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Instruction Manual

Book No.:

9017368-02 V7

Product no.:

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

X

X

Alfa Laval Emmie

Mobile hydraulic oil cleaning system

Содержание Emmie

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

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

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

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

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

Страница 6: ......

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

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

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

Страница 10: ...2 Application...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 34: ...6 Control Cabinet...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 65: ...9 Maintenance G0449671 65...

Страница 66: ...9 Maintenance G0449681 66...

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

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

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

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

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

Страница 72: ...12 Lifting instruction...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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