a belt transmission. The belt pulley
on the motor shaft includes a centrifugal
clutch.
Flat belt
The flat belt transmission has a
ratio which increases the bowl
speed several times compared
with the motor speed.
To reduce bearing wear and the

transmission of bowl vibrations to The centrifugal clutch ensures a
the frame and foundation, the top gentle start and smooth acceleration,
bearing of the bowl spindle is and at the same time prevents
mounted in a spring dampened overloading of the belt and motor.
bearing seat.
The bearings on the spindle are

lubricated by the oil spray produced
by an oil pump mounted on the
lower end of the spindle.
G0870741
1810828-02 3
1.3 The Process Section

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

The inlet and outlet unit consists of the
following parts:
A connection house for pipe connections.
A pipe with a paring disc and a paring tube is
located inside the connection house. The pipe
has channels for incoming and outgoing
process liquid.
The paring disc and paring tube pump the
cleaned oil and water respectively out of the
bowl.
The paring tube can move radially. During
separation it surfs on the liquid surface. It is
balanced by a spring.
Under certain operating conditions, the paring
tube radial position can be locked in place by
two adjustable screws on the connection house.
The paring disc and tube are located inside and
at the top of the separator bowl.
The inlet and outlet device is held together
against the frame hood by a nut on the end of
the inlet pipe.
Height adjusting rings determine the height
position of the paring disc and paring tube
relative to the bowl.
4 1810828-02
Pipe
Spring
Uncleaned oil
Cleaned oil
Water
Arm
Paring tube
Paring disc
Connection house
G0886141
1810828-02 5
Separator bowl
The separator bowl, with its sludge discharge
mechanism, is built-up as follows:
The bowl body and bowl hood are held together
by a lock ring (Centrilock). Inside the bowl are
the distributor and the disc stack. The disc stack
is kept compressed by the bowl hood. The
discharge slide forms a separate bottom in the
bowl body.
The upper space between the bowl hood and the
top disc forms the water paring chamber and
contains the paring tube, which pumps the
separated water out of the bowl. The oil paring
chamber, with its paring disc, is located inside
the top of the distributor. From here the cleaned
oil is pumped out of the bowl.
The sludge space is in the bowl periphery. The
bowl is kept closed by the discharge slide, which
seals against a seal ring in the bowl hood.
At fixed intervals, decided by the operator, the
discharge slide drops down to empty the bowl of
sludge.
The sludge discharge mechanism, which controls
the movement of the discharge slide, is
comprised of an operating slide and an operating
water device. Passive parts are: nozzle and valve
plugs. The operating water cover, beneath the
bowl, supplies operating water to the discharge
mechanism via the operating water ring.
6 1810828-02
Water paring chamber

Bowl hood
Top disc
Oil paring chamber
Bowl body
Disc stack
Lock ring
Seal ring
Discharge
slide
Operating slide
Sludge space
Nozzle
G0886951
Holder Operating water ring
1810828-02 7
1.4 Sensors
The separator is equipped with a speed
sensor. As options, an unbalance sensor and
an interlocking kit can be fitted.
Speed sensor Monitoring kit (option)

A speed sensor indicates the speed of the separator. The For indication of any abnormal unbalance, the separator can
correct speed is needed to achieve the best separating be equipped with a sensor monitoring the radial position of
results and for reasons of safety. Refer to name plate for the bowl spindle.
speed particulars.
Cover interlocking kit (option)
When the cover is closed the interlocking circuit in the control
system is closed which makes it possible to start the
separator.
Cover interlocking switch
Unbalance sensor
Speed sensor G0873471
8 1810828-02
1.5 Separating Function

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

The liquid levels in the bowl depend on many
factors (bowl geometry, liquid densities, flow
rates etc.). To get a picture of how the liquids
are distributed in the bowl, imagine that the
bowl is at standstill and turned 90° (only
influenced by gravity). The bowl can now be
compared with a settling tank:
SEPARATOR BOWL TURNED 90°
Unseparated oil
Separated oil
Water
G
R
Top disc
A Distributor
V Oil/water interface
I
T
Y Unseparated oil
Separated oil
Water
SETTLING TANK
G0886431
1810828-02 9
1.5.2 Liquid flow

Unseparated oil is fed into the bowl through the
inlet pipe and travels via the distributor towards
the periphery of the bowl.
When the oil reaches slots in the distributor, it
rises through the channels formed by the disc
stack, where it is evenly distributed.
The oil is continuously cleaned as it travels
towards the centre of the bowl. When the cleaned
oil leaves the disc stack, it flows through a
number of holes in the distributor and enters the
oil paring chamber. From here it is pumped by
the oil paring disc, and leaves the bowl through
the oil outlet. Separated water, sludge and solid
particles, which are heavier than the oil, are
forced towards the periphery of the bowl and
collect in the sludge space.
The space between the bowl hood and top disc, as
well as the water paring chamber, is filled with
oil, which is distributed over the entire
circumference via the grooves in the top disc.
During normal operation, the water drain valve
in the water outlet is closed.
1.5.3 Discharge of sludge and water

As the sludge space fills up and water enters the
disc stack, traces of water will escape with the
cleaned oil. The increase of water content in the
cleaned oil is the sign of reduced separation
efficiency.
This condition is monitored by the process
control system, and water is removed from the
bowl when minimal levels are recorded.
The water is removed by either of two ways:
• The water drain valve opens and the water
leaves the bowl through the water outlet.
• Through the sludge ports at sludge
discharge.
Which way is decided by the process control
system.
10 1810828-02
1.5.4 ALCAPTM concept

When the sludge space is filled up and water
enters the disc stack, traces of water will escape
with the cleaned oil. The increase of water
content in the cleaned oil is the sign of reduced
separation efficiency.
This condition is monitored by the process
control system, and water is removed from the
bowl when minimal levels are recorded.
1810828-02 11
DISCHARGE OF WATER THROUGH WATER OUTLET
Unseparated oil
Bowl hood
Separated oil
Oil paring disc Water
Water paring tube

Water paring chamber
Oil paring chamber
Holes in distributor
Top disc
Sludge
space
Oil/water interface
Uncleaned oil
Cleaned oil
Water
G0886231
12 1810828-02
SEPARATION UNIT 840 SERVICE MANUAL 2 TECHNICAL REFERENCE
2 Technical Reference
2.1 Technical Data
Alfa Laval ref. 569604 rev. 2
NOTE
The separator is a component operating in an

integrated system including a monitoring system.
If the technical data in the system description does
not agree with the technical data in this instruction
manual, the data in the system description is the
valid one.
Product number: 881203-03-01

Separator type: S 840
Application: Cleaning of fuel and lube oil.
Technical design: Intended for marine- and land
installations.
Total discharge.
Designed in accordance with standards:
98/37EC The Directive of the European Parliament except for the council
relating to the machinery.
89/336EEC EMC and amendments related to said directive.
EN 292-2 Safety of machines. Use of the machine in applications subject to

hygienic demands requires a well adapted cleaning program.
Restrictions:
Feed temperature: 0°C to +100°C
Ambient temperature +5°C to +55°C
Discharge intervals: min. 2 minutes max. 4 hours.
Maximum allowed density of operating liquid: 1000
kg/m3.
Viscosity max. 700 cSt at 50°C.
Not to be used for liquids with flashpoint below
60°C.
Remote restart allowed under certain conditions,
see Interface description.
1810828-02 13
2 TECHNICAL REFERENCE SEPARATION UNIT 840 SERVICE MANUAL
Subject Value Unit

General technical data:
Motor power 9,5 kW
Gear ratio 292 / 82 50Hz
Gear ratio 243 / 82 60Hz
Alarm levels for vibration monitor,
connection 752, 1st/2nd 0,3 / 0,45 mm/s
Bowl max. inner diameter 279 mm
Discharge interval, min./max. 2/240 minutes
Max. density of operating liquid, max. 1000 kg/m³
Max. density of feed/sediment 1100 / 2425 kg/m³
Feed temperature, min./max. 0 / 100 °C
Max. running time without flow,
- empty bowl 60 minutes
- filled bowl 60 minutes
Bowl body material AL 111 2377-02
Operating data:
Bowl speed, synchronous 9220/9220 r/min 50Hz/60Hz
Motor speed synchronous 3000 / 3600 r/min 50Hz/60Hz
Max. power consumption 12 kW (at starting up) (50Hz/60 Hz)
Power consumption 3 / 7,5 kW (idling/at max. capacity)
Starting time, min./max. 1,7 / 2,3 minutes
Stopping time min./max. 25 / 30 minutes
Sound power 9,1 Bel(A)
Sound pressure 76 dB(A)
Vibration level, max. 5,6 / 9,1 mm/sec (new sep./sep. in use)
Volume and capacity data:
Max. hydraulic capacity, bowl 12 m³/h
Bowl liquid volume 4,3 litres
Fixed discharge volume 4 litres
Sludge volume, efficient/total 0,65 / 1,8 litres
Lubricating oil volume 2,7 litres
Weight information:
Motor drive 84 kg
Bowl 74 kg
Separator total 445 kg
14 1810828-02
2.2 Connection List

No. Description Requirements/limits
201 Inlet for process liquid

• Allowed temperature Min. 0 °C, max. 100 °C
• Max allowed density See demand specification
• Allowed flow Max 9 m3/h
206 Inlet for conditioning and displacement liquid

• Instantaneous flow 1,6 litres/minute
220 Outlet for light phase, clarified liquid

• Counter pressure 0 - 250 kPa
221 Outlet for heavy phase No counter pressure.
222 Outlet for solid phase

• Small discharge Total discharge
• Large discharge Max 24 discharge/h.
• Discharge frequency The outlet from the cyclone must always be
arranged to prevent the cyclone from being
filled up with sludge. Solids are discharged
by gravity.
375 Inlet for discharge and make-up liquid

• Quality requirements See ‘Technical Data’ in the Installation
System Reference.
• Max density Max. 1000 kg/m3
• Pressure min. 150 kPa
Make-up liquid
• Flow (momentary) 2,8 litres/minute
• Consumption 1,7 litres/hour
• Interval 5 minutes
• Time 3 seconds
Discharge liquid
• Flow 11 litres/minute
• Consumption 0,55 litres/discharge
• Time 3 seconds
Closing liquid
• Flow 2,8 litres/minute
• Consumption 0,7 litres/discharge
• Time 15 seconds
462 Drain of frame top section, lower
1810828-02 15
701 Motor for separator

Allowed frequency variation: ± 5%
(momentarily during 5 seconds) ± 10%
740 Speed sensor for bowl spindle See page 21.
• Type Inductive promixly switch
• Supply voltage, nominal 8V
• With sensor activated (near metal) Less or equal to 1 mA.
• With sensor not activated (far from metal) More or equal to 3 mA.
• Number of pulses per revolution 1
752 Position transducer for bearing holder See page 22.

• Type Inductive analogue sensor
• Supply voltage 18 to 30 V DC
• Operation range (mild steel) 0,5 to 2,5 mm
• Output voltage within sensing range 1 to 9 mA
• Load resistance, RL 400 Ohm
760 Cover interlocking switch

• Type Mechanical limit switch
• Switch rating, resistive load max. 3 A (at 48 V DC)
1 A (at 220 V AC)
16 1810828-02
2.3 Interface Description

2.3.1 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.
2.3.2 References
This Interface Description is one complementary
document to the separator. Other such
documents that contain necessary information
and are referred to here are:
• Interconnection Diagram
• Connection List
• Technical Data
Standards referred to are:

• EN 418 Safety of machinery - Emergency stop
equipment, functional aspects - Principles of
design
• EN 1037 Safety of machinery - Prevention of
unexpected start-up
• EN 954-1 Safety of machinery - Safety related
parts of control systems - Part 1 General
principles for design.
1810828-02 17
2.3.3 Definitions
For the purpose of this document, the following
definitions apply:
• Synchronous speed: The speed the machine
will attain when it is driven by a three phase
squirrel-cage induction motor and there is no
slip in the motor and the drive system.
• Full speed: The synchronous speed minus
normal slip.
2.3.4 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.
Access to moving parts. Can cause injury to person who

accidentally touches these parts.
Insufficient cleaning of separator. Unsatisfactory product quality.
Bowl leakage. Product losses.
Information and instructions given in this

document aim at preventing these situations.
Control and supervision can be more or less
comprehensive depending on the type of used
control equipment. When a simple control unit is
used it would be impossible or too expensive to
include many of the functions specified here
while these functions could be included at nearly
no extra cost when a more advanced control unit
is used. For this reasons functions that are
indispensable or needed for safety reasons to
protect the machine and/or personnel are
denoted with shall while other functions are
denoted with should.
18 1810828-02
2.3.5 Description of separator modes

For control purposes the operation of the
separator should be divided into different modes.
The normally used modes are described below
but other modes might exist.
It is assumed that:
• The separator is correctly assembled.
• All connections are made according to
Connection List, Interconnection Diagram and
Interface Description.
• The separator control system is activated.
If above conditions are not fulfilled the separator
will be in SERVICE mode.
Stand still means:

• The power to the separator motor is off
• The bowl is not rotating.
Starting means:
• The power to the separator motor is on.
• The bowl is rotating and accelerating
Running means:
• The power to the separator motor is on.
• The bowl is rotating at full speed.
• RUNNING is a collective denomination for a
number of sub modes which e.g. can be:
– STAND BY: Separator is in a waiting mode
and not producing.
– PRODUCTION: Separator is fed with
product and producing.
– CLEANING: Separator is fed with cleaning
liquids with the intention to clean the
separator.
1810828-02 19
Stopping means:
• The power to the separator motor is off.
• The bowl is rotating and decelerating.
• STOPPING is a collective denomination for a
number of sub modes which e.g. can be:
– NORMAL STOP: A manually or
automatically initiated stop.
– SAFETY STOP: An automatically initiated
stop at too high vibrations.
– EMERGENCY STOP: A manually initiated
stop at emergency situations. This stop will
be in effect until it is manually reset.
2.3.6 Remote start

This machine may be started from a remote
location under the following conditions;
• First start after any kind of service or manual
cleaning must be supervised locally in order
to ensure that no mistakes has been made
during assembly.
• The unbalance sensor is mandatory for
remote start.
• The installation must include equipment to
prevent unintentional start-up from remote
location when the machine is disassembled.
• The installation must include equipment to
prevent unintentional start of process flow
from remote location when the machine is not
properly connected to the piping.
2.3.7 Handling of connection

interfaces
Electrical connections
701 Separator motor.
The separator is equipped with a 3-phase DOL -
(direct on line) started motor. The separator can
also be started by a Y/D starter, but then the
time in Y-position must be maximized to 5
seconds.
20 1810828-02
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.
740 Speed sensor

A proximity sensor of inductive type according to
DIN 19234 (Namur) standard is giving a number
of pulses per revolution of the bowl (see
Connection List).
Signal processing in STARTING:
• The separator should be stopped
automatically according to NORMAL STOP
procedure and an alarm should be given
when the accumulated time for acceleration is
longer than the maximum time specified in
Technical Data. An abnormal start time
indicates some malfunction of the separator
equipment and should be investigated.
• If the speed exceeds “Bowl speed,
synchronous” in Technical Data with more
than 5% the separator shall be stopped
automatically by NORMAL STOP and a high
speed alarm shall be given.
• The speed monitoring system shall be
checked continuously (e.g by checking that
pulses are coming). In case of failure
indication the separator shall be stopped
automatically by NORMAL STOP with a timer
controlled stop sequence and an alarm for
speed monitoring system failure shall be
given.
• The acceleration should be supervised to
ensure that a certain speed (e.g 250r/min.)
has been reached within a certain time (e.g 30
seconds).
1810828-02 21
Signal processing in RUNNING:

• If the speed exceeds “Bowl speed,
synchronous” in Technical Data with more
than 5% for a period longer than 1 minute or
momentarily during maximum 5 seconds more
than 10% the separator shall be stopped
automatically by NORMAL STOP and a high
speed alarm shall be given.
• If the speed falls more than 10% below the
synchronous speed for a period longer than 1
minute or 15% during more than 5 seconds a
low speed alarm should be given. Low speed
indicates some malfunction of the separator
equipment and shall be investigated.
• The speed monitoring system shall be
checked continuously (e.g. by checking that
pulses are coming). In case of a failure
indication an alarm for speed monitoring
system failure shall be given. If there is a risk
of too high speed the separator shall be
stopped by NORMAL STOP.
• The speed drop during DISCHARGE.
compared to the measured speed
immediately before, should be between 3-8%
which will indicate a proper discharge.
Signal processing in STOPPING:
• STAND STILL shall be indicated when no
pulses are detected within 30 seconds.
• Stopping the separator when alarm for speed
monitoring system failure is active, shall cause
a timer controlled stop. (See “Stop time” in
Technical Data.)
752 Unbalance sensor (option).

For indication of any abnormal unbalance and to
be able to perform appropriate countermeasures,
the separator has been equipped with a vibration
velocity transducer on the separator frame. The
signal from the transducer shall be monitored
and two alarm levels according to the vibration
alarm levels in Technical Data should be set.
22 1810828-02
The vibration level shall be high for 3 seconds to

generate an alarm. The first level is only used to
generate an alarm while the second level shall
stop the machine.
The vibration monitor shall include self check
function to be performed at least at initiation of
STARTING.
If vibrations exceed the second alarm level the
separator shall be stopped the quickest way
possible and it shall not been restarted until the
reasons for the unbalance have been found and
measures to remove them have been taken.
If vibrations exceed the second alarm level the
separator shall be stopped automatically by
SAFETY STOP.
If the self check system triggers, an alarm shall
be given and an automatic stop by NORMAL
STOP shall be initiated.
Signal processing in RUNNING:
• If vibrations exceed the first alarm level an
alarm should be given. Vibrations of this
magnitude will reduce the expected life time
of the bearings and should therefore be
eliminated.
• If vibrations exceed the second alarm level
the separator shall be stopped automatically
by SAFETY STOP.
• If the self check system triggers, an alarm
shall be given.
Signal processing in STOPPING:
• If the self check system triggers, an alarm
shall be given.
Signal processing in NORMAL STOP:
• If vibrations exceed the second level the
system shall turn over automatically to
SAFETY STOP.
1810828-02 23
760 Cover interlocking switch (option)

The separator is equipped with a interlocking
switch to detect if the cover is mounted.
Signal processing in STAND STILL:
• The circuit is closed when the cover of the
separator is mounted.
• The interlocking switch should be connected
in such a way that starting of the motor is
prevented when the separator cover is not
mounted.
Signal processing in STARTING, RUNNING
and CLEANING:
• If the circuit is broken the separator should be
stopped automatically by NORMAL STOP.
This is to minimise the risk of having access to
moving parts.
Fluid connections
Complementary information is given in the
document Connection List.
201 Inlet
Processing in STAND STILL:
• Shall be closed.
Processing in STARTING:
• Should be closed. Bowl will be open and
empty or closed and filled depending on if
start is done from STAND STILL or
STOPPING.
Processing in RUNNING:
• Could be closed or open.
Processing in CLEANING:
• A sequence of cleaning liquids should be fed
to the separator. The flow rate should be as
high as possible and preferably not less than
the production flow rate.
24 1810828-02
Processing in NORMAL STOP or EMERGENCY

STOP:
• Could be closed or open but the bowl should
be filled unless the stop is initiated in
STARTING.
Processing in SAFETY STOP:
• Could be closed or open but the bowl shall be
filled unless the stop is initiated in STARTING.
206 Inlet for conditioning and displacement
liquid
• According to process
220, 221 and 222 Outlets

Processing in STAND STILL:
• Could be closed or open.
Processing in other modes:

• Shall be open.
375 Inlet for discharge and make-up liquid

Processing in all modes:
• It is recommendable to supervise the supply
pressure. If pressure is too low (see
Connection List), start should be interlocked
and if it happens in PRODUCTION or
CLEANING turn over to STAND BY should
take place.
• Below 85 % of synchronous bowl speed no
water supply may be made.
• When coming from PRODUCTION a
discharge shall be initiated to remove
sediments from bowl to avoid problems due to
solidification, see Connection List.
Signal processing in PRODUCTION:
• Automatic discharges shall be initiated by
timer or ALCAP system.
1810828-02 25
Signal processing in CLEANING:

• Automatic discharges shall be initiated by
timer or CIP-control system.
Signal processing in NORMAL STOP:
• Discharges should not be made.
Signal processing in SAFETY STOP and
EMERGENCY STOP:
• Discharges should not be made.
26 1810828-02
2.4 Drawings
2.4.1 Basic size drawing

206
B
201
220
221
701
C
975
932
875 899
740
22
2
752
380
330
291
462
28 A 38
222
300 629
45 O
88,5 O 113
90 75
O
22
158 167
2
D
25
mi
n.
32
28
E
F 4
F
E
375
201
206
85 220 ISO-G 1/2

760
221 375
O 17 ISO-G 1/2
G08676D1
462
G 10
25
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 2.2 Connection List, page 15.
A Tightening torque 160 Nm.

B Maximum horizontal displacement at the inlet and outlet
connections during operation ± 5 mm.
C Maximum vertical displacement at the sludge connection
during operation ± 2 mm.
D 4 holes M10
E M10 depth 30
F ø28, depth 45
G ø22, depth 45
1810828-02 27
2.4.2 Foundation drawing

F
E
I
J
A K
G
L
M
H
Total static load max. 4,5 kN.

B C
G0977611
A Centre of separator bowl.
B Holes for foundation bolts (8x).
C Centre of motor.
D Min. lifting capacity required during service: 300 kg.
E Max. height of largest component incl. lifting tool.
F Service side.
G Foundation bolts.
H Installation according to stated foundation force.
I Recommended free floor space for unloading when doing
service.
J No fixed installation within this area.
K Centre of gravity (complete machine).
L Dynamic forces (static force excluded)
From separator do not exceed;
Force in any separator feet;
Vertical ± 12 kN
Horizontal ± 12 kN
M Total foundation force (sum of all feet)
Vertical ± 12 kN
Horizontal ± 12 kN
28 1810828-02
2.4.3 Interconnection diagram

Interlocking switch (frame top part)
Unbalance sensor (position trans.

for bearing holder).
Speed sensor (bowl speed).
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
G0867541
Items showed in this document are not included in all

separators. See product specification.
Demand specification wire

Approval: UL 1007/1569
CSA TR-64
Area acc. to AWG 18
1810828-02 29
2.4.4 Electric motor

Alfa Laval ref. 562534 rev.2
Knockout openings Cast lifting lugs on both side.

for cable glands on
both sides.
4 holes
M10x18
External earthing
bolt
Note: The motor

bearings have
permanent Metal fan cover
lubrication
G0977511
Manufacturer ABB Motors Protection
Type of mounting
Manuf. drawing Cat. GB 96-10 class
Standards IEC 34-series, 72, 79 and 85
Size 132 SC IM 1001
Type M2AA 132 SC
Weight 56 kg IM 2101 IP 55
Poles 2
Insulation class F
IM 2111 IP 55
Bearings D-end 6208-2Z/C3
N-end 6206-2Z/C3
IM 2131 IP 55
Method of cooling IC 411 (IEC 34-6)
Spec. Totally enclosed three-phase

motor for marine service 2)
Motor with feet and small flange.
30 1810828-02
Article Output Speed Freq Voltage Current Pow.fac | st / |1) Note

No. kW rpm Hz V A cos j
562534-17 11 3455 60 690D 11,2 0,93 9,1
562534-16 11 3455 60 380D 20,3 0,93 9,1
562534-15 11 3455 60 230 D 33,5 0,93 9,1 -
562534-14 11 3455 60 220 D 35,0 0,93 9,1
562534-13 11 3455 60 575D 13,4 0,93 9,1 CSA- plated
562534-12 11 3455 60 480D 16,0 0,93 9,1 -
562534-11 11 3455 60 460D 16,7 0,93 9,1 -
562534-10 11 3455 60 440 D 17,5 0,93 9,1 -
562534-9 9,5 2855 50 230 D 29,1 0,94 8,8 -
562534-8 9,5 2855 50 220 D 30,4 0,94 8,8 -
562534-7 9,5 2855 50 690 D 9,7 0,94 8,8 -
562534-6 9,5 2855 50 660D 10,1 0,94 8,8 -
562534-5 9,5 2855 50 500 D 13,4 0,94 8,8 -
562534-4 9,5 2855 50 440 D 15,2 0,94 8,8 -
562534-3 9,5 2855 50 415 D 16,1 0,94 8,8 -
562534-2 9,5 2855 50 400 D 16,7 0,94 8,8 -
562534-1 9,5 2855 50 380 D 17,6 0,94 8,8 -
1) lst /l=starting current /rated current at direction line starting.
2) The motors can be designed to fulfil requirements of following Classification

Societies (Essential Service, if required).
Lloyds Register of Shipping (LRS)
Det Norske Veritas (DnV)
Germanischer Lloyd (GL)
Bureau Veritas (BV)
American Bureau of Shipping (ABS)
Registro Italiano Navale (RINA)
Nippon Kaiyi Kyokai (NK)
Korean Register of Shipping (KR)
Polski Rejester Statkow (PRS)
China Classification Societies (ZC)
Indian Register of Shipping (IRS)
Maritime Register of Shipping (IRS)
Required classification society must always be specified when ordering.
Factory test certificate to be enclosed at the delivery.
Rated output (kW) valid for temp-rise max. 90 °C.
The motors can be provided with space heaters for 110 V or 220 V, 25 W as
option.
1810828-02 31
2.5 Nomogram paring tube

Alfa Laval ref. 566504, rev. 0
Calculated level ring ø 80
G0938051
A Density ratio
32 1810828-02
G0938151
A Paring radius
B Position of adjusting screw
1810828-02 33
34 1810828-02
SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
3 Separator Service, Dismantling,

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

The following directions for periodic
maintenance give a brief description of parts to
be cleaned, checked and renewed at different
maintenance intervals.
The maintenance log for each maintenance
interval on page 39 gives a detailed list of actions
to be performed.
Inspection i i
An Inspection consists of an overhaul of the
separator bowl, inlet/outlet and operating water
device every 6 months or 4000 operating hours.
Seals in bowl and gaskets in inlet/outlet device
are renewed.
Overhaul o
An Overhaul consists of an overhaul of the
complete separator (including separator bowl,
inlet/outlet and operating device) every 18
months or 12000 operating hours. Seals,
bearings, friction blocks and flat belt in the
separator are renewed.
Oil change
The oil should be changed every 4000 hours, or
at least once every year if the total number of
operating hours is less than 4000 hours/year.
1810828-02 35
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL
3.1.2 Maintenance procedures

At each Inspection and/or Overhaul, take a copy
of the maintenance log and use it to make notes
during the service.
An inspection and overhaul should be carried out
as follows:
1 Dismantle the parts as described in 3.3
Dismantling, page 41.
Place the separator parts on clean, soft
surfaces such as pallets.
2 Inspect and clean the dismantled separator
parts according to the maintenance log and
description in 3.4 Actions Before Assembly,
page 74.
3 Fit all the parts delivered in the service kit
while assembling the separator as described
in chapter 3.5 Assembly, page 84.
4 When the separator is assembled, make final
checks described in 3.6 Actions After
Assembly, page 121.
R
! DANGE
Disintegration Hazards
Separator parts that are either missing, worn
beyond their safe limits or incorrectly assembled,
may cause severe damage or fatal injury.
ON
CAUTI
!
Burn and Corrode Hazards

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

dismantling/assembly instructions
Parts that have to be renewed from the service
kits (see below) are marked i i and/or o in
the assembly instructions.
36 1810828-02
Example:
a Fit the O-ring ii .
When dismantling and assembling between the

service periods, some procedures do not have to
be carried out. These procedures are marked
i i and/or o .
Example:
5 Renew the valve plugs on the operating slide
ii .
All symbols used in the instructions refer to
activities mentioned in the maintenance logs.
3.1.3 Tightening of screws

Tightening all screws with the correct torque
value is important.
These figures apply unless otherwise stated:
Torque
Metric Stainless steel Carbon steel

thread
Nm kpm Ib.ft Nm kpm Ib.ft
M6 7 0,7 5 8 0,8 5,9
M8 17 1,7 13 20 2 14,7
M10 33 3,4 24 39 3,9 28,7
M12 57 5,8 42 68 6,9 50
M16 140 14 100 155 15,8 114
M20 270 28 200 325 33 239
M24 470 48 340 570 58 420
The figures apply to lubricated screws tightened

with a torque wrench.
3.1.4 Service kits

Special service kits are available for Inspection
and Overhaul.
1810828-02 37
For other services, a Support kit is available.

Spare parts not included in the Support kit have
to be ordered separately.
Note that the parts for Inspection are included
in the Overhaul kit.
The contents of the kits are described in the
Spare Parts Catalogue.
NOTE
Always use Alfa Laval genuine parts as otherwise

the warranty may become invalid.
Alfa Laval takes no responsibility for the safe
operation of the equipment if non-genuine spare
parts are used.
ING
WARN
!
Disintegration hazards
Use of imitation spare parts may cause severe
damage.
3.1.5 Cleaning
CIP (Cleaning In Place)
To prolong the intervals between manual
cleaning of the separator the use of CIP together
with repeated discharges can be used.
Some CIP liquids can be corrosive to brass- and
aluminium alloy parts which are included in the
separator.
N
CAUTIO
!
Use only Alfa Laval recommended CIP liquids.
38 1810828-02
3.2 Maintenance Log
Name of ship/plant: Local identification:
Separator: S 840 Manufacture No./Year:
Total running hours: Product No.: 881203-03-01
Date: Inspection Signature:
Overhaul
Check
Part i o Action Page Note

Frame hood
- All parts x x Clean 74
- All parts x x Check for corrosion 76
- All parts x x Check for cracks 77
- Connecting housing x x Check for erosion damages 78
- Frame hood x x Renew O-ring 115
x Control measure of paring disc height 116
x Check height adjusting rings 116
Bowl
- All parts x x Clean 74
- All parts x x Check for corrosion 76
- All parts x x Check for cracks 77
- All parts x x Check for erosion damages 78
- Bowl body x x Check for impact marks and corrosion 102
x x Renew rectangular ring 103
x x Renew O-rings 104, 107
- Operating slide x x Renew rectangular ring 103
x x Renew valve plugs 102
- Discharge slide x x Renew rectangular ring 107
- In and outlet pipe x x Renew O-rings 110
- Paring tube x x Renew O-rings and bearings 110
- Bowl hood x x Renew seal ring 112
x x Renew O-ring 112
Frame
- Frame feet Renew frame feet (including washers 80 Has to be ordered
and screws) separately
- Drain and oil filling holes x x Renew washers 101
- Oil pin x x Renew O-ring 101
1810828-02 39
Inspection
Overhaul
Check
Part i o Action Page Note
Driving device
- All parts x Clean 74
- All parts x Check for corrosion 76
- All parts x Check for cracks 77
- Bottom bearing housing x Renew O-ring 90
- Labyrinth ring holder x Renew labyrinth ring 91
x Renew O-ring 91
- Top bearing housing x Renew springs 93
- Flat belt x Renew flat belt 97
- Bowl spindle x Pre-lubricate and renew ball bearing 92
x Pre-lubricate and renew self-aligning
roller bearing 94
x Measure the radial wobble 100
- Neck bearing cover x Renew O-ring 99
- Deflector ring x Renew O-ring 99
- Water inlet pipe x Renew O-ring 100
- Operating water cover x Renew seal ring and O-ring 100
- Fan x Renew the O-ring 96
Coupling
- All parts x Clean 74
- All parts x Check for corrosion 76
- All parts x Check for cracks 77
- Coupling hub x Renew single row ball bearings
- Friction blocks x Renew friction pads (if they are worn) 84
or clean the pads if they are oily
Electrical motor
- Electrical motor x Lubricate if nipples are fitted. See sign ---
on motor
Signs and labels on separator
- Machine plate x Check attachment and legibility 121
- Power supply frequency x Check attachment and legibility 121
- Lifting instructions x Check attachment and legibility 121
- Safety labels x Check attachment and legibility 121
- Name plate x Check attachment and legibility 121
- Representative label x Check attachment and legibility 121
40 1810828-02
3.3 Dismantling
3.3.1 Introduction
To disconnect the oil inlet, oil outlet, and
water outlet, undo the two screws on the
connection plate. Hook the plate, together
with the three hoses, to the edge of the small
work table to avoid oil draining from the
hoses.
The frame hood and heavy bowl parts must

be lifted by means of a hoist. Position the
hoist exactly above the bowl centre. Use a
lifting sling and lifting hooks with safety
catches.
The parts must be handled carefully. Don’t

place parts directly on the floor, but on a
clean rubber mat, fibreboard or a suitable
pallet.
NOTE
For safety reasons, it is essential that all personnel

who work with the separator read this manual
thoroughly and completely.
Do not allow personnel to clean, assemble, operate
or maintain the separator until they have read and
fully understood this manual.
Ensure that all personnel who operate and service
the separator are well-trained and knowledgeable
concerning the separator and the work to be carried
out.
1810828-02 41
3.3.2 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.
Make sure that machine has come to a complete

standstill before starting any dismantling work
(takes about 30 minutes from switch off).
42 1810828-02
Standard Tools
5
4
3
1
2 6
7 12
9 11
10
8
13
14
G0911641
1 Screwdriver
2 Torque wrench (capacity 0-200 Nm)
3 Drift ( Ø 4 mm)
4 Dial indicator with magnetic base
5 Spanner for clutch (55 mm)
6 Heating equipment for bearings
7 Sliding calliper
8 Hammers (standard and soft-faced)
9 Pliers for internal snap rings
10 Pliers for external snap rings
11 T-handle with extension rod, sockets
(13, 16, 17, 18, 19, 27, 30 mm)
12 Spanners (various sizes)
13 Adjustable spanner
14 Shackle
1810828-02 43
3.3.3 Frame hood Lock nut

Washer
Connecting
housing
Spring
Arm
G0863331
Screws
G0860531
1
Frame hood
1 Hook spanner (lock nut)
O-ring
ING
WARN Height adjusting
! rings
G0863441
Support ring
Entrapment hazard
To avoid accidental start, switch off and lock-out the

standstill before starting any dismantling work
(after about 30 minutes from switch off).
1 Removing the connecting housing.
a Remove the lock nut using the

hook spanner.
NOTE
ING Remove connections before

WARN starting dismantling.
!
The nut must not be b Press the pipe down to loosen

removed before the the connecting housing.
separator has stopped.
Remove the washer

c Remove the connecting housing
NOTE
.
Right hand thread.

G0863531
44 1810828-02
2 Removing the spring and arm.
a Remove the spring from

the pin on the hood.
b Remove the arm

together with the
spring.
c Turn the paring tube so that the frame hood can be

removed upwards.
NOTE
To avoid the paring tube from being damaged

and preventing the inlet pipe from sticking to
the frame hood when lifting the hood, always
turn the paring tube towards the pipe before
lifting.
G0863661
Paring tube
3 Removing the frame hood.
a Remove the screws holding

the frame hood. c Lift off the frame
hood.
NOTE
b Loosen the hood
Do not place
by bending with
the hood
a screwdriver in upside down.
all grooves in the
hood.
G0863671
1810828-02 45
3.3.4 Bowl Lock ring
Bowl hood
Seal ring
O-ring
Top disc
O-rings
G0861621
Inlet and outlet
pipe
Paring tube
Axial support.
1
Splash sealing
Bowl disc
(without caulks)
Bowl discs
2
Distributor
Cap nut
6
4 Nut
3 7 Discharge slide
Rectangular ring
5 O-ring
8
9
Bowl body
10
G0860571
11 Rectangular ring
O-ring
1 Compressing tool (lock ring). Valve plugs
2 Lifting eyes.
3 Bowl hood puller. Operating slide
4 Spanner for nut (nut/discharge slide).
5 Puller (discharge slide). Rectangular ring
6 Lifting tool (distributor, spindle).
O-ring
7 Puller (Bowl body)
8 Screw (lock ring) (M5) Holder
9 Hexagon head key Nozzle
G0862681
10 Chisel (seal ring) Operating water ring

11 Pin (distributor/lifting tool)
Ring
46 1810828-02
1 Removing the lock ring.
a Fit the compressing tool.

c Compress the disc stack by
alternately tightening the
b Screw in the screws to
screws on the compressing
stop.
tool a maximum of 40 Nm at a
time.
NOTE
Be sure not to
cover the threaded
holes.
d Fit the dismantling screws

to the bowl body and
press out the lock ring by
tightening the screws
successively going
counter-clockwise. Start
with the screw nearest the
lock ring end (the one
without the guide pin).
The lock ring can be
removed when it has
passed the edge of the
groove.
e Remove the lock ring

from the groove.
f Remove the
dismantling screws.
G0862751
1810828-02 47
2 Removing the bowl hood.
a Loosen the screws on the b Fit the puller.

compressing tool.
Remove the tool.
Remove the lock ring.
c Fit the compressing tool.

Loosen the screws (de-
compress) on the
compressing tool. Pull the
bowl hood off by continuing to
unscrew the screws.
d Remove the
compressing tool
and attach the
lifting eyes to the
puller and lift off
the bowl hood.
ING
WARN
!
Crush hazard
The top disc can adhere to the bowl
hood when lifting. Be careful not to
accidentally drop it.
G0862861
48 1810828-02
3 Removing the seal ring.
a Place the bowl hood on a support

and tap out a piece of the seal ring
using a drift in the holes.
b Turn the bowl hood upside down
and remove the seal ring by
carefully knock pieces of the seal
ring out of the groove, using the
special tool: chisel.
NOTE
Seal ring
It is very important not to
damage the bottom of the
groove!
ING
WARN
!
Risk for eye injury from flying seal ring parts

or from splashing fluid
The seal ring breaks when removed from the bowl
hood and may cause trapped fluid to splash. Wear
safety goggles.
G0862441
4 Removing the inlet/outlet pipe and top disc.
a Lift out the in- and outlet pipe together with the top disc.
ING
WARN
!
Crush hazard
The distributor and disc stack can adhere to the
top disc. Separate them from the top disc so that
they do not accidentally drop.
G0862951
1810828-02 49
5 Removing the paring tube.
a Remove the top disc from

the inlet and outlet pipe.
NOTE
To avoid damaging the paring

tube, turn it towards the
centre of the pipe.
b Remove the splash sealing.
c Remove the screws

and the axial support
d Lift up and remove the

paring tube.
Turn the paring tube

upwards.
NOTE
If the paring tube sticks, use a drift

to carefully tap it out from the pipe.
Be careful not to damage the
paring tube.
G0863051
50 1810828-02
6 Removing the disc stack and distributor.
c Carefully lift off the

a Assemble the lifting tool with the pin. disc stack assembly.
b Fit the assembled tool into the

distributor and ease off the disc stack
using a spanner or wrench.
N
CAUTIO
!
Cut hazard
Sharp edges on the separator
discs may cause cuts
G0863171
7 Removing the nut
a To prevent the bowl body from rotating

when removing the nut;
Fit the compression tool to the bowl
b Use the spanner body and fit a screw together with a
for nut to remove socket into the frame, as shown in the
the nut. illustration.
Nut
Compressing tool
Screw
Socket (or similar)

G0923841
1810828-02 51
8 Removing the discharge slide.
a Fit the lifting tool by

pressing the puller rods
towards each other and
position them into the
two slots on the bowl b Ease off the discharge slide
bottom. by turning the central screw.
Slide metal ring down
over bowl nave.
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
c Lift out the discharge slide.
ING
WARN
!
Crush hazard
The ring on the lifting tool must be pushed
down against the discharge slide, otherwise the
discharge slide may come loose from the tool.
G0863251
52 1810828-02
9 Removing the cap nut.
a Remove the cap nut
NOTE
Left-hand thread!
b Remove the compressing tool.
G0860651
10 Removing the bowl body
a Fit the lifting tool to the bowl body.
b Raise the bowl body off the spindle taper

by turning the lifting eye clock-wise.
c Lift off the bowl body

G0860731
1810828-02 53
11 Turn the bowl body upside down.
ING
WARN
!
Crush hazard
G0860821
Support the bowl body when turning to prevent it from rolling.
12 Removing the holder.
a Remove the screws.
b Lift off the holder.
NOTE
If the ring sticks, use two M8

screws in threaded holes to raise
the operating slide holder up and
away from the bowl body.
G0860921
54 1810828-02
13 Removing the operating slide.
a Lift off the operating slide.
NOTE
If the ring sticks, use two M8 screws in

threaded holes to raise the operating
slide holder up and away from the bowl
body.
G0861021
14 Removing the operating water ring.
a Loosen and remove the screws .
b Lift off the ring.
NOTE
If the ring sticks, use two M8

screws in threaded holes to raise
the operating slide holder up and
NOTE
away from the bowl body.
The discoloration on the ring is oxide
protection. Do not clean with abrasives.
G0861121
1810828-02 55
3.3.5 Driving device 1 3 4 5
G0857971
G0857821
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-rings
Self-aligning roller
Fan bearing
Lubrication oil orifice
Snap ring
O-ring
Oil pump
Bowl spindle
Labyrinth ring holder
O-ring
Ball bearing Labyrinth ring
Top bearing seat Wing insert

Springs
O-ring
Top bearing housing Bottom bearing
holder
Composite springs Screw
O-ring
Plugs
G0858061
Strainer
56 1810828-02
1 Empty the oil sump.
Unscrew the oil plug and

empty the oil sump.
G0868571
.
2 Removing the clutch cover.
b Remove the clutch cover.

G0858131
1810828-02 57
3 Loosen the flat belt, by tilting the motor.
a Loosen, but do not remove, the screws holding

the motor. Start with the two screws at the bottom. Motor
Do not loosen more than shown in the illustration.
Separator frame
Nut
Screw
b Loosen the two upper screws a little bit more so

that the motor can be tilted. Do not loosen more
than shown in the illustration.
ING
WARN
!
Crush hazard
c Remove the flat belt from the motor pulley. The motor will come off if the screws are
G 0 8 5 8 8 A1
unscrewed.
58 1810828-02
4 Removing the operating water cover.
b Lift off the operating water cover.
NOTE
If the cover sticks, fit two

M10 screws to the threaded
holes and tighten.
G0858931
5 Removing the neck bearing cover and deflector ring.
d Lift off the neck bearing cover

together with the deflector ring.
a Attach the tools.
b Fasten the tool to

c Ease off the the cover.
cover by
tightening
the screw.
Cover
Frame
G0859051
1810828-02 59
6 Prepare for removal of spindle assembly.
NOTE
a To facilitate later removal of

plugs, loosen (do not remove)
the plugs on the bearing
housing.
b Remove the screws
NOTE
If the cover sticks, fit two

M10 screws to the threaded
holes and tighten.
G0859151
60 1810828-02
7 Lifting the spindle assembly from the frame.
a Fit the lifting tool to the spindle end.
b Slowly raise and lift out the spindle

assembly.
ING
WARN
!
Crush hazard
Do not rotate the spindle assembly
during lifting. The spindle assembly
may otherwise come loose from the
lifting tool.
NOTE
Take care not to damage the oil

pump.
G0907831
1810828-02 61
8 Place the spindle assembly upside down on a support.
Make a support
~180 mm
~135 mm
~3,0 mm
free space
G0859211
9 Removing the air deflector.
Remove the screws and the air

deflector.
G0859221
62 1810828-02
10 Removing the fan.
a Turn the spindle assembly the right way up.
b Place a spanner (or similar) on

the spindle pulley key-grip, as
holder-up.
c Fit the pin spanner and
remove the fan.
NOTE
Key-grip
Left-hand thread!
G0923921
11 Removing the bottom bearing assembly.
a Turn the spindle assembly up-side down and
Puller tool
remove the oil pump by using spanners.
b Pull off the belt pulley and the

self-aligning roller bearing using
the puller tool.
NOTE
Always discard a used

bearing.
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.
G0865981
Compressed air
1810828-02 63
12 Removing the top bearing housing.

a Turn the spindle
Composite b Remove the plugs
assembly over.
springs and the composite
springs.
c Carefully remove the spindle

from the top bearing seat.
Plug
NOTE
Be careful not to damage

d Collect the
the vibration indicator.
axial springs.
G0858221
64 1810828-02
13 Removing the ball bearing.
a Remove the snap ring.
ING
WARN
!
Risk for eye injury from flying snap ring

Use the correct pliers for dismantling of snap ring to
avoid accidental release.
b Fit the cap nut on the spindle to

protect the threads.
c Use the puller tool to remove the

top bearing seat from the spindle.
NOTE
Do not damage threads on

spindle. NOTE
Take care not to damage the

vibration indicator when
separating the top bearing
seat from the spindle.
Vibration indicator
Piece of wood to
protect the spindle
threads.
NOTE
Always discard
d Place the top bearing seat on a support to used bearings.
protect the vibration indicator.
Remove the bearing. Use a drift in the two
holes.
G0858331
1810828-02 65
14 Removing the labyrinth ring holder.
NOTE
If the holder sticks, fit two screws M8

to the threaded holes and tighten.
G08586B1
66 1810828-02
15 Removing the bottom bearing holder.
a Fit the tool into the bottom bearing holder and attach the
socket, extension rod and T-handle.
T-handle
Extension rod
Socket
Tool
b Loosen the bottom bearing

holder by turning it counter
clockwise.
Remove it by hand.
c Remove the strainer.

G08586D1
1810828-02 67
3.3.6 Centrifugal clutch

Snap rings
Ball bearings
Spacing ring
Belt pulley
G0864711
Coupling
hub
ING
WARN
!
Parallel pin
Entrapment hazard
To avoid accidental start, switch off and lock-out
Friction blocks
(3=60 Hz)
standstill before starting any dismantling work Cover
(takes about 30 minutes from switch off).
Snap ring
G0865141
NOTE
50 Hz = 5 Friction blocks
The illustration shows 60 Hz
2
G0865021
1 Mounting /dismantling tool (centrifugal clutch).

2 Mounting /dismantling tool (ball bearing).
68 1810828-02
1 Removing the clutch cover.
a Loosen and remove the screws.
b Remove the clutch cover.
G0858131
2 Loosen the flat belt, by tilting the motor.
a Loosen, but do not remove, the screws holding

the motor. Start with the two screws at the bottom. Motor
Do not loosen more than shown in the illustration.
Separator frame
Nut
Screw
b Loosen the two upper screws a little bit more so

that the motor can be tilted. Do not loosen more
than shown in the illustration.
ING
WARN
!
Crush hazard
c Remove the flat belt from the motor pulley. The motor will come off if the screws are
G08588A1
unscrewed.
1810828-02 69
3 Removing the motor.
a Disconnect the electrical cables.
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.
ING
Weight of motor with WARN
coupling: approx. 80 !
kg.
Crush hazard
If not supported, the motor with coupling
will drop when removing the screws.
G0864641
d Lower the motor onto a suitable pallet.
4 Removing the friction blocks.
ON
CAUTI
a Remove the snap ring, cover
! and friction blocks.
Inhalation hazard
When handling friction Friction blocks
blocks/pads wear a (3=60 Hz)
mask to avoid inhalation
of dust.
Cover
Do not use compressed
air to remove dust.
Remove dust using Snap ring
vacuum or a damp cloth.
NOTE
G0865231
70 1810828-02
5 Checking the condition of the friction blocks o .
If the blocks are worn:

Fit new friction blocks.
N
CAUTIO
!
NOTE
Inhalation hazard Replace all blocks, even if only one is
When handling friction worn.
blocks/pads wear a
mask to avoid inhalation
of dust. a Clean the pins of coupling hub and apply a thin
Do not use compressed film of lubricating paste to the pins.
air to remove dust.
Remove dust using
vacuum or a damp cloth.
NOTE
Make sure that there is no oil on the pads.
NOTE
Be sure that the pins on the back of the

blocks project into the grooves in the
clutch hub.
b If only friction block service is to be done,

proceed to ‘‘Assembly of friction blocks” on page
86.
G0865331
1810828-02 71
Complete dismantling of centrifugal clutch
6 Removing the coupling from the motor.
a Remove the screw, spring washer and washer.
Washer
Spring washer
Screw
NOTE
Use a spanner (55 mm) on the

coupling hub to prevent rotation
during dismantling.
b Check that the brass plug is mounted

Flat areas for spanner (55 mm). on the puller tool.
Fit the tool to the friction clutch.
c Ease off the friction coupling.
ING
WARN
!
Crush hazard
The centrifugal clutch is heavy and
can fall, causing injury, when
loosened from the motor shaft.
Puller tool
Flat areas for spanner (50 mm).

G0865421
72 1810828-02
7 Dismantling of the coupling assembly.
a Remove the snap rings.
b Drive out the coupling hub.
Wooden support
Support
c Turn the coupling the other way round

and drive out the ball bearings using the
mounting tool.
NOTE
Always discard used bearings.

G0865511
1810828-02 73
3.4 Actions Before Assembly
3.4.1 Cleaning i o
Clean the separator parts according to the
diagram below. Afterwards, protect all cleaned
carbon steel parts against corrosion by oiling.
Part Procedure Cleaning agents
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.
74 1810828-02
Part Procedure Cleaning agents
Bowl Cleaning of bowl discs A chemical cleaning agent must

Inlet/ outlet Handle the bowl discs carefully in order to avoid damage to dissolve the deposits quickly without
the surfaces during cleaning attacking the material of the separator
parts.
1 Remove the bowl discs from the distributor and place them
individually in the cleaning agent. Fuel oil sludge mainly consists of
complex organic substances such as
2 Allow the discs to remain in the cleaning agent until the asphaltenes. The most important
deposits have been dissolved. This will normally take property of a cleaning liquid for the
between two and four hours. removal of fuel oil sludge is the ability to
3 Lastly, clean the discs with a soft brush. dissolve these asphaltenes.
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.
Centrifugal Use a sponge or a soft brush. White spirit, cleaning-grade kerosene

clutch or diesel oil.
Belt pulley Use a a steel brush. Solvent
1810828-02 75
3.4.2 Inspection for corrosion i

o
Inspect the separator parts for corrosion.
Evidence of corrosion attacks should be looked
for and rectified each time the separator is
dismantled.
Max. 0,2 mm
! D
ANGER
G0205241
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.
Material Type of corrosive Appearance Measure

environment
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
such as pitting, grooves or cracks. mm 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.
R
! DANGE
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.
76 1810828-02
3.4.3 Inspection for cracks i o

Check the separator parts for cracks. It is
particularly important to inspect for cracks in
rotating parts, and especially the pillars between
the sludge ports in the bowl wall.
R
! DANGE
All forms of cracks are potentially dangerous as they
reduce the strength and functional ability of
components.
Always replace a part if cracks are present.
Cracks can occur from cyclic material stresses

and corrosion. Keeping the separator and its
parts clean and free from deposits will help to
prevent corrosion attacks.
R
! DANGE
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.
1810828-02 77
3.4.4 Inspection for erosion i o

Erosion may occur when particles suspended
in the process liquid slide along or strike
against a surface.
Erosion is characterised by:

Surfaces particularly subjected to erosion are:
1 Burnished traces in the
material.
2 Dents and pits having a
granular and shiny surface.
The sealing edge of the

discharge slide.
Paring disc and paring tube
Lock ring
Bowl body and holder.
Pillars between the

Holder and operating slide. sludge ports in the
bowl wall
The sealing edge of the discharge

slide for the seal ring in the bowl
hood
The underside of the distributor in the vicinity of the
G0911831
distribution holes and wings
1 Inspect the bowl and inlet/outlet parts for

erosion damages.
NOTE

suspect that the depth of the damage exceeds 0,2
mm for bowl body and bowl hood (0,5 for other
parts). Do not continue to use the separator until it
has been inspected and cleared for operation by
Alfa Laval.
78 1810828-02
2 Replace parts if erosion is suspected.
R
! DANGE
Erosion damage weakens parts by reducing the
thickness of the material.
Pay special attention to the pillars between the
sludge ports in the bowl wall.
Replace parts if erosion is suspected of affecting
strength or function.
1810828-02 79
3.4.5 Exchange of frame feet

The frame feet have to be changed
occasionally due to rubber deterioration from
age.
When replacing the frame feet, the separator

must be lifted. Follow 3.8.1 Lifting the
separator, page 129.
NOTE
Discard the old frame feet, screws and washers.
a Loosen the bolts and prepare to remove

the separator frame
b Lift the separator. See ‘‘Lifting the separator” on

page 129
c Remove the existing frame feet.
d Fit the new feet, screws and washers. Tightening

torque: 160 Nm.
e Place the separator in its original position and

fasten the mounting bolts.
G0874421
80 1810828-02
3.4.6 Lubrication of bowl parts
a Apply a thin layer of Molykote 1000, or equivalent

lubrication, on all the following contact surfaces. Apply D321
on the operating slide and the bowl body, guide pin and
bowl hood.
= Molykote 1000
= D321 + Molykote 1000
Bowl hood
( apply D321)
Bowl body
(also apply D321 on guide pin)
Discharge slide
Operating slide
( apply D321)
Holder
G0911751
Operating water ring Nut
1810828-02 81
3.4.7 How to lubricate bowl parts

with slide laquer
1
1
NOTE
This instruction is also valid for

the operating slide and the holder.
a Carefully clean the contact surfaces (1) on bowl body

and bowl hood.
b Apply Molykote D321R on surfaces.
c Air-cure for 15 minutes.
d Use a smooth fibre brush to polish to an even and

homogenous contact film.
e Apply a second layer slide laquer.
f Air-cure for 15 minutes.
g Polish the film to a shiny surface, the film should look

like well-polished leather when properly done.
G0874861
h Finish the treatment by lubricating the contact surfaces

with Alfa Laval lubricating paste or Molykote 1000
paste. Use a well cleaned brush and rub it into the
surface, do not leave any excessive paste.
82 1810828-02
3.4.8 Check for galling on operating

slide and bowl body
1
1
If any friction marks are found on the guide surfaces (1)

of operating slide and bowl body, proceed as follows:
a Clean the surface thoroughly with a degreasing

agent, i.e. white spirit.
This is important!
NOTE
To avoid the risk of galling, the

b Using an emory cloth (e.g. No. 320) to smooth the
guiding surface of the operating
metal edges. slide should be primed with a slide
lacquer at every inspection
service.
c Finish by polishing the damaged spots with polishing
paper (e.g No. 600).
d Apply Molykote D321R on surfaces.
e Air-cure for 15 minutes.
f Polish to an even, homogenous surface.
g Apply a second layer.
h Air-cure for 15 minutes.
i Polish to a shiny surface, the surface should look like

well-polished leather when properly done.
j Finish the treatment by lubricating the guiding surfaces

with Alfa Laval lubricating paste or Molykote 1000
paste. Use a well cleaned brush. Rub it into the
surface, do not leave any excessive paste.
G0874851
1810828-02 83
3.5 Assembly
3.5.1 Centrifugal clutch
1 Assembly of the coupling.
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.
d=253,5 mm 50 Hz
d=211 mm 60 Hz NOTE
Remove rust from the

belt pulley using a steel
brush.
b Apply a thin film of oil onto the

external and internal surfaces of the
ball bearings o .
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
Never re-fit used ball bearings.

The ball bearings must not be heated as they are
packed with grease and sealed with plastic
membranes.
d Fit the snap rings.

G0865621
84 1810828-02
2 Fitting the coupling to the motor.
a Clean the motor shaft and apply a

thin oil film.
NOTE
Make sure that the key is in place on b Apply lubricating paste to the tool
the motor shaft. threads (keep lubricated).
c Remove the brass plug.
d Fasten the sleeve of the tool to the

motor shaft with the same screw that
normally holds the centrifugal clutch
to the motor.
e Use a spanner to turn the nut on the

tool. This will press the centrifugal
clutch on to the shaft. Remove the
tool.
f Install and tighten the washer, spring

washer and screw.
G08654D1
1810828-02 85
Assembly of friction blocks
3 Fitting the friction blocks.
Guide pin
a Fit the friction blocks onto the

guide pins
NOTE
NOTE
Be sure that the pins on the
back of the blocks project into
the grooves in the clutch hub.
b Place the cover in position and secure it with

the snap ring.
Snap ring
Cover
G0865451
86 1810828-02
4 Fitting the motor.
a Fit a lifting sling to the motor.

Use a shackle from the
separator lifting tool.
Weight of motor with
coupling: approx. 80 kg.
ING
WARN
!
b Lower the motor (while
supported) on to the
separator frame. Crush hazard
It will set on the ledge. If not supported, the motor with
coupling may drop when lifted.
c Fit the screws.

Do not tighten until the
belt has been mounted.
d Connect the electrical cables.
G0864641
NOTE
If carrying out change of friction blocks only,

continue with steps 5 to 6.
If carrying out a complete machine assembly,
continue with the driving device instructions on
page 90.
1810828-02 87
5 Fitting the flat belt.
NOTE
Clean the inside of the frame before fitting

the flat belt, and make sure that there is no
oil on the belt.
a Lift up the belt to the middle (centre) of the

spindle pulley.
NOTE
For correct position,

centre the belt on the
spindle pulley camber.
Clearance
b Fit the flat belt to the motor belt pulley.
c Tighten the two upper screws.
d Tighten all motor attachment screws.
NOTE
Do not turn the spindle until the

motor is tightened properly to the
frame.
G08588D1
88 1810828-02
6 Fitting the clutch cover.
b Tighten the screws.
a Fit the clutch cover.
G0858141
1810828-02 89
3.5.2 Driving device
1 Fitting the bottom bearing holder.
a Fit the wing insert, O-rings

NOTE and strainer.
Clean the strainer and bearing
holder thoroughly before fitting.
b Secure the wing insert

with the screw secured d Thread the bottom bearing
with Loctite 222 holder into the frame and fit
c To secure the bottom
the tool into the bottom
bearing holder into the
bearing housing.
frame, apply Loctite
222 on the surfaces
directly above and
below the upper O-
ring.
Socket
Tool
Bottom bearing holder
e Tighten the holder to a torque of 200 Nm.

G0866191
90 1810828-02
2 Fitting the labyrinth ring holder.
a Fit the O-ring using

silicone grease o .
b Lubricate and fit the

labyrinth ring o .
c Fit and seal the holder with Loctite 222. Fit

and tighten the screws.
G0866361
1810828-02 91
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.
c Fit the snap ring.
ING
WARN
!
Risk for eye injury from flying snap ring

Use the correct pliers for assembly of snap ring to
avoid accidental release.
d Heat the top bearing seat Puller

together with the bearing in oil to
maximum 125 °C.
Sleeve
e Wipe off the spindle

and fit the top bearing
seat to the spindle
using the sleeve and
puller.
NOTE
Make sure to fit the bearing seat

correctly or it might get stuck!
G0984831
92 1810828-02
4 Fitting the top bearing housing.
a Fit the axial springs o to the top

bearing housing.
Axial springs
b Carefully lower the bowl spindle.
Make sure that the springs enter the
recesses on the top bearing seat.
c Lubricate the threads before

assembly.
d Fit the composite springs o and

plugs to the top bearing housing.
Do not tighten the plugs.
Make sure that the springs enter the
recesses in the top bearing seat.
The plugs should be tightened when
the spindle assembly is mounted into
the frame.
0866621
1810828-02 93
5 Fitting the spindle pulley.
a Turn the spindle assembly

upside down.
b Wipe off the spindle pulley c Fit the spindle pulley

seat on the spindle and nave firmly on the bowl
bore in the spindle pulley with spindle.
a dry cloth.
NOTE
At least 1mm free space between

support and spindle assembly to
protect the bearing.
Mount the cap nut to protect the

threads and support the spindle.
G0866731
6 Fitting the self-aligning roller bearing o .
a Heat the bearing in oil to maximum

125 °C.
b Lower the bearing
NOTE onto the spindle
and press down
Always fit a new bearing. onto the spindle
Pre-lubricate before fitting. pulley using the
special mounting
tool.
ING
WARN
!
Burn hazard
Use protective gloves when
handling the heated bearing.
G0866841
94 1810828-02
7 Fitting the oil pump.
a Fit O-ring onto lubrication oil orifice. Spread oil film on c Lubricate all threads with a few
O-ring. drops of oil before assembly.
b Push lubrication oil orifice into oil pump. Be sure to
line up tabs on orifice with slots in pump.
d Fit the oil pump (65 + 5 Nm) using

spanners.
NOTE
Clean the oil pump and make

sure that the bottom hole is not
clogged.
G0866961
1810828-02 95
8 Fitting the fan
a Turn the spindle assembly up-side down.
NOTE
Ensure that the spindle is seated against

the inner ring of the ball bearing.
b Apply a thin layer of silicone grease

and fit the O-rings o into the fan.
NOTE
Make sure that the bearing

is pre lubricated before
fitting the fan.
c Place a spanner (or similar) on the

spindle pulley key-grip, as holder-up and
fit the fan. Tighten firmly, by hand, with
the pin spanner.
Key-grip
G0924061
9 Fitting the air deflector.
a Turn the spindle assembly up-side

down and fit the air deflector.
G0859231
96 1810828-02
10 Lowering the spindle assembly into the frame.
a Remove the cap nut from the spindle.

Fit the lifting tool to the spindle assembly and lift it.
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.
Carefully blow
compressed air
b Position the flat belt o so
through the hole in
the bearing housing. that the spindle assembly can
pass through when lowering.
Check the bottom hole. See note below.
c Carefully lower the spindle assembly and position

the bolt holes over the threaded frame holes.
Make sure that the bottom bearing, enters the
bottom bearing holder correctly. Do not use force.
ING
WARN
!
Space
Cut hazard
Do not put fingers between the frame and air
deflector while lowering the assembly.
d Fit and tighten the screws.
NOTE
Check the direction arrows on the belt and the

machine plate for correct position.
Make sure that the belt does not get smudged

with oil or grease during handling.
e Tighten the plugs firmly.
G0867971
1810828-02 97
11 Fitting the flat belt.
NOTE
Clean the inside of the frame before fitting

the flat belt, and make sure that there is no
oil on the belt.
a Lift up the belt to the middle (centre) of the

spindle pulley.
NOTE
For correct position,

centre the belt on the
spindle pulley camber.
Clearance
b Fit the flat belt to the motor belt pulley.
c Tighten the two upper screws.
d Tighten all motor attachment screws.
NOTE
Do not turn the spindle until the

motor is tightened properly to the
frame.
G08588B1
98 1810828-02
12 Fitting the neck bearing cover and deflector ring.

a Apply a thin layer of silicone grease and fit the O- Deflector ring
rings and the seal ring in the lower groove o
b Fit the neck bearing cover.
NOTE Neck bearing cover
The guide pin on the cover should enter one of

the two holes in the bearing housing.
c Push the deflector ring

down until it stops.
G0868051
1810828-02 99
13 Fitting the operating water cover.
O-ring
a Lubricate with oil and fit the seal

ring and O-ring o into the
operating water cover.
Renew the O-ring o

b Fit the operating water cover. Fit and
tighten the screws.
NOTE
The water pipe in the frame should

enter the hole in the cover.
G0868141
14 Measuring the radial wobble of the bowl spindle.
a Fit a dial indicator in a support

and fasten it in position as
illustrated. Use the flat belt to NOTE
turn the spindle.
Permissible radial wobble: max. 0,04
mm. If the spindle wobble exceeds
this value, contact an Alfa Laval
representative.
Max. 0,04 mm
G0858711
100 1810828-02
15 Fitting the clutch cover.
b Tighten the screws.
a Fit the clutch cover.
G0858141
16 Fill oil in the oil sump.
NOTE
The separator should be level and at

standstill when oil is filled.
a Remove the oil pin, plug and washer.
b Fit new washer i and refit the drain

plug.
c Fill with new oil until oil flows out from
the filler hole.
For correct oil volume see
‘‘Lubricating oil volume” on page 14.
d Fit new O-ring i onto the oil pin. NOTE

G0868781
e Refit the plug with new washer i

For grade and quality of oil see
3.7.6 Lubricating oils, page 128
f Fit the oil pin.
1810828-02 101
3.5.3 Bowl
1 Check for impact marks and corrosion in bowl

body nave and on spindle taper i o .
a Remove any impact marks using

N
CAUTIO a scraper and/or a whetstone.
!
Impact marks may cause the separator to
vibrate while running.
b Rust can be removed by using a

fine-grain emery cloth (e.g. No. 320).
c Finish with polishing paper (e.g. No. 600).
d Lubricate to prevent further corrosion.
G0874611
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
Make sure that the plugs are fitted as

described in the illustration.
G0874841
102 1810828-02
3 Fitting the operating slide.
a Apply a thin layer of silicone grease and fit the

rectangular ring on the operating slide and the b Fit the operating slide.
rectangular ring and O-ring on the bowl body.
i o . NOTE
The guide pin in the bowl body

should enter the hole in the
operating slide (this hole is
marked with a drill mark).
Nozzle secured with Loctite 222
Alignment hole
Operating slide
Bowl body
Guide pin
G0861241
4 Fitting the operating slide holder.
a Fit the holder over the

operating slide.
b Apply a thin layer of molykote grease
and fit and tighten the screws to a
torque of min.15 Nm and max. 20
Nm.
G0861331
1810828-02 103
5 Fitting the operating water ring.
NOTE
a Fit the ring i
The discoloration on the ring is oxide protection.
Do not clean with abrasives.

and fit the O-ring i o
c Fit the operating water ring.
NOTE
The drilled assembly mark on the water ring should

face the corresponding mark on the bowl body.
d Grease, fit and tighten the screws to a torque of

min.15 Nm and max. 20 Nm.
G0861441
104 1810828-02
6 Lifting the bowl body onto the spindle taper.
a Put a drop of oil on the spindle taper.
b Wipe off the spindle taper and

nave bore with a dry cloth.
c Turn the bowl body over.
ING
WARN
!
Crush hazard
Support the bowl body when turning to
prevent it from rolling.
d Fit the lifting

tool and lift the
bowl body.
e Carefully lower the bowl body

onto the spindle taper.
f Remove the lifting tool.

G0861731
1810828-02 105
7 Fitting and tightening the cap nut.
a To prevent the bowl body from rotating

when fitting the cap nut;
Fit the compressing tool to the bowl b Apply a thin layer of
body and fit a screw together with a molykote grease. Fit and
socket into the frame, as shown in the tighten the cap nut to a
illustration. torque of 50 Nm.
NOTE
Left-hand thread!
Compressing tool
Screw
Socket (or similar)
G0861851
Cap nut
106 1810828-02
8 Fitting the discharge slide.
a Apply a thin layer of silicone grease and

fit the rectangular ring i o .
O-ring

and fit the O-ring i o
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
d Remove the lifting tool. slide, otherwise it may come loose
from the tool.
e Fit the nut.
f Fit the spanner for nut and

tighten the nut with a torque
wrench to a torque of min.
150 Nm.
g Remove the compressing tool and the

G0861951
spanner for nut.
1810828-02 107
9 Assembly of the disc stack.
a Fit the discs one by one onto the distributor.

The distributor has a guide rib for the correct
ING
positioning of the bowl discs. Always end with WARN
!
the disc without caulks.
The number of discs may have to be increased

to adjust the disc stack pressure. Always check
before operating the separator. See ‘‘Checking
the disc stack pressure .” on page 114
N
CAUTIO
!
Cut hazard
Sharp edges on the bowl discs may cause
cuts.
Recess on bowl disc
Guide rib on distributor

G0862051
108 1810828-02
10 Fitting the disc stack assembly to the bowl body.
a Fit the lifting tool into the

distributor.
b Lower the disc stack into the bowl.
Guide pin on bowl

NOTE body
The guide pin on the bowl body should face

the guide rib on the distributor.
The guide ribs inside the distributor then

enter the recesses on the bowl body nave.
Guide rib on
distributor
Guide ribs inside the distributor.
Recesses on the bowl body nave.

G0862171
1810828-02 109
11 Assembling the paring tube i .
Tolerance ring
a Fit the O-rings i bearings

i and tolerance ring to the
paring tube.
G0984961
12 Mounting the paring tube and fitting the inlet and outlet pipe.
b Mount the splash sealing

a Insert the
paring tube
and mount
the axial
support to c Apply a thin layer of
the inlet and silicone grease and fit
d Carefully lower the inlet and outlet
outlet pipe. the O-rings i o
pipe assembly into the top of the
distributor.
G0862291
110 1810828-02
13 Fitting the top disc.
a Move the paring tube

b Lower the top disc. to the centre.
The guide rib on the

distributor should enter
one of the two larger
recesses on the top disc.
NOTE
To avoid damaging
the paring tube, turn
it towards the centre
of the pipe.
G0862341
1810828-02 111
14 Fitting the bowl hood.
a Apply a thin layer of silicone grease and fit the

O-ring i o
b Fit the seal ring i o Press

the ring down evenly until bulges
appear.
c Carefully tap down the bulges crosswise with a soft

rubber mallet, until the ring is completely fitted.
d Fit the lifting tool and lower the bowl

hood so that its recess fits into the guide
pin in the bowl body.
Recess on bowl hood
Guide pin on bowl body

G0862471
e Remove the lifting tool.
112 1810828-02
15 Fitting the lock ring.
a Place the lock ring on the bowl hood

with its guide pin close to the
corresponding hole in the bowl
body.
NOTE
Make sure that the groove in

the bowl body which retains
the lock ring is clean.
b Fit the compressing tool and

compress the disc stack by
alternately turning the screws a
NOTE
maximum of 40 Nm at a time until
the lock ring fits into the bowl
body. The lock ring is correctly Check that the lock ring is
fitted when the lock ring ends are correctly positioned all way
facing each other. around!
For correct disc stack pressure

see page 114
c Release the pressure on the

compressing tool and remove it.
Lock ring
Bowl hood
NOTE
Bowl body Never remove any material

from the lock ring. A
hazardous situation could
result.
G0862531
Before compressing Lock ring in position
1810828-02 113
16 Checking the disc stack pressure i i .
a Remove bowl hood, top disc and inlet and outlet pipe.
b Add one disc to the disc stack.
c Refit the disc without caulks, the top disc

and bowl hood.
d Fit the lock ring and fully

compress the disc stack with the
compressing tool.
NOTE
NOTE
Always refit the disc

Do not use more power than
without caulks on top
40 Nm/screw at a time,
of the disc stack!
alternately.
e If the lock ring enters the groove,

repeat a-d until the lock ring does
not enter the groove.
f Dismantle the bowl and remove

one disc to get the correct disc
stack pressure.
g Assemble the bowl with inlet and

outlet pipe.
G0874961
114 1810828-02
3.5.4 Frame hood
1 Fitting the frame hood i o .
a Turn the paring tube so that the frame hood can

pass the paring tube. NOTE
Paring tube. Make sure that the frame

b Apply a thin layer of silicone grease and hood is mounted in its
fit the O-ring onto the frame hood correct position
i o according to the piping
arrangement.
c Lower the frame hood.
d Fit and tighten the

screws.
NOTE
G0863771
Make sure to fit the frame hood
groove and the projection of the
pipe.
1810828-02 115
2 Control measurement of paring disc height o .
a Remove the guide screw (A).
D Quantity height
b Measure the distance D. adjusting rings
mm
Assemble the correct
number of height 29 ± 0,5 3
adjusting rings (B)
according to the table. Guide screw 28 ± 0,5 2
27 ± 0,5 1
c Refit the guide screw (A)
Support ring
Height adjusting rings Guide screw

Frame hood
Important!
Bowl hood Distributor Paring disc

G09115E1
116 1810828-02
3 Fitting the spring o and arm.
Spring
a Fit the spring on the arm
and fit the arm to the top
of the paring tube end.
Arm
Pin Paring tube
b Fit the spring to the pin

on the frame hood and
make sure that it is
properly attached on
both ends.
G0863781
1810828-02 117
4 Fitting the connection housing.
a Fit the connection housing over

the inlet/outlet pipe.
NOTE
Make sure that the screw, on top of

the frame hood, enters the guide
hole at the underside of the
connecting housing.
b Fit the washer and the lock
nut using the hook spanner.
G0863941
118 1810828-02
3.5.5 Unbalance sensor (option)
1 Fitting the unbalance sensor holder.
a Remove the cover.
Sensor holder.
Sensor arm Frame
Screw M8 b Fit the O-ring on the holder.

Fit the screw into the holder and
M10 mount the holder into the
separator frame.
Sensor
holder
O-ring NOTE
If removing the sensor holder;

use a M10 screw as a puller.
NOTE
See next page for fitting and

correct adjustment of the sensor.
G0873481
1810828-02 119
2 Adjusting the unbalance sensor
a Fit the sensor into the holder. Do not forget the nut.
b Adjust the sensor so that a value of 1,5 appears on the

display.
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 2.2 Connection List, page 15 and 752
against the holder. Unbalance sensor (option)., page 22.
Fit the cover (see previous page).
G08734A1
3.5.6 Speed sensor
1 Adjusting the speed sensor
a Adjust the speed sensor according to the illustration.
b Fit the sensor to the frame, see 1.4 Sensors, page 8.
102 + 0,1
G08734B1
120 1810828-02
3.6 Actions After Assembly
3.6.1 Control of machine plates and

safety labels o
Alfa Laval ref. 561498 rev.2
1 Check that the following signs are attached.
Machine plate
Lifting instructions
Space for label indicating representative.
Safety label.
Space for additional label as specified.
S0 0 5 0 1 A 1
Indicating direction of rotation of horizontal driving device.
1810828-02 121
2 Check legibility. Following texts should be read on the labels.
Separator S 840
Manufacturing serial No. / Year
Product No. 881203-03-01
In and outlet device 563094-01
Bowl 561904-04
Machine bottom part 562967-01
Max. speed (bowl) 9220 r/minute (50 Hz)
9220 r/minute (60 Hz)
Direction of rotation (bowl) ←
Speed motor shaft 3000 r/min (50 Hz),3600 r/min (60 Hz)
El. current frequency 50/60 Hz
Recommended motor power 9,5 kW
Max. density of feed 1100 kg/m3
Max. density of sediment 2425 kg/m3
Max. density of operating liquid 1000 kg/m3
Process temperature min./max. 0/100 °C
DANGER
Read the instruction manuals before installation, operation and maintenance.
Consider inspection intervals.
Failure to strictly follow instructions can lead to fatal injury.
If excessive vibration occurs, stop separator and keep bowl filled with liquid
during rundown.
Out of balance vibration will become worse if bowl is not full.
Separator must stop rotating before any dismantling work is started.
Read instruction manual before lifting.
122 1810828-02
3.7 Oil Change

The separator should be level and at
standstill when oil is filled or the oil level is
checked.
3.7.1 Lubricating oil

Do not mix different oil brands.
Always use clean vessels when handling lubricating oil.
Great attention must be paid not to contaminate the lubricating oil. Of
particular importance is to avoid mixing of different types of oil. Even a
few drops of motor oil mixed into a synthetic oil may result in severe
foaming.
Any presence of black deposits in a mineral type oil is an indication that
the oil base has deteriorated seriously or that some of the oil additives
have precipitated. Always investigate why black deposits occurs.
If changing from one oil brand to another it is recommended to do this
in connection with an overhaul of the separator. Clean the gear housing
and the spindle parts thoroughly and remove all deposits before filling
the new oil.
NOTE
Always clean and dry parts (also tools) before lubricants are applied.
ON
CAUTI
!
Check the oil level before start. Top up when necessary.

Oil volume = see “Technical Data”.
It is of utmost importance to use the lubricants recommended in our
documentation.
This does not exclude, however, the use of other brands, provided they
have equivalently high quality properties as the brands recommended.
The use of oilbrands and other lubricants than recommended, is done
on the exclusive responsibility of the user or oil supplier.
Applying, handling and storing of lubricants

Always be sure to follow lubricants manufacturer's instructions.
1810828-02 123
3.7.2 Check oil level

1 Remove the oil pin and make sure that the oil
level is above the lower end of the pin.
3.7.3 Oil change procedure

1 Remove the oil pin, plug and washer.
2 Remove the drain plug.
ON
CAUTI
!
Oil fill
Burn hazard
The lubricating oil and various machine surfaces Plug and washer
can be sufficiently hot to cause burns.
3 Collect the oil in a vessel.

Oil drain plug
4 Fit and tighten the drain plug.
5 Fill with new oil until oil flows out of oil filler Max.
hole. Min.
NOTE
G08687C1
See 3.7.6 Lubricating oils, page 128.
6 Fit the washer and the oil filling plug. Tighten

NOTE
the plug.
For Inspection service procedures; See
7 Fit the oil pin. “Fill oil in the oil sump.” on page 101.
124 1810828-02
3.7.4 Lubrication chart

Alfa Laval ref. 567329-01, rev. 0
Bowl (3), Rubber seal rings (4)
Electric motor (6)

Bowl spindle taper (2)
Buffers (3)
Bowl spindle and bearings (1)

Friction clutch bearings (5)
G0875441
Lubricating points Type of lubricant Interval
1 The oil bath. Bowl spindle bearings See 3.7.1 Lubricating oil, page 123 Oil change:
are lubricated by oil mist from the oil Volume: 2.1 Technical Data, page 13 1. Continous operation: 4000 hours
bath. Ambient temperature 0 to +55°C 2. Seasonal operation:
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 assembling
rust protection.
3 Bowl: Sliding contact surfaces, thread Pastes specified in 3.7.5 Lubricants, At assembling.
of lock nut and cap nut. page 126
4 Rubber seal rings. Grease as specified in 3.7.5 At assembling

Lubricants, page 126
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.
NOTE ON
CAUTI
!
Check and pre lubricate new spindle bearings and
those that have been out of service for six months or
longer. Check the oil level before start.
If not otherwise specified, follow the suppliers Top up when necessary.
instructions about applying, handling and storing of Do not overfill.
lubricants.
1810828-02 125
3.7.5 Lubricants
Alfa Laval ref. 553217-01 rev. 7
Pastes for non-food applications:
NOTE
The data in below tables is based on supplier

information in regards to lubrication properties.
Trade names and designations might vary from
country to country, contact your local supplier for
more information.
Brands with Alfa Laval article numbers are approved

and recommended for use.
Manufacturer Designation Alfa Laval No.
Fuchs Lubritech Gleitmo 805 K

Gleitmo 705 K
Dow Corning Molykote 1000 (Paste) 537086-02 (1000 g)

Molykote 1000 (Paste) 535586-01 (100 g)
Molykote G-rapid plus 535586-02 (50 g)
(Paste)
Rocol Antiscuffing (ASP) (Paste)
Kluber Wolfracoat C (Paste)
Bonded coatings
Fuchs Lubritech Gleitmo 900 (Varnish or

spray)
Dow Corning Molykote D321R (Spray) 535586-01 (300 ml)

Molykote D321R (Varnish) 535586-02 (60 ml)
126 1810828-02
Silicone grease for rubber rings
Dow Corning Molykote 111 (Compound) 539474-02 (100 g)

Molykote 111 (Compound) 539474-03 (25 g)
Fuchs Lubritech Gleitmo 750
Kluber Unisilkon L 250 L
Wacker Silicone P (Paste)
Greases for ball and roller bearings:
NOTE
Always follow the specific recommendation for

lubrication as advised by the manufacturer.
Manufacturer Designation
BP Energrease MM-EP2
Energrease LS2
Castrol APS 2 Grease

EPL 2
Chevron Duralith grease EP2
Elf Epexa 2
Esso/Exxon Beacon EP2

Unirex N2
Mobil Mobilith SHC 460

Mobilux EP2
Gulf Gulflex MP2
Q8/Kuwait Petroleum Rembrandt EP2
Shell Albida Grease EP2

Alvania EP Grease 2
SKF LGEP2 or LGMT2
Texaco Multifak AFB 2
1810828-02 127
3.7.6 Lubricating oils

Alfa Laval ref. 567330-01, rev. 1
Paraffinic mineral lubricating oil, category

(ISO-L-) HM 68.
Viscosity grade (ISO-3448/3104) VG 68.
The oil shall follow the requirements in one of
the standards below.
Standard Designation
DIN 51524 part 2 (German standard) DIN 51524-HLP or HVLP 68
ISO 11158 (International standard) ISO-L-HM or HV 68
The following is the list of recommended oil

brands. Trade names and designations might
vary from country to country. Please contact
your local oil supplier for more information.
Manufacturer Designation
Alfa Laval 567334-01 1 litre

567334-02 4 litres
BP Bartran 68
Bartran HV 68
Castrol Hyspin AWS 68

Hyspin AWH 68
Chevron Hydraulic oil AW 68
Esso / Exxon Nuto H 68

Univis N 68
Mobil DTE 26 (ISO VG 68)

DTE 16 (ISO VG 68)
DTE 16M (ISO VG 68)
Shell Tellus Oil 68

Tellus Oil S 68
Tellus Oil T 68
Statoil HydraWay HMA 68

Hydra Way HVX 68
Total Fina Elf Azolla ZS 68

Lubmarine Visga 68
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 other lubricants
than recommended is done on the exclusive responsibility of the user or
oil supplier.
128 1810828-02
3.8 Lifting instructions
3.8.1 Lifting the separator
Weight to lift 350 kg
Sling length: Min. 750 mm
Fasten all four bolts. Tightening

torque 35 - 45 Nm
G0868451
1 Remove the inlet and outlet device, the frame
hood and the bowl according to the
instructions in 3.3 Dismantling, page 41.
NOTE
Never lift or transport the separator with the bowl

still inside.
2 Disconnect all connections.

3 Fit the lifting tool (not included in set of tools).
All four bolts on the lifting tool must be
fastened to the frame.
4 Use two lifting slings to lift the separator. Total

length of each loop: minimum 1,5 metres.
5 Unscrew the foundation bolts.
1810828-02 129
6 When lifting and moving the separator, follow

normal safety precautions for lifting large
heavy objects.
ING
WARN
!
Crush hazards
A falling separator can cause accidents resulting
in serious injury and damage.
Never lift the separator by any other method than
described in this manual.
NOTE
When lifting parts without weight specifications,

always use lifting straps with the capacity of at
least 500 kg.
130 1810828-02
3.8.2 Lifting the bowl
When lifting and moving an assembled bowl, Weight to lift 75 kg

always follow these instructions.
1 Fit the lifting tool with lifting eyes to the bowl

assembly.
2 Check that the lock ring is mounted correctly Tightening torque 35 - 45 Nm
before lifting the complete bowl.
3 Lift the bowl using a sling with the proper
rating.
Lock ring
NOTE
Make sure that
Never try to lift the bowl while it is still in the frame. lock ring is fitted.
G0868441
The bowl body is fastened to the frame with the
cap nut.
1810828-02 131
4 CHANGE OF CIRCUIT BOARD SEPARATION UNIT 840 SERVICE MANUAL
4 Change of Circuit Board

If a circuit board has to be changed, proceed as
follows:
Note down the run time (days only) as shown in
the function list of the EPC 50.
Change the board according to the instructions
below.
Go to parameter Fa 90, and insert the run time.
OP-Board
• Switch power off.
• Remove the snap-in transparent cover.
• Disconnect the two cable plugs (do not
remove the cables from the plugs).
• Disconnect the flatcable connector at the top.
• Unscrew the five hexagon nuts.
• Mount the new board, and connect in reverse
order.
I/O-Board
If there is no optional board installed:
• Disconnect all the cable plugs on the large
board (do not remove the cables from the
plugs).
• Unscrew the hexagon nuts. Take care to note
where the special nuts for optional board(s)
are located.
order.
132 1810828-02
SEPARATION UNIT 840 SERVICE MANUAL 4 CHANGE OF CIRCUIT BOARD
If one or more optional board is installed:

• Disconnect the cable plug(s) on the optional
plug(s)).
• Disconnect the flatcable connector at the top.
• Unscrew the three hexagon nuts.
• Note the position of the board and remove the
board.
• Disconnect all the cable plugs on the large
plugs).
• Unscrew the hexagon nuts. Take care to note
where the special nuts for optional board(s)
are located.
• Mount the new board in the same position as
the old, and connect in reverse order.
MT-Board
• Disconnect the cable plug (do not remove the
cables from the plug).
• Disconnect the centrally connected cable.
• Unscrew the four screws holding the board
and lift out the board.
order.
• Check that the central hexagon nut is properly
tightened.
1810828-02 133
4 CHANGE OF CIRCUIT BOARD SEPARATION UNIT 840 SERVICE MANUAL
4.1 Circuit Board

Temperatures
Circuit board temperature information can be
read as follows:
• Set Pr 7 = 2.
• Push ‘+’ and ‘–’ at the same time (‘Standst.’
now shows on the display).
• Push ‘–’
The actual temperature, max. temperature, and
the number of times the temperature has been
above 70 °C for the transducer scrolls across the
display.
• For further circuit board temperatures, push
the ‘–’ button.
• To leave the list push the ‘+’ and the ‘–’ buttons
at the same time.
• Reset Pr 7 = 0.
134 1810828-02
SEPARATION UNIT 840 SERVICE MANUAL 5 CLEANING IN PLACE
5 Cleaning in Place
The use of Cleaning In Place (CIP)
equipment is recommended for best
separation results. For further information
concerning the CIP equipment, see the CIP
booklet, bookno. 1817261.
Before connecting the CIP equipment to the

Separation Unit, the switch on the control
cabinet must be turned to the CIP position.
This is so that oil is not accidentally pumped
when the pipeline is opened up.
5.1 Cleaning in Place,

Separator
1 Remove the pipe connecting plate with pipes
from the separator.
2 Attach the CIP equipment as shown in the
illustration.
NOTE
The top outlet on the CIP unit should be connected to

the top inlet on the separator.
G065054A
The middle inlet on the CIP unit should be connected
to the middle oil outlet on the separator.
The lower CIP inlet should be connected to the lower
water outlet on the separator.
1810828-02 135
5 CLEANING IN PLACE SEPARATION UNIT 840 SERVICE MANUAL

Heatpac® CBM Heater
For systems including a Heatpac® CBM heater,
cleaning in place of the heater should be carried
out circa every 6 months, or according to
experience. Cleaning in place of the heater
should also be carried out in the event of a
pressure drop increase greater than 0.3 – 0.5 bar
(which indicates that the heater is beginning to
clog).
We recommend that you use Alfa Laval cleaning
liquids. These are specially suitable for the
materials used in the Heatpac® CBM heater.
Liquids that are corrosive to copper or stainless
steel, for example hydrochloric acid, phosphoric
acid, or nitric acid, must not be used.
ING
WARN
!
Burn hazard
Shut off the oil flow and the heating medium flow
before starting maintenance work.
ING
WARN
!
Corrosion hazard
Pay strict attention to the safety instructions for the
cleaning liquid used.
NOTE
Use only specified cleaning liquids. Other cleaning

agents may corrode the metal surfaces.
136 1810828-02
SEPARATION UNIT 840 SERVICE MANUAL 5 CLEANING IN PLACE
Proceed as follows:
1 Close the valves before and after the heater.

2 Open the heater drain valve until oil remaining
in the heater has drained.
3 Close the drain valve.
4 Loosen the turnable connections before and
after the heater. Turn the connections 90 ° so
that the special CIP connections can be
connected.
5 Connect the CIP equipment. The top inlet on
the CIP unit should be connected to the oil
G065053A
outlet on the heater. The hose from the heater
inlet should be inserted into the tank and
secured with the help of the cover.
NOTE
The middle and lower CIP unit outlets must be

closed.
6 Clean with CIP fluid.

7 Flush with water.
After cleaning:
1 Open the heater drain valve until the flushing
water has drained.
2 Close the drain valve.
3 Remove the CIP connections.
4 Return the turnable connections to their
former positions and re-tighten.
5 Re-open the valves before and after the
heater.
1810828-02 137
5 CLEANING IN PLACE SEPARATION UNIT 840 SERVICE MANUAL

Separator and Heater
Connect the CIP equipment as shown in the

illustration. Proceed with cleaning as described Oil outlet Water outlet
above.
G065062A
138 1810828-02
SEPARATION UNIT 840 SERVICE MANUAL 6 HEATPAC® CBM HEATER (OPTIONAL)
6 Heatpac® CBM Heater (Optional)

6.1 Technical Data
Operating pressure, maximum 1.6 MPa (16 bar)
Test pressure 2.4 MPa (24 bar)
Operating temperature, maximum 225 °C
Medium Mineral oil
Heating media Steam, hot water, thermal oil
The following shall apply to the heating media:
Steam:condensate pH 8.8 - 9.2
sodium in condensate < 0.01 mg/l
Water:pH value Shall be neutral to minimize corrosion risk
Thermal oil The thermal oil must be highly resistant to oxidation and
thermal desintegration. It must also have good corrosion
protection properties.
6.1.1 Manual Cleaning

Manual cleaning is carried out as follows:
1 Disconnect the heater.
2 Drain the heater.
3 Flush the heater through with fresh water.
4 Drain the heater from water.
5 Fill the heater with hot cleaning liquid (50-
70 °C). Use the type and concentration
required for the deposits present.
6 Let the liquid stay in the heater for at least 60
minutes. If possible, let the cleaning liquid
circulate in the heater.
7 Drain the cleaning liquid.
8 Flush through with clean water.
9 Reconnect the heater using new gaskets.
NOTE
Take care to reinstall the heater the right way up.
1810828-02 139
6 HEATPAC® CBM HEATER (OPTIONAL) SEPARATION UNIT 840 SERVICE MANUAL
140 1810828-02
SEPARATION UNIT 840 SERVICE MANUAL 7 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL)
7 Heatpac® EHM Electric Heater

(Optional)
7.1 Technical Data
Media Mineral oil
Max. testing pressure 2.4 MPa (24 bar)
Operating pressure and media temp According to PN 16:
Max. 1.6 MPa (16 bar) up to 150 °C
Max. 1.5 MPa (15 bar) up to 160 °C
Material:
Heating element Aluminium
Pressure vessel Pressure vessel steel
Cover Aluminium
Insulation 20 mm mineral wool
Mounting style Vertically or horizontally
Voltage supply 230, 400, 440, 460/480/500, 690 V AC, 50/60 Hz
Connections Acc. to DIN standard 2633 or JIS standard B2213
Terminal box IP 65
Elements; resistance, surface load, output 400 V: 63 Ω, 1.3 W/cm2, 2.5 kW
440 V: 70 Ω, 1.4 W/cm2, 2.8 kW
460 V: 83 Ω, 1.3 W/cm2, 2.5 kW
480 V: 83 Ω, 1.4 W/cm2, 2.8 kW
500 V: 83 Ω, 1.5 W/cm2, 3.0 kW
690 V see 400 V (= Y-connected 400 V elements)
Tightening Torques
Flange bolts M16 240 Nm
Ground screw M8 21 Nm
Connections on elements M4 3 Nm
Element nut h = 9 M14 70 Nm
Element nut h = 5 M14 30-50 Nm
Relief valve G1/2 80 Nm
Spring pocket for Pt 100 and safety guard G1/2 30 Nm
Temperature sensors 80 Nm
1810828-02 141
7 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL) SEPARATION UNIT 840 SERVICE MANUAL
7.2 Dismantling and

Cleaning
The electric heater requires regular opening for
cleaning. The heater block resistance, and the
insulation resistance of the heating elements
should be checked and an inspection of the
general condition carried out.
Any malfunctions of the heater are indicated in
the control unit. For further information see the
Alarms and Fault Finding booklet.
As a general guideline, the heater should be
opened up for cleaning whenever an excessive
pressure drop occurs, or if capacity falls and oil
temperature is low.
Where heavy fuel is used, dismantle the heater
when warm as described below:
1 Lift off the junction box cover.

2 Loosen the cable nipples.
3 Mark the signal wires, disconnect them and
pull out the cables.
4 Remove the flange bolts.
5 Remove the earth connections between the
flanges and the junction box.
6 Lift off the heater insert. If cold heavy fuel has
stiffened the heater insert, a couple of
screwdrivers may be used to ease off the
insert. Avoid using a sling.
7 Clean the insert in a bath using Alfa-Laval
cleaning liquid part no. 1762852-01 for lube
oil heater; part no. 1763500-02 alternatively
diesel oil, white spirit, or equivalent for fuel oil
heater. Blow all parts dry with compressed air.
8 Assemble the heater in reverse order.
9 Measure the heater block resistance and the
insulation resistance to ground before
G003313A
reconnecting the wires.
142 1810828-02
7.2.1 Replacing Heater Element

1 Place the heater insert on a work bench.
2 Use a box spanner to disconnect the wires
and the connecting plates. A wiring diagram
is placed on the inside of the junction box
cover.
3 Disconnect the junction box by removing the
nuts on the heater element connecting rods
inside the the junction box, using a box
spanner. Be careful not to damage the
insulation sleeves.
4 Remove the junction box.
5 Remove the O-rings above the tightening nuts
of the heater element connecting rods.
6 Remove the nuts using a box spanner.
7 Pull out the heater element.
8 When reassembling:
9 Use a new copper packing.
10 Screw fast the elements in the top counter
flange.
11 Before refitting the junction box, change the
O-rings.
For tightening torques, see page 141.
ON
CAUTI
!
It is very important that the appropriate heater

element is installed.
1810828-02 143
7.2.2 Insulation Resistance Megger

Test
The heating elements are electrically insulated
by means of compact magnesium oxide. Under
certain conditions, e.g. during storage, transport,
etc., magnesium oxide can attract damp which
lowers the insulation resistance. The insulation
resistance between terminal and ground for each
heater block must therefore be measured before
the heater is taken into use. This is done by
means of a megger test.
Megger Test Procedure

• Disconnect the wires from the terminal in the
heater junction box before starting
measurement.
• Test the insulation resistance for the heater
blocks by means of a megger connected
between the heater terminals and ground in
the heater junction box. The test voltage to
use is 500 V DC.
The total insulation resistance for the heater
should be ≥1 MΩ.
G003322A
144 1810828-02
Action to Increase Insulation Resistance

If the insulation resistance is between 100 kΩ
and 1 MΩ, the heater can be reconditioned in
place simply by taking it into use.
Please note that during the first period of
operation the insulation resistance can be
somewhat reduced before it starts to increase.
This is due to the accumulation of moisture in
the element top during heating.
In the event the insulation resistance is below
100 kΩ in any group of elements, the elements in
the group must be measured separately. The
insulation resistance in a single element is
measured between the connecting pin on the
element, with the closing links disconnected, and
the ground.
A single element with resistance below 100 kΩ
can be reconditioned in place by indirect
warming. Do not connect the connecting pins via
the closing link to the terminal. Connect the
remaining elements in the block to the terminal
and allow the heater to be taken into operation.
New Megger Test

If the insulation resistance at start-up was
under 1 MΩ, a new megger test should be carried
out after 14 days operation. The elements should
now have a resistance of over 1 MΩ. If this is not
the case, any element still below 1 MΩ should be
replaced.
1810828-02 145
7.2.3 Measuring of Heater Block

Resistance
The heater block resistances are measured from

the power unit. This ensures that the heater
elements and the heater blocks are correctly
connected.
G003171A
Resistances of available heater sizes and
applicable voltage supply are given in the
following table:
.
Heater Block Resistance (Ω)

Size Voltage (V) Part load 1 Part load 2 Part load 3 Part load 4
7 kW 400 42 ---- ---- ----
8 kW 440 47 ---- ---- ----
8 kW 480 55 ---- ---- ----
7 kW 690 V 126 ---- ---- ----
14 kW 400 21 ---- ---- ----
16 kW 440 23 ---- ---- ----
16 kW 480 28 ---- ---- ----
14 690 63 ---- ---- ----
22 kW 400 21 42 21 ----
24 kW 440 23 47 23 ----
24kW 480 28 55 28 ----
22 690 63 126 63 ----
36 kW 400 21 42 21 ----
40 kW 440 23 47 23 ----
40 kW 480 23 47 23 ----
36 690 63 126 63 ----
50 kW 400 21 42 21 21
56 kW 440 23 47 23 23
56 480 28 55 28 28
50 690 63 126 63 63
65 kW 400 21 42 21 11
72 kW 440 23 47 23 12
72kW 480 28 55 28 14
65 690 63 126 63 32
146 1810828-02
Terminals for Block Resistance Measuring

Power unit Part load 1 Part load 2 Part load 3 Part load 4
X11:4-5 X11:7-8 X11:10-11 X11:13-14
X11:4-6 X11:8-9 X11:10-12 X11:14-15
X11:5-6 X11:7-9 X11:11-12 X11:13-15
Control unit X11:4-5 X11:7-8 ---- ----
X11:4-6 X11:8-9 ---- ----
X11:5-6 X11:7-9 ---- ----
Contactor box ---- ---- K21:2-4 K22:2-4
---- ---- K21:4-6 K22:4-6
---- ---- K21:2-6 K22:2-6
1810828-02 147
148 1810828-02
SEPARATION UNIT 840 SERVICE MANUAL 8 HEATPAC® POWER UNIT (OPTIONAL)
8 Heatpac® Power Unit (Optional)

8.1 Technical Data
Power circuits. Up to 24 kW (smaller cabinet )
31830-6356-1
Mains supply (3 phase) 400, 440, 460/480/500 V AC +10% /-15% ,
50/60 Hz ±5%
External fuse Max. 35 A
Overcurrent protection Thermal relays, 16-23 A/8.5-12.5 A
Triac circuit current Max. 23 A
Power circuits. 36 kW to 72 kW (larger cabinet )
31830-6407-1
Mains supply (3 phase) 400, 440, 460/480/500 V AC +10% /-15% ,
50/60 Hz ±5%
External fuse Max. 100 A
Overcurrent protection Fuses, 25 A, 16 A, 25 A, 63 A
Triac circuit current Max. 23 A
Control circuits
Control voltage 24 V AC +10% /-15% , 50/60 Hz ±5% (from external
control unit)
Power consumption (inrush/hold) 31830-6356-1 Max. 120 VA/30 VA
31830-6407-1 Max. 200 VA/55 VA
General
High voltage tested at 2000 V
Max. ambient temperature 55 °C
Protection class IP 65
Material Steel
Weight
Smaller cabinet 40 kg
Larger cabinet 54 kg
External inputs and outputs
Inputs Mains supply
Control signals (24 V AC)
Aux. contact on contactor for pump
Pt 100 temp. sensor (to internal high temp. switch).
Outputs Power to heater
Safety alarm feedback to control unit
1810828-02 149
8 HEATPAC® POWER UNIT (OPTIONAL) SEPARATION UNIT 840 SERVICE MANUAL
8.2 Working principle

Power for the electric heater is supplied from an
external power source via the main switch and
the different contactors.
The contactor K11 supplies power to a variable
heater load of 0-7/8 kW or
0-14/16 kW, which is controlled from the triac
modules A1 and A2. This contactor is activated
at all times once the heater is started and as long
as the control unit signals no function fault. The
remaining contactors (K12 and K16-K17, if
applicable) supply power to fixed heater loads as
on/off functions in accordance with the size of the
heater. By combining the variable load and the
fixed loads, an overall stepless heater is
achieved.
8.3 Electric Heater

Function
By using the proportional and integral (PI)
functions in the EPC, it is possible to activate the
power unit load functions to feed the electric
heater with variable and fixed power.
The power unit is equipped with the necessary
contactors, fuses and terminals.
The power unit also holds two triac modules (A1
and A2) for regulating the variable load.
The electric heater requires an extra
temperature sensor (on the heater) connected to
a temperature switch (in the power unit) to
prevent overheating.
150 1810828-02
8.4 Heating Performance

Principle
The oil temperature is regulated from the control

unit which gives the appropriate signals to the
power unit. The power unit feeds the electric
heater with both variable and fixed power.
The fixed power is fed in steps as a constant part
load. The variable load operates on top of the
fixed part load for fine tuning of temperature.
Sequential switching of the fixed part load and
regulation of the variable part load are
automatically controlled by the control unit, and
results in an overall smooth operation.
G025651A
A Load (kW)
B Size (kW)
1. Part load #1 (variable 0 –16 kW)
2. Part load #2 (fixed 8 kW)
3. Part load #3 (fixed 16kW)
4. Part load #4 (fixed 32kW)
Heating Performance Principle for 440 V
1810828-02 151
8.5 Load Control and

Functions
8.5.1 Variable Part Load
Power for the variable part load (#1) is fed via

contactor K11 in the power unit and regulated
by means of the two triac modules A1 and A2.
Contactor K11 is activated provided that there is
a closed circuit through the safety switch (TS)
and that there are no function faults in the
control unit (see electrical diagram in System
Reference/Installation Instructions). The triac
modules are controlled from the control unit.
The required electric power is then supplied to
the heater in accordance with the present load.
Contactor K11 is furnished with a variable
overload protection relay (F11).
8.5.2 Fixed Part Load
Power to the fixed part loads (#2 – #4) is fed via

contactors K12, K16, and K17, and controlled
from the control unit as on/off functions in
accordance with the present load.
The contactors are switched off by the heater
safety switch function (TS, K14) in the case of
excessive temperature or low oil flow (pump
interlocking).
152 1810828-02
8.5.3 External Safety Stop
The contactor circuits for switching power on/off

to the different part loads are interlocked by
means of the external safety stop switch (which
is connected in series to the internal
temperature switch TS), to prevent the electric
heater from overheating.
The contactors K11, K12, K16, and K17 in the
power unit are connected in series to the internal
temperature switch TS. Excessive temperature
or no oil flow (pump stopped) will deactivate the
contactors, thus switching off the heater.
Overload relays/fuses F11, F12, F16, and F17 in
the power unit are used for overload protection.
8.5.4 Start and Reset Functions
During normal operation, the contactors in the

power unit are activated from the Control Unit
and interlocked by the pump starter and
contactor K14. Contactor K14 is interlocked by
the temperature switch.
• If the temperature switch has been released,
the heater must be restarted using the Alarm
Reset on the Control Unit after the cause has
been remedied.
1810828-02 153
154 1810828-02

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Separation Unit 840

8 Heatpac® Power Unit

The frame hood contains the processing parts of

1.2 The Drive Section

To reduce bearing wear and the

The bearings on the spindle are

1.3 The Process Section

Inlet and outlet

Water paring chamber

Holder Operating water ring

Speed sensor Monitoring kit (option)

Cover interlocking switch

Speed sensor G0873471

1.5 Separating Function

1.5.1 The liquid balance in the bowl

SEPARATOR BOWL TURNED 90°

1.5.2 Liquid flow

1.5.3 Discharge of sludge and water

1.5.4 ALCAPTM concept

DISCHARGE OF WATER THROUGH WATER OUTLET

Oil paring disc Water

Water paring tube

The separator is a component operating in an

Product number: 881203-03-01

89/336EEC EMC and amendments related to said directive.

EN 292-2 Safety of machines. Use of the machine in applications subject to

Alfa Laval ref. 562576 rev. 3

Subject Value Unit

2.2 Connection List

No. Description Requirements/limits

201 Inlet for process liquid

206 Inlet for conditioning and displacement liquid

220 Outlet for light phase, clarified liquid

221 Outlet for heavy phase No counter pressure.

222 Outlet for solid phase

375 Inlet for discharge and make-up liquid

• Max density Max. 1000 kg/m3

• Pressure min. 150 kPa

• Consumption 1,7 litres/hour

• Consumption 0,55 litres/discharge

• Consumption 0,7 litres/discharge

462 Drain of frame top section, lower

701 Motor for separator

752 Position transducer for bearing holder See page 22.

760 Cover interlocking switch

2.3 Interface Description

Standards referred to are:

Access to moving parts. Can cause injury to person who

Insufficient cleaning of separator. Unsatisfactory product quality.

Bowl leakage. Product losses.

Information and instructions given in this

2.3.5 Description of separator modes

Stand still means:

2.3.6 Remote start

2.3.7 Handling of connection

There shall be an emergency stop circuit

740 Speed sensor

Signal processing in RUNNING:

752 Unbalance sensor (option).

The vibration level shall be high for 3 seconds to

760 Cover interlocking switch (option)

Processing in NORMAL STOP or EMERGENCY

220, 221 and 222 Outlets

Processing in other modes: