Alfa Laval S946 System Manual Download Page 88 | Manualshive

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Operating

SV15 Discharge valve
Verify the operation of the valve, see also that the green diode
on the valve connector is lit.

Valid for:
All S and P types

SV16 – Closing water valve
Verify the operation of the valve, see also that the green diode
on the valve connector is lit.

Valid for:
All S and P types

Steam decrease – Closing of steam valve
Verify that the valve is moving towards closing position. Note
that if the valve is already closed, an opening operation (see
below) needs to be done prior to this test.

Optional
Valid for:
All S and P types

Steam increase – Opening of steam valve
Verify that the valve is moving towards opening position.

Optional
Valid for:
All S and P types

Programmable output 1
Not to be tested

Programmable output 2
Not to be tested

Programmable output 3
Not to be tested

Programmable output 4
Not to be tested

Programmable output 5
Not to be tested

Programmable output 6
Not to be tested

Electric heater test Optional

Before the electric heater i/o-test, please ensure that the
electric power to the electric heater cabinet is turned OFF!
The operating voltage for the relays is supplied from control
cabinet.

Elheatvar – Variable output
Check that the diodes on the 2 triacs inside the electric heater
cabinet are lit.

Optional
Valid for:
All S and P types

Heater on signal
Check that the relay KA11 (diode, see picture below) and
K11 (mechanical indication) in the electric heater cabinet is
activated.
Note, leave this output activated (indicating 1 on display) when
proceeding with the tests of the fixed power steps below!

Optional
Valid for:
All S and P types

ElheatPS1 – Power step 1
Check that the relay KA12 (diode, see picture below) and
K12 (mechanical indication) in the electric heater cabinet is
activated. Optional Valid for: All S and P types

ElheatPS2 – Power step 2
Check that the relay KA13 (diode, see picture below) and
K13 (mechanical indication) in the electric heater cabinet is
activated.

Optional
Valid for:
All S and P types

ElheatPS3 Power step 3
Check that the relay KA14 (diode, see picture below) and
K14 (mechanical indication) in the electric heater cabinet is
activated.

Optional
Valid for:
All S and P types

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Summary of Contents for S946

Page 1: ... Separation Module System Manual English S 946 Flex Separation Module 1 MAN Diesel Turbo MANAGUA Order No 4500968861 Al Order No 84 6893 31 MAN Material 11 63010 0244 MAN Diesel Turbo MANAGUA Order No 4500968861 Al Order No 84 6893 31 ...

Page 2: ...Finding 6 Installation System Reference 7 Marine Diesel Equipment Separator Manual With Spare Parts Catalogue 8 Printed June 2008 Document No 587876 02 Configuration No 108918 25 MAN Diesel Turbo MANAGUA Order No 4500968861 Al Order No 84 6893 31 S 946 Flex Separation Module Anncillary Components With Spare Parts Catalogue 9 ANNEX 10 2 ...

Page 3: ...MAN Diesel Turbo SE D 86224 Augsburg Process data Lubeoil Separator type S946 Delivery as Flex Modules Order Managua December 16 th 2014 3 ...

Page 4: ...vision of changes in water content in the clean oil outlet Measuring principle independent from the conductivity of the separated water Separators of the S type 921 to 987 series Self cleaning ALCAPTM separators EPC 60 control unit with multilingual clear text messages English German French Spanish Portuguese Finnish Discharge without pressure pulse and remarkably reduced sludge tank load due to C...

Page 5: ...nciple screw pump type ALP 0075 quantity 1 per separator pump capacity 5 090 l h suction height 4 4 m delivery height approx 2 bar speed 1 700 1 min electric motor IE2 2 0 kW Steam heater type CBM 30 40 quantity 1 per separator steam pressure temperature of the system 9 bar 175 C design steam pressure temperature heater 6 bar 164 C pressure drop steam oil 0 03 bar 0 36 bar oil temperature 50 95 C ...

Page 6: ...etween 2 and 8 bar required capacity of water min flowrate 11 l per minute average water consumption per discharge 6 4 liter Compressed air feed pressure between 5 and 8 bar average air consumption 1 01 Nm3 h Adjustments and set points 01MJV22 CT960 temperature transmitter 01MJV22 CT960 temperature alarm low 90 C 01MJV22 CT960 temperature alarm high 100 C 01MJV22 CP980 pressure transmitter clean o...

Page 7: ...Power factor 19 PLL determined from residual loss 100 17 0 90 9 IE2 0 93 20 75 13 1 91 5 0 9 21 50 9 4 91 2 0 84 22 Start 145 0 5 23 Maximum starting time from hot 15 s 24 Maximum starting time from cold 27 s 25 Insulation class Temperature class F B 26 Ambient temperature 55 C 27 Altitude 1000 m a s l 28 Enclosure IP55 29 Cooling system IC411 self ventilated 30 Bearing DE NDE 6308 2Z C3 6208 2Z C...

Page 8: ...ue 0 r min Load characteristics IEC 60034 2 1 2007 Load Current A Efficiency Power factor 19 PLL determined from residual loss 100 4 2 87 6 IE2 0 75 20 75 3 5 87 0 67 21 50 3 0 84 3 0 54 22 Start 38 0 58 23 Maximum starting time from hot 15 s 24 Maximum starting time from cold 27 s 25 Insulation class Temperature class F B 26 Ambient temperature 40 C 27 Altitude 1000 m a s l 28 Enclosure IP55 29 C...

Page 9: ...ial velocity m s 2 0 2 0 moment of inertia kgm2 0 0001645 0 0001645 capacity subject to change 04 2013 ND Field1051744 VI Field1051745 Auslegung Field64 20 09 2012 Field1051747 148414 Field1056706 0010 Field1 17 Dezember 2014 Version 14 4 1 COPY RIGHT by KRAL Three screw Pump Sizing performance data power required Lube Oil starting torque www alfalaval com E mail info dk alfalaval com Alfa Laval K...

Page 10: ...10 ...

Page 11: ...S and P Flex Separation Safety Printed Book No Feb 2008 584610 02 V 1 11 ...

Page 12: ...ssible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated Copies of this publication can be ordered from your local Alfa Laval company Published by Alfa Laval Tumba AB Marine Diesel Equipment SE 147 80 Tumba Sweden Copyright Alfa Laval Tumba AB 2008 12 ...

Page 13: ...lance reduction of material strength etc that could lead to serious breakdown with fatal injury or damage to property For safe operation strictly follow the instructions for installation operation and maintenance in this manual Important read this The centrifugal separator includes parts that rotate at very high speeds generating huge forces It is therefore essential for the safe operation of this...

Page 14: ...the discharge intervals according to instructions in the instruction book 5 Never ignore alarms Always eliminate the cause before resuming operation 6 Never use the separator for other liquids than those specified by Alfa Laval 7 Never operate a separator with a different power supply frequency than stated on the machine plate 8 Clean the operating system regularly to avoid sludge discharge malfun...

Page 15: ...r instruction indicates a potentially hazardous situation which if not avoided could result in death or serious injury Example WARNING Disintegration hazard If unusually strong vibration occurs press the Emergency Stop button and leave the room Do not enter the room after an emergency stop while the separator is still rotating Caution minor or moderate injury This type of safety sign or instructio...

Page 16: ...e control panel must be ON Be specially observant during start up If there is any abnormal vibration immediately stop the separator and investigate the cause Clean the bowl if it contains sediment WARNING Breakdown hazard Assemble the separator completely before start All couplings covers and guards must be in place and properly tightened Failure to do so may lead to breakdown WARNING Electrical h...

Page 17: ... purpose and within the limits specified by Alfa Laval Failure to do so could cause a violent breakdown CAUTION If power cable polarity has been reversed the separator will rotate in reverse and vital rotating parts can loosen CAUTION Check the oil level before start Top up when necessary Do not overfill 17 ...

Page 18: ...kdown hazard If strong vibration occurs press the emergency stop button and evacuate the room Never discharge a vibrating separator Vibration may then become violent and result in breakdown WARNING Disintegration hazard After an emergency stop the cause of the fault must be identified If all parts have been checked and the cause not found contact Alfa Laval for advice before restarting the separat...

Page 19: ...n can increase if solidified sludge is only partially discharged CAUTION Burn hazard Avoid contact with hot surfaces Process pipes various machine surfaces and processed liquid can be hot and cause burns CAUTION Slip hazard Check all connections for leakage Oil leakage may make the floor slippery If speed or starting power is not correct WARNING Stop and change the belt transmission to suit the po...

Page 20: ...connection with stop Emergency stop WARNING Disintegration hazard If unusually strong vibration occurs press the Emergency Stop button and leave the room Do not enter the room after an emergency stop while the separator is still rotating WARNING 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 cle...

Page 21: ...and lock power supply before starting any dismantling work Make sure that separator has come to a complete standstill before starting any dismantling work WARNING 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 DANGER Entrapment hazard Make sure that rotating parts have come ...

Page 22: ...ill remain in the separator after stop WARNING Disintegration hazards Use of imitation spare parts may cause severe damage WARNING Entrapment hazard To avoid accidental start switch off and lock power supply before starting any dismantling work Make sure that the separator has come to a complete standstill before starting any dismantling work WARNING The nut must not be removed before the separato...

Page 23: ... Separate them from the top disc so that they do not accidentally drop CAUTION Cut hazard Sharp edges on the separator discs may cause cuts WARNING Crush hazard The ring on the lifting tool must be pushed down against the discharge slide otherwise the discharge slide may come loose from the tool WARNING Crush hazard Support the bowl body when turning to prevent it from rolling WARNING Crush hazard...

Page 24: ...ental release WARNING Crush hazard If not supported the motor with coupling will drop when removing the screws WARNING Electrical hazard If the cables are not disconnected during lifting procedures they may become damaged CAUTION Inhalation hazard When handling friction blocks pads wear a mask to avoid inhalation of dust DO NOT USE COMPRESSED AIR TO REMOVE DUST Remove dust using vacuum or a damp c...

Page 25: ...eds 0 5 mm 0 2 mm for bowl body and bowl hood or if cracks have been found Do not continue to use the separator until it has been inspected and given clearance for operation by Alfa Laval WARNING Disintegration hazard Pits and spots forming a line may indicate cracks beneath the surface All forms of cracks are a potential danger and are totally unacceptable Replace any part where corrosion can be ...

Page 26: ...y must be renewed check that the new pulley has the correct diameter An incorrect pulley will cause the separator bowl to run at either an excessive or insufficient speed WARNING Burn hazard Use protective gloves when handling any heated parts WARNING Risk for eye injury from flying snap ring Use the correct pliers for assembly of snap ring to avoid accidental release WARNING Cut hazard Do not put...

Page 27: ...ING Crush hazards A falling separator can cause accidents resulting in serious injury and damage Never lift the separator by any other method than described in this manual WARNING Crush hazards Use correct lifting tools and follow lifting instructions WARNING Disintegration hazard Separator parts that are either missing worn beyond their safe limits or incorrectly assembled may cause severe damage...

Page 28: ...azard Assemble the separator completely before restart All couplings covers and guards must be in place and properly tightened Failure to do so may lead to breakdown CAUTION Health Risk Do not forget to disconnect the CIP equipment and re connect connections CAUTION Use only Alfa Laval recommended CIP liquids X0 2 47 61 A 28 ...

Page 29: ... leakage CAUTION Burn Hazard To prevent pressure or heat shocks in the system adjustment of the flow rate must be carried out slowly The heater can otherwise be damaged WARNING Burn Hazard Shut off the oil flow and the heating medium flow before starting maintenance WARNING Corrosion Hazard Pay strict attention to the safety instructions for the cleaning liquid used WARNING Burn Hazard Make sure t...

Page 30: ...ATION SAFETY 18 584610 02 1 4 2 Electric heaters DANGER Electrocution Risk Switch off the main power before opening the heater junction box or dismantling the heater CAUTION It is very important that the correct heater element is installed 30 ...

Page 31: ...S Flex Separation System Description Printed Book No Jul 2010 584621 02 V3 31 ...

Page 32: ...rs and omissions or suggestions for improvement of this publication would be gratefully appreciated Copies of this publication can be ordered from your local Alfa Laval company Published by Alfa Laval Tumba AB Marine Diesel Equipment SE 147 80 Tumba Sweden Copyright Alfa Laval Tumba AB 2010 Original instructions 32 ...

Page 33: ...ontents 584621 02 1 System Overview 1 1 1 Oil Flow 1 1 2 System Layout 2 1 3 System Components 4 2 The Process 5 2 1 Principle 5 2 2 Process Cycle Start 6 2 3 Discharge 8 2 4 Increased Water Content 9 33 ...

Page 34: ...584621 02 34 ...

Page 35: ... the entire operation of the separation system performing monitoring control and alarm functions The process adapts automatically to certain changes in conditions such as increased water content in the unprocessed oil high or low oil feed temperature etc 1 1 Oil Flow The unprocessed oil is fed through a heater by a feed pump operating at a constant flow A change over valve directs the oil to the s...

Page 36: ...he settling tank recirculation fuel oil only Heater Heats unprocessed oil to separation temperature Separator Cleans the oil by removing water and solid particles Solenoid valve block water Distributes separator opening closing water and conditioning water Sludge outlet Unprocessed oil inlet Oil return Conditioning water Opening water Closing water Water inlet Pressure transmitter oil PT1 Measures...

Page 37: ...ice tank Regulating valve RV4 To manually regulate the backpressure in the clean oil outlet Water transducer MT60 Measures change in water content in the cleaned oil and signals the control unit Water drain Pressure transmitter water PT5 Measures the pressure in the water drain outlet and signals the control unit Pneumatically controlled shut off valve V4 Closes the clean oil outlet Drain valve V5...

Page 38: ...nd starter Water out Sludge outlet Oil out Oil in Drain valve V5 Pressure transmitter water PT5 Pressure transmitter oil outlet PT4 Temperature transmitter TT1 TT2 Pressure transmitter oil inlet PT1 Operating air Operating water Change over valve V1 Combined regulating valve RV4 and shut off valve V4 Clean oil outlet EPC 60 Control unit Safety valve SV10A Lube oil only 38 ...

Page 39: ...wl between discharges The cleaned oil leaving the separator is tested for traces of water Any increase in water is detected by the water transducer The signal from the water transducer is continuously transmitted to the control unit in which a reference value is stored The control unit compares the transducer signal with the reference value A significant deviation from the reference value will cau...

Page 40: ... is empty The control unit then starts the process cycle 1 The change over valve directs the oil to the recirculation line Conditioning water is added to the separator bowl until the pressure sensor in the oil outlet senses pressure and signals the control unit 2 The control unit registers the time taken for water addition This water flow reference value is later used to calculate the correct amou...

Page 41: ...bove the control unit signals the solenoid valve to open so that the correct amount of conditioning water is added to the separator bowl 5 The change over valve opens so that oil is directed to the separator bowl When pressure in the oil outlet is sensed the pressure sensor PT signals the control unit The control unit calculates and stores the time taken to add oil to the bowl Controller P 00 35 6...

Page 42: ...on 2 Using the flow rate calculated in paragraph 2 under 2 2 Process Cycle Start page 6 the control unit signals the solenoid valve to open so that displacement water is added to push the oil towards the disc stack 3 After the calculated time for displacement water addition has elapsed the separator discharges 4 Conditioning water is then added and a new separation cycle begins Controller P0 0 35 ...

Page 43: ...alve V5 opens for a number of seconds 2 The water drain valve closes again and the transducer signal is evaluated 3 If there is still an increase in water content the drain valve opens again If the water content is still high after the drain valve has opened five times a discharge is initiated 4 If the water content has decreased the separation cycle returns to normal MT Controller PT P 00 35 6K C...

Page 44: ...2 THE PROCESS S FLEX SEPARATION SYSTEM DESCRIPTION 10 584621 02 44 ...

Page 45: ...S and P Flex Separation Operating instructions Printed 03 2014 Book No 584612 02 rev 8 45 ...

Page 46: ... 46 8 530 650 00 Telefax 46 8 530 310 40 Alfa Laval Tumba AB 03 2014 The original instructions are in English This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB 46 ...

Page 47: ...ground 34 1 12 2 Recommended intervals between sludge discharges 34 1 12 3 Fuel oil cleaning 35 1 12 4 Lubricating oil cleaning 35 1 12 5 Bowl inspection 37 1 13 Heater Control optional 38 1 13 1 Control of the electric heater optional 40 1 13 2 Control of the CBM heater optional 41 1 13 3 If heater not controlled or external 42 1 13 4 Heater shut down 42 1 14 Cross connection serial operation 43 ...

Page 48: ...stem With PT1 Disabled 52 1 17 5 System With PT4 Disabled 52 1 17 6 System With PT5 Disabled S separator only 52 1 17 7 System With TT1 TT2 Disabled 53 1 17 8 Control of Sludge Pump Level in Sludge Tank and Butterfly Valve 53 1 17 9 System Without Feed Pump 54 1 17 10 System Without Water Transducer S separator only 55 1 17 11 Purifier Operation only valid for S 805 and S 815 56 4 48 ...

Page 49: ...etely before start All couplings covers and guards must be in place and properly tightened Failure to do so may lead to breakdown X024761A WARNING Electrical hazard Follow local regulations for electrical installation and earthing grounding NOTE Check that the Emergency Stop Box is properly installed and functioning correctly WARNING Breakdown hazard Check that the power frequency is in agreement ...

Page 50: ...E Too much or too little oil can damage the separator bearings X024762A Rotation Direction Check the rotation of the bowl using the I O test function See 1 16 I O Test Function on page 47 The motor fan must rotate in a clockwise direction CAUTION If power cable polarity has been reversed the separator will rotate in reverse and vital rotating parts can loosen X023719B Operating Air Pressure Check ...

Page 51: ...nnectors indicate that the valve has power on They do not indicate if the valve is clogged an alarm is given if this is the case Emergency Stop Push Box Check that the Emergency Stop Box is located close to the separator system and electrically connected to the Control Panel NOTE If the Emergency Stop Box is not connected the system will not start 7 51 ...

Page 52: ...r value 9 6 3 8 2 0 7 4 1 i 5 SLUDGE PUMP CLEANING IN PLACE REMOTE CONTROL CIP DISCHARGE FEED PUMP HEATER SEPARATOR X023912A Press the arrow buttons to go up or down in the list NOTE During operation the Operation list is active on the display The present stage of operation for example SEPARATION shows on display together with operating information such as present temperature Press the downward Ar...

Page 53: ...r can initiate a STOP sequence by pressing the Stop button 9 6 3 8 2 0 7 4 1 i 5 SLUDGE PUMP CLEANING IN PLACE REMOTE CONTROL CIP DISCHARGE FEED PUMP HEATER SEPARATOR X023920A NOTE If control panel black screen appear See Alarms Fault finding manual 9 53 ...

Page 54: ...lways be carried out manually NOTE If a butterfly valve is installed it must be opened manually before that the system can start CAUTION If power cable polarity has been reversed the separator will rotate in reverse and vital rotating parts can loosen If speed sensor vibration sensor and frame cover switch are installed P113 P114 and P115 yes the operator can select to start the system automatical...

Page 55: ...eed without calibration appears on the display Stepwise automatic start is possible set using parameter P 130 For P type separators the system then goes to Standstill NOTE If this is the first start answer YES Assembled according to manual YES NO 2 If the bowl has been dismantled and assembled according to the instructions in the Service Manual choose YES If NO is chosen the system goes to STANDST...

Page 56: ...ights and text Starting feed pump shows on the display The start button LED shines steadily and the display shows either To start heater press start button or To start separator press start button 9 6 3 8 2 0 7 4 1 i 5 SLUDGE PUMP CLEANING IN PLACE REMOTE CONTROL CIP DISCHARGE FEED PUMP HEATER SEPARATOR X023911A 12 56 ...

Page 57: ... in parameter P125 Above this temperature the normal P constant P123 is used If the temperature has not reached the value in parameters P184 HFO LO low temperature limit within the time specified in parameter P169 alarm delay alarm A24 Temperature increase too slow will show on the display If the temperature feedback is correct reading on temperature sensor TT1 above value in parameter P184 the st...

Page 58: ...er contactor K2 response alarm A96 Slow start acceleration shows on the display If the low speed limit value in parameter P180 has not been reached before the separator max start time has elapsed alarm A95 Separator motor run up time too long shows on the display If the separator is running above the low speed limit the start button LED shines steadily and the display shows the heading RECIRCULATI...

Page 59: ...tically to SEPARATION mode via a transition sequence which is shown on the display The start button LED shines steadily and the display shows the heading TRANSITION If speed sensor not installed P113 no or disabled P148 0 change over to RECIRCULATION SEPARATION takes place when the separator max start time has elapsed NOTE The time in RECIRCULATION is limited by timer P178 to avoid overheating of ...

Page 60: ...or stepwise start possible Yes Proceed with calibration local stepwise start only Change to SEPARATION Change to SEPARATION Transition consists of Start discharge step 4 Displacement step 1 Calibration discharge step 5 Discharge step 2 with P244 instead of P231 Bowl leak water transd test step 3 Transition consists of Discharge step 2 with P244 instead of P231 Bowl leak water transd test step 3 SE...

Page 61: ...1 Operating Start P type separator start sequence START command No Assembled according to manual STANDSTILL Yes Proceed with start sequence local start only 17 61 ...

Page 62: ...me procedure as described under Manual Start from Standstill If the bowl has not been dismantled or cleaned the previously calculated filling time parameter P233 is used a discharge sequence and a bowl leakage water transducer test are run and the system goes into SEPARATION mode The following equipment must be installed for automatic start Vibration monitor Speed sensor Frame cover switch 18 62 ...

Page 63: ...vibrating separator Vibration may then become violent and result in breakdown P003606A WARNING Noise hazard Use ear protection if noise levels are high WARNING Breakdown hazard Never reset an alarm without first finding and remedying the cause CAUTION Burn hazard Avoid contact with hot surfaces Process pipes various machine surfaces and processed liquid can be hot and cause burns X023716A CAUTION ...

Page 64: ...ces run automatically at preset intervals timer P220 Discharge sequence can also be run manually by pressing the Discharge button 9 6 3 8 2 0 7 4 1 i 5 CLEANING IN PLACE REMOTE CONTROL CIP FEED PUMP HEATER SEPARATOR X023923A 20 64 ...

Page 65: ...n the sludge pump longer than necessary If the pump is run while dry it can be damaged 9 6 3 8 2 0 7 4 1 i 5 CLEANING IN PLACE REMOTE CONTROL CIP DISCHARGE FEED PUMP HEATER SEPARATOR X023922A In SEPARATION mode the feed pump is running the feed has reached separation temperature the heater is working and the separator is running at full speed Feed valve V1 is open to the separator inlet 21 65 ...

Page 66: ...stem when in the START RECIRCULATION or SEPARATION modes 1 Stop the system by pushing the Stop button on the control panel The following sequence takes place A stop discharge and flushing sequence are initiated does not apply to stop from START NOTE Filling and flushing are not performed if the discharge feedback has not been received 9 6 3 8 2 0 7 4 1 i 5 SLUDGE PUMP CLEANING IN PLACE REMOTE CONT...

Page 67: ...he feed pump is turned off The system waits for the speed sensor if installed to indicate zero speed When the bowl has been still for 60 seconds STAND STILL shows on the display If speed sensor not installed P113 no or disabled P148 0 STAND STILL is shown when the stop timer has elapsed The sludge pump runs for 10 seconds after STAND STILL is reached if stopped from SEPARATION mode or RECIRCULATIO...

Page 68: ...rator is still rotating X024579A The following sequence occurs The power to heater pump and separator motor is shut down immediately Stop timer starts If a steam heater is installed the steam shutoff valve is forced to close Closing water valve SV16 opens for 15 seconds SV10 is open for 15 seconds if the speed is supervised and the speed is over P255 or if there is no speed supervision All other e...

Page 69: ...rd 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 Remedy the cause The cause of the emergency must be remedied before attempting to restart the separator If the cause is not found an overhaul must be performed on the separator and all moving parts thoroug...

Page 70: ...tem WARNING Breakdown hazard Assemble the separator completely before restart All couplings covers and guards must be in place and properly tightened Failure to do so may lead to breakdown X023714B NOTE Check that the Emergency Stop Box is properly installed and functioning correctly NOTE Check that all ancillary equipment in particular the heater is functioning correctly 26 70 ...

Page 71: ...eparator and Feed Pump will start immediately when these terminals are bridged but can be stopped with the Emergency Stop pushbutton NOTE No supervision of the separator is performed as the Control System is deactivated The system must be manually supervised by trained operator when running All actions must be performed by trained operator such as closing bowl discharge sludge pump running and it ...

Page 72: ...e CIP button to select CIP NOTE During CIP the separator is running at full speed but feed pump heater process valves temperature and pressure supervision and water transducer MT60 are neither controlled nor supervised CAUTION Avoid accidental start of feed pump To avoid accidental start switch off and lock power supply for feed pump Leakage of Hot oil may occur if feed pump is accidentally starte...

Page 73: ... alarm A96 Slow start acceleration will be shown on the display Speed limit in parameter P180 has to be reached within 4 minutes otherwise alarm A95 Separator motor run up time too long will be shown on the display When the separator is running above low speed limit P180 or 4 minutes has elapsed if speed sensor not installed P113 no or disabled P148 0 a message to start the cleaning liquid supply ...

Page 74: ...edly The sludge pump runs when there is high level in the sludge tank or when activated by pressing the SLUDGE PUMP button on the control panel 9 6 3 8 2 0 7 4 1 i 5 CLEANING IN PLACE REMOTE CONTROL CIP DISCHARGE FEED PUMP HEATER SEPARATOR X023922A A discharge can be activated manually during the CIP process by pressing the DISCHARGE button on the control panel 9 6 3 8 2 0 7 4 1 i 5 CLEANING IN PL...

Page 75: ...tem waits for the speed sensor if installed to indicate zero speed When the bowl has been still for 60 seconds STAND STILL shows on the display If there is no speed sensor installed parameter P113 no or if speed sensor disabled parameter P148 0 STAND STILL is shown when stop timer has elapsed If the bowl speed has been above P180 or the start timer has elapsed the sludge pump runs for 10 seconds a...

Page 76: ...1 Operating CAUTION Health Risk Do not forget to disconnect the CIP equipment and re connect the process connections 32 76 ...

Page 77: ...y open manually the SV10 solenoid valve on the Operating Water Block Check that this water is coming out from the bowl by unscrewing the Inspection Plug on the sludge pipe Please however make sure that the machine is not about to make a discharge Splash hazard X027007A If water is seen flowing in the pipe turn off SV10 and keep operating as before The bowl is not clogged If no water is seen then t...

Page 78: ...eading on TT where k point of time The tuning of the regulator is done by modifying the amplification Kp Ki 100 P123 P123 is known as the proportional band width and integral time Ti P124 Every second a new output Y is calculated i e the interval between each k is 1s With P119 it is possible to select heater control mode no no heater controlled electric electric heater controlled P120 active steam...

Page 79: ...1 Operating Example P123 30 P126 40 results in a P band of 0 40 x 30 12 as long as the temperature is below P125 39 79 ...

Page 80: ...ariable load output have to be activated continuously Output signal 0 means that all outputs are deactivated If the output signal is a value between 0 and 100 the activation pattern of the outputs has to be calculated using the table below Output power in of the total available power Heater size kW nominal selected with P120 Power step 1 Power step 2 Power step 3 Variable load output 7 8 0 0 0 10 ...

Page 81: ...e 130 kW and output signal to heater 88 Activate steps 1 2 and 3 for 1s To prevent problems with too heavy momentary load at start of the heater only one output can be activated per second during the first 6 seconds After that time all outputs can be used simultaneously 1 13 2 Control of the CBM heater optional P119 steam In this case alarm A05 is not supervised The steam heater is controlled usin...

Page 82: ... given via a programmable output In this case alarm A05 is not supervised The description for the system with external heater is also valid if one of the temperature sensors is disabled or on sensor error A22 A30 1 13 4 Heater shut down The system waits for the feed temperature to decrease 5 degrees or below P184 If the time in P173 has elapsed and the temperature feedback was not received alarm A...

Page 83: ...ivered with the same default address e g set one EPC60 to have address 192 168 0 1 and the other to have address 192 168 0 2 1 Direct connection requires a crossover twisted pair cable to be used since the EPC60 does not have automatic MDI MDI X configuration 1 14 2 Configure parameters The parameter to select desired function is P145 The following values are possible disabled default cross master...

Page 84: ...ferred to the slave panel Heater and feed pump are started stopped and controlled from the slave panel Alarms for the heater and feed pump are generated in the slave panel 1 14 4 Serial operation This function is required when two separators should operate in series i e the oil coming from the first separator usually a purifier is further purified in the second one usually a clarifier but may be a...

Page 85: ...123 Closed alarm 5 Remote recirculation Request Recirculation only if REMOTE selected on operator panel pushbutton Closed recirculation 6 New temperature set point EPC 60 uses temperature set point P250 during start when the separator is switched off 1 15 2 Outputs See parameters P133 to P138 altId Alternative Comments 0 None default 1 Indication heater on start external heater program request hea...

Page 86: ...ting status of the alarms One is standard and the other is available through the programmable outputs Standard output When there is no alarm active the contact is closed When an alarm is triggered the contact opens If another alarm is triggered the contact will close for 0 5s and then open again When all alarms have been acknowledged by the operator the contact will close Programmable output Progr...

Page 87: ...lectrical diagram V1 3 way valve Verify the operation of the valve see also that the green diode on the valve connector is lit Valid for All S and P types V4 Oil outlet valve Verify the operation of the valve see also that the green diode on the valve connector is lit Valid for All S and P types Cabinet fan Verify the operation of the fan mounted inside the electrical cabinet WARNING Electrocution...

Page 88: ...er i o test please ensure that the electric power to the electric heater cabinet is turned OFF The operating voltage for the relays is supplied from control cabinet Elheatvar Variable output Check that the diodes on the 2 triacs inside the electric heater cabinet are lit Optional Valid for All S and P types Heater on signal Check that the relay KA11 diode see picture below and K11 mechanical indic...

Page 89: ...ally operate the cover switch the input should be 1 when switch and cover is closed Optional Valid for All S and P types Sludge valve interlock Manually operate the sludge valve the input should be 1 when the valve is closed Optional Valid for All S and P types Programmable input 1 Not to be tested Programmable input 2 Not to be tested Programmable input 3 Not to be tested Programmable input 4 Not...

Page 90: ...uld not deviate from TT1 with more than 2 C PT100 input Valid for All S and P types Speed sensor In order to test this input use the Separator motor K2 sect 1 I O test to start the separator for a few seconds then go back to this input and check the value it shall be higher then 0 rpm Namur input Optional Valid for All S and P625 626 P635 636 types Vibration switch Check that this input goes to 0 ...

Page 91: ... separator is started within 4 minutes and stopped with stop timer This also applies if the speed sensor is disabled P148 0 or on alarm A92 Bowl speed sensor error 1 17 2 System Without Vibration Sensor It is possible to run the system without vibration sensor P114 no In this case alarms A100 A103 are not supervised Remote start is not allowed This also applies if the vibration sensor is disabled ...

Page 92: ...system with PT4 disabled P153 0 In this case alarms A50 A52 and A54 A59 are not supervised As a result calibration of the water flow is not possible The old values are used for displacement and conditioning water Cold start function is disabled Bowl leakage test is disabled This also applies on alarm A52 Oil pressure sensor PT4 error 1 17 6 System With PT5 Disabled S separator only It is possible ...

Page 93: ...le select this mode if the system is controlling a heater P119 steam or electric If P146 TT2 custom then all alarm from TT2 is blocked It is intended for installations where TT2 is permanently not connected to the EPC60 1 17 8 Control of Sludge Pump Level in Sludge Tank and Butterfly Valve The sludge accumulated in the bowl can be discharged into an optional small sludge tank with level switch At ...

Page 94: ...r sludge outlet can contain a manual butterfly valve which is used to close the outlet when the separator is standing still Select with P131 no manual If P131 no alarm A122 is blocked 1 17 9 System Without Feed Pump It is possible to run the system without feed pump P127 no In this case alarms A01 and A44 are not supervised Remote start is not allowed 54 94 ...

Page 95: ... not supervised There is no calibration of the water flow In separation automatic discharges are initiated every 15 minutes overrides P220 SV10 is never activated this means no displacement before discharge and no conditioning water Water draining from the bowl is not allowed This also applies if the water transducer is disabled P128 standby or on alarm A85 MT60 fault 55 95 ...

Page 96: ...S Flex Separation Parameter List Printed 10 2014 Book No 584613 02 rev 8 96 ...

Page 97: ... 46 8 530 650 00 Telefax 46 8 530 310 40 Alfa Laval Tumba AB 10 2014 The original instructions are in English This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB 97 ...

Page 98: ...ntents 1 Parameter list 5 1 1 Setting List 5 2 Operation Modes 15 2 1 Change over Sequence 15 2 1 1 Change over without calibration 15 2 1 2 Calibration of the water flow via SV10 15 2 2 Discharge 17 3 98 ...

Page 99: ...99 ...

Page 100: ...arameters Password protected To go directly to a parameter enter the parameter number 2 Time settings For setting date time etc Password protected To go directly to a parameter enter the parameter number 3 Operation time Different counters and timers can be read 4 I O Test Here it is possible to activate all outputs and to read the status for all inputs for testing purposes 5 Alarm history List of...

Page 101: ...rite in a value or by choosing a value from the list Save any change by pressing the Enter button NOTE Certain parameters can only be changed by the factory the chief engineer or an Alfa Laval service engineer 9 6 3 8 2 0 7 4 1 i 5 SLUDGE PUMP CLEANING IN PLACE REMOTE CONTROL CIP DISCHARGE FEED PUMP HEATER SEPARATOR X023913A Parameters are divided into three password levels Level 0 No password nee...

Page 102: ...ble on the HMI 1 00 0 00 2 00 P111 1 Separator size 0 See Parameters depending on the setting of P111 page 12 P112 1 Oil type HF380 See Parameters depending on the setting of P112 page 14 P114 1 Vibration sensor installed yes no no Can be changed in even in STOP See also System without vibration sensor in the Operating instructions manual P115 1 Frame cover switch installed yes no no Can be change...

Page 103: ...olled see also P125 P126 cold start 75 10 500 P124 1 I constant heater if heater controlled 0 4 min 0 1 10 0 P125 1 Breakpoint cold start if heater controlled 0 C P101 0 99 P126 1 Gain factor cold start if heater controlled 40 1 100 P127 1 Feed pump controlled yes no no Can be changed in even in STOP P128 1 MT60 on standby Standby MT60 disabled Discharge every 15 min overrides P220 SV10 not activa...

Page 104: ...8 1 Speed sensor disabled no P149 1 Level switch disabled Run sludge pump 30 s at discharge overrides P234 no Parame ter Pass word level Denomination Default value Unit Min value Max value Alarm related parameters delays limits etc P151 Not used P152 1 Power failure alarm used yes no yes P153 1 High oil pressure limit PT4 0 0 pressure sensor disabled 3 0 bar 0 0 6 0 P154 1 Low oil pressure limit P...

Page 105: ...ature supervision 5 min 0 30 P175 2 Alarm delay A59 PT4 pressure high after cold start 5 s 0 60 P177 1 Alarm limit A32 Difference TT1 TT2 too large 10 C P10 1 0 30 P178 1 Time limit in RECIRCULATION 10 min 0 30 Setpoints P220 1 Discharge interval 120 min 1 300 P222 1 V5 open time at drain sequence 25 s 0 250 P224 1 MT60 limit stop draining 70 0 100 P225 2 Test of MT60 signal frequency every xxx di...

Page 106: ...ly s 0 120 P234 1 Sludge pump additional manual running time 15 s 0 60 P236 2 Water drain time during STOP 10 s 0 30 P237 1 Sludge pump running and V5 opening time before discharge 10 s 0 30 P238 2 Feed on after discharge and test of water content in oil outlet 60 s 0 90 P239 2 Time for stabilization of the transducer signal 60 s 0 300 P242 2 Test of calibration value interval no of discharges 60 ...

Page 107: ...t high vibration shutdown 0 3 0 3 0 5 0 5 0 5 0 5 0 5 0 0 2 5 mm P182 1 Alarm limit high vibration warning 0 2 0 2 0 3 0 3 0 3 0 3 0 3 0 0 2 5 mm P240 1 Filling time displacement water initial value calcu lated during calibration see also P254 77 63 108 48 80 61 72 0 150 s SV10 constant flow orifice 0 9 1 6 1 6 5 5 5 5 11 0 15 0 l min P243 1 SV16 open after dis charge 15 s 15 s 15 s 15 s 25 s 25 s...

Page 108: ...1 Parameter list NOTE If P111 0 default value the operator is automatically forced to go through a system configuration procedure to setup the system 13 108 ...

Page 109: ...00 0 115 C P101 P184 1 Low tem perature limit 20 85 90 85 0 115 C P101 P249 1 Tempera ture set point 30 98 95 90 0 110 C P101 P187 2 Number of drainings before alarm A84 High water content 5 2 0 20 P251 MT60 trig ger fac tor corre sponds to 100 in crease of the trans ducer sig nal 3 0 0 6 0 1 10 0 pF P252 1 MT60 trigger limit 100 100 100 0 250 P189 2 Alarm limit A80 Trans ducer value high 110 85 7...

Page 110: ...wl leakage water transducer test step 3 is run through see 2 2 Discharge page XX The opening time of SV15 is in this case set with P244 not P231 Finally the system ends up in SEPARATION 2 1 2 Calibration of the water flow via SV10 During 170 seconds the oil outlet valve V4 is closed and the bowl is filled with water through SV10 until the pressure on PT4 has increased by 0 2 bar The conditioning w...

Page 111: ...red time to fill the bowl is then compared with the saved time used to calculate the SV10 flow rate the old value is not changed If the time to fill the bowl has decreased with the relative value in P160 the alarm A131 Sludge in bowl is given and the system goes to STOP Restart is not possible 16 111 ...

Page 112: ...the system will go to STOP immediately without waiting the time in P238 Alarm A57 Oil leaking from bowl Vibration supervision blocked SV15 discharge P2 31 P23 2 SV16 closing water P2 43 SV10 conditioning displacement P1 72 P2 40 a P2 33 V4 clean oil outlet NO P2 45 V1 feed inlet deactiv recirculation P17 1 P2 38 P2 39 V5 water drain NC a Sludge pump optional P2 37 P2 34 Sep ara tion Displacement s...

Page 113: ...S Flex Separation Alarms and Fault Finding Printed 07 2014 Book No 584614 02 rev 6 113 ...

Page 114: ...46 8 530 650 00 Telefax 46 8 530 310 40 Alfa Laval Tumba AB 07 2014 The original instructions are in English This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB 114 ...

Page 115: ...Contents 1 Alarms 5 1 1 Alarms List 5 1 2 Alarm History List 8 2 Display Alarms and Actions 9 3 EPC 60 Control panel 21 3 115 ...

Page 116: ...116 ...

Page 117: ...larm History List See below 9 6 3 8 2 0 7 4 1 i 5 SLUDGE PUMP CLEANING IN PLACE REMOTE CONTROL CIP DISCHARGE FEED PUMP HEATER SEPARATOR X023912B Press the arrow buttons to go up or down in the list 9 6 3 8 2 0 7 4 1 i 5 SLUDGE PUMP CLEANING IN PLACE REMOTE CONTROL CIP DISCHARGE FEED PUMP HEATER SEPARATOR X023914A 5 117 ...

Page 118: ...an alarm go through the alarm list to make sure that there are no other unacknowledged alarms If after all alarms have been acknowledged fault s remain in the system the alarm LED stops blinking and remains on An A appears at the end of an alarm which has not been rectified The alarms disappear automatically when the fault is rectified When all the alarms have been rectified the alarm LED goes out...

Page 119: ...1 Alarms Press the Return button to leave the list 9 6 3 8 2 0 7 4 1 i 5 SLUDGE PUMP CLEANING IN PLACE REMOTE CONTROL CIP DISCHARGE FEED PUMP HEATER SEPARATOR X023912A 7 119 ...

Page 120: ...all parameters Password protected To go directly to a parameter enter the parameter number 2 Time settings For setting date time etc Password protected To go directly to a parameter enter the parameter number 3 Operation time Different counters and timers can be read 4 I O Test Here it is possible to activate all outputs and to read the status for all inputs for testing purposes 5 Alarm history Li...

Page 121: ...hat to do Feed pump if P127 yes A01 Pump starter failure Delayed by P168 Feedback signal from contactor K3 missing Check the contactor function Check input terminal in the PLC Power to heater interrupted Check the power supply to the heater A05 Heater fault electric Delayed 2 s High temp switch released Check temp setpoint in the control unit Check the heater and clean if necessary When the temper...

Page 122: ...pply insufficient Investigate cause and remedy Steam trap faulty Investigate cause and remedy Steam supply valve insufficient Investigate cause and remedy Faulty fuses or burned contactors electric heater Check and renew broken fuses Reset overcurrent protection applicable for 8 7 24 22 kW power unit Check wiring and contactor coils A21 Oil feed temperature low Delayed by P150 Limit in P184 Broken...

Page 123: ...f no spare sensor available set parameter P146 TT2 to be able to run the system A31 Temperature control sensor disabled Reminder only if P146 TT2 A32 Difference TT1 TT2 too large Delayed by P176 Alarm limit in P177 Blocked if A22 A23 A30 or A31 Pressure transmitter feed inlet PT1 A40 Feed pressure PT1 high Delayed by P150 Limit in P157 Pipe restricted Check recirculation for restriction Pump not w...

Page 124: ...zzle Rectangular ring in discharge slide is defective Renew the rectangular ring Valve plugs are defective Renew all plugs A51 Oil backpressure PT4 low Delayed by P150 Alarm limit in P154 Supply valves SV15 and SV 16 are leaking Rectify the leak A52 Oil pressure sensor PT4 error Delayed by P150 Sensor or cable damaged Check cable connections Replace sensor If no spare sensor available set paramete...

Page 125: ...ayed by P150 Limit in P156 Paring tube not moving correctly Check that movement is not impeded by friction A72 Water pressure sensor PT5 error Delayed by P150 Sensor or cable damaged Check cable connections Replace sensor If no spare sensor available set parameter P155 0 A73 PT5 disabled Reminder only if P155 0 A74 Water outlet restricted Delayed 3s V5 not opening or line restricted Check V5 funct...

Page 126: ...d high Delayed 5 s Limit in P179 Incorrect transmission parts 50 Hz belt pulley and belt for 60 Hz power supply WARNING Disintegration hazard Stop and change the belt transmission to suit the power supply frequency Slipping belt Change belt Worn coupling pads Check change pads Bowl not properly closed Check closing water supply valve SV 16 Check bowl operating system for leakage Check nozzle Bowl ...

Page 127: ...of paring disc is incorrect Stop Check and adjust the height Motor failure Repair the motor A95 Separator motor run up time too long Delayed by P230 Limit in P180 Bearing s damaged or worn in coupling or spindle drive Renew all bearings A96 Slow start acceleration Speed 90 rpm 10s after response from motor contactor A97 Discharge feedback error Alarm limit in P161 Test during P232 one extra discha...

Page 128: ...0 High vibration warning Delayed by P150 Alarm limit in P182 Bowl wrongly mounted Check assembly Disc stack compression incorrect Check assembly Bowl assembled with parts from other separators Check assembly Height position of paring disc is incorrect Stop the separator measure and if necessary adjust the height Bowl spindle bent Renew the bowl spindle Bearing s damaged or worn Renew all bearings ...

Page 129: ...tarting up again Bowl wrongly mounted Check assembly Disc stack compression incorrect Check assembly Bowl assembled with parts from other separators Check assembly Height position of paring disc is incorrect Stop the separator measure and if necessary adjust the height Bowl spindle bent Renew the bowl spindle Bearing s damaged or worn Renew all bearings The frame feet are worn out Renew the frame ...

Page 130: ...e blocked Pump has not drained the tank Check the pump function A121 Level switch disabled Reminder only if P149 yes A122 Valve in sludge outlet closed Discharge not possible Start not possible Delayed by P150 Valve closed Open manual valve A123 External alarm Delay 2 s System A130 Emergency stop button pushed Delay 1s No restart Emergency stop button pushed Check for the cause Reset pushbutton A1...

Page 131: ... status not OK Alarm is created if the separator has been out of operation for one month or more It is reset if the separator has been running for at least 5 hours Pre lubricate spindle bearings After service always run the separator continuously for at least 5 hours to ensure proper lubrication A141 Permanent variables have not been correctly backed up Check the CPU is well mounted Check EMC conn...

Page 132: ...2 Display Alarms and Actions 132 ...

Page 133: ...3 EPC 60 Control panel Fault Remedy Black screen Press and hold Enter button and adjust contrast with up and down button This can be done regardless of which page is currently displayed 21 133 ...

Page 134: ...Separator Sizes S 976 S987 Single Flex Module Installation System Reference Printed 02 2013 Book No 9006452 02 rev 0 134 ...

Page 135: ...possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated Copies of this publication can be ordered from your local Alfa Laval company Published by Alfa Laval S p A Marine Diesel Equipment 20900 Monza MB Italy Copyright Alfa Laval Italy Feb 2013 135 ...

Page 136: ...ator Full Options 20 2 1 8 Single Module P separator with Optional Feed Pump Block and Heating System Block 21 2 1 9 Single Module P separator with Optional Feed Pump Block and Flow Control Blcok 22 2 1 10 Single Module P separator with Optional Heating System Block 23 2 1 11 Single Module P separator with Optional Feed Pump Block 24 2 1 12 Single Module P separator without Block Options 25 2 2 Si...

Page 137: ...ic Heater optional Interconnection Diagram 58 3 3 8 I O optional Interconnection Diagram 59 3 3 9 Heat Tracing optional Interconnection Diagram 61 3 3 10 Emergency Shutdown Interconnection Diagram 62 3 3 11 Separator Circuit Diagram 63 3 3 12 Separator Circuit Diagram 73 3 3 13 Steam Regulating Valve optional Circuit Diagram 83 3 3 14 Speed Transmitter optional Circuit Diagram 84 3 2 15 Vibration ...

Page 138: ... Steam Hot Water Thermal Oil Heater 105 5 2 Lifting Single Module with Electric Heater 106 5 3 Lifting Single Module without Heater 107 6 Commissioning and Initial Start 109 6 1 Completion Check List 109 6 2 Initial Start up 110 6 2 1 Calculating Operating Pressure 113 7 Shut down and Storage 115 7 1 Shut down after Use 115 7 2 Protection and Storage 116 7 3 Reassembly and Start up 118 138 ...

Page 139: ...6 139 ...

Page 140: ...ain areas in the system 2 Total hardness less than 180 mg CaCO3 per litre which corresponds to 10 dH or 12 5 E Hard water may with time form deposits in the operating mechanism The precipitation rate is accelerated with increased operating temperature and low discharge frequency These effects become more severe the harder the water is 3 Chloride content max 1 00 ppm NaCl equivalent to 60 mg Cl l C...

Page 141: ...00 800 kPa 5 8 bar 2 Free from oil and solid particles larger than 0 01 mm 3 Dry with dew point min 10 C below ambient temperature Electrical interconnections must be made by qualified electricians Mechanical interconnections must be made by qualified mechanical technicians NOTE 1 2 Demand Specifications Air 141 ...

Page 142: ...5 C to 55 C Feed Capacity In accordance with the separator size capacity table Pressure Oil inlet Max 2 bar at separator inlet Oil outlet Max 2 5 bar Sludge outlet from separator without pressure Sludge outlet from sludge pump Max 5 bar at 6 bar air pressure Separated water Max 4 bar if not diverted into sludge outlet Temperature According to capacity table depending on oil viscosity 2 C Max 100 C...

Page 143: ... pump pneumatic 1000 N l h at max 1l s For further details see 1 2 Demand Specifications Air Mechanical design part Oil and heating media piping Design pressure Max 6 bar for steam condensate Max 9 bar Test pressure Max 9 bar for steam condensate Max 14 bar Design temperature 5 C 180 C Flange connections PN 16 DIN 2573 2633 Pipe data Material ASTM A 106 gr B seamless schedule 40 thickness Sizes fr...

Page 144: ...r el motor power range From 7 5 kW up to 11 kW Feed Pump el Motor In accordance with the pump size selected and related data sheet Feed Pump el motor power range From 1 1 kW up to 4 kW EPC Voltage 24 V DC internal Control voltage operating supply 24 V AC from internal transformer Frequency 50 or 60 Hz 5 Control cabinet Enclosure class IP 55 Material Steel sheet Ambient temp Max 55 C 1 3 System Dat...

Page 145: ...ing wear items Hours Period Separator Module Sludge pump Feed pump Control cabinet El heater CBM 1000 2000 4000 6 months Inspection 12000 18 months Overhaul Overhaul 24000 3 years Overhaul Overhaul Overhaul Overhaul As necessary CIP Repair compo nents Repair CIP With delivery Inspection Tools Backup Support Support Separator Module Type Steam Electric Without Heater Separator type see dimension dr...

Page 146: ...13 2 Mechanical Drawings 146 ...

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Page 150: ...150 MAN Managua LO S946 Module 4500968861 10 to 80 Mat Nr 11 63010 0244 ...

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Page 152: ...e side of the panel Unscrew the four screws holding the panel and remove the panel Mount the new panel and connect in reverse order I O Board Switch power off X 0 2 5 0 0 1 A X 0 2 5 0 0 2 A 2 6 Change of EPC 60 Components Hold down the plastic clip on the top of the cable terminal and pivot the cable terminal towards you 152 ...

Page 153: ...ngle on the top of the I O board and loosen the board Compare the part number of the new I O board to the old board to make sure it is correct If changing more than one board at a time check with the electrical diagram to ensure that the boards are mounted in the right places Pull the board straight out otherwise it can fasten in one of its guides 153 ...

Page 154: ... into place Make sure the board is firmly in place otherwise it will be impossible to mount the cable terminal Remount the cable terminal Make sure that the clip on the bottom of the terminal fastens properly in place on the axel on the bus holder Pivot the terminal on the axel until the clip on the terminal top fastens into place in the I O board 154 ...

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Page 190: ... beam is located above the centre of gravity Slings or wires used for lifting the Double Module must be of the same length to avoid instability Slings wires must be dimensioned locally depending on equipment used For information on how to lift the separator see the Separator Manual booklet Crush hazard When lifting the Module use only the lifting eyes specifically for this purpose Always use a lif...

Page 191: ...ted to and from Alfa Laval equipment Follow the instructions given in the cable list Examples of cable types that can be used Steel armoured cable Copper armoured cable with a separate earth core Steel armoured and sheilded single cable pair twisted or parallel Sheilded single cable pair twisted or parallel G 0 3 2 2 2 4 A G 0 3 2 2 4 4 A G 0 3 2 2 1 4 A G 0 3 2 2 3 4 A 4 1 Cables 191 ...

Page 192: ...nd signal cables routed on a cable rack should be separated Sattbus cables should be routed away from power cables If the space is limited cables can be routed in tubes 4 2 Cable Routing S 0 0 2 8 9 1 A S 0 0 2 8 9 1 A S 0 0 2 8 9 1 A S 0 0 2 8 9 1 A S 0 0 2 8 9 1 A G 0 3 2 2 7 3A G 0 3 2 2 7 3A G 0 3 2 2 7 3A G 0 3 2 2 7 3A G 0 3 2 2 7 3A Power Cables Power Cables Power Cables Power Cables Power ...

Page 193: ...The oil feed pump must be of positive displacement type The pump must be positioned close to the oil tank The heater must be installed close to the separation module to maintain correct feed oil temperature The recirculation line should be connected either directly to the settling tank HFO or to the oil outlet line from the separator LO The oil outlet line from the separator must be connected to t...

Page 194: ...gulation it is essential that electrical and electronic components have good ventilation and temperature control X 0 2 4 6 7 5 A X 0 2 4 6 7 5 A X 0 2 4 6 7 5 A X 0 2 4 6 7 5 A X 0 2 4 6 7 5 A 4 5 Heat Tracing and Insulation of Fuel Oil Sludge and Steam Pipes Alfa Laval can on request supply modules which are heat traced and insulated as optional equipment 4 5 Heat Tracing and Insulation of Fuel o...

Page 195: ...suction and the outlet lines should be fitted with change over valves To avoid oil transfer from one tank to another these valves must be interlinked 4 6 More than one Oil Tank P 0 0 0 0 6 2 A Unprocessed oil Clean oil Change over valve Inter link Change over valve 4 6 More than one Oil Tank 195 ...

Page 196: ...t have the same diameter as the flange opening The pipe hose must be as straight as possible with a steady upward incline The connection to the oil tank ventilation pipe must point upwards as shown For HFO separation it is not recommended to make the connection to the separator room ventilation system For LO separation connection to the separator room ventilation system should be made only if the ...

Page 197: ...inside of the tank using diesel oil Check the seals and gaskets and change if necessary Loosen the hose clip and check the inside of the ventilation hose Clean if necessary ToavoidbreakdownoftheSludgeRemovalsystem the sludge pump must be regularly overhauled as follows using spare parts kit specified in the spare parts catalogue Replace the diaphragms and the O rings with those delivered in the sp...

Page 198: ...ting coil should be used to keep the sludge warm and fluid while being pumped out Tank ventilation must follow the classification rules for evacuation of gases There should be a ventilation pipe to fresh air The ventilation pipe should be straight If this is not possible any bends must be gradual The ventilation pipe must not extend below the tank top A sludge tank with partition walls must have v...

Page 199: ... below The Module generates almost no air during operation At any discharge the maximum volume of air produced is the same as the bowl volume see technical data Type 1 module 2 3 modules 4 moudles P 636 1 x ø 60 mm 1 x ø 90 mm 1 x ø100 mm Type 1 module 2 3 modules 4 moudles S 936 S 947 1 x ø 60 mm 1 x ø 90 mm 1 x ø115 mm 4 8 Sludge Tank 199 946 modules modules ...

Page 200: ...ndation In cases where sludge tank ventilation is not adequate and more than one separator is connected to the same sludge tank we recommend that a butterfly valve is installed in each sludge pipe If a butterfly valve is not used the bowl and the operating system may be affected by corrosive fumes and sludge from the sludge tank If a butterfly valve is used it should be equipped with an interlocki...

Page 201: ...4 Specifications 104 5 2 Lifting Single Module with Electric Heater 201 ...

Page 202: ...gle Module with Steam Hot Water Thermal Oil Heater Weight max 790 kg Weight max 865 kg X 525 Y 580 Centre of gravity Z 650 Secure the module to prevent tipping A Weight max 790 kg Weight max 865 kg X 525 Y 580 Centre of gravity Z 650 A X024663b X024664b 202 ...

Page 203: ...reement with the machine plate If incorrect resulting overspeed may cause breakdown 1 Check that transport seals are removed from all pipes 2 Use flushing filters to prevent pipe work debris from being pumped into the separation module The flushing filters must be removed after initial flushing 3 Check that all separators are in proper working condition Follow the manufacturer s instructions 4 Mak...

Page 204: ...ctly the separator will rotate in reverse and vital rotating parts can unscrew 8 Check the pump function and direction 9 If a Sludge Removal Kit is used check that the sludge pump speed is set to circa 60 strokes min If necessary adjust the throttling valve positioned after solenoid valve SV 6 6 2 Initial Start up After every start the separator must always be run continously for a minimum of 1 ho...

Page 205: ...n module due to the pipe bends and the height head to the cleaned oil tank If the cleaned oil tank is below the separation module the delivery height pressure may be very low The oil paring disc pressure will have to be greater than the delivery height pressure for any oil to flow Proceed as follows Ensure the valves in the oil system are in the correct positions The oil should be at separation te...

Page 206: ...e heater has cooled For P type separators Fully open the back pressure regulating valve RV4 Open SV15 for 5 seconds to prime the operating slide Open SV16 for 15 seconds to close the bowl Open SV10 for 5 seconds to put water into the bowl Feed oil to the separator at the normal flow rate by opening SV1 Note the pressure in the oil outlet PT4 both on the pressure gauge and in the EPC 60 display Thi...

Page 207: ...r 11 as follows Pmin Pnormal Plow press 2 Calculate the value for high pressure alarm setting Pr 10 as follows Pnormal Pmax Phigh press 2 Adjust the back pressure to Pnormal Set P154 to give alarm at pressure decreasing below the Plow press value Set P153 to give alarm at pressure increasing above the Phigh press value 6 2 1 Calculating Operating Pressure 6 2 Initial Start up 207 ...

Page 208: ...6 Commissioning and Initilal Start 114 6 2 Initial Start up 208 ...

Page 209: ...from dust dirt water etc X X This chapter Protect with anti rust oil X X This chapter Action before installation Inspection service X Service manual Overhaul service X Service manual 7 1 Shut down after Use Shut down period 1 6 months stand by 6 18 months 18 months See Action before storage Remove bowl X X X Dismantling and Assembly in the Service Manual Protect from dust dirt water etc X X X This...

Page 210: ...nt oil film Solvent e g white spirit to remove the anti rust oil after the shut down Moist remover to be packed together with separator equipment If the storage time exceeds 12 months the equipment must be inspected every 6 months and if necessary the protection be renewed Modules Clean unpainted steel parts with solvent and treat external surfaces with anti rust oil type 112 If necessary clean ot...

Page 211: ... Water pipes should be drained and treated with anti rust oil type 112 Articles made of rubber or plastics e g seals must not be treated with anti rust oil Electric Heater Fill the heater with a non corrosive lubricating oil Place a number of bags of silica gel inside the connection box to absorb humidity Pump Clean the pump housing outside from oil and grease with solvent Protect the pump by fill...

Page 212: ...tructions in this booklet and in the Separator Manual Before operating the heater Check by lifting the safety valve handle that it functions correctly Follow the start up check list for the heater in the manufacturer s instructions For plate heat exchangers check the bolt connections to ensure that all gaskets are tight Always lubricate the bearings before start up After every start the separator ...

Page 213: ...Separator Manual High Speed Separator S 946 Specification No 881203 05 02 2 Book No 9006919 02 rev 3 213 ...

Page 214: ...46 8 530 650 00 Telefax 46 8 530 310 40 Alfa Laval Tumba AB 08 2014 The original instructions are in English This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB 214 ...

Page 215: ...Design and function 21 4 1 Overview 22 4 2 Drive section 23 4 3 Process section 24 4 4 Sensors and indicators 26 4 5 Separating function 27 4 5 1 The liquid balance in the bowl 27 4 5 2 Liquid flow 28 4 5 3 Discharge of sludge and water ALCAP concept 29 4 5 4 Discharge of water through water outlet 30 5 Operating instructions 31 5 1 Before first start 31 5 1 1 Start after service 32 5 2 Normal ope...

Page 216: ...ication of bowl parts 106 6 5 Assembly 107 6 5 1 Centrifugal clutch 108 6 5 2 Driving device 115 6 5 3 Bowl 133 6 5 4 In and outlet device 151 6 5 5 Unbalance sensor optional 155 6 5 6 Speed sensor optional 157 6 5 7 Actions after assembly 158 6 6 Oil change 160 6 6 1 Lubricating oil 160 6 6 2 Check oil level 161 6 6 3 Oil change procedure 161 6 6 4 Lubrication chart 162 6 6 5 Recommended lubrican...

Page 217: ... Goal 186 8 4 5 Description of separator modes 186 8 4 6 Remote start 188 8 4 7 Handling of connection interfaces 188 8 5 Demand specification water 194 8 6 Drawings 195 8 6 1 Basic size drawing 195 8 6 2 Foundation drawing 196 8 6 3 Interconnection diagram 197 8 6 4 PX sealing diagram 198 8 6 5 Electric motor 199 9 Installation 201 9 1 Introduction 201 9 2 Upon arrival at the storage area 202 9 2...

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Page 219: ...vice and maintenance Not following the instructions can result in serious accidents In order to make the information clear only foreseeable conditions have been considered No warnings are given therefore for situations arising from the unintended usage of the machine and its tools 7 219 ...

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Page 221: ...ons Pay special attention to the safety instructions for the separator Accidents causing damage to equipment and or serious injury to persons or personnel can result if the safety instructions are not followed Basic principles of separation This chapter describes the purpose of separation and separation principles Design and function This chapter contains a description of the separator Operating i...

Page 222: ...arator and drawings Installation This chapter contains specifications and recommendations concerning separator 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 se...

Page 223: ...and must not be used for any other purpose Incorrect operation and maintenance can result in unbalance due to build up of sediment reduction of material strength etc that subsequently could lead to serious damage and or injury The following basic safety instructions therefore apply Use the separator only for the purpose and parameter range specified by Alfa Laval Applies not only to the process bu...

Page 224: ...may result in a serious break down 50Hz 60Hz Welding or heating of parts that rotate can seriously affect material strength Inspect regularly for corrosion and erosion damage Inspect frequently if process or cleaning liquid is corrosive or erosive Entrapment hazards Make sure that rotating parts have come to a complete standstill before accessing parts inside the machine or starting any dismantlin...

Page 225: ...nging load Noise hazards Use ear protection in noisy environments Burn hazards Lubrication oil machine parts and various machine surfaces can be hot and cause burns Wear protective gloves Skin irritation hazards When using chemical cleaning agents make sure you follow the general rules and suppliers recommendation regarding ventilation personnel protection etc Use of lubricants in various situatio...

Page 226: ... Risk for accidental release of snap rings and springs when dismantling and assembly Wear safety goggles Health hazards Risk for unhealthy dust when handling friction blocks pads Use a dust mask to make sure not to inhale any dust 14 226 ...

Page 227: ...es an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTE NOTE indicates a potentially hazardous situation which if...

Page 228: ...tenance 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...

Page 229: ...mechanics can create In some cases special skilled personnel may need to be hired like electricians and others In some of these cases the personnel has to be certified according to local regulations with experience of similar types of work 2 4 Remote start If the separator is operated from a remote position where the separator cannot be seen or heard the power isolation device shall be equipped wi...

Page 230: ...2 Safety instructions 230 ...

Page 231: ... a stationary bowl will clear slowly as the heavy particles in the liquid mixture sink to the bottom under the influence of gravity A lighter liquid rises while a heavier liquid and solids sink G0870111 Continuous separation and sedimentation can be achieved in a settling tank having inlet and outlet arranged according to the illustration Heavier particles in the liquid mixture will settle and for...

Page 232: ...ier liquid C Centrifugal force 3 4 Separating temperatures For some types of process liquids a high separating temperature will normally increase the separation capacity The temperature influences viscosity and density and should be kept constant throughout the separation Viscosity Density difference Viscosity is a fluids resistance against movement Low viscosity facilitates separation Viscosity c...

Page 233: ...balance sensor and an interlocking switch are optional 3 Frame feet The separator rests on vibration damping frame feet 4 Lubrication system Lubricates the bearings driven by the flat belt transmission 5 Sludge outlet Separated solids are discharged at preset intervals 6 Drive section The rotating separator bowl is driven by a flat belt transmission with friction coupling 7 Electric motor Rotating...

Page 234: ...indle The lower body also contains an oil sump for lubrication of spindle bearings The frame hood contains the processing parts of the separator the inlets outlets and piping The process liquid is cleaned in the separator bowl The bowl is fitted on the upper part of a vertical spindle and rotates at high speed inside the frame hood The bowl also contains the discharge mechanism which empties the s...

Page 235: ... To reduce bearing wear and the transmission of bowl vibrations to the frame and foundation the top bearing of the bowl spindle is mounted in a spring dampened bearing seat 3 The bearings on the spindle are lubricated by the oil spray produced by an oil mist generator 4 mounted on the lower end of the spindle The flat belt 1 transmission has a ratio which increases the bowl speed several times com...

Page 236: ...d water respectively out of the bowl The paring tube can move radially During separation it surfs on the liquid surface It is balanced by a spring Under certain operating conditions the paring tube radial position can be locked in place by two adjustable screws on the connection house The paring disc and tube are located inside and at the top of the separator bowl The inlet and outlet device is he...

Page 237: ...pumped out of the bowl The sludge space is in the bowl periphery The bowl is kept closed by the discharge slide which seals against a seal ring in the bowl hood At fixed intervals decided by the operator the discharge slide drops down to empty the bowl of sludge The sludge discharge mechanism which controls the movement of the discharge slide is comprised of an operating slide and an operating wat...

Page 238: ...arating results and for reasons of safety Refer to type plate for speed particulars Monitoring kit optional For indication of any abnormal unbalance the separator can be equipped with a sensor 2 monitoring the radial position of the bowl spindle Cover interlocking kit optional When the cover is closed the interlocking circuit in the control system is closed 1 which makes it possible to start the s...

Page 239: ... bowl The liquid levels in the bowl depend on many factors bowl geometry liquid densities flow rates etc To get a picture of how the liquids are distributed in the bowl imagine that the bowl is at standstill and turned 90 only influenced by gravity The bowl can now be compared with a settling tank 1 2 3 1 2 3 6 5 4 7 A B G0886481 A Separator bowl turned 90º B Settling tank 1 Unseparated oil 2 Sepa...

Page 240: ...e disc stack it flows through a number of holes in the distributor and enters the oil paring chamber From here it is pumped by the oil paring disc and leaves the bowl through the oil outlet Separated water sludge and solid particles which are heavier than the oil are forced towards the periphery of the bowl and collect in the sludge space The space between the bowl hood and top disc as well as the...

Page 241: ... the cleaned oil is the sign of reduced separation efficiency This condition is monitored by the process control system and water is removed from the bowl when maximum levels are recorded The water is removed by either of two ways The water drain valve opens and the water leaves the bowl through the water outlet Through the sludge ports at sludge discharge Which way is decided by the process contr...

Page 242: ... 4 5 6 7 8 9 A B C G08862b1 Discharge of water through water outlet A Unseparated oil B Separated oil C Water 1 Water paring tube 2 Water paring chamber 3 Holes in distributor 4 Top disc 5 Sludge space 6 Oil Water interface 7 Oil paring chamber 8 Oil paring disc 9 Bowl hood 30 242 ...

Page 243: ...d 5 1 Before first start Technical demands for connections and limitations for the separator are listed in Technical reference Technical data Connection list Interface description Operating water demands Basic size drawing Foundation drawing G0868741 Before first start Ensure the machine is installed and assembled correctly and that feed lines and drains have been flushed clean Fill oil in the oil...

Page 244: ...uld be level and at standstill when oil is filled g08687h1 Make sure that the bearings on the spindle are pre lubricated Check the direction of rotation by doing a quick start stop The motor fan should rotate clockwise 5 1 1 Start after service Pay special attention to any unusual sounds or vibrations when starting the separator after a service Different fault symptoms are listed in chapter 7 Faul...

Page 245: ...s well as the belt cover are fully tightened the direction of rotation by doing a quick start stop The motor fan 4 should rotate clockwise the oil bath level and top up if necessary NOTE The separator should be level and at standstill when oil is filled CAUTION If power cable polarity has been reversed the separator will rotate in reverse and vital rotating parts can loosen CAUTION Disintegration ...

Page 246: ...tics during the critical speeds R O I G08717c1 2 Check the separator for vibration WARNING Excessive vibration If vibration increases or continues at full speed keep bowl filled and stop the separator The cause of the vibration must be determined and corrected before starting again Excessive vibration may be due to incorrect assembly or insufficient cleaning of the bowl G0871881 NOTE Normal vibrat...

Page 247: ...ble value 2 For normal length of the start up period see 8 2 Technical data on page 182 R O I 1 2 G0871931 4 Perform a discharge to fill up the operating water system a Add opening water until a discharge sound is heard 10 seconds b Wait 15 seconds c Add closing water for 15 seconds 5 Add some hot conditioning water 6 Turn on the oil feed NOTE Before turning on the feed make sure that the oil has ...

Page 248: ...ctions for leakage b Check that the feed has correct flow and temperature c Check the back pressure d Check that the starter ammeter reading 1 is the normal low and steady value e Check for abnormal vibrations and sounds WARNING Disintegration hazard Do not discharge a vibrating separator Vibration can increase if solidified sludge is only partially discharged R O 1 1 G08715c1 36 248 ...

Page 249: ...l by adding hot water not more than bowl volume 3 Perform a sludge discharge a Add opening water until a discharge sound is heard max 3 seconds b Wait 15 seconds c Add closing water for 15 seconds 4 Turn on the oil feed NOTE Before turning on the feed make sure that the oil has the correct temperature 37 249 ...

Page 250: ...ard max 3 seconds b Wait 15 seconds c Add closing water for 15 seconds R O I G0872331 4 Fill the bowl up with water and stop the separator NOTE Keep the bowl filled during run down to minimize the vibrations 5 Wait until the separator has stopped after about 35 minutes Check rotation of motor fan 1 WARNING Entrapment hazard Make sure that rotating parts have come to a complete standstill before st...

Page 251: ...NG Disintegration hazard Never discharge a vibrating separator WARNING Entrapment hazard Make sure that rotating parts have come to a complete standstill before starting any dismantling work WARNING Disintegration hazard After an emergency stop the cause of the fault must be identified If all parts have been checked and the cause not found contact Alfa Laval for advice before restarting the separa...

Page 252: ...5 Operating instructions 252 ...

Page 253: ...ge 46 gives a detailed list of actions to be performed Inspection i An Inspection consists of an overhaul of the separator bowl inlet outlet and operating water device at max 6 months or 4000 operating hours Seals in bowl and gaskets in inlet outlet device are renewed Overhaul o An Overhaul consists of an overhaul of the complete separator including separator bowl inlet outlet and operating device...

Page 254: ...service consists of an overhaul of the motor at max 36 months or 24000 operating hours Bearings fan seals and washers for the motor are renewed Ancillary Verify correct flow at inspection service overhaul water valveblock at least every 36 months 42 254 ...

Page 255: ...to the maintenance log and description in 6 4 Actions before assembly on page 99 3 Fit all the parts delivered in the service kit while assembling the separator as described in 6 5 Assembly on page 107 4 When the separator is assembled make final checks described in 6 5 7 Actions after assembly on page 158 WARNING Disintegration hazard Separator parts that are either missing worn beyond their safe...

Page 256: ...sed in the instructions refer to activities mentioned in the maintenance logs 6 1 3 Tightening of screws Tightening all screws with the correct torque value is important These figures apply unless otherwise stated Torque Stainless steel Carbon steel Metric thread Nm kpm lb ft Nm kpm Ib ft M4 1 7 0 17 1 2 2 25 0 25 1 8 M5 3 4 0 34 2 5 4 9 0 49 3 6 M6 7 0 7 5 8 0 8 5 9 M8 17 1 7 13 20 2 14 7 M10 33 ...

Page 257: ... Alfa Laval genuine parts as otherwise the warranty may become invalid Alfa Laval takes no responsibility for the safe operation of the equipment if non genuine spare parts are used WARNING Disintegration hazard Use of imitation spare parts may cause severe damage 6 1 5 Cleaning CIP Cleaning In Place To prolong the intervals between manual cleaning of the separator the use of CIP together with rep...

Page 258: ...isc height 151 x Check height adjusting rings 151 x Renew the spring 151 Inlet pipe thread x x Lubricated 151 Bowl All parts x x Clean 99 All parts x x Check for corrosion 101 All parts x x Check for cracks 102 All parts x x Check for erosion damages 103 Bowl body x x Check for impact marks and corrosion 55 x x Renew rectangular ring 55 x Renew guide ring 55 x x Renew O rings 55 x x Renew holder s...

Page 259: ... Check for cracks 102 Bottom bearing housing x Renew O ring 115 Labyrinth ring holder x Renew labyrinth ring 115 x Renew O ring 115 Top bearing housing x Renew springs 115 Flat belt x Renew flat belt 115 Bowl spindle x Pre lubricate and renew ball bearing 115 x Pre lubricate and renew self aligning roller bearing 115 x Lubricate the spindle 115 x Measure the radial wobble 115 Neck bearing cover x ...

Page 260: ...earings x Renew bearings fan seals and washers 41 Check maintenance interval Electric motor Signs and on separator Machine plate x Check attachment an legibility 158 Power supply frequency x Check attachment an legibility 158 Lifting instructions x Check attachment an legibility 158 Safety labels x Check attachment an legibility 158 Name plate x Check attachment an legibility 158 Representative la...

Page 261: ...ate or maintain the separator until they have read and fully understood this manual Ensure that all personnel who operate and service the separator are well trained and knowledgeable concerning the separator and the work to be carried out 6 3 2 Tools Special tools from the tool kit must be used for dismantling and assembly as well as Standard tools not included The special tools are specified in t...

Page 262: ... with magnetic base 5 Hexagon head keys various sizes 6 Heating equipment for bearings 7 Sliding calliper 8 Hammers standard and soft faced 9 Pliers for internal snap rings 10 Pliers for external snap rings 11 T handle with extension rod sockets 13 16 17 18 19 27 30 mm 12 Spanners various sizes 13 Adjustable spanner 14 Shackle 50 262 ...

Page 263: ...Frame hood G0863331 1 G1019211 1 Hook spanner for the lock nut 8 9 10 11 6 5 4 3 2 1 7 G08634M1 1 Lock nut 2 Washer 3 Connecting housing 4 Spring 5 Screw 6 Arm 7 Screws 8 Frame hood 9 O ring 10 Height adjusting rings 11 Support ring 51 263 ...

Page 264: ...ng b Lubricate the inlet pipe thread c Remove the lock nut using the hook spanner and the washer WARNING The nut must not be removed before the separator has stopped d Press the inlet pipe 1 down with a soft material to loosen the connecting housing e Remove the connecting housing 1 G08635c1 1 Inlet pipe 52 264 ...

Page 265: ...crew B and lock washer C from the arm c Remove the arm D together with the spring d Turn the paring tube 1 so that the frame hood can be removed upwards NOTE To avoid the paring tube from being damaged and preventing the inlet pipe from sticking to the frame hood when lifting the hood always turn the paring tube towards the pipe before lifting 1 G08636J1 1 Paring tube 53 265 ...

Page 266: ...me hood a Remove the screws A holding the frame hood b Loosen the hood by bending with a screwdriver B in all grooves in the hood c Lift off the frame hood NOTE Do not place the hood upside down A B C G08636I1 A Screw B Screwdriver C Frame hood 54 266 ...

Page 267: ...10 G1019221 1 Compressing tool lock ring 2 Lifting eyes 3 Spanner for nut nut discharge slide 4 Puller discharge slide 5 Lifting tool distributor spindle 6 Puller Bowl body 7 Screw lock ring M5 8 Hexagon head key 9 Chisel seal ring 10 Pin distributor lifting tool 55 267 ...

Page 268: ...6 Service dismantling assembly 1 2 3 6 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 28 29 31 26 30 G1029061 56 268 ...

Page 269: ... sealing 10 Bowl disc without caulks 11 Bowl discs 12 Distributor 13 Cap nut 14 Nut 15 Discharge slide 16 Rectangular ring 17 O ring 18 Bowl body 19 Guide ring 20 Rectangular ring 21 O ring 22 Valve plugs 23 Nozzle 24 Rectangular ring 25 O ring 26 Operating slide 27 Holder 28 Operating water ring 29 Screws 30 Seal ring 31 Screws washers 57 269 ...

Page 270: ...e cases a compression torque up to 60 Nm can be used to open the bowl d Fit the dismantling screws D to the bowl body and press out the lock ring by tightening the screws successively according to the numbering in the illustration 1 6 Start with the screw 1 nearest to the lock ring end G the one without pin I and then continue around until the other end H is reached The lock ring can be removed wh...

Page 271: ... evenly until the bowl hood come loose NOTE The bowl hood must be pulled off straight up in order not to get stuck Recommendation Take measurements with a calliper around the bowl between the upper edge of the bowl body and the bowl hood to check that the bowl hood is being pulled off straight up d Remove the clamps and attach lifting eyes D to the compressing tool and lift off the bowl hood using...

Page 272: ...h nuts Make sure that the holder is in a level position the bowl hood must be pulled off straight up f Attach the hose from the hand pump to the hydraulic oil inlet F Ease off the bowl hood by pumping the handle on the pump NOTE The bowl hood must be pulled off straight up in order not to get stuck g Remove the hydraulic tool and clamps Fit lifting eyes G and lift off the bowl hood using slings an...

Page 273: ...es b Turn the bowl hood upside down and remove the seal ring by carefully knock pieces of the seal ring out of the groove using the special chisel B tool NOTE It is very important not to damage the bottom of the groove A B G08624A1 A Seal ring B Chisel 5 Removing the inlet outlet pipe and top disc a Lift out the in and outlet pipe together with the top disc WARNING Crush hazard The distributor and...

Page 274: ...e paring tube turn it towards the centre of the pipe b Remove the splash sealing B c Lift up and remove the paring tube C NOTE If the paring tube sticks use a drift to carefully tap it out from the pipe Be careful not to damage the paring tube Turn the paring tube C upwards B A C C G08630H1 A Top disc B Splash sealing C Paring tube 62 274 ...

Page 275: ...tool B Disc stack C Bowl discs D Pin a Assemble the lifting tool A with the pin D b Fit the assembled tool into the distributor and ease off the disc stack using a spanner or wrench c Carefully lift out the disc stack B assembly CAUTION Cut hazard Sharp edges on the bowl discs C may cause cuts 63 275 ...

Page 276: ...mp will not loosen b Fit one of the frame hood screws D to the frame NOTE Make sure that the screw D in frame bottom part is sufficiently tightened so as not to loosen c Fasten the other end of the lifting sling C on the screw D Make sure that the lifting sling is fully tensed before starting to uncrew the nut NOTE Make sure that the lifting sling is positioned below the head of the screw D d Use ...

Page 277: ...e discharge slide C by turning the central screw B NOTE If discharge slide is difficult to remove tap lightly on outside edge with a soft faced hammer c Lift out the discharge slide C WARNING Crush hazard The ring on the lifting tool must be pushed down against the discharge slide otherwise the discharge slide may come loose from the tool B C A D E C F E G0863291 A Lifting tool B Screw C Discharge...

Page 278: ...Left hand thread A G08606F1 A Cap nut 11 Removing the bowl body A B G0860741 A Lifting tool B Lifting eye a Fit the lifting tool A to the bowl body b Raise the bowl body off the spindle taper by turning the lifting eye B clock wise c Lift off the bowl body using sling and hoist 66 278 ...

Page 279: ...6 Service dismantling assembly 12 Turn the bowl body upside down G0860841 WARNING Crush hazard Support the bowl body when turning to prevent it from rolling 67 279 ...

Page 280: ... C Threaded hole D Washer a Remove and discard the screws A and washers D New screws and washers are included in the Inspection kit b Remove the holder B NOTE If the ring sticks use two M8 screws in threaded holes C to raise the operating slide holder up and away from the bowl body 68 280 ...

Page 281: ...ing slide NOTE If the ring sticks use two M8 screws in threaded holes to raise the operating slide holder up and away from the bowl body A G08610N1 A Operating slide 15 Removing the valve plugs from the operating slide a Remove the valve plugs using a drift A A G0874891 A Drift 69 281 ...

Page 282: ...de ring O a Gently pry loose the guide ring and remove it from the bowl Discard the guide ring A new guide ring is included in the Overhaul kit NOTE Do NOT remove the guide ring if only an Inspection service I is performed G08610o1 A Guide ring 70 282 ...

Page 283: ...0861141 A Screw B Ring C Threaded hole a Remove and discard the screws A New screws are included in the Inspection kit b Lift off the ring B NOTE If the ring sticks use two M8 screws in threaded holes C to raise the operating slide holder up and away from the bowl body 71 283 ...

Page 284: ...7 6 8 G08579G1 1 Puller spindle pulley ball bearing 2 Tool bearing housing 3 Cover puller neck bearing cover 4 Lifting tool spindle assembly 5 Drift bottom bearing 6 Sleeve ball bearing in top bearing seat 7 Pin spanner fan 8 Crowfoot wrench head oil mist generator 72 284 ...

Page 285: ...6 Service dismantling assembly 285 ...

Page 286: ...6 Service dismantling assembly 1 2 3 9 10 11 12 13 14 15 16 17 18 19 20 22 21 23 25 26 27 29 30 31 33 34 35 36 37 38 39 4 5 6 7 8 24 28 32 G08580h1 74 286 ...

Page 287: ... Fan 15 Snap ring 16 Bowl spindle 17 Ball bearing 18 Top bearing seat 19 Helical Spring 20 Composite spring 21 Plug 22 Top bearing housing 23 Screw 24 Air deflector 25 Spindle pulley 26 Belt 27 Self aligning roller bearing 28 Oil mist generator 29 Nozzle 30 Screw 31 Labyrinth ring holder 32 O ring 33 Labyrinth ring 34 Pipe 35 O ring 36 Bottom bearing holder 37 Screw 38 O ring 39 Strainer 75 287 ...

Page 288: ...tling assembly 1 Empty the oil sump Unscrew the oil plug A and empty the oil sump A G08685A1 A Oil plug 2 Removing the belt cover a Remove the screws 1 b Remove the belt cover 2 1 2 G0858191 1 Screw 2 Belt cover 76 288 ...

Page 289: ...th the two screws 4 at the bottom b Remove the two upper screws so that the motor can be tilted Do not loosen more than shown in the illustration WARNING Crush hazard The motor will come off if the screws are unscrewed c Remove the flat belt from the motor pulley 1 2 3 4 5 G08588y2 1 Motor 2 Separator frame 3 Nut 4 Screw 5 Flat belt 77 289 ...

Page 290: ...g the operating water cover A B C G0858951 A Screw B Operating water cover C Threaded holes a Remove the screws A b Lift off the operating water cover B NOTE If the cover B sticks fit two M10 screws to the threaded holes C and tighten 78 290 ...

Page 291: ...lector ring A B C D E G0859081 A Tool B Mounting screw C Screw D Cover E Frame a Attach the tools A b Fasten the tool to the cover using mounting screw B c Ease off the cover D by tightening the screw C d Remove the neck bearing cover together with the deflector ring 79 291 ...

Page 292: ... spindle assembly a To facilitate later removal of the plugs loosen but do not remove the plugs A on the bearing housing b Remove the screws B NOTE If the housing sticks fit two M10 screws to the threaded holes and tighten A B G0859181 A Plug B Screw 80 292 ...

Page 293: ...ft out the spindle assembly using a hoist WARNING Crush hazard Do not rotate the spindle assembly during lifting The spindle assembly may otherwise come loose from the lifting tool NOTE Take care not to damage the oil mist generator 2 NOTE Protect the inside of the frame by covering the hole g0907861 1 Lifting tool 2 Oil mist generator 81 293 ...

Page 294: ...rt Make a support 1 with a free space A between the spindle top and the floor A 1 G08592c1 A 5 mm NOTE Always use a support as per this sketch when overhaul service is performed on the spindle assembly It is very important that the top of the spindle does not touch the ground 82 294 ...

Page 295: ...6 Service dismantling assembly 9 Removing the air deflector a Remove the screws 2 and the air deflector 1 G08592b1 1 Air deflector 2 Screw 83 295 ...

Page 296: ...moving the fan a Turn the spindle assembly the right way up b Place a spanner or similar on the spindle pulley key grip 1 as holder up c Fit the pin spanner and remove the fan 2 NOTE Left hand thread 1 2 1 G0923981 1 Key grip 2 Fan 84 296 ...

Page 297: ... oil mist generator 1 by using spanners b Remove the two nozzles 2 using an Allen key 1 2 G1036811 1 Oil mist generator 2 Nozzle 12 Removing the bottom bearing assembly a Pull off the belt pulley and the self aligning roller bearing using the puller tool 1 NOTE Always discard a used bearing 1 G1036821 1 Puller tool 85 297 ...

Page 298: ...the snap ring 5 CAUTION Risk for eye injury from flying snap ring Use the correct pliers for dismantling of snap ring to avoid accidental release c Remove the plugs 2 and the composite springs 1 d Carefully remove the spindle 3 and bearing seat from the top bearing housing NOTE Be careful not to damage the vibration indicator 6 e Collect the axial springs 4 5 6 g08583A1 86 298 ...

Page 299: ...care not to damage the vibration indicator 3 when separating the top bearing seat from the spindle NOTE Do not damage threads on spindle c Place the top bearing seat A on a support to protect the vibration indicator Remove the bearing Use a drift in the two holes 1 2 3 4 G0858381 1 Cap nut 2 Puller tool 3 Vibration indicator 4 Piece of wood to protect the spindle A G0858371 A Top bearing seat 87 2...

Page 300: ...tling assembly 15 Removing the labyrinth ring holder a Remove the screws 1 NOTE If the holder sticks fit two screws M8 to the threaded holes and tighten b Remove the O ring and labyrinth ring 1 G08586G1 1 Screw 88 300 ...

Page 301: ... tool 4 into the bottom bearing holder and attach the socket 3 extension rod 2 and T handle 1 1 2 3 4 G08586J1 1 T handle 2 Extension rod 3 Socket 4 Tool b Loosen the bottom bearing holder A by turning it counter clockwise Remove it by hand G08586k1 A Bottom bearing holder 89 301 ...

Page 302: ...ng assembly 17 Dismantling the bottom bearing holder when necessary a Unscrew the screw 3 b Remove the pipe 1 O rings 2 4 and strainer 5 G1015731 1 Pipe 2 O ring 3 Screw 4 O ring 5 Strainer 6 Bottom bearing holder 90 302 ...

Page 303: ...dstill before starting any dismantling work takes about 30 minutes from switch off NOTE 50 Hz 5 Friction blocks 60 Hz 3 Friction blocks The illustration shows 50 Hz 1 2 G0865071 1 Mounting dismantling tool centrifugal clutch 2 Mounting dismantling tool ball bearing G08651l1 1 Snap ring 2 Snap ring 3 Ball bearing 4 Spacing ring 5 Ball bearing 6 Belt pulley 7 Coupling hub 8 Parallel pin 9 Friction b...

Page 304: ...y before starting dismantling work NOTE If the cables are not disconnected during lifting procedures they may become damaged b Fit a sling to the motor using a shackle on the upper part Weight of motor with coupling approx 84 kg c Tense the lifting sling to support the motor and remove the screws Lift the motor while supported WARNING Crush hazard If not supported the motor with coupling will drop...

Page 305: ...accidental release of snap ring Wear safety goggles CAUTION Inhalation hazard When handling friction blocks pads 1 wear a mask to avoid inhalation of dust Do not use compressed air to remove dust Remove dust using vacuum or a damp cloth NOTE 50 Hz 5 Friction blocks 60 Hz 3 Friction blocks G08652g1 1 Friction blocks 3 60 Hz 2 Cover 3 Snap ring 93 305 ...

Page 306: ...oth If the blocks are worn Fit new friction blocks NOTE Replace all blocks even if only one is worn NOTE Be sure that the pins on the back of the blocks project into the grooves in the clutch hub a Clean the pins of coupling hub and apply a thin film of lubricating paste to the pins NOTE Make sure that there is no oil on the pads b If only friction block service is to be done proceed to fitting th...

Page 307: ...eat until screw is loose Remove the screw 5 spring washer 4 and washer 3 b Check that the brass plug 6 is mounted on the puller tool 8 Fit the tool to the friction clutch c Ease off the friction coupling WARNING Crush hazard The centrifugal clutch is heavy and can fall causing injury when loosened from the motor shaft NOTE See dismantling with optional hydraulic puller tool on page 96 if purchased...

Page 308: ... 3 4 6 7 8 G08654Q1 1 Sleeve 2 Nut 3 Hydraulic cylinder 4 Hydraulic oil inlet 5 Plate 6 Holder 7 Coupling nave 8 Motor shaft a Fit the sleeve 1 to the stud bolt Fit the stud bolt with sleeve to the motor shaft 8 b Fit the holder 6 to the coupling nave 7 c Fit nut 2 and sleeve to the stud bolt as shown d Fit hydraulic cylinder 3 as shown e Fit the plate 5 and fasten with screws through plate and ho...

Page 309: ...Ease off the friction coupling by pumping the handle on the pump until stop Release pressure on the hand pump and adjust the nut on the stud bolt Repeat until coupling is loose WARNING Crush hazard The centrifugal clutch is heavy and can fall causing injury when loosened from the motor shaft 97 309 ...

Page 310: ... Risk for accidental release of snap ring Wear safety goggles b Drive out the coupling hub 3 c Turn the coupling the other way round and drive out the ball bearings 5 using the mounting tool NOTE Always discard used bearings 1 2 3 4 5 G0865571 1 Snap ring 2 Wooden support 3 Coupling hub 4 Support 5 Ball bearing 98 310 ...

Page 311: ... steel parts against corrosion by oiling WARNING Electrical hazard Never wash down a separator with a direct water stream Never play a water jet on the motor Totally enclosed motors can be damaged by direct hosing to the same extent as open motors resulting in short circuit and internal corrosion CAUTION Cut hazard Sharp edges on the separator discs may cause cuts 99 311 ...

Page 312: ...erating water ring and operating slide with nozzle Use 10 acetic acid solution to dissolve lime deposits The acid should be heated to 80 C Clean the nozzle on the operating slide using a soft iron wire or a similar object A chemical cleaning agent must dissolve the deposits quickly without attacking the material of the separator parts Use Alfa Laval bowl disc cleaning agent Mix 1 part cleaning age...

Page 313: ...damage exceeds 0 5 mm contact Alfa Laval Stainless steel Chlorides or acidic solutions Acidic solutions cause general corrosion Chloride corrosion begins as small dark spots that can be difficult to detect and goes on to local damage such as pitting grooves or cracks Polish dark coloured spots and other corrosion marks with a fine grain emery cloth This may prevent further damage If damage exceeds...

Page 314: ... functional ability of components Always replace a part if cracks are present Cracks can occur from cyclic material stresses and corrosion Keeping the separator and its parts clean and free from deposits will help to prevent corrosion attacks WARNING Disintegration hazards Always contact your Alfa Laval representative if you suspect that the depth of the damage exceeds 0 2 mm for bowl body and bow...

Page 315: ...you suspect that the depth of the damage exceeds 0 2 mm for bowl body and bowl hood 0 5 for other parts Do not continue to use the separator until it has been inspected and cleared for operation by Alfa Laval 2 Inspect inside and outside of the frame hood NOTE Pay extra attention at the groove G1034011 3 Replace parts if erosion is suspected WARNING Disintegration hazard Erosion damage weakens par...

Page 316: ...c Holder and operating slide d The underside of the distributor in the vicinity of the distribution holes and wings e Paring disc and paring tube f Lock ring g Pillars between the sludge ports in the bowl wall h The sealing edge of the discharge slide for the seal ring in the bowl hood i Groove in frame hood Inspect both the inside and outside of the frame hood 104 316 ...

Page 317: ...ing instructions on page 170 a Loosen the central bolts 1 and prepare to remove the separator frame b Remove the separator See 6 7 Lifting instructions on page 170 c Remove the existing screws 2 washers and frame feet NOTE Discard the old frame feet screws and washers d Fit the new feet screws and washers e Place the separator in its original position and fasten the central mounting bolts 1 Tighte...

Page 318: ...l parts Apply a thin layer of Molykote or equivalent lubrication on all the contact surfaces shown in the illustration G09117j1 A Molykote 1000 1 Bowl hood 2 Bowl body 3 Discharge slide 4 Operating slide 5 Holder 6 Operating water ring 7 Screw 8 Nut 106 318 ...

Page 319: ...6 Service dismantling assembly 6 5 Assembly WARNING Entrapment hazard To avoid accidental start switch off and lock power supply before starting any assembly work 107 319 ...

Page 320: ...ient speed d 252 mm 50 Hz d 210 mm 60 Hz NOTE Remove rust from the belt pulley using a steel brush b Apply a thin film of oil onto the external and internal surfaces of the ball bearings 2 o c Press the ball bearings 2 down one at a time into the coupling hub preferably using a hydraulic press Place the spacing ring 4 between them NOTE Never re fit used ball bearings The ball bearings must not be ...

Page 321: ...rew 4 on the tool e Use a spanner to turn the nut on the tool This will press the centrifugal clutch on to the shaft Remove the tool f Install and tighten the washer 5 spring washer 6 and screw 7 g Attach a socket with extension rod and handle 8 to the screw h Place a piece of wood 9 according to the illustration i Push the handle to start the rotor moving When the handle hits the piece of wood th...

Page 322: ... pressure on the hand pump and adjust the nut on the stud bolt i Repeat procedure until coupling is mounted Note The pressure on the hand pump should not exceed 200 bar j Remove the hydraulic tool k Install and tighten the washer 8 spring washer 9 and screw 10 l Attach a socket with extension rod and handle 11 to the screw Place a piece of wood 12 according to the illustration m Push the handle to...

Page 323: ... on the back of the blocks project into the grooves in the clutch hub NOTE 50 Hz 5 Friction blocks 60 Hz 3 Friction blocks b Place the cover 3 in position and secure it with the snap ring 4 CAUTION Flying objects Risk for accidental release of snap ring Wear safety goggles G08654x1 1 Guide pin 2 Friction block 3 Cover 4 Snap ring 111 323 ...

Page 324: ... hazard If not supported the motor with coupling may drop when lifted c Fit the screws Do not tighten until the belt has been mounted d Connect the electrical cables WARNING Electrical hazard To avoid electrical shock switch off and lock power supply before starting assembly work G08646b1 NOTE If carrying out change of friction blocks only continue with steps 6 to 7 If carrying out a complete mach...

Page 325: ...the belt 1 to the middle centre of the spindle pulley NOTE For correct position centre the belt on the spindle pulley camber b Fit the flat belt to the motor belt pulley c Tighten the two upper screws 3 d Tighten all motor attachment screws 3 NOTE Do not turn the spindle until the motor is tightened properly to the frame 2 3 1 G08588T1 1 Flat belt 2 Clearance 3 Screw 113 325 ...

Page 326: ...6 Service dismantling assembly 7 Fitting the belt cover a Fit the belt cover b Tighten the screws 1 2 G08581A1 1 Screw 2 Belt cover 114 326 ...

Page 327: ... necessary NOTE Clean the pipe and strainer before fitting NOTE Make sure to fit the pipe the right way up a Fit the pipe 1 O rings 2 4 and strainer 5 b Secure the pipe 1 with the screw 6 secured with Loctite 222 G1015741 1 Pipe 2 O ring 3 Bottom bearing holder 4 O ring 5 Strainer 6 Screw 115 327 ...

Page 328: ...ing holder 3 into the frame apply Loctite 222 on the surfaces directly above the upper O ring b Thread the bottom bearing holder 3 into the frame and fit the tool into the bottom bearing housing c Tighten the holder to a torque of 200 Nm G10157051 1 Socket 2 Tool 3 Bottom bearing holder 116 328 ...

Page 329: ...ing holder 1 2 G0866381 1 O ring 2 Labyrinth ring a Lubricate and fit the O ring 1 o b Lubricate and fit the labyrinth ring 2 o c Fit the labyrinth ring holder into the frame Apply Loctite 222 to screws 3 Fit and tighten the screws 3 G08663h1 3 Screw 117 329 ...

Page 330: ... gloves when handling any heated parts b Drop some oil onto the bearing and fit the bearing 2 into the top bearing seat NOTE Always fit a new bearing Pre lubricate before fitting c Fit the snap ring 3 CAUTION Risk for eye injury from flying snap ring Use the correct pliers for assembly of snap ring to avoid accidental release NOTE Make sure snap ring is correct fitted and slides easily in the groo...

Page 331: ...clean oil or induction heater WARNING Burn hazard Use protective gloves when handling any heated parts b Wipe off the spindle and fit the top bearing seat to the spindle using the sleeve 3 and puller 2 NOTE Make sure to fit the bearing seat correctly or it might get stuck NOTE Be careful not to damage the vibration indicator 1 2 3 G0984881 1 Top bearing seat 2 Puller 3 Sleeve 119 331 ...

Page 332: ... Lubricate the threads A and both ends of the composite springs B with oil before assembly d Fit the composite springs B and plugs to the top bearing housing Do not tighten the plugs Make sure that the springs enter the recesses in the top bearing seat The plugs should be tightened when the spindle assembly is mounted into the frame o 2 1 G0866661 1 Bowl spindle 2 Axial spring A B G0866651 A Threa...

Page 333: ...t of its position and damage the neck bearing when the bottom bearing is mounted otherwise The cartridge has to stand on the spindle top with a clearance of minimum 1 mm A in the picture between top bearing housing and the support c Wipe off the spindle pulley seat on the spindle 1 and nave bore in the spindle pulley 2 with a dry cloth d Fit the spindle pulley firmly on the bowl spindle 2 3 4 1 A ...

Page 334: ...th clean oil b Heat the bearing 1 to minimum 30 C and maximum 50 C WARNING Burn hazard Use protective gloves when handling any heated parts c Lower the bearing onto the spindle and press down onto the spindle pulley using the special drift tool NOTE Always fit a new bearing 1 G08668B1 1 Bearing 122 334 ...

Page 335: ...before assembly a Apply Loctite 222 and screw the two nozzles 1 into the pump 2 so that they lie level with the pump edge using an Allen key b Lubricate all threads 3 with a few drops of oil before assembly c Fit the oil mist generator Use a spanner and a crowfoot wrench head together with a torque wrench handle Tighten to 150 Nm G08669g1 Crowfoot wrench head 123 335 ...

Page 336: ... ring of the ball bearing b Apply a thin layer of oil and fit the O rings 1 into the fan o NOTE Make sure that the bearing is pre lubricated before fitting the fan c Place a spanner or similar on the spindle pulley key grip 3 as holder up and fit the fan Tighten firmly by hand with the pin spanner 2 2 1 3 G09240L1 1 O ring 2 Pin spanner 3 Key grip 124 336 ...

Page 337: ...6 Service dismantling assembly 11 Fitting the air deflector a Turn the spindle assembly up side down and fit the air deflector 1 b Tighten screws 2 1 2 G08592A1 1 Air deflector 2 Screw 125 337 ...

Page 338: ...g o NOTE When replacing the belt with new one make sure it has the right article number according to SPC Check the direction arrows on the belt and the machine plate for correct position Make sure that the belt does not get smudged with oil or grease during handling c Carefully lower the spindle assembly and position the bolt holes over the threaded frame holes Make sure that the bottom bearing en...

Page 339: ... the middle centre of the spindle pulley NOTE For correct position centre the belt on the spindle pulley camber b Fit the flat belt to the motor belt pulley 4 c Tighten the two upper screws 3 d Tighten all motor attachment screws 3 NOTE Do not turn the spindle until the motor is tightened properly to the frame 4 3 1 2 G08588V1 1 Flat belt 2 Clearance 3 Screw 4 Belt pulley 127 339 ...

Page 340: ...l ring 2 O rings 3 Neck bearing cover 4 Deflector ring a Apply a thin layer of oil and fit the O rings 2 and seal rings 1 o b Fit the neck bearing cover 3 NOTE The guide pin on the cover should enter one of the two holes in the bearing housing c Push the deflector ring 4 down until it stops 128 340 ...

Page 341: ...ailure of the separator discharge function b Lubricate with oil and fit the seal ring 1 and O ring 3 into the operating water cover 2 o Renew the O ring 4 o c Fit the operating water cover Fit washers and tighten the screws NOTE The water pipe in the frame should enter the hole in the cover 1 3 4 2 4 5 G08681T1 1 Seal ring 2 Operating water cover 3 O ring 4 O ring 5 Operating water channel 129 341...

Page 342: ...spindle A G0858721 A max 0 04 mm a Fit a dial indicator in a support and fasten it in position as illustrated Use the flat belt to turn the spindle NOTE Permissible radial wobble max 0 04 mm If the spindle wobble exceeds this value contact an Alfa Laval representative 130 342 ...

Page 343: ...6 Service dismantling assembly 17 Fitting the belt cover a Fit the belt cover 2 b Tighten the screws 1 1 2 G08581A1 1 Screw 2 Belt cover 131 343 ...

Page 344: ...fit the drain plug 5 i c Fill with new oil until oil flows out from the filler hole For correct oil volume see Lubricating oil volume on page 182 NOTE For grade and quality of oil see 6 6 6 Lubricating oils on page 168 d Fit new O ring 2 onto the oil pin i e Refit the plug 3 with new washer 4 i f Fit the oil pin 1 1 2 3 4 5 6 G08687Z1 1 Oil pin 2 O ring 3 Plug 4 Washer 5 Drain plug 6 Washer 132 34...

Page 345: ...i o a Remove any impact marks using a scraper and or a whetstone CAUTION Disintegration hazard Impact marks may cause the separator to vibrate while running b Rust can be removed by using a fine grain emery cloth e g No 320 c Finish with polishing paper e g No 600 d Lubricate to prevent further corrosion G0874621 133 345 ...

Page 346: ...ng assembly 2 Fitting new valve plugs on the operating slide i a Carefully tap in new valve plugs using a clean soft faced hammer NOTE Make sure that the plugs are fitted as described in the illustration G0874871 134 346 ...

Page 347: ...d mount the guide ring 1 into the groove on bowl body Secure that the guide ring is fully inserted into the groove and that it is secured in its position by the silicone grease WARNING If too much silicon grease is applied to the guide ring there is a risk that the silicone grease will clog the nozzles on the operating slide G08610p1 135 347 ...

Page 348: ... NOTE The guide pin 4 in the bowl body 3 should enter the hole 1 in the operating slide this hole is marked with a drill mark Nozzle 5 secured with Loctite 243 NOTE Take special care to ensure that the guide ring 9 is not pressed out of its position in the groove during the fitting of operating slide G0861261 1 Alignment hole 2 Operating slide 3 Bowl body 4 Guide pin 5 Nozzle 6 Rectangular ring 7 ...

Page 349: ... of molykote grease and fit and tighten new screws 2 and washers 3 to a torque of 30 2 Nm i o NOTE It is very important NOT to refit used screws and washers Always fit new ones included in the Inspection kit Every washer 3 consists of two parts which must be correctly locked together 1 3 2 G0861351 1 Holder 2 Screw 3 Washer 137 349 ...

Page 350: ...luded in the Inspection kit b Apply a thin layer of silicone grease and fit the O ring 3 i o c Fit the ring 2 with screws 1 onto the bowl body i o NOTE The drilled assembly mark 4 on the water ring 2 should face the corresponding mark on the bowl body d Grease fit and tighten the screws 1 to a torque of 30 2 Nm 1 2 3 4 5 G0861461 1 Screw 2 Operating water ring 3 O ring 4 Drill mark 5 Seal ring 138...

Page 351: ...ore 2 with a dry cloth c Turn the bowl body over WARNING Crush hazard Support the bowl body when turning to prevent it from rolling d Fit the lifting tool 3 and lift the bowl body using sling and hoist e Carefully lower the bowl body 4 onto the spindle taper f Remove the lifting tool 1 3 2 4 G0861741 1 Spindle taper 2 Nave bore 3 Lifting tool 4 Bowl body 139 351 ...

Page 352: ...t one of the clamps 2 to the bowl body and one of the screws 4 for the frame hood in the frame Fasten a sling 1 between the clamp and the screw around the bowl body b Apply a thin layer of molykote grease Fit and tighten the cap nut 3 to a torque of 100 Nm NOTE Left hand thread 1 4 3 2 G0861891 1 Sling 2 Clamp 3 Cap nut 4 Screw 140 352 ...

Page 353: ...r the discharge slide into the bowl WARNING Crush hazard The ring on the lifting tool must be pushed down against the discharge slide otherwise it may come loose from the tool d Remove the lifting tool e Fit the nut 4 f Fit the spanner for nut 5 and tighten the nut with a torque wrench to a torque of min 200 Nm g Remove the spanner for nut 1 2 3 4 5 G0861981 1 Rectangular ring 2 Lifting tool 3 O r...

Page 354: ...scs Always end with the disc without caulks WARNING The number of discs may have to be increased to adjust the disc stack pressure Always check before operating the separator See Checking the disc stack pressure on page 150 CAUTION Cut hazard Sharp edges 2 on the bowl discs may cause cuts 2 3 4 1 G0862081 1 Bowl disc 2 Sharp edge 3 Recess on bowl disc 4 Guide rib on distributor 142 354 ...

Page 355: ...g sling and hoist NOTE The guide pin 2 on the bowl body should face the drill mark 3 on the distributor The guide ribs 4 inside the distributor will then fit the recesses 5 on the bowl body nave in the right way 1 2 3 4 5 G08621D1 1 Lifting tool 2 Guide pin on bowl body 3 Drill mark on distributor 4 Guide ribs inside the distributor 5 Recesses on bowl body nave 143 355 ...

Page 356: ...e dismantling assembly 12 Assembling the paring tube i a Apply a thin layer of silicone grease to the O rings 1 Fit the O rings 1 and bearings 2 to the paring tube i o 1 2 2 G09849G1 1 O ring 2 Bearing 144 356 ...

Page 357: ...inlet and outlet pipe b Apply a thin layer of silicone grease and mount the splash sealing 2 i o c Apply a thin layer of silicone grease and fit the O rings 3 i o d Carefully lower the inlet and outlet pipe assembly into the top of the distributor 2 1 3 4 G08622N1 1 Paring tube 2 Splash seal 3 O ring 4 Inlet and outlet pipe 145 357 ...

Page 358: ...e paring tube turn it towards the centre of the pipe b Lower the top disc 2 The drill mark 3 on the top disc should face the guide pin on the bowl body The guide rib 4 on the distributor should enter one of the two larger recesses on the top disc 1 2 3 4 G08623D1 1 Paring tube 2 Top disc 3 Drill mark 4 Guide rib 146 358 ...

Page 359: ...i o c Gently tap down the seal ring crosswise with a soft rubber mallet until the entire ring is fitted all the way around d Fit the compressing tool 3 and attach lifting eyes Lower the bowl hood so that its recess 4 fits into the guide pin 5 in the bowl body e Remove the compressing tool 1 2 3 4 5 G08624D1 1 O ring 2 Seal ring 3 Lifting tool 4 Recess in bowl hood 5 Guide pin on bowl body 147 359 ...

Page 360: ...ny tool to knock the lock ring into the groove It must be possible to fit by hand For correct disc stack pressure see page 150 c Make sure that the lock ring is fully engaged over it s full length in the groove and does not flex anywhere The lock ring ends must be facing each other with a gap between them The lock ring ends must not be flush or overlap each other NOTE If there is not a gap between...

Page 361: ...RNING Health hazard Welding of the lock ring is not allowed as this can seriously affect the material strength If the lock ring is either worn beyond the safety limits or incorrectly assembled it may cause severe damage or fatal injury WARNING Health hazard Never remove any material from the lock ring This may cause severe damage or fatal injury e Release the pressure on the compressing tool and r...

Page 362: ...t the lock ring 3 and fully compress the disc stack with the compressing tool 4 NOTE Tighten the screws alternately in increments of 5 Nm up to a maximum of 20 Nm e If the lock ring enters the groove 5 repeat step a d until the lock ring does not enter the groove f Dismantle the bowl and remove one disc to get the correct disc stack pressure g Assemble the bowl with inlet and outlet pipe 1 2 4 3 5...

Page 363: ...rease and fit the O ring 3 onto the frame hood i o c Lower the frame hood NOTE Make sure to fit the frame hood groove into the projection of the pipe 5 NOTE Make sure that the frame hood is mounted in its correct position according to the piping arrangement d Fit and tighten the screws 4 1 3 2 4 5 G08637K1 1 Paring tube 2 Frame hood 3 O ring 4 Screw 5 Frame hood groove Projection of pipe 151 363 ...

Page 364: ... the guide screw A b Measure the distance D through the screw hole Assemble the correct number of height adjusting rings B according to the list 29 0 5 mm 3 rings 28 0 5 mm 2 rings 27 0 5 mm 1 ring c Refit the guide screw A D 2 A B G09115T1 A Guide screw B Height adjusting rings 152 364 ...

Page 365: ...ith the screw 1 b Fit the spring to the pin 5 on the frame hood and make sure that it is properly attached on both ends 1 2 3 4 5 G08637l1 1 Screw 2 Spring 3 Arm 4 Paring tube 5 Pin A B G08637r1 A Spring correctly fitted Spring hook opening facing towards paring tube B Spring wrongly fitted Spring hook opening facing away from paring tube 153 365 ...

Page 366: ...w on top of the frame hood enters the guide hole at the underside of the connecting housing c Lubricate the lock nut threads d Fit the washer 3 and the lock nut 2 using the hook spanner NOTE Fine threads on the pipe Make sure that the lock nut has entered the pipe threads correctly before tightening with the hook spanner 1 2 3 G0863981 1 Connecting housing 2 Lock nut 3 Washer 154 366 ...

Page 367: ...ing 3 on the holder 2 Fit the screw 4 into the holder and mount the holder into the separator frame 6 NOTE If removing the sensor holder use a M10 screw as a puller NOTE See next page for fitting and correct adjustment of the sensor 1 2 3 2 4 A 6 5 G08734G1 1 Cover 2 Sensor holder 3 O ring 4 Screw M8 5 Sensor arm 6 Frame A M10 155 367 ...

Page 368: ...r Do not forget the nut 2 b Adjust the sensor so that a value of 1 5 appears on the display c When correct distance is achieved tighten the nut against the holder Fit the cover see previous page A G 2 1 2 3 4 5 6 G08734H1 1 Sensor 2 Nut 3 brown or red 4 J black or white 5 OV blue 6 24 V DC 156 368 ...

Page 369: ...nd indicators on page 26 G08734E1 A Speed sensor distance NOTE If the sensor does not work properly check the distance between the sensor and the spindle belt pulley Adjust the sensor to achieve measure B shown below B 1 G08588W1 1 Spindle belt pulley B Distance between sensor and pulley NOTE The distance B between the sensor and the spindle belt pulley 1 must be 2 5 0 5 mm 157 369 ...

Page 370: ...xxx xxxxxx Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxx XX XX XX XX XX XX XX XX XX XX XX XX XX XXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXX XXXXXXX XXXXXXXXXXXXXXXX X XXXXXXXXX XXXXXXXXXXXXXXX X XXXX XXX XXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXX XXXX XXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXX XXXXXXXXXXXXXXXXXXX XXXXXXXXX XXXXXXX XX XXX W A R N I N G XXXX...

Page 371: ...ure min max Inside diameter of bowl body Manufacturer Service enquiries www alfalaval com Safety label Text on label Warning Read the instruction manuals before installation operation and maintenance Consider inspection intervals Failure to strictly follow instructions can lead to fatal injury If excessive vibration occurs stop separator and keep bowl filled with liquid during rundown Out of balan...

Page 372: ...its in a mineral type oil is an indication that the oil base has deteriorated seriously or that some of the oil additives have precipitated Always investigate why black deposits occurs If changing from one oil brand to another it is recommended to do this in connection with an overhaul of the separator Clean the oil bath housing and the spindle parts thoroughly and remove all deposits before filli...

Page 373: ... the lower end of the pin 6 6 3 Oil change procedure 1 Remove the oil pin plug and washer B 2 Place a vessel under the drain plug C 3 Remove the drain plug CAUTION Burn hazard The lubricating oil and various machine surfaces can be sufficiently hot to cause burns 4 Collect the oil in the vessel 5 Fit and tighten the drain plug C 6 Fill with new oil until oil flows out of oil filler hole A NOTE For...

Page 374: ...n page 168 Volume 8 2 Technical data on page 182 Ambient temperature Between 0 to 55 C Oil change Continuous operation 4000 hours Seasonal operation before every operating period Short periods operation 12 months even if total numbers of operating hours is less than stated above 2 Bowl spindle taper Lubricating oil only a few drops for rust protection At assembly 3 Bowl Sliding contact surfaces th...

Page 375: ...rt up the spindle bearings that have been out of service for a shorter period than six months must also be prelubricated The lubrication chart can be complemented with more detailed charts showing the lubricating points in detail and what type of lubricants to use Instructions related to a specific design of the machine refer to general assembly drawings Instructions related to a specific design o...

Page 376: ...ore information Paste for assembly of metallic parts non hygienic applications Part no Quantity Designation Manufacturer Remark 537086 02 1000 g Molykote 1000 Paste Dow Corning 537086 03 537086 06 100 g 50 g Molykote G n plus Paste Dow Corning 537086 04 50 g Molykote G rapid plus Paste Dow Corning Gleitmo 705 Fuchs Lubritech Wolfracoat C Paste Klüber Dry Moly Paste Rocol MTLM Rocol Bonded coating ...

Page 377: ...tered H1 3 Sep 2004 Geralyn F L A Fuchs Lubritech NSF Registered H1 2 April 2007 German 5 Absatz 1 LMBG approved 554336 01 55 g Gleitmo 1809 Fuchs Lubritech Gleitmo 805 Fuchs Lubritech DVGW KTW approval for drinking water TZW prüfzeugnis Klüberpaste 46 MR 401 Klüber White contains no lead cadmium nickel sulphur nor halogens Klüberpaste UH1 84 201 Klüber NSF Registered H1 26 Aug 2005 Klüberpaste UH...

Page 378: ...Silicone Oil Used as a Lubricant depending on viscosity 569415 01 50 g Molykote G 5032 Dow Corning NSF Registered H1 3 June 2005 Geralyn SG MD 2 Fuchs Lubritech NSF Registered H1 30 March 2007 Chemplex 750 Fuchs Lubritech DVGW approved according to the German KTW recommendations for drinking water Paraliq GTE 703 Klüber NSF Registered H1 25 Feb 2004 Approved according to WRAS Unisilkon L 250 L Klü...

Page 379: ...P Energrease LS EP2 BP Energrease MP MG2 BP APS 2 Castrol Spheerol EPL 2 Castrol Multifak EP2 Chevron Multifak AFB 2 Chevron Molykote G 0101 Dow Corning Molykote Multilub Dow Corning Unirex N2 ExxonMobil Mobilith SHC 460 ExxonMobil Mobilux EP2 ExxonMobil Lagermeister EP2 Fuchs Lubritech Rembrandt EP2 Q8 Kuwait Petroleum Alvania EP2 Shell LGEP 2 SKF LGMT 2 SKF LGFP 2 SKF NSF Registered H1 17 Aug 20...

Page 380: ...8 ExxonMobil Mobil DTE 26 ISO VG 68 ExxonMobil Haydn 68 Q8 Kuwait Petroleum Tellus Oil S2 M 68 Shell Tellus Oil S3 M 68 Shell HydraWay HMA 68 Statoil Azolla AF 68 Total Azolla ZS 68 Total Recommended oil brands General demands oils for use at cold start Viscosity grade ISO 3448 3104 VG 68 Viscosity index ISO 2909 VI 95 These oils should be used at cold start when the ambient temperature is below 2...

Page 381: ...stration see www nsf org http www nsf org business nonfood_compounds Part no Quantity Designation Manufacturer No Tox HD oil 68 Bel Ray Lubricating oil FM 68 Chevron Cygnus Hydraulic Oil 68 Chevron Mobil DTE FM 68 ExxonMobil Lubriplate FMO AW 350 Fiske Brothers Keystone Nevastane AW 68 Total Standard requirements Other oil brands may be used as long as they fulfill the standard requirements Please...

Page 382: ... torque 35 45 Nm 1 Disconnect all connections 2 Remove the inlet and outlet device the frame hood and the bowl according to the instructions in 6 3 Dismantling on page 49 NOTE Never lift or transport the separator with the bowl still inside 3 Fit the lifting tool not included in set of tools All four bolts on the lifting tool must be fastened to the frame 4 Unscrew the foundation bolts 170 382 ...

Page 383: ...follow normal safety precautions for lifting large heavy objects WARNING Crush hazard A falling separator can cause accidents resulting in serious injury and damage Never lift the separator by any other method than described in this manual NOTE When lifting parts without weight specifications always use lifting straps with the capacity of at least 500 kg 171 383 ...

Page 384: ...bly 2 Check that the lock ring is mounted correctly before lifting the complete bowl 3 Lift the bowl using a sling with the proper rating NOTE Never try to lift the bowl while it is still in the frame The bowl body is fastened to the frame with the cap nut 2 1 A G08684A1 A Weight to lift 80 kg 1 Lifting eye Tightening torque 40 5 Nm 2 Lock ring Make sure that lock ring is fitted 172 384 ...

Page 385: ...nd stopping sequences when the separator passes through its critical speed Cause Corrective action Bowl out of balance due to poor cleaning incorrect assembly incorrect disc stack compression bowl assembled with parts from other separators Dismantle the separator and check the assembly and cleaning Uneven sludge deposits in the sludge space Dismantle and clean the separator bowl Height position of...

Page 386: ...ing s damaged or worn Renew all bearings 7 1 4 Speed too low Cause Corrective action Friction blocks are oily or worn Clean or renew friction blocks Bowl is not closed or leaking Dismantle the bowl and check Motor failure Repair the motor Bearing s damaged Renew all bearings Incorrect transmission parts 60 Hz belt pulley for 50 Hz power supply WARNING Stop and change the belt transmission to suit ...

Page 387: ...rective action Incorrect transmission parts 50 Hz belt pulley for 60 Hz power supply WARNING Stop and change the belt transmission to suit the power supply frequency Friction blocks are oily or worn Clean or renew friction blocks Motor failure Repair the motor 7 1 8 Starting time too long Cause Corrective action Friction blocks are oily or worn Renew or clean friction blocks Height position of par...

Page 388: ...open for sludge discharge Cause Corrective action Strainer in the operating water supply is clogged Clean the strainer Water flow too low Check the water flow Hoses between the supply valves and separator are incorrectly fitted Correct Nozzle in operating slide missing Fit the nozzle Rectangular ring in the operating slide or bowl body is defective Renew the rectangular rings 7 2 3 Unsatisfactory ...

Page 389: ...ve action Nozzle in operating slide clogged Clean nozzle Hoses reversed Adjust Rectangular ring in discharge slide is defective Renew rectangular ring Valve plugs in operating slide missing or defective Renew valve plugs No water Turn on water supply 177 389 ...

Page 390: ...7 Fault finding 390 ...

Page 391: ... oil Technical Design Intended for marine and land installations Total discharge Centrilock lock ring Directives and standards 8 1 1 Directives and standards on page 180 Operational limits Feed temperature 0 C to 100 C Ambient temperature 5 C to 55 C Maximum allowed speed 9340 r min Discharge intervals Min 2 minutes max 4 hours Maximum allowed density of operating liquid 1000 kg m3 Viscosity max 7...

Page 392: ... for design Risk assessment and risk reduction ISO 3744 Acoustics Determination of sound power levels of noise sources using sound pressure Declaration of Conformity The machinery complies with the following Directives Designation Description 2004 108 EC Electromagnetic Compatibility Directive To meet the requirements the following standards have been applied Designation Description EN 60204 1 Saf...

Page 393: ...will be sent by post to national authorities This machinery is to be incorporated into other equipment and must not be put into service until it has been completed with starting stopping equipment control equipment auxiliary equipment e g valves according to the instructions in the technical documentation and after the completed machinery has been declared in conformity with the directives mention...

Page 394: ...al AL 111 2377 02 Operating data Bowl speed synchronous 50 Hz 60 Hz 9220 9220 r min Motor speed synchronous 50 Hz 60 Hz 3000 3600 r min Maximum allowed speed r min Max power consumption start up 12 kW Power consumption idling max capacity 3 7 5 kW Starting time min max 1 5 2 5 minutes Stopping time min max 18 35 minutes Stop time without brake average 27 minutes Sound power 9 1 Bel A Sound pressur...

Page 395: ...tlet from the cyclone must always be arranged to prevent the cyclone from being filled up with sludge Solids are discharged by gravity Small discharge Large discharge Total discharge Discharge frequency Max 24 discharge h 375 Inlet for discharge and make up liquid Quality requirements See Demand specification water Max density 1000 kg m min Pressure 150 kPa Make up liquid Flow momentary 2 8 litres...

Page 396: ... V With sensor activated near metal 1 2 mA With sensor not activated far from metal 2 1mA Number of pulses per revolution 1 752 Position transducer for bearing holder See interface description Type Inductive analogue sensor Supply voltage 15 to 30 V DC Operation range mild steel 3 5 mm 0 25 mm Output current analog 4 to 20 mA Load resistance RL 1 kOhm max 760 Cover interlocking switch Type Mechani...

Page 397: ...rmation and are referred to here are Interconnection Diagram Connection List Technical Data Standards referred to are EN 418 Safety of machinery Emergency stop equipment functional aspects Principles of design EN 1037 Safety of machinery Prevention of unexpected start up EN 954 1 Safety of machinery Safety related parts of control systems Part 1 General principles for design 8 4 3 Definitions For ...

Page 398: ...mprehensive depending on the type of used control equipment When a simple control unit is used it would be impossible or too expensive to include many of the functions specified here while these functions could be included at nearly no extra cost when a more advanced control unit is used For this reasons functions that are indispensable or needed for safety reasons to protect the machine and or pe...

Page 399: ... 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 Stopping means The power to the separator motor is off The bowl is rotating and decelerating STOPPING is a collective denomination for a number of sub modes which e g can be NORMAL STOP A m...

Page 400: ...location when the machine is not properly connected to the piping 8 4 7 Handling of connection interfaces Electrical connections 701 Separator motor The separator is equipped with a 3 phase DOL direct on line started motor The separator can also be started by a Y D starter but then the time in Y position must be maximized to 5 seconds There shall be an emergency stop circuit designed according to ...

Page 401: ...tion of the separator equipment and should be investigated If the speed exceeds Bowl speed synchronous in Technical Data with more than 5 the separator shall be stopped automatically by NORMAL STOP and a high speed alarm shall be given The speed monitoring system shall be checked continuously e g by checking that pulses are coming In case of failure indication the separator shall be stopped automa...

Page 402: ...d by NORMAL STOP The speed drop during DISCHARGE compared to the measured speed immediately before should be between 3 8 which will indicate a proper discharge Signal processing in STOPPING STAND STILL shall be indicated when no pulses are detected within 30 seconds Stopping the separator when alarm for speed monitoring system failure is active shall cause a timer controlled stop See Stop time in ...

Page 403: ...alarm should be given Vibrations of this magnitude will reduce the expected life time of the bearings and should therefore be eliminated If vibrations exceed the second alarm level the separator shall be stopped automatically by SAFETY STOP If the self check system triggers an alarm shall be given Signal processing in STOPPING If the self check system triggers an alarm shall be given Signal proces...

Page 404: ... or STOPPING Processing in RUNNING Could be closed or open Processing in CLEANING A sequence of cleaning liquids should be fed to the separator The flow rate should be as high as possible and preferably not less than the production flow rate Processing in NORMAL STOP or EMERGENCY STOP Could be closed or open but the bowl should be filled unless the stop is initiated in STARTING Processing in SAFET...

Page 405: ...ronous bowl speed no water supply may be made When coming from PRODUCTION a discharge shall be initiated to remove sediment from bowl to avoid problems due to solidification see Connection List Signal processing in PRODUCTION Automatic discharges shall be initiated by timer or ALCAP system Signal processing in CLEANING Automatic discharges shall be initiated by timer or CIP control system Signal p...

Page 406: ... total hardness of 180 mg CaCO3 per litre which corresponds to 10 dH or 12 5 E Hard water may with time form deposits in the operating mechanism The precipitation rate is accelerated with increased operating temperature and low discharge frequency These effects become more severe as the hardness of the water increase 4 A chloride content of maximum 100 ppm NaCl equivalent to 60 mg Cl l A chloride ...

Page 407: ...ng operation 5 mm C Maximum vertical displacement at the sludge connection during operation 2 mm D M10 depth 30 E ø28 depth 45 F ø22 depth 45 G M10 depth 30 H ø28 depth 45 Connection house with connections 201 220 and 221 turnable in 60 steps all around All connections to be installed non loaded and flexible All dimensions are nominal Reservation for individual deviations due to tolerances 195 407...

Page 408: ...rvice side G Foundation bolts H Installation according to stated foundation force I Recommended free floor space for unloading when doing service J No fixed installation within this area K Centre of gravity complete machine L Dynamic forces static force excluded from separator do not exceed L Force in any separator foot L Vertical 12 kN L Horizontal 12 kN M Total foundation force sum of all feet M...

Page 409: ...connector X Wire colour codes B Junction box 740 Speed sensor 752 Unbalance sensor position trans for bearing holder 760 Interlocking switch frame top part RD A BU B WT C YE D GN E BK F BN G PU H BK Black BN Brown BU Blue RD Red GN Green PU Purple YE Yellow WT White Demand specification wire Approval UL 1007 1569 CSA TR 64 Area acc to AWG 18 Items showed in this document are not included in all se...

Page 410: ...2 4 0 6 0 8 1 1 2 1 4 1 6 1 8 f s A B C G08697j1 A No sealing B Operational envelope C Non physical Separator bowl speed 9220 r min Separator bowl number 561904 03 References density for Feed 1100 kg m3 References density for Wet solids 2425 kg m3 NOTE Max allowed operating liquid density 1000 kg m3 198 410 ...

Page 411: ...039421 Manufacturer ABB Type of mounting Degree of protection Type M3AA132SMB2 IEC 34 7 IEC 34 5 Poles 2 G0541421 IM2111 IP 55 Bearings D end 6308 2Z C3 N end 6206 2Z C3 NOTE For complete information about motor variants please contact your Alfa Laval representative 199 411 ...

Page 412: ...turer ABB Motors Type of mounting Degree of protection Type M2AA 132 SC2 IEC 34 7 IEC 34 5 Poles 2 G0541421 IM 2111 IP 55 Bearings D end 6208 2Z C3 N end 6208 2Z C3 NOTE For complete information about motor variants please contact your Alfa Laval representative 200 412 ...

Page 413: ...ions which are compulsory requirements Any specific requirements from classification societies or other local authorities must be followed NOTE If the specifications are not followed Alfa Laval can not be held responsible for any malfunctions related to the installation 201 413 ...

Page 414: ...ake sure that tools and lifting devices are fastened securely See 6 7 1 Lifting the separator on page 170 WARNING Crush hazard Use correct lifting tools and follow lifting instructions 2 When lifting the bowl see 6 7 2 Lifting the bowl on page 172 3 During transport of the separator the in and outlet device frame hood and bowl must always be removed G0873591 202 414 ...

Page 415: ...inspected every 6 months and if necessary the protection be renewed The following protection products are recommended 1 Anti rust oil Dinitrol 112 or equivalent with long lasting effective treatment for external surfaces The oil should prevent corrosion attacks and leaves a waxy surface 2 Anti rust oil Dinitrol 40 or equivalent is a thin lubricant for inside protection It gives a lubricating trans...

Page 416: ...ing bowl parts shortest distance between driving motor and wall space for control and operation free passage for dismantling and assembly space for maintenance work space on floor for machine parts during maintenance work For more detailed information see 8 6 1 Basic size drawing on page 195 and 8 6 2 Foundation drawing on page 196 204 416 ...

Page 417: ...nce work easier An overhead hoist with capacity of 300 kg is required for transport of bowl parts to the working bench Lifting point should be above the centre of the separator NOTE When two or more separators are installed the lifting height should be increased to enable bowl parts from one separator to be lifted and moved over an adjoining separator See 8 6 2 Foundation drawing on page 196 205 4...

Page 418: ...ce media electric power operating and safety liquids etc required for the separator have the correct quality and capacity G0874021 Sludge discharge tank If the sediment from the separator is discharged into a tank this tank must be sufficiently ventilated The connection between the separator and the tank must be of the size and configuration specified If the solids are discharged from the separato...

Page 419: ...age of goods on page 203 9 5 Before start up If the separator has been out of operation for 1 months or longer Pre lubricate the spindle bearings if the ambient temperature at start up is below 25 C 6 months or longer Perform an Inspection service i and make sure to pre lubricate the spindle bearings Change the oil before starting 18 months or longer Perform an Overhaul service o and make sure to ...

Page 420: ...S 946 Specification No 881203 05 02 2 Book No 9007138 02 Rev 4 420 ...

Page 421: ... parts catalogue Catalogo parti di ricambio Reservdelskatalog Catalogo de pecas sobressalentes Ersatzteilkatalog Varaosaluettelo Catalogue de piéces de rechange Καταλογοσ ανταλλακτικων Catalogue de piezas de recambio Reserveonderdelen catalogus Каталог запасных частеи Reservedelskatalog 421 ...

Page 422: ...lephone 46 8 530 650 00 Telefax 46 8 530 310 40 Alfa Laval Tumba AB 2013 09 12 Original instructions This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB 422 ...

Page 423: ...kit for speed 16 3 Separator bowl 18 4 Inlet and outlet device 20 5 Belt driving device 22 5 1 Centrifugal clutch 24 6 Set of plates 26 7 Monitoring kit for vibration 28 8 Set of tools 30 9 Inspection kit 32 10 Overhaul kit 34 11 Lifting tool 36 12 Support kit 38 13 Cover interlocking kit 40 14 Hydraulic tool kit 42 14 1Hydraulic components 44 3 423 ...

Page 424: ...14 2Hydraulic tool 46 15 Motor service kit 48 16 Motor service kit 50 17 Cross reference list 52 4 424 ...

Page 425: ...e correct La placa marca de la máquina guía del número correcto del repuesto Фирменная табличка машины указатель правилного номера запасной части La targhetta della macchina guida al corretto numero dei ricambi La placa do fabricante da máquina um guia do número correto das partes sobressalentes Konekilpi opastin oikeaan varaosanumeroon Η πινακίδα της μηχανής είναι ο οδηγός του σωστού ανταλλακτικο...

Page 426: ...Alfa Laval Originalersatzteile benutzen Vergessen Sie nicht Alfa Laval kann keine Verantwortung für das Versagen eines Separators übernehmen der nicht mit Originalersatzteilen versehen ist Wir garantieren Qualität und Zuverlässigkeit unserer Produkte Préservez la qualité de vos équipments en n employant que des pièces de rechange Alfa Laval N oubliez pas q Alfa Laval décline toute responsabilité e...

Page 427: ... o seu cometimento a qualidade usando sempre peças sobressalentes genuinas Alfa Laval Não esqueça que Alfa Laval não aceita responsabilidade por falha de uma separadora equipada com peças sobressalentes não genuinas Nós garantimos a qualidade e a confiança dos nossos produtos Varmistakaa vastuunne laadusta käyttämällä aina alkuperäisiä Alfa Laval varaosia Muistakaa Alfa Laval ei voi hyväksyä vastu...

Page 428: ...l niet verantwoordelijk is voor een defecte separator die niet originele onderdelen bevat Wij garanderen de kwaliteit en betrouwbaarheid van onze eigen produkten Hold Dem til den kvalitet De har valgt at satse på ved altid at anvende ægte Alfa Laval reservedele Husk at Alfa Laval ikke kan påtage sig noget ansvar for fejl på en separator som indeholder uoriginale dele Vi kan kun garantere kvalitet ...

Page 429: ... Undergruppsbenämning Bezeichung der Untergruppe Dénomination de sous ensemble Descripción de subconjunto Subassembly no Undergruppsnr Untergruppe Nr Nº de sous ensemble Número de subconjunto See page Se sidan Siehe Seite Vòir page Véase la página Fig ref Figurhänvisning Bildhinweise Réf de fig Referencia de figura Product name Produktnamn Produktname Nom du produit Nombre del producto Exchange ne...

Page 430: ...o subconjunto Alaryhmän nimitys Subassembly no Группа Nr sottogruppo Número de subconjunto Alaryhmän no See page См страницу Vedi pagina Véase la página Ks sivu Fig ref Ссылка на зскиз Rif fig Referencia de figura Kuvaviite Product name Наименование артикула Nome prodotto Nombre del producto Tuotteen nimi Exchange necessitates rebalancing of bowl Замена требует балансировки барабана La sostituzion...

Page 431: ...ssembly description Περιγραφή υποσυγκροτήματος Subgroepbenamning Undergruppsbetegnelse Subassembly no Αριθμός υποσυγκροτήματος Subgroepnr Undergruppenr See page Βλέπε σελίδα Zie blz Se side Fig ref Παραπομπή σε εικόνα Afb ref Figurhenvisning Product name Ονομασία προϊόντος Produktnaam Produktnavn Exchange necessitates rebalancing of bowl Ανταλλαγή απαιτεί επαναρρύθμιση ισορροπίας του τύμπανου Verv...

Page 432: ...221711 18 Screw 1 21 223412 48 O ring 1 22 566788 01 Seal ring 2 23 565056 04 Deflector ring 1 Brass 23 598744 01 Deflector ring 1 SS 24 223406 29 O ring 2 25 560202 01 Pipe 1 26 223404 20 O ring 1 27 539418 02 Elbow 1 28 526352 06 Bushing 1 29 564591 02 Operating water cover 1 30 41456 Washer 3 31 221040 46 Screw 3 32 566718 82 Monitoring kit for speed 1 See page 16 34 221716 23 Screw 1 35 561773...

Page 433: ...2 Machine bottom part 6 10 35 36 37 34 38 56 32 2 4 3 1 1A 9 8 12 13 11 5 52 53 51 5 A 16 14 15 17 18 19 29 24 23 20 21 26 25 30 31 49 27 28 54 55 22 20A A 38B 38A 38C 38D 58 59 57 60 2052S 13 433 ...

Page 434: ...223642 38 Snap ring 1 5 580044 02 Top bearing housing 1 6 562109 03 Helical spring 3 7 562110 02 Composite spring 6 8 560406 01 Plug 6 9 564149 01 Spindle pulley 1 10 548744 03 Self align roller bearing 1 11 545869 03 Nozzle Ø 1 5 mm 2 13 586513 01 Oil mist generator 1 14 565057 02 Fan 1 Brass 14 599092 01 Fan 1 Steel 15 580042 01 Air deflector 1 16 221716 22 Screw 3 17 223406 29 O ring 2 99 90007...

Page 435: ...2 1 Driving device vertical 2 Machine bottom part 16 2 1 4 14 17 3 6 7 8 5 15 9 10 13 11 2275B 15 435 ...

Page 436: ...d Machine unit number or Subassembly description 566718 Ref Part No Description 82 Notes Quantity 1 562902 81 Sensor with support 1 3 552870 41 Tube gland angle 90 degr 1 5 556416 14 Protective tube 1 6 566692 80 Junction box 1 16 436 ...

Page 437: ...2 2 Monitoring kit for speed 2 Machine bottom part 1 6 5 3 1904E 17 437 ...

Page 438: ...8011 O ring 1 10 579464 02 Operating water ring 1 11 546095 77 O ring 1 12 574233 01 Discharge slide 1 13 565295 02 Rectangular ring 1 14 561897 01 Nut 1 15 586120 80 Distributor 1 15A 560652 02 Guide rib 1 15B 73103 Grooved pin 4 16 561804 80 Bowl disc 96 16 1 561804 80 Bowl disc 2 16 5 561804 80 Bowl disc 5 17 563114 02 Top disc 1 19 564405 01 Bowl hood 1 20 564406 01 Seal ring 1 21 546198 15 O ...

Page 439: ...3 Separator bowl 22 22A 19 20 21 17 26 16 16 1 16 5 15 15A B 23 14 12 13 11 1 1A C 27 2 9 6 4 5 25 7 10 8 8 8 1 3 24 2593A 19 439 ...

Page 440: ...socket set screw 1 7 563317 01 Splash sealing 1 8 566022 02 Support ring 1 9 561957 01 Height adjusting ring 3 10 567078 80 Frame hood 1 10A 567078 02 Frame hood 1 10B 561208 01 Spring holder 1 10C 561960 01 Support sleeve 1 10D 221711 13 Screw 1 10E 221716 09 Screw 1 11 221036 27 Screw 4 14 562844 80 Arm 1 15 566407 03 Spring 1 16 223406 30 O ring 2 17 223406 20 O ring 2 18 563457 80 Connection h...

Page 441: ...4 Inlet and outlet device 20 19 1 17 16 3 5 6 24 27 25 C A B 4 18 9 8 26 10 7 15 14 11 A D C E B 2052T 21 441 ...

Page 442: ... 221721 37 Screw 4 4 3 564594 80 Centrifugal clutch 1 See page 24 3 564594 81 Centrifugal clutch 1 See page 24 4 221045 60 Screw 1 1 5 223107 35 Spring washer 1 1 6 547837 01 Washer 1 1 7 563468 01 Flat belt 1 7 563469 01 Flat belt 1 8 221040 58 Screw 4 4 9 41456 Washer 8 8 10 35120 Nut 4 4 11 579817 80 Clutch cover 1 1 12 221040 42 Screw 3 3 13 41456 Washer 3 3 22 442 ...

Page 443: ...5 Belt driving device 1524E 23 443 ...

Page 444: ... 50 Hz 60 Hz 1 564589 02 Motor belt pulley 60 Hz 1 1 564590 02 Motor belt pulley 1 2 548051 49 Ball bearing 2 2 3 547833 01 Spacing ring 1 1 4 66251 Snap ring 1 1 5 564102 80 Coupling hub 1 5 564103 80 Coupling hub 1 6 223641 18 Snap ring 1 1 8 564557 80 Friction block 5 3 9 549325 01 Cover 1 1 10 223641 20 Snap ring 1 1 24 444 ...

Page 445: ...5 1 Centrifugal clutch 5 Belt driving device 1523D 25 445 ...

Page 446: ... 66169 Drive screw 4 3 1270019 Set of safety labels 1 4 577803 01 Name sign 1 4 591263 01 Name sign 1 DNV approval see order 5 66169 Drive screw 4 6 553171 01 Label 50 Hz 1 6 553272 01 Label 60 Hz 1 7 555529 01 Plate with arrow 1 8 1270001 Lifting instruction 1 9 554214 02 Cable tie 1 11 66169 Drive screw 4 12 9006227 Separator checkpoints 1 26 446 ...

Page 447: ...6 Set of plates 2161E 27 447 ...

Page 448: ...Subassembly description 566727 Ref Part No Description 03 Notes Quantity 1 570142 01 Inductive analogue sensor 1 2 561773 04 Sensor holder 1 Stainless steel 2 561773 08 Sensor holder 1 Brass 4 552870 21 Tube gland straight 1 6 556416 18 Protective tube 1 28 448 ...

Page 449: ...7 Monitoring kit for vibration 1769F 29 449 ...

Page 450: ...sc stack 9A 575135 80 Compressing tool 1 9B 575139 02 Clamp 3 9C 575098 01 Screw 3 9D 221045 52 Screw 3 9E 561551 01 Screw 3 10 563084 80 Puller 2 Neck bearing cover 10A 221040 05 Screw 1 10B 221035 46 Screw 1 11 260154 01 Lifting eye bolt 2 12 561607 81 Puller 1 Discharge slide 12A 562249 01 Support ring 1 12B 221040 43 Screw 1 13 221706 05 Screw 6 Lock ring Bowl body 14 548043 01 Mounting tool 1...

Page 451: ...8 Set of tools 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 A A B A 17 A B 18 19 A B C E D 16 20 2043D 31 451 ...

Page 452: ...20 O ring 2 Inlet and outlet pipe Connecting housing 12 260190 05 O ring 1 Frame hood Frame bottom part 13 552766 07 Washer 2 Frame bottom part Plug 15 9000764 02 Lubriaction Paste G n Plu 1 16 223404 05 O ring 1 Oil pin Plug 17 221706 05 Screw 6 Lock ring Bowl body 18 66414 Hexagon socket head key 1 Lock ring Bowl body 19 566408 03 Plain bearing bushing 2 Paring tube 20 563317 01 Splash sealing 1...

Page 453: ...9 Inspection kit 3 2 4 1 5 6 8 7 21 22 13 16 13 11 10 9 12 23 19 20 17 18 24 25 29 26 27 27 2551D 33 453 ...

Page 454: ...2 38 Snap ring 1 1 Top bearing seat Ball bearing 15 562109 03 Helical spring 3 3 Top bearing seat Top bering housing 16 562110 02 Composite spring 6 6 Top bearing seat Plug 17 548744 03 Self align roller bearing 1 1 Bowl spindle Bottom bearing housing 19 545869 03 Nozzle Ø 1 5 mm 1 1 Operating slide 20 597777 05 Guide ring 1 1 Bowl body Operating slide 22 548051 49 Ball bearing 2 2 Coupling hub Mo...

Page 455: ...10 Overhaul kit 18 20 12 8 6 9 5 4 31 29 3 2 11 17 19 16 15 14 13 30 1 27 28 24 23 22 22 25 26 7 2637A 35 455 ...

Page 456: ... 11 Lifting tool Separator Machine unit number or Subassembly description 563453 Ref Part No Description 80 Notes Quantity 2 563454 01 Lug 4 3 221035 53 Screw 4 5 27345 Nut M8 4 6 260236 03 Shackle 2 36 456 ...

Page 457: ...11 Lifting tool 1686E 37 457 ...

Page 458: ...61724 01 Cap nut 1 Bowl spindle Bowl body 19 561954 01 Axial support 1 Inlet and outlet device Pipe 20 260080 61 Hexagon socket set screw 1 Inlet and outlet device Axial support 21 561957 01 Height adjusting ring 3 Frame hood Height adjusting ring 22 561208 01 Spring holder 1 Frame hood 23 221036 27 Screw 4 Frame hood Height adjusting ring 24 562844 80 Arm 1 Frame hood Paring tube 25 561962 01 Was...

Page 459: ...12 Support kit 10 35 13 29 9 8B 8A 8 7 6 5 2 1 33 34 31 32 30 28 27 24 23 22 4 21 19 20 26 25 16 15 36 3 35 2274D 39 459 ...

Page 460: ...Machine unit number or Subassembly description 570819 Ref Part No Description 03 Notes Quantity 1 552870 21 Tube gland straight 1 2 566054 01 Limit switch 1 3 556416 25 Protective tube 1 4 532333 03 Clamp 1 5 221125 20 Screw 1 40 460 ...

Page 461: ...13 Cover interlocking kit 1 2 3 4 5 1769E 41 461 ...

Page 462: ... Hydraulic tool kit Machine unit number or Subassembly description 574986 Ref Part No Description 04 Notes Quantity 1 574618 80 Hydraulic components 1 See page 44 2 574626 82 Hydraulic tool 1 See page 46 42 462 ...

Page 463: ...14 Hydraulic tool kit 1 3 2047D 43 463 ...

Page 464: ...S 946 14 1 Hydraulic components Machine unit number or Subassembly description 574618 Ref Part No Description 80 Notes Quantity 1 574618 01 Pump with hose 1 2 574618 02 Hydraulic cylinder 1 44 464 ...

Page 465: ...14 1 Hydraulic components 14 Hydraulic tool kit 1 2 2050A 45 465 ...

Page 466: ... number or Subassembly description 574626 Ref Part No Description 82 Notes Quantity 1 571628 01 Stud bolt 1 2 574627 03 Sleeve 1 3 571627 01 Holder 1 4 221803 35 Nut M20 1 5 574954 01 Sleeve 1 6 571620 01 Plate 1 7 571622 01 Screw 3 46 466 ...

Page 467: ...14 2 Hydraulic tool 14 Hydraulic tool kit 2047A 47 467 ...

Page 468: ...Subassembly description 9007346 Ref Part No Description 80 Notes Quantity 1 548051 04 Ball bearing 1 D end 2 548051 04 Ball bearing 1 ND end 3 9001768 01 Fan 1 4 9007344 02 Spring washer 1 5 9001768 03 O ring 1 D end 6 9001768 03 O ring 1 ND end 48 468 ...

Page 469: ...15 Motor service kit 2585B 49 469 ...

Page 470: ...Subassembly description 9001769 Ref Part No Description 80 Notes Quantity 1 548051 69 Ball bearing 1 D end 2 548051 04 Ball bearing 1 ND end 3 9001768 01 Fan 1 4 9001768 02 Spring washer 1 5 9001769 01 O ring 1 D end 6 9001768 03 O ring 1 ND end 50 470 ...

Page 471: ...16 Motor service kit 2585B 51 471 ...

Page 472: ...6 30 20 16 223406 30 32 10 223412 23 12 16 223412 23 34 5 223412 48 12 21 223412 48 34 6 223412 48 34 31 223412 48 12 54 2234121 38 34 2 2234121 38 12 9 2234121 40 12 13 2234121 40 34 3 223641 18 24 6 223641 18 34 24 223641 20 24 10 223641 20 34 26 223642 38 34 14 223642 38 14 4 2522302 09 12 1A 260080 61 20 6 260080 61 38 20 260104 22 32 24 260154 01 30 11 260190 05 20 25 260190 05 32 12 260236 0...

Page 473: ... 22 7 563469 01 34 28 564102 80 24 5 564103 80 24 5 564149 01 14 9 564405 01 18 19 564406 01 18 20 564406 01 32 7 564557 80 24 8 564557 80 34 25 564589 02 24 1 564590 02 24 1 564591 02 12 29 564594 80 22 3 564594 81 22 3 565056 04 12 23 565056 04 38 5 565057 02 14 14 565295 02 32 6 565295 02 18 13 565308 01 32 3 565308 01 18 6 565378 01 38 33 565378 01 12 52 565673 01 30 16 565673 02 30 16 565679 ...

Page 474: ...77 05 34 20 598744 01 12 23 598744 01 38 5 599092 01 14 14 66169 26 2 66169 26 5 66169 26 11 66251 24 4 66251 34 23 66414 30 17 66414 32 18 68011 32 4 68011 18 9 68564 18 1C 70490 12 3 73103 18 15B 74067 34 11 74067 12 36 9000764 02 32 15 9000794 01 14 99 9001768 01 48 3 9001768 01 50 3 9001768 02 50 4 9001768 03 48 5 9001768 03 48 6 9001768 03 50 6 9001769 01 50 5 9006114 01 34 1 9006227 26 12 90...

Page 475: ...31 Configuration no 108918 25 Flex Module with Separator Type S 946 Main Power Supply 460 V 60 Hz Chapter 9 Optional Equipment Specification of equipment as delivered for the above mentioned order 9 1 Feed Pump ALP 75 9 2 Heatpac CBM 30 40 9 3 Sludge Removal Kit 475 ...

Page 476: ...Marine Diesel Equipment Oil Feed Pumps ALP 15 85 X02 7 35 1A Product No Printed Book No Feb 2014 9006009 02 V5 Component Description 476 75 ...

Page 477: ...ssions or suggestions for improvement of this publication would be gratefully appreciated Copies of this publication can be ordered from your local Alfa Laval company Published by Alfa Laval Tumba AB Marine Diesel Equipment S 147 80 Tumba Sweden Copyright Alfa Laval Tumba AB 2014 The original instructions are in English 477 ...

Page 478: ...ault Finding 19 4 1 Possible faults 19 4 2 Troubleshooting 19 5 Maintenance 23 5 1 Safety instructions on maintenance and repairs 23 5 2 Required maintenance 24 5 3 Mechanical seal 24 5 4 Ball bearing 24 5 5 Cleaning the leakage vent hole 25 5 6 Replacing the elastomer coupling 26 5 7 Replacing the mechanical seal and ball bearing 29 5 7 1 Dismantling 29 5 7 2 Assembly 31 6 Technical Data 33 6 1 O...

Page 479: ...illing the pump 44 7 6 3 Checking the direction of rotation 45 7 6 4 Taking the pump out of operation 47 7 6 5 Recommissioning the pump 48 8 Transportation storage and disposal 49 8 1 Unpacking and checking the state of delivery 49 8 2 Lifting the pump pump unit 50 8 2 1 Pump 51 8 2 2 Pump unit 51 8 3 Storage 51 8 3 1 Preservation 52 8 3 2 Preserving the internal surfaces of the pump 52 8 3 3 Pres...

Page 480: ...vice and maintenance Not following the instructions can result in serious accidents In order to make the information clear only foreseeable conditions have been considered No warnings are given therefore for situations arising from the unintended usage of the machine and its tools 5 480 ...

Page 481: ... 481 ...

Page 482: ... with Machinery Directive 2006 42 EC and furthermore declares that if motorised the following applicable directives have been used Directive 2006 95 EC on low voltage EMC Directive 2004 108 EC The technical construction file for this machinery has been drawn up The signer of this declaration is authorized to compile the technical file Manager Product Center Fluid Handling Bjarne Søndergaard Title ...

Page 483: ...1 EC Declaration of Conformity 483 ...

Page 484: ... an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTE NOTE indicates a potentially hazardous situation which if n...

Page 485: ...2 Warning signs in text 485 ...

Page 486: ...ations on the machine plate please contact the manufacturer The pump is specifically configured for the operating pressure stated in chapter 5 3 1 1 Safety information The following general safety instructions must be observed No liability is accepted for damage arising through non observance of the operating instructions Read the operating instructions carefully and observe them The operator owne...

Page 487: ...lacement effect results from the meshing of three rotating screws and the enclosing housing The radial support of the screws is effected by the sliding contact in the housing which requires lubrication by the pumped liquid Screw pumps are therefore not suitable for dry running and can only be used up to specific pressure and viscosity limits Due to the narrow tolerances pumping of suspended solids...

Page 488: ... in a matter of minutes 3 2 2 Direction of Rotation Standard direction of rotation clockwise viewed from the drive marked on the housing by two arrows see 7 6 3 Checking the direction of rotation on page 45 Flow direction marked on the housing by two arrows see 7 6 3 Checking the direction of rotation on page 45 3 2 3 Pressure relief valve The integrated pressure relief valve prevents very high pr...

Page 489: ...eal 2 Screw plug 11 Pump 3 Idle screw 12 adapter housing 4 End cover 13 Motor 5 Sealing sleeve 14 adapter housing foot 6 Ball bearing 15 Motor side coupling half 7 Main screw 16 Coupling intermediate ring 8 Pump housing 17 Pump side coupling half 9 Leakage vent hole 14 489 ...

Page 490: ...3 Function Description X027101A Fig 1 Structure of ALP pump X027111A Fig 2 Structure of ALP pump with elastomer coupling and motor 15 490 ...

Page 491: ... End cover 817 Ball bearing 131 Pump housing 859 Adapter sleeve 165 1 Screw plug 866 Feather key 165 2 Screw plug 894 Hexagon nut 180 Adapter housing 914 1 Socket screw 222 Flat gasket 914 2 Socket screw 305 Valve body 914 3 Socket screw 457 Mechanical seal 914 4 Socket screw 471 Circlip 472 Circlip Only for sizes 15 20 In case of wear of the screw set it is recommended to replace the pump 16 491 ...

Page 492: ...3 Function Description 070 914 1 165 1 222 131 165 2 305 501 859 866 661 457 739 1 043 817 056 471 472 056 8 X027151A Fig 1 ALP 15 85 X027161A Fig 2 Completion elastomer coupling ALP 15 85 17 492 ...

Page 493: ...3 Function Description 493 ...

Page 494: ...in the suction pipe and open them if necessary 2 Suction valve or pipe obstructed Check the suction valve and pipe for clear passage 3 Suction pipe or shaft seal leaks Check suction pipe or shaft seal for leaks Pay particular attention to leakage at valves and connection points If necessary replace parts Reinstall the pump at lower suctiion head level or Reduce pipe length or Increase pipe diamete...

Page 495: ...alve leaks Clean the pressure relief valve and reseat if necessary Check screw set and housing and replace the pump if necessary 16 Advanced wear of rotating pump components Replace the seal and check the pumped liquid for abrasive content 17 Advanced wear of sealing surfaces Support the weight of the pipe system 18 Pump distorted Loosen pipework connections and mount stress free see 7 3 Piping on...

Page 496: ...e If necessary replace the pump 27 Differential pressure is too high and has overloaded the screws Reduce the differential pressure Dismantle the pump and clean it Smooth the superficial damage to the housing and the rotating parts with an oilstone If necessary replace the pump 28 Viscosity is too low and has overloaded the screws Increase the viscosity for example by reducing the operating temper...

Page 497: ...4 Fault Finding 497 ...

Page 498: ...thing during all the work Switch off the motor and secure it against being switched back on Before beginning the work let the pump the pump unit cool down to the ambient temperature and remove it from the pipe system Ensure that the pump is depressurized Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible manner Also observe the general drawings during all t...

Page 499: ...sing Replace the pump Tab 1 Check table for required maintenance 1 Check the pump visually and acoustically every four weeks 2 Check for signs of wear as listed in the table above and eliminate the cause 5 3 Mechanical seal Mechanical seals are subject to a natural wear that depends strongly on the respective conditions of use General statements about the durability can therefore not be given In c...

Page 500: ...leaning the leakage vent hole CAUTION Bearing damage due to insufficient drainage of shaft seal leakage Check permeability of leakage vent hole regularly 1 Remove any drainage line that is connected 2 Check the permeability of the drainage line Observe whether a small amount of added liquid drains or Check visually or Insert an arbor made of a soft material wood plastic etc see Fig 1 3 Clean the l...

Page 501: ...he pump pump unit fall Lift large pumps pump units using the crane Do not stand under raised loads 1 Before dismantling close the suction and pressure connection of the pump with protective covers 2 Loosen the connecting screws 914 3 between the motor 529 and adapter housing 180 and lift the pump with adapter housing from the motor see Fig 2 3 Loosen the fixing screw on the motor side coupling hal...

Page 502: ...levers Installing the coupling 1 Slide the pump side coupling half 052 1 onto the shaft until it stops Heating the coupling to 80 100 C facilitates mounting Tighten the fixing screw of the coupling half 2 Place the adapter housing 180 on the pump and tighten the connecting screws 914 2 see Fig 4 X027201A 3 Measure and write down the distance X between the face of the coupling and the connecting su...

Page 503: ...sert the coupling intermediate ring 525 and tighten the fixation screw at the coupling half 052 2 7 Place the pump with the adapter housing on the motor 8 Turn the pump slightly until the teeth of the pump side coupling half 052 1 mesh correctly into the spaces of the coupling intermediate ring 525 spaces of the spider 052 3 9 Tighten the connecting screws 914 3 between the motor and adapter housi...

Page 504: ...Open end wrench Extractor 1 Remove the circlip 472 screw plug 165 1 and feather key 866 see Fig 7 X027231A 2 Screw in the disassembly tool A by using the open end wrench B see Fig 8 The main screw will be pressed out of the pump housing Remove the main screw from the pump housing X027241A 3 Remove the circlip 471 and supporting ring 056 see Fig 9 X027251A 29 504 ...

Page 505: ...10 X027261A 5 Remove L ring 058 supporting ring 056 sealing sleeve 043 along with o ring 739 1 and stationary seal ring of the mechanical seal along with o ring see Fig 11 457 043 056 739 1 Fig 11 8 X027271A 6 Remove the remaining parts of the mechanical seal 457 from the main screw see Fig 11 30 505 ...

Page 506: ...e position of the clearance for the adapter sleeve 859 into account X027281A 3 Slide the remaining parts of the mechanical seal 457 onto the main screw see Fig 13 457 Fig 13 X027561A 4 Slide the new o ring 739 1 onto the sealing sleeve 043 and slide the sealing sleeve onto the main screw see Fig 14 Mount the supporting ring 056 and the L ring 058 043 056 739 1 Fig 14 8 X027301A 5 Press the ball be...

Page 507: ...sealing sleeve into the pump housing until the main screw engages into the idle screws see Fig 16 In doing so turn the main screw and take the position of the clearance for the adapter sleeve into account X027321A 7 Mount the screw plug 165 1 circlip 472 and feather key 866 see Fig 17 X027331A 32 507 ...

Page 508: ...2 900 at 60 Hz 3 500 6 2 Required Net Positive Suction Height NPSH values The following table lists the required NPSH values during operation with a low volatile liquid such as lubricating oil or hydraulic liquid When liquids have a readily volatile component content the required NPSH values increase notably when the pumped liquid contains water e g heavy fuel oil the values in the table have to b...

Page 509: ... 4 0 6 2 0 6 2 0 2 6 3 0 37 2 0 37 2 0 2 9 3 4 152 2 0 2 4 2 7 152 2 3 2 5 3 3 4 1 ALP 20 380 2 2 2 4 3 2 3 8 ALP 75 380 2 7 3 0 4 4 5 0 6 2 0 6 2 0 2 8 3 4 37 2 0 37 2 0 3 1 3 8 152 2 0 2 3 2 6 152 2 4 2 6 3 8 4 6 ALP 30 380 2 2 2 4 3 1 3 7 ALP 85 380 2 8 3 1 4 6 5 8 6 2 0 2 3 37 2 0 2 1 2 6 152 2 0 2 8 3 5 ALP 40 380 2 5 2 7 4 0 4 8 6 3 Weights ALP weights with elastomer coupling Motor size Size...

Page 510: ...mp unit mm LP LL LM LG L5 L5 1 L6 L7 L8 L9 H1 H2 B2 B3 S4 15 20 80 157 110 60 90 21 89 12 112 210 180 Ø11 90 157 118 60 90 19 99 12 112 210 180 Ø11 100 112 157 128 185 230 106 109 15 155 250 215 14x24 30 40 80 208 110 60 90 21 97 12 112 210 180 Ø11 90 208 118 60 90 19 107 12 112 210 180 Ø11 100 112 208 128 185 230 106 117 15 155 250 215 14x24 55 85 90 226 118 60 90 19 114 12 112 210 180 Ø11 100 11...

Page 511: ...6 Technical Data 6 4 1 Dimension drawing of ALP pump and pump unit X027341A 36 511 ...

Page 512: ...0 75 934 1 014 1 038 1 067 1 096 1 121 1 144 1 149 1 158 ALP 40 2 2 4 606 4 713 4 746 4 784 4 822 4 856 4 887 4 893 4 905 1 1 2 129 2 236 2 268 2 307 2 345 2 379 2 409 2 416 2 427 0 75 1 244 1 351 1 384 1 422 1 460 1 494 1 525 1 531 1 543 ALP 55 3 6 326 6 464 6 505 6 555 6 604 6 647 6 687 6 695 6 710 2 2 2 939 3 077 3 118 3 168 3 217 3 260 3 300 3 308 3 323 1 5 1 729 1 867 1 909 1 958 2 008 2 051 ...

Page 513: ... 5 668 5 775 5 807 5 846 5 884 5 918 5 948 5 955 5 966 1 1 2 659 2 767 2 799 2 838 2 876 2 910 2 940 2 947 2 958 0 75 1 598 1 705 1 738 1 776 1 814 1 848 1 879 1 885 1 896 ALP 55 3 7 777 7 915 7 957 8 006 8 056 8 099 8 138 8 146 8 161 2 2 3 665 3 803 3 844 3 893 3 943 3 986 4 026 4 033 4 048 1 5 2 213 2 351 2 393 2 442 2 491 2 535 2 574 2 582 2 597 ALP 75 3 10 050 10 212 10 261 10 318 10 376 10 42...

Page 514: ...os Designation Type 1 Model ALP 2 Size Corresponds to flow rate in l min at 1 450 min 1 3 Shaft seal B Mechanical seal of hard material D Magnetic coupling 4 Pressure stage A 6 bar overflow valve B 10 bar A Pump with free shaft end B With adaptor housing and coupling flange mounted C With adaptor housing coupling and foot foot mounted D B with motor 5 Completion E C with Motor 6 Frame size 080 090...

Page 515: ...6 Technical Data 515 ...

Page 516: ...an be carried out easily 7 1 Installing the pump The pump must be installed to meet the following demands The pump must be mounted on a solid foundation and on a drip tray or in a cofferdam The pump can be operated vertically or horizontally However if vertically mounted the pump should not be mounted above the motor since pumped liquid could enter the motor should a leak occur The pump must be ea...

Page 517: ...mage through impurities in the pipe system 1 During welding work attach protective covers in front of the connecting flanges 2 Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and the pump 3 After the connecting work clean the pipe system thoroughly see 7 6 1 Cleaning the pipe system on page 44 42 517 ...

Page 518: ...e should be arranged so it forms a liquid trap together with the pump The liquid trap should secure that the pump is kept at least half filled with oil at stand still Shut off valves must be installed on both sides of the pump The suction line should be dimensioned for an oil flow speed between 0 5 and 1 2 m s and the pressure line for 1 to 3 m s The suction line must be equipped with a port near ...

Page 519: ...followed when the pump is taken into operation after installation and whenever the pump casing has been emptied of oil for example when the pump has been dismantled WARNING Entrapment hazard Do not start filling the pump unless the power is switched off 1 Remove the fan cover from the electric motor 2 Turn the pump shaft or the fan impeller of the motor This tests that the pump runs smoothly If th...

Page 520: ...ng the motor fan in the direction indicated by the rotation arrow on the motor or connection flange There are arrows for inlet and outlet directions on the pump Do not mix them up with the rotation arrow 9 When the pump is filled close the filling port and refit the fan cover 10 Check that all valves necessary for operation are open X027371A 1 Suction connection 2 Pressure connection 3 Vent hole 7...

Page 521: ...n immediately CAUTION Dry running can damage pump equipment Ensure that the pump is filled properly If the pump does not deliver after 10 15 seconds abort commissioning 1 Ensure that the pump is filled In case of doubt prelubricate the pump and mechanical seal by pouring in liquid via the vent hole see 5 5 Cleaning the leakage vent hole on page 25 2 Switch on the pump The pump will deliver when th...

Page 522: ...hing during all the work Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible manner Carry out the following measures during shutdowns Pump is Measure shut down for longer period Depending on pumped liquid see below drained Close the pressure side and suction side shut off devices dismantled Disconnect the motor from the power supply and secure it against bei...

Page 523: ...ive burden Preserve the pump Measures depending on behavior of the pumped liquid Drain the pump via the pressure and suction line and vent screw 7 6 5 Recommissioning the pump Carry out all the steps as for the commissioning process see 7 6 Commissioning on page 44 48 523 ...

Page 524: ...checking the state of delivery 1 Upon delivery unpack the pump pump unit and check for transport damage 2 Report any transport damage immediately to the manufacturer 3 Dispose of packing materials in accordance with the locally applicable regulations 49 524 ...

Page 525: ...ment The used hoisting equipment conforms to the local regulations and health and safety regulations D ANGER Risk of injury and or damage to equipment should the pump pump unit fall Use intact and correctly dimensioned hoisting equipment suitable for the weight to be lifted Fasten the hoisting equipment in accordance with figures 1 or 2 50 525 ...

Page 526: ...ures to prevent the pump unit from tilting 2 Secure the slings against slipping for example with screwed in eye bolts 3 Attach the slings onto the crane hook and lift the pump unit 8 3 Storage During the test run the internal components of the pump are wetted with test oil which has a preservative effect The pipe connections are fitted with protective covers The external components of the pump are...

Page 527: ...sin free oil into the pressure connection until it reaches approx 2 cm under the pressure flange while slowly turning the main screw against the direction of rotation 3 Close the pressure connection of the pump with a blind flange After about 6 months storage check the oil level in the pump and top up if necessary 8 3 3 Preserving the external surfaces of the pump Aids Preservative e g Castrol Rus...

Page 528: ...mp Collect the emitted oil safely and dispose of it in an environmentally compatible manner 1 Clean the outside of the pump with solvents if necessary using a steam jet cleaning device 2 Remove the blind flange on the pressure side 3 Drain the pump collecting the preservative oil in a suitable vessel 4 Remove the blind flange on the suction side 5 To remove the residual oil rinse the pump with the...

Page 529: ...harging pumped liquid and oil and dispose of it in accordance with the locally applicable regulations Neutralize any residues of the pumped liquid 1 Disassemble the pump 2 Clean residues of the pumped liquid from the individual parts 3 Separate sealing elements made of elastomers and ceramics SiC from the pump and dispose of them in the residual waste 4 Recycle metal parts 54 529 ...

Page 530: ...n A Commissioning kit 1 457 1 O ring stationary seal ring 1 457 2 O ring rotary seal ring 1 472 Circlip 1 471 Circlip 1 056 Supporting ring 1 056 Supporting ring 1 058 L ring 1 Disassembly tool X027121A Only for sizes 15 20 B Overhaul kit 1 457 Mechanical seal 1 222 Flat gasket 1 817 Ball bearing 1 739 1 O ring 1 472 Circlip 1 471 Circlip 1 056 Supporting ring 1 056 Supporting ring 1 058 L ring 1 ...

Page 531: ... 13 M4 2 9 4 1 2 3 3 2 G1 4 30 M5 6 0 8 0 4 8 6 0 3 9 3 5 4 7 G3 8 60 M6 9 5 14 7 6 10 3 6 9 6 8 G1 2 80 M8 23 1 34 18 4 25 17 16 22 G3 4 120 M10 46 68 36 8 47 33 32 43 G1 200 M12 80 117 64 84 56 56 75 G1 1 4 400 M14 127 186 101 133 89 G1 1 2 450 M16 194 285 155 204 136 135 180 M18 280 390 224 284 191 M20 392 558 313 399 267 280 370 M24 675 960 540 687 460 455 605 reduced tightening torque when sc...

Page 532: ...Marine Diesel Equipment Heating System Kit including Heatpac CBM Brazed plate heat exchanger P 00 32 61 A Product No Printed Book No 583382 11 to 20 Apr 2014 9007143 02 V5 Component Description 532 ...

Page 533: ...ions or suggestions for improvement of this publication would be gratefully appreciated Copies of this publication can be ordered from your local Alfa Laval company Published by Alfa Laval Tumba AB Marine Diesel Equipment S 147 80 Tumba Sweden Copyright Alfa Laval Tumba AB Apr 2014 The original instructions are in English 533 ...

Page 534: ... 1 System Design 21 6 2 Heater Mounting 22 6 3 Installation of Ancillary Components 23 6 4 Installation Drawings 24 6 4 1 Heatpac CBM Heating Kit for Separator System 24 6 4 2 Installation drawing steam system 25 6 4 3 Installation drawing thermal oil hot water system 26 6 4 4 Heatpac CBM connection kit for CIP unit 27 7 Spare Parts 29 8 Ancillary Equipment 31 8 1 Steam Regulating Valve 31 8 1 1 A...

Page 535: ...ty Valve 48 8 2 1 Application 48 8 2 2 Design 48 8 2 3 Working Principle 48 8 2 4 Technical Data 49 8 2 5 Dimensions 49 8 3 Steam Shut off Valve 50 8 3 1 Technical Data 50 8 4 Steam Trap 52 8 4 1 Technical Data 52 8 5 Vacuum Breaker 53 8 5 1 Technical Data 53 8 6 Inlet Strainer 54 8 6 1 Technical Data 54 535 ...

Page 536: ...clear only foreseeable conditions have been considered No warnings are given therefore for situations arising from unintended usage of the machine and its tools A summary of the safety information is found in the Safety chapter under divider 1 Study instruction manuals and observe the warnings before installation operation service and maintenance Not following the instructions can result in seriou...

Page 537: ...537 ...

Page 538: ...g system is primarily for heating of mineral oils The heating medium can be steam hot water or thermal oil The main components in the heating system are supplied separately The heating system is suitable for both separator systems and fuel conditioning systems 538 ...

Page 539: ...t heat transfer is generated by allowing the two liquids to flow in opposite directions The heater has a manufacturing plate which can be found behind the cover plate between the connection flanges When contacting Alfa Laval please state the heater type and manufacturing number P0 0 35 31 A Heat transfer priciple 2007 30 X0 24 6 22 B 1 Manufacturer manufacturing year 2 Manufacturing serial number ...

Page 540: ...e heater must not be used without the insulated protection cover This shields the hot surfaces and also acts as a safety cover in the unlikely event of leakage 1 Make sure that all valves in the oil line are fully open 2 Start the oil feed pump 3 If necessary vent air from the heater through the safety valve 4 Start the heater controller 5 Open the heating media supply and outlet valves 6 Check th...

Page 541: ...ver regularly check the pressure indicators if installed before and after the heater The pressure difference indicates the pressure drop in the heater If the pressure drop increases to more than approx 0 5 1 bar the heater is starting to clog and needs to be cleaned see Maintenance CAUTION Burn Hazard To prevent pressure or heat shocks in the system adjustment of the flow rate must be carried out ...

Page 542: ...Adjust process condition Regulating valve not functioning Check fuse in the control unit or check for broken wiring Check the regulating valve Deposits inside the heater Clean the heater see the maintenance chapter Incorrect installation Check if the heater is connected according to the installation drawings see Technical data Steam trap not functioning By pass the steam trap for a while to ensure...

Page 543: ...HEATING SYSTEM KIT 3 FAULT FINDING 12 9007143 02 543 ...

Page 544: ...uld be carried out every six months or at other intervals based on experience If the heating medium is steam or hot water the heating cirquit must also be cleaned Recommended cleaning agents For fuel oil heater Alfa Laval fuel oil liquid Art No 1763500 02 For lube oil heater Alfa Laval lube oil liquid Art No 1762852 01 The Alfa Laval cleaning liquids are specially suitable for the materials used i...

Page 545: ... carried out as follows 1 Disconnect the heater 2 Drain the heater 3 Flush the heater through with fresh water 4 Drain the heater from water 5 Fill the heater with hot cleaning liquid 50 70 C Use the type and concentration required for the deposits present 6 Let the liquid stay in the heater for at least 60 minutes If possible let the cleaning liquid circulate in the heater 7 Drain the cleaning li...

Page 546: ... Connect a hose between the highest connection on the CIP unit and the heat exchanger oil outlet 2 4 Connect a hose to the heat exchanger oil inlet and put the free end into the CIP tank 1 5 Plug the two remaining connections on the CIP 3 Make sure that the bottom valve on the CIP tank is closed Close the valve in the CIP tank also 6 Fill the CIP with hot water 50 70 C and cleaning liquid at recom...

Page 547: ...TEM KIT 4 MAINTENANCE 16 9007143 02 14 Empty the CIP tank by opening the CIP drain valve 15 Disconnect the CIP Reconnect the CBM heater using new gaskets NOTE Take care not to reinstall the heater upside down 547 ...

Page 548: ...dium in condensate 8 8 9 2 0 01 mg l Water pH value Shall be neutral to minimize corrosion risk Thermal oil The thermal oil must be highly resistant to oxidation and thermal desintegration It must also have good corrosion protection properties Materials Plates and connections Brazing material Insulation Cover Stainless steel AISI 316 Copper Mineral wool 30 mm Aluminium Mounting style for hot water...

Page 549: ...0 5 litres 10 kg 583382 12 CBM 30 40 160 1 0 litres 13 kg 583382 13 CBM 30 60 260 1 6 litres 15 kg 583382 14 CBM 30 80 260 2 1 litres 17 kg 583382 15 CBM 30 100 310 2 7 litres 19 kg X0 0 65 63 A Ref 9007089 Rev 0 A Mounting brackets 2x D Mounting holes 4x Ø9 B Identification plate E For welding C Installation label F Depth of heater see table below 549 ...

Page 550: ...0 litres 27 kg 583382 17 CBM 110 40 190 4 0 litres 35 kg 583382 18 CBM 110 60 310 6 2 litres 44 kg 583382 19 CBM 110 80 310 8 2 litres 47 kg 583382 20 CBM 110 100 370 10 5 litres 55 kg X00 65 5 2A Ref 9007096 Rev 0 A Mounting brackets 2x D Mounting holes 4x Ø11 B Identification plate E For welding C Installation label F Depth of heater see table below 550 ...

Page 551: ...HEATING SYSTEM KIT 5 TECHNICAL DATA 20 9007143 02 551 ...

Page 552: ...ssible reaction rate It should also be installed close to the steam inlet in order to avoid condensate build up The temperature sensor TT1 TT2 should be placed as close to the oil outlet of the heater as possible This will give rapid reaction even at low media flow The heating media inlet should be equipped with a strainer to trap impurities in the heating system Strainer mesh size should be For S...

Page 553: ...an result in high stress The heater should be connected so that the media flow in opposite directions The heating medium shall always be connected to the upper and lower left connections as seen from the front of the Heatpac CBM Make sure that the installation and identification labels are right side up Consequently the oil should be connected to the right connections Use the flange bolts supplied...

Page 554: ...re shocks in the heater When using steam as heating medium a mechanical float type steam trap must be installed at least 200 mm lower than the outlet of the heater providing a hydraulic head above the steam trap The condensate collection should be installed below the steam trap Otherwise there is a risk that the discharge pressure becomes too high and the condensate can not be drained off A vacuum...

Page 555: ...6 Shut off valve F Min 200 mm 7 Safety valve 8 Temperature controller 9 Pressure indicator 10 Vacuum breaker Steam heating only 11 Non return valve 12 Strainer Compulsory for good operation 0 5 mm mesh for Steam and Hot Water 0 8 mm mesh for Thermal Oil 13 CIP connection 14 Draining point All low points in the steam pipe should be drained Technical data Media Mineral oil Heating media Steam hot wa...

Page 556: ...of supply 7 Safety valve 8 Ball valve not Alfa Laval scope of supply 9 Heating shut off kit optional Connections CBM30 A DN15 DN20 DN25 CBM110 A DN20 DN25 DN32 CBM30 A1 DN20 CBM110 A1 DN25 CBM30 B DN25 CBM110 B DN40 C G 1 2 Male C1 G 1 2 Female D G 1 4 Male E G 3 4 Male a Vertical or horizontal installation e Steam inlet b Oil outlet f Alternative c Oil inlet g Plugged for drain d CIP connections ...

Page 557: ...Alfa Laval scope of supply 6 Ball valve not Alfa Laval scope of supply 7 Safety valve 8 Heating shut off kit Connections CBM30 A DN15 DN20 DN25 CBM110 A DN20 DN25 DN32 CBM30 B DN25 CBM110 B DN40 C G 1 2 Male D G 1 4 Male E G 3 4 Male a Vertical or horizontal installation e Hot water thermal oil inlet b Oil outlet f Alternative c Oil inlet g Plugged for drain d CIP connections h Hot water thermal o...

Page 558: ...1764630 Rev 2 1 Flange complete A CIP Unit 2 Gasket B To CIP tank 3 Couplings nut C CBM heater 4 O ring D Oil outlet side 5 Caps E Oil inlet side 6 Nut F Lower 2x connections on CIP unit blinded G For CIP connection R 1 1 2 Kit No CBM26 CBM 30 1764630 80 H For CIP connection R 1 1 4 CBM76 CBM 110 1764630 81 558 ...

Page 559: ...HEATING SYSTEM KIT 6 INSTALLATION 28 9007143 02 559 ...

Page 560: ...ery Recommended for 3 years operation 1 583382 11 Heater CBM 30 20 incl insulation 583382 12 Heater CBM 30 40 incl insulation 583382 13 Heater CBM 30 60 incl insulation 583382 14 Heater CBM 30 80 incl insulation 583382 15 Heater CBM 30 100 incl insulation 2 1764629 01 Gasket for flange 4 24 G 0 52 89 1 A 560 ...

Page 561: ...cluded in delivery Recommended for 3 years operation 1 583382 16 Heater CBM 110 20 incl insulation 583382 17 Heater CBM 110 40 incl insulation 583382 18 Heater CBM 110 60 incl insulation 583382 19 Heater CBM 110 80 incl insulation 583382 20 Heater CBM 110 100 incl insulation 2 1764628 01 Gasket for flange 4 24 561 ...

Page 562: ...valve is designed to regulate the flow of steam water of all temperatures or thermal oil 8 1 2 Design The valve has a two way valve housing and a 24 V AC motor drive The valve spindle is moved to the open closed or any intermediate position by the motor drive mounted on the valve housing X02 3 96 3A 562 ...

Page 563: ...n position Otherwise if not already mounted click a level indicator into place Wind the crank handle back until the valve is in the completely closed position Check that the level indicator disc is mounted correctly showing that the valve is in the closed position Otherwise if not already mounted click a level indicator into place When the valve is closed fold the crank handle back into its locked...

Page 564: ...ill apppear as though the LED flashes This is because power is only supplied when the valve moves Both LEDs flashing red initialisation procedure Upper LED lit red upper limit stop or CLOSED position reached Lower LED lit red lower limit stop or OPEN position reached Upper LED flashing green drive running moving towards CLOSED position Upper LED lit green drive stationary last direction of running...

Page 565: ... Preventive Maintenance No preventive maintenance of the motor drive is recommended The stuffing box seals should be periodically checked and the valve inspected for erosion and cavitation damages Any worn parts must be replaced Power supply 24 V 50 60 Hz AC should be supplied by a 4 core cable providing common open and close signals Terminal 21 is only valid for drive with spring return NOTE The ...

Page 566: ...ARY EQUIPMENT HEATING SYSTEM KIT 9007143 02 35 The frequency of valve maintenance necessary to avoid breakdown can vary between every three months and a number of years depending on the working environment 566 ...

Page 567: ...ht or horizontal Ref 578787 Rev 0 Media Steam water or thermal oil Maximum media temperature 240 C Maximum working pressure 25 bar up to 120 C 20 bar up to 240 C Permanent working temp with teflon packing box 20 C 240 C for steam and water Max 230 C for thermal oil Leakage 0 5 of kvs value Valve characteristic Equal percentage logarithmic Valve plug with soft sealing GF PTFE Material Housing Ducti...

Page 568: ...tuator without spring return 578787 07 94 396 150 60 6 3 DN20 Actuator without spring return 578787 06 84 402 130 60 4 DN15 Actuator without spring return 578787 05 84 402 130 60 2 5 DN15 1 Actuator without spring return 578787 04 84 402 130 60 1 6 DN15 2 Actuator without spring return 578787 03 84 402 130 60 1 DN15 3 Actuator without spring return 578787 02 84 402 130 60 0 63 DN15 4 Actuator with...

Page 569: ...7 398 160 73 10 DN25 Actuator with spring return 578788 07 94 396 150 73 6 3 DN20 Actuator with spring return 578788 06 84 402 130 73 4 DN15 Actuator with spring return 578788 05 84 402 130 73 2 5 DN15 1 Actuator with spring return 578788 04 84 402 130 73 1 6 DN15 2 Actuator with spring return 578788 03 84 402 130 73 1 DN15 3 Actuator with spring return 578788 02 84 402 130 73 0 63 DN15 4 Actuator...

Page 570: ...ge 5 to 55 C The valve must be installed to close against the operating pressure The valve must not be installed with the motor drive upside down 1 Fit the valve and motor assembly to the piping system 2 Remove the motor drive cover and the plastic protection in the cable entry 3 Slide the cable gland parts on to the cable 4 Insert the cable and secure it by tightening the gland nut X 02 39 66 A X...

Page 571: ...e Time Module terminals Common Terminal GND 1 Valve Close Terminal 2a Valve Open Terminal 2b Power supply Terminal 24 V Solenoid for spring Terminal 21 with spring return only 6 Fit the motor drive cover and run a system test to check that the valve assembly is operating properly X0 2 47 40 A 571 ...

Page 572: ... Extension kit 240 C Use an extenssion kit at temperatures above 180 C 1 Unscrew the two Allen screws and remove the clamp 2 Release the spring loaded grip 3 Push the intermediate piece into the grip X 02 39 79 A X0 2 39 81 A click X02 39 8 2A click OK 572 ...

Page 573: ...HEATING SYSTEM KIT 8 ANCILLARY EQUIPMENT 42 9007143 02 4 Fasten the mounting rod extensions and mount the clamp X0 23 98 3 A 573 ...

Page 574: ...EQUIPMENT HEATING SYSTEM KIT 9007143 02 43 Potentiometer mounting 1 Switch off the power supply 2 Remove the cover of the motor drive 3 Adjust and hold the position of the crank handle X0 23 98 4A hold position 574 ...

Page 575: ...NT 44 9007143 02 4 Connect the terminals X0 23 9 85 A stroke 14 mm connection terminal front side stroke 20 mm connection terminal rear side stroke connection connection terminal side adjustment position rear R front F Position stroke s 575 ...

Page 576: ...8 ANCILLARY EQUIPMENT HEATING SYSTEM KIT 9007143 02 45 5 Mount the potentiometer 6 Adjust the position X023986A front or rear side see step 3 X023987A adjustment position see step 3 576 ...

Page 577: ...tor A B Part no Description 578785 07 Response Time Module 578785 05 Adaptor kit 578785 04 Potentiometer kit 578785 03 Extension kit 240 C 73 578785 02 Valve drive 60 578785 01 Valve drive 410 With extension kit 578785 03 350 Without extension kit Ref 578785 Rev 5 XO 2 39 70 C 577 ...

Page 578: ...asket 1 111 5 126 230 40 DN50 578784 11 Valve 1 107 5 116 200 25 DN40 578784 10 Valve 1 103 5 110 180 16 DN32 578784 09 Valve 1 94 5 97 160 I0 DN25 578784 08 Valve 1 92 5 94 150 6 3 DN20 57878407 Valve 1 98 5 84 130 4 DN15 0 578784 06 Valve 1 98 5 84 130 2 5 DN15 1 578784 05 Valve 1 98 5 84 130 1 6 DN15 2 578784 04 Valve 1 98 5 84 130 1 DN15 3 578784 03 Valve 1 98 5 84 130 0 63 DN15 4 578784 02 Va...

Page 579: ... a housing with a spring loaded cone and spindle A gasket ensures efficient sealing between the cone and the housing seat The safety valve is delivered with preset opening pressure If the pressure in the system exceeds the preset pressure the spring loaded cone is affected and the valve opens The cone movement can be tested by lifting the spindle using the manual relief on the top of the valve G00...

Page 580: ... 4 Technical Data Specifications 8 2 5 Dimensions Nominal pressure 1600 kPa 16 bar PN16 Material Housing Brass Cone and seat Stainless steel Max temperature 160 C Weight 0 3 kg Part no Preset at 1761805 01 600 kPa 6 bar 1761805 02 1500 kPa 15 bar X011561A 580 ...

Page 581: ...aximum media temperature 198 C Material Valve body steel Ball SS Sealing carbographite Ref 1766465 Rev 3 Operating pressure 500 700 kPa 5 7 bar Max pressure 1 MPa 10 bar Ambient temperature 20 C 85 C Material aluminium elax Ref 1766465 Rev 3 Media air Ambient temperature 20 C 60 C Material aluminium elax Supply voltage 24 VAC 50 60 Hz Ref 1766465 Rev 3 581 ...

Page 582: ...213 173 90 35 M12 65 SR 52 0 126 Nl stroke Conn 15 3 2 1765948 05 1766465 02 20 184 234 193 100 40 M12 75 SR 63 0 233 Nl stroke Conn 20 4 5 1765948 01 1766465 03 25 188 243 196 110 46 M12 85 SR 63 0 233 Nl stroke Conn 25 5 3 1765948 02 1766465 04 32 221 286 250 130 54 M16 100 SR 85 0 531 Nl stroke Conn 32 7 6 1765948 09 Ref 1766465 Rev 3 X024628A Air inlet G 1 4 582 ...

Page 583: ...orking temp max 250 C Working pressure max 16 MPa 16 bar Valve seat 10 bar Ref 1766169 Rev 1 Part no Conn A B C D Dh E Weight kg 1766169 01 DN 15 150 107 101 95 65 51 4 5 1766169 02 DN 20 150 107 101 105 75 55 5 0 1766169 03 DN 25 160 117 70 115 85 100 6 5 Ref 1766169 Rev 1 X024629A Ref 1766169 Rev 1 583 ...

Page 584: ...EATING SYSTEM KIT 9007143 02 53 8 5 Vacuum Breaker 8 5 1 Technical Data Dimensions Media Steam Media temp max 260 C Media pressure max 16 bar Material Brass Ref 1766607 Rev 2 Part no 1766607 01 X024630B Ref 1766607 Rev 2 584 ...

Page 585: ...s B C 15 130 7060128 01 7060128 09 95 65 14 80 110 20 150 7060128 02 7060128 10 105 75 14 85 130 25 160 7060128 03 7060128 11 115 85 14 105 150 32 180 7060128 04 7060128 12 140 100 18 110 225 Media Steam Thermal oil Gasket Graphite Flanges UNI PN 16 40 DIN 2633 Material body Cast steel GS C25 Strainer insert Stainless steel Ref 7060128 Rev 1 X027590A 585 ...

Page 586: ...Marine Diesel Equipment Sludge Removal Kit Product No Printed Book No 582522 01 02 580258 01 to 12 July 2011 584692 02 V5 Component Description 586 ...

Page 587: ...sible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated Copies of this publication can be ordered from your local Alfa Laval company Published by Alfa Laval Tumba AB Marine Diesel Equipment SE 147 80 Tumba Sweden Copyright Alfa Laval Tumba AB 2011 587 ...

Page 588: ...Contents 584692 02 1 Sludge Removal Kit 3 1 1 Function 3 1 2 Operation 5 1 3 Installation 5 1 4 Maintenance 7 1 5 Technical Data 8 1 6 Dimension Drawings 9 2 Spare Parts 12 588 ...

Page 589: ...584692 02 589 ...

Page 590: ...e separation system to a larger common sludge tank If the Sludge Removal Kit tank is filled between the pre set intervalls a level switch inside the tank is activated and the the pump empties the tank The Sludge Removal Kit makes positioning of the separator much easier as it does not have to be positioned directly over the common sludge tank X024594A P 605 615 S 805 815 Sludge Removal Kit P 625 6...

Page 591: ...ludge tank The heating element keeps the oil sludge and water in the sludge tank at a suitable temperature The heating element is activated automatically when power to the Control Cabinet is switched on The temperature is regulated by a termostat inside the heating element NOTE If the separation system has not been run for a longer period the Sludge Removal Kit must be started 1 hour before restar...

Page 592: ...lation The Sludge Removal Kit must be connected to the ventilation pipe for the sludge outlet the separator sludge outlet and the sludge pipe system for the larger common sludge tank NOTE The sludge removal pump must be set to the correct speed circa 60 strokes min otherwise the lifetime of the diaphragm valve balls and air motor will be severely shortened Adjust the air quality to the sludge pump...

Page 593: ... separator room ventilation system For LO separation connection to the separator room ventilation system should be made only if the separator room ventilation is adequate Use the optional connection hose part no 568023 80 81 or 82 for this purpose This hose is designed to entrap oil drops in the vent hose and lead the oil back to the Sludge Removal Kit tank Pipe to common sludge tank A pipe must b...

Page 594: ... the complete sludge discharge arrangement NOTE To operate the sludge pump manually use the screw on the air solenoid valve Clean the level switch if necessary Check the seals and gaskets and change if necessary Loosen the hose clip and check the inside of the ventilation hose Clean if necessary To avoid breakdown of the Sludge Removal system the sludge pump must be regularly overhauled as follows...

Page 595: ...MPONENT DESCRIPTION 8 584692 02 1 5 Technical Data Media oil sludge water Media temperature max 120 C Flow max 70 l min at 8 bar water Delivery head 5 bar Particle size max 4 mm Air pressure 5 7 bar Air consumption normal max 1m3 h 1 l sec 595 ...

Page 596: ... DESCRIPTION 1 SLUDGE REMOVAL KIT 1 6 Dimension Drawings X024645A Sludge outlet G1 Flexible hose Ventilation DN50 PN6 Separator sludge outlet Separator vertical axis P 605 615 S 805 815 Ref 584126 Rev 0 Level switch Air inlet G1 4 to MV6 596 ...

Page 597: ...7 Air inlet G1 4 to MV6 Base plate fixing A B C D E F G H S 811 S 927 P 625 626 465 350 350 DN50 PN6 618 210 463 180 S 831 S 937 P 635 636 503 350 350 DN50 PN6 618 210 463 180 S 841 S 947 513 340 350 DN50 PN6 618 210 463 180 S 851 S 957 595 490 390 DN65 PN6 798 270 643 240 S 861 S 967 595 490 390 DN65 PN6 798 270 643 240 S 871 S 977 750 530 446 DN80 PN6 868 300 713 240 S 881 S 987 750 530 446 DN80...

Page 598: ...DGE REMOVAL KIT COMPONENT DESCRIPTION 1 SLUDGE REMOVAL KIT Floor level differences between SRK and separators S 811 S 947 P 605 P 636 80 mm S 851 S 987 100 mm Customer supplied Separator Sludge Removal Kit X024650A 598 ...

Page 599: ...12 584692 02 2 SPARE PARTS SLUDGE REMOVAL KIT COMPONENT DESCRIPTION 2 Spare Parts 599 ...

Page 600: ...Spare parts catalogue Catalogo parti di ricambio Reservdelskatalog Catalogo de pecas sobressalentes Ersatzteilkatalog Varaosaluettelo Catalogue de piéces de rechange Καταλογοσ ανταλλακτικων Catalogue de piezas de recambio Reserveonderdelen catalogus Каталог запасных частеи Reservedelskatalog 600 ...

Page 601: ...lephone 46 8 530 650 00 Telefax 46 8 530 310 40 Alfa Laval Tumba AB 2011 07 06 Original instructions This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB 601 ...

Page 602: ... 14 3 1 Sludge outlet S 821 S 836 16 3 2 Sludge outlet S 881 S 886 18 3 3 Sludge outlet S 851 S 856 20 3 4 Sludge outlet S 861 S 866 22 3 5 Sludge outlet S 871 S 876 24 4 Sludge removal kit 26 4 1 Sludge outlet S 881 S 886 28 4 2 Sludge outlet S 881 S 886 30 5 Slugde pump T70 spare parts 32 6 Cross reference list 34 3 602 ...

Page 603: ...4 603 ...

Page 604: ...e correct La placa marca de la máquina guía del número correcto del repuesto Фирменная табличка машины указатель правилного номера запасной части La targhetta della macchina guida al corretto numero dei ricambi La placa do fabricante da máquina um guia do número correto das partes sobressalentes Konekilpi opastin oikeaan varaosanumeroon Η πινακίδα της μηχανής είναι ο οδηγός του σωστού ανταλλακτικο...

Page 605: ...ie nur Alfa Laval Originalersatzteile benutzen Vergessen Sie nicht Alfa Laval kann keine Verantwortung für das Versagen eines Separators übernehmen der nicht mit Originalersatzteilen versehen ist Wir garantieren Qualität und Zuverlässigkeit unserer Produkte Préservez la qualité de vos équipments en n employant que des pièces de rechange Alfa Laval N oubliez pas q Alfa Laval décline toute responsab...

Page 606: ... o seu cometimento a qualidade usando sempre peças sobressalentes genuinas Alfa Laval Não esqueça que Alfa Laval não aceita responsabilidade por falha de uma separadora equipada com peças sobressalentes não genuinas Nós garantimos a qualidade e a confiança dos nossos produtos Varmistakaa vastuunne laadusta käyttämällä aina alkuperäisiä Alfa Laval varaosia Muistakaa Alfa Laval ei voi hyväksyä vastu...

Page 607: ...a Laval niet verantwoordelijk is voor een defecte separator die niet originele onderdelen bevat Wij garanderen de kwaliteit en betrouwbaarheid van onze eigen produkten Hold Dem til den kvalitet De har valgt at satse på ved altid at anvende ægte Alfa Laval reservedele Husk at Alfa Laval ikke kan påtage sig noget ansvar for fejl på en separator som indeholder uoriginale dele Vi kan kun garantere kva...

Page 608: ... Undergruppsbenämning Bezeichung der Untergruppe Dénomination de sous ensemble Descripción de subconjunto Subassembly no Undergruppsnr Untergruppe Nr Nº de sous ensemble Número de subconjunto See page Se sidan Siehe Seite Vòir page Véase la página Fig ref Figurhänvisning Bildhinweise Réf de fig Referencia de figura Product name Produktnamn Produktname Nom du produit Nombre del producto Exchange ne...

Page 609: ...criao do subconjunto Alaryhmän nimitys Subassembly no Группа Nr sottogruppo Número de subconjunto Alaryhmän no See page См страницу Vedi pagina Véase la página Ks sivu Fig ref Ссылка на зскиз Rif fig Referencia de figura Kuvaviite Product name Наименование артикула Nome prodotto Nombre del producto Tuotteen nimi Exchange necessitates rebalancing of bowl Замена требует балансировки барабана La sost...

Page 610: ...sembly description Περιγραφή υποσυγκροτήματος Subgroepbenamning Undergruppsbetegnelse Subassembly no Αριθμός υποσυγκροτήματος Subgroepnr Undergruppenr See page Βλέπε σελίδα Zie blz Se side Fig ref Παραπομπή σε εικόνα Afb ref Figurhenvisning Product name Ονομασία προϊόντος Produktnaam Produktnavn Exchange necessitates rebalancing of bowl Ανταλλαγή απαιτεί επαναρρύθμιση ισορροπίας του τύμπανου Verva...

Page 611: ...83 04 Rubber hose 1 4 1767084 04 Rubber hose 1 7 574351 04 Flexible hose L 860 1 1 8 569763 02 Nipple G3 4 G3 4 2 2 9 1766002 01 Non return valve 1 1 10 1765934 01 Flexible connection 2 2 11 1766893 01 Plug 1 1 13 1762017 12 Hose 1 1 15 569763 03 Nipple G1 2 G1 2 1 1 16 569763 08 Nipple G1 G3 4 1 1 17 572915 01 Solenoid valve 1 1 18 571395 01 Elbow coupling G1 4 1 1 19 1766081 02 Regulating valve ...

Page 612: ...2 Sludge removal kit 2200H 13 612 ...

Page 613: ...ble hose L 400 1 1 1 1 1 9 580773 80 Pipe connection 1 1 1 1 1 10 1762672 03 Hexagon plug 1 1 1 1 1 11 1762672 01 Hexagon plug 1 1 1 1 1 12 580758 06 Push In Fittings 2 2 2 2 2 13 580769 03 Flexible hose air D 8 1 1 1 1 1 14 1763780 02 Nipple 4 4 4 4 4 15 221030 49 Screw 8 8 8 8 8 16 223101 47 Washer 12 12 12 12 12 17 2210293 27 Screw 2 2 2 2 2 18 223101 41 Washer 2 2 2 2 2 19 1763780 06 Nipple 1 ...

Page 614: ...3 Sludge removal kit 2205M 15 614 ...

Page 615: ...S 821 S 836 Machine unit number or Subassembly description 580403 Ref Part No Description 80 Notes Quantity 1 580303 80 Cover 1 2 580358 80 Sludge outlet 1 3 1762017 06 Hose 1 4 1766096 01 Plug 1 5 1762020 03 Hose clip Ø 58 x Ø 75 2 16 615 ...

Page 616: ...3 1 Sludge outlet S 821 S 836 3 Sludge removal kit 2219L 17 616 ...

Page 617: ... S 881 S 886 Machine unit number or Subassembly description 580407 Ref Part No Description 80 Notes Quantity 1 580301 80 Cover 1 2 580374 80 Sludge outlet 1 3 1762017 07 Hose 1 4 1766096 01 Plug 1 5 2245101 01 Hose clip 2 Ø83 x Ø93 18 617 ...

Page 618: ...3 2 Sludge outlet S 881 S 886 3 Sludge removal kit 2217E 19 618 ...

Page 619: ...utlet S 851 S 856 Machine unit number or Subassembly description 583361 Ref Part No Description 80 Notes Quantity 1 583362 80 Cover 1 2 583389 80 Sludge Outlet 1 3 1762017 09 Hose 1 4 1766096 01 Plug 1 5 2245102 02 Hose clip 2 20 619 ...

Page 620: ...3 3 Sludge outlet S 851 S 856 3 Sludge removal kit 2223K 21 620 ...

Page 621: ...utlet S 861 S 866 Machine unit number or Subassembly description 583268 Ref Part No Description 80 Notes Quantity 1 583304 80 Cover 1 2 583163 80 Sludge Outlet 1 3 1762017 08 Hose 1 4 1766096 01 Plug 1 5 2245102 02 Hose clip 2 22 621 ...

Page 622: ...3 4 Sludge outlet S 861 S 866 3 Sludge removal kit 2223L 23 622 ...

Page 623: ...utlet S 871 S 876 Machine unit number or Subassembly description 583746 Ref Part No Description 80 Notes Quantity 1 583747 80 Cover 1 2 583163 80 Sludge Outlet 1 3 1762017 10 Hose 1 4 1766096 01 Plug 1 5 2245102 02 Hose clip 2 24 623 ...

Page 624: ...3 5 Sludge outlet S 871 S 876 3 Sludge removal kit 2223N 25 624 ...

Page 625: ...00 1 1 1 1 1 1 1 9 580773 80 Pipe connection 1 1 1 1 1 1 1 10 1762672 03 Hexagon plug 1 1 1 1 1 1 1 11 1762672 01 Hexagon plug 1 1 1 1 1 1 1 12 580758 06 Push In Fittings 2 2 2 2 2 2 2 13 580769 03 Flexible hose air D 8 1 1 1 1 1 1 1 14 1763780 02 Nipple 4 4 4 4 4 4 4 15 221030 49 Screw 8 8 8 8 8 8 8 16 223101 47 Washer 12 12 12 12 12 12 12 17 2210293 27 Screw 2 2 2 2 2 2 2 18 223101 41 Washer 2 2...

Page 626: ...4 Sludge removal kit 2205T 27 626 ...

Page 627: ...t 4 1 Sludge outlet S 881 S 886 Machine unit number or Subassembly description 583750 Ref Part No Description 80 Notes Quantity 1 583751 80 Cover 1 3 1762017 11 Hose 1 4 1766096 01 Plug 1 5 2245102 02 Hose clip 2 28 627 ...

Page 628: ...4 1 Sludge outlet S 881 S 886 4 Sludge removal kit 2223M 29 628 ...

Page 629: ... S 881 S 886 Machine unit number or Subassembly description 580407 Ref Part No Description 80 Notes Quantity 1 580301 80 Cover 1 2 580374 80 Sludge outlet 1 3 1762017 07 Hose 1 4 1766096 01 Plug 1 5 2245101 01 Hose clip 2 Ø83 x Ø93 30 629 ...

Page 630: ...4 2 Sludge outlet S 881 S 886 4 Sludge removal kit 2219L 31 630 ...

Page 631: ...re parts Machine unit number or Subassembly description 1766702 Ref Part No Description 80 Notes Quantity 1 1766702 01 O ring Packing kit 4 2 1766702 02 Diaphragm 2 3 1766702 03 O ring 6 4 1766702 04 Air valve 1 5 1766702 05 Muffler 1 32 631 ...

Page 632: ...5 Slugde pump T70 spare parts 2123N 33 632 ...

Page 633: ... 28 223101 41 26 18 223101 41 14 18 223101 47 26 16 223101 47 14 16 2245101 01 30 5 2245101 01 18 5 2245102 02 28 5 2245102 02 20 5 2245102 02 22 5 2245102 02 24 5 546229 08 26 23 546229 08 14 23 569763 02 12 8 569763 03 12 15 569763 08 12 16 571395 01 12 18 572215 04 26 20 572215 04 14 20 572915 01 12 17 572915 01 14 6 572915 01 26 6 574351 04 12 7 574351 05 14 8 574351 05 26 8 580259 80 14 1 580...

Page 634: ...01 Product No 597400 91 Spare parts catalogue Catalogo parti di ricambio Reservdelskatalog Catalogo de pecas sobressalentes Ersatzteilkatalog Varaosaluettelo Catalogue de piéces de Καταλογοσ ανταλλακτικων rechange Catalogue de piezas de Reserveonderdelen catalogus recambio Каталог запасных Reservedelskatalog частеи 634 ...

Page 635: ...possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated Copies of this publication can be ordered from your local Alfa Laval company Published by Alfa Laval S p A Marine Diesel Equipment 20900 Monza MB Itlay Copyright Alfa Laval Italy Jan 2014 635 ...

Page 636: ...ransmitter 24 5 3 Way valve block 26 6 3 way valve Spare Parts 28 7 Flexible hoses block 30 7 1 Flexible hoses kit 32 8 Operating water valve block 34 8 1 Valve block water 36 8 2 SV10A Assembly 38 9 Air distributor kit 40 10 Control Block 42 10 1 Control_Unit incl Starter 44 10 1 1 Control Cabinet 46 10 1 2 PLC standard kit 48 10 1 3 Main switch 50 10 1 4 RJ45 connector kit 52 10 1 5 Motor starte...

Page 637: ...637 ...

Page 638: ...nge correct La placa marca de la máquina guía del número correcto del repuesto Фирменная табличка машины указатель правилного номера запасной части La targhetta della macchina guida al corretto numero dei ricambi La placa do fabricante da máquina um guia do número correto das partes sobressalentes Konekilpi opastin oikeaan varaosanumeroon Η πινακίδα της μηχανής είναι ο οδηγός του σωστού ανταλλακτι...

Page 639: ...zteile benutzen Vergessen Sie nicht Alfa Laval kann keine Verantwortung für das Versagen eines Separators übernehmen der nicht mit Originalersatzteilen versehen ist Wir garantieren Qualität und Zuverlässigkeit unserer Produkte Préservez la qualité de vos équipments en n employant que des pièces de rechange Alfa Laval N oubliez pas q Alfa Laval décline toute responsabilité en cas de panne d un sépa...

Page 640: ... laadusta käyttämällä aina alkuperäisiä Alfa Laval varaosia Muistakaa Alfa Laval ei voi hyväksyä vastuuta ei alkuperäsillä varaosilla varustetun separaattorin vaurioista Me takaamme tuotteidemme laadun ja käyttövarmuuden Εξασφαλίοτε υψηλή ποιότητα χρησιμοποιώντας μόνο γνήσια ανταλλακτικά της Alfa Laval Έχετε υπόψην ότι η Alfa Laval δεν αναλαμβάνει καμμιά ευθύνη για βλάβες βουτυρομηχανής οτην οποία...

Page 641: ...s voor een defecte separator die niet originele onderdelen bevat Wij garanderen de kwaliteit en betrouwbaarheid van onze eigen produkten Hold Dem til den kvalitet De har valgt at satse på ved altid at anvende ægte Alfa Laval reservedele Husk at Alfa Laval ikke kan påtage sig noget ansvar for fejl på en separator som indeholder uoriginale dele Vi kan kun garantere kvalitet og driftsikkerhed på vore...

Page 642: ...ruppsnr Untergruppe Nr Nº de sous ensemble Número de subconjunto See page Se sidan Siehe Seite Vòir page Véase la página Fig ref Figurhänvisning Bildhinweise Réf de fig Referencia de figura Product name Produktnamn Produktname Nom du produit Nombre del producto Exchange necessitates rebalancing of bowl Utbyte nödvändiggör ombalansering av kulan Austausch erfordert Wiederauswuchtung der Trommel Le ...

Page 643: ...laryhmän no See page См страницу Vedi pagina Véase la página Ks sivu Fig ref Ссылка на зскиз Rif fig Referencia de figura Kuvaviite Product name Наименование артикула Nome prodotto Nombre del producto Tuotteen nimi Exchange necessitates rebalancing of bowl Замена требует балансировки барабана La sostituzione comporta la equilibratura del tam buro El racmbio requiere el reequilibrado del rotor Vaih...

Page 644: ...dergruppsbetegnelse Subassembly no Αριθμός υποσυγκροτήματος Subgroepnr Undergruppenr See page Βλέπε σελίδα Zie blz Se side Fig ref Παραπομπή σε εικόνα Afb ref Figurhenvisning Product name Ονομασία προϊόντος Produktnaam Produktnavn Exchange necessitates rebalancing of bowl Ανταλλαγή απαιτεί επαναρρύθμιση ισορροπίας του τύμπανου Vervangning vereist herbalanceren van de kogel Udskriftning kraever afb...

Page 645: ... 599048 81 Sludge Outlet 1 Separator Type S921 S926 S927 S936 S937 See page 14 1 599048 82 Sludge Outlet 1 Separator Type S946 S947 See page 14 3 598546 80 Butterfly Valve Kit 1 Separator Type S921 S926 S927 S936 S937 3 598546 81 Butterfly Valve Kit 1 Separator Type S946 S947 2 Sludge outlet block 645 ...

Page 646: ...13 S921 S926 S927 S936 S937 S946 S947 Flex Module 646 ...

Page 647: ...592 80 Sludge outlet 1 2 561339 01 Gasket 1 3 221040 08 Screw 4 4 41456 Washer 4 S921 S926 S927 S936 S937 Ref Part No Description Subassembly description 599048 82 Notes Quantity 1 582593 80 Sludge outlet 1 2 561339 02 Gasket 1 3 221040 08 Screw 4 4 41456 Washer 4 S946 S947 2 Sludge outlet block 647 ...

Page 648: ...15 S921 S926 S927 S936 S937 S946 S947 Flex Module 648 ...

Page 649: ...ision block 3 Feed supervision block Ref Part No Description Subassembly description 9000152 AA Notes Quantity 1 1761626 01 Thermometer 1 Optional 2 582752 81 Pressure Transmitter 1 3 597256 01 Temperature Sensor 1 649 ...

Page 650: ...17 S921 S926 S927 S936 S937 S946 S947 Flex Module 650 ...

Page 651: ...s Quantity 1 598547 80 Water Transducer Kit DN25 1 2 580920 81 Cable 19 5 m 1 3 582752 81 Pressure Transmitter 1 4 569304 01 Ball Valve 1 Optional 5 543054 05 Pressure Gauge 1 Normal This is an optional 5 584372 05 Pressure Gauge 1 Green field This is an optional 4 Light phase regulating Block 651 ...

Page 652: ...19 S921 S926 S927 S936 S937 S946 S947 Flex Module 652 ...

Page 653: ... regulating Block 4 1 Water Transducer Kit DN25 Ref Part No Description Subassembly description 598547 80 Notes Quantity 1 582551 80 Water Transducer DN25 1 2 1763491 01 Nipple 1 3 574409 83 3 way solenoid valve 1 653 ...

Page 654: ...21 S921 S926 S927 S936 S937 S946 S947 Flex Module 654 ...

Page 655: ...er Transducer DN25 Ref Part No Description Subassembly description 582551 80 Notes Quantity 7 1765130 01 Gasket 1 18 581017 01 MT60 Circuit Board 1 28 582554 01 Valve Seat DN25 1 29 582584 01 Pneumatic Actuator DN25 1 30 586248 03 Gasket 1 655 ...

Page 656: ...23 S921 S926 S927 S936 S937 S946 S947 Flex Module 656 ...

Page 657: ...se regulating Block 4 3 Pressure transmitter Ref Part No Description Subassembly description 582752 81 Notes Quantity 1 597255 01 Pressure transmitter 1 2 1763903 03 Needle valve 1 Optional 3 53551716 02 Washer 2 657 ...

Page 658: ...25 S921 S926 S927 S936 S937 S946 S947 Flex Module 658 ...

Page 659: ... valve block 5 3 Way valve block Ref Part No Description Subassembly description 9001721 80 Notes Quantity 1 597909 01 3 Way Valve DN25 DIN 1 2 574409 83 3 way solenoid valve 1 3 1763491 01 Nipple 1 G1 8 G1 4 659 ...

Page 660: ...27 S921 S926 S927 S936 S937 S946 S947 Flex Module 660 ...

Page 661: ...ty 1 598018 01 Gasket 1 SMC code 00090 A 2 598018 02 Stuffing box 1 SMC code 01184 3 598018 03 Body gasket 1 SMC code MD2119 GRAF 4 598018 04 O Ring 1 SMC code 04185 5 598018 05 O Ring 1 SMC code 01047 6 598018 06 O Ring 1 SMC code 01053 7 598018 07 Plug gasket 2 SMC code MD2106 PK 8 598018 08 Flat gasket 1 SMC code 23180 661 ...

Page 662: ...29 S921 S926 S927 S936 S937 S946 S947 Flex Module 662 ...

Page 663: ...le hose kit 1 S 921 S 926 S 927 IF 30 IF 40 IF 60 IF 100 MDO GO 1 9000188 17 Flexible hose kit 1 S 936 S 937 HFO 180 HFO 380 HFO 460 HFO 600 HFO 700 LO Trunk Piston Engine LO Cross Head Engine 1 9000188 18 Flexible hose kit 1 S 936 S 937 IF 30 IF 40 IF 60 IF 100 MDO GO 1 9000188 23 Flexible hose kit 1 S 946 S 947 HFO 180 HFO 380 HFO 460 HFO 600 HFO 700 LO Trunk Piston Engine LO Cross Head Engine 1...

Page 664: ...31 S921 S926 S927 S936 S937 S946 S947 Flex Module 664 ...

Page 665: ... 582476 10 Throttle washer block kit 1 HFO 180 HFO 380 HFO 460 HFO 600 HFO 700 LO Trunk Piston Engine LO Cross Head Engine 2 582476 11 Throttle washer block kit 1 IF 30 IF 40 IF 60 IF 100 MDO GO 2 582476 12 Throttle washer block kit 1 HFO 180 HFO 380 HFO 460 HFO 600 HFO 700 LO Trunk Piston Engine LO Cross Head Engine 2 582476 13 Throttle washer block kit 1 IF 30 IF 40 IF 60 IF 100 MDO GO 3 1760924...

Page 666: ...33 S921 S926 S927 S936 S937 S946 S947 Flex Module Alt S 936 S 977 Alt S 921 S 927 Alt P 605 P 615 S 986 S 987 P 626 P 636 666 ...

Page 667: ...ription 9000340 AA Notes Quantity 1 598371 02 Valve block water 1 S 921 S 926 S 927 1 598371 04 Valve block water 1 S 936 S 937 S 946 S 947 2 598372 02 Flexible connection kit 1 S 921 S 926 S 927 2 598372 03 Flexible connection kit 1 S 936 S 937 S 946 S 947 3 592550 80 SV10A Assembly 1 Only for LO Version 667 ...

Page 668: ...35 S921 S926 S927 S936 S937 S946 S947 Flex Module 668 ...

Page 669: ...96 80 Valve block water 1 S 921 S 926 S 927 S 936 S 937 S 946 S 947 2 1766037 04 Flow valve 0 9 l min 1 S 921 S 926 S 927 2 1766037 07 Flow valve 1 6 l min 1 S 936 S 937 S 946 S 947 3 1766037 02 Flow valve 11 0 l min 1 S 921 S 926 S 927 S 936 S 937 S 946 S 947 4 1766037 03 Flow valve 2 8 l min 1 S 921 S 926 S 927 S 936 S 937 S 946 S 947 669 ...

Page 670: ...37 S921 S926 S927 S936 S937 S946 S947 Flex Module 670 ...

Page 671: ...on Subassembly description 592550 80 Notes Quantity 1 591719 80 Actuator assembly 1 2 546600 06 Pipe union 1 3 569197 01 Hose nipple 1 4 1761834 09 Cu washer 1 5 53551320 06 Hose 1 6 1762020 01 Hose clip 1 8 Operating water valve block water 671 ...

Page 672: ...39 S921 S926 S927 S936 S937 S946 S947 Flex Module 672 ...

Page 673: ... 1 4 1763491 03 Nipple 1 1 5 53551400 01 Flexible connection G 1 4 1 5 53551400 02 Flexible connection 1 7 582450 01 Air distributor G1 4 1 1 12 580769 02 Flexible hose air D 6 3 3 15 580769 03 Flexible hose air D 8 1 1 17 580769 02 Flexible hose air D 6 1 1 Only for LO application 599043 80 Air Pressure Regulator Kit 1 1 9 Air distributor Kit 673 ...

Page 674: ...41 S921 S926 S927 S936 S937 S946 S947 Flex Module 674 ...

Page 675: ...ol Block Ref Part No Description Subassembly description 9000341 AA Notes Quantity 1 9000221 AA Control_Unit incl Starter 1 See page 44 3 581009 01 Emergency stop 1 On request only contact your local Alfa Laval representative 675 ...

Page 676: ...43 S921 S926 S927 S936 S937 S946 S947 Flex Module 676 ...

Page 677: ...3B 580991 06 Ammeter transformer Only for Ammeter 60A 13C 580991 11 Ammeter 10A 13C 580991 10 Ammeter 20A 13C 580991 05 Ammeter 40A 13C 580991 07 Ammeter 60A 13D 580991 03 Rubber Seal 14 581044 80 Steam Heater kit 1 OPTIONAL Heating Media Steam Thermal Oil Hot Water 15 581045 80 Speed Transmitter Kit 1 16 581046 80 Vibration Transmitter kit 1 OPTIONAL Vibration Sensor 17 581047 80 Extra I O board ...

Page 678: ...45 S921 S926 S927 S936 S937 S946 S947 Flex Module 678 ...

Page 679: ... 80 PLC standard kit 1 See page 48 2 1 581058 01 Flex S921 987 1 4 580992 26 Circuit Breaker 1 5 580992 27 Circuit Breaker 1 6 580994 01 Copper Plait 1 7 580992 08 Circuit Breaker 1 8 580992 09 3 pole busbar 1 9 580992 80 Main switch 1 See page 50 10 580936 01 Cable 1 11 581016 01 Fan 1 12 580989 01 Terminal 14 13 581040 80 RJ45 connector kit 1 See page 52 679 ...

Page 680: ...47 S921 S926 S927 S936 S937 S946 S947 Flex Module 680 ...

Page 681: ...580986 26 Terminal block 1 0TB103 91 5 580986 04 6 Digital input 1 X20DI6371 6 580986 05 2 Relay output 1 X20DO2649 7 580986 06 6 Relay output 1 X20DO6529 8 580986 07 4 Relay output 1 X20DO4529 9 580986 08 4 Analogue input 1 X20AI4622 10 580986 09 2 Analogue input 1 X20AT2222 11 580986 17 Bus module 6 X20BM11 14 580986 16 Terminal block 12 pin 7 X20TB12 15 580986 03 Power supply 1 0AC524 9 16 5809...

Page 682: ...49 S921 S926 S927 S936 S937 S946 S947 Flex Module 682 ...

Page 683: ...description 580992 80 Notes Quantity 1 580992 01 Circuit Breaker 1 2 580992 02 Handle and front 1 3 580992 03 Shaft Extension 1 4 580992 04 Door Interlock Plate 1 5 580992 05 Input Terminal Protection 1 6 580992 06 Auxiliary Contact Block 1 7 580992 07 Input Terminal Protection 1 683 ...

Page 684: ...51 S921 S926 S927 S936 S937 S946 S947 Flex Module 684 ...

Page 685: ...k 10 1 4 RJ45 connector kit Ref Part No Description Subassembly description 581040 80 Notes Quantity 1 580987 01 RJ45 cable 1 2 580987 02 RJ45 connector 1 3 580987 03 RJ45 mounting frame 1 4 580987 04 RJ45 protective cover 1 685 ...

Page 686: ...53 S921 S926 S927 S936 S937 S946 S947 Flex Module 686 ...

Page 687: ...r Starter 4 5 18 0A 2 580987 05 Control Unit 1 Motor Starter 8 0 32 0A 2 580987 12 Control Unit 1 Motor Starter 1 25 5 0A 2 580987 13 Control Unit 1 Motor Starter 0 35 1 4A 3 580987 25 Auxiliary Contact Block 1 1 1 1 Ref Part No Description Subassembly description 580998 Notes 87 Quantity 1 580987 30 Motor Circuit Breaker 1 2 580987 11 Contactor 1 3 580987 35 Auxiliary Contact Block 1 4 580987 09 ...

Page 688: ...55 S921 S926 S927 S936 S937 S946 S947 Flex Module 688 ...

Page 689: ...ity 1 1765993 01 Retaining clip 1 2 1765993 02 Spring 1 3 1765993 03 Core 1 4 1765993 04 Spring washer 1 5 1765993 05 O ring 1 6 1765993 06 Piston 1 7 1765993 07 Disc 1 8 1765993 08 Non return valve 1 9 1765993 09 O ring 1 10 1765993 10 O ring 1 11 1765993 11 Coil 24 V 1 14 1765993 13 Drain valve 1 15 1765993 16 Strainer 1 689 ...

Page 690: ...57 S921 S926 S927 S936 S937 S946 S947 Flex Module 690 ...

Page 691: ...80986 17 48 11 580986 18 48 16 580986 26 48 4 580987 01 52 1 580987 01 54 1 580987 02 52 2 580987 02 54 1 580987 03 52 3 580987 04 52 4 580987 04 54 2 580987 05 54 2 580987 09 54 4 580987 11 54 2 580987 12 54 2 580987 13 54 2 580987 25 54 3 580987 30 54 1 580987 35 54 3 580989 01 46 12 580991 03 44 13D 580991 04 44 13B 580991 05 44 13C 580991 06 44 13B 580991 07 44 13C 580991 10 44 13C 580991 11 4...

Page 692: ... 1 598018 02 28 2 598018 03 28 3 598018 04 28 4 598018 05 28 5 598018 06 28 6 598018 07 28 7 598018 08 28 8 598371 02 34 1 598371 04 34 1 598372 02 34 2 598372 03 34 2 598546 80 12 3 598546 81 12 3 598547 80 18 1 599043 80 40 599048 81 12 1 599048 82 12 1 9000188 09 30 1 9000188 10 30 1 9000188 17 30 1 9000188 18 30 1 9000188 23 30 1 9000188 24 30 1 9000221 AA 42 1 692 ...

Page 693: ...60 693 ...

Page 694: ...694 ...

Page 695: ...ve 2004 108 EC To meet these requirements the following standards have been used EN 12100 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN 12100 2 Safety of machinery Basic concepts general principles for design Part 2 Technical principles EN 954 1 Safety of machinery Safety related parts of control systems part 1 General principles for des...

Page 696: ...ve 2004 108 EC To meet these requirements the following standards have been used EN 12100 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN 12100 2 Safety of machinery Basic concepts general principles for design Part 2 Technical principles EN 954 1 Safety of machinery Safety related parts of control systems part 1 General principles for des...

Page 697: ...ve 2004 108 EC To meet these requirements the following standards have been used EN 12100 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN 12100 2 Safety of machinery Basic concepts general principles for design Part 2 Technical principles EN 954 1 Safety of machinery Safety related parts of control systems part 1 General principles for des...

Page 698: ...ve 2004 108 EC To meet these requirements the following standards have been used EN 12100 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN 12100 2 Safety of machinery Basic concepts general principles for design Part 2 Technical principles EN 954 1 Safety of machinery Safety related parts of control systems part 1 General principles for des...

Page 699: ...ve 2004 108 EC To meet these requirements the following standards have been used EN 12100 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN 12100 2 Safety of machinery Basic concepts general principles for design Part 2 Technical principles EN 954 1 Safety of machinery Safety related parts of control systems part 1 General principles for des...

Page 700: ...ve 2004 108 EC To meet these requirements the following standards have been used EN 12100 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN 12100 2 Safety of machinery Basic concepts general principles for design Part 2 Technical principles EN 954 1 Safety of machinery Safety related parts of control systems part 1 General principles for des...

Page 701: ...ve 2004 108 EC To meet these requirements the following standards have been used EN 12100 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN 12100 2 Safety of machinery Basic concepts general principles for design Part 2 Technical principles EN 954 1 Safety of machinery Safety related parts of control systems part 1 General principles for des...

Page 702: ...ve 2004 108 EC To meet these requirements the following standards have been used EN 12100 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN 12100 2 Safety of machinery Basic concepts general principles for design Part 2 Technical principles EN 954 1 Safety of machinery Safety related parts of control systems part 1 General principles for des...

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