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GEA OSE 20-0136-067, Instruction Manual, Page: 1 / 216

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GEA OSE 20-0136-067 Instruction Manual Download Page 1

 

 

GEA Mechanical Equipment /

 

GEA Westfalia Separator Group

 

 

 

Instruction manual

 

 

 

Designation 

Mineral oil centrifuge with self-cleaning bowl

 

Type 

OSE 20-0136-067

 

 

   

 

 

 

No. 

2064-9001-001

 

Edition 

1010

 

 

Summary of Contents for OSE 20-0136-067

Page 1: ...GEA Mechanical Equipment GEA Westfalia Separator Group Instruction manual Designation Mineral oil centrifuge with self cleaning bowl Type OSE 20 0136 067 No 2064 9001 001 Edition 1010 ...

Page 2: ...uthors are always grateful for comments and suggestions for improving the documentation They can be addressed to GEA Mechanical Equipment GEA Westfalia Separator Group GmbH Werner Habig Str 1 59302 Oelde Germany Phone 49 2522 77 0 Fax 49 2522 77 2488 ws info geagroup com www westfalia separator com ...

Page 3: ...ture Max admissible rated bowl speed in min 1 Max admissible density in kg dm 3 of product Heavy liquid kg dm 3 Solids kg dm 3 Min max throughput m 3 h Min max temp of product in C Min max housing pressure range in bar This nameplate must be filled in by the operator Please transfer the data from the centrifuge nameplate ...

Page 4: ...in electrical components take adequate preventive measures according to the national provisions in Germany in accor dance with the rules and regulations of the VDE Verein Deutscher Elektrotechnik Association of German Electrical Engineering or of the local electric power company Non compliance with the protective measures can result in serious damage to persons or property Any work on electrical c...

Page 5: ...ionally to the owner or operator irrespective of existing warranty periods in so far as the machine is improperly maintained or serviced by persons other than GEA Westfalia Separator service personnel or if the machine is not applied in accordance with the intended use GEA Westfalia Separator shall not be liable for damage which occurs as a result of non observance of the above Warranty and liabil...

Page 6: ...ersonal protective measures 36 2 Machine description 37 2 1 Standard dimensioned drawing of the separator 38 2 2 Section through separator 40 2 3 General 41 2 4 OSE 0136 41 2 4 1 Separator with water content and sludge space monitoring system WMS and SMS for fuel oil treatment 42 2 5 Main components of the separator 43 2 5 1 Centripetal pump 45 2 5 2 Bowl 46 2 5 3 Bowl hydraulics 47 2 5 4 Drive 50...

Page 7: ...enance schedule 105 4 3 2 Hoses and hose pipes 112 4 3 3 Lubrication 113 4 3 4 Lubrication Chart 116 4 3 5 Table of lubricating oils 118 4 3 6 Comments on table of lubricating oils for separators from GEA Westfalia Separator 119 4 4 Bowl 120 4 4 1 Dismantling the bowl 122 4 4 2 Cleaning the bowl 138 4 4 3 Cleaning the frame 139 4 4 4 Cleaning the strainer and the operating water feeding system 139...

Page 8: ...201 4 10 Storage 202 4 10 1 After delivery 202 4 10 2 Separator 202 4 10 3 Control system 202 4 11 Before restarting 203 4 12 Disposal 204 4 12 1 Gear and lubricating oils 204 4 12 2 Cleaning liquids 205 4 12 3 Separator 205 4 13 Standard tools 206 4 14 Special tools 208 5 Spare parts 211 5 1 Spare part requirements 212 5 2 Guide to ordering spare parts 212 ...

Page 9: ... 1 5 1 Demands on the operating and maintenance personnel 18 1 5 2 Spare part requirements 19 1 5 3 Assembly 19 1 5 4 Electrical installation 22 1 5 5 Before start up 23 1 5 6 Start up 25 1 5 7 Shut down and Emergency Off 27 1 5 8 Voltage cutoff during operation 28 1 5 9 Maintenance and repair 29 1 6 Corrosion 33 1 7 Erosion 34 1 8 The health hazards involved when handling heavy oils and lube oils...

Page 10: ...rator agreed with GEA Westfalia Separator Refer to the data sheet and contractually agree ments in accordance with the admissible utilities cleaning agents lubricants operat ing liquids etc specified in the documentation or on the data sheet Intended use involves paying attention to the safety precautions the instruction manual of the sepa rator and the safety markings on the separator adhering to...

Page 11: ...r may not be operated when the product fed does not conform to the specifications on the name plate Product with excessively high density Solids with excessively high density Product with excessively high temperature when the max admissible bowl speed has been exceeded through electrical or electronic manipulation of the drive in an incomplete state of assembly e g required supervisory equipment i...

Page 12: ...clearly visible All safety markings on the separator control system and plant components must always be in perfect condition Clean dirty safety markings Replace damaged safety markings Fig 1 Example of markings on a separator 1 Pictograms safety stickers 2 Oil quality 3 Plates 4 Nameplate 5 Maker s nameplate The texts and part numbers of the safety markings change depending on the languages requir...

Page 13: ...labels Fig 2 Refer to the machine documen tation Every person who is assigned the task of installing operating main taining and repairing the machine must have read and understood the documentation The documentation must be com plete kept near to the machine and be readily accessible to the opera tors It must be available to the op erators at all times Fig 3 ...

Page 14: ...prevent it from being accidentally switched on Fig 4 Danger to life and limb through rotating machine parts Do not loosen any part and do not carry out maintenance or repair work on the separator before the separator is at a standstill Methods of how to check standstill are described in the machine docu mentation Fig 5 Warning of unusual noises or vibrations When unusual noises or vibrations occur...

Page 15: ...easures can result in serious dam age to persons or property Before working on electrical separa tor plant components Switch off all electrical appliances via the main switch Fig 9 CAUTION The parts marked in this way can carry voltage even when the main switch is off Lock the separator plant to prevent it from being accidentally switched on Take adequate preventive measures according to the natio...

Page 16: ... The circuits marked in this way can carry voltage even when the main switch is off Fig 10 Example 1 ACHTUNG Auch bei ausgeschaltetem Hauptschalter können orangefarbige Leitungen unter Spannung stehen ATTENTION Also in case of switched off main isolator orange coloured cores can be under voltage ATTENTION Lorsque le commutateur principal est éteint les files orange peuvent être sous tension Danger...

Page 17: ... High centrifugal forces are produced in the rotating bowl Fig 13 Under the influence of the centrifugal forces separation of the liquid mixture and or ejection of the solids particles takes place most rapidly The specifically heavier components are displaced to the bowl periphery whe reas the specifically lighter components are displaced towards the centre of the bowl The high centrifugal force i...

Page 18: ...ing assembly and handling errors and severe damage to persons and property GEA Westfalia Separator accepts no liability for damage caused by un qualified or unauthorized personnel For operation maintenance and repair work personnel may only be deployed who have reached a minimum age of 18 years are demonstrably familiar with the state of the art through briefings and train ing are adequately quali...

Page 19: ...rability of these parts reduced availability of the separator and increased service requirement If a safety risk occurs when using non original spare parts this may have legal consequences for the responsible persons In such cases GEA Westfalia Separator accepts no liability or war ranty claims Fig 15 1 5 3 Assembly If the plant has several centrifuges be careful not to interchange parts of differ...

Page 20: ... replacing some bowl parts like Lock ring Bowl top Distributor Bowl bottom Water chamber bottom GEA Westfalia Separator must be consulted These parts are marked with a footnote in the separator manual see section Bowl are marked in the column ETS of the parts list with a 3 or 4 Fig 19 Some bowl parts are arranged in fixed positions relative to one an other Locking devices and alignment marks must ...

Page 21: ...arks on the bowl bottom or bowl top and on the lock ring must be in line with each other Pay attention to the position of the marks CAUTION A loose lock ring can endanger life Fig 23 Tighten the spindle screw with the separator specific torque left hand thread CAUTION A loose spindle screw can endanger life Fig 24 Tighten the centripetal pump cham ber lock ring or cover securely left hand thread C...

Page 22: ...electri cian The governing accident prevention regulations apply for the electrical appliances and installations Special attention must be paid to the installation guidelines of GEA West falia Separator The frequency and voltage of the power supply must correspond to the machine specifications Fig 28 Carry out voltage equalization Observe legal regulations e g in the EU Low voltage guideline 2006 ...

Page 23: ...he O marks on bowl bottom or bowl top and on the lock ring must be aligned Fig 29 The bowl must rotate in clockwise direction see arrow on frame or sol ids collector Fig 30 The separator may only be operated with protection devices conforming to EN 294 Equip solid and liquid discharges accordingly where appropriate Fig 31 ...

Page 24: ...ted When hoods concentrate collectors and vessels are pressurized e g by inert gas blanketing cooling steam sterilization etc the pressures stated on the boiler plate must not be exceeded Fig 33 Check that the product lines are set to operation Regularly check hoses for signs of ageing Check sight glasses for mechanical damage Damaged parts must be replaced immediately by new or reconditioned part...

Page 25: ...ity of the solids centrifugally dry are maximum values and must not be exceeded Fig 35 Wear ear protection Fig 36 In case of frequency converter operation Do not under any circumstances manipulate the frequency converter to exceed the permissible bowl speed see nameplate The separator may only be operated with an independent device for speed limiting Fig 37 ...

Page 26: ...et of the product Use protective gear e g Protective clothing Eye protection Protective mask Fig 39 When unusual noises or vibrations occur on the separator Immediately shut down the separa tor with filled bowl via emergency off Never trigger a bowl ejection Evacuate the room Do not re enter the room until the separator has come to a standstill Fig 40 Only in case of hot operation Product contacti...

Page 27: ...liquid supply for more than 15 30 minutes as otherwise it would result in overheating of the bowl ma terial Fig 42 1 5 7 Shut down and Emergency Off For shut down of the separator refer to the chapter Operation of this manual and follow the start up and shut down instructions Fig 43 ...

Page 28: ...r motor and product feed pump will be switched off The control system switches itself back on automatically when the power returns After the power returns Switch on the separator motor and product feed pump A closing water pulse after run up of the separator triggers a total ejection automatically When unusual noises or vibrations occur on the separator Immediately shut down the separa tor with fi...

Page 29: ...nt operation Fig 45 Timely maintenance of the separator and replacement of worn or damaged ma chine parts is essential for safe operation of the machine Use only genuine spare parts from Westfalia Separator Otherwise safety risks may arise see section 1 5 2 Carry out the required cleaning thoroughly One sided solid deposits in the bowl cause severe unbalance Maintenance and repair work may only be...

Page 30: ...witched on Fig 46 Do not loosen any part and do not carry out maintenance or repair work on the separator before the separator is at a standstill The standstill check is described in the section bowl Fig 47 Do not climb onto or stand on the machine or parts of the machine Make provision for and use a sturdy working platform Fig 48 Place dismantled machine parts on a suitable base e g rubber mat Se...

Page 31: ...oists the applicable legislation and safety rules have to be strictly observed CAUTION Danger to life when transporting heavy parts Do NOT step under hanging load Special tools e g compressing assembly devices pin spanners may only be used for their intended purpose i e the work routines as described in this instruction manual Before using the standard and special tools supplied check them for dam...

Page 32: ...llect dripping oil to prevent danger of slipping or product infection When handling waste oils note They can be injurious to health depending on their chemical com position Waste oil must be disposed of in accordance with local regulations Fig 52 ...

Page 33: ... is generally caused by chlorine ions Depending on the stressing of the part pit shaped corrosion can result in crack shaped corrosion Possible formation of pit shaped cor rosion Fig 53 Such pittings can only be investigated by a materials expert In case of crack shaped corrosion attack with or without superposed flat spread and pit shaped corrosion on main bowl components the machine must be shut...

Page 34: ... of erosion should be carefully observed and documented Ero sion can deepen rapidly thereby weakening the bowl material Contact your nearest Westfalia Separator representative for a thorough exami nation Information on the nature of the damage can be provided by photos plaster casts or lead molds Fig 55 The surfaces most susceptible to erosion are 1 the bottom of the distributor the rising channel...

Page 35: ...erosion which you should immediately report to your nearest Westfalia Separator representative The bottom of the erosion mark has a radius smaller than 1 mm large notch effect The depth of erosion mark exceeds 1 mm 0 04 inch at the deepest point Fig 56 ...

Page 36: ...mation of the skin pores oil acne damage to the central nervous system after inhalation over a long period skin cancer caused by direct skin contact over a long period Lung cancer or cancer of the digestive organs after inhalation over a long period not certain as the causes are difficult to separate from the effects of smoking and alcohol 1 8 1 Code of practice and personal protective measures Av...

Page 37: ... 5 1 Centripetal pump 45 2 5 2 Bowl 46 2 5 3 Bowl hydraulics 47 2 5 4 Drive 50 2 5 5 Solenoid valve block 51 2 6 Supervisory equipment 55 2 6 1 Pressuretransmitter 55 2 6 2 Water detector 56 2 6 3 Solenoid valve 58 2 6 4 Vibration monitoring Option 60 2 6 5 Speed monitoring 61 2 7 Product feed line and product discharge line 62 2 7 1 Throughput monitoring product feed line A 62 2 7 2 Throughput de...

Page 38: ...d Solids discharge Water discharge operating water discharge Water discharge Opera ting water discharge The complete bowl can then be transported over adjacent separators of identical type These dimensions must be adhered to Do not discharge residuals into public waters Refer to the installation guidelines for further information Centre of gravity Minimum lifting capacity hoist 100 kg For repair a...

Page 39: ... The separator foundation must not have contact with foundations of other units e g aux iliary diesel engine pumps to avoid damage to roller bearings Operating side Socket Product discharge Filling displacement and operating water feed Pressure transmitter product dis charge Pressure transmitter Self thinker system 2 2 way solenoid valve water dis charge 2 2 way solenoid valvel circuit Terminal bo...

Page 40: ...40 2064 9001 001 1010 Westfalia Separator 2 2 Section through separator Fig 59 ...

Page 41: ... solids from a liquid Prerequisite for treatment technology separation is that the components of the product can be separated mechanically have different densities and do not emulsify 2 4 OSE 0136 The OSE separator 0136 with unitrolplus System is equipped with a self cleaning disk bowl It is used for clarification and purification of fuel oil heavy oil up to a density of 1 01 g ml The separator wi...

Page 42: ... occurs 1 through a closed line system The clean oil is discharged 2 under pressure by centripetal pump 12 via the clean oil discharge The bowl is automatically opened and closed for desludging at full bowl speed by means of a solenoid valve 19 in the operating water line The partial flow 9 diverted from the bowl via the separating disk 13 and the sensing liquid pump 11 is monitored by a water det...

Page 43: ... and discharges see section 2 7 4 Sensor block is fitted to the hood can be replaced as a complete unit contains the following parts Regulating ring see section 2 6 1 Pressure transmitter unitrolplus system SMS function see section 2 6 1 2 2 way solenoid valve water outlet see section 2 6 3 2 2 way solenoid valve circulation see section 2 6 3 Water detector unitrolplus system WMS function see sect...

Page 44: ...ction 7 Sight glass allows checking the oil level 8 Sight glass for checking the drive belt 9 Solenoid valve block See section 2 5 5 10 Drive See section 2 5 4 11 Motor accelerates the separator to the required speed is protected against overload during operation ...

Page 45: ... with channels dips into the liquid rotating with the bowl The liquid is pared off by the centripetal pump and flows through its spiral channels from the outside to the inside By this means the kinetic energy is converted into pressure energy which makes possible discharging the liquid under pressure 3 Sensing liquid pump operates on the same principle as centripetal pump 1 conveys the sensing liq...

Page 46: ...nents consists of a large number of conical disks positioned on top of one another Each disk is provided with spacers so that pre cisely defined interspaces are formed between the individual disks The smooth disk surfaces facilitate sliding of the solids and hence self cleaning of the disks Separation chamber The separation space consists of a large number of parallel chambers of low height This p...

Page 47: ... ating liquid generates a high centrifugal pres sure This pressure is utilised for actuating the annular piston and sliding piston which closes and opens the bowl 2 Annular piston is inside the bowl bottom rotates with the same angular velocity as the other bowl parts is axially movable 3 Sliding piston is located inside the bowl bottom rotates with the same angular velocity as the other bowl part...

Page 48: ... the bowl is closed as follows Pos Designation Function 1 Operating liquid flows into the injection chamber 4 of bowl bottom 5 and from there through feed holes into closing chamber 6 This initiates closing of the bowl 2 Annular piston moves into closed position 3 Sliding piston is raised due to the hydrostatic pressure in closing chamber 6 is pressed against the gasket 7 of bowl top due to the hy...

Page 49: ...pened with the aid of the control unit and the ejection cycle is triggered as follows Pos Designation Function 1 Operating liquid flows first into injection chamber 4 and from there into opening chamber 8 2 Annular piston rises and empties closing chamber 6 3 Sliding piston moves downwards and opens the ejection ports in bowl bottom 5 for the separated solids 9 A B ...

Page 50: ...elt and motor Important The driving effect of new clutch shoes will improve after several starts Smoking of the centrifugal clutch during the first few starts is perfectly normal and will dis appear after a short time of operation Wear to the clutch shoes depends on the number of starts and the ejection frequency see section 4 3 1 3 Drive belt transfers the drive power of the drive motor 1 to the ...

Page 51: ...es with servo control They are equipped with a man ual override for testing purposes Fig 68 10 Pressure controller 90 Diaphragm 20 Sleeve type ball valve 100 Magnet core 30 Pressure gauge 110 Coupler socket 40 Filter insert 130 Hose 70 Magnet coil 80 Housing A Manual override Manual override A The manual override can only be actuated with a screwdriver 1 closed 2 open Fig 69 ...

Page 52: ...span 7 Pressure setpoint correction Open the operating water valve using the manual override see Fig 69 Pressure setpoint is too low Increase the pressure setpoint Turn setpoint screw clockwise Pressure setpoint is too high Decrease the pressure setpoint Turn setpoint screw counter clockwise The adjusted pressure setpoint is indi cated on pressure gauge 30 SW jaw span Fig 70 ...

Page 53: ... 0 to 10 bar Control range 1 to 6 bar Pressure setpoint 2 bar with open operating water solenoid valve Temperature Medium 10 to 80 C 14 176 F In case of electrical faults CAUTION Danger due to electrical current Switch off the main switch and lock it Close the main valve for operating water filling and displacement water CAUTION Danger of injury through very hot separator parts When carrying out m...

Page 54: ...rt Wire break in the connect ing terminal Replace wire Connecting terminal on the connector block is loose Tighten the screw of the connecting terminal Bad contact on the con necting terminal Clean or replace the con tact Coupler socket loose Tighten coupler socket Magnet coil defective Replace the solenoid head Diaphragm defective Replace diaphragm ...

Page 55: ...The pressure transmitter PT1 is installed in the product discharge line PT2 is installed on the Unitrolplus System Note Refer to the circuit diagram in the control cabinet and the manual of the control system Setting the switching points The switching points are set at the factory using appropriate software Factory settings Product discharge line Unitrolplus System Pressure transmitter PT1 Pressur...

Page 56: ...257 F Medium temperature 2 6 2 Water detector The WMSwater detector WMS sen sor is included in the standard equip ment is built into the unitrolplus System monitors the partial flow that is dis charged from the bowl via the sepa rating disk and the sensing liquid pump can be checked for functionality using appropriate software Fig 72 Note Refer to the terminal connection plan in the control cabine...

Page 57: ...0 to 100 C 22 to 212 F Temperature drift dependent on medium Enclosure according to IEC 60529 Terminal strip IP 54 Probe IP 68 10 bar Housing material MS Immersion tube PTFE Connector plug Terminals See terminal allocation Connection M 30 x 1 5 Jaw span 32 Supply voltage UB 10 to 35 V DC Conformity EMC electromagnetic compatibility according to IEC 60947 5 2 ...

Page 58: ... closed Nominal width 3 mm Gasket material FKM Material CuZn Line connection G 1 4 sleeve Voltage 24 V Kind of current DC direct current Rating 8 W In case of electrical faults CAUTION Danger due to electrical current Switch off the main switch and lock it Close the main valve for operating water filling and displacement water CAUTION Danger of injury through very hot separator parts When carrying...

Page 59: ...rvice backup support Wire break in the connect ing terminal Replace wire Connecting terminal on the connector block is loose Tighten the screw of the connecting terminal Bad contact on the con necting terminal Clean or replace the con tact Magnet coil defective Replace the solenoid head Diaphragm defective Replace diaphragm ...

Page 60: ...d in the control cabinet evaluates the signals coming from the vibra tion pickup The evaluation of the signal depending on the version takes place in the control cabinet on the control unit or directly on the vibration pickup When the limit value or values are exceeded an alarm and follow up measures are triggered and the separator motor switches off automati cally The operating status can be read...

Page 61: ...pulses triggered from the spindle to control unit 3 ATTENTION Align the proximity switch as illustrated The distance X between the spindle and the proximity switch must be 2 5 mm 3 Control unit evaluates the speed pulses triggers an alarm if the bowl speed is too low or too high initiates a shut down process if the bowl speed is too low or too high indicates the current bowl speed and permits sett...

Page 62: ...e effective throughput capacity of the separator is stated on the project de pendent data sheet The inner diameters of the orifice plates required for the different throughput ca pacities can be read from the following table Flowmeter Scale 0 10 Throughput capacity Inner diameter of orifice plate l h mm 1 000 1 400 6 1 400 2 200 8 2 200 3 300 10 3 300 4 800 12 4 800 7 000 14 7 000 13 000 no orific...

Page 63: ...value and the setpoint value can be adapted in the control unit 2 7 2 Throughput determination product feed line A only for control D10 Fig 77 Diagram for determining the throughput rate A Inner diameter of orifice plate mm B Throughput capacity x 1000 l h C Scale area of flowmeter The throughput capacity of the separator volume of product to be treated fed by unit of time can be determined with t...

Page 64: ...ct to be processed Viscosity Temperature Density The parameters mentioned here can lead to inexact determination of the throughput rate 2 7 3 Pressure monitoring product discharge line B The pressure in the discharge line is displayed on pressure gauge 1 see Fig 76 Note factory adjusted switch points see section 2 6 1 The inner diameters of the orifice plates required for the different throughput ...

Page 65: ...x 2 4 min Run down time after switching off the motor with drive belt 45 min Run down time without drive belts i e in the case of torn jumped off or defective drive belt 90 min Centripetal pump Output depending on medium max 10 000 l h Pressure head 1 2 bar Operating water Qty min 1 800 l h Pressure with open valve 2 3 bar Standard operating water specification Suspended matter max 10 mg l Particl...

Page 66: ...n this manual The exact separating temperature of the product in C is stated in the order specific data sheet Motor Power rating 50 Hz 7 5 kW 60 Hz 8 6 kW Speed 50 Hz 3 000 RPM 60 Hz 3 600 RPM Design IM V1 Enclosure IP 55 Drive 50 60 Hz Oil filling approx 2 5 l Oil quality see section 4 3 3 Product feed pump Pump unit gear or screw pump Output depending on plant rating Suction height max 0 4 bar P...

Page 67: ... up 70 3 2 1 Before the first start up after maintenance and repair 70 3 2 2 Before every start up 72 3 3 Starting the separator 73 3 4 Monitoring of operation 74 3 5 Setting the separation time 76 3 5 1 Mathematical calculation 76 3 6 Ejecting the bowl 77 3 7 Shutting down the separator 78 3 7 1 Shut down Emergency Off 80 3 8 Trouble shooting 82 3 8 1 Trouble shooting 82 3 8 2 Bowl faults 84 ...

Page 68: ...solids level in the bowl if SMS was selected on the control unit the sludge space is full before the separating time has elapsed For determining the separating time see 3 5 Sequence of an ejection example without Filling 1 Separating time has elapsed 2 Product feed valve is closed 3 Displacement water displaces the fuel oil to the clean oil side 4 Operating water opens and closes the bowl hydrauli...

Page 69: ... time in the bowl or are stuck too firmly on the wall of the solids holding space due to the solids properties either the separating time must be shortened or a flush ejection must be carried out after the total ejection by filling the bowl with water or product and emptying it again Program control Displacement ejection and flush ejections at precisely defined intervals are best carried out with ...

Page 70: ... separator has been out of operation for longer than 12 months e g due to a long standstill period or storage check all separator parts in accordance with the maintenance schedule table Maintenance after 8000 operating hours or after 1 year at the lat est replace if necessary Ensure that the sight glass in the frame for observing the drive belt is clean the sight glass in the frame for observing t...

Page 71: ...product heating devices are ready for operation option Pay attention to the volumes pressure and temperature see order specific operating data sheet the plant components such as valves water pressure reducer compressed air control unit etc are operational the motor is correctly connected see 4 1 3 the motor is correctly mounted Important Check the remaining plant components such as hose pipes sigh...

Page 72: ... see 4 5 the hoses and hose pipes are undamaged and connected see section 4 3 2 the feed and discharge lines are connected see 4 5 the supervisory equipment is complete mechanically and electrically func tional the product and supply lines are ready for operation Pay attention to the air and water pressures see order specific operating data sheet the product heating devices are ready for operation...

Page 73: ...f rotation of the bowl is correct when the drive belt rotates clockwise check through the sight glass in the frame When the direction of rotation is incor rect the motor connections must be reversed by an authorised specialist Fig 78 Switch on the product feed pump option Ensure that the product feed valves to the suction and pressure side are open ATTENTION Before the first start up after mainten...

Page 74: ...ox 1 5 to 2 5 bar see order specific operating data sheet Adjust the desired throughput capacity while doing so maintain the back pressure in the product discharge line in the specified area ATTENTION Check the discharges for solids and dirty water there must be no oil flow during the separating process 3 4 Monitoring of operation The machine is monitored largely by the separator control Operation...

Page 75: ...spected by our service engineers once a year These checks help to maintain the operating safety of the machine and avoid unscheduled downtime Important Regularly check plant components such as hose pipes sight glasses for signs of aging and mechanical damage Damaged plant components must be replaced immediately by new parts ...

Page 76: ... throughput Given constant conditions the separating time can be determined by calcula tion The following times have proven appropriate in practice examples Product Total ejection Partial ejection HFO max 2 h max 1 h MDO max 2 h max 1 h DO max 4 h max 2 h LO mild max 4 h max 2 h LO HD max 2 h max 1 h 3 5 1 Mathematical calculation Example for mathematical calculation of the separating time Given S...

Page 77: ...eed recovery Filling water process dependent The product valve opens again Manual operation in the case of unscheduled shut down Close the product feed line Close the product feed valve manually Eject the bowl Open the operating liquid valve using the manual override for approx 2 3 seconds Speed recovery Wait for approx 20 30 seconds New separating operation Open the product feed valve manually ...

Page 78: ...EED button shows the post run phase by slow flashing The control valves for thermal oil and steam preheater close automatically ATTENTION If the control unit or the control voltage 24 VDC fails the automatic post run phase of the product feed pump is disabled The product feed pump may never be switched off to the steam shut off valve without a delay time The pre heater could get damaged All heater...

Page 79: ...ife through high speed rotating separator parts In the case of torn or defective drive belts or if the belts have come off Do not loosen any part of the separator before the bowl has come to a stand still Be sure to observe the run down time of 90 minutes until dismantling the separator ATTENTION Only after standstill of the bowl Close the shut off flap in the solids discharge option 1 Shut off fl...

Page 80: ...a main switch grey black and ad ditional connection for an external Emergency Off switch example 2 or an Emergency Off switch yellow red a main switch grey black and ad ditional connection via approved Emergency Off relay for several Emer gency Off switches example 2 Main switch yellow red with inte grated Emergency Off function Actuate the main switch with Emer gency Off function The complete con...

Page 81: ...or N No ot te e N No ot te es s N No ot ti iz ze en n A An no ot ta ac ci io on ne es s Д Дл ля я з за ап пи ис се ей й M Mu ui is st ti ii in np pa an no ot t Σ Ση ημ με ει ιώ ώσ σε ει ις ς N No ot ta at te er r N No ot te es s N No ot te e ...

Page 82: ... slipping on the bowl spindle Replace drive belt Drive belt has not been fitted correctly Check position of drive belt on cen trifugal clutch and bowl spindle Liquid or dirt has collected in the upper section of frame and is braking the bowl Check operating water discharge Liquid must flow off freely Clean inside of upper section of frame The bowl speed drops during operation Friction surfaces of ...

Page 83: ... as sembled or parts of different bowls if plant has several separators have been interchanged Assemble bowl properly 3 The tension in the disk stack has slackened The bowl top is not screwed on until O mark alignment CAUTION A loose bowl top can endanger life The O marks of the bowl bottom and the bowl top must be aligned Insufficient number of disks Check number of disks add a spare disk if nece...

Page 84: ... 14 Bowl bottom 5 Gasket closing chamber bottom 15 Drain hole 6 Gasket annular piston 16 Annular piston 7 Gaskets closing chamber bottom 17 Drain hole 8 Gasket bowl bottom 18 Sliding piston 9 Piston guide ring bowl bottom 19 Bowl top 10 Gasket water chamber bottom 20 Solenoid valve block 21 Solenoid valve for operating water 22 Solenoid valve for filling and displacement water 23 Filling and displ...

Page 85: ...auge the capacity by litres 1 0 l in 3 secs The operating water line 26 has be come constricted due to dirt accumula tion or damage Insufficient operating water is entering the injection cham ber Clean or replace operating water line 26 The operating water solenoid valve 21 does not open properly Check solenoid valve 21 and re place if necessary Bowl hydraulics Bowl hydraulic system is soiled or R...

Page 86: ...bottom 5 Gasket closing chamber bottom 15 Drain hole 6 Gasket annular piston 16 Annular piston 7 Gaskets closing chamber bottom 17 Drain hole 8 Gasket bowl bottom 18 Sliding piston 9 Piston guide ring bowl bottom 19 Bowl top 10 Gasket water chamber bottom 20 Solenoid valve block 21 Solenoid valve for operating water 22 Solenoid valve for filling and displacement water 23 Filling and displacement w...

Page 87: ...he capacity by litres 1 0 l in 3 secs The operating water line 26 has be come constricted due to dirt accumula tion or damage Insufficient operating water is entering the injection cham ber Clean or replace operating water line 26 The operating water solenoid valve 21 does not open properly Check solenoid valve 21 and re place if necessary Bowl hydraulics Bowl hydraulic system is soiled or Remove ...

Page 88: ...bottom 5 Gasket closing chamber bottom 15 Drain hole 6 Gasket annular piston 16 Annular piston 7 Gaskets closing chamber bottom 17 Drain hole 8 Gasket bowl bottom 18 Sliding piston 9 Piston guide ring bowl bottom 19 Bowl top 10 Gasket water chamber bottom 20 Solenoid valve block 21 Solenoid valve for operating water 22 Solenoid valve for filling and displacement water 23 Filling and displacement w...

Page 89: ...r with open valve Volume flow min 1 800 l h gauge the capacity by litres 1 0 l in 3 secs The separating time has been set too long with the result that the solids con tent is too high Shorten the separating time see section 3 5 The bowl opens during sepa ration Closing water pulse is too short Closing water evaporates Readjust the closing water impulse see control unit documentation Closing water ...

Page 90: ...or N No ot te e N No ot te es s N No ot ti iz ze en n A An no ot ta ac ci io on ne es s Д Дл ля я з за ап пи ис се ей й M Mu ui is st ti ii in np pa an no ot t Σ Ση ημ με ει ιώ ώσ σε ει ις ς N No ot ta at te er r N No ot te es s N No ot te e ...

Page 91: ...structions for assembling the bowl 141 4 4 7 Assembling the bowl 143 4 4 8 Replacing the polyamide gasket bowl top 157 4 4 9 Replacing the polyamide gasket bowl top 159 4 4 10 Reworking the sliding piston 166 4 5 Closing the hood 167 4 6 Drive 170 4 6 1 Important instructions for fitting and removing the drive 172 4 6 2 Removing the drive belt and spindle assembly 174 4 6 3 Dismantling the spindle...

Page 92: ... discharge Water discharge operating water discharge Water discharge Opera ting water discharge The complete bowl can then be transported over adjacent separators of identical type These dimensions must be adhered to Do not discharge residuals into public waters Refer to the installation guidelines for further information Centre of gravity Minimum lifting capacity hoist 100 kg For repair and maint...

Page 93: ... The separator foundation must not have contact with foundations of other units e g aux iliary diesel engine pumps to avoid damage to roller bearings Operating side Socket Product discharge Filling displacement and operating water feed Pressure transmitter product dis charge Pressure transmitter Self thinker system 2 2 way solenoid valve water dis charge 2 2 way solenoid valvel circuit Terminal bo...

Page 94: ... suitably rated intact hoists for transport and installation CAUTION Danger to life under hoists Do NOT step under hanging load Always transport the separator without installed bowl For special tools see section 4 14 or parts list Unscrew the screw plug 1 from the lower part of the frame Fig 90 Screw double nipple 1 into the hole in the frame Fig 91 ...

Page 95: ...as tening the ropes Attach the transport ropes to the machine A as illustrated around the double nipple and hang them into the load hook of the hoist as illustrated ATTENTION Prevent the ropes from slipping Wind one piece of rope twice round the hook see detail Make sure the machine touches down gently Fig 92 Unscrew double nipple 1 Fig 93 Screw in the screw plug 1 Fig 94 ...

Page 96: ...e machine the foundation is not connected to foundations of other vibrating units to avoid the transfer of vibrations Align separator 1 with feet 2 and plates 3 on foundation 4 Tack plates 3 Unscrew screws 5 Lift separator with feet see section 4 1 1 Weld plates 3 to foundation 4 Place the separator on plates 3 and bolt tight with hexagon nuts 5 Screw tight hex head screws 6 Fig 95 ...

Page 97: ...ratings are minimum values which are based on the in creased starting current Since the current consumption of the motor drops after start up overloading of the motor during operation is not possible The starting time depends on the flywheel effect of the bowl number of clutch shoes used condition of the clutch shoes The starting current can peak at about 1 8 2 times the rated current see start up...

Page 98: ...ature feelers When testing for continuity use an ohmmeter and not a test lamp Electrical connection CAUTION Danger to life and limb through electric current There might be residual voltage In the case of motors with space heaters residual voltages in the motor terminal box are possible despite switched off main switch Prior to working on the motor Refer to the motor nameplate Refer to the motor in...

Page 99: ...dditional electrical components PTC thermistors or space heaters refer to the motor manual Shipboard operation When operating the machine on board of ship pay attention to the installation guidelines issued by the respective classification societies When using ship wiring cables cable entry must be by means of marine type glands ...

Page 100: ...the bowl is correct when the drive belt rotates clockwise check through the sight glass in the frame When the direction of rotation is incor rect the motor connections must be reversed by an authorised specialist Fig 101 In case of frequency converter operation Before working on the motor note that residual voltage may be present In this connection Read the documentation supplied by the frequency ...

Page 101: ...peed has been rated so as to ensure the operating safety of the separator Before the first start up Check spindle speed bowl speed with a hand tachometer before fitting the bowl CAUTION Risk of injury through rotating spindle Keep a safe distance away from the rotating spindle Do not wear long open hair or wide loose clothing Wear a hairnet IMPORTANT Do not exceed the maximum spindle running time ...

Page 102: ...s CAUTION Operate the separator with fre quency converter speed monitor ing device and hardware controlled speed shut off device Do not under any circumstances manipulate the frequency con verter to exceed the permissible bowl speed see nameplate Check from time to time that the bowl speed see nameplate and motor frequency see nameplate and frequency converter display coincide with the separator s...

Page 103: ...1 Pressure gauge 2 Orifice plate 3 Orifice plate 4 Flow indicator option for control D10 5 Pressure transmitter option for control E40 6 3 2 way valve ATTENTION Before starting up the separator check that the following parts are installed Orifice plates 2 and 3 Select the orifice plates from the set of plates supplied according to the re quired throughput capacity see section 2 7 Install orifice p...

Page 104: ...am The circuit diagram is kept inside the control cabinet 4 2 1 Installing the orifice plates Installation of the orifice plates is explained here for product feed line B for ex ample Required material Open ended wrench Lubricating grease Unscrew corrugated hose 3 Insert the selected orifice plate 2 into connection piece 1 and press in evenly by hand Fig 106 Slightly grease the threaded area of co...

Page 105: ...mal operating conditions Negative operating conditions e g low grade fuel excessively high temperature strong vibrations frequent starting and stopping of the separator etc can necessitate shorter maintenance intervals To assure correct functioning and operating safety in case of non routine shut down see section 3 7 manual operation Pay attention to the following points during servicing Oil level...

Page 106: ...106 2064 9001 001 1010 Westfalia Separator Fig 108 Set of spare parts bowl hood operation 1 year or 8000 hours ...

Page 107: ... of spare parts bowl hood Operation 1 year or 8 000 hours See spare parts list Important Time consuming installation Only replace polyamide gasket 100 if damaged see section 4 4 9 Check the motor Re lubricate motor bearings if required See instructions of motor manufacturer When using mineral oil Oil change and thorough cleaning of the drive chamber See section 4 3 3 oil quality and oil change Cle...

Page 108: ...108 2064 9001 001 1010 Westfalia Separator Fig 109 Set of spare parts bowl hood operation 1 year or 8000 hours ...

Page 109: ... h smaller than 18 mm New condition of clutch shoe h 26 mm Check the motor Re lubricate motor bearings if required See instructions of motor manufacturer Oil change and thorough cleaning of the drive chamber When using mineral oil 2 When using synthetic oil 2 Check the bowl height See section 4 7 1 In case of direct current Check the spindle speed bowl Check only after motor or drive replacement S...

Page 110: ...110 2064 9001 001 1010 Westfalia Separator Fig 110 Set of spare parts bowl hood operation 1 year or 8000 hours ...

Page 111: ... bearings if required See instructions of motor manufacturer Oil change and thorough cleaning of the drive chamber When using mineral oil 2 When using synthetic oil 2 Check the bowl height See section 4 7 1 In case of direct current Check the spindle speed bowl Check only after motor or drive replacement See section 4 1 5 In case of three phase current Check the spindle speed bowl Check only after...

Page 112: ...en an inspection reveals one or more of the following de fects Damage of the outer layer down to the fabric e g chafe marks cuts or cracks Leaky spots Damage to or deformation of the hose fittings Slight surface damage is not a reason for replacement The hose becomes dislodged from the fitting Corrosion of the fitting diminishing function and strength Protective hose 1 Fit the protective hoses at ...

Page 113: ...100 Viscosity class SAE 30 Viscosity at 40 o C 104 o F 100 10 mm 2 s cSt Part Number 0015 0003 080 2 5 litres Dispose of the oil as per instructions of the oil manufacturer The viscosity class SAE 30 covers a larger viscosity range than specified here However only oils with the viscosity range specified here may be used OIL QUALITY synthetic oil Use the synthetic lube oil tested by Westfalia Separ...

Page 114: ... the sight glass dur ing operation 1 Maximum oil level 2 Minimum oil level Fig 113 Minimum oil level at separator standstill approx up to lower third of sight glass Maximum oil level at separator standstill up to middle of sight glass OIL CHECK Check the oil level every week From time to time undo the oil drain screw and check whether there is water in the oil bath When the oil exhibits a milky co...

Page 115: ...or N No ot te e N No ot te es s N No ot ti iz ze en n A An no ot ta ac ci io on ne es s Д Дл ля я з за ап пи ис се ей й M Mu ui is st ti ii in np pa an no ot t Σ Ση ημ με ει ιώ ώσ σε ει ις ς N No ot ta at te er r N No ot te es s N No ot te e ...

Page 116: ...116 2064 9001 001 1010 Westfalia Separator 4 3 4 Lubrication Chart Fig 114 Lubrication schedule ...

Page 117: ...100 4 000 2 x 2 500 cm 3 Drive chamber CC 100 ISO 3498 Lube oil synthetic ISO VG 68 8 000 1 x 2 500 cm 3 Drive chamber 2 according to instructions of motor manufacturer Motor bearings 3 Lubricating grease see parts list as required 2 x apply sparingly Threads and sliding sur faces of bowl 4 1 x Threads of fittings Check oil level regularly through sight glass Manual lubrication Refer to lube oil t...

Page 118: ...mm 2 s cSt HYSPIN AWS 100 100 BTC 3 1 3 CLP 100 90 to 110 0015 0003 080 2 5 l ALPHA ZN 100 CTC 1 MARINE HEAVY 99 CTC 3 MTC 3 GST OIL 100 100 OTC 2 NL Gear Compound 100 OTC 3 Veritas Marine Oil R O 30 108 WTC 2 DELO 3000 Marine Oil 30 104 OSE 5 1 ATLANTA MARINE 30 105 CSD 1 1 3 DISOLA M 3015 OSD 2 TURBINE T 100 95 SD 1 SSD 2 EXX MAR XP 110 TSD 2 NUTO H 100 100 SPARTAN EP 100 ESD 18 2 5 GULF HARMONY...

Page 119: ... tions e g high temperatures the quality of the oils may be insufficient so that more efficient oils e g synthetic oils must be used If necessary consult GEA Westfalia Separator For the different separator types and oil types the viscosity ranges are specified in the table of lubricating oils The operating temperature of the separator exceeds normally 80 o C 176 o F At those temperatures some oils...

Page 120: ...120 2064 9001 001 1010 Westfalia Separator 4 4 Bowl Fig 115 Exploded view of the bowl and centripetal pump ...

Page 121: ... Gasket 260 Gasket 290 Threaded pin ISO 4026 M 10 x 10 1 4571 310 Gasket 320 Centripetal pump chamber cover 330 Centripetal pump chamber cover 340 Lock ring 350 Spindle screw 360 Gasket 510 Centripetal pump compl 520 Gasket 530 Sensing liquid pump 540 Gasket 550 Spacer ring 560 Gasket 570 Gasket 1 IMPORTANT This part can only be replaced by a WS service specialist The complete bowl must be re bala...

Page 122: ...rotating separator parts In the case of torn or defective drive belts or if the belts have come off Do not loosen any part of the separator before the bowl has come to a stand still Be sure to observe the run down time of 90 minutes until dismantling the separator CAUTION Danger of injury through very hot separator parts When carrying out maintenance work there is a danger of injury through hot se...

Page 123: ...g For standard tools see section 4 13 Do not use force when removing or fitting parts Treat all bowl parts gently Always set them down on a rubber mat or a wooden pallet CAUTION Danger of imbalance If an installation is equipped with several separators Do not interchange parts from different bowls The bowl parts are marked with the serial number of the machine or the last three digits of the seria...

Page 124: ...ood Unscrew filling and displacement water line 1 Fig 118 Unscrew handle connection piece 1 by lightly hammering with a mallet left hand thread at the same time hold the centripetal pump with offset screwdriver 2 Fig 119 Remove handle connection piece 1 Fig 120 ...

Page 125: ... hex head screws with their washers Fig 121 Hinge up the hood CAUTION Danger of injury by in correct hinging up of the hood The stirrup must register properly Fig 122 If necessary see section 4 3 1 Take gasket 1 out of the upper sec tion of the frame Fig 123 ...

Page 126: ...wrench left hand thread and re move it Fig 124 Screw handle connection piece into the centripetal pump left hand thread Remove the complete centripetal pump together with the centripetal pump chamber covers Fig 125 Required special tool Pressure piece 1 Insert pressure piece 1 into spacer ring 2 Pull off spacer ring 2 with fitted gas kets with the aid of a commercial puller Fig 126 ...

Page 127: ...ing out the bowl Required special tool Socket wrench 1 Unscrew the spindle screw with inserted gasket with socket wrench 1 and a commercially available rat chet wrench left hand thread and remove it Fig 128 Required special tool Eye bolt 1 Bolt unit 1 comprises ring nut hexagon nuts and bolt CAUTION Avoid accidents by using undamaged and complete tools The ring nut and the upper hexagon nut must a...

Page 128: ...under hanging load Lift the bowl out of the frame with the aid of a hoist Set the bowl down on a rubber mat or a wooden pallet for further dis mantling Fig 131 Compressing the disk stack Required special tools Compressing device Eye bolt 1 Bell shaped piece 3 Grease the contact surface of bell shaped piece 3 see chapter 4 3 4 Place bell shaped piece 3 on the bowl top Unscrew hexagon nut 2 Screw ey...

Page 129: ...ss the disk stack firmly Screw tight hexagon nut 1 Fig 133 Lifting off the bowl top Unscrew two threaded pins out of the bowl top with a screwdriver Fig 134 Required special tool ring spanner 1 Remove two hexagon nuts 3 from hex head screws 2 Fig 135 ...

Page 130: ...bowl top Screw in two hex head screws 2 of the ring spanner and tighten firmly Fig 136 CAUTION Danger of injury through rotating lever Be careful when working in the area around the lever ATTENTION Pay attention to the point of impact A Strike open the bowl top with a mal let left hand thread and unscrew it Fig 137 Remove eye bolt bell shaped piece and ring spanner Fig 138 Lift off the bowl top wi...

Page 131: ...or Removing the separating disk Remove the Separating disk from the distributor neck Fig 140 Removing the disk stack and the distributor Remove the disks out of the distribu tor one by one or group wise Fig 141 Remove the distributor Fig 142 ...

Page 132: ...nsert the spindle screw into the hub Fig 143 Required special tools Eye bolt 1 Bell shaped piece 2 Unscrew hexagon nut 3 Fig 144 Assemble eye bolt 1 and bell shaped piece 2 Screw eye bolt 1 into bell shaped piece 2 Screw eye bolt 1 into hexagon nut 3 by approx 20 mm Fig 145 ...

Page 133: ... fitted eye bolt into the thread of the sliding piston Fig 146 Required special tool Socket wrench 1 Press off the sliding piston from the bowl bottom by turning the socket wrench clockwise Fig 147 Remove the sliding piston with fitted gasket with bell shaped piece and eye bolt Remove the bell shaped piece and the eye bolt Fig 148 ...

Page 134: ...crew the Allen screws holding the bowl bottom and the closing chamber bottom together Fig 149 Required special tools Eye bolt 1 Bell shaped piece 2 Assembling device 3 Unscrew hexagon nut 4 Fig 150 Assemble eye bolt 1 and bell shaped piece 2 Screw eye bolt 1 into bell shaped piece 2 Screw eye bolts 1 into hexagon nut 3 by approx 20 mm Fig 151 ...

Page 135: ...nnular piston 6 Make sure that disks 5 are properly positioned in the mounting groove of the annular piston Firmly re tighten Allen screws 4 Fig 152 Force off closing chamber bottom 3 together with annular piston 4 by turning wrench 5 clockwise Fig 153 Remove closing chamber bottom 3 and annular piston 4 with fitted gaskets with the bell shaped piece and the eye bolt Remove the bell shaped piece a...

Page 136: ...136 2064 9001 001 1010 Westfalia Separator Unscrew spindle screw 1 Fig 156 If necessary Remove gasket 1 and piston guide ring 2 Fig 157 ...

Page 137: ...ter chamber bottom Required special tool Socket wrench 1 Turn bow bottom through 180 o up side down Unscrew four Allen screws 2 from water chamber bottom 3 Fig 158 Force off water chamber bottom 1 with a screwdriver and remove it with inserted gaskets Fig 159 ...

Page 138: ...th citric acid For cleaning the individual disks and bowl parts Do not use metal scrapers and metal brushes Take the gaskets out of the bowl parts Clean the grooves and gaskets to avoid corrosion in the grooves Replace damaged very swollen hardened or brittle gaskets immedi ately Fig 160 Clean the small holes for the feed and discharge of the operating liquid with particular care to ensure trouble...

Page 139: ...nto the drive belt via the spindle Make sure that protective cap 2 and spindle cap 1 with inserted gasket are installed Fig 162 4 4 4 Cleaning the strainer and the operating water feeding system The strainer and the operating water feeding system must be cleaned de pending on the quality of the operating water and overall load See section 4 3 1 Maintenance schedule Use citric acid in case of furri...

Page 140: ... furring Thoroughly clean the parts with water Fig 163 Fit the cleaned or new filter element 3 IMPORTANT Cooper strip to the inside Firmly screw in screw 1 with fitted gasket 2 so that it seals well 4 4 5 Cleaning the motor CAUTION Danger to life through electrical components Never rinse off the motor with a direct water jet Keep the motor clean as specified in the manual ...

Page 141: ...owl are clean Grease the guide surfaces as specified in the lubrication schedule see 4 3 4 Some bowl parts are arranged in fixed positions relative to one an other Locking devices and alignment marks must be in perfect condition IMPORTANT The bowl must otherwise not be op erated Fig 164 When fitting the bowl parts make sure that the O marks on all parts are aligned Only then will the parts fit cor...

Page 142: ... when removing or fitting parts CAUTION Danger of imbalance If the plant has several separators be sure not to interchange parts of different bowls The parts are marked with the serial number or the last three digits of the serial number Fig 166 Thoroughly clean the gasket grooves of the individual bowl parts and apply a thin coat of grease After fitting check that the gaskets are not twisted the ...

Page 143: ...bot tom Turn bow bottom through 180 o up side down Place water chamber bottom 3 on the bowl bottom The O marks of the bowl bottom and the water chamber bottom must be aligned Screw in the four Allen screws 5 holding the water chamber bottom and bowl bottom together tight Torque 25 Nm Fig 168 Installing the annular piston and the closing chamber bottom Grease guide surfaces as specified in the lubr...

Page 144: ...irmly Grease guide surfaces as specified in the lubrication schedule see 4 3 4 Fig 170 Insert annular piston 1 into bowl bottom 2 Fig 171 Required special tools Compressing device Eye bolt 1 Bell shaped piece 2 Unscrew hexagon nut 3 Fig 172 Turn sliding piston 3 through 180 o upside down Place sliding piston 3 bell shaped piece 2 and eye bolt 1 on the annu lar piston Fig 173 ...

Page 145: ...Insert gaskets 1 and 3 in the grooves of the closing chamber bot tom Grease guide surfaces as specified in the lubrication schedule see 4 3 4 Fig 175 Insert closing chamber bottom 1 into the annular piston The O marks of the closing cham ber bottom and the bowl bottom must be aligned Fig 176 Fasten closing chamber bottom 1 onto the bowl bottom by tightening Allen screws 2 crosswise Fig 177 ...

Page 146: ...g the closing chamber bottom and the bowl bottom together Torque 25 Nm Fig 178 Make sure that piston guide ring 1 is firmly located in the groove Fig 179 Installing the sliding piston Insert the gasket in the groove of the sliding piston Grease guide surfaces as specified in the lubrication schedule see 4 3 4 Fig 180 ...

Page 147: ...d into the bolt and be secured with Loctite 275 Grease thread 1 of the sliding piston see chapter 4 3 4 Screw bell shaped piece 2 into the thread of the sliding piston Fig 182 Install the sliding piston with fitted gasket into the bowl bottom with screwed in bell shaped insert Screw the eye bolt into the bowl bottom through the bell shaped piece Press the sliding piston into its seat as far as it ...

Page 148: ...d Fig 184 ATTENTION Pay attention for cor rect total number of disks It is marked on the blind disk e g 84 1 Total number of disks A and B 84 number of disks with spacers A number of blind disks B Number of blind disks B 1 Fig 185 ATTENTION The last disks must be properly located in the guide ribs of the distributor Carefully stack the disks on the dis tributor neck one by one or group wise Fig 18...

Page 149: ...ned Fig 187 Slightly compress the disk stack with the bell shaped piece and the eye bolt Fig 188 Installing the bowl top Thoroughly clean the grooves for gaskets 1 and 2 in the bowl top Check gaskets 1 and 2 replace when damaged install if missing Check the inserted gasket 3 replace when damaged For replacing the polyamide gas ket 3 see section 4 4 8 Fig 189 ...

Page 150: ...190 Required special tool ring spanner 1 Remove two hexagon nuts 3 from hex head screws 2 Important If threaded pins are screwed into the bowl top undo them with a screw driver The O mark of the bowl top must be visible Do NOT hide them under ring spanner 1 The arrow and the open mark must show upwards Fig 191 Bolt ring spanner 1 to the bowl top Screw in two hex head screws 2 of the ring spanner a...

Page 151: ... again and Screw in the bowl top using the ring spanner left hand thread Fig 194 CAUTION Danger of injury through rotating lever Be careful when working in the area around the lever ATTENTION Pay attention to the point of impact A CAUTION A loose bowl top can endanger life Strike the bowl top with a mallet until the O mark is reached left hand thread Fig 195 ...

Page 152: ... bell shaped piece and ring spanner Fig 196 Screw in two threaded pins using a screwdriver Fig 197 Installing the complete bowl and the centripetal pump Clean and wipe dry the spindle cone with a suitable cloth ATTENTION Do not grease the conical parts Fig 198 ...

Page 153: ...e cloth ATTENTION Do not grease the bowl hub Fig 200 CAUTION Danger to life when transporting heavy parts Do NOT step under hanging load Carefully place the bowl using eye bolt and hoist on the spindle cone Unscrew the eye bolt from the bowl bottom and remove the hoist Fig 201 Required tools Socket wrench Torque wrench Provide spindle screw 2 with gasket 1 Put spindle screw into socket wrench and ...

Page 154: ... The control dimension B is 4 1 5 mm between the bowl and the upper section of the frame Pay attention to bowl height A see section 4 7 1 Fig 204 Insert gasket 1 in the centripetal pump groove Lightly grease threads and contact surfaces of the centripetal pump Install centripetal pump 2 Fig 205 Insert gaskets 1 and 2 in the grooves of the centripetal pump chamber cover Fig 206 ...

Page 155: ...id pump Fig 208 Mount the centripetal pump chamber cover The O marks of the centripetal pump chamber cover and the bowl top must be aligned Fig 209 Required special tool Double hook wrench Grease the threads on the bowl top and on the centripetal pump cham ber lock ring as specified in the Lu brication schedule see 4 3 4 CAUTION A loose centripetal pump chamber lock ring can endanger life Screw ti...

Page 156: ... 1010 Westfalia Separator Insert gaskets 1 and 2 in spacer ring Grease the guide surfaces of the centripetal pump as specified in the lubrication schedule see 4 3 4 Fit spacer ring Fig 211 Pay attention to section 4 7 1 ...

Page 157: ...T damage the bowl top groove when screwing in Screw two wooden screws in the holes in the polyamide gasket Force off the old polyamide gasket with the wood screws and lever it bit by bit out of the groove using a screwdriver Fig 213 Note If the polyamide gasket can t be removed repeat this procedure FITTING Thoroughly clean and dry the groove Heat the gasket in approx 80 o C 176 F water for 5 minu...

Page 158: ...g time of 30 minutes Start the program This running time must be adhered to so that the polyamide gasket is pressed properly into the bowl top If the separator is switched off by the program switch on the separator motor by pressing the start key Compare the starting current and starting time with the diagram section 4 1 3 until the bowl reaches the speed specified on the separator nameplate Note ...

Page 159: ...en drilling Drill through the damaged polyam ide gasket twice centrically and vertically with a 2 mm drill bit at a distance of approx 50 to 60 mm Fig 215 ATTENTION Sensitive bowl part Do NOT damage the ring piston groove when screwing in Screw two wooden screws in the holes in the polyamide gasket Force off the old polyamide gasket with the wood screws and lever it bit by bit out of the groove us...

Page 160: ...mide gasket in approx 80 o C 176 F water for 5 minutes Wipe the gasket dry and press it evenly and firmly into the groove at four opposite points Fig 217 Insert annular piston 1 into bowl bottom 2 Fig 218 Required special tools Compressing device Eye bolt 1 Bell shaped piece 2 Unscrew hexagon nut 3 Fig 219 ...

Page 161: ...g 220 Press the annular piston 1 into the bowl bottom by turning hexagon nut 2 clockwise with the wrench Remove special tools and sliding piston Fig 221 Insert gaskets 1 and 3 in the grooves of the closing chamber bot tom Grease guide surfaces as specified in the lubrication schedule see 4 3 4 Fig 222 Clamp mounting ring 1 under the rim of the closing chamber bottom Fig 223 ...

Page 162: ...m and the bowl bottom must be aligned Fig 224 Fasten closing chamber bottom 1 onto the bowl bottom by tightening Allen screws 2 crosswise Fig 225 Required special tool Socket wrench 1 Screw tight the Allen screws holding the closing chamber bottom and the bowl bottom together Torque 25 Nm Fig 226 Insert spindle screw 1 into the hub Fig 227 ...

Page 163: ...ell shaped piece 2 Screw eye bolts 1 into hexagon nut 3 by approx 20 mm Fig 230 Place the bell shaped piece with fitted eye bolt into the bowl bottom Fit assembling device 3 onto the bell shaped piece Loosen three Allen screws 4 using the ratchet wrench with extension and socket Slip three disks 5 of the assembling device towards the periphery under the rim of annular piston 6 Make sure that disks...

Page 164: ...nch 5 clockwise Fig 232 Remove closing chamber bottom 3 and annular piston 4 with fitted gas kets with the bell shaped piece and the eye bolt Remove the bell shaped piece and the eye bolt Fig 233 Separate annular piston 1 from clos ing chamber bottom 2 by tapping with a mallet as illustrated Remove the mounting ring Fig 234 ...

Page 165: ...65 Westfalia Separator Unscrew the spindle screw Fig 235 By carrying out several measure ments around the entire circumfer ence of the annular piston check that the polyamide gasket is seated parallel in the groove Fig 236 ...

Page 166: ... the first erosion marks 0 2 mm deep are detected i e as soon as the bowl starts to leak Remachine the sealing surface of the sliding piston Fig 237 When remachining make sure that the sealing surface is machined cleanly and shoulder H at diameter X is still at least 1 5 mm high Fig 238 Standard parameters for remachining the sealing surface Surface quality Ra 2 µm Rz 12 5 µm Tool Hard metal steel...

Page 167: ... gasket has been removed to keep to the service intervals insert a new gasket 1 in the groove of the upper part of the frame Fig 240 CAUTION Danger of injury Unlock the shackle Carefully close the hood Fig 241 Screw in three hex head screws M 12 x 30 with washers Fig 242 ...

Page 168: ...ation schedule see 4 3 4 Fig 243 Required special tool Offset screwdriver 2 Introduce handle connection piece 1 into the hood Hold the centripetal pump with the offset screwdriver and tighten it by lightly hammering the handle con nection piece with a mallet left hand thread Fig 244 Carefully clean the holes in the non return valve and rinse with water Check the functionality of the non return val...

Page 169: ...or N No ot te e N No ot te es s N No ot ti iz ze en n A An no ot ta ac ci io on ne es s Д Дл ля я з за ап пи ис се ей й M Mu ui is st ti ii in np pa an no ot t Σ Ση ημ με ει ιώ ώσ σε ει ις ς N No ot ta at te er r N No ot te es s N No ot te e ...

Page 170: ...170 2064 9001 001 1010 Westfalia Separator 4 6 Drive Fig 247 Exploded view of the drive ...

Page 171: ...2 14 Drive belt 15 Spindle 16 Hex head screw M 10 x 20 17 Bearing cover 18 Bearing cover 19 Grooved ball bearing 20 Retaining ring 35 x 1 5 21 Ball bearing protection ring 22 Angular contact ball bearing 23 Bearing sleeve 24 Gasket 25 Rubber metal cushion 26 Pivoting bearing 27 Retaining ring 90 x 3 28 Gasket 29 Cup spring 30 Bearing cover 31 Washer 32 Hex head screw This hex head screw is glued i...

Page 172: ...through high speed rotating separator parts In the case of torn or defective drive belts or if the belts have come off Do not loosen any part of the separator before the bowl has come to a stand still Be sure to observe the run down time of 90 minutes until dismantling the separator CAUTION Danger of injury through very hot separator parts When carrying out maintenance work there is a danger of in...

Page 173: ...Use tools only for their intended use For special tools see section 4 14 or spare parts catalog For standard tools see section 4 13 Do not use force when removing or fitting parts Treat all drive parts gently Always set them down on a rubber mat or a wooden pallet ATTENTION Before fitting the drive parts Thoroughly clean and dry the drive chamber Use only a cleaning agent that is approved for the ...

Page 174: ...oving the drive belt and spindle assembly Pay special attention to section 4 6 1 Undo the oil drain screw and Drain the oil into an oil pan approx 2 5 l Fig 249 Undo three hex head screws 1 Take off cover 2 Fig 250 Unscrew four hex head screws 1 Fig 251 ...

Page 175: ...ackened ATTENTION Pull the drive belt off the clutch pul ley centrifugal clutch downwards Fig 252 Lift the motor with centrifugal clutch out of the lower section of frame Fig 253 Remove the operating water feeding device in the upper section of frame Undo nut 2 Take off pipe 3 Fig 254 Remove spindle cap 1 with fitted gasket Fig 255 ...

Page 176: ...ce 2 and lay it down in the lower section of frame Fig 257 Take the drive belt out of the lower section of frame Fig 258 Undo three hex head screws 1 Unscrew spindle assembly 2 from the lower part of the frame For dismantling the spindle assem bly see section 4 6 3 Note If the vibration absorber is also pulled out of the lower section of the frame Loosen it from the spindle assembly by striking th...

Page 177: ...he lower part of frame Gasket 1 Rubber metal cushion 2 Fig 260 If necessary Undo three hex head screws 1 remove bearing cover 2 with sealed hex head screws disk and cup springs 3 from the lower part of the frame Fig 261 If necessary Take out gasket 1 Fig 262 ...

Page 178: ... 1010 Westfalia Separator 4 6 3 Dismantling the spindle assembly Spindle assembly Required tools Pulling device Open ended wrench Pliers with outer snap jaws Fig 263 Detach the bearing sleeve 1 from the spindle Fig 264 ...

Page 179: ...ia Separator Pull off from the spindle Angular contact ball bearing 2 Ball bearing protection ring 3 Fig 265 Remove the retaining ring Fig 266 Pull off from the spindle Grooved ball bearing 1 bearing cover 2 bearing cover 3 Fig 267 ...

Page 180: ...ntion to section 4 6 1 Undo three hex head screws 1 Take off cover 2 Fig 268 Unscrew four hex head screws 1 Fig 269 Pull the motor out of the flange guide by means of the hoist approx 5 mm Drive belt is slackened ATTENTION Pull the drive belt off the clutch pul ley centrifugal clutch downwards Fig 270 ...

Page 181: ...or with fluid clutch out of the lower section of the frame Fig 271 Turn the motor together with the centrifugal clutch 90 o upside down with the aid of the hoist CAUTION Secure from rolling away and overturning using suit able aids Fig 272 Undo retaining ring 1 Take off disk 2 Fig 273 Pull the clutch shoes out of the clutch driver Fig 274 ...

Page 182: ...nch ATTENTION For protecting the mo tor shaft end Screw threaded pin 2 into the thread of the motor shaft end Fig 276 Required special tools Eye bolt 1 Socket wrench 3 Unscrew hexagon nut 2 Screw eye bolt 1 into the clutch driver Arrest the clutch driver with an open ended wrench Force the centrifugal clutch off the motor shaft end by turning the eye bolt clockwise Fig 277 Remove eye bolt 1 from t...

Page 183: ...k Drive the clutch driver downwards by means of light hammer blows Loosen the clutch driver from the seat of the two ball bearings Fig 280 Turn the clutch pulley through 90 o opposite the fitting position with the aid of the hoist CAUTION Secure from rolling away and overturning using suit able aids Take the retaining rings out of the clutch drum grooves Fig 281 Required tools Disk Ø 86 94 mm Wood...

Page 184: ...ATTENTION Pay attention to the correct fitting position of the cup springs Fit bearing cover 1 with sealed hex head screws and washer with cup springs 2 and bolt tight with hex head screws 3 Fig 284 ATTENTION Pay attention to the correct fitting position of the rub ber metal cushion The two opposite inner holes 2 of the rubber metal cushion must be directed upwards Fit rubber metal cushion 1 Inser...

Page 185: ... of the ball bearing inner ring faces upwards Slide ball bearing protection ring 1 and angular contact ball bearings 2 onto the spindle Fig 287 Heat bearing sleeve 1 in oil up to 100 o C 212 o F Important Before fitting bearing sleeve 1 make sure that the in stalled angular contact ball bearing has cooled down to room tempera ture Slide bearing bush 1 over the angu lar contact ball bearings and th...

Page 186: ...lutch pulley Insert retaining ring 1 in the lower groove Check that retaining ring 1 is cor rectly fitted Fig 290 Required tools Disk 2 Ø 86 94 mm Wooden block Hammer ATTENTION Bearing damage is caused by incorrect fitting Disk 2 may only contact the outer ring of grooved ball bearing 1 Carefully drive the first grooved ball bearing 1 with disk 2 up to the re taining ring Fig 291 ...

Page 187: ...ball bearing inner ring Fig 292 ATTENTION Bearing damage is caused by incorrect fitting Disk 2 may only contact the outer ring of grooved ball bearing 1 Carefully drive the second grooved ball bearing 1 with a suitable disk 2 up to the distance sleeve Fig 293 CAUTION Danger of imbalance by incorrect fitting Insert retaining ring 2 180 o offset relative to retaining ring 1 in the up per groove Fig ...

Page 188: ...ing damage is caused by incorrect fitting Disk 1 may only contact the inner ring of the grooved ball bearing Place the ball bearing inner ring on disk 1 ATTENTION Pay attention to the correct fitting position of the dis tance bush Distance bush 1 must be flush with the inner rings of the grooved ball bearings Fig 296 Required tools Wooden block Rubber hammer Carefully hammer the clutch driver into...

Page 189: ... o with the aid of the hoist CAUTION Secure from rolling away and overturning using suit able aids Fig 299 Required tools ring spanner 2 Hex head screw 3 M 10 x 200 Hexagon nut 4 M 10 ATTENTION Pay attention to the feather key groove Fit the assembled centrifugal clutch on the motor shaft end Arrest the clutch driver 1 with an open ended wrench Insert ring spanner 2 as shown and Screw hex head scr...

Page 190: ...hex head screw 3 together with hexagon nut 4 and detach ring spanner 2 Fig 302 With driver 1 arrested Provide hex head screw 2 M 12 x 60 with washer 3 and thread it into the motor shaft end Fig 303 CAUTION Danger of imbalance Be sure to replace all clutch shoes simultaneously Never replace individual clutch shoes Make sure that the clutch shoes are evenly spaced Fit clutch shoes Fig 304 ...

Page 191: ...2064 9001 001 1010 191 Westfalia Separator Insert disk 2 Fit the retaining ring 1 in the groove of the clutch driver Fig 305 ...

Page 192: ...o not yet let the motor flange lock into the frame opening Fig 306 ATTENTION Degrease the belt contact surfaces of the spindle and clutch drum Fit the drive belt through upper section of frame opening 1 and through brake housing opening 2 centrifugal clutch Pay attention to correct seating of the drive belt on clutch pulley and spindle pulley Fig 307 Unscrew the screw plug 1 from the lower part of...

Page 193: ...e until the mo tor flange locks into the frame open ing Fig 309 Fasten the motor with four hex head screws 2 M 12 x 30 Unscrew hex head screw 1 with hexagon nut and washer from the centrifugal clutch Fig 310 Screw in the screw plug 1 Remove the hoist Fig 311 Note Due to the design concept used the spindle is at an inclined angle relative to the opposite side of the motor when the drive belt has no...

Page 194: ... 312 Installing the speed monitoring de vice Place speed monitoring device 2 on the lower section of frame and fasten with hex head screw 1 Fig 313 Align proximity switch 1 as illu strated ATTENTION The distance X between the spindle and the proximity switch must be 2 5 mm Fig 314 Insert protective cap 3 with fitted gasket 4 and ring 2 and bolt tight with four hex head screws 1 M 8 x 12 Fig 315 ...

Page 195: ...ver pipe 3 Fit pipe with nit into the screwed connection 1 and slide on as far as it will go ATTENTION The narrow end of the pipe must be directed upwards Tighten nut 2 firmly Fig 317 Fit cover 2 to the lower section of the frame with three hex head screws 1 M 8 x 20 Fig 318 Screw in oil drain screw 1 with fitted gasket Screw in the sight glass 2 Fill in oil as described in section 4 3 3 and Screw...

Page 196: ...196 2064 9001 001 1010 Westfalia Separator Danger to life and limb through electric current Have the motor connected by an authorized electrician ...

Page 197: ...ghtened drive belt A bowl height check is necessary e g after replacing the drive parts after fitting another bowl after fitting a different centripetal pump as soon as the centripetal pump exhibits grinding marks CAUTION A loose bowl top can endanger life Tighten the bowl top firmly The O marks of the bowl bottom and the bowl top must be aligned Fig 320 The control dimension A is 25 2 mm between ...

Page 198: ...irmly Fig 322 Lightly apply a thin coat of lubricant to the threads of the centripetal pump as specified in the lubrication schedule Fit handle connection piece 1 into the centripetal pump Hold the centripetal pump with offset screwdriver 2 Screw handle connection piece into the centripetal pump as far as it will go left hand thread Fig 323 Hold the handle connection piece 1 Turn the offset screwd...

Page 199: ...2064 9001 001 1010 199 Westfalia Separator Raise the handle connection piece to its maximum Measure the axial clearance A 2 4 6 mm Fig 325 ...

Page 200: ... if the bowl is operating correctly 3 3 4 9 Before a long term shut down of the separator Disconnect all electrical connections Thoroughly clean the separator see section 4 4 2 4 4 3 and 4 4 4 Dry and grease the clean bowl parts and all unvarnished machine parts to avoid corrosion damage Store the clean greased bowl in a dry place until reuse Store the gaskets in a cool dry dust free dark room to ...

Page 201: ...y through rotating separator parts Keep a safe distance away from the rotating spindle After switching off the separator wait until the spindle has stopped rotating Take off the drive belt 4 9 2 Preserving the motor Follow the instructions of the motor manufacturer ...

Page 202: ...torage temperature 5 to 50 C 41 122 F IMPORTANT A storage time of more than 12 months of the separator and control unit is only possible after consulting the manufacturer 4 10 2 Separator The following procedure applies for storing the separator before commissioning and for storing the separator before a prolonged standstill period IMPORTANT Store the separator with dismantled bowl Store the clean...

Page 203: ...eparator has been out of operation for longer than 12 months e g due to a long standstill period or storage check all separator parts in accordance with the maintenance schedule table Maintenance after 8000 operating hours or after 1 year at the latest Replace if necessary Procedure Drain the slushing oil Observe the local regulations on disposal of the slushing oil Remove the grease from all unpa...

Page 204: ...OTECTION Be sure to adhere to applicable environment protection legislation More information on disposal matters can be obtained from local authorities 4 12 1 Gear and lubricating oils Replacement and disposal of waste oils recovered during the oil changes and maintenance work must be carried out carefully Collect dripping oil to prevent danger of slipping or product infection They can be injuriou...

Page 205: ...sed carelessly can cause severe damage to persons Note Pay particular attention to the directive issued by the operator on handling the cleaning agents used and the local disposal regulations 4 12 3 Separator Before disposing of the separator Drain the gear oil and dispose of it properly in accordance with section 4 12 1 Dismantle the separator remove any lubricant sticking to separator parts and ...

Page 206: ...206 2064 9001 001 1010 Westfalia Separator 4 13 Standard tools are commercially available tools to be supplied by the customer Fig 327 ...

Page 207: ...or ball bearings 5 Ratchet with inserts and extension 6 Standard hammer and mallet 7 Inner snap pliers with offset jaws Ø 40 mm 8 Outer snap pliers Ø 35 mm 9 Hand tachometer 10 Wrench adjustable 11 Brushes 12 Puller 200 x 200 mm H x W 13 Open ended wrench jaw spans 19 32 55 mm 14 Wooden blocks 15 Drill 16 Drill bit Ø 2 mm 17 Wooden screws max Ø 4 mm x 50 mm length ...

Page 208: ...208 2064 9001 001 1010 Westfalia Separator 4 14 Special tools Fig 328 ...

Page 209: ... chamber lock ring 40 Hexagon nut M 10 centrifugal clutch 50 Hex head screw M 10 x 200 centrifugal clutch 60 Disk 11 x 27 x 2 centrifugal clutch 70 Eye bolt complete bowl centrifugal clutch 80 Bell shaped piece bowl top disk stack sliding piston 90 Assembling device complete closing chamber bottom annular pis ton 100 Ring spanner bowl top 110 Mounting ring annular piston 120 Double nipple transpor...

Page 210: ...or N No ot te e N No ot te es s N No ot ti iz ze en n A An no ot ta ac ci io on ne es s Д Дл ля я з за ап пи ис се ей й M Mu ui is st ti ii in np pa an no ot t Σ Ση ημ με ει ιώ ώσ σε ει ις ς N No ot ta at te er r N No ot te es s N No ot te e ...

Page 211: ...2064 9001 001 1010 211 Westfalia Separator 5 Spare parts 5 1 Spare part requirements 212 5 2 Guide to ordering spare parts 212 ...

Page 212: ...3 Designation see order specific parts catalog e g frame Part Number see order specific parts catalog e g 2050 1100 020 The part number is also marked on almost all the individual parts Only when ordering spare parts for bowls Bowl S N If this differs from the serial number The bowl serial number is engraved on the bowl lock ring bowl bottom and bowl top Only required when ordering spare parts for...

Page 213: ...or N No ot te e N No ot te es s N No ot ti iz ze en n A An no ot ta ac ci io on ne es s Д Дл ля я з за ап пи ис се ей й M Mu ui is st ti ii in np pa an no ot t Σ Ση ημ με ει ιώ ώσ σε ει ις ς N No ot ta at te er r N No ot te es s N No ot te e ...

Page 214: ...or N No ot te e N No ot te es s N No ot ti iz ze en n A An no ot ta ac ci io on ne es s Д Дл ля я з за ап пи ис се ей й M Mu ui is st ti ii in np pa an no ot t Σ Ση ημ με ει ιώ ώσ σε ει ις ς N No ot ta at te er r N No ot te es s N No ot te e ...

Page 215: ...2064 9001 001 1010 215 Westfalia Separator ...

Page 216: ...GEA Mechanical Equipment GEA Westfalia Separator Group GmbH Werner Habig Str 1 59302 Oelde Germany Phone 49 2522 77 0 Fax 49 2522 77 2488 ws info geagroup com www westfalia separator com ...

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