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Instruction Manual

Book No.:

9017368-02 V7

Product no.:

9016161-80, -81, -82, -83
9016162-80, -81, -82, -83

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X

Alfa Laval Emmie

Mobile hydraulic oil cleaning system

Summary of Contents for Emmie

Page 1: ...Instruction Manual Book No 9017368 02 V7 Product no 9016161 80 81 82 83 9016162 80 81 82 83 X X Alfa Laval Emmie Mobile hydraulic oil cleaning system...

Page 2: ...Telephone 46 8 530 650 00 Telefax 46 8 530 310 40 Alfa Laval Tumba AB 05 2016 Original instruction This publication or any part there of may not be reproduced or transmitted by any process or means w...

Page 3: ...nk 18 5 Working principle of the separator 19 5 1 Introduction 19 5 2 Clarifier operation 21 5 3 Purifier operation 21 5 4 Changing operation mode 22 6 Control Cabinet 25 6 1 Operator panel 25 6 2 Con...

Page 4: ...8 11 Some liquid escaping through drain outlet to collecting tank 51 8 12 Oil flow through drain outlet to collecting tank only 51 8 13 Oil leakage through drain outlet to collecting tank when separat...

Page 5: ...echnical data system 67 10 2 Declaration 68 11 Installation 69 11 1 Installation alternatives 69 11 1 1 Replacement of filler cap 69 11 1 2 Connection to drain hole in tank 70 11 1 3 Using separate su...

Page 6: ......

Page 7: ...or injury The following basic safety instructions therefore apply Use the cleaning unit only for the purpose and parameter range specified by Alfa Laval Only use the cleaning unit in non explosion en...

Page 8: ...fore moving the cleaning unit or starting any dismantling work To avoid accidental start switch off the power supply and remove the electric cable from the socket before starting any dismantling work...

Page 9: ...and with a maximum viscosity VG of 150 cSt at 40 C WARNING Disintegration hazard The cleaning system must not be operated in an explosion environment NOTE Never use Alfa Laval Emmie on engine lube oi...

Page 10: ...2 Application...

Page 11: ...3011 NOTE When ordering spare parts for the cleaning unit except the separator please specify the article and serial numbers stamped on the machine plate 1 for the complete unit NOTE When ordering spa...

Page 12: ...separation G Manufacturer H Serial No I Enclosure Article No Serial No Year Manufacturer Alfa Laval Krakow Service enquiries www alfalaval com A B C G1102721 Example of machine plate complete unit A...

Page 13: ...cription of main parts 4 1 System overview The Alfa Laval Emmie unit consists of the following parts numbered in process order Parts marked with are further described on pages 16 to 18 Please turn ove...

Page 14: ...a The setting is supervised by the starter control unit 9 10 Hose 3 8 from separator to tank 11 Collecting tank 20 litres Collects the bowl drain oil and the water separated out from the oil at purifi...

Page 15: ...4 Description of main parts X X 1 2 3 8 12 9 10 7 6 5 4 11 13 G1115011 15...

Page 16: ...es are fitted into each other remember to secure the coupling by turning the locking ring until it engages G0906711 A Locking ring in unlocked position B Locking ring in locked position NOTE When the...

Page 17: ...motor For a description of the separator function see 5 Working principle of the separator on page 19 G0907931 4 4 Pump The flow is controlled by the VFD in the control cabinet see chapter 6 Control...

Page 18: ...y a spring with adjustable tension The spring can be adjusted by the handle 1 on the underside of the support When the collecting tank is nearly full the weight will overcome the spring tension and a...

Page 19: ...ator is stopped The bowl 1 and motor 6 are suspended on three vibration dampers 5 If the unseparated oil contains water the separator should be operated as a purifier otherwise clarifier operation is...

Page 20: ...fier or as a purifier Choose clarifier operation when no or only traces of water in the oil At delivery the separator is assembled for clarifier operation Choose purifier operation when the oil contai...

Page 21: ...outlet B under a constant pressure The particles accumulated on the bowl wall are removed periodically every 1 3 days by hand 5 3 Purifier operation When operating the separator as a purifier a water...

Page 22: ...way as when cleaning the bowl see 9 4 2 Cleaning of bowl on page 56 2 Remove the level ring O ring lower part of paring chamber and the sleeve with wings G05191b1 3 Unscrew the centre screw G05191e1...

Page 23: ...insert G1114411 Purifier bowl insert 1 Bowl bottom clarifier 2 Bottom disc purifier 3 Bowl bottom purifier with three holes 6 When fitting the insert check that the cylindrical pin 1 in the shaft is...

Page 24: ...itted under the screw G05191c1 8 Fit the sleeve with wings lower part of paring chamber level ring and O ring NOTE See the instructions in 9 4 2 Cleaning of bowl for fitting the level ring and O ring...

Page 25: ...the separator and the pump a 24VDC power supply and a PLC There are no operator controls inside the cabinet so it should not be opened Qualified personnel only are allowed to open the cabinet On top...

Page 26: ...the corresponding button is circled in green The Alarm button takes the operator directly to the Alarm list see Alarm list on page 30 If there is an active alarm the button will be red The Back Overv...

Page 27: ...sub equipment On the left hand side there is a status row for the sub equipment and if applicable setpoints for the devices and control functions for that subequipment On the right hand side is a grap...

Page 28: ...re control screen shows the pressure sensor and the pressure regulation valve Pressure set point can be changed from here By tapping the set point value a touch dial will appear G1113841 When the unit...

Page 29: ...istrator NOTE Administrator access level is only for Alfa Laval service engineers Alarm history A list of all past alarms System time Set system time so correct time stamps are made in the alarm list...

Page 30: ...an be for operator information only but in most cases it also forces the unit to another operating mode See 6 4 Alarm table on page 33 The operator acknowledges alarms with the two buttons on the righ...

Page 31: ...uld be equipped with a transformer 1 Other possible voltages are then 100 110 and 120 V Switching between voltages requires changing of transformer connection inside the control cabinet See circuit di...

Page 32: ...shine During START If an active alarm that has been acknowledged exists During STOP as long as separator is not in standstill Blinking 0 5s on 0 5s off When feed pump speed is boosted Startup speed I...

Page 33: ...temp cabinet 15s High temperature in control cabinet Check ventilation for control cabinet A100 Feed pump motor overload 1s Frequency converter fault for feed pump Check motor connection Check pump mo...

Page 34: ...6 Control Cabinet...

Page 35: ...olume in complete system in litres Formula for calculating minimum separation time 7 2 Separation mode Introduction To learn the correct running strategy first read the information below carefully bef...

Page 36: ...sure the thickness A of the sludge collected on the bowl wall see 9 4 2 Cleaning of bowl on page 56 The thickness should never exceed 10 mm Max recommended cleaning interval is 3 days A longer interva...

Page 37: ...ain parts Make sure that the hoses to the pump are correctly connected G0978741 3 The separator is set up as clarifier when delivered In case purifier mode is needed please convert the bowl as describ...

Page 38: ...NOTE Do not connect the return outlet to a pressurized system with the same or higher pressure than the pressure switch set point 50 kPa Otherwise the safety function of the switch will be overridden...

Page 39: ...7 Operating instructions 7 Make sure that the three hood screws 3 and the knob 1 are firmly tightened and that the bowl hood interlock 2 is in closed vertical position G0908811 39...

Page 40: ...e connected to an earthed outlet 2 When all alarms are acknowledged the operator can tap the Start button and the cleaning unit will start The separator starts G1107911 3 For purifier mode only Purifi...

Page 41: ...separation speed and the automatic pressure regulation starts The cleaning unit is now running in Production mode NOTE Make sure that oil is available when starting the pump Running dry for a longer...

Page 42: ...NOTE Make sure that oil is available when starting the pump Running dry for a longer period can damage the pump G1106011 7 When oil starts to flow through the pump the counter pressure will increase...

Page 43: ...al flow proceed as follows When the oil temperature has reached the set point check the throughput of the separated oil 100 120 l h is recommended With this flow the enclosed filler cup will be filled...

Page 44: ...and the lamp on the control unit lights up Empty the tank and restart the pump to continue the cleaning It is possible to recover any oil by proceeding as described in 4 6 Collecting tank on page 18 1...

Page 45: ...nnect the hoses NOTE If the check valves are not sealing properly there is a risk that oil may be siphoned from the hydraulic oil tank and drained via the separator into the collecting tank g0906911 N...

Page 46: ...outlet 1 and inlet 2 3 Start the unit 4 When the pump is started press the bleeding valve 3 to allow air to enter the heater The hoses will be drained If possible check the oil flow If there is still...

Page 47: ...ansformer Separator stops See 8 4 Separator stops on page 48 Pump stops See 8 3 Pump stops on page 47 8 2 Pump does not start Possible cause Action Microswitch for filled collecting tank activated Emp...

Page 48: ...k Overload due to incorrect assembly Check the bowl assembly Tripped frequency converter due to too low or too high supplied voltage 5 of nominal voltage Check the voltage Check the voltage If unstabl...

Page 49: ...aged bearings Replace the bearings 8 7 Insufficient separation result Possible cause Action Separator disc stack clogged Clean separator bowl and disc stack Too high flow rate Reduce the flow by adjus...

Page 50: ...mantle and check the separator bowl parts Especially check that no O rings are missing are defective or incorrectly fitted Ensure that the separator is assembled correctly Separator or pump rotates in...

Page 51: ...nd or the knob 8 12 Oil flow through drain outlet to collecting tank only Possible cause Action If operating in purifier mode broken liquid seal in separator bowl Stop the pump and add water through t...

Page 52: ...8 Trouble shooting 8 15 Separation temperature too low Possible cause Action Throughput too high Reduce the flow 52...

Page 53: ...al surfaces 9 1 Cleaning 9 1 1 Separator The separated solids collected inside the separator bowl must be removed manually The length of the cleaning interval depends on the liquid flow rate and on th...

Page 54: ...e 1 Sludge 2 Bowl wall See 9 4 2 Cleaning of bowl on page 56 for information on procedure For further information see 7 2 Separation mode on page 35 9 1 2 Strainer When using the suction pipe with bui...

Page 55: ...in the separation efficiency See 9 4 3 Replacement of O rings in purifier bowl on page 60 and 9 4 4 Replacement of O rings in clarifier bowl on page 62 for procedure 9 4 Dismantling assembly instructi...

Page 56: ...oo soon the following could happen The pin on the inside of the connecting housing breaks The pin inside the top of the paring disc breaks Excessive wear of top of level ring Illustration 8 A few drop...

Page 57: ...9 Maintenance Dismantling G04491c1 See comments on opposite page 57...

Page 58: ...fit the level ring and then the O ring outside the level ring Finally press down the O ring by pressing the cover 3 firmly with both hands G0912121 G0907211 Illustration 18 Check that the distance il...

Page 59: ...d on the connecting housing before tightening the screws shown in illustration 23 Otherwise there is a risk that the pin inside the connecting housing could break Assembly 16 0 5 mm 21 24 25 20 17 18...

Page 60: ...site page Illustration 5 Take care of the washer Illustration 14 Check that the washer is fitted Otherwise there is a risk that the bowl will not make firm contact with the spindle If two or more wash...

Page 61: ...9 Maintenance First dismantle the separator bowl as described in 9 4 2 Cleaning of bowl on page 56 G05191k1 See comments on opposite page 61...

Page 62: ...site page Illustration 5 Take care of the washer Illustration 14 Check that the washer is fitted Otherwise there is a risk that the bowl will not make firm contact with the spindle If two or more wash...

Page 63: ...9 Maintenance First dismantle the separator bowl as described in 9 4 2 Cleaning of bowl on page 56 G05191L1 See comments on opposite page 63...

Page 64: ...9 Maintenance 9 4 5 Replacement of motor bearings First dismantle the separator bowl as described in 9 4 2 Cleaning of bowl on page 56 G0449461 64...

Page 65: ...9 Maintenance G0449671 65...

Page 66: ...9 Maintenance G0449681 66...

Page 67: ...Separation temperature 15 70 C Recommended operating flow 80 120 litres hour Max ambient temperature 45 C Power supply 230 V 10 or 100 230 V 10 1 phase 50 60 Hz Amperage 10 A 230 V 16 A 100 120 V Soun...

Page 68: ...al requirements EN 61000 6 2 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments EN 61000 6 4 Electromagnetic compatibility EMC Part 6 4 Generic standards...

Page 69: ...e NOTE Never separate an unfiltered system unless a strainer is fitted in the suction line When separating an unfiltered system use the diver tube with fitted strainer as described in 11 1 3 on next p...

Page 70: ...he outlet Inside the tank the return pipe should be located about 100 mm A below the oil surface to prevent aeration of the oil in the tank G0912711 11 1 3 Using separate suction and return pipes The...

Page 71: ...d crane hook should be min 1 metre A NOTE Weight of unit is approx 60 kg WARNING Entrapment hazard Only attach the lifting straps to the two lifting hooks when lifting the cleaning unit A falling unit...

Page 72: ...12 Lifting instruction...

Page 73: ...13 Diagrams 13 1 Electrical system Alfa Laval ref 9014733 Rev 7 73...

Page 74: ...2015 10 23 Approved by SETUNLN CAT Department 2014 04 01 Created date Document No 9014733 Page Revision Latest Revision 07 Project Title page cover sheet Location Mounting Title Alfie Emmie Revised da...

Page 75: ...s Shield SH shall be connected to cable glands except for power supply cables they shall be connected to PE bar Page 25 244 IF2 1 CP01 A1 1 CP01 OP1 Ethernet to OP 1 GN YE GN YE Page 27 261 Tank full...

Page 76: ...202 W401 W402 Location Mounting Title Alfie Emmie Revised date 07 3 4 Next page Page 2015 10 07 Internal targets External targets Shield SH shall be connected to cable glands except for power supply c...

Page 77: ...connected to earth as shown in the electrical drawings For power cables armour must be connected to the earth bar Providing the armour is connected to the earth as shown in the electrical drawings gi...

Page 78: ...ment 2014 04 01 Created date Document No 9014733 Page Revision Latest Revision 07 Project Wiring table Location Mounting 9014733 CP01 Title Alfie Emmie Revised date 02 10 11 Next page Page 2014 09 05...

Page 79: ...abinet assembly Location Mounting 9014733 CP01 Title Alfie Emmie Revised date 07 11 12 Next page Page 2015 10 23 Technical data Hatch Back G1 O P T I O N A L 1 PE U2 11 12 10 10 2 9 5 3 7 6 4 IP54 SSA...

Page 80: ...2015 10 23 Approved by SETUNLN CAT Department 2014 04 01 Created date Document No 9014733 Page Revision Latest Revision 07 Project Control cabinet assembly Location Mounting 9014733 CP01 Title Alfie...

Page 81: ...document constitutes a contractual obligation on our part only to the extent expressly agreed upon SETUTBL Created by SETUTBL Revised by Approved date 2015 10 23 Approved by SETUNLN CAT Department 201...

Page 82: ...n This document constitutes a contractual obligation on our part only to the extent expressly agreed upon SETUTBL Created by SETUTBL Revised by Approved date 2015 10 23 Approved by SETUNLN CAT Departm...

Page 83: ...utes a contractual obligation on our part only to the extent expressly agreed upon SETUTBL Created by SETUTBL Revised by Approved date 2015 10 23 Approved by SETUNLN CAT Department 2014 04 01 Created...

Page 84: ...Page 2015 10 23 Power Supply 1x230V 50 60Hz Max fuse 10A Option 1x100 110 120V 50 60Hz Max fuse 10A 24V DC PLUS G1 AC 100 120 200 240V DC 24V 2 5A 120W 144W L N PE 24V DC MINUS EMC 2 stage filter Remo...

Page 85: ...date Document No 9014733 Page Revision Latest Revision 07 Project Separator Location Mounting 9014733 CP01 Title Alfie Emmie Revised date 05 22 23 Next page Page 2015 01 13 S1 I ON Separator Note Set...

Page 86: ...oved date 2015 10 23 Approved by SETUNLN CAT Department 2014 04 01 Created date Document No 9014733 Page Revision Latest Revision 07 Project Pump Location Mounting 9014733 CP01 Title Alfie Emmie Revis...

Page 87: ...igation on our part only to the extent expressly agreed upon SETUTBL Created by SETUTBL Revised by Approved date 2015 10 23 Approved by SETUNLN CAT Department 2014 04 01 Created date Document No 90147...

Page 88: ...cument constitutes a contractual obligation on our part only to the extent expressly agreed upon SETUTBL Created by SETUTBL Revised by Approved date 2015 10 23 Approved by SETUNLN CAT Department 2014...

Page 89: ...proved by SETUNLN CAT Department 2014 04 01 Created date Document No 9014733 Page Revision Latest Revision 07 Project X1 Inputs Location Mounting 9014733 CP01 Title Alfie Emmie Revised date 06 26 27 N...

Page 90: ...Project X2 Inputs Location Mounting 9014733 CP01 Title Alfie Emmie Revised date 06 27 28 Next page Page 2015 03 26 Tank full Cover open Separator Fault Pump Fault 11 DI1 DigitalInput1 12 DI3 DigitalIn...

Page 91: ...Outputs Location Mounting 9014733 CP01 Title Alfie Emmie Revised date 06 28 29 Next page Page 2015 03 24 Separator start Indication Common Alarm Pump start External Alarm ON NO ALARM Note 24VDC Max 0...

Page 92: ...6 Next page Page 29 Revised date 9014733 Document No 2015 03 26 Pump VFD speed Chanel 1 Chanel 2 Chanel 3 Chanel 4 X1 11 AO 01I AnalogOutput01 X1 14 AO 03I AnalogOutput03 X1 12 AO 01U AnalogOutput01 F...

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