Professional Documents
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Wartsila Purifier Manual
Wartsila Purifier Manual
Mechanical Separation
Mineraloil Systems GmbH
Division
No.: 2057-9001-110
Edition: 1005
Subject to modification!
The authors are always grateful for comments and suggestions for improving
the documentation. They can be sent to
GEA Westfalia Separator Mineraloil Systems GmbH
Werner-Habig-Str. 1
D-59302 Oelde
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Model S/N
Built in ø in mm
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• Take special care when carrying out operations marked with this
symbol -
otherwise danger to life.
Note: • This symbol is not a safety precaution but rather a reference to infor-
mation which help to better understand the separator or plant compo-
nents and the processes.
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1 Safety precautions 9
2 Machine description 31
3 Operation 53
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5 Accessories 173
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7 Appendix 215
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1 Safety precautions
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1 Safety sticker
2 Oil quality
3 Plates
4 Nameplate
5 Maker's nameplate
The texts and part numbers of the safety markings change depending on the
languages required by the customer.
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Fig. 2
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Fig. 5
Fig. 6
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Note:
This adhesive plate is only used for
frequency converter operation.
Fig. 7
Note:
This adhesive plate is only used for
hot operation.
Fig. 8
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Fig. 9
Under the influence of the centrifugal forces, separation of the liquid mixture
and/or ejection of the solids particles takes place most rapidly.
The specifically heavier components are displaced to the bowl periphery, whe-
reas the specifically lighter components are displaced towards the centre of the
bowl.
The high centrifugal force is produced by very high bowl speeds. On the one
hand, high bowl speeds signify high efficiency, while on the other hand, they
signify high material stressing of the separator.
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Fig. 11
1.6.1 Assembly
Fig. 12
Fig. 13
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Fig. 14
Fig. 15
Fig. 16
Fig. 17
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Fig. 18
Fig. 20
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Fig. 21
Fig. 22
Fig. 23
Fig. 24
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Fig. 25
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1.6.4 Starting
Fig. 26
Fig. 27
Fig. 28
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Fig. 29
Fig. 30
Fig. 31
Fig. 32
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Fig. 33
Fig. 34
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Fig. 35
Maintenance and repair work may only be carried out by the customer to the ex-
tent as described in this instruction manual.
Maintenance and repair work not described in this manual may only be
carried out by the manufacturer or by "repair shops" authorized by the
manufacturer.
We, therefore, recommend in your own interest to have your separator in-
spected by our service engineers at regular intervals. Such inspections will keep
your separator working reliably and prevent undesirable shut-downs.
Fig. 36
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Fig. 37
Fig. 38
Fig. 39
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Fig. 40
Fig. 41
• All load suspension devices have to be checked for completeness and for
possible damage at least once a year.
• In addition, when using load suspension devices and hoists, the applicable
legislation and safety rules have to be strictly observed.
Fig. 42
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1.7 Corrosion
Corrosion can also affect bowl parts made of stainless steel. This corrosion can
be flat-spread or pit- or crack-shaped and merits special attention.
Corrosion on stainless steel bowl material should be examined thoroughly and
documented.
Flat-spread corrosion can usually be measured (reduction of wall thickness)
Pit- or crack-shaped corrosion cannot be measured without the risk of damage.
At the initial stage pit-shaped corrosion is generally caused by chlorine ions.
Depending on the stressing of the part, pit-shaped corrosion can result in crack-
shaped corrosion.
Fig. 43
Pittings
Pittings which are close together or
form a linear pattern can signify crack
formation beneath the surface.
Such pittings should be investigated
by a materials expert.
Fig. 44
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1.8 Erosion
Erosion is caused by solid particles in the process liquid.
These solid particles grind marks into the surfaces with which they come into
contact.
The following factors favour the occurrence of erosion:
• hard solids particles
• high throughput capacities
The first signs of erosion should be carefully observed and documented. Ero-
sion can deepen rapidly, thereby weakening the bowl material.
Contact your nearest Westfalia Separator representative for a thorough exami-
nation. Information on the nature of the damage can be provided by photos,
plaster casts or lead molds.
Fig. 45
1) the bottom of the distributor, the rising channels and the ribs,
2) the centripetal pump (cavitation),
3) all surfaces in the area of the solids discharge ports,
4) the nozzles.
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Fig. 46
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2 Machine description
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Centre of
gravity
Solids discharge
Water discharge
Operating water discharge
Arrangement of feet
Product discharge
Water discharge
Operating water discharge
Product feed
Solids discharge
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Centre of gravity
Connector
Product discharge
Discharge via the centripetal pump installed in
the separator
Solenoid valve block
Feed for operating water, Product feed
filling and displacement Terminal box Water discharge
water Operating water discharge
Solids discharge
Service side
The foundation must not contact the foundations of other units (e.g. auxiliary diesel en-
gines, pumps) in order to prevent damage to ball bearings.
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2.3 General
The machine described in this manual is a high-speed centrifugal separator with
self-cleaning bowl.
"Separation" means the separation of liquid mixtures which consist of two liq-
uids, with simultaneous removal of the solids contained in the liquids.
"Clarification" is the removal of solids from a liquid.
Prerequisite for treatment technology (separation) is that the components of the
product
– can be separated mechanically,
– have different densities and
– do not emulsify.
Fig. 50
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Fig. 51
Fig. 52
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The bowl is automatically opened and closed for desludging at full bowl speed
by means of a remote controlled solenoid valve (17) in the operating water line.
The opening time of the solenoid valve is up to 3 seconds.
The control and monitoring unit (8) ensures unmanned operation.
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Fig. 53
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2.5.1 Bowl
Fig. 54
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Separation Discharging
Bowl closed Bowl opened
Fig. 55
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Separation Ejection
Bowl closed Bowl open
Fig. 56
After starting the separator the solenoid valve for operating liquid is actuated
with the aid of the control unit, and the bowl is closed as follows:
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Separation Ejection
Bowl closed Bowl open
Fig. 57
The solenoid valve for operating liquid is opened with the aid of the control unit,
and the ejection cycle is triggered as follows:
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Fig. 58
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Fig. 60
3 Sensing liquid pump • Sensing liquid pump works on the same prin-
ciple as the centripetal pump 1 (see section
2.5.3).
• Discharges the heavy liquid.
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2.5.5 Drive
Fig. 61
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2.6.1 Determining the size of the regulating ring with the aid of the
diagram
(using oil purification as an example)
The diagram can be used to determine
– the inner diameter of the regulating ring and,
– if desired, the density of the oil
for a given separating temperature, provided that the density of the oil is known
at a temperature between 15 oC and 90 oC.
Example
Given:
– Density of oil at 15 oC ρoil 15 °C = 0.90 kg/dm3
– Separating temperature t = 90 oC
To be determined:
– Inner diameter of regulating ring d = ?
o
– Density of oil at 90 C ρoil 90 °C = ?
Determined:
– Inner diameter of the regulating ring
d = 110 mm
according to the diagram
– Density of oil at 90 oC
ρoil 90 °C = 0.852 kg/dm3
according to the diagram
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Separating temperature
ρ water
ρ oil
Separating temperature
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Effect:
– The discharging clean oil is free of
water.
– The discharging water is free of oil.
Fig. 63
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Effect:
– The discharging clean oil contains
water.
– The discharging water is free of oil.
Fig. 65
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Bowl
Solids holding space (total) 4 dm3
Speed 8 200 min–1
- for densities of the product up to
(see nameplate)
1.05 kg/dm3 (at 15 oC) and
- for densities of the separated solids up to
1.4 kg/dm3
Speed for higher densities contact the factory
Starting time approx. 3 - 6 min
Run-down time (without braking) 90 min
Run-down time (with braking) approx. 7 min
Centripetal pump
Output (depending on medium) max. 21 500 l/h
Pressure head 2 – 3 bar
Operating water
Quantity min. 1 800 l/h
Pressure 2 - 3 bar
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Motor
Power rating 50 Hz 11 - 15 kW
60 Hz 15 - 18 kW
Speed 50 Hz 3 000 RPM
60 Hz 3 600 RPM
Design IM V1
Enclosure IP 55
Drive 50/60 Hz
Oil filling approx. 3.7 l
Oil quality, see section 4.2.3
Product pump
Pump unit (gear or screw pump)
Output depending on plant rating
Suction height max. 0.4 bar
Pressure head 2 bar
Weights
Separator (with motor, without bowl) 860 kg
Bowl 190 kg
Motor 107 kg
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3 Operation
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Procedure:
• Select the desired operating mode on the control unit.
• Set the separating time on the control unit.
• Start the separator (see 3.2).
Displacement
• When separating, the loss of feed liquid unavoidable during ejection can be
reduced to a minimum by displacing the feed liquid with water before sludge
ejection takes place (especially important when processing valuable feed liq-
uid).
• The duration of displacement water supply is given in the timer overview (see
control unit manual).
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• If the displacement time is too long, water will discharge through the light liq-
uid outlet.
• If the displacement time is too short, part of the product remains in the bowl
and is lost during desludging.
Flush ejection
If the solids cant be completely ejected,
– due to an excessively long dwell time in the bowl or
– are stuck to firmly on the wall of the solids holding space due to the solids
properties,
• either the separating time must be shortened or
• a flush ejection must be carried out after the total ejection by filling the bowl
with water or product and emptying it again.
Program control
• "Displacement", "ejection", "filling" and "flush ejections" at precisely defined
intervals are best carried out with the automatic control unit.
• The clean oil discharge and water discharge can be monitored.
• Faults can be signalled visually or audibly.
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V’ 1.13
t = ——— • 60 • 100 = —————— • 6 000 = 67.8 min = 1.1 h
V° • p 2 000 • 0.05
(1)
Solids content and throughput capacity must be determined on site or taken from
the order specification.
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Automatic operation
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Automatic operation
Then
• Clean the sight glass and screw it back on.
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In the case of torn or defective drive belts or if the belts have come off:
• Do not loosen any part of the separator before the bowl has come to a stand-
still.
• Be sure to observe the run-down time of 90 minutes until dismantling the
separator!
• Applying the brake is not effective!
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The bowl does not come up Brake is applied. Release the brake by turning the
to rated speed or takes too handle clockwise.
long to do so.
Product has dripped down along the Clean the belt running surface of the
spindle onto the drive belt; drive belt spindle and flat belt pulley and
is slipping on the bowl spindle.
replace the drive belt.
Motor is incorrectly connected. Check connection
Too few clutch shoes have been fit- Increase the number of clutch shoes
ted. (see section 4.5).
Drive belt has become stretched and Replace the drive belt.
is slipping on the bowl spindle.
Drive belt has not been correctly fit- Check the position of the drive belt
ted. on centrifugal clutch and bowl spin-
dle.
Liquid or dirt has accumulated in the Check the operating water discharge.
upper section of the frame, thereby The liquid must flow off freely.
braking the bowl.
Clean the inside of the upper part of
the frame.
The bowl speed drops dur- Friction surfaces of clutch shoes are Wipe dry the friction surfaces.
ing operation. oily. Do not use benzene, tri-
chloroethylene or other
solvents!
Motor speed drops during operation. Check motor and line voltage.
The bowl comes up to rated Too many clutch shoes have been Reduce the number of clutch shoes.
speed too quickly (in less fitted.
Make sure that the clutch shoes are
than 1.5 minutes). Motor
evenly spaced. See section 4.5.
pulls too high a starting cur-
rent.
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Uneven run of the separator. Bowl is out of balance for the follow- For pos. 1-4:
ing reasons. • Stop the separator.
• Apply brake.
• Close product feed and discharge.
• The bowl may not be emptied
as otherwise the vibrations occur-
ring during run-down would inten-
sify.
If the bowl leaks,
• Open the water feed completely.
1. The separated dirt has deposited Clean bowl.
unevenly in the bowl.
2. Bowl is not properly assembled or, Assemble bowl properly.
if plant has several separators,
parts of different bowls may have
been interchanged.
3. Tension of disc stack has slack- Make sure bowl lock
ring is screwed on
ened.
tightly.
CAUTION:
A loose bowl lock ring can
endanger life.
Check number of disks.
4. Bowl parts are damaged. Send the bowl to the factory for re-
pair.
Do not make your own re-
pairs!
Do now weld or solder sin-
ce this would weaken the
bowl.
Ball bearings are worn. Replace damaged bearings.
IMPORTANT!
Only use those ball bearings speci-
fied in the parts list.
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The bowl does not close. Hole 7 in the bowl bottom is blocked Clean hole and injection chamber.
or
the injection chamber 21 is fouled.
A rim of dirt has deposited beneath Dismantle and clean the bowl.
the sliding piston.
Gaskets 3, 4, 5 or 8 are damaged or Replace gaskets.
their edges are frayed.
Replace only the damaged
polyamide gasket 4 (see
section 4.3.7)!
The bowl does not close Gasket 2 in the bowl top is damaged. Replace damaged gasket (see
properly or mist sprays out. 4.3.8).
Sealing edge of sliding piston is da- Contact the factory.
maged.
The bowl does not open or The operating water capacity is too Check line pressure and increase if
not properly. low. necessary.
Operating water data:
- Pressure 2 - 3 bar (with open val-
ve)
- Volume flow min 1 800 l/h (gauge
the capacity in litres) ≅ 1.0 l in
2 sec
Strainer in operating water line is dir- Clean strainer.
ty.
The operating water line has become Clean or replace operating water li-
constricted due to dirt accumulation ne.
or damage. Insufficient operating wa-
ter is entering the injection chamber
21.
The operating water shut-off device Replace shut-off valve.
does not open properly.
Opening pulse for operating water Set 3 seconds.
too short.
Hole 14 is clogged. Clean hole and bowl parts.
Gaskets 6 and 8 are damaged. Replace gaskets.
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The bowl does not open or Dry dirt or rubber particles have de- Clean bowl parts.
not properly. (con'd) posited:
Replace damaged gaskets.
- between the guides of the closing
chamber bottom and annular pis- Grease guides (see 4.2.4 - lubrica-
ton or tion schedule).
- between annular piston and bowl
bottom or
- between sliding piston and bowl
bottom.
The closing chamber is dirty. Dismantle bowl.
Clean closing chamber.
Gasket 2 of polyamide has a loose fit Replace polyamide gasket (see
in the groove of the bowl top. 4.3.8).
Product seeps into the gasket groove
and presses the gasket out of the
groove while the sliding piston moves
downwards, so that there is no gap
for solids ejection.
The bowl does not empty The operating water capacity is too Check line pressure and increase if
completely. Solids remain in low. necessary.
the bowl.
Operating water data:
- Pressure 2 - 3 bar (with open val-
ve)
- Volume flow min 1 800 l/h (gauge
the capacity in litres) ≅ 1.0 l in
2 sec
Gasket 2 in the bowl top The product contains abrasive solids. Remove the abrasive solids by in-
wears too quickly. stalling a strainer.
The bowl opens during se- The operating water in the closing Set the operating water pulse and
paration. chamber has diminished during a time (see manual of the control sys-
long separating time (evaporation tem).
etc.).
Time pulse for the operating water in- Set the operating water pulse (see
jection is too long. manual of the control system).
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The bowl does not close or The bowl was not thoroughly cleaned Before removing
open properly after a long- before a long-term standstill of the - the closing-chamber bottom,
term shut-down of the sepa- separator. Scale has deposited and - the sliding piston and
rator. dried out. - the annular piston
- between closing-chamber bottom dislodge the dried-up scale with citric
and annular piston or acid in the gaps
- between annular piston and bowl
- between closing-chamber bottom,
bottom or
sliding piston and annular piston
- between sliding piston and bowl
or
bottom.
- between sliding piston and bowl
bottom.
Dismantle and thoroughly clean the
bowl.
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Centre of
gravity
Solids discharge
Water discharge
Operating water discharge
Arrangement of feet
Product discharge
Water discharge
Operating water discharge
Product feed
Solids discharge
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Centre of gravity
Connector
Product discharge
Discharge via the centripetal pump installed in
the separator
Solenoid valve block
Feed for operating water, Product feed
filling and displacement Terminal box Water discharge
water Operating water discharge
Solids discharge
Service side
The foundation must not contact the foundations of other units (e.g. auxiliary diesel en-
gines, pumps) in order to prevent damage to ball bearings.
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• Attention!
Prevent accidents by using suitably rated hoists for transport and installation.
Fig. 72
Fig. 73
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Fig. 74
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4.1.3 Motor
Rated current %
Waiting
Separation Separation
at
De- Enclo-
50 Hz 60 Hz 50 Hz 60 Hz
sign sure *
rpm min s kW rpm rpm
IP 55
* WS standard
The separator is driven by a three-phase AC motor via a centrifugal clutch and
the drive belt.
The specified motor ratings are minimum values which are based on the in-
creased starting current. Since the current consumption of the motor drops after
start-up, overloading of the motor during operation is not possible.
The starting time depends on the
– flywheel effect of the bowl,
– number of clutch shoes used,
– condition of the clutch shoes.
The starting current can peak at about 1.8–2 times the rated current (see start-
up diagram). This is to be considered when selecting switches, lead-in wires
and fuses.
The motor
– can be started direct on-line,
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Note:
• The temperature feelers must be connected to a commercial tripping device.
• External voltage higher than 2.5 volts must not be applied to the connection
terminals of the temperature feelers.
• When testing for continuity, use an ohmmeter and not a test lamp.
Fig. 76
The bowl must rotate in clockwise direction when looked at from above.
Fig. 77
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The bowl speed has been rated so as to ensure the operating safety of the se-
parator.
If the densities exceed those stated above, check with the factory.
Fig. 78
Important instructions
• When the bowl has been removed,
no oil must spill onto the drive belt
via the spindle.
• After removing the bowl, place a
cloth over the spindle immediately.
Fig. 79
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• Special care must be taken when performing maintenance and lubrication operations.
Conscientiously performed maintenance and lubrication operations improve the service life of
the separator.
• In the case of accessories (motor, product pump, preheater, solenoid valve block etc.) the manu-
facturer’s maintenance and lubrication instructions must be observed.
Operations Remark
Maintenance(1)
To assure correct functioning and operating safety,
• in case of abnormal shut-down, see section 3.7 - manual operation.
• pay attention to the following points during servicing:
– Oil level – Leakage – Starting time
– Temperatures – Vibrations – Hoses and hose pipes
after
at the latest – Pressures – Current consumption (see 4.2.2)
operating (2)
hours after • Before assembling, grease the guide and contact surfaces of the main bowl components.
• in the case of frequent starting and stopping of the separator, shaft-driven alternator opera-
tion and in power plants, the condition of the clutch shoes must be checked more often than
stated in this schedule. It is not possible to state a definitive time. We recommend checking
the clutch shoes after 1,000 operating hours or after 2 months at the latest.
Bowl inspection • Dismantle bowl and centripetal pump.
• Clean the bowl and centripetal pump parts
and check for corrosion and erosion.
• Clean all holes, nozzles and chambers of
the hydraulic system.
• The cones of bowl and spindle must be
clean and dry when fitting.
Replace gaskets (bowl and hood). • Use set of spare parts "bowl/hood“ (opera-
tion: 1 year or 8000 hours). See section
Parts list.
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Maintenance(1)
after Operations Remark
at the latest
operating
hours after
Bowl inspection • Dismantle bowl and centripetal pump.
• Clean the bowl and centripetal pump parts
and check for corrosion and erosion.
• Clean all holes, nozzles and chambers of
the hydraulic system.
• The cones of bowl and spindle must be
clean and dry when fitting.
Replace gaskets (bowl and hood). • Use set of spare parts "bowl/hood“ (opera-
tion: 1 year or 8000 hours). See section
Parts list.
• Replace only the damaged
polyamide gasket 70 (see sec-
tion 4.3.7)!
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Maintenance(1)
after Operations Remark
at the latest
operating
hours after
Bowl inspection • Dismantle bowl and centripetal pump.
• Clean the bowl and centripetal pump parts
and check for corrosion and erosion.
• Clean all holes, nozzles and chambers of
the hydraulic system.
• The cones of bowl and spindle must be
clean and dry when fitting.
Replace gaskets (bowl and hood). • Use set of spare parts "bowl/hood“ (opera-
tion: 1 year or 8000 hours). See section
Parts list.
• Replace only the damaged
polyamide gasket 70 (see sec-
tion 4.3.7)!
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Maintenance(1)
after Operations
at the latest Remark
operating
after
hours
Legend:
(1) = The specified maintenance intervals are recommendations which apply only for normal conditions.
Negative operating conditions (e.g. low-grade fuel, excessively high temperature, strong vibrations, frequent starting and stopping of
the separator etc.) can necessitate shorter maintenance intervals.
(2) = see section 4.2.4 - Lubrication schedule
(3) = see section 4.2.3 - Oil quality and oil change
(4) = In the case of frequent starting and stopping of the separator, shaft-driven alternator operation and power plants shorter mainte-
nance intervals are required. It is not possible to state a definitive time. We recommend checking the clutch shoes after 1,000 oper-
ating hours or after 2 months at the latest.
Protective hose 1
• Fit the protective hoses at all con-
tact points to the separator.
• Fit the protective tube along the en-
tire length of the cable tree (contact
points to the machine).
• Adapt the length of the protective
hose.
Fig. 80
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4.2.3 Lubrication
The spindle ball bearings are splash-lubricated from a central oil bath.
Motor bearings
For re-greasing the motor bearings, refer to the instructions of the motor manu-
facturer.
Designation
according to DIN 51502 CLP
100
Designation CC 100
as per ISO 3498
Viscosity class SAE 30
Viscosity
100 ± 10 mm2/s (cSt)
(at 40 oC/104 oF)
Part-No. 0015-0003-080 (2.5 litres)
Dispose of the oil as per instructions of the oil manufacturer.
The viscosity class SAE 30 covers a larger viscosity range than specified here.
However, only oils with the viscosity range specified here may be used.
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Fig. 81
During operation the oil level must never drop below the lower third of the sight
glass; be sure to top up oil in good time!
OIL CHECK
• Check the oil level every week!
• From time to time undo the oil drain screw and check whether there is water
in the oil bath. When the oil exhibits a milky colouring (emulsification), the oil
must be changed immediately.
OIL CHANGE
• Change oil after about
– 4000 operating hours or 6 months at the latest (mineral oil).
– 8000 operating hours or 1 year at the latest (synthetic oil).
• Clean sight glass.
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CLP
100
Lubricating see
4 as required 1x apply sparingly Threads of fittings
grease parts list
Manually-operated parts
5 1x
such as locking brake
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4.3 Bowl
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(1) IMPORTANT: After replacing this part, the complete bowl must be rebal-
anced.
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Then:
• Clean the sight glass and screw it in again.
In the case of torn or defective drive belts or if the belts have come off:
• Do not loosen any part of the separator before the bowl has come to a stand-
still.
• Be sure to observe the run-down time of 90 minutes until dismantling the
separator!
• Applying the brakes is not effective!
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Fig. 85
Fig. 86
Fig. 87
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• Hinge up hood.
Fig. 88
Fig. 89
Fig. 90
Fig. 91
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Fig. 92
Fig. 93
Fig. 94
Fig. 95
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Fig. 96
Fig. 97
• Bowl
– off the spindle cone with a jack
and
– lift out of the frame with the aid of
a hoist.
Fig. 98
Fig. 99
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Fig. 100
Fig. 101
Fig. 102
Fig. 103
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Fig. 104
Fig. 105
Fig. 106
Fig. 107
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Fig. 108
IMPORTANT:
When mounting the pressure disk
2, do not damage the threaded
pins of the bowl top.
Fig. 109
Fig. 110
Fig. 111
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Fig. 112
Fig. 113
Fig. 114
Fig. 115
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Fig. 116
Fig. 117
Fig. 118
Fig. 119
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Fig. 120
Fig. 121
Fig. 122
Fig. 123
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Fig. 124
Fig. 125
Fig. 126
Fig. 127
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• Install angle 1.
• Press off the closing chamber bot-
tom 2 by turning the spindle.
• Lift out closing chamber bottom 2
(with fitted gaskets).
• Take out angle 1.
Fig. 128
• Screw components 2 - 8
– to mounting plate 1 and
– slide to centre of the bowl in slots.
• Insert assembling device in the
bowl.
Fig. 129
Fig. 130
Fig. 131
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Fig. 132
Fig. 133
Fig. 134
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Fig. 135
• Clean the small holes for the feed and discharge of the operating liquid with
particular care to ensure trouble-free bowl ejections.
Fig. 136
• Apply a thin coat of grease to the guide surfaces and threads of the bowl
parts after drying (see 4.2.4 Lubrication schedule).
• Reassemble the bowl immediately after cleaning.
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• Use only a cleaning agent that is approved for the field of application!
Fig. 137
4.3.4 Cleaning the strainer and the operating water feeding system
• The strainer and the operating water feeding system must be cleaned de-
pending on the quality of the operating water and overall load. See section
4.2.1 - Maintenance schedule.
• Use citric acid in case of furring.
• Thoroughly clean the parts with water.
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• Before assembling the bowl, check to be sure that the guide and contact sur-
faces of the bowl are clean.
• Grease the guide surfaces as specified in the lubrication schedule (see 4.2.4).
Fig. 138
Fig. 139
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Fig. 140
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43 Nm
Fig. 141
Fig. 142
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Fig. 143
Fig. 144
Fig. 145
Fig. 146
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Fig. 147
Fig. 148
Fig. 149
Fig. 150
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Fig. 151
Fig. 152
Fig. 153
Fig. 154
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Fig. 155
Fig. 156
Fig. 157
Fig. 158
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Fig. 159
Fig. 160
Fig. 161
Fig. 162
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Fig. 163
Fig. 164
Fig. 165
Fig. 166
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Fig. 167
Fig. 168
Fig. 169
Fig. 170
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CAUTION:
A loose lock ring can endanger life!
Fig. 171
Fig. 172
Fig. 173
Fig. 174
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Fig. 175
Fig. 176
Fig. 177
Tools:
Socket wrench
Commercially available ratchet
Fig. 178
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CAUTION:
A loose spindle screw can endan-
ger life!
Fig. 179
Fig. 180
Fig. 181
Fig. 182
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Fig. 183
Fig. 184
Fig. 185
Fig. 186
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Fig. 187
Fig. 188
CAUTION:
A loose lock ring can endanger life!
Fig. 189
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ATTENTION:
Replace only the damaged polyamide gasket!
• For standard tools, see section 4.11 .
REMOVAL – VARIANT I
• Drill through the damaged polyam-
ide gasket twice centrically and ver-
tically.
– with a 2 mm drill bit
– at a distance of approx. 50 to
60 mm.
ATTENTION:
The groove of the annular piston must
not get damaged!
Fig. 190
Note:
If the polyamide gasket can’t be re-
Fig. 191
moved, repeat this procedure.
REMOVAL – VARIANT II
• Heating the ring with a hot-air blo-
wer facilitates removal.
• Remove the old polyamide gasket.
ATTENTION:
The groove of the annular piston must
not get damaged!
Fig. 192
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FITTING – VARIANT I
Fig. 193
Fig. 194
Fig. 195
Fig. 196
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Fig. 197
Fig. 198
Fig. 199
Fig. 200
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Fig. 201
Fig. 202
Fig. 203
Fig. 204
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Fig. 205
Fig. 206
Fig. 207
Fig. 208
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Fig. 209
Fig. 210
Fig. 211
Fig. 212
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Fig. 213
FITTING – VARIANT II
• Thoroughly clean and dry the groo-
ve.
• Heat the gasket in approx. 80 oC
(176 °F) water for 5 minutes.
• Gasket:
– clean and wipe dry
– lightly press into the groove.
Fig. 214
Fig. 215
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Fig. 216
Fig. 217
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REMOVAL
• Drive the gasket out of the groove
with the aid of a pin punch.
To do this:
• Insert a commercial pin punch alter-
nately in holes 1.
Fig. 218
FITTING
• Heat the gasket in approx. 80 oC (176 °F) water for 5 minutes.
• Wipe dry the gasket.
• Fit the gasket into the clean groove of the bowl top (with the narrow side fac-
ing the bowl top).
VARIANT I
Fig. 219
VARIANT II
Fig. 220
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Fig. 221
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Fig. 222
Fig. 223
Fig. 224
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Fig. 225
Fig. 226
Fig. 227
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Fig. 228
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4.6 Drive
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Then
• Clean the sight glass and screw it back on.
In the case of torn or defective drive belts or if the belts have come off:
• Do not loosen any part of the separator before the bowl has come to a stand-
still.
• Be sure to observe the run-down time of 90 minutes until dismantling the
separator!
• Applying the brake is not effective!
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Fig. 231
Fig. 232
Fig. 233
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Fig. 234
Fig. 235
Fig. 236
Fig. 237
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Fig. 238
Fig. 239
Fig. 240
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Fig. 241
Fig. 242
Fig. 243
Fig. 244
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• Bearing housing 2:
– press off with two (M 10 x 40) hex
head screws and
– remove from lower section of
frame together with pivoting bear-
ing 3, washers 4 and inserted
gasket 5.
Fig. 245
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Spindle assembly
Fig. 246
Tool:
commercially available pulling de-
vice
Fig. 247
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Fig. 248
Fig. 249
Tool:
commercially available pulling de-
vice
Fig. 250
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Fig. 251
Fig. 252
Fig. 253
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Fig. 254
Fig. 255
Fig. 256
Fig. 257
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Fig. 258
Fig. 259
Fig. 260
Fig. 261
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Fig. 262
Fig. 263
Fig. 264
Tools:
Disk (Ø 86 – 94 mm)
Wooden block
Hammer
Fig. 265
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Fig. 266
Fig. 267
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Fig. 269
• Set collar 4:
– slide onto the spindle and
– secure in spindle groove via four threaded pins 5.
Fig. 270
Fig. 271
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Fig. 272
Fig. 273
Fig. 274
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Fig. 275
Tools:
Disk (Ø 86 – 94 mm)
Wooden block
Hammer
Fig. 276
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Tools:
Disk (Ø 86 – 94 mm)
Wooden block
Hammer
Fig. 277
Fig. 278
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Tools:
Disk (Ø 86 – 94 mm)
Wooden block
Hammer
Fig. 279
Tool:
Disk (Ø 61 – 69 mm)
Fig. 280
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Fig. 281
Fig. 282
Fig. 283
Fig. 284
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Fig. 285
Fig. 286
Fig. 287
Fig. 288
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Fig. 289
• Insert washer 1.
• Fit the retaining ring 2 in the groove
of the clutch driver.
Fig. 290
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General
The neck bearing springs 2 are ex-
posed to different stresses due to the
drive belt tension (stronger stress on
the motor side of the neck bearing
Motor side bridge).
To check the condition of the neck
bearing springs 2,
• they must be dismantled periodically
(see section 4.2.1) and individually
(see Fig. 292).
• and their length measured (see Fig.
Fig. 291 293, dimension A).
Fig. 292
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Fig. 294
Fig. 295
Note:
Do not forget to order a new set of neck bearing springs from Westfalia Separa-
tor!
The deformed neck bearing springs must be replaced after 8000 operating
hours.
Fig. 296
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Fig. 297
• Screw the six threaded plugs 1 together with the neck bearing springs 2 and
spring pistons 3 into the six tapholes of the neck bearing bridge 5 and tighten.
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Fig. 298
Fig. 299
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Fig. 301
Note:
Due to the design concept used, the spindle is at an inclined angle relative to
the opposite side of the motor when the drive belt has not been fitted or ten-
sioned (see Fig. 302, pos. 2).
The spindle is pulled into the centric axis when the belt is tensioned (see Fig.
302, pos 1)!
• Check
– that the spindle 1 can be turned
easily.
– whether the spindle has been
pulled into the centric axis by
tensioning the drive belt 3 (see
Fig. 180).
Fig. 302
Fig. 303
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Fig. 304
Fig. 305
Fig. 306
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The bowl height may only be measured with fitted drive belt.
CHECKING
Check the bowl height and readjust if necessary:
• after replacing the drive parts,
• after fitting another bowl,
• after fitting a different centripetal pump,
• as soon as the centripetal pump exhibits grinding marks.
CAUTION:
A loose lock ring can endanger life!
Fig. 307
Fig. 308
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ADJUSTING
Washer:
Inner diameter, 12.5 mm – outer diameter, 22 mm – thickness, 1 mm
Fig. 309
Fig. 310
Fig. 311
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Fig. 312
Fig. 313
Fig. 314
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Fig. 315
Check:
• Axial play too large:
– Raise bowl, see section 4.7.1 - Adjustment.
• Axial play too small:
– Lower the bowl, see section 4.7.1 - Adjustment.
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Checks Section
1. Bowl height 4.7.1
2. Oil level in drive chamber 4.2.3
3. Direction of rotation of the bowl 4.1.4
4. Bowl speed 4.1.5
5. Starting time of bowl / current consumption 4.1.5
6. Running characteristics of the separator 3.8.1
7. Suction line of the product pump (if installed) for leakage
Checks Section
1. Temperature of product
2. Observe discharges for water, solids and oil to see if the 3.3
bowl is operating correctly.
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• Check gaskets.
Replace damaged, very swollen, hardened or brittle gaskets immediately.
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Fig. 316
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Pos. Designation
1 Screwdriver
2 Torque wrench with socket (0 - 200 Nm)
3 Pin punch (Ø 4 mm)
4 Caliper gauge
5 Electric oil heater for ball bearings
6 Ratchet
7 Standard hammer and mallet
8 Inner snap pliers with offset jaws
(Ø 40 mm)
9 Outer snap pliers (Ø 35 mm)
10 Hand tachometer
11 Vice
12 Wrench, adjustable
13 Brushes
14 Puller (300 x 300 mm)
15 Open-ended wrench (various sizes)
16 Wooden blocks
17 Drill
18 Drill bit (Ø 2 mm)
19 Wooden screws (max. Ø 4 mm x 70 mm length)
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5 Accessories
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Fig. 317
Manual override A
1 closed
2 open
Fig. 318
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Technical data
Part-No. 0018-6654-000
Operating principles 2/2-way valve normally closed
Nominal width 13 mm
Material: Gasket EPDM
Housing CuZn
Line connection: Input G 3/4 in sleeve
Output G 1/5.08 cm sleeve
Coil size 32 mm
Voltage 24 V DC
Rating 8W
Pressure Medium 0.2 -16 bar
Coupler socket with built-in electronics,
24 VDC, LED and free-wheeling diode
with fitted cable (1.5 m long)
Temperature: Medium -10 to +80 °C (14 – 176 °F)
Ambient max. +35 °C (95 °F)
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Setpoint adjustment
Note:
By adapting the status signal “0” or “1”
to the control with the indicating pres-
sure on the pressure gauge, the set-
ting on the pressure gauge can be
read off. (See control unit instruction
manual.)
Fig. 319
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Fig. 320
Fig. 321
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Technical data
Part-No. – pressure switch 0005-4315-000
Working pressure: 0 to 6 bar
Enclosure IP 65
Standard DIN 43650-A
Cable 1.5 m marine cable type MGG-J,
3 x 1.5 mm²
Medium temperature –25 to +120 °C (–13 to +248 °F)
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6 Parts list
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A rapid and correct supply of spare parts can only be guaranteed if your order
includes the following details:
Only required when ordering pare parts for pump and pump connection parts:
• Model and number of see pump nameplate
pump
The details must be complete when the part number ends with a letter (e.g.
2050-6600-L), since this indicates that the parts are available in different de-
signs.
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Fig. 323
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Fig. 324
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Fig. 325
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Fig. 326
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Fig. 327
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Fig. 328
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Fig. 329
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Fig. 330
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Fig. 331
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Fig. 332
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Fig. 333
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(1) This part can only be replaced by one of our service engineers or by a special repair shop authorized by
us, because of special re-fitting to machine and possible re-balancing of bowl.
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Fig. 334
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Fig. 335
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Fig. 336
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Fig. 337
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Fig. 338
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Fig. 339
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Fig. 340
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IMPORTANT:
The specified number of gaskets has been adapted to take account of the respective maintenance in-
tervals (see maintenance schedule).
Only one gasket may be inserted per groove!
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Fig. 341
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Fig. 342
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7 Appendix
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DISOLA M 3015
ing to DIN 51502)
Kinematic
Symbol
ATLANTA MARINE 30
105
CSD 1 DISOLA M 3015
OSD 2 1,3 TURBINE T 100 95
SD 1
EXX-MAR XP 110
NUTO H 100
100
SPARTAN EP 100
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7.1.1 Comments on table of lubricating oils for separators from Westfalia Separator
Faultless functioning of separators very much depends on the proper type of lubricating oil used, since a
high grade oil, selected to meet all service requirements, will minimize the wear, thus extending the ser-
vice life and increasing the operating safety.
For the lubrication of our separators we recommend to use the oils specified by us since continuous qual-
ity checks are performed by Westfalia Separator. Oils proposed from some firms are not subjected to
these tests.
Therefore, Westfalia Separator cannot give a performance guarantee for those oils.
Be sure to select only high grade solvent refined products.
The specified oil types meet the requirements according to DIN. Under unfavourable operating condi-
tions, e.g. high temperatures, the quality of the oils may be insufficient so that more efficient oils, e.g.
synthetic oils, must be used. If necessary, consult Westfalia Separator.
For the different separator types and oil types the viscosity ranges are specified in the table of lubricating
oils.
The operating temperature of the separator exceeds normally 80 oC (176 oF). At those temperatures so-
me oils age quickly, so that they have to be changed prematurely.
Be sure not to use lubricating oils with viscosities lower than those specified in the table. Due to the pos-
sibility of the oil film breaking down, oil of too low a viscosity will give insufficient lubrication, resulting in
increased wear. However, oils with a slightly higher viscosity than specified may be used.
Bear in mind that the viscosity groups SAE 30, 40 and 50 (SAE = Society of Automotive Engineers)
cover larger viscosity ranges and be sure to select lubricating oils with viscosities not lower than the mini-
mum values of the viscosity ranges restricted for the different separator types.
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7.2 The health hazards involved when handling heavy oils and lube oils
As a result of the deterioration in quality of fuel oils, the danger has arisen that the heavy oils used on
board contain greater amounts of substances injurious to health. These include:
- polycyclic aromatic hydrocarbons,
- lead compounds,
- chemical residues.
An increased amount of polycyclic aromatic hydrocarbons is also present in used lube oils (waste oils).
The health hazards for the engine room staff depend to a large extent
• on the concentrations of the dangerous substances,
• the ambient air (inhalation of oil vapours/oil mist),
• the intensity and duration of the contact with the skin or mucous membrane.
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Take the Best – Separate the Rest
Westfalia Separator Mineraloil Systems GmbH ● Werner-Habig-Straße 1 ● D-59302 Oelde (F.R. Germany)
Tel.: +49 (0) 25 22/77-0 ● Fax: +49 (0) 25 22/77-23 94 ●
http://www.westfalia-separator.com/ ● mailto:info@gea-westfalia.de