Professional Documents
Culture Documents
Service Manual
Printed Jun 2001
Book No. 1810690-02 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 2001.
Contents
1 Separator Design ................................. 1 2.8 Oil Change ........................................98
1.1 Overview .............................................1 2.8.1 Lubricating oil .......................................98
1.2 The Drive Section.............................3 2.8.2 Check oil level ......................................99
1.3 The Process Section .......................4 2.8.3 Oil change procedure...........................99
1.4 Sensors................................................8 2.8.4 Lubrication chart.................................100
1.5 Separating Function ........................9 2.8.5 Recommended lubricants ..................101
1.5.1 The liquid balance in the bowl ...............9 2.8.6 Recommended lubricating oils...........103
1.5.2 Liquid flow ............................................10 2.8.7 Recommended oil brands ..................104
1.5.3 Discharge of sludge and water ............10 2.9 Lifting instructions ......................105
1.5.4 ALCAPTM concept................................11 2.9.1 Lifting the separator............................105
2.9.2 Lifting the bowl ...................................106
2 Separator Service,
Dismantling, Assembly ................. 13 3 Change of Circuit Board ............ 108
2.1 Technical Data ................................13 3.1 Circuit Board Temperatures .....110
2.2 Periodic Maintenance ...................14
4 Cleaning in Place ........................... 111
2.2.1 Maintenance intervals ..........................14
4.1 Cleaning in Place,
2.2.2 Maintenance procedures .....................16 Separator ........................................111
2.2.3 Tightening of screws ............................17 4.2 Cleaning in Place, Heatpac®
2.2.4 Service kits ...........................................18 CBM Heater ....................................112
2.2.5 Cleaning ...............................................18 4.3 Cleaning in Place, Separator
2.3 Maintenance Log ............................19 and Heater ......................................114
2.4 Dismantling ......................................21
5 Heatpac® CBM Heater
2.4.1 Introduction...........................................21
(Optional) ............................................. 115
2.4.2 Tools .....................................................22
5.1 Technical Data .............................115
2.4.3 Frame hood ..........................................24
5.1.1 Manual Cleaning.................................115
2.4.4 Bowl......................................................26
2.4.5 Driving device ......................................36 6 Heatpac® EHM Electric
2.4.6 Centrifugal clutch .................................48 Heater (Optional) ........................... 117
2.5 Actions Before Assembly ............54 6.1 Technical Data .............................117
2.5.1 Cleaning .............................................54 6.2 Dismantling and Cleaning..........118
2.5.2 Inspection for corrosion ......................55 6.2.1 Replacing Heater Element..................119
2.5.3 Inspection for cracks ..........................56 6.2.2 Insulation Resistance Megger Test ....120
2.5.4 Inspection for erosion .........................57 6.2.3 Measuring of Heater Block
2.5.5 Exchange of frame feet ........................59 Resistance .........................................122
2.5.6 Lubrication of bowl parts ......................60
2.6 Assembly...........................................61
7 Heatpac® Power Unit
2.6.1 Centrifugal clutch .................................61
(Optional) ............................................. 124
2.6.2 Driving device .....................................65 7.1 Technical Data .............................124
2.6.3 Bowl......................................................77 7.2 Working principle .........................125
2.6.4 Frame hood ..........................................90 7.3 Electric Heater Function ..........125
2.6.5 Unbalance sensor (option) ...................94 7.4 Heating Performance
Principle .........................................126
2.7 Actions After Assembly ...............96
7.5 Load Control and Functions......127
2.7.1 Control of machine plates and
safety labels ........................................96 7.5.1 Variable Part Load .............................127
7.5.2 Fixed Part Load .................................127
1810690-02
7.5.3 External Safety Stop ......................... 128
7.5.4 Start and Reset Functions ................ 128
1810690-02
SEPARATION UNIT 700 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 sensor. An The rotating separator
unbalance sensor and a bowl is driven by a flat
interlocking switch is belt transmission.
optional.
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 sump for lubrication of spindle bearings.
1810690-02 1
1 SEPARATOR DESIGN SEPARATION UNIT 700 SERVICE MANUAL
2 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 1 SEPARATOR DESIGN
Flat belt
The flat belt transmission has a
ratio which increases the bowl
speed several times compared
with the motor speed.
1810690-02 3
1 SEPARATOR DESIGN SEPARATION UNIT 700 SERVICE MANUAL
4 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 1 SEPARATOR DESIGN
Pipe
Spring
Uncleaned oil
Cleaned oil
Water
Arm
Paring tube
Paring disc
Connection house
G0886141
1810690-02 5
1 SEPARATOR DESIGN SEPARATION UNIT 700 SERVICE MANUAL
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 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 1 SEPARATOR DESIGN
Top disc
Oil paring chamber
Bowl body
Disc stack
Lock ring
Seal ring
Discharge
slide
Operating slide
Sludge space
Nozzle
G0886951
1810690-02 7
1 SEPARATOR DESIGN SEPARATION UNIT 700 SERVICE MANUAL
1.4 Sensors
The separator is equipped with a speed
sensor. As an option, an unbalance sensor
can be fitted.
Unbalance sensor
Speed sensor
G0873471
8 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 1 SEPARATOR DESIGN
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
1810690-02 9
1 SEPARATOR DESIGN SEPARATION UNIT 700 SERVICE MANUAL
10 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 1 SEPARATOR DESIGN
1810690-02 11
1 SEPARATOR DESIGN SEPARATION UNIT 700 SERVICE MANUAL
Unseparated oil
Bowl hood
Separated oil
Top disc
Sludge
space
Oil/water interface
Uncleaned oil
Cleaned oil
Water
G0886231
12 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
93/44EEC
1810690-02 13
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
14 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
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.
1810690-02 15
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
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.
N
CAUTIO
!
16 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
Example:
a Fit the O-ring ii .
Torque
M8 17 1,7 13 20 2 14,7
1810690-02 17
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
NOTE
ING
WARN
!
Disintegration hazards
Use of imitation spare parts may cause severe
damage.
2.2.5 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
!
18 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
Overhaul
Check
1810690-02 19
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Inspection
Overhaul
Check
Part i o Action Page Note
Driving device
- All parts x Clean 54
- All parts x Check for corrosion 55
- All parts x Check for cracks 56
- Bottom bearing housing x Renew O-ring 65
- Labyrinth ring holder x Renew labyrinth ring 66
x Renew O-ring 66
- Top bearing housing x Renew springs 68
- Flat belt x Renew flat belt 73
- Bowl spindle x Pre-lubricate and renew ball bearing 67
x Pre-lubricate and renew self-aligning
roller bearing 69
x Lubricate the spindle
x Measure the radial wobble 75
- Neck bearing cover x Renew O-ring 74
- Deflector ring x Renew O-ring 74
- Water inlet pipe x Renew O-ring 75
- Operating water cover x Renew seal ring and O-ring 75
- Fan x Renew the O-ring 71
Coupling
- All parts x Clean 54
- All parts x Check for corrosion 55
- All parts x Check for cracks 56
- Coupling hub x Renew single row ball bearings
- Friction blocks x Renew friction pads (if they are worn) 61
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 96
- Power supply frequency x Check attachment and legibility 96
- Lifting instructions x Check attachment and legibility 96
- Safety labels x Check attachment and legibility 96
- Name plate x Check attachment and legibility 96
- Representative label x Check attachment and legibility 96
20 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
2.4 Dismantling
2.4.1 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.
NOTE
1810690-02 21
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
2.4.2 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.
22 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
Sandard Tools
3 4
1 2 6
7 12
9 10 11
8
13
15
G0911651
14
1 Screwdriver
2 Torque wrench (capacity 0-200 Nm)
3 Drift ( Ø 4 mm)
4 Dial indicator with magnetic base
5 Spanner for clutch
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
15 Hexagon head key
1810690-02 23
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Connecting
housing
Spring
Arm
G0863331
Screws
G0860531
1
ING
WARN O-ring
!
Height adjusting
rings
Entrapment hazard
To avoid accidental start, switch off and lock-out the Support ring
G0863451
power supply before starting any dismantling work.
24 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
NOTE
G0863661
Paring tube
NOTE
b Loosen the hood
Do not place
by bending with
the hood
a screwdriver in upside down.
all grooves in the
hood.
G0863671
1810690-02 25
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
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
26 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
Be sure not to
cover the threaded
holes.
f Remove the
dismantling screws.
G0862751
1810690-02 27
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
e 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
28 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
NOTE
ING
WARN
!
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.
G0862931
1810690-02 29
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
NOTE
Axial support
NOTE
30 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
ON
CAUTI
!
Cut hazard
Sharp edges on the separator
discs may cause cuts
G0863161
7 Removing the nut
Nut
Compressing tool
Screw
1810690-02 31
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
NOTE
If discharge slide is
difficult to remove,
tap lightly on outside
edge with a soft
faced hammer.
Ring on tool
Puller rod
Discharge slide
Bowl body
ING
WARN
!
Crush hazard
The ring on the lifting tool must be pushed
down against the discharge slide, otherwise the
discharge slide may come loose from the tool.
G0863251
32 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
NOTE
Left-hand thread!
G0860651
10 Removing the bowl body
1810690-02 33
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
ING
WARN
!
Crush hazard
G0860821
Support the bowl body when turning to prevent it from rolling.
NOTE
34 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
NOTE
G0861021
14 Removing the operating water ring.
a Loosen and remove the screws .
NOTE
1810690-02 35
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
G0857961
G0857821
5 6
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
O-ring
Plugs
G0858061
Strainer
36 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
G0858151
2 Empty the oil sump.
1810690-02 37
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Nut
ING
WARN
!
Crush hazard
c Remove the flat belt from the motor pulley. The motor will come off if the screws are
G0858881
unscrewed.
38 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
NOTE
G0858931
5 Removing the neck bearing cover and deflector ring.
Cover
G0859061
Frame
1810690-02 39
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
NOTE
NOTE
G0859151
40 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
ING
WARN
!
Crush hazard
Do not rotate the spindle assembly
during lifting. The spindle assembly
may otherwise come loose from the
lifting tool.
G0907831
1810690-02 41
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Make a support
~230 mm
~205 mm
~6,5 mm
free space
G0859211
9 Removing the air deflector.
42 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
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.
NOTE
Lubrication oil orifice c Cover the the oil orifice and blow compressed
air through the bottom hole of the oil pump and
slowly ease out the lubrication oil orifice.
G0865971
Compressed air
1810690-02 43
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
G0858221
44 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
ING
WARN
!
NOTE
Vibration indicator
Piece of wood to
protect the spindle
threads.
NOTE
Always discard
c 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
1810690-02 45
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
NOTE
G08586B1
46 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
a Fit the tool into the bottom bearing holder and attach the
extension rod and T-handle
T-handle
Extension rod
Tool
1810690-02 47
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Ball bearings
Spacing ring
Belt pulley
G0864711 Coupling
ING hub
WARN
!
Parallel pin
Entrapment hazard
To avoid accidental start, switch off and lock-out
power supply before starting any dismantling work.
Friction blocks
(5=50 Hz)
Make sure that machine has come to a complete
standstill before starting any dismantling work Sleeve
(takes about 55 minutes from switch off).
Fan
G0865161
NOTE
50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks
2
G0865021
48 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
G0858151
2 Loosen the flat belt, by tilting the motor.
Nut
ING
WARN
!
Crush hazard
c Remove the flat belt from the motor pulley. The motor will come off if the screws are
G0858881
unscrewed.
1810690-02 49
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
ING
WARN
!
Electrical hazard
If the cables are not disconnected during lifting procedures,
they may become damaged.
b Fit a sling to the c Tense the lifting sling to support the motor and
motor using a remove the screws. Lift the motor while supported.
shackle on the upper
part.
ING
Weight of motor with WARN
coupling: approx. !
170 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.
Friction blocks
(5=50 Hz)
Sleeve and screw
Fan
NOTE
50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks
G0865241
50 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
NOTE
NOTE
G0865341
1810690-02 51
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Washer
Spring washer
Screw
NOTE
ING
WARN
!
Crush hazard
The centrifugal clutch is heavy and
can fall, causing injury, when
loosened from the motor shaft.
Puller tool
52 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
Wooden support
Support
NOTE
1810690-02 53
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
2.5.1 Cleaning i o
Clean the separator parts according to the
diagram below. Afterwards, protect all cleaned
carbon steel parts against corrosion by oiling.
Frame and The external cleaning of the frame and motor should be Water and de-greasing agent.
motor restricted to brushing, sponging or wiping while the motor is
running or still is hot.
ING
WARN
!
Electrical hazard
Never wash down a separator with a direct water
stream.
Never play a water jet on the motor. Totally
enclosed motors can be damaged by direct hosing
to the same extent as open motors, resulting in
short-circuit and internal corrosion.
ON
Cleaning of holder for operating slide, operating water CAUTI
ring and operating slide with nozzle. !
Driving device Use a sponge or a soft brush. White spirit, cleaning-grade kerosene
or diesel oil.
54 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
Max. 0,2 mm
! D
ANGER
G0205241
Disintegration hazards
Always contact your Alfa Laval representative if you
suspect that the depth of the corrosion damage
exceeds 0,2 mm for bowl body and bowl hood (0,5
for other parts) or if cracks have been found. Do not
continue to use the separator until it has been
inspected and given clearance for operation by Alfa
Laval.
Non-stainless steel Water or dampness Rust If damage exceeds 0,5 mm, contact
and cast iron parts Alfa Laval.
Stainless steel Chlorides or acidic Acidic solutions cause general Polish dark-coloured spots and
solutions corrosion. other corrosion marks with a fine
Chloride corrosion begins as small grain emery cloth. This may prevent
dark spots that can be difficult to further damage.
detect, and goes on to local damage If damage exceeds 0,5 mm (0,2 mm
such as pitting, grooves or cracks. for bowl body and bowl hood)
contact Alfa Laval.
Other metal parts “Aggressive” Possible corrosion damage can be If damage exceeds 0,5 mm, contact
environment in the form of pits and/or cracks. Alfa Laval.
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.
1810690-02 55
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
R
! DANGE
Disintegration hazard
All forms of cracks are potentially dangerous as they
reduce the strength and functional ability of
components.
Always replace a part if cracks are present.
R
! DANGE
Disintegration hazards
Always contact your Alfa Laval representative if you
suspect that the depth of the damage exceeds 0,2
mm for bowl body and bowl hood (0,5 for other
parts).
Do not continue to use the separator until it has
been inspected and given clearance for operation by
Alfa Laval.
56 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
Lock ring
Bowl body and holder.
G0911831
distribution holes and wings
NOTE
1810690-02 57
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
R
! DANGE
Disintegration hazard
Erosion damage weakens parts by reducing the
thickness of the material.
Pay special attention to the pillars between the
sludge ports in the bowl wall.
Replace parts if erosion is suspected of affecting
strength or function.
58 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
NOTE
1810690-02 59
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Nut
Discharge slide
Bowl body
(also apply D321 on guide pin)
Operating slide
(also apply D321)
Holder
60 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
2.6 Assembly
a Slip the belt pulley over the coupling hub and place them on a firm and level
foundation.
ING
WARN
!
Disintegration Hazard
If the belt pulley must be renewed, check that the new pulley has the
correct diameter. An incorrect pulley will cause the separator bowl to
run at either an excessive or insufficient speed.
d=265 mm 50 Hz
d=221 mm 60 Hz NOTE
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
1810690-02 61
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
NOTE
Make sure that the key is in place on b Apply lubricating paste to the tool
the motor shaft. threads (keep lubricated).
62 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
Guide pin
NOTE
NOTE
50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks
Fan
Screws
G0865461
1810690-02 63
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
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.
G0864651
5 Fitting the flat belt.
ING
WARN
!
Crush hazard
The motor will come off if the
screws are unscrewed.
G0858891
64 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
Tool
1810690-02 65
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
G0866361
66 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
3 Fitting the ball bearing and top bearing seat o to the spindle.
a Heat the top bearing seat in oil to b Fit the ball bearing.
maximum 125 °C.
ING
WARN NOTE
!
Always fit a new bearing.
Burn hazard Pre-lubricate before fitting.
Use protective
gloves when
handling any heated
parts.
ING
WARN
!
NOTE
1810690-02 67
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Axial springs
b Carefully lower the bowl spindle.
Make sure that the springs enter the
recesses on the top bearing seat.
68 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
NOTE
G0866731
6 Fitting the self-aligning roller bearing o .
ING
WARN
!
Burn hazard
Use protective gloves when
handling the heated bearing.
G0866841
1810690-02 69
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
a Fit O-ring onto lubrication oil orifice. Spread oil film on c Lubricate all threads before
O-ring. assembly.
b Push lubrication oil orifice into oil pump. Be sure to
line up tabs on orifice with slots in pump.
NOTE
G0866951
70 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
NOTE
Silicone grease
Key-grip
G0924021
1810690-02 71
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
G0859231
72 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
ING
WARN
!
Crush hazard
Do not rotate the spindle assembly during lifting. The spindle
assembly may otherwise come loose from the lifting tool.
NOTE
Check that the hole at the bottom of the oil pump is clean before
lowering the assembly down.
Carefully blow
compressed air
through the hole in
the bearing housing. b Position the flat belt
Check the bottom hole. o in correct position.
See note below.
ING
WARN
!
Cut hazard
Do not put fingers between the frame
and air deflector while lowering the
assembly.
NOTE
1810690-02 73
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
G0858891
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
74 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
O-ring
NOTE
G0868141
14 Measuring the radial wobble of the bowl spindle.
Max. 0,04 mm
G0858711
1810690-02 75
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
G0858161
a Fit the clutch cover.
NOTE
76 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
2.6.3 Bowl
Disintegration hazard
Impact marks may cause the separator to
vibrate while running.
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
1810690-02 77
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Alignment hole
Operating slide
Bowl body
Guide pin
G0861241
4 Fitting the operating slide holder.
G0861331
78 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
NOTE
a Fit the ring i
The discoloration on the ring is oxide protection.
Do not clean with abrasives.
NOTE
G0861441
1810690-02 79
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
ING
WARN
!
Crush hazard
Support the bowl body when turning to
prevent it from rolling.
80 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
NOTE
Left-hand thread!
Compressing tool
Screw
G0861851
Cap nut
1810690-02 81
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
O-ring
ING
WARN
!
c Fit the lifting tool and
lower the discharge
slide into the bowl. Crush hazard
The ring on the lifting tool must be
pushed home against the discharge
d Remove the lifting tool. slide, otherwise it may come loose
from the tool.
82 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
N
CAUTIO
!
Cut hazard
Sharp edges on the bowl discs may cause
cuts.
1810690-02 83
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Guide rib on
distributor
84 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
Tolerance ring
G0984911
12 Mounting the paring tube and fitting the inlet and outlet pipe.
1810690-02 85
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
To avoid damaging
the paring tube, turn
it towards the centre
of the pipe.
G0862341
86 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
1810690-02 87
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
NOTE
Lock ring
Bowl hood
NOTE
88 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
a Remove bowl hood, top disc and inlet and outlet pipe.
1810690-02 89
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
NOTE
G0863771
Make sure to fit the frame hood
groove and the projection of the
90 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
A Quantity height
mm adjusting rings
38 ± 0,5 5
37 ± 0,5 4
36 ± 0,5 3
35 ± 0,5 2
34 ± 0,5 1
a Remove the guide screw
Support ring
Frame hood
A
Important!
B =2
Bowl hood
Paring disc
Distributor
G0911591
1810690-02 91
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Spring
e Fit the spring on the arm
and fit the arm to the top
of the paring tube end.
Arm
Pin Paring tube
G0863781
92 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
NOTE
G0863941
1810690-02 93
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Sensor holder.
Sensor
holder
O-ring NOTE
NOTE
94 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
A
Holder edge
Sensor arm
c Fit the sensor into the holder. Do not forget the nut.
1,5 mm
Nut
Sensor
Nut.
+ = brown or red
J = black or white 24 V DC
0V = blue
e When correct distance is achieved tighten the nut Adjustment value (approx. distance 1,5 mm) for the sensor
is; 12 mA ± 1mA.
against the holder.
Fit the cover (see previous page).
G0873461
1810690-02 95
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Machine plate
Lifting instructions
Safety label.
S0 0 5 0 1 7 1
96 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
Separator S 700
Manufacturing serial No. / Year
Product No. 881206-01-01
In and outlet device 563839-01
Bowl 563319-01
Machine bottom part 563553-01
Max. speed (bowl) 7118 r/min (50 Hz)
7081 r/min (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 18,5 kW
Max. density of feed 1100 kg/m3
Max. density of sediment 2057 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.
1810690-02 97
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
NOTE
Always clean and dry parts (also tools) before lubricants are applied.
ON
CAUTI
!
98 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
ON
CAUTI
!
Burn hazard
The lubricating oil and various machine surfaces can Oil fill
be sufficiently hot to cause burns.
Oil drain
G0868771
NOTE
1810690-02 99
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
Buffers (3)
Bearings (1)
Centrifugal clutch (6)
G0875441
Lubricating points Lubricants
1 Bowl spindle ball bearings and buffers are lubricated by Lubricating oil as specified in 2.8.7 Recommended oil
oil mist. brands, page 104.
2 Bowl spindle taper. Lubricating oil, only a few drops for rust protection.
6 Friction coupling ball bearings. The bearings are packed with grease and sealed, they
need no extra lubrication.
100 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
NOTE
Bonded coatings
1810690-02 101
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
NOTE
Manufacturer Designation
BP Energrease MM-EP2
Energrease LS2
Elf Epexa 2
102 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
Oil change
interval
NOTE
1810690-02 103
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
NOTE
Manufacturer Designation
BP Bartran 100
104 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
G0868451
1 Remove the inlet and outlet device, the frame
hood and the bowl according to the
instructions in 2.4 Dismantling, page 21.
NOTE
1810690-02 105
2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 700 SERVICE MANUAL
ING
WARN
!
Crush hazards
A falling separator can cause accidents resulting
in serious injury and damage.
Never lift the separator by any other method than
described in this manual.
NOTE
NOTE
Make sure that
Never try to lift the bowl while it is still in the frame. lock ring is fitted.
G0868441
106 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 2 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY
1810690-02 107
3 CHANGE OF CIRCUIT BOARD SEPARATION UNIT 700 SERVICE MANUAL
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
• Switch power off.
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.
• Mount the new board, and connect in reverse
order.
108 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 3 CHANGE OF CIRCUIT BOARD
MT-Board
• Switch power off.
• 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.
• Mount the new board, and connect in reverse
order.
• Check that the central hexagon nut is properly
tightened.
1810690-02 109
3 CHANGE OF CIRCUIT BOARD SEPARATION UNIT 700 SERVICE MANUAL
110 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 4 CLEANING IN PLACE
4 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.
NOTE
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.
1810690-02 111
4 CLEANING IN PLACE SEPARATION UNIT 700 SERVICE MANUAL
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
112 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 4 CLEANING IN PLACE
Proceed as follows:
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
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.
1810690-02 113
4 CLEANING IN PLACE SEPARATION UNIT 700 SERVICE MANUAL
G065062A
114 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 5 HEATPAC® CBM HEATER (OPTIONAL)
NOTE
1810690-02 115
5 HEATPAC® CBM HEATER (OPTIONAL) SEPARATION UNIT 700 SERVICE MANUAL
116 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 6 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL)
Tightening Torques
Ground screw M8 21 Nm
Connections on elements M4 3 Nm
Temperature sensors 80 Nm
1810690-02 117
6 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL) SEPARATION UNIT 700 SERVICE MANUAL
118 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 6 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL)
ON
CAUTI
!
1810690-02 119
6 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL) SEPARATION UNIT 700 SERVICE MANUAL
G003322A
120 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 6 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL)
1810690-02 121
6 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL) SEPARATION UNIT 700 SERVICE MANUAL
G003171A
Resistances of available heater sizes and
applicable voltage supply are given in the
following table:
.
122 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 6 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL)
1810690-02 123
7 HEATPAC® POWER UNIT (OPTIONAL) SEPARATION UNIT 700 SERVICE MANUAL
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
124 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 7 HEATPAC® POWER UNIT (OPTIONAL)
1810690-02 125
7 HEATPAC® POWER UNIT (OPTIONAL) SEPARATION UNIT 700 SERVICE MANUAL
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)
126 1810690-02
SEPARATION UNIT 700 SERVICE MANUAL 7 HEATPAC® POWER UNIT (OPTIONAL)
1810690-02 127
7 HEATPAC® POWER UNIT (OPTIONAL) SEPARATION UNIT 700 SERVICE MANUAL
128 1810690-02