Professional Documents
Culture Documents
Product No.
Book No.
881100-04-02/1
577461-02 Rev. 4
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:
+46 8 530 310 40
Contents
1
Periodic maintenance............................................ 28
Maintenance Logs................................................... 31
Check points at Intermediate Service ............. 36
Check points at Major Service ........................... 48
3-year service ........................................................... 51
Lifting instructions ................................................. 52
Cleaning ..................................................................... 53
Oil change.................................................................. 56
Vibration..................................................................... 58
General directions .................................................. 60
577461-02
577461-02
2 Safety Instructions
G0010421
S0151211
2 Safety Instructions
S01512G1
S0151241
S01512L1
S01512P1
S01512N1
S01512F1
Disintegration hazards
10
2 Safety Instructions
Entrapment hazards
S0151261
S01512O1
S0151271
Electrical hazard
Crush hazards
S01512M1
11
2 Safety Instructions
Noise hazards
Burn hazards
12
S01512D1
2 Safety Instructions
Cut hazards
Flying objects
Health hazard
13
2 Safety Instructions
2.1
R
DANGE
ING
WARN
ON
CAUTI
NOTE
14
2 Safety Instructions
2.2
Environmental issues
Unpacking
Packing material consists of wood, plastics,
cardboard boxes and in some cases metal straps.
Wood and cardboard boxes can be reused,
recycled or used for energy recovery.
Plastics should be recycled or burnt at a licensed
waste incineration plant.
Metal straps should be sent for material recycling.
Maintenance
During maintenance oil and wear parts in the
machine are replaced.
Oil must be taken care of in agreement with local
regulations.
Rubber and plastics should be burnt at a licensed
waste incineration plant. If not available they
should be disposed to a suitable licensed land fill
site.
Bearings and other metal parts should be sent to
a licensed handler for material recycling.
Seal rings and friction linings should be disposed
to a licensed land fill site. Check your local
regulations.
Worn out or defected electronic parts should be
sent to a licensed handler for material recycling.
15
2 Safety Instructions
2.3
Requirements of
personnel
16
Contents
2.1 Read This First
16
18
2.2.1
Application
18
2.2.2
Design
19
2.2.3
Outline of function
19
2.2.4
Separating function
20
2.2.5
22
2.2.6
Power transmission
24
2.2.7
25
2.3 Definitions
26
15
Safety Instructions
Operating Instructions
16
Fault Finding
Technical Reference
Installation
NOTE
A complete reading of this manual by personnel in
contact with the machine is essential to safety.
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 machine and the work to be carried
out.
17
ING
WARN
Disintegration hazards
Use the separator only for the purpose and
parameters (type of liquid, rotational speed,
temperature, density etc.) specified in chapter
5 Technical Reference, page 117 and in the Purchase
Order documents.
Consult your Alfa Laval representative before any
changes outside these parameters are made.
18
G 0 46 4 88 1
2.2.2 Design
The P 615 separator comprises a frame
consisting of the frame lower part, the
intermediate part and the frame top part with a
frame hood.
The separator bowl (C) is driven by an electric
motor (A) via a flat-belt power transmission (D)
and bowl spindle (B). The motor drive is
equipped with a friction coupling to prevent
overload.
G 0 73 9 54 1
Sectional view
Main parts, inlets and outlets
A
B
C
D
E
F
Electric motor
Bowl spindle
Bowl
Flat belt
Closing water tank
Brake handle
19
G 01 1 23 61
F
G
H
I
K
L
R
S
T
U
20
Paring disc
Disc stack
Sludge space
Top disc
Gravity disc
Sludge ports
Bowl body
Bowl hood
Distributor
Paring chamber cover
G 0 11 23 71
Displacement of oil
Sludge space
Top disc
Gravity disc
Normal interface position
Interface position just before
discharge
Gravity disc
21
Clarifier disc
22
G 01 12 4 11
Bowl opening
Bowl closing
G 0 11 25 21
23
G 0 11 2 72 1
Bowl spindle
Fan
Rubber buffers
Oil pump
Sleeve
Belt drive
24
G 0 11 2 82 1
Friction coupling
G 0 11 29 1 1
S0 00 9 41 1
G 0 5 48 42 1
25
2.3 Definitions
2.3 Definitions
Back pressure
Clarification
Clarifier disc
Counter pressure
Density
Gravity disc
Interface
Intermediate
Service (IS)
Phase
Purification
Sediment (sludge)
Sludge discharge
Throughput
Viscosity
Water seal
26
SEPARATOR MANUAL
3 SERVICE INSTRUCTIONS
3 Service Instructions
Contents
3.1 Periodic maintenance
28
3.1.1
Introduction
28
3.1.2
Maintenance intervals
28
3.1.3
Maintenance procedure
30
3.1.4
Service kits
30
31
3.2.1
Daily checks
31
3.2.2
31
3.2.3
IS - Intermediate Service
32
3.2.4
MS - Major Service
34
56
56
3.9 Vibration
58
3.9.1
Vibration analysis
58
3.9.2
59
60
60
63
Corrosion
36
3.3.2
Erosion
38
3.3.3
Cracks
39
3.3.4
Discharge mechanism
40
3.3.5
41
3.3.6
43
3.3.7
43
3.3.8
44
46
3.3.9
47
48
3.4.1
48
3.4.2
50
51
52
3.7 Cleaning
53
3.7.1
Cleaning agents
54
3.7.2
55
577461-02
27
ING
WARN
Disintegration hazards
Separator parts that are worn beyond their safe
limits or incorrectly assembled may cause severe
damage or fatal injury.
28
3 Service Instructions
3 Service Instructions
Service schedule
Oil change
Intermediate Service = IS
Major Service = MS
3-year Service
MS
IS
IS
Installation
IS
IS
MS
IS
IS
1st year
IS
IS
MS
IS
2nd year
IS
IS
IS
IS
IS
IS
MS
IS
3-year
Service
Other
29
3 Service Instructions
30
S0 02 10 3 1
3 Service Instructions
Part
Page
Notes
Connecting housing
Separator bowl
Check for vibration and noise
Belt transmission
Check for vibration and noise
Oil sump
Check
Oil level
Electrical motor
Check for vibration, heat and noise
See manufacturers instructions
Part
Page
Notes
Belt tension
107
Change
56
31
3 Service Instructions
Local identification:
P 615
Manufacture No./Year:
Product No.:
Date:
Signature:
881100-04-02/0
Renew all parts included in the Intermediate Service kit (IS) and do the following activities.
Main component and activity
Part
Page
43
Paring disc
43
Separator bowl
Clean and inspect
Check
Bowl hood
44
Top disc
55
Bowl discs
55
Distributor
40
41
Discharge mechanism
40
44
43
47
44
36 - 38
Power transmission
Check
107
Change
56
Electrical motor
Lubrication (if nipples are fitted)
32
Notes
3 Service Instructions
Part
Page
Notes
149
149
33
3 Service Instructions
Local identification:
P 615
Manufacture No./Year:
Product No.:
Date:
Signature:
881100-04-02/0
Renew all parts included in the Intermediate and Major Service kits and do the following
activities.
Main component and activity
Part
Page
43
Paring disc
43
Separator bowl
Clean and inspect
Check
Bowl hood
44
Top disc
55
Bowl discs
55
Distributor
40
41
Discharge mechanism
40
44
43
48
47
44
34
36 - 38
Notes
3 Service Instructions
Part
Page
Notes
89
Oil pump
89
Water tank
113
Pump sleeve
Bowl spindle
86
86
50
Clean
Oil sump
56
Change
Oil
56
112
Friction coupling
103
Check
Oil sump
Friction coupling
Clean and inspect
Electrical motor
Replace
Bearings1)
149
149
35
3 Service Instructions
ING
WARN
G 01 7 21 11
Disintegration hazard
Inspect regularly for corrosion damage. Inspect
frequently if the process liquid is corrosive.
36
3 Service Instructions
Stainless steel
in a crevice,
covered by deposits,
S 00 20 61 1
S 00 20 51 1
ING
WARN
Disintegration hazard
Pits and spots forming a line may indicate cracks
beneath the surface.
All forms of cracks are a potential danger and are
totally unacceptable.
Replace the part if corrosion can be suspected of
affecting its strength or function.
37
3 Service Instructions
3.3.2 Erosion
Erosion can occur when particles suspended in
the process liquid slide along or strike against a
surface. Erosion can become intensified locally
by flows of higher velocity.
ING
WARN
Disintegration hazard
Inspect regularly for erosion damage. Inspect
frequently if the process liquid is erosive.
38
G 0 20 52 2 1
3 Service Instructions
3.3.3 Cracks
Cracks can initiate on the machine after a
period of operation and propagate with time.
ING
WARN
Disintegration hazard
All forms of cracks are potentially dangerous as
they reduce the strength and functional ability of
components.
Always replace a part if cracks are present
39
3 Service Instructions
G 01 2 15 11
40
3 Service Instructions
G 00 71 0 31
G 0 0 71 12 1
41
3 Service Instructions
G 0 07 1 23 1
G 0 07 1 22 1
42
3 Service Instructions
G 0 07 1 61 1
43
3 Service Instructions
G 0 07 13 11
Wear
ING
WARN
Disintegration hazards
Wear on threads must not exceed safety limit. f mark
on bowl hood must not pass f mark on bowl body by
more than 25.
44
(MAX 25 )
G 05 78 11 1
3 Service Instructions
Damage
ON
CAUTI
Cut hazard
The threads have sharp edges which can
cause cuts.
G 00 71 51 1
45
3 Service Instructions
46
G 0 88 77 31
Before assembly:
3 Service Instructions
If one or more discs have been added recheck the disc stack pressure by repeating
the procedure above.
G 00 71 9 11
1
2
3
Bowl hood
Bowl body
Disc stack. Number of discs
- below wing insert: 42
- above wing insert: at least 41
NOTE
The top disc can stick inside the bowl hood
and fall when the hood is lifted.
G 0 3 57 65 1
47
3 Service Instructions
48
G 0 07 29 A 1
G 0 88 39 1 1
G 01 72 9 51
3 Service Instructions
49
3 Service Instructions
50
G 01 2 12 11
3 Service Instructions
Friction coupling
51
3 Service Instructions
NOTE
Make sure to remove the cap nut fixing the bowl to
the bowl spindle.
G 0 82 06 21
NOTE
Separator without bowl: Use lifting slings for
WLL 300 kg.
ING
WARN
Crush hazards
Use only the two special lifting eyes (M12) for lifting
the machine. They are to be screwed into the special
threaded holes.
Other holes are not dimensioned for lifting the
machine.
A falling separator can cause accidents resulting in
serious injury and damage.
52
3 Service Instructions
3.7 Cleaning
3.7 Cleaning
External cleaning
G 0 61 53 6 1
G 06 13 6 61
53
3.7 Cleaning
3 Service Instructions
ON
CAUTI
54
S0 00 8 51 1
3 Service Instructions
3.7 Cleaning
Bowl discs
G 00 65 8 31
Cut hazards
The discs have sharp edges that can cause cuts.
55
3 Service Instructions
Pull out (A) the oil filling device and turn it half
a turn (B).
G 0 06 8 91 1
ON
CAUTI
56
G 01 7 38 11
Burn hazards
3 Service Instructions
G 00 6 92 11
G 0 0 69 11 1
57
3.9 Vibration
3 Service Instructions
3.9 Vibration
3.9.1 Vibration analysis
A separator normally vibrates and produces a
different sound when passing through its critical
speeds during run-up and run-down.
It also vibrates and sounds to some extent when
running. It is good practice to be acquainted with
these normal conditions.
Excessive vibrations and noise indicate that
something is wrong. Stop the separator and
identify the cause.
ING
WARN
Disintegration hazards
When excessive vibration occurs, keep bowl filled
and stop separator.
The cause of the vibration must be identified and
corrected before the separator is restarted.
Excessive vibration can be due to incorrect
assembly or poor cleaning of the bowl.
58
G 0 07 5 25 1
3 Service Instructions
3.9 Vibration
Back-off the setpoint adjusting screw counterclockwise (A) two or three turns. Press the
reset button. If the armature does not remain
in the reset position, turn the adjusting screw
another turn or two until the armature stays in
position when the reset button is pressed.
Back-off the adjusting screw counterclockwise a three-quarter turn. Press the reset
button. If the armature now rocks, turn the
adjusting screw counter-clockwise another
quarter turn and so on until the armature
remains in the reset position.
Refit the cap and fasten with the screws.
NOTE
G 0 54 65 2 1
Setpoint adjustment
1. Adjusting screw
2. Pointer
A. Direction of increased checkpoint
(admit higher vibration)
59
3 Service Instructions
G 05 87 3 21
1.
2.
3.
4.
Outer race
Ball/roller
Inner race
Cage
NOTE
Using an incorrect bearing can cause a serious
breakdown with injury to personnel and damage to
equipment as a result.
Do not re-fit a used bearing.
Always replace it with a new one.
Dismantling
60
G 05 87 4 11
3 Service Instructions
G 05 87 51 1
G 0 5 87 61 1
61
3 Service Instructions
G 0 5 87 71 1
62
G 05 87 21 1
3 Service Instructions
G 0 46 6 85 1
63
64
3 Service Instructions
4 Dismantling/Assembly
Contents
4.1 Inlet/outlet and bowl
68
4.1.1
71
4.1.2
76
86
4.2.1
4.2.2
92
100
4.3.1
101
4.3.2
103
Dismantling/assembly
107
107
112
112
113
4.7 Brake
113
4.7.1
Exploded view
113
4.7.2
114
115
115
65
4 Dismantling/Assembly
Check point
S00 51 0 11
Tools
66
6, 7
G 02 7 88 21
4 Dismantling/Assembly
Hammer
G 0 27 89 2 1
67
4 Dismantling/Assembly
ING
WARN
1. Safety device
2. Nut
6. Insert
Entrapment hazard
The support ring is removed
from the frame hood top, at
paring disc adjustment (Major
Service).
3. Inlet/outlet housing
5. Support ring
7. Height adjusting ring
8. Frame hood
9. Lock ring
G 0 0 73 75 1
68
4 Dismantling/Assembly
20. Distributor
G 0 8 87 75 1
69
4 Dismantling/Assembly
Left-hand thread
70
G 00 74 25 1
4 Dismantling/Assembly
ING
WARN
Entrapment hazard
G 08 19 7 51
G 0 46 7 36 1
G 0 82 1 53 1
71
4 Dismantling/Assembly
G 00 70 02 1
Left-hand thread!
G 0 0 70 13 1
72
4 Dismantling/Assembly
G 00 70 2 21
15
G 03 57 41 1
attached.
73
4 Dismantling/Assembly
11 Lift out the top disc, the bowl discs with wing
G 0 35 75 21
G 0 07 2 03 1
special tool.
Ease the sliding bowl bottom off with the
central screw of the tool. If necessary, knock
on the handle.
G 0 0 70 63 1
by jerking, or
by tightening the nuts equally
74
4 Dismantling/Assembly
G 0 0 70 72 1
G 0 07 08 21
75
Check point
3.3.1 Corrosion, page 36,
3.3.2 Erosion, page 38,
3.3.3 Cracks, page 39,
3.3.4 Discharge mechanism, page 40,
3.3.6 Spindle top cone and bowl body nave,
page 43,
3.3.7 Threads of inlet pipe, paring disc, page
43,
3.3.8 Threads on bowl hood and bowl body,
page 44,
3.3.10 Disc stack pressure, page 47,
3.4.1 Paring disc height adjustment, page 48.
76
4 Dismantling/Assembly
4 Dismantling/Assembly
Left-hand thread
G 0 07 42 5 1
77
4 Dismantling/Assembly
20. Distributor
NOTE
Be sure bowl parts are not
interchanged.
Out of balance vibration
will reduce ball bearing
life.
G 08 87 75 1
78
4 Dismantling/Assembly
1. Safety device
2. Nut
6. Insert
IS Intermediate service kit
MS Major service kit
3. Inlet/outlet housing
5. Support ring
7. Height adjusting ring
8. Frame hood
9. Lock ring
NOTE
Be sure bowl parts are not
interchanged.
G 00 73 7 51
79
Check point
4 Dismantling/Assembly
Oil
G 0 0 71 72 1
G 0 0 71 83 1
G 0 07 18 4 1
80
4 Dismantling/Assembly
G 0 3 78 03 1
G 0 37 81 11
Left-hand thread!
G 0 07 2 03 1
81
4 Dismantling/Assembly
Check point
Before assembling the bowl discs, check the
threads of the bowl hood and bowl body, see
3.3.8 Threads on bowl hood and bowl body,
page 44.
G 03 5 75 61
Molykote
Paste1000
Left-hand thread!
82
G 0 07 22 3 1
4 Dismantling/Assembly
Check point
G 0 07 2 36 1
ING
WARN
Disintegration hazard
G 03 5 77 11
G 0 07 2 72 1
83
4 Dismantling/Assembly
G 0 07 33 41
G 0 07 4 33 1
Molykote
paste 1000
84
G 00 7 35 81
Check point
4 Dismantling/Assembly
G 01 72 9 51
85
4 Dismantling/Assembly
Check point
3.4.2 Radial wobble of bowl spindle, page 50.
1. Lip seal ring
2. Screen
3. Gasket
G 0 11 3 2A 1
86
4 Dismantling/Assembly
5. Deflector ring
6. Top bearing cover
7. Gasket
8. Fan
MS Parts to be renewed at
Major Service
9. Buffer holder
10. Rubber buffer
20. O-ring
G 01 13 1 A1
22. O-ring
87
G 01 1 34 61
G 01 13 3 E1
4 Dismantling/Assembly
88
4 Dismantling/Assembly
G 0 11 35 21
G 01 13 62 1
89
4 Dismantling/Assembly
Screw the cap nut counter-clockwise (lefthand thread) onto the spindle top to protect
the top and bore.
Left-hand thread
G 0 07 61 3 2
90
G 00 76 25 1
4 Dismantling/Assembly
Thrust washer
Puller
G 0 07 63 21
In case of 3-year-service
G 0 09 37 9 1
91
4 Dismantling/Assembly
G 01 13 7 71
2. Screen
3. Gasket
G 0 11 3 2A 1
92
4 Dismantling/Assembly
5. Deflector ring
8. Fan
9. Buffer holder
10. Rubber buffer
Silicone grease (thin layer)
G 0 11 31 B 1
Loctite 242
22. O-ring
93
4 Dismantling/Assembly
In case of 3-year-service
G 0 0 93 78 1
G 01 1 37 61
G 0 07 63 4 1
94
4 Dismantling/Assembly
Mounting tool
G 0 11 3 83 1
Oil
G 0 1 13 94 1
95
G 0 11 43 41
4 Dismantling/Assembly
G 00 7 61 22
96
4 Dismantling/Assembly
G 0 1 14 42 1
Silicone grease
(thin layer)
G 0 11 45 21
97
4 Dismantling/Assembly
Silicone grease
(thin layer)
G 0 11 46 61
Silicone grease
(thin layer)
G 0 11 47 51
98
4 Dismantling/Assembly
Check point
3.4.2 Radial wobble of bowl spindle, page 50.
G 0 11 33 A 1
99
4 Dismantling/Assembly
ING
WARN
Entrapment hazards
Make sure that rotating parts have come to a
complete standstill before starting any dismantling
work.
1. Snap ring
2. Snap ring
3. Ball bearings
5. Belt pulley
5. Belt pulley
6. Coupling hub
7. Friction element
G 0 37 21 2 1
8. Cover
9. Snap ring
10. Washer
11. Spring washer
12. Screw
(MS) = Set of friction elements
included in the Major service Kit for
50 Hz or 60 Hz
100
4 Dismantling/Assembly
G 0 11 3 39 1
G 0 07 7 33 1
G 0 17 08 4 1
101
4 Dismantling/Assembly
G 01 71 0 21
Mounting tool
G 0 17 1 13 1
102
4 Dismantling/Assembly
Loctite 641
103
4 Dismantling/Assembly
G 0 17 13 21
Loctite 641
Oil
104
G 0 17 1 02 1
Mounting tool
Molykote 1000 Paste
(thin layer to be rubbed into
surface)
4 Dismantling/Assembly
G 0 1 70 92 1
105
4 Dismantling/Assembly
G 0 07 73 41
106
4 Dismantling/Assembly
ING
WARN
Entrapment hazards
Make sure that rotating parts have come to a
complete standstill before starting any dismantling
work.
G 08 84 72 1
G 0 46 7 36 1
107
4 Dismantling/Assembly
G 0 07 66 22
G 0 47 39 1 1
NOTE
G 08 85 71 1
G 01 71 53 1
108
4 Dismantling/Assembly
G 00 77 34 1
G 04 89 8 21
G 01 71 66 1
109
G 0 07 66 22
G 0 47 7 11 1
4 Dismantling/Assembly
G 04 77 21 1
110
4 Dismantling/Assembly
G 0 47 73 1 1
NOTE
Do not start the separator unless the flat belt has
been re-tightened after 30 minutes.
If started, the belt may slip and be damaged.
111
4 Dismantling/Assembly
If plate (8) is to be replaced, wipe the sight glass (7) with a degreasing agent.
Fit the new plate on the outside of the sight glass. The plate is self-adhesive.
Mark the position of the plate relative to the recess in sleeve (1).
G 01 55 8 11
Assemble the oil filling device and fit it into the frame. Note that the mark on sleeve (1) must be
positioned opposite the mark on the frame. Fill the sump with new oil.
5. Sealing ring
4. Nipple
2. O-ring
1. Sleeve for oil filling
7. Sight glass
112
8. Plate
G 01 55 91 1
3. O-ring
4 Dismantling/Assembly
G 08 8 47 11
2. Elbow
1. Water container
2. Elbow
4.7 Brake
4.7.1 Exploded view
5. Split pin
6. Brake handle
G 0 17 17 3 1
3. Bracket
4. Cylindrical pin with hole
113
4.7 Brake
4 Dismantling/Assembly
A = Coupling surface
Molykote 1000 Paste
114
G 0 17 19 31
Oil
4 Dismantling/Assembly
G 03 5 83 51
115
116
4 Dismantling/Assembly
SEPARATOR MANUAL
5 TECHNICAL REFERENCE
5 Technical Reference
Contents
5.1 Product description
118
119
120
122
5.8.8
5.8.9
Dimensions of connections
123
153
Power consumption
156
5.4.1
Performance data,
in- and outlet device
Introduction
158
159
159
161
124
5.10.2
Before start-up
161
5.10.3
Connections to surrounding
equipment
162
163
5.5.1
Scope
124
5.5.2
References
124
5.5.3
Definitions
124
5.10.4
5.5.4
Goal
125
163
5.5.5
126
166
5.5.6
5.10.7 Foundations
168
5.5.7
Fluid connections.
128
132
5.7 Lubricants
133
5.7.1
Lubrication chart
133
5.7.2
134
5.7.3
Recommended lubricants
135
5.7.4
138
5.7.5
139
5.8 Drawings
143
5.8.1
Foundation drawing
143
5.8.2
144
5.8.3
Electric motor
146
5.8.4
5.8.5
149
5.8.6
151
152
5.8.7
577461-02
117
5 Technical Reference
ISO 3744
EN 292-2
Operational limits:
Max. Allowed speed 9510 r/minute
Discharge interwall: 2 - 60 minutes
Feed temperature: 0 C to + 100 C
Ambient temperature: + 5 C to + 55 C
Not to be used for liquids with flashpoint below 60 C
Maximum allowed density of operating liquid: 1000 kg/m3
Risks for corrosion and erosion have to be investigated in each
case.
118
5 Technical Reference
Maximum density
feed
sediment
1100 kg/m3
2332 kg/m3
Power consumption
idling
0,9 kW
2,0 kW
9512/9307
rev/min. 50Hz/60Hz
3000/3600
rev/min. 50Hz/60Hz
Stopping time
average 19 minutes
With brake
Empty bowl
180 minutes
Filled bowl
180 minutes
2,2 litre
218 mm
0,5 litre
75 dB(A)
Sound power
8,9 Bel(A)
Vibration level
Separator in use
Max. 9 mm/sec
Weight
Motor
21 kg
Complete bowl
37 kg
Motor power
3 / 3,7 Kw
Bowl material
AL 111 2377-02
stainless steel
2,9
1,9
kgm2
kgm2
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.
119
5 Technical Reference
Connection
No.
Description
201
206
220
Requirements/limits
8 litres/minute
(221)
222
- Discharge volume:
120
18 litres/minute
- Quality requirements:
5 Technical Reference
Connection
No.
Description
373
Requirements/limits
- Quality requirements:
- Consumption:
377
462
463
701
753
5%
(10%)
Mechanical switch
- Frequency range:
< 300 Hz
< 4,5 g
- Internal impedance:
4 k 5%
48 V DC
Max. 14 W
2 A @ 24 V DC
121
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G 09 2 29 51
122
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G 0 9 22 96 1
123
5.5.1 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 for designing auxiliary equipment
and control system for the separator.
5.5.2 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
5.5.3 Definitions
For the purpose of this document, the following
definitions apply:
124
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5.5.4 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
Bowl leakage.
Product losses.
125
STARTING means:
RUNNING means:
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.
126
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STOPPING means:
Electrical connections.
127
128
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Shall be closed.
Processing in STARTING:
Processing in RUNNING:
Shall be closed.
Processing in STARTING:
Shall be closed.
Processing in RUNNING:
129
Shall be open.
Shall be closed.
Processing in STARTING:
Shall be closed.
Processing in RUNNING:
130
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Shall be closed.
Processing in STARTING:
Shall be closed.
Processing in RUNNING:
131
pH>6
Increased acidity (lower pH) increases the risk for corrosion; this
is accelerated by increased temperature and high chloride ion
content.
NOTE
132
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5.7 Lubricants
G 0 11 21 2 2
5.7 Lubricants
.
Lubricating points
Lubricants
Lubricating oil.
Electric motor.
133
5.7 Lubricants
5 Technical Reference
Group A oil: a high quality gear oil on paraffin base with stable AW (anti wear)
additives.
Group B oil: a high quality gear oil on paraffin base with stable EP (extreme pressure)
additives.
Group D oil: a synthetic base oil with additives stable at high operating temperatures.
Group E oil: Characteristics as a group D-oil but suitable at a higher operation power
(55 kW)
Do not mix different oil brands or oils from different oil groups.
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 it is necessary to change from one group of 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 5.2 Technical data, page 119.
134
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5.7 Lubricants
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.
Pastes:
Manufacturer
Designation
Alfa Laval No
Dow Corning
537086-02 (1000 g)
537086-03 (100 g)
537086-04 (50 g)
Fuchs Lubritech
Gleitmo 705
Gleitmo 805K
Klber
Wolfracoat C (Paste)
Rocol
Bonded coatings:
Manufacturer
Designation
Fuchs Lubritech
Dow Corning
Alfa Laval No
535586-01(375 g)
135
5.7 Lubricants
5 Technical Reference
Manufacturer
Designation
Hygienic comment
Dow Corning
(Molykote) 111
(Compound)
539474-02 (100 g)
Molykote G-5032
569415-01 (50 g)
Chemplex 750
Geralyn SG MD 2
Unisilkon L 250 L
Bel-Ray
No-Tox Silicone
Valve Seal
MMCC
ALCO 220
Rocol
Foodlube HiTemp
Bremer &
Leguil,
Fuchs Lubritech
Klber
136
539474-03 (25 g)
5 Technical Reference
5.7 Lubricants
Manufacturer
Designation
BP
Energrease MP-MG2
Hygienic comment
Energrease LS2
Energrease LS-EP2
Castrol
Chevron
Dow Corning
ExxonMobil
Beacon EP2
Unirex N2
Mobilith SHC 460
Mobilux EP2
Fuchs Lubritech
Lagermeister EP2
Q8/Kuwait Petroleum
Rembrandt EP2
Shell
Alvania EP 2
Albida EP2
SKF
LGEP 2
LGMT 2
LGFB 2
Total
Multis EP2
BP
Energrease MP-MG2
NSF Registered H1
(14 Sept 2005)
Energrease LS2
Energrease LS-EP2
137
5.7 Lubricants
5 Technical Reference
Time in operation
A/150
1500 h
D/220
2000 h
138
5 Technical Reference
5.7 Lubricants
Designation
ISO-L-HM or HV 150
VG 150
VI >95
Manufacturer
Designation
Alfa Laval
546098-81
546098-83
BP
Bartran 150
Bartran HV 150
Castrol
Alpha ZN 150
Hyspin AWH(-M) 150
Hyspin AWS 150
Chevron
Rando HD 150
Paper Machine oil XL 150
ExxonMobil
4 litres
1 litre
139
5.7 Lubricants
5 Technical Reference
Q8/Kuwait Petroleum
Haydn 150
Shell
Morlina 150
Statoil
LubeWay XA 150
Total
Azolla ZS 150
Lubmarine Visga 150
VG 150
VI >95
Manufacturer
Designation
ExxonMobil
Bel-Ray
Total
140
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5.7 Lubricants
Designation
Alfa Laval
542690-84
542690-85
BP
Castrol
Alphasyn EP 220
Alphasyn HG 220
Optigear Synthetic A 220
Chevron
ExxonMobil
Q8/Kuwait Petroleum
Schumann 220
Shell
Omala RL 220
Statoil
Mereta 220
Total
Carter SH 220
Elf Epona SA 220
141
5.7 Lubricants
5 Technical Reference
Designation
Shell
142
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5.8 Drawings
5.8 Drawings
5.8.1 Foundation drawing
G 06 45 7 21
A
B
C
D
E
F
Service area
143
5.8 Drawings
5 Technical Reference
G 09 31 7K 1
Example II in nomogram
Reference in graph:
Reference in graph:
Oil density
965 kg/m3
at 15 C (60 F)
Oil density
875 kg/m3
at 15 C (60 F)
Separation
temperature
70 C (158 F)
Separation
temperature
60 C (140 F)
Throughput
1,0 m3/h
Throughput
2 m3/h
144
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5.8 Drawings
145
5.8 Drawings
5 Technical Reference
8h9
24
31
60
298,5
100
67
47
M10
97
33
O 28j6
11
136
O199
93,5
j6
O 180
O 250
22
21
45
Type of mounting
IEC 34-7
Degree of protection
IEC 34-5
NOTE
The motor bearings are permanent lubricated.
Manufacturer
ABB Motors
Size
100L
Type
M2AA 100L
Weight
21 kg
Poles
Insulation class
Bearings
Method of cooling
Specification
NOTE
For complete information about motor variants, please
contact your Alfa Laval representative.
146
IM 3011
IP 55
G 08 31 1 31
5 Technical Reference
5.8 Drawings
G 0 83 11 8 1
A.
B.
C.
D.
E.
M6 external earth
20 conduit entry
4 holes drilled 15 through equi-spaced on A
215 P.C.D
Hole tapped M10x22 deep. To DIN 332 form D.
View on "X"
Manufacturer
Manufacturers drawing
Standards
Size
Type
Weight
Poles
Insulation class
Bearings
Method of cooling
Specification
147
5.8 Drawings
5 Technical Reference
Type of mounting
IEC 34-7
IM 3011
Degree of
protection
IEC 34-5
IP 55
NOTE
The motor bearings are permanently lubricated.
NOTE
For complete information about motor variants,
please contact your Alfa Laval representative.
148
5 Technical Reference
5.8 Drawings
G 06 35 1 41
1. Machine plate
Separator
Manufacturing serial No / Year
Inlet and outlet
Bowl
S0 06 1 41 1
Product No
149
5.8 Drawings
5 Technical Reference
3. Safety label
! WA R N I N G
WARNING
Read the instruction manuals before
installation, operation and maintenance.
Consider inspection intervals.
XXXXXXXXXXXXXXXXX
XXXX XXXX XXXX
XXXXXXXXXXXX XXX
XXXXXXX XXXXX XX
XXXXX XXXXXXX
XXXXXXXXX.
XX X XXXXX XX X XXXX
XXX XXX X XXXXXX
XXX XXX XXX X XXXXX
XXX X XXXX .
S00 6 90 N1
Text on label:
S0 06 3 21 1
4. Name plate
S0 06 31 1 1
7. Label
Text on label:
S0 06 91 11
150
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5.8 Drawings
G 0 93 1 7A 1
Performing a discharge:
Open connection 373 and perform a displacement (of the interface) by opening
connection 206.
G 0 9 31 7B 1
151
5.8 Drawings
5 Technical Reference
G0931771
Performing a discharge:
G0931781
152
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5.8 Drawings
G09 3 17 H1
A.
B.
10 cSt
30 cSt
48 cSt
153
5.8 Drawings
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G 0 93 17 I1
A.
B.
154
Pressure kPa
Throughput m3/h
5 Technical Reference
5.8 Drawings
G 09 31 7J 1
A.
B.
litres/hour
Gravity disc
155
5.8 Drawings
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G09317E1
Max.
150 kPa
Min.
156
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5.8 Drawings
G 09 3 17 F1
Max.
150 kPa
Min.
157
5.8 Drawings
5 Technical Reference
G 0 9 31 7G 1
Max.
150 kPa
Min.
5.8.10Interconnection diagram
1
2
Reset Coil
NO
Common
NC
6
7
8
Heater
G0931791
158
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159
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G 08 73 61 1
160
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6 months or longer
18 months or longer
161
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G 0 8 73 91 1
Service media
G 0 87 4 02 1
G 0 87 43 1 1
162
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Storage
Specification
Upon arrival to the store, check all
components and keep them:
163
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G 0 05 7 11 1
Fixed on a pallet
G 0 0 57 21 1
G 0 05 73 1 1
164
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Transport
Specification
During transport of the separator, the bowl
must always be removed from the machine
and transported separately.
When lifting a separator it must always be
hung securely. See details in chapter 3.6
Lifting instructions, page 52.
ING
WARN
Crush hazard
Use correct lifting tools and follow lifting
instructions.
H = minimum 750 mm
165
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5.10.6Planning of installation
Introduction
G 00 20 61 1
166
G 0 02 07 21
5 Technical Reference
Specification
A minimum height is required to lift the bowl,
bowl parts and the bowl spindle, see the
drawing 5.8.1 Foundation drawing, page 143.
Recommendation
When two or more separators are installed, the
lifting height may have to be increased to
enable parts from one separator to be lifted and
moved over an adjoining assembled separator.
Specification
The oil filling device must not be blocked by
floor plate arrangement, etc.
Recommendation
It should be possible to place a portable
collecting tray under the oil filling device drain
hole.
167
5.10.7Foundations
NOTE
When lifting a separator it must always be hung
securely. see separate lifting instructions in this
book.
168
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SEPARATOR MANUAL
6 OPERATING
6 Operating
Contents
6.1 Operating routine
168
168
6.2.1
169
170
6.3.1
6.3.2
6.3.3
Separation
174
6.3.4
Stopping procedure
175
6.3.5
Safety stop
176
170
177
577461-02
169
6 Operating
ING
WARN
Breakdown hazard
Assemble the separator completely before start. All
couplings, covers, and guards must be in place and properly
tightened. Non compliance may lead to breakdown.
ING
WARN
Electrical hazard
Follow local regulations for electrical installation and
earthing (grounding).
ING
WARN
P00 35 9 5B
Breakdown hazard
Check that the power frequency is in agreement with the
machine plate. If incorrect, resulting overspeed may cause
breakdown.
Use the separation system for the purpose, and within the
limits, specified by Alfa Laval. Failure to do so could cause a
violent breakdown.
170
50 Hz?
60 Hz?
P0 0 39 92 A
ING
WARN
6 Operating
NOTE
G 0 86 85 43
171
6 Operating
G0465431
Slip hazard
Check all connections for leakage.
Oil leakage may make the floor slippery.
172
6 Operating
S0009411
ON
CAUTI
P00 35 9 6B
ING
WARN
Disintegration hazards
After change of feed the sludge discharge interval
must be adjusted.
Too long intervals between discharges can result in
breakdown.
173
6 Operating
ON
CAUTI
174
P0 04 07 3 C
Burn hazard
6 Operating
4
3
6
7
8
1
10
S0009121
Water supply
ING
WARN
Disintegration hazards
When excessive vibration occurs, keep bowl filled
and stop separator.
The cause of the vibration must be identified and
rectified before the separator is restarted.
Excessive vibration may be due to incorrect
assembly or insufficient cleaning of the bowl.
175
6 Operating
6. For purification:
a. Supply water to form the water-seal.
The water should have the same
temperature as the process liquid.
c.
7. For clarification:
a. Start the oil feed with full flow.
8. For both purification and clarification
modes:
Check the separator inlet and outlet
pressures. See recommended values in your
system documentation.
9. Adjust to desired throughput.
6.3.3 Separation
Do regular checks on:
back pressure
motor current.
176
S0009631
6 Operating
Separator standstill
R
DANGE
Entrapment hazard
I0 02 93 CB
177
6 Operating
S0055611
Hazard!
ING
WARN
Disintegration hazards
S0009911
178
6 Operating
R
DANGE
Entrapment hazard
I 00 29 3 CB
ING
WARN
Entrapment hazard
To avoid accidental start, switch off and lock power
supply before starting any dismantling work.
Make sure that separator has come to a complete
standstill before starting any dismantling work
ING
WARN
Disintegration hazard
Do not start the separator after an emergency stop
without first remedying the cause of the emergency.
Make sure that the bowl is clean before restart.
179
6 Operating
Separator reassembled
ING
WARN
Breakdown hazard
P00 3 59 5B
180