Marine & Diesel Manuals
c Copyright 2003 Alfa La
System Manuals -
-
MDPC
1817356 - SA 821
Manual type
Product
Product type
Book no
Book title
System Manuals
SA
1. Oil separators
1817356
SA 821
1
1810737
Safety
2
1810738
System Description
3
1810739
Operating Instructions
4
1810572
Parameter List
5
1810573
Alarms and Fault Finding
6
1810947
Installation System Reference
7
578701
577190
Instruction Book, separator S 821/826
Service Manual, ancillary equipment
8
574322
579616
Spare Parts Catalogue, separator
Spare Parts Catalogue, ancillary equipment
This System Manual is at the moment available in the following
languages:
Language
Swedish (01)
English (02)
German (03)
French (04)
Spanish (05)
Russian (06)
Italian (07)
Portuguese (08)
Polish (09)
Greek (10)
Finnish (11)
Chinese (12)
Danish (13)
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Dutch (15)
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Document published on Web
Created by PavelMikaelSeparation Minarik on 2003/03/31
Modified by Beatrice Holmberg on 2007-02-21
Marine & Diesel Manuals
Illustrations, indications of material, dimensions and weights etc. herein, do not constitute any commitment on our part.
We reserve the right to change such specifications when necessary.
Page: 1
SA Separation System
Safety
Printed
May 2002
Book No.
1810737-02 V 1
Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by:
Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2002.
SA SEPARATION SYSTEM SAFETY
1 SAFETY INSTRUCTIONS
1 Safety Instructions
The centrifugal separator includes parts
that rotate at very high speeds, generating
huge forces. It is therefore essential for the
safe operation of this separator system that
you read and understand this manual,
including the warning signs and safety
precautions presented in this manual.
Failure to do so may cause a fatal accident.
P003702A
Important – read this!
1.1 Key Factors for Safe
Operation
P0 0 3 6 2 3 A
The separation system is designed and supplied
for a specific function (type of liquid, rotational
speed, temperature, density, etc.). The system
must be used for this function only, and strictly
within Alfa Laval´s specifications.
Incorrect operation or maintenance may result
in a heavy unbalance, reduction of material
strength, etc. that could lead to serious
breakdown with fatal injury or damage to
property.
For safe operation, strictly follow the
instructions for installation, operation and
maintenance in this manual.
1810737-02
1
1 SAFETY INSTRUCTIONS
SA SEPARATION SYSTEM SAFETY
The following is compulsory for safe
operation:
1
Never start up a separator before the bowl is
completely assembled, and all fastenings
securely tightened.
2
Never discharge a vibrating separator. Always
stop with the emergency stop button.
3
Never begin to disassemble a separator
before it has come to a complete standstill.
4
Always set the discharge intervals according
to instructions in the instruction book.
5
Never ignore alarms. Always eliminate the
cause before resuming operation.
6
Never use the separator for other liquids than
those specified by Alfa Laval.
7
Never operate a separator with a different
power supply frequency than stated on the
machine plate.
8
Clean the operating system regularly to avoid
sludge discharge malfunction.
9
Ensure that personnel are fully trained and
competent in installation, operation,
maintenance, and emergency procedures.
10 Use only Alfa Laval genuine spare parts and
the special tools supplied.
2
1810737-02
SA SEPARATION SYSTEM SAFETY
1 SAFETY INSTRUCTIONS
1.2 Warning Sign
Definitions
Below are definitions of the warning signs used.
Example:
Danger – serious injury or death
This type of safety sign or instruction
indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
!
R
DANGE
Entrapment hazard
Make sure that rotating parts have come to a
complete standstill before starting any
dismantling work.
Example:
Warning – serious injury or death
This type of safety sign or instruction indicates
a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
!
ING
WARN
Disintegration hazard
If unusually strong vibration occurs, press the
Emergency Stop button and leave the room.
Do not enter the room after an emergency stop
while the separator is still rotating.
Caution – minor or moderate injury
Example:
This type of safety sign or instruction indicates
a situation which, if not avoided, could result in
minor or moderate injury.
!
‘CAUTION’ used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
equipment damage.
1810737-02
ON
CAUTI
Burn hazard
Various machine surfaces can be hot and cause
burns.
3
1 SAFETY INSTRUCTIONS
SA SEPARATION SYSTEM SAFETY
1.3 Summary of Safety
Hazards
Below follows a selection of the warnings which
have been used in the text of this instruction
manual to ensure safe installation, start-up,
operation, stop, and maintenance. Further
warnings are to be found in the appropriate
places throughout the manual.
Start-up
Be especially observant during start-up. If there
is any abnormal vibration, immediately stop the
separator and investigate the cause. Clean the
bowl if it contains sediment.
!
ING
WARN
Breakdown hazard
Assemble the separator completely before start. All
couplings, covers, and guards must be in place and
properly tightened. Failure to do so may lead to
breakdown.
Continued on next page
4
1810737-02
SA SEPARATION SYSTEM SAFETY
!
1 SAFETY INSTRUCTIONS
ING
WARN
Electrical hazard
Follow local regulations for electrical installation
and earthing (grounding).
Disintegration hazard
If the system is operated from a position from
which the separator is not visible, a vibration
sensor must be fitted.
Breakdown hazard
Check that the power frequency is in agreement
with the machine plate. If incorrect, resulting
overspeed may cause breakdown.
Use the separation system for the purpose, and
within the limits, specified by Alfa Laval. Failure to
do so could cause a violent breakdown.
50 Hz?
60 Hz?
P0 0 3 6 0 6 A
Breakdown hazard
Breakdown hazard
Always observe the separator during start-up after
assembly. If strong vibration occurs, stop by using
the Emergency Stop button and evacuate the room.
!
ON
CAUTI
If power cable polarity has been reversed, the
separator will rotate in reverse, and vital rotating
parts can loosen.
1810737-02
5
1 SAFETY INSTRUCTIONS
SA SEPARATION SYSTEM SAFETY
Operation
!
ING
WARN
Disintegration hazard
If the system is operated from a position from which
the separator is not visible, an unbalance sensor
must be fitted.
!
ING
WARN
If strong vibration occurs, press the emergency
stop button and evacuate the room.
Never discharge a vibrating separator. Vibration
may then become violent and result in breakdown.
!
P003606A
Breakdown hazard
ING
WARN
Noise hazard
Use ear protection if noise levels are high.
!
ING
WARN
Breakdown hazard
Never reset an alarm without first finding and
remedying the cause.
!
ON
CAUTI
Burn hazard
P0 0 4 0 8 1 B
Avoid contact with hot surfaces. Process pipes,
various machine surfaces, and processed liquid can
be hot and cause burns.
!
ON
CAUTI
Slip hazard
Check all connections for leakage.
Oil leakage may make the floor slippery.
6
1810737-02
SA SEPARATION SYSTEM SAFETY
1 SAFETY INSTRUCTIONS
Stop
!
N
CAUTIO
Breakdown hazard
Stop the separator by means of the control unit, and
not by turning off the motor.
Never attempt to clean the bowl by manual discharge
in connection with stop.
Emergency stop
ING
WARN
Disintegration hazard
If unusually strong vibration occurs, press the
Emergency Stop button and leave the room
Do not enter the room after an emergency stop
while the separator is still rotating.
!
P0 0 3 6 0 6 A
!
ING
WARN
Disintegration hazard
Do not start the separator after an emergency stop
without first remedying the cause of the emergency.
Make sure that the bowl is clean before restart.
1810737-02
7
1 SAFETY INSTRUCTIONS
SA SEPARATION SYSTEM SAFETY
Maintenance
!
R
DANGE
Entrapment hazard
Always contact your Alfa Laval representative if you
suspect that the depth of the corrosion damage
exceeds 0.5 mm (0.2 mm for bowl body and bowl
hood) or if cracks have been found. Do not continue
to use the separator until it has been inspected and
given clearance for operation by Alfa Laval.
Disintegration hazard
Pits and spots forming a line may indicate cracks
beneath the surface.
All forms of cracks are a potential danger and are
totally unacceptable.
Replace any part where corrosion can be
suspected of affecting its strength or function.
Disintegration hazard
All forms of cracks are potentially dangerous as
they reduce the strength and functional ability of
components.
Always replace a part if cracks are present.
Disintegration hazard
Erosion damage weakens parts by reducing the
thickness of the material.
Pay special attention to the pillars between the
sludge ports in the bowl wall.
Replace parts if erosion is suspected of affecting
strength or function.
8
1810737-02
Max. 0,2 mm
G0205241
Disintegration hazards
I00293AA
Make sure that rotating parts have come to a
complete standstill before starting any dismantling
work. The rotation indicator lamp, where applicable,
must be off.
SA SEPARATION SYSTEM SAFETY
ING
WARN
To avoid accidental start, switch off and lock power
supply before starting any dismantling work.
Make sure that the separator has come to a
complete standstill before starting any dismantling
work.
I002933A
Entrapment hazard
Disintegration hazard
I002935A
Separator parts that are either missing, worn
beyond their safe limits, or incorrectly assembled,
may cause severe damage or fatal injury.
Disintegration hazard
I0 0 2 9 3 B A
Do not weld nor heat parts that are subject to highspeed rotation.
Breakdown hazard
Assemble the separator completely before restart.
All couplings, covers, and guards must be in place
and properly tightened. Failure to do so may lead to
breakdown.
P0 0 3 5 9 4 A
!
1 SAFETY INSTRUCTIONS
1810737-02
9
1 SAFETY INSTRUCTIONS
10
SA SEPARATION SYSTEM SAFETY
1810737-02
SA Separation System
System Description
Printed
Apr 2002
Book No.
1810738-02 V 1
Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by:
Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2002.
Contents
1
System Overview ................................. 1
1.1
1.2
1.3
2
Oil Flow................................................1
System Layout .................................2
System Components ......................4
The Process............................................. 5
2.1
2.2
2.3
2.4
Principle ..............................................5
Process Cycle Start.........................6
Discharge............................................8
Increased Water Content ..............9
1810738-02
1810738-02
SA SEPARATION SYSTEM SYSTEM DESCRIPTION
1 SYSTEM OVERVIEW
1 System Overview
The SA Separation System is designed for
cleaning of fuel and lube oils for diesel engines,
and fuel oil for gas turbine engines, in marine
and power applications.
Cleaned oil leaves the separator through the oil
outlet while separated water and sludge
accumulate at the periphery of the rotating
separator bowl.
Heated oil is fed through the separator to clean
the oil from solid particles and water.
The control unit supervises the entire
operation of the separation system, performing
monitoring, control, and alarm functions.
The basic separation unit comprises:
•
A separator.
•
Ancillary equipment including control unit.
•
Optional equipment such as, butterfly valve,
vibration sensor, etc.
1.1 Oil Flow
The process adapts automatically to certain
changes in conditions, such as increased water
content in the unprocessed oil, high or low oil
feed temperature, etc.
Settling tank
Change-over
valve
Backpressure
regulating
valve
The unprocessed oil is fed through a heater by a
feed pump, operating at a constant flow.
A change-over valve directs the oil to the
separator. The cleaned oil is pumped from the
separator to either the daily service tank (fuel
oil), or back to the engine (lube oil).
Pump
Heater
Separator
Daily
service tank
P003714A
During separator start and stop procedures,
during alarm conditions, or if the oil
temperature is outside the preset range, the oil
is directed by the change-over valve to a return
line back to the engine sump or settling tank.
1810738-02
1
1 SYSTEM OVERVIEW
SA SEPARATION SYSTEM SYSTEM DESCRIPTION
1.2 System Layout
Heater
Heats unprocessed
oil to separation
temperature.
Temperature
transmitter (TT1,
TT2)
Measures the oil
temperature and
signals the control
unit.
Pressure transmitter,
oil (PT1)
Pneumatically controlled
change-over valve (V1)
Measures the pressure
in the oil inlet, and
signals the control unit.
Directs the unprocessed oil to
the separator, or back to the
settling tank (recirculation –
fuel oil only).
Separator
Cleans the oil by
removing water
and solid
particles.
Feed pump
Feeds
unprocessed oil to the
separator.
Unprocessed oil
inlet
Oil return
Conditioning water
Opening water
Water inlet
Closing water
Solenoid valve block, water
Additional equipment
not part of the SA System
2
Distributes separator opening/
closing water, and conditioning
water.
1810738-02
Sludge outlet
SA SEPARATION SYSTEM SYSTEM DESCRIPTION
Control unit
Supervises the separation
system.
Pressure transmitter, oil
(PT4)
Measures the pressure in
the oil outlet, and signals the
control unit.
1 SYSTEM OVERVIEW
Water transducer (MT50)
Regulating valve (RV4)
Measures change in water
content in the cleaned oil,
and signals the control
unit.
To manually regulate the
backpressure in the
clean oil outlet.
Pneumatically controlled
shut-off valve (V4)
Closes the clean oil outlet.
Clean oil outlet
to service tank
Water drain
Pressure transmitter,
water (PT5)
Measures the pressure in
the water drain outlet, and
signals the control unit.
Drain valve (V5)
Opens to drain separated water
from the separator.
1810738-02
3
1 SYSTEM OVERVIEW
SA SEPARATION SYSTEM SYSTEM DESCRIPTION
1.3 System Components
Control unit
EPC50
Combined regulating
valve (RV4) and shut-off
valve (V4)
M AN
CIP
CIP
AUT
AUT
Clean oil
outlet
Temperature
transmitter
(TT1,TT2)
Pressure
transmitter, oil
inlet (PT1)
Operating
Operating air
water
Water transducer
(MT50)
Oil inlet
Pressure transmitter,
oil outlet (PT4)
Oil recirculation
Change-over
valve (V1)
Oil in
Pressure
transmitter,
water (PT5)
Oil out
Water
out
Drain valve
(V5)
P0 0 3 7 3 6 A
Sludge
outlet
4
1810738-02
SA SEPARATION SYSTEM SYSTEM DESCRIPTION
2 THE PROCESS
2 The Process
2.1 Principle
During the separation process, sludge and
water accumulate at the periphery of the
separator bowl.
Oil
P00356BA
Sludge and
water
P00356CA
Sludge and water are discharged at preset time
intervals. During discharge, the oil inlet is
closed.
Excessive water can also be drained from the
separator bowl between discharges.
The cleaned oil leaving the separator is tested
for traces of water. Any increase in water is
detected by the water transducer.
Disc stack
MT
Water
P00356DA
Water
transducer
P00356EA
The signal from the water transducer is
continuously transmitted to the control unit, in
which a reference value is stored. The control
unit compares the transducer signal with the
reference value. A significant deviation from
the reference value will cause draining of water.
1810738-02
5
2 THE PROCESS
SA SEPARATION SYSTEM SYSTEM DESCRIPTION
2.2 Process Cycle Start
The temperature transmitter (TT) and the
speed transmitter (ST) signal the EPC-50
control unit continuously. When the correct
separator speed and the correct temperature
are reached, a sludge discharge is carried out to
ensure the bowl is empty. The control unit then
starts the process cycle.
The change-over valve directs the oil to the
recirculation line. Conditioning water is
added to the separator bowl until the
pressure sensor in the oil outlet senses
pressure and signals the control unit.
2
The control unit registers the time taken for
water addition. This water flow reference
value is later used to calculate the correct
amount of conditioning water and
displacement water to be added.
3
The separator discharges.
P00356OA
P0 0 3 5 6 G A
1
P 0 0 3 5 6 FA
First the oil pump, separator, and heater are
started.
6
1810738-02
SA SEPARATION SYSTEM SYSTEM DESCRIPTION
2 THE PROCESS
Using the flow rate calculated in paragraph 2
above, the control unit signals the solenoid
valve to open so that the correct amount of
conditioning water is added to the separator
bowl.
5
The change-over valve opens so that oil is
directed to the separator bowl. When
pressure in the oil outlet is sensed, the
pressure sensor (PT) signals the control unit.
The control unit calculates and stores the
time taken to add oil to the bowl.
P00356MA
P0 0 3 5 6 N A
4
The cleaning process is now running.
Unprocessed oil is fed to the separator, and clean
oil is pumped from the separator.
1810738-02
7
2 THE PROCESS
SA SEPARATION SYSTEM SYSTEM DESCRIPTION
2.3 Discharge
The separator discharges after a preset time has
elapsed. The following sequence takes place:
The change-over valve changes to oil
recirculation.
2
Using the flow rate calculated in paragraph 2
under 2.2 Process Cycle Start, page 6, the
control unit signals the solenoid valve to
open so that displacement water is added to
push the oil towards the disc stack.
3
After the calculated time for displacement
water addition has elapsed, the separator
discharges.
4
Conditioning water is then added, and a new
separation cycle begins.
8
1810738-02
P00356JA
P0 0 3 5 6 R A
1
SA SEPARATION SYSTEM SYSTEM DESCRIPTION
2 THE PROCESS
2.4 Increased Water
Content
1
The water drain valve (V5) opens for a
number of seconds.
2
The water drain valve closes again, and the
transducer signal is evaluated.
3
If there is still an increase in water content,
the drain valve opens again. If the water
content is still high after the drain valve has
opened five times, a discharge is initiated.
4
If the water content has decreased, the
separation cycle returns to normal.
1810738-02
V5
P00356KA
If the water transducer senses increased water
content in the oil, the following takes place:
9
2 THE PROCESS
10
SA SEPARATION SYSTEM SYSTEM DESCRIPTION
1810738-02
SA Separation System
Operating Instructions
Printed
Apr 2005
Book No.
1810739-02 V 2
Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by:
Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2005.
Contents
1
Operating................................................... 2
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.12.1
Before Startup ...................................2
Operators Panel ................................5
Startup .................................................6
Manual Startup..................................7
During operation .............................11
Stop.....................................................14
Emergency Stop .............................15
After Emergency Stop ..................16
Cleaning In Place ...........................18
Automatic Operation.....................19
Remote Operation ..........................21
Emergency Operation ...................22
Manual Operation of the Separation
System..................................................22
1810739-02
1 OPERATING
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1 Operating
1.1 Before Startup
1
Check that the separator is correctly
assembled and connected to power supply of
correct voltage and frequency. The EPC 50
Control Unit must be ON.
!
ING
WARN
Breakdown hazard
Assemble the separator completely before start. All
couplings, covers, and guards must be in place and
properly tightened. Failure to do so may lead to
breakdown.
!
ING
WARN
Electrical hazard
!
P0 0 3 5 9 4 A
Follow local regulations for electrical installation and
earthing (grounding).
ING
WARN
Breakdown hazard
!
ING
WARN
Use the separation system for the purpose, and
within the limits, specified by Alfa Laval. Failure to do
so could cause a violent breakdown.
2
50 Hz?
60 Hz?
P0 0 3 6 0 6 A
Check that the power frequency is in agreement with
the machine plate. If incorrect, resulting overspeed
may cause breakdown.
1810739-02
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
2
1 OPERATING
Check the oil sump level. If necessary, top up
until oil starts to run from the oil-filling hole.
NOTE
G0868542
Too much or too little oil can damage the separator
bearings.
Rotation Direction
To check the rotation of the bowl, do a quick
start/stop. The motor fan must rotate in a clockwise
direction.
!
ON
CAUTI
If power cable polarity has been reversed, the
separator will rotate in reverse, and vital rotating
parts can loosen.
P0 0 3 5 9 3 A
NOTE
To make this check, the Mode Selector Switch should
be in the CIP position.
1810739-02
3
1 OPERATING
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
Air Valve Block
For further information concerning air, see chapter
1 Technical Data in the Installation System
Reference booklet.
Operating Water Pressure
Check that the operating water pressure is
sufficient (200 – 600 kPa or 2 – 6 Bar).
For further information concerning water, see
chapter 1 Technical Data in the Installation System
Reference booklet.
4
1810739-02
P003682A
Use the pressure gauge situated in the air valve
block to check that the air supply is correct
(500 – 700 kPa or 5 – 7 Bar).
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1 OPERATING
1.2 Operators Panel
General principle for changing control
parameters
The ‘Enter’ button is used to:
– enter into a parameter list
– enter into a parameter
– accept/store a new parameter value.
The ‘+’ or the ‘–’ buttons are used to change the
value flashing in the display window.
Process parameters
OP
Set the process parameters to suit the
installation as follows:
TT
PT
Push ‘Enter’. Parameter no. 1 in the process
parameter list is shown.
You have now come to the process parameter
list. Go through the list and set parameters.
15
10
PT
SEPARATION
STOP
EPC-50
DISCHARGE
INFO
Standst.
OP ACTIVE
ENTER
P00361HB
2
MT
HEATER
16
1
PT
ALARM
When the parameters have been set, ‘End I/O’
(flashing) shows. Push ‘+’. ‘Standst.’ now
shows in the display.
For information on how to set discharge
intervals, see chapter 3 Process Parameters in
the Parameter list booklet.
NOTE
Make sure that the operators panel is ‘active’ (LED
green) before operating.
1810739-02
5
1 OPERATING
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1.3 Startup
The control panel mode switch has three
positions: ‘MANUAL’, ‘AUTO’, and ‘CIP’.
The ‘MANUAL’ mode is for use on all Separation
Systems.
M AN
CIP
G046604A
AUT
The ‘AUTO’ mode is for use on systems supplied
for fully automatic control and/or fully automatic
remote control. The following general rules apply
for use of the ‘AUTO’ mode:
The EPC 50 must have control of the oil feed
pump.
•
The EPC 50 must have control of the heater.
•
The EPC 50 must have control of vibration
monitoring.
•
The cover interlock must be fitted.
AUT
G046605A
•
M AN
The ‘CIP’ mode is for use with Cleaning in Place
equipment. See ‘‘Cleaning In Place” on page 18.
M AN
CIP
G046606A
CIP
6
1810739-02
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1 OPERATING
1.4 Manual Startup
The first startup must always be carried out
manually.
Before startup make sure that all the main
supply valves for air, oil, and water are open.
Open heating media supply valve if applicable.
Switch on the power supplies. Make sure the
mode selection switch is in the ‘MANUAL’
position.
1
Start the oil feed pump from the pump starter.
M AN
AUT
G046602A
CIP
2
If necessary, vent air from the heater through
the relief valve (if applicable).
Switch on the heater from the operator panel
(if applicable).
OP
TT
PT
PT
MT
HEATER
16
15
PT
10
SEPARATION
STOP
EPC-50
NOTE
DISCHARGE
INFO
OP A CTIVE
ENTER
The operators panel must be’ active’ to allow
operation.
P0 0 3 6 1 J B
ALARM
Press the ‘SEPARATION’ button to activate the
EPC-50.
OP
TT
PT
MT
PT
HEATER
16
15
10
PT
SEPARATION
STOP
EPC-50
DISCHARGE
INFO
OP A CTIVE
ENTER
ALARM
P00361LB
3
1810739-02
7
1 OPERATING
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
Before the separator can be started, a number of
questions scroll across the display which have to
be answered:
‘Has the bowl been dismantled? + = YES, – = NO’
If the bowl has been dismantled press the ‘+’
button.
P0 0 3 6 1 4 A
4
P0 0 3 6 1 3 A
If no work has been carried out on the bowl, press
the ‘–’ button. The start sequence begins and the
text ‘Start’ appears in the display.
NOTE
If this is the first start, answer ‘YES’.
‘Assembled according to manual? + = YES, – =
NO’
If the bowl has been dismantled and
assembled according to the instructions in the
Service Manual, press the ‘+’ button.
P003614A
5
‘Bowl cleaned? + = YES, – = NO’
If the bowl has been cleaned press the ‘+’
button.
P003614A
6
An automatic calibration of the system is
carried out. See display.
.
7
Push the separator start button.
M AN
AUT
G046603A
CIP
8
1810739-02
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
8
1 OPERATING
Listen and observe.
Vibration may occur during start up, when
passing critical speeds.This is normal and
should pass without danger.
P003606A
If vibration increases, or continues at full
speed, press the emergency stop button and
stand clear until the vibration stops. The
separator, feed pump, and heater are stopped
when the emergency stop button is pushed.
The emergency stop will only reset when the
speed sensor indicates zero speed.
Once the zero speed signal has been
received, the alarm reset button can be
pushed. The message ‘ Switch power on/off.’
will be displayed. This refers to the EPC 50
power indside the control cabinet.
The cause of vibration must be determined
and corrected before starting again!
See the Alarms and Fault Finding booklet.
!
ING
WARN
Breakdown hazard
Always observe the separator during start-up after
assembly. If strong vibration occurs, stop by using
the Emergency Stop button and evacuate the room.
NOTE
If the system is equipped with a vibration sensor, and
has control of heater and feed pump, the Auto Start
can be used.
1810739-02
9
1 OPERATING
9
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
The separator speed, and ‘Start.’ are shown
alternately in the display until the separator is
at full speed.
OP
TT
PT
PT
MT
HEATER
16
15
PT
10
SEPARATION
STOP
EPC-50
DISCHARGE
INFO
OP A CTIVE
ENTER
ALARM
10 Check the oil feed temperature by pressing
the ‘+’ button until ‘TT1’ is shown on the
display.
11 Wait until the oil feed temperature is correct:
P00361KB
Heavy fuel mode 98 °C
Lube oil mode 95 °C (trunk engines), or 90 °C
(cross-head engines)
Diesel oil mode 40 °C
12 When the separator has reached the correct
speed, and the oil is at the correct
temperature, press the process start/stop
button on the operator panel to start the
separation process.
OP
TT
PT
MT
PT
HEATER
16
15
10
PT
SEPARATION
STOP
EPC-50
DISCHARGE
INFO
OP A CTIVE
ENTER
ALARM
13 Adjust the backpressure to the normal running
10
P00361LB
value. Normal running backpressure is
determined at commissioning. See the
Installation System Reference booklet.
1810739-02
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1 OPERATING
1.5 During operation
Operator panel information
Observe the operator panel information:
•
Heater operation LED lit (green)
•
Separator system operation LED lit (green)
•
Activated valve LED lit (green)
During normal operation, the ALCAP trigger
signal is shown on the left of the display, and the
time to next sludge discharge is shown on the
right.
Any alarm is indicated on the display. For
further information see the Alarms and Fault
Finding booklet.
NOTE
Regularly check connections. Tighten if necessary.
1810739-02
11
1 OPERATING
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
OP
NOTE
The values displayed in the examples below are not
recommendations.
TT
PT
MT
PT
HEATER
16
15
10
PT
SEPARATION
STOP
EPC-50
More operational information may be read as
required, by pressing the ‘+’ button repeatedly.
DISCHARGE
INFO
OP A CTIVE
ENTER
ALARM
Pressure, water outlet
•
Water transducer value
•
Speed
•
Accumulated operating time in hours
12
1.4
PT5
1.4
MT
89
Rpm
10300
Run time 5 hours
1810739-02
P00361RA
•
PT4
P0 0 3 6 1 Q A
Oil pressure, oil outlet
1.4
P0 0 3 6 1 PA
•
PT1
P0 0 3 6 1 O A
Oil pressure, oil inlet
98 °C
P0 0 3 6 1 TA
•
TT1
P0 0 3 6 1 U A
Oil feed temperature. For the correct
separation temperature see the Installation
System Reference booklet.
P003625A
•
P0 0 3 6 1 MB
To return to normal display, i.e. the trigger
value, and time to next sludge discharge,
continue pressing the ‘+’ button.
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
!
1 OPERATING
ING
WARN
Noise hazard
Use ear protection if noise levels are high.
!
ING
WARN
Breakdown hazard
Never reset an alarm without first finding and
remedying the cause.
!
N
CAUTIO
Burn hazard
!
P004081B
Avoid contact with hot surfaces. Process pipes,
various machine surfaces, and processed liquid can
be hot and cause burns.
ON
CAUTI
Slip hazard
Check all connections for leakage.
Oil leakage may make the floor slippery.
1810739-02
13
1 OPERATING
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1.6 Stop
To stop the system:
1
Stop the system by pushing the
‘SEPARATION’ button on the operators panel.
The yellow LED for separator stop sequence
starts to flash.
OP
TT
PT
MT
PT
HEATER
16
15
10
PT
SEPARATION
STOP
A sludge discharge is initiated.
EPC-50
DISCHARGE
INFO
‘Stop’ is displayed.
If the heater is controlled by the EPC 50, it is
switched off automatically.
When the oil feed temperature has started to
drop, the oil feed pump is switched off
automatically.
When the separator comes to a complete
standstill, ‘Standst.’ is displayed.
!
N
CAUTIO
Breakdown hazard
Stop the separator by means of the control unit, and
not by turning off the motor.
!
ON
CAUTI
Never attempt to clean the bowl by manual discharge
in connection with stop.
14
1810739-02
OP A CTIVE
ENTER
ALARM
P0 0 3 6 1 SB
The stop sequence LED changes to steady
yellow, and the green LED for separation
system operation goes out, when the sludge
discharge is completed.
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1 OPERATING
If the system is switched off for reasons other
than high vibration, it is not necessary to wait
for the separator to slow down before restarting
the process.
!
ING
WARN
Breakdown hazard
The system must not be restarted with the separator
rotating if high vibration alarm has been given.
1.7 Emergency Stop
!
M AN
CIP
AUT
G046608A
If an emergency situation occurs, press the
emergency stop button and evacuate the room.
Do not return until the separator has come to a
complete standstill.
ING
WARN
Disintegration hazard
If unusually strong vibration occurs, press the
Emergency Stop button and leave the room
Do not enter the room after an emergency stop
while the separator is still rotating.
NOTE
In order to be able to restart, the system must be at
standstill, and then the EPC power switched off – on.
1810739-02
15
1 OPERATING
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1.8 After Emergency Stop
Separator standstill
Dismantling work must not be started before all
rotating parts have come to a complete
standstill.
!
R
DANGE
Make sure that rotating parts have come to a
complete standstill before starting any dismantling
work. The rotation indicator lamp, where applicable,
must be off.
Avoid accidental start
!
ING
WARN
Entrapment hazard
To avoid accidental start, switch off and lock power
supply before starting any dismantling work.
Make sure that separator has come to a complete
standstill before starting any dismantling work
Remedy the cause
The cause of the emergency must be remedied
before attempting to restart the separator.
If the cause is not found, an overhaul must be
performed on the separator, and all moving parts
thoroughly checked
!
ING
WARN
Disintegration hazard
Do not start the separator after an emergency stop
without first remedying the cause of the emergency.
Make sure that the bowl is clean before restart.
16
1810739-02
I0 0 2 9 3 A A
Entrapment hazard
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1 OPERATING
Separator reassembled
The separator must be fully reassembled with all
covers and guards in place and tightened before
unlocking the power supply and starting the
system.
ING
WARN
Breakdown hazard
Assemble the separator completely before restart. All
couplings, covers, and guards must be in place and
properly tightened. Failure to do so may lead to
breakdown.
P003594A
!
1810739-02
17
1 OPERATING
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1.9 Cleaning In Place
The use of Cleaning In Place (CIP) equipment is
recommended for best separation results. For
further information on the CIP equipment, see
the CIP booklet, bookno. 1817261.
Before connecting the CIP equipment to the
Separator, the switch on the control cabinet must
be turned to the CIP position. This is to avoid
accidental pumping of oil when the pipeline is
opened up.
For instructions on how to connect the CIP
equipment to the Separator, see the Service
Manual booklet.
For recommended CIP intervals see chapter 1
Technical Data in the Installation System
Reference booklet.
18
1810739-02
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1 OPERATING
1.10 Automatic Operation
For automatic operation, the system must be
equipped for automatic start. Make sure the
mode selection switch is in the ‘AUTO’ position
and Pr3 has the correct setting.
NOTE
If local control is needed (for example in an
emergency situation), turn the switch to manual
mode. This will automatically override the Pr3
setting.
NOTE
The first startup must always be carried out
manually.
The system can thereafter be run automatically as
long as no changes are made to it between runs.
1
Press the ‘SEPARATION’ button
OP
TT
PT
MT
PT
HEATER
16
15
10
PT
SEPARATION
STOP
EPC-50
DISCHARGE
INFO
OP A CTIVE
ENTER
P00361LB
ALARM
Before the separator can be started, a number of
questions scroll across the display which have to
be answered:
1810739-02
19
1 OPERATING
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
‘Has the bowl been dismantled? + = YES, – = NO’
If the bowl has been dismantled press the ‘+’
button.
P003614A
2
P0 0 3 6 1 3 A
If no work has been carried out on the bowl, press
the ‘–’ button. The start sequence begins and the
text ‘Start’ appears in the display.
‘Assembled according to manual? + = YES, – =
NO’
If the bowl has been dismantled and
assembled according to the instructions in the
Service Manual, press the ‘+’ button.
P0 0 3 6 1 4 A
3
‘Bowl cleaned? + = YES, – = NO’
If the bowl has been cleaned press the ‘+’
button.
P0 0 3 6 1 4 A
4
An automatic calibration of the system is
carried out. See display.
To stop the process, press the ‘SEPARATION’
button (see 1.6 Stop, page 14.)
OP
TT
PT
MT
PT
HEATER
If the system is to be restarted, the system
valves can remain in operating positions.
16
15
10
PT
SEPARATION
STOP
EPC-50
DISCHARGE
INFO
OP A CTIVE
ENTER
P00361LB
ALARM
20
1810739-02
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1 OPERATING
1.11 Remote Operation
Remote Operation
NOTE
After maintenance, the system must be started
locally.
If in Remote, and ‘+’ is pushed in answer to the
question ‘Has the bowl been dismantled?’, the
system reverts to local control.
Follow the instructions in chapter 1.10
Automatic Operation, page 19.
1810739-02
21
1 OPERATING
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1.12 Emergency Operation
In the event of a water transducer failure, the
system can still be operated by setting
parameter Pr 4 in the EPC to standby mode (see
the Parameter List booklet). The transducer is
then disabled and the time to discharge
automatically changes to 15 minutes. ‘Nc’ (not
connected) is shown on the display. All Alcap
functions are disabled. Water is removed only
during a discharge. A reminder alarm is
activated after 24 hours.
If the system oil contains plenty of water, and
the oil density is less than 991 kg/m3, emergency
operation as described below is possible.
1.12.1 Manual Operation of the
Separation System
In the event of extemely high water content, the
system can be run manually by a competent
engineer using the following instructions:
1
Ensure all oil system manual valves are in the
correct position.
2
Set the selection switch on the control unit to
the MANUAL position.
3
Fit a jumper between terminals X9:1, and X9:2
in the EPC.
4
Start the feed pump.
5
Start the separator.
6
Heat the oil to the correct separating
temperature.
Where there is a Heatpac® EHM electric
heater, use jumpers in the power unit to bridge
terminals X12.11 – X12.6, X12.11 – X12.9, and
X12.11 – X12.7. Switch on the heater and use
the switch to regulate the temperature.
NOTE
Remove the jumpers after emergency operation.
22
1810739-02
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1 OPERATING
7
When the separator is up to speed and the
correct oil flow and temperature are achieved,
close the bowl. Open SV15 for time specified
in timer Ti60 (See Parameter List booklet).
Wait for 15 seconds. Open SV16 for time
specified in timer Ti62. The bowl is now
closed.
8
Temperature, flow, and backpressure must
remain constant throughout.
9
Remove the water outlet pipe at D.
G065022A
D
1810739-02
23
1 OPERATING
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
10 Screw in screw A to move the paring tube to
its innermost position.
11 Open SV10 as follows:
Time
(secs.)
Amount bowl
filled (litre)
SA 811/816/821/826
40
0.7
SA 820/825/830/831/835/836
40
1,1
SA 840/841/845/846
70
1.9
SA 850/851/855/856
30
3.0
SA 860/861/865/866
50
4.5
SA 870/871/875/876
40
7.0
SA 880/881/885/886
45
11.0
G065011A
A
12 Open SV1 to open oil feed V1.
13 Open SV5. This will open the water outlet
valve V5.
14 Carefully screw out screw A until water starts
to come from D.
15 Lock screw A in position.
!
ING
WARN
Breakdown hazard
During operation open SV16 for about 5 seconds
every 10 to 15 minutes to ensure that the bowl
remains closed.
24
1810739-02
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
1 OPERATING
Discharge
1
Close oil feed V1 using SV1.
2
Close water outlet V5 using SV5.
3
Open SV10 to add displacement water as
follows:
Time
(secs.)
Amount bowl
filled (litre)
SA 811/816/821/826
60
0.9
SA 820/825/830/831/835/836
49
1.3
SA 840/841/845/846
79
2.1
SA 850/851/855/856
44
4.0
SA 860/861/865/866
59
5.4
SA 870/871/875/876
47
8.4
SA 880/881/885/886
84
15.0
4
Open SV15 until a discharge is heard (about 3
seconds).
5
Wait 15 seconds.
6
Open SV16 for time specified in timer Ti62.
1810739-02
25
1 OPERATING
7
SA SEPARATION SYSTEM OPERATING INSTRUCTIONS
Open SV10 as follows:
Time
(secs.)
Amount bowl
filled (litre)
SA 811/816/821/826
40
0.7
SA 820/825/830/831/835/836
40
1,1
SA 840/841/845/846
70
1.9
SA 850/851/855/856
30
3.0
SA 860/861/865/866
50
4.5
SA 870/871/875/876
40
7.0
SA 880/881/885/886
45
11.0
8
Open V1.
9
Open V5.
10 Maintain backpressure at normal setting
throughout.
!
ING
WARN
Breakdown hazard
Discharging of the bowl, and supervision of the operation,
is now completely manual and under the direct
responsibility of the engineer who has placed the
separation system in the manual control mode.
26
1810739-02
S-type Separation System
Parameter List
Printed
Aug 2005
Book No.
1810572-02 V 11
Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by:
Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2005.
Contents
1
Parameter Setting ............................... 2
2
Installation Parameters .................. 5
3
Process Parameters .......................... 8
4
Factory Set Parameters ............... 11
5
Sequence Diagram .......................... 24
5.1
Separation Sequence....................26
1810572-02
1 PARAMETER SETTING
S-TYPE SEPARATION SYSTEM PARAMETER LIST
1 Parameter Setting
The parameters are set in the operator panel
for the different separator systems, and for
different conditions within the systems.
There are three parameter types: Installation,
Process, and Factory Set parameters.
The parameters are initially set at installation.
The process parameters can also be set as
required during operation.
Parameters not in use are not displayed.
The parameter list in this booklet is valid for
Separation Units (SU) and SA systems.
General principle
The ‘ENTER’ button is used to:
– enter into a parameter list
– enter into a parameter
– accept/store a new parameter value.
The ‘+’ or the ‘–’ buttons are used to change the
value flashing in the display window.
2
1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST
1 PARAMETER SETTING
To change parameters, proceed as follows:
1
4
Push the ‘+’ or ‘–’ button to change the
parameter value.
5
Push the ‘ENTER’ button. The new value is
stored.
Push the ‘ENTER’ button.
‘Time to discharge P1 60’ is shown. ‘P1 is
the parameter, and ‘60’ is the set value.
The parameter number is now flashing.
The ‘1’ of the ‘P1’ is flashing.
2
Push the ‘+’ button until the number of the
parameter you wish to program appears in
the display window.
6
Push the ‘+’ or ‘–’ button to go to the next
parameter to be changed.
7
To leave the list, push the ‘+’ and the ‘–’
buttons at the same time. The display shows
‘Standst.’ or, when in operation, the trigger
value to the left, and time remaining to
discharge on the right.
The chosen parameter number is now
flashing.
Push the ‘ENTER’ button.
The chosen parameter number is now
shown on the left side in the display. The
parameter value is shown flashing on the
right side of the display.
LED for heater
(green)
Heater on/off
push-button
OP
TT
PT
MT
LED for control
program running
(green)
PT
HEATER
16
15
PT
10
SEPARATION
STOP
Control program
on/off push-button
EPC-50
Schematic
diagram with
position LEDs
DISCHARGE
INFO
OP A CTIVE
ENTER
ALARM
LED for stop
sequence running
(yellow)
Sludge
discharge pushbutton
Display window
– pushbutton
+ pushbutton
Enter
pushbutton
Alarm reset
LED for common
main alarm (red)
LED showing
this panel
active
P0 0 2 2 1 2 B
3
1810572-02
3
1 PARAMETER SETTING
S-TYPE SEPARATION SYSTEM PARAMETER LIST
The following lists are available for viewing
from a menu in the EPC-50 control unit:
•
Install (parameters)
•
Factory (parameters)
•
Alarms
•
Test
For detailed information see each list.
To open the menu and select a list, proceed as
follows:
1
Push the ‘ENTER’ button. The process
parameter list is now open.
2
Push the ‘+’ button until ‘End’ is displayed.
3
Push the ‘ENTER’ button and the ‘+’ button at
the same time. ‘Install’ will show flashing on
the display.
4
Use the ‘+’ button to select a list.
5
Use the ‘Enter’ button to enter into the
selected list.
6
To leave the list, push the ‘+’ and the ‘–’
buttons at the same time.
7
To leave the menu, press the ‘+’ button
repeatedly until ‘Exit’ is displayed. Push the
‘ENTER’ button.
4
1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST
2 INSTALLATION PARAMETERS
2 Installation Parameters
The installation parameters must be set before
the initial start-up and before process
parameters are set. These parameters rarely
need to be adjusted again. If a new parameter
value is to be stored, it is necessary to go through
the whole list, and confirm at the end.
NOTE
Alfa Laval cannot be held responsible for injuries
and damage caused by usage of parameter values
which are not in proximity to the factory values set
by Alfa Laval.
Parameter
Factory set
value
In 1
en
Plant set
value
Range
Description
en = English
Language. All information displayed
on the operators panel is shown in
the selected language.
de = German
es = Spanish
fr = French
It = Italian
pt = Portuguese
fi = Finnish
se = Swedish
In 3
Alcap
Alcap
Separator type
In 4
836
811, 816
Separator size
200, 820, 821, 825, 826
Parameters depending on separator
size are set automatically according
to the value in In 4
300, 830, 831, 835, 836
400, 840, 841, 845, 846
500, 850, 851, 855, 856
600, 860, 861, 865, 866
700, 870, 871, 875, 876
800. 880, 881, 885, 886
In 5
1
1–9
Separator identity
If more than one EPC on
same Sattbus
If more than one separator system is
connected to the internal Sattbus
communication, each system must
be given its own identity (1 or 2 or 3
etc.).
1810572-02
5
2 INSTALLATION PARAMETERS
Parameter
Factory set
value
In 6
Yes
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Plant set
value
Range
Description
No
Speed sensor
Yes
In 7
No
No
Vibration sensor
Yes
In 8
No
No
OP remote
Yes
In 9
Yes
No
Water transducer
Yes
In 15
No
No
Sludge pump used
Yes
In 16
No
No
I/O expansion board used
Yes
In 17
°C
°C
Celsius or Fahrenheit
°F
In 18
No
No (no heater)
Heater type
El. (electrical heater)
Steam (steam heater)
In 19
In 20
16
120
7, 8, 14, 16, 22, 24, 36, 40,
50, 56, 65, 72, 86, 96, 98,
100, 110, 112, 126, 128,
130, 144 kw
El heater size
0 – 999 seconds
Steam-valve run time
Activated when El. is selected in
In 18
Activated when Steam is selected in
In 18
6
1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Parameter
Factory set
value
In 22
In 23
Plant set
value
2 INSTALLATION PARAMETERS
Range
Description
15
0 – 30 seconds
Alarm delay time
15
0 – 240 seconds
Change-over valve V1 temp. alarm
delay
Prevents false alarm due to any
fluctuations in temperature caused
by valve actions.
In 24
No
No
Yes
Change-over valve V1 action at extra
alarm
When the extra alarm input is used,
action at alarm can be none (No) or
feed off (Yes).
In 25
In 26
Yes
No
No
Power fail alarm used
Yes
If this alarm is not required, set the
parameter to ‘No*.
No
Type of computer communication
board used
ExtPC = Fieldbus
I-Net = Internet
In 27
0
0 – 255
Internet IP address, part 1
In 28
0
0 – 255
Internet IP address, part 2
In 29
0
0 – 255
Internet IP address, part 3
In 30
0
0 – 255
Internet IP address, part 4
In 31
No
No
Feed pump controlled
Yes
Feed pump has to be connected by
EPC when running in auto mode.
m3/h
Flow rate in m3/h per hour or
US gallons per hour.
In 32
m3/h
USG/h
The feed flow measurement, based
on inlet pressure, can be displayed in
one of these ways.
1810572-02
7
3 PROCESS PARAMETERS
S-TYPE SEPARATION SYSTEM PARAMETER LIST
3 Process Parameters
The process parameters can be adjusted easily
and as often as required, even during operation,
to meet changes in the operating conditions, e.g.
time between sludge discharges, oil temperature,
alarm points.
NOTE
Regularly check the condition of the bowl. If there is
no noticeable amount of hard sludge in the sludge
space, the discharge interval may be increased by 30
minutes at a time. The total discharge interval must
not exceed three times the factory set value in order
to avoid an uneven build-up of sludge.
Parameter
Factory set
value
Pr 1
Pr 2
Pr 3
Range
Description
120
1 – 300 minutes
Time to discharge
HF380
MDO = Marine Diesel Oil
GO = Gas Oil
IFxxx = Intermediate Fuel Oil
HFxxx = Heavy Fuel Oil
LO TP = Lubricating Oil for
Trunk Piston Engines
LO CH = Lubricating Oil for
Cross Head Engines
Oil type
OPloc = Local OP in control
Control location
OPrem = Remote OP
OPloc is standard. OPrem, ExtPC
and RemSW are shown only when
installed.
OPloc
Plant set
value
Rmind = Remind using
Sattbus
(xxx represents viscosity in Cst at
50 °C)
ExtPC = Extern Computer
Board
RemSw = Remote switches
Pr 4
Pr 5
8
On
0.0
On
Alcap On/Standby
Stb.
MT-50 function disabled when in
standby (Stb.). Discharge every 15
minutes (overrides Pr1). No
displacement water added.
0.0 = Not used
Countdown service timer
0.1 to 10.0x1000 hours
Action is to be taken when the timer
reaches 0.
1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Parameter
Factory set
value
Pr 6
0
Pr 7
0
Plant set
value
3 PROCESS PARAMETERS
Range
Description
0 = service time elapsed
Type of service
1 – 9 = Service text 1...9
When service timer Pr5 reaches 0,
an alarm is given and a message
shown
Information
Keys to special functions used by
service engineer
1 = timers shown
Pr 10
3.0
2 = Service mode
When Pr7 is set to 1 during normal
operation, the actual timer is
displayed if the ‘+’ button is pressed
once.
0.0 – 6.0 bar
0.0 = oil pressure sensor
disabled
High oil pressure limit
(cleaned oil outlet)
Pr 11
1.0
0.0 – 6.0 bar
Low oil pressure limit
Pr 12
5.5
0.0 – 6.0 bar
0.0 = water pressure sensor
disabled
High water pressure limit
(water outlet)
Pr 13
0.2
0.0 – 6.0 bar
Low water pressure limit
Pr 14
3.0
0.0 – 6.0 bar
0.0 = feed pressure sensor
disabled
High feed pressure limit
Pr 15
0.20
0.00 – 6.00 bar
Low feed pressure limit
Low pressure indicates insufficient
flow. The low pressure limit must be
higher than any static pressure and
lower than normal pressure.
Pr 16
105 °C
0 – 115 °C or
HFO/LO high temp. limit
0 – 255 °F
0 = Temp sensor disabled
Pr 17
85 °C
0 – 115 °C or
HFO/LO low temp. limit
0 – 255 °F
1810572-02
9
3 PROCESS PARAMETERS
Parameter
Factory set
value
Pr 18
95 °C
Pr 19
40 °C
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Plant set
value
Range
Description
0 – 110 °C or
HFO/LO setpoint1)
0 – 240 °F
0 = Temp sensor disabled
Setpoint for feed temperature is valid
only when a temperature controller is
installed in the EPC.
0 – 115 °C or
DO high temp. limit
0 – 255 °F
Pr 20
20 °C
0 – 115 °C or
DO low temp. limit
0 – 255 °F
Pr 21
Pr 22
30 °C
40
0 – 110 °C or
DO setpoint1)
0 – 240 °F
Setpoint for feed temperature is valid
only when a temperature controller is
installed in the EPC.
10 – 500 %
P-constant1)
Preset value based on experience
with Alfa Laval Heatpac heaters.
Pr 23
1.2
0.1 – 10.0 minutes
I-constant1)
Preset value based on experience
with Alfa Laval Heatpac heaters.
Pr 24
0
0–9
Heater control location
0 = disabled
To be set when more than one EPC
temperature controller can be used
for one heater.
Pr 25
2
0 – 240 seconds
Sludge tank alarm delay (during
Ti 68)
Pr 40
60
0 – 100 discharges
Test of sludge in bowl
Pr 41
15
0 – 100 %
Max. decrease of displacement
water
1)
10
Parameter appears only when heater board installed.
1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST
4 FACTORY SET PARAMETERS
4 Factory Set Parameters
Parameter
Factory set
value
Fa 3
Plant set
value
Range
Description
See table on page
22
0.1 – 99.99 litre
Conditioning water volume to be fed
after discharge
Fa 6
0.2
0.0 – 9.9 bar
PT4 pressure increase or decrease.
(Test during Ti 59, Ti 64, Ti 70, Ti 71,
Ti 82) Signal that the bowl is filled.
Fa 10
See table on page
22
0 – 14000 rpm
High speed
0 = sensor disabled
Is set depending on
separator size
Fa 11
See table on page
22
0 – 14000 rpm
Low speed
Fa 12
300
0 – 2000 rpm
Speed decrease during discharge
Fa 16
See table on page
22
0.0 – 2.5
0.0 = sensor disabled
Shutdown limit for separator spindle
amplitude
Fa 17
See table on page
22
0.0 – 2.5
Vibration alarm prewarning
Fa 18
0.5
0.0 – 2.5
Vibration sensor adjustment zero
point. Zero point should be within
1.5 ± Fa 18
Fa 20
3.0 if Pr 2 = fuel oil
0.01 – 10.0 pF
Alcap trigger factor
Is set depending on
separator size
0.6 if Pr 2 = lube oil
This is the amplification factor for the
transducer signal so that the proper
trigger range is achieved.
Fa 21
100
0 – 250 %
Trigger limit HFO
Fa 22
100
0 – 250 %
Trigger limit LO/DO
Fa 23
120 if Pr 2 = fuel oil
0 – 999.9 pF
90 if Pr 2 = TPLO
0 = water transducer
disabled
Alarm limit for high water transducer
value.
83 if Pr 2 = CHLO
1810572-02
11
4 FACTORY SET PARAMETERS
Parameter
Factory set
value
Fa 24
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Plant set
value
Range
Description
70
0 – 999.9 pF
Alarm limit for low water transducer
value
Fa 25
25
0 – 250 seconds
Pulse time for open drain valve
Fa 26
5
0 – 30 seconds
Drain pause time. With the valve
closed, the system waits for the
result of the draining.
Fa 27
70
0 – 100 %
The limit below which the trigger
value must be to interrupt draining.
Fa 28
5
0 – 20
Limit for number of HFO drainings. If
the trigger value has not fallen below
the value of Fa 27 after Fa 28, an
alarm is given.
Fa 29
5
0 – 40
0 = disabled
Test of water transducer trigger
signal every x discharge.
(x = 0 – 100)
Fa 30
250
0 – 900 %
Trigger level during Ti 64 – Ti 65
Fa 31
2
0–4
Reduction of Ti 72 due to trigger
signals during Ti 64, Ti 65.
0 = No reduction
1 = Reduction after every
trigg
2 = Reduction after 2
consecutive triggs
3 = Reduction after 2 triggs
within 3 discharges
4 = Reduction after 2 triggs
within 4 discharges
12
1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Parameter
Factory set
value
Fa 32
1.0
Plant set
value
4 FACTORY SET PARAMETERS
Range
Description
0.0 – 1.0
Reduction of Ti 72 in DO mode.
Timer Ti 72 is reduced by Fa 32
Fa 33
2
0 – 10
Limit for number of LO drainings. If a
higher no. of drainings than Fa 33
takes place within one separation
period (Ti 68), an alarm will be given.
Fa 34
+0.00
-2.00 – +2.00
HFO temperature adjustment, MT 50
0 = -2.00
Temperature compensation for the
water transducer, HFO mode.1)
200 = 0.00
400 = +2.00
Fa 35
+0.00
-2.00 – +2.00
LO temperature adjustment, MT 50
0 = -2.00
Temperature compensation for the
water transducer, LO mode.1)
200 = 0.00
400 = +2.00
Fa 36
+0.00
-2.00 – +2.00
DO temperature adjustment, MT 50
0 = -2.00
Temperature compensation for the
water transducer, DO mode.1)
200 = 0.00
400 = +2.00
Fa 37
20
0 – 100
Flush water every x disch.
Fa 41
5
1 – 30 minutes
Closing water pulse time
Time between closing water pulses
1)
The transducer value can be influenced by temperature variations. This can be compensated for by using this
parameter. Proceed as follows:
Note the transducer value. N.B. The transducer value must be steady (no water in oil) in order to do this test.
At normal stable running temperature, decrease the temperature by 10 °C.
At stable new temperature, read the temperature and transducer value.
Example:
Temperature decrease = 10 °C
Transducer value change = + 1 (from 82.6 to 83.6)
Since the transducer value increased, this must be compensated by making Fa34 negative.
Fa 34 = (1.0 x 10) /10 °C = – 1.0
1810572-02
13
4 FACTORY SET PARAMETERS
Parameter
Factory set
value
Fa 42
No
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Plant set
value
Range
Description
No
V4 activated in Ti 64
Yes
To get a faster pressure response
when oil feed fills the bowl (see
Ti 64) valve V4 could be closed =
Yes.
Fa 44
See table on
page 22
0 – 15 seconds
Delay for close of V4 at leak test.
Automatically adjusted during test.
(Ti 66)
Fa 45
See table on
page 22
0 – 15 seconds
Delay of PT4 pressure reference
value registration during the
automatic adjustment of pressure
range for leakage test (see Ti 66).
Fa 46
1.0
0 – 4 bar
Acceptable PT4 decrease during
leakage test
Alarm for leaking bowl if the pressure
decreases more than Fa 46 during
leakage test.
Fa 47
3.0
0 – 4 bar
PT4 high limit during leakage test
Fa 48
1.0
0 – 4 bar
PT4 low limit during leakage test
Fa 49
5
0 – 10
Max. no. of leakage tests to establish
the test pressure within high-low
limits.
NOTE
For parameters Fa 90 – Fa 95, see page 21.
14
1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST
4 FACTORY SET PARAMETERS
Timer Sequence Parameters (separation
start, sludge discharge, stop)
Parameters for timers are listed under Factory,
but are called ‘Ti’.
When expected feedback from a timer is given,
the timer is interrupted and the next timer
starts.
If feedback is not received within the preset
time, an alarm is given.
Timers for start are 50 - 59.
Timers for operation are 60 - 69.
Timers for discharge are 70 - 79.
Timers for stop are 80 - 89.
Timers 50, 51, 52 and 87 are intended for the
‘fully automatic’ system (Auto mode) with pump
and heater controlled by EPC 50.
If pump and heater are started independent of
EPC and Alfa Laval starter, X6:4 - X40 must be
connected to a free closing contact at the
external pump contactor. Increasing
temperature is the only process condition needed
for timers 51 and 52. The program skips directly
to timer 55 when not ‘fully automatic’.
1810572-02
15
4 FACTORY SET PARAMETERS
Parameter
Factory set
value
Ti 50
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Plant set
value
Range
Description
60
2 – 300 seconds
Feed pump on
Ti 51
15
0 – 30 seconds
Feed pressure feedback
Ti 52
4
0 – 60 minutes
Separator start-up (Speed feedback)
Speed above low limit (Fa 11)
expected. Condition of belt, coupling,
motor bearings, height adjustment,
and speed sensor supervised.
Ti 53
15
0 – 60 minutes
Heater on (temp. feedback)
Temperature above low limit (Pr 17,
Pr 20) expected to confirm that the
heater works normally.
Ti 55
0
0 – 30 minutes
0 = no standby
Max. time for ‘Standby’ mode. During
‘Standby’ mode, the system is
waiting for an order to start the
process sequence. The process
sequence is started with a push of
the start button.
When Ti 55 = 0 the process starts
without delay.
Ti 56
3.0
0.1 – 5.0 seconds
Discharge if Ti 59 has expired after
alarm.
Ti 57
15
0 – 30 seconds
Pause = Draining of operating
system
Ti 58
See table on
page 22
0 – 60 seconds
Close bowl
16
1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Parameter
Factory set
value
Ti 59
170
Plant set
value
4 FACTORY SET PARAMETERS
Range
Description
0 – 300 seconds
Water flow rate calibration
At start three questions are
displayed:
• Bowl dismantled?
• Assembled according to manual?
• Bowl cleaned?
When the answer to the third
question is Yes, calibration of the
water flow rate through SV 10 takes
place. SV 10 is open until pressure in
the water outlet increases (Fa 6).
The water volume is defined for each
separator size. Based on this and the
time taken to fill the bowl, the EPC
calculates the water flowrate.
When the answer is No, this means
that stored calibration data will be
used and consequently the program
performs Ti 63.
Ti 60
See table on
page 22
0.1 – 30.0 seconds
Discharge
– when starting, the operating
system needs some extra water to
support the operating slide before
closing the bowl. (This is not a
proper discharge, since the bowl is
empty.),
– after a power failure to prevent a
period between discharges greater
than Pr 1.
Ti 61
15
0 – 30 seconds
Pause = Draining of operating
system
Ti 62
See table on
page 22
0 – 60 seconds
Close bowl
1810572-02
17
4 FACTORY SET PARAMETERS
Parameter
Factory set
value
Ti 63
120
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Plant set
value
Range
Description
Seconds, calculated
Conditioning water added
Based on the calibration of the water
flow rate, the EPC calculates the
time to which Ti 63 is set, so that the
correct volume of conditioning water
is added to the bowl. Data
concerning the bowl is activated
when size of separator is choosen
(In 4). The preset value is just for
start. After the calculation, the
correct value for Ti 63 is set
automatically.
Ti 64
60
0 – 60 seconds
Oil feed on. Max 60 secs.
Ti 65
15
0 – 30 seconds
Water transducer pulse control time
Test of the signal from the water
transducer. If this shows water in the
oil, the displacement time prior to
next discharge will be reduced.
Ti 66
Ti 67
18
See table on
page 22
0 – 30 seconds
60
0 – 300 seconds
Bowl leakage check
(See also Fa 44 – 49)
1810572-02
Time for stabilisation of the
transducer signal. When the time
has elapsed the EPC stores the
actual transducer value as a
reference for changes in water
content.
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Parameter
Factory set
value
Ti 68
120 ( = Pr1)
Plant set
value
4 FACTORY SET PARAMETERS
Range
Description
1 – 300 minutes
Time between discharges. This is the
same as Pr 1. If one is changed, the
other one is automatically changed.
During Ti 68 the water transducer
supervises changes of the water
content in the clean oil. If the trigger
value is greater than 100, the drain
valve (V5)opens. For details see Fa
25–28.
Ti 70
15
0 – 30 seconds
Oil feed off. Oil outlet pressure below
low limit (Pr 11) expected.
Ti 71
20
0 – 120 seconds
Displacement of oil. During Ti 71, V4
is closed until increasing pressure is
sensed, indicating displacement
water has entered the bowl.
Ti 72
150
Seconds, calculated (max.
300 seconds)
Displacement water (SV 10)
continues for the calculated time.
Ti 73
10
0 – 30 seconds
Opening of the drain valve to wash
out any oil from the paring tube and
piping.
Ti 74
3.0
0.1 – 5.0 seconds
Discharge
1810572-02
19
4 FACTORY SET PARAMETERS
Parameter
Factory set
value
Ti 75
15
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Plant set
value
Range
Description
0 – 30 seconds
Pause = Draining of operating
system
Discharge feedback (as shown by
decreased speed, Fa 11).
If the speed sensor is out of order/
disabled, feedback is automatically
taken over by timer Ti 64. (If time
close to 0 there was no discharge).
Draining of operating system takes
place during Ti 75.
After Ti 75, the program returns to
Ti 62, provided stop is not ordered.
If however any value or timer
influencing the water calibration has
been changed, the program returns
to Ti 58.
When stop is ordered the discharge
precedes the stop sequence.
Ti 81
See table on
page 22
0 – 60 seconds
Close bowl
Ti 82
150
Seconds, calculated
Heater off.
Addition of water until 80% of bowl
volume, or increased pressure is
sensed in the oil outlet (Fa 6). This is
to keep the bowl filled during stop
sequence.
Ti 83
10
0 – 30 seconds
Opening of the drain valve to wash
out any oil from the paring tube and
the pipe.
Ti 85
5
0 – 30 minutes
Temperature decrease
The EPC switches the separator
motor off.
Decreasing oil feed temperature
greater than 5 °C expected.
If Ti 85 = 0, no temperature control.
20
1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Parameter
Factory set
value
Ti 86
Ti 87
Plant set
value
4 FACTORY SET PARAMETERS
Range
Description
3
0 – 30 minutes
Decreasing speed expected (Fa11).
60
0 – 300 seconds
Pump off
In Auto mode, the EPC switches the
feed pump off. By doing so after
switching off the separator, further oil
is fed to the heater (which is already
switched off) to help cooling.
Ti 89
30
30 – 60 minutes
The EPC is waiting for zero speed.
As long as the separator is rotating
at a speed greater than 6 revs/min.
(1 puls/ rev.), the speed is displayed
alternating with ‘Stop.’ Speed less
than 6 revs/min. is displayed as 0.
When speed 0 has been displayed
for 1 minute (alternating with ‘Stop’),
‘Standst.’ will be displayed.
Fa 90
---
0 – 9999 days
Set runtime. See chapter 4 Change
of Circuit Board in the Service
Manual booklet.
Fa 91
50
0 – 99 °C
Break point, cold start.
0 – 210 °F
The temperature up to which gain
factor Fa92 is active. Above this
temperature normal gain (Pr 22) is
active.
1 – 100 %
Gain factor, cold start
Fa 92
40
This factor is used to increase the
normal P-band (Pr 22) when
temperature is below that defined in
Fa 91.
Ex. Normal P-band = 30, Fa 92 = 40
gives an actual P-band below Fa 91
of 0.40 x 30 = 12.
1810572-02
21
4 FACTORY SET PARAMETERS
Parameter
Factory set
value
Fa 93
SBSU
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Plant set
value
Range
Description
SBSU (Sattbus on RS232)
Communication type
ASCII (ASCII protocol)
PRINT (Printer output)
Fa 94
9.6
1.2, 2.4, 4.8, 9.6, 19.2, or
38.4
Serial communication Baudrate
channel A
(4.8 = 4800)
Fa 95
No
No
Communication parity channel A
Odd
Even
Fa 96
3.0 if Pr 2 = fuel
oil
0.1 – 10.0 pF
Alcap trigger range during discharge
0.6 if Pr 2 = lube
oil
Parameters depending on separator size
Separator size
Fa3
Fa10
Fa11
Fa16
Fa17
Fa44
Fa45
S 811, S 816, S 200, S 821, S 826
0.16
13.300
11.000
0.30
0.20
2
5
S 820, S 825, S 300, S 830, S 831,
0.3
11.000
9.900
0.30
0.20
2
5
S 400, S 840, S 841, S 845, S 846
0.4
9.600
8.600
0.50
0.30
4
10
S 500, S 850, S 851, S 855, S 856
0.7
8.300
7.400
0.50
0.30
6
10
S 600, S 860, S 861, S 865, S 866
0.9
7.800
6.400
0.50
0.30
8
10
S 700, S 870, S 871, S 875, S 876
1.5
6.700
5.500
0.50
0.30
10
10
S 800, S 880, S 881, S 885, S 886
2.5
5.800
4.700
0.50
0.30
10
10
S 835, S 836
Separator size
Ti58
Ti60
Ti62
Ti66
Ti81
Ti89
S 811, S 816, S 200, S 821, S826
15
5
15
10
15
30
S 820, S 825, S 300, S 830, S 831, S 835,
S 836
15
5
15
10
15
30
S 400, S 840, S 841, S 845, S 846
15
5
15
20
15
30
S 500, S 850, S 851, S 855, S 856
15
5
15
20
15
40
S 600, S 860, S 861, S 865, S 866
25
15
25
25
25
45
S 700, S 870, S 871, S 875, S 876
35
25
35
30
35
45
S 800, S 880, S 881, S 885, S 886
60
25
60
30
60
65
22
1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST
4 FACTORY SET PARAMETERS
1810572-02
23
5 SEQUENCE DIAGRAM
S-TYPE SEPARATION SYSTEM PARAMETER LIST
5 Sequence Diagram
Autostart
Start
Separation
Ti50 Ti51 Ti52 Ti53 Ti55 Ti56 Ti57 Ti58 Ti59
Ti60 Ti61 Ti62 Ti63 Ti64 Ti65 Ti66 Ti67 Ti68
Activity
1)
Feed pump
motor on
Flow stabilized
Separator
motor on
Heater on
temp. increase
Heater max.
start time
Discharge,
SV15
Drain of
operating water
Closing water,
SV16
Calibration of
water flow rate
SV 10
Conditioning
water SV 10
Feed on V1
1)
1) )
1)
2)
1)
1)
Oil outlet
closed, V4
Leak test
Ref. time
Separation
3)
Drain of water;
V5
Feed off
Displacement
water
SV 10
Water
SV10
Optional
sludge pump
1)
Interrupted by feedback signal
2) Pulse 1 sec. every 5 min.
3) Activated when needed
4) Interrupted by decreasing temperature
11)
5)
6)
7)
8)
Interrupted by decreasing speed
Interrupted by pump off feedback
Interrupted by 0-speed during 1 min.
Interrupted by calculated time
or trigger signal
9) 1 sec. pulse at 4000 rpm
10) 5 sec. every 30 minutes
11) 15 sec. only
NOTE
Note! This diagram is valid for normal operation only. See the flow chart on page 30 for a more detailed
sequence description.
24
1810572-02
10)
S-TYPE SEPARATION SYSTEM PARAMETER LIST
5 SEQUENCE DIAGRAM
Discharge
Stop
Ti70 Ti71 Ti72 Ti73 Ti74 Ti75 Ti62 Ti63 Ti64 Ti65 Ti66 Ti67 Ti81 Ti82
Ti83 Ti85 Ti86 Ti87 Ti89
4)
9)
1)
1)
1)
5)
6)
7)
Activity
Feed pump
motor on
Flow stabilized
Separator
motor on
Heater on
temp. increase
Heater max.
start time
Discharge,
SV15
Drain of
operating
water
Closing water,
SV16
Calibration of
water flow rate
SV 10
Conditioning
water SV 10
Feed on V1
Oil outlet
closed, V4
Leak test
Ref. time
1)
1)
8)
1)
11)
If ‘Stop’ after Ti62 skip to
Ti81
Separation
Drain of water;
V5
Feed off
Displacement
water
SV 10
Water
SV10
Optional
sludge pump
Flow rates for
S811, S816, S200,
S821, S826
Flow rates for
S820, S825, S300
S830, S831, S835,
S836, S400, S840,
S841, S 845, S846
Flow rates for
S500, S850, S851,
S855, S856, S600,
S860, S861, S865,
S866
Flow rates for
S700,S870, S871,
S875, S876
Flow rates for
S800, S880, S881,
S885, S886
SV10: 0.9 l/m
SV10: 1.6 l/m
SV10: 5.5 l/m
SV10: 11 l/m
SV10: 15 l/m
SV15: 11.0 l/m
SV15: 11 l/m
SV15: 11 l/m
SV15: 11 l/m
SV15: 11 l/m
SV16: 2.8 l/m
SV16: 2.8 l/m
SV16: 2.8 l/m
SV16: 2.8 l/m
SV16: 2.8 l/m
1810572-02
25
5 SEQUENCE DIAGRAM
S-TYPE SEPARATION SYSTEM PARAMETER LIST
5.1 Separation Sequence
Start
Timer
Action
Alarms
Ti 56 = 3 sec.
Discharge
SV 15
To ensure that the operating system gets sufficient
water before closing.
Ti 57 = 15 sec.
Draining of operating water
Ti 58 = See table
chapter 4.
Bowl closing
SV 16
Ti 59 = calculated
Calibration of water flow
V 4, SV 10
Bowl filled with water until pressure is indicated in the
oil outlet (Parameter Fa6 = 0.2 bar). Flow rate is
calculated based on the known bowl volume and time
taken to fill with water.
Ti 60 = See table
chapter 4.
SV 15
Ti 61 = 15 sec.
‘NO PT4 PRESSURE
FEEDBACK DURING Ti 59’
Ti 59 has a max. value of 170
sec. Alarm is given if no
pressure response within this
time.
Discharge
Normal start begins here. There are two reasons for
this:
1. To ensure that the operating system gets sufficient
water before closing.
2. To empty the bowl before start after power failure.
Pause
During this timer, water is drained from the operating
system.
Ti 62 = See table
chapter 4.
Bowl closing
SV 16
26
Ti 63 = calculated
Filling of conditioning water
SV 10
The time (volume) is based on the calibrated flow rate
and bowl volume.
1810572-02
Max. 120 sec.
S-TYPE SEPARATION SYSTEM PARAMETER LIST
5 SEQUENCE DIAGRAM
Separation
Timer
Action
Alarms
Ti 64 = 60 sec.
Feed on to separator
V 1, (V 4 automatic
selection)
‘Oil backpressure PT4 – LOW’
Alarm is given if no pressure
response in oil outlet within
Ti 64.
Ti 65 = 15 sec.
Test of water content in oil outlet
V1
If traces of water are detected in the oil outlet, the time
for displacement (Ti 72) will be reduced before next
discharge.
After calibration start, the oil outlet pipe is filled with oil
and the system now skips to Ti 70 to perform a
discharge. Ti 72 max 90 sec interrupted by
transducer response.
Ti 66 = See table
chapter 4.
Bowl leaking test
‘OIL LEAKING FROM BOWL’
With the feed off and the oil outlet closed, a
decreasing pressure indicates that the bowl is
leaking.
In order to find a suitable pressure range (1 – 2 bar)
for test, Ti 65 and Ti 66 may be repeated (see Fa 49).
Alarm is given if the pressure
falls by more than 1.0 bar.
V4
Ti 67 = 60 sec.
Reference time
V1
After the process has stabilized, the transducer
(MT 50) reference value is stored.
Ti 68 = 120 min.
Separation.
‘Water drain - INSUFFICIENT’
V1 (V5)
When necessary, the drain valve (V5) in the water
outlet opens for a short while. The trigger value is then
checked during a few seconds. Draining stops when
the trigger value is lower than 70. Draining can
continue max. 5 openings. After 5 openings, skip to
Ti 74.
During separation all necessary
functions are supervised.
Alarm given if more than 5
openings and trigger value not
less than 70.
1810572-02
27
5 SEQUENCE DIAGRAM
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Discharge
Timer
Action
Ti 70 = 15 sec.
Feed off.
Alarms
Oil outlet pressure decreases.
‘OIL PRESSURE PT4 HIGH
DURING Ti70’.
Alarm given if no pressure
feedback.
Ti 71 = 20 sec.
Displacement water.
V4, SV10
Oil outlet pressure increase more than 0.5 bar
indicates that water is fed. The timer is then
interrupted.
Ti 72 = 0 – 150 sec.
V5
Ti 74 = 3 sec.
Alarm given if no pressure
feedback.
Max. 15 sec.
Displacement water.
SV10
Ti 73 = 10 sec
‘NO PT4 PRESSURE
FEEDBACK DURING Ti71’.
Max. to calibrated value.
Water pumped out through the water outlet to wash
out any remaining oil.
Sludge pump in operation.
Discharge.
SV15
Ti 75 = 15 sec.
Discharge feedback and draining of operating
system
‘Discharge feedback –
ERROR’.
After’bowl cleaned’ at start, the program continues
with Ti 58 – 68. Once Ti 68 has elapsed, the program
skips from Ti 75 to Ti 62 after every discharge, or to
Ti 81 if stop is ordered.
Alarm is given if bowl speed
after discharge is not below
Fa 11 minus Fa 12.
Ti 62 to 67
repeated.
or Ti 81
28
1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Stop
Timer
Action
Ti 81 = See table
chapter 4.
Bowl closing
5 SEQUENCE DIAGRAM
Alarms
SV16
Ti 82 = 150 sec.
Water to the bowl.
V4, SV10
Heater off
Timer interrupted when 80% of bowl volume is filled,
or when pressure in oil outlet is increased by more
than 0.2 bar.
Ti 83 = 10 sec
Water pumped out through the water outlet to wash
out any remaining oil from the paring tube and pipes.
V5
Ti 85 = 5 min.
Waiting for oil feed temp. decrease.
Separator motor off
Timer is interrupted when temp. decrease below low
limit.
Ti 86 = 3 min.
Ti 87 = 60 sec.
Max. 300 sec.
‘Temperature - NOT
DECREASING’
If temp. not decreased within Ti
85.
Waiting for speed decrease.
‘Bowl speed – HIGH xxxxx’
Time for cooling of heater
If speed not decreased within
timer.
Timer is interrupted by pump off feedback.
Feed pump off
Ti 89 = 30 – 60 min.
Waiting for zero speed
When speed = 0, timer is interrupted and ‘Standst’ is
indicated.
1810572-02
Max. 60 min.
29
5 SEQUENCE DIAGRAM
S-TYPE SEPARATION SYSTEM PARAMETER LIST
Process Start
Start With Calibration
Ti58 Bowl Closing
Push
‘Separation’
Ti50-54 Feed,
speed, and
temp check
Ti 57 Pause
Ti59 Water
calibration
No
Bowl
dismantled?
Ti55 Standby.
Push
‘Separation’ to
continue
TI 56
Discharge
Max. time Yes
expired?
Alarm
Yes
Ti 60 Discharge
No
Assembled
according to
manual?
No
Standst.
Ti60 Discharge
Ti 61 Pause
Ti61 Pause
Yes
Bowl
cleaned?
Yes
Ti62 Bowl
closing
No
Go to Start
Without
Calibration
Ti62 Bowl
closing
Ti64 Feed on
Ti63 Conditioning
water
Ti65 Stabilizing
Ti64 Feed on
Go to Start With
Calibration
Ti70 Feed off
Ti65 Mt 50
signal test
Ti71 Displ.
water check
Ti66 Leak test
Ti 72
Displacement
Repeated at start
Ti67 MT50
reference
Ti68 Time to
discharge
Yes
No
Stop?
Ti 73 Water
outlet flushing.
No
Ti74 Discharge
Ti75 Pause and
discharge
feedback
Ti68
elapsed?
1810572-02
Man.
discharge?
Yes
Yes
Discharge
30
No
S-TYPE SEPARATION SYSTEM PARAMETER LIST
5 SEQUENCE DIAGRAM
Start Without
Calibration
Discharge
Stop
Ti50-54 Feed,
speed, and temp
check
Ti70 Feed off
Ti81 Bowl
closing
Ti82 Water into
bowl.Heater off
Ti55 Standby.
Push ‘Separation’
to continue
Yes
Ti68
interrupted by
draining ?
Ti 60 Discharge
Ti83 Water outlet
flushing
No
Ti85 Sep. motor
off. Check
decreasing temp
Ti71 Displ.
water check
Ti 61 Pause
Ti62 Bowl closing
Ti 72
Displacement
Ti63 Conditioning
water
Ti 73 Water
outlet flushing.
Ti86 Check
decreasing speed
Ti87 Pump off
Ti64 Feed on
Ti74 Discharge
Ti89 Waiting for
0-speed
Ti65 Mt 50
signal test
Ti75 Pause and
discharge
feedback
Standst.
Ti66 Leak test
Repeated at start
Ti67 MT50
reference
Ti68 Time to
discharge
Stop?
No
Ti62
Yes
No
Stop?
Yes
No
Ti68
elapsed?
No
Stop
Man.
discharge?
Yes
Yes
Discharge
1810572-02
31
5 SEQUENCE DIAGRAM
32
S-TYPE SEPARATION SYSTEM PARAMETER LIST
1810572-02
S-type Separation System
Alarms and Fault Finding
Printed
Mar 2005
Book No.
1810573-02 V 10
Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by:
Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2004.
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
1
Alarms ......................................................... 2
1.1
1.2
1.2.1
1.3
1.4
Alarm Functions................................2
Reading Alarm History List ...........2
Alarm message explanation: ..................3
Alarm Reset........................................3
Abnormalities not displayed.........4
2
Display Alarms and Actions ......... 5
3
Alarm Tests .......................................... 19
1810573-02
1
1 ALARMS
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
1 Alarms
1.1 Alarm Functions
The alarm system is designed to ensure a safe
separation system.
All alarms are shown on the operator panel
display, and most of them are complemented by
light emitting diodes (LEDs).
The alarms are displayed in order of occurrence.
1.2 Reading Alarm History
List
To read the stored list of alarms, do as follows:
•
Push ‘Enter’.
•
Push ‘+’ until ‘End’ is shown on the display.
•
Push ‘Enter’ and ‘+’ at the same time.
•
Push ‘+’ repeatedly until ‘AL list’ shows on the
display.
•
Push ‘Enter’.
•
Go through the list using the ‘+’ pushbutton
until ‘End’ shows on the display.
•
Push ‘Enter’.
•
Push ‘+’ repeatedly until ‘Exit’ shows on the
display.
•
Push ‘Enter’ to return to normal display.
NOTE
The texts ‘Alcap Pr4 = On/ Standby’, and ‘Discharge
Repeated’ are reminders to the operator, and not
alarms.
2
1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
1 ALARMS
1.2.1 Alarm message explanation:
The display shows:
Alarm no. 5
Alarm number
0:13
This alarm occured 13 minutes ago.
Feed pressure low
Type of alarm
P1
Parameter Pr 1 was set to 60 minutes.
60
00:02:13
The alarm was reset after 2 minutes 13 seconds.
1.3 Alarm Reset
!
ING
WARN
Breakdown hazard
1
Acknowledge the alarm signal by pressing the
alarm pushbutton.
The flashing LED then changes to steady
shine.
2
Remedy the cause.
3
Reset the alarm function by pressing the
alarm pushbutton a second time.
G001648A
Never reset an alarm without first finding and
remedying the cause.
ALARM
G001649A
The LED will go out.
ALARM
It is possible to reset the system without
remedying the cause, but the alarm signal will
be repeated.
NOTE
The STOP sequence is automatically initiated if an
alarm is not remedied within 30 minutes.
1810573-02
3
1 ALARMS
!
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
ON
CAUTI
Risk of injury
Never return to the operator panel to acknowledge or
reset an alarm if doing so is by any means
hazardous.
1.4 Abnormalities not
displayed
There are some abnormalities not shown on the
display. Below are listed the most common:
Why?
Smell
Noise
Unsatisfactory separation result
What to do
• Normal occurrence during start
while the friction blocks are
slipping.
None.
• Oil level in oil sump too low.
Check oil level and add oil if
necessary.
• Height position of paring disc is
incorrect.
Stop the separator, measure and
adjust the height.
• Bearing(s) damaged or worn.
Renew all bearings.
• Improper bowl assembly
Check and reassemble.
• Incorrect separation
temperature.
Adjust.
• Throughput too high.
Adjust.
• Disc stack is clogged.
Clean disc stack.
• Sludge space in bowl is filled.
Clean and reduce the time
between sludge discharges.
• Bowl speed too low.
Examine the motor and power
transmission for correct frequency
parts.
Check belt and coupling pads.
• Bowl rotates in wrong direction
4
1810573-02
Check the electrical connections
to the motor.
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
2 DISPLAY ALARMS AND ACTIONS
2 Display Alarms and Actions
on page
on page
The display
shows
The display
shows
Alcap in standby - MORE THAN 24 HOURS
17
IO expansion board - ERROR
18
xxxxx board - ERROR
18
IP address - FAULT
13
Bowl speed - HIGH xxxxx
11
Level switch - DISABLED
18
Bowl speed - LOW xxxxx
12
Local OP in control
17
Bowl speed sensor - ERROR
13
Lockswitch - FAILURE
Communication - ERROR xxxxx
18
NO PT5 DRAIN FEEDBACK DURING Tixx
17
Computer communication board - ERROR
18
NO PT4 PRESSURE FEEDBACK DURING Tixx
15
Discharge feedback - ERROR
17
NO SIGNAL FROM EXTRA INPUT X6:8
16
7
Emergency stop - BUTTON PUSHED
9
Oil backpressure PT4 - HIGH
13
Feed flow PT1 - ERROR DURING Tixx
11
Oil backpressure PT4 - LOW
14
Feed pressure PT1 - HIGH
15
Oil feed temperature - HIGHxxxxx
9
Feed pressure PT1 - LOW
15
Oil feed temperature - LOWxxxxx
10
Feed pressure sensor PT1 - ERROR
15
OIL LEAKING FROM BOWL
13
Heater - FAULT
16
OIL PRESSURE PT4 HIGH DURING Ti70
15
Heater board - ERROR
18
Oil pressure sensor PT4 - ERROR
14
Heater connection - ERROR
18
Parameter xx:xx - ILLEGAL
18
High vibration - SHUTDOWN
7
Parameter changes - LOCKED
13
High vibration - WARNING
8
POWER FAILURE
17
HIGH WATER CONTENT
16
Pressure in water outlet PT5 - HIGH
15
HIGH WATER CONTENT IN OIL
17
Pressure in water outlet PT5 - LOW
15
1810573-02
5
2 DISPLAY ALARMS AND ACTIONS
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
on page
The display
shows
Pump starter - FAILURE
15
Separator motor - FAILURE
13
Separator run-up time - TOO LONG
16
Service alarm
18
SLUDGE IN BOWL
13
Sludge tank level - HIGH
13
Switch power off/on
17
Temperature increase - TOO SLOW
18
Temperature - NOT DECREASING
18
Temperature alarm sensor - ERROR
10
Temperature control sensor - ERROR
11
Transducer - NO RESPONSE
17
MT 50 board - ERROR
16
Transducer value - HIGH
16
Transducer value - LOW
16
Vibration board - ERROR
18
Vibration sensor - ERROR
8
Water drain pressure - HIGH
17
Water pressure sensor PT5 - ERROR
15
6
1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
The display
shows
Lockswitch - FAILURE
2 DISPLAY ALARMS AND ACTIONS
Why?
• Separator not mounted as
described in the Service Manual
booklet.
What to do
Mount the separator according to
the instructions in the Service
Manual booklet.
NOTE
The cause of this alarm must
be remedied within 30
minutes. If not, the STOP
sequence will begin.
High vibration - SHUTDOWN
!
• Sludge remaining in part of the
bowl
Dismantle, clean and check the
bowl before restart. See Service
Manual.
ING
WARN
!
ING
WARN
Disintegration hazards
If excessive vibration occurs, stop
separator and keep bowl filled with
liquid during rundown.
The cause of the vibration must be
identified and corrected before the
separator is restarted.
Disintegration hazard
The separator bowl must be
manually cleaned before
starting up again.
• Bowl wrongly mounted
Check assembly. See Service
• Disc stack compression incorrect Manual.
• Bowl assembled with parts from
other separators
• Height position of paring disc is
incorrect.
Stop the separator, measure and if
necessary adjust the height.
• Bowl spindle bent.
Renew the bowl spindle.
• Bearing(s) damaged or worn.
Renew all bearings.
• The frame feet are worn out.
Renew the frame feet.
• Spindle top bearing spring
broken.
Renew all springs.
1810573-02
7
2 DISPLAY ALARMS AND ACTIONS
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
The display
shows
High vibration - WARNING
Why?
•
Sludge remaining in part of the
bowl
What to do
Dismantle, clean and check the
bowl before restart.
!
ING
WARN
Disintegration hazard
The separator bowl must be
manually cleaned before
starting up again.
• Bowl wrongly mounted
Check assembly. See Service
• Disc stack compression incorrect Manual.
• Bowl assembled with parts from
other separators
Vibration sensor - ERROR
• Height position of paring disc is
incorrect.
Stop the separator, measure and if
necessary adjust the height.
• Bowl spindle bent.
Renew the bowl spindle.
• Bearing(s) damaged or worn.
Renew all bearings.
• The frame feet are worn out.
Renew the frame feet.
• Spindle top bearing spring
broken.
Renew all springs.
• Sensor or cable damaged
Replace sensor. If no spare sensor
available, set parameter Fa 16 =
0.0 to be able to run the system.
Note that it is not possible to run
in AUTO mode.
8
1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
The display
shows
Emergency stop - BUTTON PUSHED
2 DISPLAY ALARMS AND ACTIONS
Why?
• Emergency button pushed
What to do
Remedy cause for pushing button.
Reset pushbutton.
Oil feed temperature - HIGHxxxxx
•
Steam supply valve faulty
• Faulty triac module(s) in the
power unit or faulty controller in
the control unit (electric heater).
Investigate cause and remedy.
If relay K11 is on:
Disconnect X12:10.
If the temperature is falling,
replace the control module in the
control unit.
If the temperature is not falling,
replace the triac module(s).
If relay K11 is off, but contactor
K12, K16, or K17 is on, and the
temperature is not falling:
Check if power is supplied from
the control unit to the contactor
which is on (X12:6 – X12:12, X12:7
– X12:12, X12:9 – X12:12). If it is,
replace the control module in the
control unit.
• Broken wiring or defective heater
resistance, or faulty controller in
the control unit.
Check adjustment of P and I
functions in the control unit.
If contactor sequence correct:
Check wiring and heater
resistance of each block or heater
element. See EHM heater
component booklet.
If contactor sequence not correct:
Replace the control module in the
control unit.
1810573-02
9
2 DISPLAY ALARMS AND ACTIONS
The display
shows
Oil feed temperature - LOWxxxxx
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
Why?
• Heater clogged
What to do
Investigate cause and remedy.
• Steam supply insufficient
• Steam trap faulty
• Steam supply valve faulty
• Faulty fuses or burned
contactors
(electric heater)
Check and renew broken fuses.
Reset overcurrent protection
(applicable for 8/7 – 24/22 kW
power unit).
Check wiring and contactor coils.
Temperature alarm sensor - ERROR
• Broken wiring or defective heater
resistance
(electric heater)
Check wiring and heater
resistance of each block or heater
element. See the Service Manual
booklet.
• Short circuit / broken sensor or
cable.
Disconnect cable at sensor.
Measure resistance between 1-3.
Resistance shall be within 100-142
ohms = 0-110 C / 32-230 F.
Test of EPC 50 input:
• Disconnect cables from sensor,
(terminal X 5:1-2-3).
• Move jumpers Xj1 and Xj2
upwards - from Normal to Test.
(The jumpers can be found in
the upper left corner of the I/O
Board)
• Indication within 50-60 C when
OK.
• If no spare sensor available set
parameter Pr 16 = 0, or if control
sensor free, move connection
to that one.
10
1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
The display
shows
2 DISPLAY ALARMS AND ACTIONS
Why?
What to do
Temperature control sensor - ERROR
• Short circuit / broken sensor or
cable.
Disconnect cable at sensor.
Measure resistance between 1-3.
Resistance shall be within 100-142
ohms = 0-110 C / 32-230 F. If no
spare sensor available set
parameter Pr 18 = 0. Heater is then
out of function.
Feed flow PT1 - ERROR DURING Tixx
• Pump not working
Check pump.
• Pressure in feed line too low
Check feed line.
• High power (net) frequency
Check power supply before
restart.
Bowl speed - HIGH xxxxx
• Incorrect transmission parts
(50 Hz belt pulley and belt for
60 Hz power supply).
!
ING
WARN
Disintegration hazard
Stop and change the belt
transmission to suit the
power supply frequency.
1810573-02
11
2 DISPLAY ALARMS AND ACTIONS
The display
shows
Bowl speed - LOW xxxxx
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
Why?
What to do
• Slipping belt
Change belt.
• Worn coupling pads
Check / change pads.
• Bowl not properly closed
Check closing water supply (valve
SV 16).
Check bowl operating system for
leakage.
Check nozzle.
• Bowl not properly assembled
Check that the lock ring is in
place.
• Low power net frequency
Check power.
• Motor failure.
Repair the motor.
• Bearing(s) damaged.
Renew all bearings.
• Incorrect transmission parts (60
Hz belt pulley and belt for 50 Hz
power supply).
!
ING
WARN
Disintegration hazard
Stop and change the belt
transmission to suit the
power supply frequency.
12
1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
The display
shows
2 DISPLAY ALARMS AND ACTIONS
Why?
What to do
• Sensor or cable damaged
Replace sensor. If no spare sensor
available set parameter In 6 = No
to be able to run the system. Note
that it is not possible to run in
AUTO mode.
Separator motor - FAILURE
•
Feedback signal from contactor
K 2 missing
Check the contactor function.
Input terminal
X 6:5 in EPC 50.
OIL LEAKING FROM BOWL
•
Bowl periphery sealing
damaged
Change seal ring in bowl hood.
Bowl speed sensor - ERROR
SLUDGE IN BOWL
Sludge tank level - HIGH
Parameter changes - LOCKED
IP address - FAULT
Oil backpressure PT4 - HIGH
Check/change rubber rings and
valve plugs.
• Leakage somewhere in oil outlet
Check for leakage.
• Closing water leaking
Check/change sealings and plugs.
• Too much sludge in bowl
This alarm cannot be
acknowledged. The separator will
come to a stop. Wait until EPC
comes to ‘Standstill’. Investigate
cause and remedy.
•
Check the pump function.
Pump has not drained the tank
• A code has been set to make
parameter changes not possible
Unlock the code.
• Wrong IP address used in
In 27-30
Check the setting.
•
Check. Reduce backpressure.
Increased throughput
• Regulating valve too restricted
1810573-02
Adjust valve
13
2 DISPLAY ALARMS AND ACTIONS
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
The display
shows
Oil backpressure PT4 - LOW
Why?
•
Decreased throughput
What to do
Check feed pump and adjust flow.
• Regulating valve open too much
Adjust valve
• Change over valve V1 in
recirculation position
Check air pressure, solenoid valve
SV1 and output from EPC 50
terminal X 8:1-X 41.
Bowl opens unintentionally during
operation because:
Oil pressure sensor PT4 - ERROR
14
• Strainer in the operating water
supply is clogged.
Clean the strainer.
• No water in the operating water
system.
Check the operating water system
and make sure any supply valves
are open.
• Hoses between the supply
valves and separator are
incorrectly fitted.
Fit correctly.
• Nozzle in bowl body clogged
Clean the nozzle.
• Rectangular ring in discharge
slide is defective.
Renew the rectangular ring.
• Valve plugs are defective.
Renew all plugs.
• Supply valve SV15 for opening
water is leaking.
Rectify the leak.
• Sensor or cable damaged
Replace sensor. If no spare sensor
available set parameter Pr 10=0.0
to be able to run the system.
1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
The display
shows
2 DISPLAY ALARMS AND ACTIONS
Why?
What to do
OIL PRESSURE PT4 HIGH DURING Ti70
• No decrease in oil pressure
during this timer.
Check function of change-over
valve V1.
NO PT4 PRESSURE FEEDBACK DURING
• No increase in oil pressure
during this timer.
Check supply of displacement
water. Valve SV 10.
Pressure in water outlet PT5 - HIGH
•
Pressure in water outlet PT5 - LOW
• Paring tube not moving correctly
Check that movement is not
impeded by friction.
• Sensor or cable damaged
Check cable connections
Water pressure sensor PT5 - ERROR
Paring tube not moving correctly Check that movement is not
impeded by friction.
Replace sensor. If no spare sensor
available set parameter Pr 12=0.0
to be able to run the system.
Feed pressure sensor PT1 - ERROR
• Sensor or cable damaged
Check cable connections
Replace sensor. If no spare sensor
available set parameter Pr 14=0.0
to be able to run the system.
Feed pressure PT1 - HIGH
• Pipe restricted
Check recirculation for restriction
Feed pressure PT1 - LOW
• Low flow
Check pump and flow regulation.
Check heater for fouling.
Pump starter - FAILURE
• Feedback signal from contactor
K 3 missing
1810573-02
Check the contactor function.
Check input terminal X 9:1 in the
EPC.
15
2 DISPLAY ALARMS AND ACTIONS
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
The display
shows
NO SIGNAL FROM EXTRA INPUT X6:8
Separator run-up time - TOO LONG
Heater - FAULT
Why?
What to do
• Depends on use of the input
Depends on use of the input
•
Check the coupling.
Separator coupling slipping
• Belt slipping
Check the belt.
• Height position of paring disc is
incorrect.
Stop. Check and adjust the height.
• Motor failure
Repair the motor.
• Bearing(s) damaged or worn.
Renew all bearings.
• Separator start button not
pushed.
Push start button.
• 0V in cable heater X 12:3 to EPC
50 X 51:4
(electric heater)
Check the power supply to the
heater.
• High temp. switch released
(electric heater)
Check temp. setpoint in the
control unit.
Check the heater and clean if
necessary.
Reset temp. switch in power unit.
Restart heater.
MT 50 board - ERROR
Transducer value - HIGH
Transducer value - LOW
HIGH WATER CONTENT
16
•
Faulty board
Change MT50 Board (see Change
of Circuit Board in the Service
Manual booklet).
• Extremely high water content
Check the dirty oil quality.
• Fouling in the monitor MT 50
Dismantle and clean with
detergent.
• Too much air in oil outlet
Check oil back pressure
For HFO and DO
• Too much water in oil
Investigate cause and remedy.
• Much water in the feed
Check the dirty oil quality.
• Paring tube not moving properly
Check that movement is not
impeded by friction.
1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
The display
shows
HIGH WATER CONTENT IN OIL
2 DISPLAY ALARMS AND ACTIONS
Why?
For LO
• Too much water in oil
Investigate cause and remedy.
• Much water in the feed
Check the dirty oil quality.
• Paring tube not moving properly
Check that movement is not
impeded by friction.
Alcap in standby - MORE THAN 24 HOURS • Reminder
Water drain pressure - HIGH
NO PT5 DRAIN FEEDBACK DURING Tixx
Transducer - NO RESPONSE
Discharge feedback - ERROR
Local OP in control
POWER FAILURE
Switch power off/on
What to do
Check the reason for stand by and
try to get back to normal operation
as soon as possible.
• Water pressure has not
decreased sufficiently though
valve V5 open.
Check V5 function.
• Restriction in water outlet
causing no reduction in pressure
Clean the outlet pipe.
• Expected increase of trigger
signal during Ti 64 and Ti 65
failed
Check water supply. Valve SV 10.
Speed not decreased as discharge
feedback (below Fa12) caused by:
• Strainer in the operating water
supply is clogged.
Clean the strainer.
• Water flow too low.
Check opening water. Valve SV 15.
• Hoses between the supply
valves and separator are
incorrectly fitted.
Correct.
• Rectangular ring in the operating
slide is defective.
Renew the rectangular ring.
• Attempt to operate remote OP
Not legal when local OP is active.
• Black-out has occurred with EPC
in operation
Check plant conditions and
restart.
• Alarms comes at standstill after
emergency or vibration shut
down
Investigate the cause for the stop
and switch the power off and then
on to the EPC 50.
1810573-02
17
2 DISPLAY ALARMS AND ACTIONS
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
The display
shows
Parameter xx:xx - ILLEGAL
Why?
•
If parameters are changed
automatically by "thunderstorm"
type influence, alarm is given to
indicate out of range.
What to do
Switch EPC50 power off. Move X
J4 on I/O board to position right.
Switch power on. Parameters are
now all set to default values. Move
X J4 back to original position.
Adjust all parameter settings to
correct value.
Switch power off and on again.
• X71:2 and X71:3 are both set to
0 or both set to 1
Set X71:2 to X41 and jumper
between X71:3 and X40
• Transducer board, operator
panel board, or I/O board in EPC
not working
Check cables to board or replace
the board (see Change of Circuit
Board in the Service Manual
booklet).
• Bad connection
Check connection
• Board faulty
Replace the board
• Cable errors
Check cables to board or replace
the board (see Change of Circuit
Board in the Service Manual
booklet).
Heater board - ERROR
• Optional heater board in EPC not
working
Check cables to board or replace
the board (see Change of Circuit
Board in the Service Manual
booklet).
Vibration board - ERROR
• Optional vibration board in EPC
not working
Check cables to board or replace
the board (see Change of Circuit
Board in the Service Manual
booklet).
Heater connection - ERROR
• System cross-connection heater
communication error
Check parameters and cable.
Level switch - DISABLED
• If Pr 25=0 the high level alarm is
disabled
The alarms comes as warning to
operator.
Service alarm
• If Pr 5 is used, the text in Pr 6 is
displayed
Take action according to what the
text means (plant dependant).
Temperature increase - TOO SLOW
• Insufficient heating during start
(Ti 53)
Check heater function.
IO expansion board - ERROR
xxxxx board - ERROR
Computer communication board - ERROR
Communication - ERROR xxxxx
Temperature - NOT DECREASING
• Heating on during stop sequence Check heater function.
• Recirculating oil not cooling
18
1810573-02
Reset alarm to continue.
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
3 ALARM TESTS
3 Alarm Tests
NOTE
If any parameter value is changed to activate an
alarm, do not forget to reset to the original value
before operation.
Alarm message
Red
diode
Sequence
Method
Termin
al
Bowl speed sensor - ERROR
Standst.
Start separator with sensor
disconnected.
X6:1
POWER FAILURE
Start
Switch power off / on during
operation
Reaction
Standard functions
Feed pressure PT1 - HIGH
PT1
Start
Decrease limit (Pr14)
Feed pressure PT1 - LOW
PT1
Start
Increase limit (Pr15)
Feed pressure sensor PT1 ERROR
PT1
Start
Disconnect sensor
Pump starter - FAILURE
Pump
Start
Switch pump off
Start
Decrease limit (Pr16/Pr19)
Oil feed - TEMPERATURE HIGH TT
X5:4
V1 off.
Heating off.
Oil feed - TEMPERATURE LOW
TT
Start
Increase limit (Pr17/Pr20) or
decrease Ti 53
.
V1 off
Temperature alarm sensor ERROR
TT
Start
Disconnect sensor
X5:2
V1 off
Heating off.
Bowl speed - HIGH
Separation
Decrease limit (Fa10)
Stop
sequence.
Bowl speed - LOW
Separation
Increase limit (Fa11)
Stop
sequence.
Oil backpressure PT4 - HIGH
PT4
Separation
Increase backpressure
V1 off
Oil backpressure PT4 - LOW
PT4
Separation
Decrease backpressure
V1 off
Timer Ti 71
Disconnect V4
X8:3
Separation
Disconnect sensor
X5:6
NO PT4 PRESSURE
FEEDBACK DURING Tixx
Oil pressure sensor PT4 ERROR
PT4
1810573-02
19
3 ALARM TESTS
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING
Alarm message
Red
diode
Sequence
Method
Termin
al
Reaction
Pressure in water outlet PT5 HIGH
PT5
Separation
Force the paring tube
outwards or decrease limit
(Pr12)
Pressure in water outlet PT5 LOW
PT5
Separation
Force the paring tube
inwards or increase limit
(Pr13)
Water pressure sensor PT5 ERROR
PT5
Separation
Disconnect sensor
Transducer value - HIGH
MT
Separation
Decrease limit (Fa23)
V1 off
Transducer value - LOW
MT
Separation
Increase limit (Fa24)
V1 off
Transducer - ERROR
MT
Separation
Disconnect X2 cable plug
HIGH WATER CONTENT IN
OIL
Separation
Add much water to the feed
and wait for 5 draining
actions. Discharge. After
another 5 drainings alarm is
given.
Discharge feedback - ERROR
Discharge
Disconnect SV15
Emergency stop - BUTTON
PUSHED
Separation
Push the button
X5:8
V1 off
X8:5
A second
attempt to
discharge will
take place
before alarm
and stop.
Sep.motor off,
heater off, feed
on for max.3
minutes. Feed
stops when
pressure
reaches Pr11.
Optional functions
Temperature control sensor ERROR
TT
Start
Disconnect
X51:3
Heater - FAULT
Heater
Start
Disconnect
X51:4
Sludge tank level - HIGH
Tank
Start
Disconnect
X201
Start
Decrease Ti 52 to 1. Start
the separator.
Start
Start separator and EPC but
not heater, or start system
with Ti 53 set to 1.
Separator run-up - TOO LONG
Temperature increase - TOO
SLOW
20
TT
1810573-02
Sep. motor off.
SA 811/816/821/826 Separation Systems
Installation System Reference
Printed
Jun 2006
Book No.
1810947-02 V 6
Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by:
Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB Jun 2006.
Contents
1
Technical Data ........................................................................................................ 1
1.1
1.2
1.3
2
Demand Specification Water.......................................................................... 1
Demand Specifications Air ............................................................................. 1
System Data ....................................................................................................... 2
Drawings ...................................................................................................................... 4
2.1
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.2.8
2.2.9
2.2.10
2.2.11
2.2.12
2.3
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
2.4.8
2.4.9
2.4.10
2.4.11
2.4.12
Flow Chart ............................................................................................................ 4
Drawings ............................................................................................................... 5
Separator Mounting Drawing, DIN ........................................................................... 5
Separator Mounting Drawing with Sludge Removal Kit, DIN ................................... 6
Separator Mounting Drawing, JIS ........................................................................... 7
Separator Mounting Drawing with Sludge Removal Kit, JIS..................................... 8
Separator Basic Size Drawing.................................................................................. 9
Separator Foundation Drawing ............................................................................. 10
Valve Block Oil, DN 25 Dimension Drawing ........................................................... 11
Valve Block Oil, DN 25 Assembly Drawing ............................................................ 12
Valve Block Water Assembly Drawing ................................................................... 13
Valve Block Air, Assembly Drawing ....................................................................... 14
Control Unit EPC 50 Dimension Drawing ............................................................... 15
Starter Dimension Drawing..................................................................................... 16
Electrical System Layout ............................................................................. 17
Electrical Diagrams ......................................................................................... 18
Cable List .............................................................................................................. 18
Interconnection Diagram, Starter ........................................................................... 21
Interconnection Diagram, Starter, cont. ................................................................. 22
Interconnection Diagram, Transmitters .................................................................. 23
Interconnection Diagram, Solenoid Valves ............................................................ 24
Interconnection Diagram, Solenoid Valves cont. ................................................... 25
Interconnection Diagram, Optional Equipment ...................................................... 26
Transformer Connection Diagram ......................................................................... 27
Circuit Diagram, Power Circuits ............................................................................. 28
Circuit Diagram, Separator Starter and Feed Pump ............................................. 29
Circuit Diagram, Remote Start Interlock (optional)................................................. 30
Circuit Diagram, ESD-relay and Trip Contacts (optional)....................................... 31
1810947-02
3
Remote Operation Systems......................................................................... 33
4
Specifications ....................................................................................................... 36
4.1
4.2
4.3
4.4
4.5
4.6
4.7
5
Cables ..................................................................................................................36
Cable Routing ....................................................................................................37
Oil, Water, Steam, and Condensate Piping ..............................................37
Ambient Temperature Limitation................................................................38
Sludge Removal Kit (Optional Equipment) .............................................39
Sludge Tank .......................................................................................................41
Sludge Piping .....................................................................................................43
Commissioning and Initial Start ............................................................... 46
5.1 Completion Check List ...................................................................................46
5.2 Initial Start-up ...................................................................................................48
5.2.1 Calculating Operating Pressure .............................................................................50
6
Shut-down and Storage .................................................................................. 51
6.1
6.2
6.3
Shut-down after Use........................................................................................51
Protection and Storage ..................................................................................52
Reassembly and Start up...............................................................................53
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
1 TECHNICAL DATA
1 Technical Data
1.1 Demand Specification Water
Alfa Laval ref. 574487 rev. 0
Poor quality of the operating water may with time cause erosion, corrosion and/or
operating problems. The water shall be treated to meet certain demands.
The following requirements are of fundamental importance:
1
Turbidity-free water, solids content <0,001% by volume.
Max. particle size 50 µm.
Deposits shall not be allowed to form in certain areas in the system.
2
Total hardness less than 180 mg CaCO3 per litre, which corresponds to 10 °dH or 12,5 °E. Hard
water may with time form deposits in the operating mechanism. The precipitation rate is
accelerated with increased operating temperature and low discharge frequency. These effects
become more severe the harder the water is.
3
Chloride content max. 100 ppm NaCl (equivalent to 60 mg Cl/l). Chloride ions contribute to
corrosion on surfaces in contact with the operating water.Corrosion is a process that is
accelerated by increased separating temperature, low pH, and high chloride ion concentration.
4
6,5 < pH < 9
Bicarbonate content (HCO3) min. 70mg HCO3 per litre, which corresponds to 3,2 °dKH.
NOTE
Alfa Laval accepts no liability for consequences
arising from unsatisfactorily purified operating
water supplied by the customer.
1.2 Demand Specifications Air
Specific requirements regarding the quality
of air
1
Pressure 500 – 700 kPa (5 – 7 bar).
2
Free from oil, and solid particles larger than
0.01 mm.
3
Dry, with dew point min. 10 °C below
ambient temperature.
NOTE
1810947-02
Electrical interconnections must be made by
qualified electricians.
Mechanical interconnections must be made by
qualified mechanical technicians.
1
1 TECHNICAL DATA
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
1.3 System Data
Media
Fuel oil and lube oils for diesel engines
Feed density, max.
1010 kg/m³ at 15 °C
Viscosity, max.
55 cSt at 100 °C (700 cSt at 50 °C)
Pressure:
oil inlet
Max. 200 kPa (2 bar) at separator inlet
oil outlet
Max. delivery head 250 kPa (2.5 bar)
sludge outlet from separator
open outlet
sludge outlet from sludge pump
Max. 5 bar at 6 bar air pressure
Feed temperature, max.
100 °C
Ambient temperature
Min. +5 °C, max. +55 °C
Discharge volume
1.6 litre/discharge
Operating water pressure
Min 200 kPa (2 bar), max. 600 kPa (6 bar)
Operating water temp.
Min. +5 °C, max. +55 °C (unheated water)
Operating water consumption (without make-up water)
2.9 litre/discharge
Make up water
1.1 litre/hour
Operating water flow
from SV 10: 0.9 l/m
from SV 15: 11.0 l/m
from SV 16: 2.8 l/m
Air quality
Instrument air
Air pressure
Min. 500 kPa (5 bar), max. 700 kPa (7 bar)
Drain connection size
2x1” (internally threaded)
Mains supply voltage
3x230/400/440/480/575/690 V ± 10%
EPC supply voltage (from starter)
230 V /110V/115 V/100V ± 10%, max. fuse 10 A
Control voltage, operating
24 V AC
Power consumption, startup
6.4 kW
Power consumption idling/max. capacity
2.6 kW/6.3 kW
Frequency
50 or 60 Hz ± max. 5%
Enclosure class
Min. IP 54
Storage time before use (with bowl removed)
max. 6 months
Storage temp.
Min. +0 °C, max. +70 °C
Storage humidity
Relative humidity (RH) 10% – 95 % Non Condensing
Service intervals:
Note! Regularly check connections. Tighten if necessary.
Separator
Inspection every 4000 hours or 6 months operation
Overhaul every 12000 hours or 18 months operation
Note! Cleaning In Place (CIP) is recommended to avoid
manual internal cleaning of the bowl. The following intervals
are recommended:
Prior to inspection and overhaul
HFO 1 – 2 months depending on oil quality
LO (Cross-head engines) 1 – 2 months depending on oil
quality and engine condition.
LO (Trunk engines) 1 month
2
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
1 TECHNICAL DATA
Separation System Planned Maintenance Kits
Hours
Period
Separator
4000
6 months
Inspection
12000
18 months
Overhaul
24000
3 years
Overhaul
Ancillary
Equipment
1000
2000
As necessary
Repair
(components)
With delivery
Inspection
Tools
1810947-02
3
Ref. 568110 Rev. 2
4
1810947-02
X019211B
Alt
MCFR
Flow Control
FC
Flow Control
Heating system
Feed pump
Lo-application
Alt
To sludge
pump
Alt
Sludge tank
Drain
Starter
Opening/closing water
Drain
375
462
Not included in
Alfa Laval
standard delivery
Block mounted
Optional Alfa Laval
delivery
Operating water
Ventilation
Sludge discharge outlet
222
371
Operating air
Water outlet
501
Clean oil outlet
220
221
540
Oil Recirculation to tank
Water for water seal and
displacement
206
209
Oil inlet
201
Control unit
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 Drawings
2.1 Flow Chart
X023595A
Drain
Starter
The EPC-50 Control Unit must be
postioned close to the separator.
It must be possible to see the separator
from the EPC-50 Control Unit position.
Opening water/closing water
Operating air. Instrument air,
pressure 500-700 kPa (5-7 bar).
Mains supply 3x230/400/440/480/
575/690 V
EPC 50 supply voltage, 230V, 110/
115V or 100V. AC
375
501
709
799
1810947-02
ISO G 1/8
ISO G 1/2
Flange DN25-PN16-DIN2633
C
D
F
Internal flexible connection (enclosed
with delivery)
If there is more than one separator system in the
same installation, the EPC-50 Control Units and their
corresponding separators must be clearly marked
*
DIN Flange DN50-PN16-DIN2543
B
Optional
DIN Flange DN25-PN16-DIN2633
A
Connections
Sludge discharge outlet
Operating water – see 1.1 Demand
Specification Water.
Pressure 200-600 kPa (2-6 bar).
Temp. min +5°C, max. +55°C.
Water outlet
221
371
Clean Oil outlet
220
222
Water for conditioning/displacement
Oil Recirculation to tank
209
Oil inlet
206
201
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 DRAWINGS
2.2 Drawings
2.2.1 Separator Mounting Drawing, DIN
Ref. 568079 Rev. 4
5
6
X023862A
Drain
Starter
4 holes ∅ 12 for
foundation bolt
The EPC-50 Control Unit must be
If there is more than one separator system in the
postioned close to the separator.
same installation, the EPC-50 Control Units and their
It must be possible to see the separator corresponding separators must be clearly marked
from the EPC-50 Control Unit position.
EPC 50 supply voltage, 230V, 110/
115V or 100V. AC
799
Ref. 577895 Rev. 1
1810947-02
ISO G 1/8
ISO G 1/2
C
D
*
Internal flexible connection (enclosed
with delivery)
Optional
Pipe ∅ 48.3
DIN Flange DN25-PN16-DIN2543
B
G
DIN Flange DN25-PN16-DIN2633
A
Connections
Mains supply 3x230/400/440/480/
575/690 V
Operating air. Instrument air,
pressure 500-700 kPa (5-7 bar).
501
Ventilation
Opening water/closing water
375
540
Operating water – see 1.1 Demand
Specification Water.
Pressure 200-600 kPa (2-6 bar).
Temp. min +5°C, max. +55°C.
709
Sludge discharge outlet
221
222
Water outlet
220
371
Oil Recirculation to tank
Clean Oil outlet
209
Water for conditioning/displacement
Oil inlet
206
201
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2.2.2 Separator Mounting Drawing with Sludge Removal Kit, DIN
X023596A
Drain
Starter
The EPC-50 Control Unit must be
postioned close to the separator.
It must be possible to see the separator
from the EPC-50 Control Unit position.
Oil Recirculation to tank
Clean Oil outlet
209
220
Opening water/closing water
Operating air. Instrument air,
pressure 500-700 kPa (5-7 bar).
Mains supply 3x230/400/440/480/
575/690 V
EPC 50 supply voltage, 230V,
110/115V or 100V. AC
375
501
709
799
1810947-02
ISO G 1/2
D
Internal flexible connection (enclosed
with delivery)
If there is more than one separator system in the
same installation, the EPC-50 Control Units and their
corresponding separators must be clearly marked
*
ISO G 1/8
Optional
Flange 50A-10K-JIS B2222
B
Welding connection ∅ 34.5
C
A
Connections
Sludge discharge outlet
Operating water – see 1.1
Demand Specification Water.
Pressure 200-600 kPa (2-6 bar).
Temp. min +5°C, max. +55°C.
222
371
Water outlet
Water for conditioning/
displacement
206
221
Oil inlet
201
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 DRAWINGS
2.2.3 Separator Mounting Drawing, JIS
Ref. 568080 Rev. 4
7
8
X023863A
Drain
The EPC-50 Control Unit must be
postioned close to the separator.
It must be possible to see the separator
from the EPC-50 Control Unit position.
Starter
4 holes ∅ 12 for
foundation bolt
If there is more than one separator system in the
same installation, the EPC-50 Control Units and their
corresponding separators must be clearly marked
EPC 50 supply voltage, 230V,
110/115V or 100V. AC
799
Ref. 577912 Rev. 1
1810947-02
ISO G 1/2
Pipe ∅ 48.3
D
G
*
ISO G 1/8
C
Internal flexible connection (enclosed
with delivery)
Optional
Welding connection ∅ 34.5
Flange 25A-16K-JIS B2222
A
B
Connections
Ventilation
Mains supply 3x230/400/440/480/
575/690 V
540
Operating air. Instrument air,
pressure 500-700 kPa (5-7 bar).
709
Opening water/closing water
375
501
Water outlet
221
Sludge discharge outlet
Clean Oil outlet
220
Operating water – see 1.1
Demand Specification Water.
Pressure 200-600 kPa (2-6 bar).
Temp. min +5°C, max. +55°C.
Oil Recirculation to tank
209
371
Water for conditioning/
displacement
206
222
Oil inlet
201
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2.2.4 Separator Mounting Drawing with Sludge Removal Kit, JIS
1810947-02
X0 2 3 5 9 7 A
All dimensions are nominal. Reservation for
individual deviations due to tolerances.
All connections to be installed non-loaded and
flexible.
Connection house with connections 201, 220,
and 221, turnable in 60 ° steps all round.
Tightening torque 160 Nm
4 holes M10
Maximum vertical
displacement at the
sludge connection
during operation ±2 mm
Maximum horizontal displacement
at the inlet/outlet connections
during operation ±5 mm
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 DRAWINGS
2.2.5 Separator Basic Size Drawing
Ref. 574283 Rev. 0
9
10
Ref. 574284 Rev. 1
1810947-02
X0 2 3 5 9 8 B
Centre of separator bowl
Centre of motor
8 holes ∅ 13.5 for foundation bolts
Installation acc. to stated
foundation forces
Foundation turnable 360 °
Foundation bolt
Max. height of largest
component incl. lifting tool.
Service side.
Dynamic force (static forces excluded)
from separator do not exceed:
Force in any separator foot:
Vertical ±8 kN
Horizontall ±8 kN
Total foundation force (sum of all feet):
Vertical ±8 kN
Horizontall ±8 kN
Centre of gravity (complete machine)
No fixed installation within this area
Recommended free floor space for
unloading when doing service.
Min. lifting capacity required
when doing service: 300 kg
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2.2.6 Separator Foundation Drawing
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 DRAWINGS
X019208A
Weight circa 50 kg
2.2.7 Valve Block Oil, DN 25 Dimension Drawing
Ref. 568054 Rev. 0
1810947-02
11
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2.2.8 Valve Block Oil, DN 25 Assembly Drawing
Cable 19
Connection kit
Water transducer
Connection
Valve
Pressure
transmitter
* Angular coupling
Needle valve
Non-return valve
Nipple
Elbow
*
Pressure
gauge *
Connection
Pressure
transmitter
Needle valve
Valve block
Temperature sensor
Nipple
Needle valve
Shut-off valve
Nipple
*
Pressure
transmitter
Pneumatic
change-over valve
Connection
Non-return valve
Nipple
Washer
Hexagon plug
Elbow
*
* To be sealed with locking liquid
Ref. 567802 Rev. 3
12
1810947-02
Silencer
Flexible connection
X019208D
Screw
*
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 DRAWINGS
2.2.9 Valve Block Water Assembly Drawing
Connection for solenoid valve
Flow valve for SV 10
Flow valve for SV 15
Flow valve for SV 16
Quick coupling
Valve block
Non return
valve kit
Flexible connection
X0 1 9 2 1 5 A
Flexible connection
Ref. 567940 Rev. 0
1810947-02
13
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2.2.10 Valve Block Air, Assembly Drawing
Spade connection
Valve block
X0 1 9 2 1 6 A
Flexible connection
Ref. 568048 Rev. 0
14
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 DRAWINGS
2.2.11 Control Unit EPC 50 Dimension Drawing
Operating panel
Separator interlock
indication (optional)
Emergency stop,
separator
Sludge valve
interlock indication
(optional)
On-off, feed
pump
On-off,
separator
PC connection
Plugged holes
for extra cable
glands
Technical Data
Ambient temperature
Max. 55 °C
Protection class
IP 65
Material in cabinet
Sheet steel
Power supply
100,115, or 230 V AC 50/60 Hz
Operating voltage
24 v AC 50/60 Hz
Power consumption
70 VA (+200 VA for I/O)
Weight
19 kg
X0 2 3 3 6 9 B
Optional
Ref. 568304 Rev. 3
1810947-02
15
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
X0 1 9 2 0 7 A
2.2.12 Starter Dimension Drawing
Ref. 568025 Rev. 1
16
1810947-02
1810947-02
X019203B
Heating system
See also 1765867 for
electric heater; 1765868
for steam heater
Feed pump
Control unit
Circuit board
–Vibration
–Communication
–Heater control
–Remote alarms
Tank
SRK
Sludge
pump
SUM
Mains supply
Start/Stop
Remote
OP unit
Remote
Functional blocks
Optional Alfa Laval
delivery
Interconnection diagram 568030
Cable list 568031
Starter
Emergency
Comm.
System
Data
Temp. Al.
Remote
Alarm
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 DRAWINGS
2.3 Electrical System Layout
Ref. 568029 Rev. 1
17
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2.4 Electrical Diagrams
2.4.1 Cable List
No.
Type
Connection point
A
Instruction
Connection point
B
Remarks
Power cables (currents according to order)
1
MPRXCX
3x4
Mains supply
Starter
Fuse 20 A
1
MPRXCX
3x10
Mains supply
Starter
Fuse 35 A
1
MPRXCX
3x16
Mains supply
Starter
Fuse 50 A
1
MPRXCX
3x25
Mains supply
Starter
Fuse 63 A
1
MPRXCX
3x35
Mains supply
Starter
Fuse 80 A
2
MPRXCX
2x1.5
Starter
EPC 50
3
MPRXCX
3x1.5
Starter
Separator motor
2.5 – 6.3 A
3
MPRXCX
3x2.5
Starter
Separator motor
6.3 – 16 A
3
MPRXCX
3x4
Starter
Separator motor
16 – 20 A
3
MPRXCX
3x6
Starter
Separator motor
20 – 25 A
3
MPRXCX
3x10
Starter
Separator motor
25 – 32 A
3
MPRXCX
3x16
Starter
Separator motor
32 – 45 A
3
MPRXCX
3x25
Starter
Separator motor
45 – 63 A
71
MPRXCX
2x1.5
Starter
Separator motor
4
MPRXCX
3x1.5
Starter
Feed pump
0.4 – 6.3 A
4
MPRXCX
3x2.5
Starter
Feed pump
6.3 – 16 A
72
MPRXCX
2x1.5
Starter
Feed pump
Ref. 568031 Rev. 1
18
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
No.
Type
Connection point
A
Instruction
2 DRAWINGS
Connection point
B
Remarks
Signal cables
11
RFE–HF
1x2x0.75
EPC 50
SV1
12
RFE–HF
1x2x0.75
EPC 50
SV4
13
RFE–HF
1x2x0.75
EPC 50
SV5
14
RFE–HF
1x2x0.75
EPC 50
SV10
15
RFE–HF
1x2x0.75
EPC 50
SV15
16
RFE–HF
1x2x0.75
EPC 50
SV16
17
RFE–HF
1x2x0.75
EPC 50
SSC
PT1
18
RFE–HF
1x2x0.75
EPC 50
SSC
PT4
19
PUR-cable
4x0.34
EPC 50
SSC + EMC
MT
20
RFE–HF
4x2x0.50
EPC 50
SSC + EMC
ST, (YT, SS)
21
RFE–HF
1x2x0.75
EPC 50
SSC
PT5
22
RFE–HF
1x2x0.75
EPC 50
23
RFE–HF
4x2x0.75
EPC 50
50
RFE–HF
4x2x0.75
EPC 50
Starter
51
RFE–HF
4x2x0.75
EPC 50
Starter
52
RFE–HF
1x4x0.75
EPC 50
Starter
2)
SUM Alarm
SSC
TT1/TT2
Options (as ordered)
31
RFE–HF
1x4x0.75
EPC 50
32
RFE–HF
1x4x0.75
EPC 50
Rem. Temp. al.
33
MPRXCX
5x1.5
EPC 50
Rem. Start/Stop
34
RFE–HF
1x4x0.75
EPC 50
35
RFE–HF
1x4x0.75
Starter
GS, Valve switch
36
RFE–HF
1x2x0.75
EPC 50
LS, Sludge Level
37
RFE–HF
1x2x0.75
EPC 50
SV6, Sol. Valve
For pneumatic
sludge pump
38
MPRXCX
4x1.5
EPC 50
Syst. Emergency
1)
40
RFE–HF
4x2x0.75
EPC 50
Power unit
45
RFE–HF
1x2x0.75
Starter
Power unit
41
RFE–HF
1x4x0.75
EPC 50
Steam reg. valve
44
RFE–HF
1x2x0.75
EPC 50
Shut-off valve
1)
2)
SSC + EMC
SSC + EMC
Rem. OP unit
Comm. module
This cable cannot be longer than 25 m to avoid voltage drop.
Cable with moulded connector included in Alfa Laval delivery.
Ref. 568031 Rev. 1
1810947-02
19
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
Other equivalent and approved cables may be
used.
Cable areas are calculated with correction
factor 0.7.
Cables used are Shipboard Cables, designed
according to IEC 92-3.
Flame retardant according to IEC 332-3/A.
Halogen-free according to IEC 754-1
Code designations for cables obtainable
through cable producers Helkama, Finland,
and Acatel, France.
Where SSC is indicated it should be a Signal
Shielded Cable with the shield properly
connected to earth as shown in the electrical
drawings.
For other connections, an armoured cable may
be used provided the armour is connected to
earth, as shown in the electrical drawings, and
gives sufficient EMI protection. Copper wire
armouring is normally used.
20
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 DRAWINGS
2.4.2 Interconnection Diagram, Starter
Mains suppy
3x230,400, 440, 480, 575 or 690 V AC
Select correct voltage on transformer T8
Separator motor
Space heater 230 VAC
Separator motor
optional
Contactor response, separator
Potential free contacts, max. 250 V 0.5 A
STARTER
Feed pump motor
optional
Space heater 230 VAC
Separator motor
optional
Contactor response, separator
Potential free contacts, max. 250 V 0.5 A
ESD-relay option,
sheet 2
Systems emergency stop
(Control voltage off)
X0 1 9 2 0 2 A
Power supply to EPC 50 (Sheet 5)
230 V AC, 50/60 Hz
Ref. 568030 Sheet 1, Rev. 4
1810947-02
21
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2.4.3 Interconnection Diagram, Starter, cont.
* = Replaces jumper in terminals
** = Internal connections
To EPC 50 (sheet 5)
To EPC 50 (sheet 5)
Separator emergency stop
(optional, external)
STARTER
Sludge valve interlock switch
optional
Feed pump
Remote stop
Remote start
Feed pump interlock
Heater interlock
Potential free contact, max. 250 V 0.5 A
(Feed pump running = contact closed)
Tripped motor circuit breakers (optional)
Potential free NC contacts, max. 250 V 0.5 A
Emergency Shut Down (ESD) signal (optional)
Emergency Shut Down (ESD) feedback
X0 1 9 2 0 2 G
To EPC 50 (sheet 3)
Ref. 568030 Sheet 2, Rev. 4
22
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 DRAWINGS
2.4.4 Interconnection Diagram, Transmitters
Internal
connections
MT
Water transducer
* Termination
jumper. Only at
sattbus end units.
Remote OP unit
* Termination
jumper. Only at
sattbus end units.
Heater board
Optional
Temp. sensor,
2xPT 100
TT 1 (Alarm)
TT 2 (Control)
CONTROL UNIT EPC 50
PT1
PT4
PT5
Speed sensor
(Cable included in
separator delivery)
Blue
Brown
Brown
Blue
Sheet 5
Vibration transmitter
(Optional
Internal connections
Separator interlock
switch
optional
From starter (sheet 2)
LS
Level Switch
Sludge Tank
(Optional)
Note!
X0 1 9 2 0 2 J
Alt. wiring when using junction box
on separator
Speed transmitter
Ref. 568030 Sheet 3, Rev. 4
1810947-02
23
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2.4.5 Interconnection Diagram, Solenoid Valves
Preset
internal
connection
to S1
Signal to alarm panel.
Pot. free contact, opens at alarm
Max. 50 V AC/DC, 1.0 A
SV6
Solenoid Valve for
control of
Pneumatic Sludge
Pump
(Optional)
SV1
Oil feed
CONTROL UNIT EPC 50
SV4
Oil outlet
SV5
Water outlet
SV10
Water seal
SV15
Opening water
SV16
Closing water
X0 1 9 2 0 2 I
Internal connections
Ref. 568030 Sheet 4, Rev. 4
24
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 DRAWINGS
2.4.6 Interconnection Diagram, Solenoid Valves cont.
24 V phase
Systems emergency stop
(Control voltage off)
24 V neutral
Jumper at 230 V AC
Connections for alternative
voltages
Jumper at 110/115 V AC
Jumper at 100 V AC
CONTROL UNIT EPC 50
From starter (sheet 2)
From starter (sheet 2)
From starter (sheet 2)
X0 1 9 2 0 2 E
* Replaces jumper in terminals
Sheet 6
Ref. 568030 Sheet 5, Rev. 4
1810947-02
25
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2.4.7 Interconnection Diagram, Optional Equipment
HEATER BOARD
CONTROL UNIT EPC 50
VIBR. BOARD
For elecrtric heater see 1765867
For steam heater see 1765868
Remote alarm indication
High temp. indication
Low temp. indication
Pot. free contacts
Max. 50 V AC/DC, 1.0 A
Contact closes at alarm.
Remote operation
Note
Jumper X71:1 to X71:3 to
avoid false alarm when not
used.
I/O-EXPANSION BOARD
Remote mode selected
(output 24 V AC)
Sep. status indication
(output 24 V AC)
Separation Start/Stop
Start
Stop
COMM. BOARD
Data communication
X0 1 9 2 0 2 F
Bus GND
Line A
Line B
Shield
Ref. 568030 Sheet 6, Rev. 4
26
1810947-02
X018921A
To I/O
board
Protective earth
To I/O
board
Line neutral
Line phase
(Alarm)
1810947-02
Red
Red
Red
Red
Red
Red
Green
Blue
Black
White
Brown
Black
Brown
Yellow/green
Main switch
Line filter
Yellow
Green
Blue
Black
Brown
Red
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 DRAWINGS
2.4.8 Transformer Connection Diagram
Ref. 31830-6337-0 Rev. 2
27
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2.4.9 Circuit Diagram, Power Circuits
Mains supply
Separator
Space heater
(optional)
Feed pump
(optional)
Cont.
Ref. 568028 Sheet 1, Rev. 0
28
1810947-02
X0 1 9 2 0 4 A
Space heater
(optional)
1810947-02
X0 1 9 2 0 4 B
START FEED PUMP
FEED PUMP FEEDBACK
SEPARATOR FEEDBACK
AUTO MODE
MAN
OP
AUTO
START SEPARATOR
EMERGENCY STOP
(Optional)
SLUDGE
VALVE
INTERLOCK
SWITCH
(Optional)
(Remote indication)
CONTACTOR, FEED
PUMP
PILOT LAMP, FEED
PUMP
SLUDGE VALVE INDICATION
Optional
(Remote indication)
PILOT LAMP,
SEPARATOR
CONTACTOR,
SEPARATOR
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 DRAWINGS
2.4.10 Circuit Diagram, Separator Starter and Feed Pump
Ref. 568028 Sheet 2, Rev. 0
29
2 DRAWINGS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
Separator interlock
indication
Aux. relay
Ref. 568028 Sheet 3, Rev. 0
30
1810947-02
X0 1 9 2 0 4 C
Vibration
Board
Separator Interlock
Switch
(Optional)
Aux. relay
2.4.11 Circuit Diagram, Remote Start Interlock (optional)
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
2 DRAWINGS
X0 1 9 2 0 4 D
ESD relay kit
(optional)
Trip contact kit
(optional)
2.4.12 Circuit Diagram, ESD-relay and Trip Contacts (optional)
Ref. 568028 Sheet 4, Rev. 0
1810947-02
31
2 DRAWINGS
32
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
3 REMOTE OPERATION SYSTEMS
3 Remote Operation Systems
!
ING
WARN
Disintegration hazard
If the system is operated from a position from
which the separator is not visible, a Remote
Operation System must be installed, including
vibration sensor and frame cover interlock switch.
Connection to steering system via
PROFIBUS or MODBUS fieldbus systems.
PROFIBUS or MODBUS communication
protocol can be used to connect an EPC 50
Control Unit to a central steering system. The
EPC 50 Control Unit uses a PROFIBUS DP or
MODBUS RTU. Every node, or EPC 50 Control
Unit, on the bus has a unique address, and can
use 200 bytes for data exchange. An interface
board is needed to connect an EPC 50 Control
Unit to the respective fieldbus system. This is
mounted on the I/O card.
Remote fieldbus connection for EPC 50 Control
Unit is for use in those cases where the user
wants access to data and operation information
from the control cabinet, and supervision and/
or remote control from his own steering
system.
1810947-02
33
3 REMOTE OPERATION SYSTEMS
Alternative
PROFIBUS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
MODBUS
User interface
To be arranged by
customer.
To be arranged by
customer.
Cable
Cable for PROFIBUS
aquired and installed
by customer.
Cable for MODBUS
aquired and installed
by customer.
Manual
Hardware and software
instructions exist.
Hardware and software
instructions exist.
Board
Part no. 31830-6559-1
Part no. 31830-6558-1
34
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
1810947-02
3 REMOTE OPERATION SYSTEMS
35
4 SPECIFICATIONS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
4 Specifications
4.1 Cables
Cable Identification
All cables are to be marked to simplify
identification and fault finding.
Specifications
The following specifications apply to cables
connected to and from Alfa Laval equipment.
Follow the instructions given in the cable list.
Examples of cable types that can be used:
Steel armoured cable.
•
Copper armoured cable with a separate earth
core.
•
Steel armoured and shielded signal cable;
pair twisted or parallel.
•
Shielded signal cable; pair twisted or parallel.
G032234A
G032214A
G032244A
G032224A
•
36
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
4 SPECIFICATIONS
4.2 Cable Routing
Recommendations
S0 0 2 8 9 1 A
Power cables carry the power supply to motors,
heaters, etc.
Any distance between signal and power cables
reduces electrical noise transfer.
Examples of recommended routing of various
cable types.
Power cables and signal cables routed on a
cable rack should be separated.
•
Sattbus cables should be routed away from
power cables.
Power
Cables
Signal
Cable
G032273A
•
If the space is limited, cables can be routed in
tubes.
4.3 Oil, Water, Steam, and Condensate Piping
For piping to and from Alfa Laval equipment,
see the specifications below.
Specifications
•
The correct pipe size must be used in the oil
system.
•
The number of bends in the oil pipes must
be minimized.
•
The suction height must be as low as
possible.
•
The oil feed pump must be of positive
displacement type.
•
The pump must be positioned close to the
oil tank.
•
The heater must be installed close to the
separation system to maintain correct feed
oil temperature.
•
The recirculation line should be connected
either directly to the settling tank (HFO) or to
the oil outlet line from the separator (LO).
•
The oil outlet line from the separator must be
connected to the system tank for lube oil, or
the service tank for fuel oil.
1810947-02
37
4 SPECIFICATIONS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
4.4 Ambient Temperature Limitation
Specification
Leading classification societies state in their
regulations for engine room equipment that the
maximum ambient temperature permissible is
+55 ° C. To meet this regulation, it is essential
that electrical and electronic components have
good ventilation, and temperature control.
38
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
4 SPECIFICATIONS
4.5 Sludge Removal Kit (Optional Equipment)
If you have a Sludge Removal Kit, this must be
connected to a ventilation pipe.
NOTE
The sludge removal pump must be set to the correct
speed – circa 60 strokes/min, otherwise the lifetime
of the diaphragm, valve balls, and air motor will be
severely shortened.
!
ING
WARN
Health Risk
Oil mist and vaporized oil constituents from hot oily
sludge may be dangerous to health and must not be
inhaled.
A pipe or hose must be drawn from the flange to
the nearest oil tank ventilation pipe.
The pipe /hose must have the same diameter as
the flange opening.
The pipe/hose must be as straight as possible,
with a steady upward incline.
The connection to the oil tank ventilation pipe
must point upwards as shown.
NOTE
Oil tank ventilation
pipe
1810947-02
SA system
~ 5 mm
P000063A
For HFO separation, it is not recommended to make
the connection to the separator room ventilation
system.
For LO separation, connection to the separator room
ventilation system should be made only if the
separator room ventilation is adequate. Use the
optional connection hose (part no. 568023-80, -81, or
-82) for this purpose. This hose is designed to entrap
oil drops in the vent hose, and lead the oil back to the
Sludge Removal Kit tank.
39
4 SPECIFICATIONS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
NOTE
Impurities gather in the Sludge Removal Kit tank.
Regularly check the tank and level switch. See
instructions below.
Proceed as follows:
•
From the Control Panel, run the sludge pump
manually for a few seconds.
•
Undo the four screws at the top of the sludge
tank and remove the sludge pump.
•
If necessary, clean the level switch and the
inside of the tank using diesel oil.
•
Check the seals and gaskets, and change if
necessary.
•
Loosen the hose clip and check the inside of
the ventilation hose. Clean if necessary.
To avoid breakdown of the Sludge Removal
system, the sludge pump must be regularly
overhauled as follows using spare parts kit
1766702-81.
•
Replace the diaphragms and the O-rings with
those delivered in the spare parts kit.
•
Perform a 4000 hour Inspection Service.
For Service and Overhaul intervals, see ‘‘1.3
System Data” on page 2.
40
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
4 SPECIFICATIONS
4.6 Sludge Tank
Sludge tank volume per separation system
should cover approximately up to 2 days
storage at a discharge interval of 2 hours (for
discharge volumes see technical data).
A manhole should be installed for inspection
and cleaning.
•
The tank should be fitted with a sounding
pipe.
•
The tank floor, or most of it, should have a
slope (B) of minimum 15°.
•
The sludge outlet pump connection should be
positioned in the lowest part of the tank.
•
A high level alarm switch, connected to the
sludge pump, should be installed.
•
A heating coil should be used to keep the
sludge warm and fluid while being pumped
out.
•
Sludge pipe
connection
Min. slope 15°
Bowl casing drain
connection
Tank ventilation must follow the classification
rules for evacuation of gases.
•
There should be a ventilation pipe to fresh air.
•
The ventilation pipe should be straight. If this
is not possible, any bends must be gradual.
•
The ventilation pipe must not extend below the
tank top.
•
A sludge tank with partition walls must have
ventilation pipes in all compartments, or
cutouts in the upper edge, to allow vapours to
travel through the tank.
Min. height
400 mm
Sludge outlet
pump connection
1810947-02
Manhole
Water drain
connection
G004273A
•
Ventilation pipe
High level
alarm
switch
Heating
coil
G004270A
•
41
4 SPECIFICATIONS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
The number of ventilation pipes, and their
minimum dimension, depend on the size and
number of separators connected to the same
tank. See table below.
Type
1 system
2 systems
SA 811, SA 816
1 x ∅50mm
1 x ∅50mm
SA 821, SA 826
1 x ∅75mm
1 x ∅75mm
1 x ∅100mm
1 x ∅100mm
1 x ∅100mm
1 x ∅125mm
SA 831, SA 836
SA 841, SA 846
SA 851, SA 856
SA 861, SA 866
SA 871, SA 876
SA 881, SA 886
The separation system generates almost no air
during operation. At any discharge, the
maximum volume of air produced is the same as
the bowl volume (see technical data).
42
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
4 SPECIFICATIONS
4.7 Sludge Piping
Specification
•
The sludge pipe from the separator to the
sludge tank should be vertical.
If a vertical pipe is not possible, the deviation (A)
from the vertical line must not exceed 30°.
G004401A
A
The sludge pipe must not extend below the
tank top.
NOTE
An extended sludge pipe will obstruct ventilation and
create back pressure that could cause separator
problems.
G004316A
•
1810947-02
43
4 SPECIFICATIONS
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
If more than one separator is connected to the
same sludge tank, a butterfly valve should be
installed in each sludge pipe.
NOTE
If a butterfly valve is not used, the bowl and the
operating system may be affected.
If a butterfly valve is used, it should be
equipped with an interlocking switch
(connected to the separator starter) to prevent
the separator from being started when the
valve is not fully open.
G004411A
•
44
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
1810947-02
4 SPECIFICATIONS
45
5 COMMISSIONING AND INITIAL START
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
5 Commissioning and Initial Start
5.1 Completion Check List
It is essential before starting up the separation
system that all units are in good operating
condition and that all pipelines and control
equipment are properly connected to assure
correct operation.
Use this check list as a guide for completing the
system installation:
!
ING
WARN
Breakdown hazard
Check that the power frequency is in agreement with
the machine plate. If incorrect, resulting overspeed
may cause breakdown.
1
Check that transport seals are removed from
all pipes.
2
Use flushing filters to prevent pipe work debris
from being pumped into the separation
system.
NOTE
The flushing filters must be removed after initial
flushing.
3
Check that all separators are in proper
working condition. Follow the manufacturer’s
instructions.
4
Make sure that separators are lubricated in
accordance with instructions.
NOTE
Make sure that the spindle bearings are prelubricated
5
46
Separators are delivered without oil in the oil
sump. For information on oil filling and oil type,
see the Service Manual booklet.
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
5 COMMISSIONING AND INITIAL START
NOTE
Too much, or too little oil may result in damage to
separator bearings.
Neglecting an oil change may result in damage to
separator bearings.
Power on.
7
With the mode selector switch in the CIP
postion, check that the separator rotation
direction corresponds with the arrow on the
frame by doing a quick start/stop (1–2
seconds.) and looking at the motor fan
rotation.
!
M AN
CIP
CIP
G046606A
6
N
CAUTIO
If power cables have been installed incorrectly, the
separator will rotate in reverse, and vital rotating
parts can unscrew.
8
Check the pump function and direction.
9
If a Sludge Removal Kit is used, check that the
sludge pump speed is set to circa
60 strokes/min.If necessary, adjust the
throttling valve (positioned after solenoid valve
SV 6).
1810947-02
47
5 COMMISSIONING AND INITIAL START
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
5.2 Initial Start-up
Use this check list for initial system start up:
1
Check that there is oil in the feed oil tank.
2
Check water and air supply. See ‘‘System
Data” on page 2.
3
Check power supplies to the control unit and
that the voltage is in accordance with data in
‘‘System Data” on page 2.
4
Check all parameter settings in the control
unit. See Installation Parameters in the
Parameter List booklet.
5
Check the separator.
NOTE
6
Always lubricate the bearings before start-up.
NOTE
The Control Unit is supplied with standard
configuration parameters. You may have to make
some changes to suit your installation.
7
Start the separation system as described in
the Operating Instructions booklet.
8
Start up step by step, checking that the
machine and units function properly.
9
Establish system pressures.
The delivery height pressure is the pressure in
the oil pipe work down stream from the
separation system, due to the pipe bends and
the height (head) to the cleaned oil tank. If the
cleaned oil tank is below the separation
system the delivery height pressure may be
very low. The oil paring disc pressure will have
to be greater than the delivery height pressure
for any oil to flow.
Proceed as follows:
•
Ensure the valves in the oil system are in the
correct positions.
• The oil should be at separation temperature.
Cont.
48
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
5 COMMISSIONING AND INITIAL START
The adjustment screw for the water paring
tube should be in the outer position. The
paring tube should be able to move freely.
Ensure that V5 is closed.
Fully open the back pressure regulating valve
RV4.
The shut off valve V4 should be open.
Open SV15 for 3 seconds to prime the
operating slide.
Open SV16 for 15 seconds to close the bowl.
Open SV10 for 1 minute to put water into the
bowl.
Feed oil to the separator at the normal flow
rate by opening SV1.
Note the pressure in the oil outlet PT4, both on
the pressure gauge and in the EPC50 display.
This pressure is P min.
Gradually close the back pressure regulating
valve RV4. The pressure on PT4 will increase.
The water pressure (PT5) decreases slightly
as the paring tube moves inwards. The water
pressure will suddenly drop when oil passes
from the oil paring chamber to the water
paring chamber. Note the pressure of PT4
both on the pressure gauge and in the EPC50
display. This pressure is P max.
Open RV4.
Stop the oil feed to the separator and note the
pressure in the oil outlet. This is the delivery
height pressure P del.
Stop the heater.
Stop the separator.
Stop the feed pump when the heater has
cooled.
1810947-02
49
5 COMMISSIONING AND INITIAL START
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
5.2.1 Calculating Operating Pressure
•
Calculate the normal back pressure level
during operation as follows:
Pmin + Pmax
2
•
= Pnormal
Calculate the value for low pressure alarm
setting (Pr 11) as follows:
Pmin + Pnormal
2
•
= Plow press.
Calculate the value for high pressure alarm
setting (Pr 10) as follows:
Pnormal + Pmax
2
= Phigh press.
Adjust the back pressure to Pnormal
Set Pr 11 to give alarm at pressure decreasing
below the Plow press. value.
Set Pr 10 to give alarm at pressure increasing
above the Phigh press. value.
50
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
6 SHUT-DOWN AND STORAGE
6 Shut-down and Storage
Storage before Installation
If the separation system is stored before
installation, the following safeguards must be
taken:
Storage period
1 – 6 months
> 6 months
See
Action
Protect from dust, dirt,
water, etc.
x
x
This chapter
Protect with anti-rust
oil
x
x
This chapter
Inspection
x
x
On commissioning
x
On commissioning
Overhaul
6.1 Shut-down after Use
If the separation system is going to be shut down
for a period of time, the following safeguards
must be taken:
Shut-down
period
1 – 6 months
(stand-by)
6 – 18
months
> 18
months
See
Action
Remove bowl
x
x
x
Dismantling and
Assembly in the
Service Manual
Protect from dust, dirt,
water, etc.
x
x
x
This chapter
Protect with anti-rust
oil
x
x
x
This chapter
Inspection
x
x
x
On new start-up
x
On new start-up
Overhaul
1810947-02
51
6 SHUT-DOWN AND STORAGE
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
6.2 Protection and Storage
All system equipment, both the separator and
the ancillary equipment, must be stored indoors
at 5 – 55°C, if not delivered in water-resistant
box for outdoor storage.
If there is a risk for condensation of water, the
equipment must be protected by ventilation and
heating above dew point.
The following protection products are
recommended:
•
Anti-rust oil (Dinitrol 112 or equivalent) with
long lasting effective treatment for external
surfaces. The oil should prevent corrosion
attacks and give a waxy surface.
•
Anti-rust oil (Dinitrol 40 or equivalent) thin and
lubricating for inside protection. It gives a
lubricating transparent oil film.
•
Solvent, e.g. white spirit, to remove the antirust oil after the shut-down.
•
Moist remover to be packed together with
separator equipment.
•
If the storage time exceeds 12 months, the
equipment must be inspected every 6 months
and, if necessary, the protection be renewed.
Rubber Parts
•
Gaskets, O-rings and other rubber parts
should not be stored for more than two years.
After this time, they should be replaced.
Separator
Dismantle the separator bowl and take out the
O-rings. Clean the bowl with oil and reassemble
without the O-rings. Place in a plastic bag with
silica dessicant bags and seal the plastic bag.
Grease the spindle.
52
1810947-02
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
6 SHUT-DOWN AND STORAGE
Valves, Pipes and Similar Equipment
•
Components such as valves need to be
cleaned with solvent and treated with anti-rust
oil (type 112).
•
Water pipes should be drained and treated
with anti-rust oil (type 112).
•
Articles made of rubber or plastics (e.g. seals)
must not be treated with anti-rust oil.
6.3 Reassembly and
Start up
•
Clean away the anti-rust oil with white spirit.
•
Remove all silica gel bags.
•
Pre-lubricate the separator spindle bearings
•
If stored for 6 months or longer, perform an
inspection service (including change of oil in
the separator sump).
•
Follow all relevant instructions in the Service
Manual and Operating Instructions.
NOTE
Always lubricate the separator bearings before startup.
1810947-02
53
6 SHUT-DOWN AND STORAGE
54
SA 811/816/821/826 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE
1810947-02
Separator Manual
High Speed Separator
S 821 & S 826
Product No. 881201-05-01/2 & 881201-06-01/3
Book No.
578701-02 Rev. 1
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:+46 8 530 310 40
© Alfa Laval Tumba AB 14 August 2006
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of
Alfa Laval Tumba AB.
2
Contents
1
Read This First .............................................................. .5
2
Safety Instructions ..................................................... .7
2.1
2.2
2.3
3
Basic Principles Of Separation ....................... .15
3.1
3.3
4
Overview .................................................................... 18
The Process Section .............................................. 20
Sensors ....................................................................... 24
The liquid balance in the bowl ...................................... 25
Discharge of sludge and water ..................................... 26
ALCAPTM concept......................................................... 26
Operating Instructions.......................................... .29
5.1
5.2
5.4
5.5.1
5.7
6
Separation By Gravity............................................ 15
Temperatures ........................................................... 16
Design ............................................................................... .17
4.1
4.3
4.4
4.5.1
4.5.3
4.5.4
5
Warning signs in text ............................................. 12
Environmental issues ............................................ 13
Requirements of personnel.................................. 14
Before First Start-up .............................................. 29
Start After Service .................................................. 30
Start ............................................................................. 31
Sludge discharge during operation .............................. 35
Emergency Stop ...................................................... 39
Service, Dismantling, Assembly..................... .41
6.1
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.3.1
6.3.2
6.3.5
6.4.1
6.4.2
6.4.3
6.4.7
6.4.8
6.5.1
6.5.6
6.6.1
6.7.2
Periodic Maintenance ............................................ 41
Maintenance intervals ................................................... 41
Maintenance procedures .............................................. 41
Tightening of screws ..................................................... 42
Service kits .................................................................... 42
Cleaning ........................................................................ 42
Introduction.................................................................... 46
Tools .............................................................................. 46
Driving device ............................................................... 61
Cleaning ...................................................................... 80
Inspection for corrosion ............................................... 82
Inspection for cracks ................................................... 83
How to lubricate bowl parts with slide laquer ............... 87
Check for galling on operating slide and bowl body ... 88
Centrifugal clutch .......................................................... 89
Speed sensor .............................................................. 128
Control of machine plates and safety labels .............. 129
Check oil level ............................................................. 132
578701-02
6.7.3
6.7.6
6.8
6.8.1
7
Fault Finding ...............................................................141
7.1
7.1.1
7.1.2
7.1.3
7.1.4
7.1.5
7.1.6
7.1.7
7.1.8
7.2.1
7.2.2
7.2.3
8
Mechanical Functions ......................................... 141
Separator vibration ...................................................... 141
Smell ............................................................................ 142
Noise ........................................................................... 142
Speed too low.............................................................. 142
Speed too high ............................................................ 142
Starting power too high ............................................... 143
Starting power too low................................................. 143
Starting time too long .................................................. 143
Bowl opens accidentally during operation .................. 144
Bowl fails to open for sludge discharge ...................... 144
Unsatisfactory separation result .................................. 144
Technical Reference .............................................147
8.1
8.2
8.4.1
8.4.2
8.4.3
8.4.4
8.4.5
8.4.6
8.4.7
8.6.1
9
Oil change procedure ................................................. 132
Lubricating oils ............................................................ 138
Lifting instructions ............................................... 139
Lifting the separator .................................................... 139
Product description .............................................. 147
Technical Data ....................................................... 148
Scope .......................................................................... 151
References .................................................................. 151
Definitions .................................................................... 152
Goal ............................................................................. 152
Description of separator modes .................................. 153
Remote start ................................................................ 154
Handling of connection interfaces .............................. 154
Basic size drawing ...................................................... 162
Installation ...................................................................167
9.1 Introduction ............................................................ 167
9.2.1 Transport...................................................................... 168
9.2.2 Protection and storage of gods
..................................................................................... 169
9.3.1 Important measurements ............................................ 170
9.4 Storage at out of operation ............................... 173
9.5 Before start-up ....................................................... 173
578701-02
1 Read This First
This manual is designed for operators,
maintenance personnel and service
engineers working with the Alfa Laval S
821 & S 826 separator.
If the separator has been delivered and
installed by Alfa Laval as a part of a
processing system, this manual should be
viewed as part of the System
Documentation. Study carefully all
instructions in any System Documentation.
In addition to this Separator Manual a
Spare Parts Catalogue, SPC is supplied.
The Separator Manual consists of:
Safety Instructions
Pay special attention to the safety instructions
for the separator. Accidents causing damage to
equipment and/or serious injury to persons or
personnel can result if the safety instructions
are not followed.
Basic Principles of Separation
This chapter describes the purpose of
separation and separation principles.
Design and function
This chapter contains a description of the
separator.
Operating Instructions
This chapter contains operating instructions
for the separator only.
5
1 READ THIS FIRST
Service, Dismantling, Assembly
This chapter gives instructions for the
maintenance procedures. It also contains stepby-step instructions for dismantling and
assembly of the separator for service and
repair.
Fault Finding
Refer to this chapter if the separator functions
abnormally.
If the separator has been installed as a part of a
processing system, always refer to the troubletracing instructions, in the System
Documentation.
Technical Reference
This chapter contains technical data
concerning the separator and drawings.
Installation
This chapter contains specifications and
recommendations concerning separator
installation.
NOTE
A complete reading of this manual by personnel in
contact with the machine is essential to safety.
Do not allow personnel to clean, assemble, operate
or maintain the separator until they have read and
fully understood this manual.
Ensure that all personnel who operate and service
the separator are well-trained and knowledgeable
concerning the machine and the work to be carried
out.
6
2 Safety Instructions
•
Kinetic energy is high
•
Great forces are generated
•
Stopping time is long
G0010421
The centrifuge includes parts that rotate at high
speed. This means that:
Manufacturing tolerances are extremely fine.
Rotating parts are carefully balanced to reduce
undesired vibrations that can cause a breakdown.
Material properties have been considered
carefully during design to withstand stress and
fatigue.
The separator is designed and supplied for a
specific separation duty (type of liquid, rotational
speed, temperature, density etc.) and must not be
used for any other purpose.
Incorrect operation and maintenance can result in
unbalance due to build-up of sediment, reduction
of material strength, etc., that subsequently could
lead to serious damage and/or injury.
•
Use the separator only for the purpose
and parameter range specified by
Alfa Laval.
•
Strictly follow the instructions for
installation, operation and maintenance.
•
Ensure that personnel are competent and
have sufficient knowledge of maintenance
and operation, especially concerning
emergency stopping procedures.
•
Use only Alfa Laval genuine spare parts
and the special tools supplied.
S0151211
The following basic safety instructions therefore
apply:
7
2 Safety Instructions
When power cables are connected,
always check direction of motor rotation.
If incorrect, vital rotating parts could
unscrew.
•
If excessive vibration occurs, stop
separator and keep bowl filled with
liquid during rundown.
•
Use the separator only for the purpose
and parameter range specified by
Alfa Laval.
•
Check that the gear ratio is correct for
power frequency used. If incorrect,
subsequent overspeed may result in a
serious break down.
•
Welding or heating of parts that rotate
can seriously affect material strength.
•
Wear on the large lock ring thread must
not exceed safety limit. φ-mark on lock
ring must not pass opposite φ-mark by
more than specified distance.
•
Inspect regularly for corrosion and
erosion damage. Inspect frequently if
process liquid is corrosive or erosive.
S01512H1
S01512G1
S0151241
S01512L1
S01512P1
S01512N1
•
S01512F1
Disintegration hazards
8
2 Safety Instructions
Entrapment hazards
Make sure that rotating parts have come
to a complete standstill before starting
any dismantling work.
•
To avoid accidental start, switch off and
lock power supply before starting any
dismantling work.
Assemble the machine completely
before start. All covers and guards must
be in place.
S0151261
S01512O1
•
•
Follow local regulations for electrical
installation and earthing (grounding).
•
To avoid accidental start, switch off and
lock power supply before starting any
dismantling work.
S0151271
Electrical hazard
Crush hazards
S01512M1
Use correct lifting tools and follow lifting
instructions.
Do not work under a hanging load.
S01512Y1
•
9
2 Safety Instructions
Noise hazards
Use ear protection in noisy
environments.
S0151291
•
Burn hazards
Lubrication oil and various machine
surfaces can be hot and cause burns.
S01512A1
•
•
When using chemical cleaning agents,
make sure you follow the general rules
and suppliers recommendation
regarding ventilation, personnel
protection etc.
•
Use of lubricants in various situations.
10
S01512D1
Skin irritation hazards
2 Safety Instructions
Cut hazards
Sharp edges on bowl discs and threads
can cause cuts.
S01512B1
•
Flying objects
Risk for accidental release of snap rings
and springs when dismantling and
assembly.
S01512C1
•
Health hazard
Risk for unhealthy dust when handling
friction blocks/pads. Use a dust mask to
make sure not to inhale any dust.
S01512V1
•
11
2 Safety Instructions
2.1
Warning signs in text
Pay attention to the safety instructions in this
manual. Below are definitions of the three grades
of warning signs used in the text where there is a
risk for injury to personnel.
!
R
DANGE
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in death or serious injury.
!
ING
WARN
WARNING indicates a potentially
hazardous situation which, if not avoided,
could result in death or serious injury.
!
ON
CAUTI
CAUTION indicates a potentially
hazardous situation which, if not avoided,
may result in minor or moderate injury.
NOTE
NOTE indicates a potentially hazardous
situation which, if not avoided, may result
in property damage.
12
2 Safety Instructions
2.2
Environmental issues
Unpacking
Packing material consists of wood, plastics,
cardboard boxes and in some cases metal straps.
Wood and cardboard boxes can be reused,
recycled or used for energy recovery.
Plastics should be recycled or burnt at a licensed
waste incineration plant.
Metal straps should be sent for material recycling.
Maintenance
During maintenance oil and wear parts in the
machine are replaced.
Oil must be taken care of in agreement with local
regulations.
Rubber and plastics should be burnt at a licensed
waste incineration plant. If not available they
should be disposed to a suitable licensed land fill
site.
Bearings and other metal parts should be sent to
a licensed handler for material recycling.
Seal rings and friction linings should be disposed
to a licensed land fill site. Check your local
regulations.
Worn out or defected electronic parts should be
sent to a licensed handler for material recycling.
13
2 Safety Instructions
2.3
Requirements of
personnel
Only skilled or instructed persons are allowed to
operate the machine, e.g. operating and
maintenance staff.
•
Skilled person: A person with technical
knowledge or sufficient experience to enable
him or her to perceive risks and to avoid
hazards which electricity/mechanics can
create.
•
Instructed person: A person adequately
advised or supervised by a skilled person to
enable him or her to perceive risks and to
avoid hazards which electricity/mechanics
can create.
In some cases special skilled personnel may
need to be hired, like electricians and others. In
some of these cases the personnel has to be
certified according to local regulations with
experience of similar types of work.
14
3 Basic Principles Of Separation
The purpose of separation can be to
•
free a liquid of solid particles,
•
separate two mutually insoluble liquids
with different densities while removing
any solids present at the same time,
•
separate and concentrate solid particles
from a liquid.
3.1 Separation By Gravity
A liquid mixture in a stationary bowl will clear
slowly as the heavy particles in the liquid
mixture sink to the bottom under the influence
of gravity.
G 08 7 01 11
A lighter liquid rises while a heavier liquid and
solids sink.
Continuous separation and sedimentation can
be achieved in a settling tank having outlets
arranged according to the difference in density
of the liquids.
Heavier particles in the liquid mixture will
settle and form a sediment layer on the tank
bottom.
Gravity
Heavier
liquid
Sediment layer of
heavier particles
G 0 8 70 21 1
Lighter
liquid
15
3.2 CENTRIFUGAL SEPARATION
3 BASIC PRINCIPLES OF SEPARATION
3.2 Centrifugal Separation
In a rapidly rotating bowl, the force of gravity
is replaced by centrifugal force, which is many
times greater.
Lighter liquid
Heavier liquid
Separation and sedimentation is continuous
and takes place very quickly.
The separation efficiency is influenced by
changes in the oil viscosity, separating
temperatures and in throughput.
Centrifugal force
G 0 87 03 1 1
The centrifugal force in the separator bowl can
achieve in a few seconds that which takes many
hours in a tank under influence of gravity.
3.3 Temperatures
For some types of process liquids (e.g.
mineral oils) a high separating temperature
will normally increase the separation
capacity. The temperature influences oil
viscosity and density and should be kept
constant throughout the separation.
Viscosity
Density difference
Viscosity is a fluids resistance against movement.
Low viscosity facilitates separation. Viscosity can be
reduced by heating.
Density is mass per volume unit. The greater the density
difference between the two liquids, the easier the
separation. The density difference can be increased by
heating.
16
Low viscosity
High density difference.
G 0 88 6 01 1
High viscosity
G 08 85 91 1
Low density difference
4 Design
Process section
The feed inlet and outlets
are situated at the top of
the separator.
Electric motor
The rotating bowl is driven
by the electric motor via a
belt transmission.
The liquid is cleaned in the
rotating separator bowl
inside the frame hood.
Sensors
Drive section
The separator is monitored
by a speed sensor. An
unbalance sensor and a
interlocking switch is
optional.
The rotating separator
bowl is driven by a flat
belt transmission with
friction coupling.
Sludge outlet
Frame feet
Separated solids are discharged at
preset intervals.
Lubrication system
Lubricates the bearings driven
by the flat belt transmission
G 0 8 70 64 1
The separator rests
on vibration damping
frame feet.
17
4.1 OVERVIEW
4.1 Overview
The separator comprises a process section and
a drive section powered by an electric motor.
The separator frame comprises a lower body
and a frame hood. The motor is attached to the
frame. The frame feet dampen vibration.
The bottom part of the separator contains a flat
belt transmission, a centrifugal clutch and a
vertical spindle. The lower body also contains
an oil sump for lubrication of spindle bearings.
The frame hood contains the processing parts
of the separator; the inlets, outlets and piping.
The process liquid is cleaned in the separator
bowl. The bowl is fitted on the upper part of a
vertical spindle and rotates at high speed
inside the frame hood. The bowl also contains
the discharge mechanism which empties the
sludge during operation.
A speed sensor, and the optional unbalance
sensor and lock switch, are parts of the
equipment for monitoring the separator
functions.
18
4 DESIGN
4 DESIGN
4.2 THE DRIVE SECTION
4.2 The Drive Section
The separator bowl is driven by an electric
motor via a belt transmission. The belt
pulley on the motor shaft includes a
centrifugal clutch.
Flat belt
The flat belt transmission has a
ratio which increases the bowl
speed several times compared
with the motor speed.
To reduce bearing wear and the
transmission of bowl vibrations to
the frame and foundation, the top
bearing of the bowl spindle is
mounted in a spring dampened
bearing seat.
The centrifugal clutch with friction
pads ensures a gentle start and
smooth acceleration, and at the
same time prevents overloading of
the belt and motor.
G 08 70 74 1
The bearings on the spindle are
lubricated by the oil spray produced
by an oil pump mounted on the
lower end of the spindle.
19
4.3 THE PROCESS SECTION
4.3 The Process Section
The separation process takes place inside
the rotating separator bowl. The feed and
outlet of process liquid takes place in the in
and outlet unit on top of the separator
frame hood.
Inlet and outlet
The inlet and outlet unit consists of the
following parts:
A connection house for pipe connections.
A pipe with a paring disc and a paring tube is
located inside the connection house. The pipe
has channels for incoming and outgoing process
liquid.
The paring disc and paring tube pump the
cleaned oil and water respectively out of the
bowl.
The paring tube can move radially. During
separation it surfs on the liquid surface. It is
balanced by a spring.
Under certain operating conditions, the paring
tube radial position can be locked in place by
two adjustable screws on the connection house.
The paring disc and tube are located inside and
at the top of the separator bowl.
The inlet and outlet device is held together
against the frame hood by a nut on the end of
the inlet pipe.
Height adjusting rings determine the height
position of the paring disc and paring tube
relative to the bowl.
20
4 DESIGN
4 DESIGN
4.3 THE PROCESS SECTION
Pipe
Spring
Cleaned oil
Water
Arm
Paring tube
Paring disc
Connection house
G 0 88 6 16 1
Uncleaned oil
21
4.3 THE PROCESS SECTION
Separator bowl
The separator bowl, with its sludge discharge
mechanism, is built-up as follows:
The bowl body and bowl hood are held together
by a lock ring (Centrilock). Inside the bowl are
the distributor and the disc stack. The disc
stack is kept compressed by the bowl hood. The
discharge slide forms a separate bottom in the
bowl body.
The upper space between the bowl hood and the
top disc forms the water paring chamber and
contains the paring tube, which pumps the
separated water out of the bowl. The oil paring
chamber, with its paring disc, is located inside
the top of the distributor. From here the
cleaned oil is pumped out of the bowl.
The sludge space is in the bowl periphery. The
bowl is kept closed by the discharge slide,
which seals against a seal ring in the bowl
hood.
At fixed intervals, decided by the operator, the
discharge slide drops down to empty the bowl of
sludge.
The sludge discharge mechanism, which
controls the movement of the discharge slide, is
comprised of an operating slide and an
operating water device. Passive parts are:
nozzle and valve plugs. The operating water
cover, beneath the bowl, supplies operating
water to the discharge mechanism via the
operating water ring.
22
4 DESIGN
4 DESIGN
4.3 THE PROCESS SECTION
Water paring chamber
Bowl hood
Top disc
Oil paring chamber
Bowl body
Disc stack
Lock ring
Seal ring
Discharge
slide
Operating slide
Sludge space
Holder
G 08 86 9 51
Nozzle
Operating water ring
23
4.4 SENSORS
4 DESIGN
4.4 Sensors
The separator is equipped with a speed
sensor. As options an unbalance sensor and
an interlocking kit can be fitted.
Speed sensor
Unbalance sensor (optional)
A speed sensor indicates the speed of the separator. The
For indication of any abnormal unbalance, the separator can
be equipped with a sensor monitoring the radial position of
correct speed is needed to achieve the best separating
results and for reasons of safety. Refer to type plate for speed the bowl spindle.
particulars.
Cover interlocking switch (optional)
When the cover is closed the interlocking circuit in the control
system is closed which makes it possible to start the
separator.
Cover interlocking switch
Unbalance sensor
G 08 73 47 1
Speed sensor
24
4 DESIGN
4.5 SEPARATING FUNCTION
4.5 Separating Function
The separator separates water and solids
from the uncleaned oil. Water normally
leaves the separator through the water
outlet. During sludge discharge, solids
(sludge) and water are removed through the
discharge ports.
4.5.1 The liquid balance in the bowl
The liquid levels in the bowl depend on many
factors (bowl geometry, liquid densities, flow
rates etc.). To get a picture of how the liquids
are distributed in the bowl, imagine that the
bowl is at standstill and turned 90° (only
influenced by gravity). The bowl can now be
compared with a settling tank:
SEPARATOR BOWL TURNED 90°
Unseparated oil
Separated oil
Water
G
R
A
V
Top disc
Distributor
Oil/water interface
I
T
Unseparated oil
Y
Separated oil
Water
G 0 88 6 43 1
SETTLING TANK
25
4 DESIGN
SEPARATOR MANUAL
4.5.2 Liquid flow
4.5.4 ALCAPTM concept
Unseparated oil is fed into the bowl through
the inlet pipe and travels via the distributor
towards the periphery of the bowl.
When the sludge space is filled up and water
enters the disc stack, traces of water will
escape with the cleaned oil. The increase of
water content in the cleaned oil is the sign of
reduced separation efficiency.
When the oil reaches slots in the distributor, it
rises through the channels formed by the disc
stack, where it is evenly distributed.
The oil is continuously cleaned as it travels
towards the centre of the bowl. When the
cleaned oil leaves the disc stack, it flows
through a number of holes in the distributor
and enters the oil paring chamber. From here it
is pumped by the oil paring disc, and leaves the
bowl through the oil outlet. Separated water,
sludge and solid particles, which are heavier
than the oil, are forced towards the periphery
of the bowl and collect in the sludge space.
This condition is monitored by the process
control system, and water is removed from the
bowl when minimal levels are recorded.
The space between the bowl hood and top disc,
as well as the water paring chamber, is filled
with oil, which is distributed over the entire
circumference via the grooves in the top disc.
During normal operation, the water drain
valve in the water outlet is closed.
4.5.3 Discharge of sludge and water
As the sludge space fills up and water enters
the disc stack, traces of water will escape with
the cleaned oil. The increase of water content
in the cleaned oil is the sign of reduced
separation efficiency.
This condition is monitored by the process
control system, and water is removed from the
bowl when minimal levels are recorded.
The water is removed by either of two ways:
•
The water drain valve opens and the water
leaves the bowl through the water outlet.
•
Through the sludge ports at sludge
discharge.
Which way is decided by the process control
system.
26
578701-02
4 DESIGN
4.5 SEPARATING FUNCTION
DISCHARGE OF WATER THROUGH WATER OUTLET
Unseparated oil
Bowl hood
Separated oil
Water
Oil paring disc
Water paring tube
Water paring chamber
Oil paring chamber
Holes in distributor
Top disc
Sludge
space
Oil/water interface
Uncleaned oil
Cleaned oil
G 0 8 86 23 1
Water
27
4.5 SEPARATING FUNCTION
28
4 DESIGN
5 Operating Instructions
These operating instructions describe
routine procedures to follow before and
during the start, running and stopping
sequences of the separator.
If system documentation is available,
always follow the operating instructions
therein. If there is no system
documentation, the instructions below are
to be followed.
5.1 Before First Start-up
•
Technical data
•
Connection list
•
Interface description
•
Basic size drawing
•
Foundation drawing.
G 0 86 87 41
Technical demands for connections and
limitations for the separator are listed in
chapter 8 Technical Reference, page 147:
Before first start:
•
Ensure the machine is installed and
assembled correctly and that feed lines and
drains have been flushed clean.
•
Fill oil in the oil bath. See 6.7 Oil Change,
page 131.Quality of oil see 6.7.6
Lubricating oils, page 138.
•
Make sure that the bearings on the spindle
are pre-lubricated.
•
Check the direction of rotation by doing a
quick start/stop. The motor fan should
rotate clockwise.
29
5.2 START AFTER SERVICE
5 OPERATING INSTRUCTIONS
5.2 Start After Service
Pay special attention to any unusual sounds or
vibrations when starting the separator after a
service. Different fault symptoms are listed in
chapter 7 Fault Finding, page 141.
5.3 Before Normal Start
To achieve the best separation results, the
bowl should be in a clean condition.
1
Check...
... that all couplings and connections are
securely tightened to prevent leakages.
Leaking hot liquid can cause burns.
... that the lock nut is fully tightened.
Do not forget the washer.
... the direction of rotation by doing a quick
start/stop. The motor fan should rotate
clockwise.
... that all frame hood bolts
as well as the clutch cover
are fully tightened
... the oil level and top up if
necessary.
30
The separator should be level and at
standstill when oil is filled.
G 0 87 14 4 1
NOTE
5 OPERATING INSTRUCTIONS
5.4 START
5.4 Start
1
Start of separator.
a Open the water
supply valve.
G 0 87 1 74 1
b Start the separator by pushing
the start button at the starter
unit.
Check the separator for vibration.
NOTE
!
ING
WARN
Excessive vibration
If vibration increases, or
continues at full speed, keep
bowl filled and stop the
separator.
The cause of the vibration must
be determined and corrected
before starting again!
Excessive vibration may be due
to incorrect assembly or
insufficient cleaning of the bowl.
Normal vibration
Vibration may occur during start
up when passing critical speed.
This is normal and should pass
without danger.
G 0 8 71 84 1
2
31
5.4 START
3
5 OPERATING INSTRUCTIONS
Ensure that the separator is at full speed (after about 190 - 210 seconds).
The time by full speed can be checked by
studying the ammeter
Current increases during
start...
G 08 71 9 21
...to decrease to a stable
value when full speed has
been reached.
4
Perform a sludge discharge.
a Add opening water until a
discharge sound is heard
(3,0 seconds).
b Wait 15 seconds.
G 0 87 21 4 1
c Add closing water for 15
seconds.
32
5 OPERATING INSTRUCTIONS
Turn on the oil feed.
NOTE
Before turning on the feed
make sure that the oil has the
correct temperature.
G 0 87 2 05 1
5
5.4 START
33
5.5 OPERATING
5 OPERATING INSTRUCTIONS
5.5 Operating
1
Checkpoints during operation:
a Check all connections for leakage.
b Check that the feed has correct flow and
temperature.
c Check the back pressure.
d Check that the starter ammeter reading
is the normal low and steady value.
e Check for abnormal vibrations
and sounds.
ING
WARN
!
ING
WARN
Disintegration hazard
Burning hazard
Do not discharge a vibrating separator.
Vibration can increase if solidified
sludge is only partially discharged.
Lubricating oil and various machine
surfaces can be hot and cause burns.
G 08 71 54 1
!
34
5 OPERATING INSTRUCTIONS
5.5 OPERATING
5.5.1 Sludge discharge during
operation
1
Turn off the oil feed.
a Turn off oil feed
G 0 87 22 4 1
b Wait 5 seconds.
Perform a sludge discharge.
a Add opening water until a
discharge sound is heard
(3,0 seconds).
b Wait 15 seconds.
c Add closing water for 15
seconds.
G 0 8 72 14 1
2
35
5.5 OPERATING
3
5 OPERATING INSTRUCTIONS
Turn on the oil feed.
ON
NOTE
G 0 87 2 05 1
Before turning on the feed,
make sure that the oil has the
correct temperature.
36
5 OPERATING INSTRUCTIONS
5.6 STOP
5.6 Stop
1
Turn off the oil feed.
a Turn off oil feed
G 0 87 2 24 1
b Wait 5 seconds.
Perform a sludge discharge.
a Add opening water until a
discharge sound is heard
(3,0 seconds).
b Wait 15 seconds.
c Add closing water for 15
seconds.
G 0 8 72 14 1
2
37
5.6 STOP
3
5 OPERATING INSTRUCTIONS
Fill the bowl up with water and stop the separator.
NOTE
G 0 87 23 11
Keep the bowl filled during run-down to
minimize the vibrations.
4
Wait until the separator has stopped (after about 30 minutes).
G 0 87 24 4 1
Check rotation of motor fan.
38
5 OPERATING INSTRUCTIONS
5.7 EMERGENCY STOP
5.7 Emergency Stop
1
If the separator vibrates excessively...
... push the emergency stop button.
NOTE
G 0 87 1 24 1
Keep the bowl filled during run-down to
minimize the vibrations.
Evacuate the room.
!
ING
WARN
Disintegration hazard
Never discharge a vibrating
separator.
!
!
ING
WARN
ING
WARN
Entrapment hazard
Disintegration hazard
After an emergency stop, the cause of the fault must be
identified.
If all parts have been checked and the cause not found,
contact Alfa Laval for advice before restarting the separator.
Make sure that rotating parts have
come to a complete standstill before
starting any dismantling work.
G 0 87 13 41
2
39
5.7 EMERGENCY STOP
40
5 OPERATING INSTRUCTIONS
SEPARATOR MANUAL
6 SERVICE, DISMANTLING, ASSEMBLY
6 Service, Dismantling, Assembly
6.1 Periodic Maintenance
6.1.2 Maintenance procedures
Periodic (preventive) maintenance reduces
the risk of unexpected stoppages and
breakdowns. Follow the maintenance log in
this chapter in order to facilitate the
periodic maintenance.
At each Inspection and/or Overhaul, take a
copy of the maintenance log and use it to make
notes during the service.
An inspection and overhaul should be carried
out as follows:
1
Dismantle the parts as described in 6.3
Dismantling, page 46.
6.1.1 Maintenance intervals
The following directions for periodic
maintenance give a brief description of parts to
be cleaned, checked and renewed at different
maintenance intervals.
The maintenance log for each maintenance
interval on page 43 gives a detailed list of
actions to be performed.
Place the separator parts on clean, soft
surfaces such as pallets.
2
Inspect and clean the dismantled separator
parts according to the maintenance log and
description in 6.4 Actions Before Assembly,
page 80.
3
Fit all the parts delivered in the service kit
while assembling the separator as
described in chapter 6.5 Assembly, page
89.
4
When the separator is assembled, make
final checks described in 6.6 Actions After
Assembly, page 129.
Inspection i i
An Inspection consists of an overhaul of the
separator bowl, inlet/outlet and operating
water device every 6 months or 4000 operating
hours.
Seals in bowl and gaskets in inlet/outlet device
are renewed.
!
ING
WARN
Disintegration Hazards
Overhaul o
Separator parts that are either missing, worn
beyond their safe limits or incorrectly assembled,
may cause severe damage or fatal injury.
An Overhaul consists of an overhaul of the
complete separator (including separator bowl,
inlet/outlet and operating device) every 18
months or 12000 operating hours. Seals,
bearings, friction blocks and flat belt in the
separator are renewed.
!
ON
CAUTI
Oil change
Burn and Corrode Hazards
The oil should be changed every 4000 hours, or
at least once every year if the total number of
operating hours is less than 4000 hours/year.
Escaping hot and/or corroding process material,
which can be hazardous, may still remain in the
separator after stop.
578701-02
41
6 SERVICE, DISMANTLING, ASSEMBLY
SEPARATOR MANUAL
6.1.4 Service kits
The use of service symbols in the
dismantling/assembly instructions
Parts that have to be renewed from the service
kits (see below) are marked i i and/or o in
the assembly instructions.
Special service kits are available for Inspection
and Overhaul.
Example:
a Fit the O-ring
ii .
When dismantling and assembling between
the service periods, some procedures do not
have to be carried out. These procedures are
marked i i and/or o .
Example:
5
A Commissioning kit is included in the delivery
which contain various O-rings that might
needs to be changed when assembly for the
first time.
For other services, a Support kit is available.
Spare parts not included in the Support kit
have to be ordered separately.
Note that the parts for Inspection are included
in the Overhaul kit.
The contents of the kits are described in the
Spare Parts Catalogue.
Renew the valve plugs on the operating
slide i i .
NOTE
All symbols used in the instructions refer to
activities mentioned in the maintenance logs.
Always use Alfa Laval genuine parts as otherwise
the warranty may become invalid.
Alfa Laval takes no responsibility for the safe
operation of the equipment if non-genuine spare
parts are used.
6.1.3 Tightening of screws
Tightening all screws with the correct torque
value is important.
These figures apply unless otherwise stated:
!
ING
WARN
Torque
Disintegration hazards
Metric
thread
Stainless steel
Carbon steel
Nm
kpm Ib.ft
Nm
M4
1,7
0,17 1,2
2,25 0,25 1,8
M5
3,4
0,34 2,5
4,9
0,49 3,6
M6
7
0,7
5
8
0,8
5,9
M8
17
1,7
13
20
2
14,7
M10
33
3,4
24
39
3,9
28,7
M12
57
5,8
42
68
6,9
50
M16
140
14
100
155
15,8 114
M20
270
28
200
325
33
239
M24
470
48
340
570
58
420
Use of imitation spare parts may cause severe
damage.
kpm Ib.ft
6.1.5 Cleaning
CIP (Cleaning In Place)
To prolong the intervals between manual
cleaning of the separator the use of CIP
together with repeated discharges can be used.
Some CIP liquids can be corrosive to brass- and
aluminium alloy parts which are included in
the separator.
!
ON
CAUTI
Use only Alfa Laval recommended CIP liquids.
The figures apply to lubricated screws
tightened with a torque wrench.
42
578701-02
6 SERVICE, DISMANTLING, ASSEMBLY
6.2 MAINTENANCE LOG
6.2 Maintenance Log
Manufacture No./Year:
Total running hours:
Product No.: 881201-05-01/2 & 881201-06-01/3
Date:
Signature:
Part
i
o
Check
Separator: S 821 & S 826
Overhaul
Local identification:
Inspection
Name of ship/plant:
Action
Page
Note
In and outlet device
- All parts
x
x
Clean
80
- All parts
x
x
Check for corrosion
82
- All parts
x
x
Check for cracks
83
- Connecting housing
x
x
Check for erosion damages
84
x
x
Renew O-rings for hoses
x
x
Renew O-ring
122
x
Control measure of paring disc height
123
x
Check height adjusting rings
123
x
Renew the spring
124
- Frame hood
-
Bowl
- All parts
x
x
Clean
80
- All parts
x
x
Check for corrosion
82
- All parts
x
x
Check for cracks
83
- All parts
x
x
Check for erosion damages
84
- Bowl body
x
x
Check for impact marks and corrosion
109
x
x
Renew rectangular ring
110
x
x
Renew O-rings
x
x
Renew holder screws and washers
110
x
x
Renew rectangular ring
110
x
x
Renew valve plugs
109
- Discharge slide
x
x
Renew rectangular ring
114
- In and outlet pipe
x
x
Renew O-rings
117
x
x
Renew splash sealing
117
- Paring tube
x
x
Renew O-ring
117
- Bowl hood
x
x
Renew seal ring
119
x
x
Renew O-ring
119
x
x
Renew seal ring and screws
111
- Operating slide
- Operating water ring
111, 114
43
i
o
Check
Overhaul
Part
6 SERVICE, DISMANTLING, ASSEMBLY
Inspection
6.2 MAINTENANCE LOG
Action
Page
Note
Frame
- Frame feet
Renew frame feet (including washers
and screws)
85
- Drain and oil filling holes
x
x
Renew washers
108
- Oil pin
x
x
Renew O-ring
108
- All parts
x
Clean
80
- All parts
x
Check for corrosion
82
- All parts
x
Check for cracks
83
- Bottom bearing housing
x
Renew O-ring
96
- Labyrinth ring holder
x
Renew labyrinth ring
97
x
Renew O-ring
97
- Top bearing housing
x
Renew springs
100
- Flat belt
x
Renew flat belt
104
- Bowl spindle
x
Pre-lubricate and renew ball bearing
99
x
Pre-lubricate and renew self-aligning
roller bearing
101
x
Lubricate the spindle
109
x
Measure the radial wobble
107
- Lubricating oil orifice
x
Renew O-ring
108
- Neck bearing cover
x
Renew O-ring
106
- Deflector ring
x
Renew O-ring
106
- Water inlet pipe
x
Renew O-ring
107
- Operating water cover
x
Renew seal ring and O-ring
107
- Fan
x
Renew the O-ring
103
- All parts
x
Clean
80
- All parts
x
Check for corrosion
82
- All parts
x
Check for cracks
83
- Coupling hub
x
Renew single row ball bearings
89
Renew snap rings
89
x
Renew friction pads (if they are worn)
or clean the pads if they are oily
89
x
Lubricate if nipples are fitted. See sign
on motor
---
Driving device
Coupling
- Friction blocks
Electrical motor
- Electrical motor
44
Has to be ordered
separately
i
o
6.2 MAINTENANCE LOG
Check
Overhaul
Part
Inspection
6 SERVICE, DISMANTLING, ASSEMBLY
Action
Page
Note
Signs and labels on separator
- Machine plate
x Check attachment and legibility
129
- Power supply frequency
x Check attachment and legibility
129
- Lifting instructions
x Check attachment and legibility
129
- Safety labels
x Check attachment and legibility
129
- Name plate
x Check attachment and legibility
129
- Representative label
x
Check attachment and legibility
129
45
6.3 DISMANTLING
6.3 Dismantling
6.3.1 Introduction
The frame hood and heavy bowl parts must
be lifted by means of a hoist. Position the
hoist exactly above the bowl centre. Use a
lifting sling and lifting hooks with safety
catches.
The parts must be handled carefully. Don’t
place parts directly on the floor, but on a
clean rubber mat, fibreboard or a suitable
pallet.
NOTE
For safety reasons, it is essential that all personnel
who work with the separator read this manual
thoroughly and completely.
Do not allow personnel to clean, assemble, operate
or maintain the separator until they have read and
fully understood this manual.
Ensure that all personnel who operate and service
the separator are well-trained and knowledgeable
concerning the separator and the work to be
carried out.
6.3.2 Tools
Special tools from the tool kit must be used
for dismantling and assembly, as well as
Standard tools (not included). The special
tools are specified in the Spare Parts Catalogue
and are illustrated at the beginning of each
dismantling section.
!
ING
WARN
Entrapment hazard
To avoid accidental start, switch off and lock-out
power supply before starting any dismantling work.
Make sure that machine has come to a complete
standstill before starting any dismantling work
(takes about 22 minutes from switch off).
46
6 SERVICE, DISMANTLING, ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
6.3 DISMANTLING
Standard Tools
5
3
2
1
4
6
12
7
9
8
10
11
13
G 0 91 16 41
14
1
Screwdriver
2
Torque wrench (capacity 0-200 Nm)
3
Drift ( Ø 4 mm)
4
Dial indicator with magnetic base
5
Spanner for clutch
6
Heating equipment for bearings
7
Sliding calliper
8
Hammers (standard and soft-faced)
9
Pliers for internal snap rings
10 Pliers for external snap rings
11 T-handle with extension rod, sockets
(13, 16, 17, 18, 19, 27, 30 mm)
12 Spanners (various sizes)
13 Adjustable spanner
14 Shackle
47
6.3 DISMANTLING
6 SERVICE, DISMANTLING, ASSEMBLY
6.3.3 Frame hood
Lock nut
Washer
Connecting
housing
Spring
G 0 8 63 35 1
Screw
G 0 86 0 53 1
1
Arm
Screws
1 Hook spanner (lock nut)
Frame hood
ING
WARN
O-ring
Height adjusting
rings
Entrapment hazard
To avoid accidental start, switch off and lock-out the
power supply before starting any dismantling work.
Support ring
G 0 86 34 81
!
Make sure that machine has come to a complete
standstill before starting any dismantling work
(after about 22 minutes from switch off).
1
Removing the connecting housing.
a Remove the lock nut using the
hook spanner.
!
NOTE
Remove connections before
starting dismantling.
ING
WARN
The nut must not be
removed before the
separator has stopped.
Remove the washer
NOTE
b Remove the connecting housing
.
G 08 63 5 81
Right hand thread.
48
6 SERVICE, DISMANTLING, ASSEMBLY
2
6.3 DISMANTLING
Removing the spring and arm.
a Remove the spring from
the pin on the hood.
b Loosen and
remove the screw
and arm together
with the spring.
c Turn the paring tube so that the frame hood can be
removed upwards.
NOTE
Removing the frame hood.
a Remove the screws holding
the frame hood.
c Lift off the frame
hood.
NOTE
b Loosen the hood
by bending with
a screwdriver in
all grooves in the
hood.
Do not place
the hood
upside down.
G 08 6 36 71
3
G 0 86 36 91
Paring tube
To avoid the paring tube from being damaged
and preventing the inlet pipe from sticking to
the frame hood when lifting the hood, always
turn the paring tube towards the pipe before
lifting.
49
6.3 DISMANTLING
6 SERVICE, DISMANTLING, ASSEMBLY
6.3.4 Bowl
Lock ring
Bowl hood
Seal ring
O-ring
Top disc
G 0 86 16 21
O-rings
Inlet and outlet
pipe
Paring tube complete
Splash sealing
1
2
Bowl disc
(without caulks)
Bowl discs
5
Distributor
3
Cap nut
Nut
4
6
Discharge slide
Rectangular ring
7
O-ring
8
9
G 08 60 5 I1
Bowl body
10
Rectangular ring
O-ring
1 Compressing tool (lock ring)
2 Lifting eyes
3 Spanner for nut (nut/discharge slide)
4 Puller (discharge slide)
5 Lifting tool (distributor, spindle)
6 Puller (Bowl body)
7 Screw (lock ring) (M5)
8 Hexagon head key
9 Chisel (seal ring)
10 Pin (distributor/lifting tool)
Valve plugs
Operating slide
Rectangular ring
O-ring
Screws & washers
50
Nozzle
Operating water ring
Screws
Seal ring
G 0 86 26 U1
Holder
6 SERVICE, DISMANTLING, ASSEMBLY
Removing the lock ring
a Fit the compressing tool.
b Fit the clamps and the
screws to stop.
c Compress the disc stack by
alternately tightening the inner
screws on the compressing
tool to a maximum of 60 Nm.
NOTE
Be sure not to
cover the threaded
holes.
2
3
4
1
Screw
Clamp
5
6
d Fit the dismantling screws
to the bowl body and
press out the lock ring by
tightening the screws
successively according to
the numbering on the
illustration (1-6). Start with
the screw nearest the lock
ring end (1).
The lock ring can be
removed when it has
passed the edge of the
groove.
e Remove the lock ring
from the groove.
NOTE
f Remove the dismantling screws.
G 0 86 27 81
1
6.3 DISMANTLING
51
6.3 DISMANTLING
2
6 SERVICE, DISMANTLING, ASSEMBLY
Removing the bowl hood.
a Remove the compressing
screws.
b Loosen the screws
on the clamp tool.
Remove the tool.
Remove the lock
ring.
NOTE
The bowl hood must be pulled off
straight up, in order not to get stuck.
Recommendation: Take
measurements with a calliper around
the bowl, between the upper edge of
the bowl body and the bowl hood, to
check that the bowl hood is being
pulled off straight up.
c Fit the compressing tool and the
puller screws.
Pull the bowl hood off by
screwing the screws alternately
(max. 1/2 turn) and gradually
increase the momentum evenly
until the bowl hood come loose.
d Remove the clamps
and attach lifting eyes
to the compressing
tool and lift off the
bowl hood.
!
ING
WARN
Crush hazard
G 0 8 62 8B 1
The top disc can adhere to the bowl
hood when lifting. Be careful not to
accidentally drop it.
52
6 SERVICE, DISMANTLING, ASSEMBLY
3
6.3 DISMANTLING
Removing the seal ring.
a Place the bowl hood on a support
and tap out a piece of the seal ring
using a drift in the holes.
b Turn the bowl hood upside down
and remove the seal ring by
carefully knock pieces of the seal
ring out of the groove, using the
special tool: chisel.
NOTE
It is very important not to
damage the bottom of the
groove!
Seal ring
!
ING
WARN
Risk for eye injury from flying seal ring parts
Removing the inlet/outlet pipe and top disc.
a Lift out the in- and outlet pipe together with the top disc.
!
ING
WARN
Crush hazard
The distributor and disc stack can adhere to the
top disc. Separate them from the top disc so that
they do not accidentally drop.
G 08 6 29 51
4
G 0 86 24 4 1
The seal ring breaks when removed from the bowl
hood.
53
6.3 DISMANTLING
5
6 SERVICE, DISMANTLING, ASSEMBLY
Removing the paring tube.
a Remove the top disc from
the inlet and outlet pipe.
NOTE
To avoid damaging the paring
tube, turn it towards the
centre of the pipe.
b Remove the splash sealing.
Bearing bushing
d Lift up and
remove the paring
tube.
Flanged bushing
Bearing holder
NOTE
G 0 8 63 0G 1
If the paring tube sticks; turn the
assembly upside down and use a
drift to carefully tap out the plug.
54
6 SERVICE, DISMANTLING, ASSEMBLY
6
6.3 DISMANTLING
Removing the disc stack and distributor.
c Carefully lift off the
disc stack assembly.
a Assemble the lifting tool with the pin.
b Fit the assembled tool into the
distributor and ease off the disc stack.
!
ON
CAUTI
Cut hazard
G 0 86 31 61
Sharp edges on the separator
discs may cause cuts
Removing the nut
a To prevent the bowl body from rotating
when removing the nut;
Fit one of the clamps (see page 51) to
the bowl body and one of the screws
for the frame hood in the frame. Fasten
a sling between the clamp and the
screw around the bowl body.
b Use the spanner
for nut to remove
the nut.
Sling
Screw
Clamp
G 0 9 23 86 1
7
Nut
55
6.3 DISMANTLING
8
6 SERVICE, DISMANTLING, ASSEMBLY
Removing the discharge slide.
a Fit the lifting tool by
pressing the puller rods
towards each other and
position them into the
two slots on the bowl
bottom.
Slide metal ring down
over bowl nave.
b Ease off the discharge slide
by turning the central screw.
NOTE
If discharge slide is
difficult to remove,
tap lightly on outside
edge with a soft
faced hammer.
Ring on tool
Puller rod
Discharge slide
Bowl body
c Lift out the discharge slide.
!
ING
WARN
The ring on the lifting tool must be pushed
down against the discharge slide,
otherwise the discharge slide may come
loose from the tool.
56
G 0 86 32 6 1
Crush hazard
6 SERVICE, DISMANTLING, ASSEMBLY
9
6.3 DISMANTLING
Removing the cap nut.
a Remove the cap nut
NOTE
G 08 60 66 1
Left-hand thread!
10 Removing the bowl body
a Fit the lifting tool to the bowl body.
b Raise the bowl body off the spindle taper
by turning the lifting eye clock-wise.
G 0 8 60 73 1
c Lift off the bowl body
57
6.3 DISMANTLING
6 SERVICE, DISMANTLING, ASSEMBLY
11 Turn the bowl body upside down.
ING
WARN
Crush hazard
Support the bowl body when turning to prevent it from rolling.
G 0 86 08 21
!
12 Removing the holder.
a Remove and discard the screws and washers.
New screws and washers are included in the
Inspection kit.
b Lift off the holder.
NOTE
G 0 8 60 92 1
If the ring sticks, use two M10
screws in threaded holes to raise
the operating slide holder up and
away from the bowl body.
58
6 SERVICE, DISMANTLING, ASSEMBLY
6.3 DISMANTLING
13 Removing the operating slide.
a Lift off the operating slide.
NOTE
G 0 86 10 21
If the ring sticks, use two M10 screws in
threaded holes to raise the operating
slide holder up and away from the bowl
body.
14 Removing the valve plugs from the operating slide.
a Remove the valve plugs using
a drift.
G 08 74 8 81
Drift
59
6.3 DISMANTLING
6 SERVICE, DISMANTLING, ASSEMBLY
15 Removing the operating water ring.
a Remove and discard the screws.
New screws are included in the Inspection kit.
b Lift off the ring.
NOTE
G 08 6 11 21
If the ring sticks, use two M8
screws in threaded holes to raise
the operating slide holder up and
away from the bowl body.
60
6 SERVICE, DISMANTLING, ASSEMBLY
6.3 DISMANTLING
6.3.5 Driving device
1
3
5
4
2
G 0 85 79 7 1
G 08 5 78 21
6
7
1 Puller (spindle pulley,
ball bearing).
2 Tool (bearing housing).
3 Cover puller
(neck bearing cover).
4 Lifting tool
(spindle assembly)
5 Drift (bottom bearing).
6 Sleeve (ball bearing in
top bearing seat
7 Pin spanner (oil fan).
Seal ring
Operating water cover
Air deflector
O-ring
O-rings
Spindle pulley
Deflector ring
Seal ring
Neck bearing cover
Belt
O-ring
O-ring
Fan
Snap ring
Self-aligning roller
bearing
Lubrication oil orifice
O-ring
Oil pump
Bowl spindle
Ball bearing
Labyrinth ring
Top bearing seat
Wing insert
O-ring
Top bearing housing
Bottom bearing
holder
Composite springs
Screw
Plugs
O-ring
G 08 5 80 71
Springs
Strainer
61
6.3 DISMANTLING
6 SERVICE, DISMANTLING, ASSEMBLY
.
1
Removing the clutch cover.
a Remove the screws.
G 0 85 8 13 1
b Remove the clutch cover.
2
Empty the oil sump.
G 0 86 85 7 1
Unscrew the oil plug and
empty the oil sump.
62
6 SERVICE, DISMANTLING, ASSEMBLY
Loosen the flat belt, by tilting the motor.
a Loosen, but do not remove, the screws holding
the motor. Start with the two screws at the bottom.
Do not loosen more than shown in the illustration.
Motor
Separator frame
Nut
Screw
b Loosen the two upper screws a little bit more so
that the motor can be tilted. Do not loosen more
than shown in the illustration.
!
ING
WARN
Crush hazard
c Remove the flat belt from the motor pulley.
The motor will come off if the screws are
unscrewed.
G 08 58 8A 1
3
6.3 DISMANTLING
63
6.3 DISMANTLING
4
6 SERVICE, DISMANTLING, ASSEMBLY
Removing the operating water cover.
a Remove the screws.
b Lift off the operating water cover.
NOTE
G 0 85 89 3 1
If the cover sticks, fit two M8
screws to the threaded holes
and tighten.
5
Removing the neck bearing cover and deflector ring.
d Lift off the neck bearing cover
together with the deflector ring.
a Attach the tools.
b Fasten the tool to
the cover.
Cover
Frame
64
G 08 5 90 51
c Ease off the
cover by
tightening
the screw.
6 SERVICE, DISMANTLING, ASSEMBLY
6
6.3 DISMANTLING
Prepare for removal of spindle assembly.
NOTE
To facilitate later removal of
plugs, loosen (do not remove)
the plugs on the bearing
housing.
b Remove the screws
NOTE
If the cover sticks, fit two M10
screws to the threaded holes
and tighten.
G 0 85 91 51
a
65
6.3 DISMANTLING
7
6 SERVICE, DISMANTLING, ASSEMBLY
Lifting the spindle assembly from the frame.
a Fit the lifting tool to the spindle end.
b Slowly raise and lift out the spindle
assembly.
!
ING
WARN
Crush hazard
Do not rotate the spindle assembly
during lifting. The spindle assembly
may otherwise come loose from the
lifting tool.
NOTE
Take care not to
damage the oil pump.
NOTE
G 0 90 7 83 1
Protect the inside of the frame
by covering the hole.
66
6 SERVICE, DISMANTLING, ASSEMBLY
8
6.3 DISMANTLING
Place the spindle assembly upside down on a support.
Make a support
~185 mm
~120 mm
Removing the air deflector.
Remove the screws and the air
deflector.
G 08 59 24 1
9
G 0 85 9 21 1
~6,5 mm
free space
67
6.3 DISMANTLING
6 SERVICE, DISMANTLING, ASSEMBLY
10 Removing the fan.
a Turn the spindle assembly the right way up.
b Place a spanner (or similar) on
the spindle pulley key-grip, as
holder-up.
c Fit the pin spanner and
remove the fan.
NOTE
Key-grip
G 09 23 9 21
Left-hand thread!
11 Removing the bottom bearing assembly.
a Turn the spindle assembly up-side down and
remove the oil pump by using spanners.
Puller tool
b Pull off the belt pulley and the
self-aligning roller bearing using
the puller tool.
NOTE
Lubrication oil orifice
Compressed air
68
c Cover the the oil orifice and blow compressed
air through the bottom hole of the oil pump and
slowly ease out the lubrication oil orifice.
G 08 6 59 81
Always discard a used
bearing.
6 SERVICE, DISMANTLING, ASSEMBLY
6.3 DISMANTLING
12 Removing the top bearing housing.
Composite
springs
b Remove the plugs
and the composite
springs.
c Carefully remove the spindle
from the top bearing seat.
Plug
NOTE
d Collect the
axial springs.
Be careful not to damage
the vibration indicator.
G 08 5 82 21
a Turn the spindle
assembly over.
69
6.3 DISMANTLING
6 SERVICE, DISMANTLING, ASSEMBLY
13 Removing the ball bearing.
a Remove the snap ring.
!
ING
WARN
Risk for eye injury from flying snap ring
Use the correct pliers for dismantling of snap ring to
avoid accidental release.
b Fit the cap nut on the spindle to
protect the threads.
c Use the puller tool to remove the
top bearing seat from the spindle.
NOTE
Do not damage threads on
spindle.
NOTE
Take care not to damage the
vibration indicator when
separating the top bearing
seat from the spindle.
Vibration indicator
Piece of wood to
protect the spindle
threads.
NOTE
Always discard
used bearings.
G 0 8 58 35 1
d Place the top bearing seat on a support to
protect the vibration indicator.
Remove the bearing. Use a drift in the two
holes.
70
6 SERVICE, DISMANTLING, ASSEMBLY
6.3 DISMANTLING
14 Removing the labyrinth ring.
a Remove the ring using a
screwdriver.
NOTE
G 0 85 8 6C 1
Be careful not do damage the groove.
71
6.3 DISMANTLING
6 SERVICE, DISMANTLING, ASSEMBLY
15 Removing the bottom bearing holder.
a Fit the tool into the bottom bearing holder and attach the
socket, extension rod and T-handle.
T-handle
Extension rod
Socket
Tool
b Loosen the bottom bearing
holder by turning it counter
clockwise.
Remove it by hand.
G 0 85 86 D1
c Remove the strainer.
72
6 SERVICE, DISMANTLING, ASSEMBLY
6.3 DISMANTLING
6.3.6 Centrifugal clutch
Snap rings
G 08 64 75 1
Spacing ring
Belt pulley
Coupling
hub
ING
WARN
Parallel pin
Entrapment hazard
To avoid accidental start, switch off and lock-out
power supply before starting any dismantling work.
Friction blocks
(3=60 Hz)
Make sure that machine has come to a complete
standstill before starting any dismantling work
(takes about 22 minutes from switch off).
Cover
G 08 65 1 B1
Snap ring
NOTE
50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks
1
2
G 0 8 65 04 1
!
Ball bearings
73
6.3 DISMANTLING
6 SERVICE, DISMANTLING, ASSEMBLY
.
1
Removing the clutch cover.
a Remove the screws.
G 0 85 81 3 1
b Remove the clutch cover.
2
Loosen the flat belt, by tilting the motor.
a Loosen, but do not remove, the screws holding
the motor. Start with the two screws at the bottom.
Do not loosen more than shown in the illustration.
Motor
Separator frame
Nut
Screw
b Loosen the two upper screws a little bit more so
that the motor can be tilted. Do not loosen more
than shown in the illustration.
!
ING
WARN
74
The motor will come off if the screws are
unscrewed.
G 08 58 8 A1
Crush hazard
c Remove the flat belt from the motor pulley.
6 SERVICE, DISMANTLING, ASSEMBLY
3
6.3 DISMANTLING
Removing the motor.
a Disconnect the electrical cables.
!
ING
WARN
Electrical hazard
If the cables are not disconnected during lifting procedures,
they may become damaged.
b Fit a sling to the
motor using a
shackle on the upper
part.
Weight of motor with
coupling: approx.
60 kg.
c Tense the lifting sling to support the motor and
remove the screws. Lift the motor while supported.
!
ING
WARN
Crush hazard
G 0 86 4 64 1
If not supported, the motor with coupling
will drop when removing the screws.
d Lower the motor onto a suitable pallet.
Removing the friction blocks.
a Remove the snap ring, cover
and friction blocks.
Friction blocks
(3=60 Hz)
Cover
Snap ring
NOTE
50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks
G 0 8 65 23 1
4
75
6.3 DISMANTLING
5
6 SERVICE, DISMANTLING, ASSEMBLY
Checking the condition of the friction blocks o
.
If the blocks are worn:
!
ON
CAUTI
Fit new friction blocks.
NOTE
Inhalation hazard
When handling friction
blocks/pads wear a
mask to avoid inhalation
of dust.
Do not use compressed
air to remove dust.
Remove dust using
vacuum or a damp cloth.
Replace all blocks, even if only one is
worn.
a Clean the pins of coupling hub and apply a thin
film of lubricating paste to the pins.
NOTE
Make sure that there is no oil on the pads.
NOTE
Be sure that the pins on the back of the
blocks project into the grooves in the
clutch hub.
G 08 65 3 31
b If only friction block service is to be done,
proceed to ‘‘Assembly of friction blocks” on page
92.
76
6 SERVICE, DISMANTLING, ASSEMBLY
6.3 DISMANTLING
Complete dismantling of centrifugal clutch
Removing the coupling from the motor.
a Remove the screw, spring washer and washer.
Washer
Spring washer
Screw
Attach a socket with extension
rod and handle to the screw.
Place a piece of wood according
to the illustration. Push the
handle to start the rotor moving,
when the handle hits the piece of
wood, the weight and movement
of the rotor loosens the screw.
Repeat until screw is loose.
Piece of wood
b Check that the brass plug is mounted
on the puller tool.
Fit the tool to the friction clutch.
Puller tool
c Ease off the friction coupling.
Flat areas for spanner.
!
ING
WARN
Crush hazard
NOTE
The centrifugal clutch is heavy and
can fall, causing injury, when
loosened from the motor shaft.
See dismantling with optional
hydraulic puller tool (if purchased) on
next page.
G 0 86 54 G 1
6
77
6.3 DISMANTLING
7
6 SERVICE, DISMANTLING, ASSEMBLY
Removing the coupling from the motor using the optional hydraulic tool.
NOTE
First remove the screw, spring washer
and washer according to instructions
a -b, on previous page.
a Fit the sleeve to the
stud bolt.
b Fit the holder to the
coupling nave.
Fit the stud bolt with
sleeve to the motor
shaft.
c Fit nut and sleeve to the
stud bolt as shown.
d Fit hydraulic cylinder as
shown.
e Fit the plate and fasten with
screws through plate and
holder.
Motor shaft
Coupling nave
Sleeve
Holder
f Attach the hose from the hand pump to the hydraulic oil inlet.
Ease off the friction coupling by pumping the handle on the
pump until stop.
Release pressure on the hand pump and adjust the nut on the
stud bolt.
Repeat until coupling is loose.
!
ING
WARN
Crush hazard
The centrifugal clutch is heavy and can fall, causing
injury, when loosened from the motor shaft.
78
G 0 86 54 N1
Hydraulic oil inlet
6 SERVICE, DISMANTLING, ASSEMBLY
Dismantling of the coupling assembly.
a Remove the snap rings.
b Drive out the coupling hub.
Wooden support
Support
c Turn the coupling the other way round and
drive out the ball bearings using the
mounting tool.
NOTE
Always discard used bearings.
G 0 86 55 6 1
8
6.3 DISMANTLING
79
6.4 ACTIONS BEFORE ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
6.4 Actions Before
Assembly
6.4.1 Cleaning i
o
Clean the separator parts according to the
diagram below. Afterwards, protect all cleaned
carbon steel parts against corrosion by oiling.
Part
Procedure
Cleaning agents
Frame and
motor
The external cleaning of the frame and motor should be
restricted to brushing, sponging or wiping while the motor is
running or still is hot.
Water and de-greasing agent.
!
ING
WARN
Electrical hazard
Never wash down a separator with a direct water
stream.
Never play a water jet on the motor. Totally
enclosed motors can be damaged by direct hosing
to the same extent as open motors, resulting in
short-circuit and internal corrosion.
Clean the inside of the frame with a clean cloth and remove
visible particles.
80
6 SERVICE, DISMANTLING, ASSEMBLY
6.4 ACTIONS BEFORE ASSEMBLY
Part
Procedure
Cleaning agents
Bowl
Cleaning of bowl discs
Inlet/ outlet
Handle the bowl discs carefully in order to avoid damage to
the surfaces during cleaning
A chemical cleaning agent must
dissolve the deposits quickly without
attacking the material of the separator
parts.
1 Remove the bowl discs from the distributor and place them
individually in the cleaning agent.
2 Allow the discs to remain in the cleaning agent until the
deposits have been dissolved. This will normally take
between two and four hours.
3 Lastly, clean the discs with a soft brush.
Cleaning of holder for operating slide, operating water
ring and operating slide with nozzle.
Use 10% acetic acid solution to dissolve lime deposits. The
acid should be heated to 80 °C.
Fuel oil sludge mainly consists of
complex organic substances such as
asphaltenes. The most important
property of a cleaning liquid for the
removal of fuel oil sludge is the ability to
dissolve these asphaltenes.
!
ON
CAUTI
Cut hazard
Clean the nozzle on the operating slide using a soft iron wire
or a similar object.
Sharp edges on the separator
discs may cause cuts.
Driving device
Use a sponge or a soft brush and clean the oil orifice, bearing
holder and oil pump thoroughly.
White spirit, cleaning-grade kerosene
or diesel oil.
Centrifugal
clutch
Use a sponge or a soft brush.
White spirit, cleaning-grade kerosene
or diesel oil.
Belt pulley
Use a a steel brush.
Solvent
81
6.4 ACTIONS BEFORE ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
6.4.2 Inspection for corrosion i
o
Inspect the separator parts for corrosion.
Evidence of corrosion attacks should be looked
for and rectified each time the separator is
dismantled.
G 0 2 05 24 1
!
Max. 0,2 mm
ING
WARN
Disintegration hazards
Always contact your Alfa Laval representative if you
suspect that the depth of the corrosion damage
exceeds 0,2 mm for bowl body and bowl hood (0,5
for other parts) or if cracks have been found. Do not
continue to use the separator until it has been
inspected and given clearance for operation by Alfa
Laval.
Material
Type of corrosive
environment
Appearance
Measure
Non-stainless steel
and cast iron parts
Water or dampness
Rust
If damage exceeds 0,5 mm, contact
Alfa Laval.
Stainless steel
Chlorides or acidic
solutions
Acidic solutions cause general
corrosion.
Polish dark-coloured spots and
other corrosion marks with a fine
grain emery cloth. This may prevent
further damage.
Chloride corrosion begins as small
dark spots that can be difficult to
detect, and goes on to local damage
such as pitting, grooves or cracks.
Other metal parts
!
“Aggressive”
environment
Possible corrosion damage can be
in the form of pits and/or cracks.
ING
WARN
Disintegration hazard
Pits and spots forming a line may indicate cracks
beneath the surface.
All forms of cracks are a potential danger and are
totally unacceptable.
Replace any part where corrosion can be
suspected of affecting its strength or function.
82
If damage exceeds 0,5 mm (0,2 mm
for bowl body and bowl hood)
contact Alfa Laval.
If damage exceeds 0,5 mm, contact
Alfa Laval.
6 SERVICE, DISMANTLING, ASSEMBLY
6.4.3 Inspection for cracks i
6.4 ACTIONS BEFORE ASSEMBLY
o
Check the separator parts for cracks. It is
particularly important to inspect for cracks in
rotating parts, and especially the pillars
between the sludge ports in the bowl wall.
!
ING
WARN
Disintegration hazard
All forms of cracks are potentially dangerous as they
reduce the strength and functional ability of
components.
Always replace a part if cracks are present.
Cracks can occur from cyclic material stresses
and corrosion. Keeping the separator and its
parts clean and free from deposits will help to
prevent corrosion attacks.
!
ING
WARN
Disintegration hazards
Always contact your Alfa Laval representative if you
suspect that the depth of the damage exceeds 0,2
mm for bowl body and bowl hood (0,5 for other
parts).
Do not continue to use the separator until it has
been inspected and given clearance for operation by
Alfa Laval.
83
6 SERVICE, DISMANTLING, ASSEMBLY
6.4.4 Inspection for erosion i
SEPARATOR MANUAL
o
Erosion may occur when particles
suspended in the process liquid slide along
or strike against a surface.
Surfaces particularly subjected to erosion are:
Erosion is characterised by:
1 Burnished traces in the
material.
2 Dents and pits having a
granular and shiny surface.
The sealing edge of the
discharge slide.
Paring disc and paring tube
Lock ring
Bowl body and holder.
Pillars between the
sludge ports in the
bowl wall
Holder and operating slide.
The sealing edge of the discharge
slide for the seal ring in the bowl
hood
1
G 0 91 18 31
The underside of the distributor in the vicinity of the
distribution holes and wings
2
Inspect the bowl and inlet/outlet parts for
erosion damages.
NOTE
!
Always contact your Alfa Laval representative if you
suspect that the depth of the damage exceeds 0,2
mm for bowl body and bowl hood (0,5 for other
parts). Do not continue to use the separator until it
has been inspected and cleared for operation by
Alfa Laval.
84
Replace parts if erosion is suspected.
578701-02
ING
WARN
Disintegration hazard
Erosion damage weakens parts by reducing the
thickness of the material.
Pay special attention to the pillars between the
sludge ports in the bowl wall.
Replace parts if erosion is suspected of affecting
strength or function.
6 SERVICE, DISMANTLING, ASSEMBLY
6.4 ACTIONS BEFORE ASSEMBLY
6.4.5 Exchange of frame feet
The frame feet have to be changed
occasionally due to rubber deterioration
from age.
When replacing the frame feet, the separator
must be lifted. Follow 6.8.1 Lifting the
separator, page 139.
NOTE
Discard the old frame feet, screws and washers.
a Loosen the bolts and prepare to remove
the separator frame
b Lift the separator. See ‘‘Lifting the separator” on
page 139
c Remove the existing frame feet.
d Fit the new feet, screws and washers. Tightening
torque: 160 Nm.
G 0 8 74 42 1
e Place the separator in its original position and
fasten the mounting bolts.
85
6.4 ACTIONS BEFORE ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
6.4.6 Lubrication of bowl parts
a Apply a thin layer of Molykote 1000, or equivalent
lubrication, on all the following contact surfaces. Apply
D321 on the operating slide and the bowl body, guide pin
and bowl hood.
= Molykote 1000
= D321R + Molykote 1000
Bowl hood
(apply D321)
Bowl body
(also apply D321 on guide pin)
Discharge slide
Operating slide
(apply D321)
Screw
Nut
Operating water ring
86
G 0 91 17 A 1
Holder
6 SERVICE, DISMANTLING, ASSEMBLY
6.4 ACTIONS BEFORE ASSEMBLY
6.4.7 How to lubricate bowl parts
with slide laquer
1
1
1
NOTE
This instruction is also valid for
the operating slide and the holder.
a Carefully clean the contact surfaces (1) on bowl body
and bowl hood.
b Apply Molykote D321R on surfaces.
c Air-cure for 15 minutes.
d Use a smooth fibre brush to polish to an even and
homogenous contact film.
e Apply a second layer slide laquer.
f Air-cure for 15 minutes.
G 0 8 74 86 1
g Polish the film to a shiny surface, the film should look
like well-polished leather when properly done.
h Finish the treatment by lubricating the contact surfaces
with Alfa Laval lubricating paste or Molykote 1000
paste. Use a well cleaned brush and rub it into the
surface, do not leave any excessive paste.
87
6.4 ACTIONS BEFORE ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
6.4.8 Check for galling on operating
slide and bowl body
1
1
If any friction marks are found on the guide surfaces (1)
of operating slide and bowl body, proceed as follows:
a Clean the surface thoroughly with a degreasing
agent, i.e. white spirit.
This is important!
NOTE
b Using an emery cloth (e.g. No. 320) to smooth the
metal edges.
c Finish by polishing the damaged spots with polishing
paper (e.g No. 600).
To avoid the risk of galling, the
guiding surface of the operating
slide should be primed with a slide
lacquer at every inspection
service.
d Apply Molykote D321R on surfaces.
e Air-cure for 15 minutes.
f Polish to an even, homogenous surface.
g Apply a second layer.
h Air-cure for 15 minutes.
j Finish the treatment by lubricating the guiding surfaces
with Alfa Laval lubricating paste or Molykote 1000
paste. Use a well cleaned brush. Rub it into the
surface, do not leave any excessive paste.
88
G 0 8 74 85 1
i Polish to a shiny surface, the surface should look like
well-polished leather when properly done.
6 SERVICE, DISMANTLING, ASSEMBLY
6.5 ASSEMBLY
6.5 Assembly
6.5.1 Centrifugal clutch
1
Assembly of the coupling.
a Slip the belt pulley over the coupling hub and place them on a firm and level
foundation.
ING
WARN
Disintegration Hazard
If the belt pulley must be renewed, check that the new pulley has the
correct diameter. An incorrect pulley will cause the separator bowl to
run at either an excessive or insufficient speed.
d=283 mm 50 Hz
d=235 mm 60 Hz
NOTE
Remove rust from the
belt pulley using a steel
brush.
b Apply a thin film of oil onto the
external and internal surfaces of the
ball bearings o .
Mounting tool
c Press the ball bearings down one at a time into the coupling
hub, preferably using a hydraulic press. Place the spacing
ring between them.
NOTE
Never re-fit used ball bearings.
The ball bearings must not be heated as they are
packed with grease and sealed with plastic
membranes.
d Fit the snap rings o
.
G 0 86 56 41
!
89
6.5 ASSEMBLY
2
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting the coupling to the motor.
a Clean the motor shaft and apply a
thin oil film.
NOTE
Make sure that the
key is in place on the
motor shaft.
b Apply lubricating paste to the tool
threads (keep lubricated).
c Remove the brass plug.
d Fasten the sleeve of the tool to the
motor shaft with the same screw that
normally holds the centrifugal clutch
to the motor.
NOTE
See mounting with optional hydraulic
puller tool (if purchased) on next
page.
e Use a spanner to turn the nut on the
tool. This will press the centrifugal
clutch on to the shaft. Remove the
tool.
f Install and tighten the
washer, spring washer and
screw.
Piece of wood
90
G08 65 4 H1
Attach a socket with extension rod and handle to the screw.
Place a piece of wood according to the illustration. Push
the handle to start the rotor moving, when the handle hits
the piece of wood, the weight and movement of the rotor
tightens the screw.
Repeat until screw is fastened.
6 SERVICE, DISMANTLING, ASSEMBLY
3
6.5 ASSEMBLY
Fitting the coupling to the motor with optional hydraulic tool.
a Clean the motor shaft and
apply a thin oil film.
NOTE
Make sure that the
key is in place on the
motor shaft.
b Fit the sleeve to the
stud bolt.
Fit the stud bolt with
sleeve to the motor
shaft.
c Screw the holder to
the coupling nave.
d Fit hydraulic cylinder as
shown.
Hydraulic oil inlet.
e Fit the sleeve and
secure with the nut.
Motor shaft
Sleeve
Hydraulic cylinder
f Attach the hose from the hand pump to the
hydraulic oil inlet.
Fit the friction coupling by pumping the
handle on the pump until stop.
Release pressure on the hand pump and
adjust the nut on the stud bolt.
Repeat procedure until coupling is
mounted. Note! The pressure on the hand
pump should not exceed 200 bar.
g Remove the hydraulic tool.
h Install and tighten the
washer, spring washer and
screw.
Attach a socket with extension rod and
handle to the screw. Place a piece of
wood according to the illustration.
Repeat until screw is fastened.
G 08 65 4 O 1
Piece of wood
Push the handle to start the rotor
moving, when the handle hits the piece
of wood, the weight and movement of
the rotor tightens the screw.
91
6.5 ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
Assembly of friction blocks
4
Fitting the friction blocks.
Guide pin
a Fit the friction blocks onto the
guide pins
NOTE
NOTE
50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks
Be sure that the pins on the
back of the blocks project into
the grooves in the clutch hub.
b Place the cover in position and secure it with
the snap ring.
Snap ring
G 0 86 54 51
Cover
92
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting the motor.
a Fit a lifting sling to the motor.
Use a shackle from the
separator lifting tool.
Weight of motor with
coupling: approx. 80 kg.
b Lower the motor (while
supported) on to the
separator frame.
It will set on the ledge.
!
ING
WARN
Crush hazard
If not supported, the motor with
coupling may drop when lifted.
c Fit the screws.
Do not tighten until the
belt has been mounted.
d Connect the electrical cables.
G 0 86 4 64 1
5
6.5 ASSEMBLY
NOTE
If carrying out change of friction blocks only,
continue with steps 6 to 7.
If carrying out a complete machine assembly,
continue with the driving device instructions on
page 96.
93
6.5 ASSEMBLY
6
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting the flat belt.
NOTE
Clean the inside of the frame before fitting
the flat belt, and make sure that there is no
oil on the belt.
a Lift up the belt to the middle (centre) of the
spindle pulley.
NOTE
For correct position,
centre the belt on the
spindle pulley camber.
Clearance
b Fit the flat belt to the motor belt pulley.
c Tighten the two upper screws.
d
Tighten all motor attachment screws.
NOTE
G0 85 8 8D1
Do not turn the spindle until the
motor is tightened properly to the
frame.
94
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting the clutch cover.
b Tighten the screws.
a Fit the clutch cover.
G 0 85 8 14 1
7
6.5 ASSEMBLY
95
6.5 ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
6.5.2 Driving device
1
Fitting the bottom bearing holder.
a Fit the wing insert, O-rings
and strainer.
NOTE
Clean the strainer before fitting.
b Secure the wing insert
with the screw secured
with Loctite 222
c To secure the bottom
bearing holder into the
frame, apply Loctite
222 on the surfaces
directly above the
upper O-ring.
d Thread the bottom bearing
holder into the frame and fit
the tool into the bottom
bearing housing.
Socket
Tool
Bottom bearing holder
G 0 8 66 1B 1
e Tighten the holder to a torque of 200 Nm.
96
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting the labyrinth ring.
Frame
a Lubricate and fit the
labyrinth ring o .
G 0 86 63 7 1
2
6.5 ASSEMBLY
97
6.5 ASSEMBLY
3
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting the ball bearing to the top bearing seat o
.
a Heat the top bearing seat in oil to
+80°C above room temperature
(max.125 °C).
!
ING
WARN
Burn hazard
Use protective
gloves when
handling any heated
parts.
b Fit the ball bearing.
NOTE
Always fit a new bearing.
Pre-lubricate before fitting.
Drop some frame oil onto the bearing.
G 0 98 48 5 1
c Fit the snap ring.
!
ING
WARN
Risk for eye injury from flying snap ring
Use the correct pliers for assembly of snap ring to
avoid accidental release.
98
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting the top bearing seat with bearing to the spindle.
Puller
a Heat the top bearing seat
together with the bearing in oil to
+80°C above room temperature
(max.125 °C).
Sleeve
b Wipe off the spindle
and fit the top bearing
seat to the spindle
using the sleeve and
puller.
NOTE
Make sure to fit the bearing seat
correctly or it might get stuck!
G 0 98 4 86 1
4
6.5 ASSEMBLY
99
6.5 ASSEMBLY
5
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting the top bearing housing.
a Fit the axial springs o
bearing housing.
to the top
Axial springs
b Carefully lower the bowl spindle.
Make sure that the springs enter the
recesses on the top bearing seat.
c Lubricate the threads with oil before
assembly.
G 08 66 6 21
d Fit the composite springs o and
plugs to the top bearing housing.
Do not tighten the plugs.
Make sure that the springs enter the
recesses in the top bearing seat.
The plugs should be tightened when
the spindle assembly is mounted into
the frame.
100
6 SERVICE, DISMANTLING, ASSEMBLY
6
6.5 ASSEMBLY
Fitting the spindle pulley.
a Turn the spindle assembly
upside down.
b Wipe off the spindle pulley
seat on the spindle and nave
bore in the spindle pulley with
a dry cloth.
c Fit the spindle pulley
firmly on the bowl
spindle.
NOTE
At least 1mm free space between
support and spindle assembly to
protect the bearing.
G 0 86 67 31
Mount the cap nut to protect the
threads and support the spindle.
Fitting the self-aligning roller bearing o
.
NOTE
Always fit a new bearing.
Pre-lubricate before fitting.
.
a Lower the bearing
onto the spindle
and press down
onto the spindle
pulley using the
special drift tool.
G 0 8 66 87 1
7
101
6.5 ASSEMBLY
8
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting the oil pump.
a Fit O-ring o
onto lubrication oil orifice. Spread oil
film on O-ring.
b Push lubrication oil orifice into oil pump. Be sure to
line up tabs on orifice with slots in pump.
c Lubricate all threads before
assembly.
d Fit the oil pump, tightening
torque 150 Nm.
NOTE
G 08 66 99 1
Clean the oil pump and make
sure that the bottom hole is not
clogged and that all parts have
room temperature before
mounting.
102
6 SERVICE, DISMANTLING, ASSEMBLY
9
6.5 ASSEMBLY
Fitting the fan
a Turn the spindle assembly up-side down.
NOTE
Ensure that the spindle is seated against
the inner ring of the ball bearing.
Silicone grease
b Apply a thin layer of silicone grease
and fit the O-ring o
into the fan.
NOTE
Make sure that the bearing
is pre lubricated before
fitting the fan.
c Place a spanner (or similar) on the spindle pulley
key-grip, as holder-up and fit the fan. Tighten
firmly, by hand, with the pin spanner.
G 0 92 4 03 1
Key-grip
G 0 8 59 24 1
10 Fitting the air deflector.
103
6.5 ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
11 Lowering the spindle assembly into the frame.
a Remove the cap nut from the spindle.
Fit the lifting tool to the spindle assembly and lift it.
!
ING
WARN
Crush hazard
Do not rotate the spindle assembly during lifting. The spindle
assembly may otherwise come loose from the lifting tool.
NOTE
Check that the hole at the bottom of the oil pump is clean before
lowering the assembly down.
b Position the flat belt o so
that the spindle assembly can
pass through when lowering.
See note below.
Check the bottom hole.
c Carefully lower the spindle assembly and position
the bolt holes over the threaded frame holes.
Make sure that the bottom bearing, enters the
bottom bearing holder correctly. Do not use force.
!
ING
WARN
Space
Cut hazard
Do not put fingers between the frame and air
deflector while lowering the assembly.
d Fit and tighten the screws.
NOTE
Check the direction arrows on the belt and the
machine plate for correct position.
e Tighten the plugs firmly.
104
G 08 67 9 71
Make sure that the belt does not get smudged
with oil or grease during handling.
6 SERVICE, DISMANTLING, ASSEMBLY
6.5 ASSEMBLY
12 Fitting the flat belt.
NOTE
Clean the inside of the frame before fitting
the flat belt, and make sure that the belt is
clean.
a Lift up the belt to the middle (centre) of the
spindle pulley.
NOTE
For correct position,
centre the belt on the
spindle pulley camber.
Clearance
b Fit the flat belt to the motor belt pulley.
c Tighten the two upper screws.
Tighten all motor attachment screws.
NOTE
Do not turn the spindle until the
motor is tightened properly to the
frame.
G 0 85 88 B 1
d
105
6.5 ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
13 Fitting the neck bearing cover and deflector ring.
a Apply a thin layer of oil and fit the
O-rings and seal rings o
Deflector ring
b Fit the neck bearing cover.
NOTE
The guide pin on the cover should enter one of
the two holes in the bearing housing.
Neck bearing cover
G 0 86 8 09 1
c Push the deflector ring
down until it stops.
106
6 SERVICE, DISMANTLING, ASSEMBLY
6.5 ASSEMBLY
14 Fitting the operating water cover.
O-ring
a Lubricate with oil and fit the seal
ring and O-ring o into the
operating water cover.
Renew the O-ring o
b Fit the operating water cover. Fit washers
and tighten the screws.
NOTE
G 08 68 14 1
The water pipe in the frame should
enter the hole in the cover.
15 Measuring the radial wobble of the bowl spindle.
NOTE
Permissible radial wobble: max. 0,04
mm. If the spindle wobble exceeds
this value, contact an Alfa Laval
representative.
Max. 0,04 mm
G 08 58 71 1
a Fit a dial indicator in a support
and fasten it in position as
illustrated. Use the flat belt to
turn the spindle.
107
6.5 ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
16 Fitting the clutch cover.
G 08 58 1 41
b Tighten the screws.
a Fit the clutch cover.
17 Fill oil in the oil sump.
NOTE
The separator should be level and at
standstill when oil is filled.
b Fit new washer i
plug.
and refit the drain
c Fill with new oil until oil flows out from
the filler hole.
For correct oil volume see
‘‘Lubricating oil volume” on page 148.
NOTE
For grade and quality of oil see
6.7.6 Lubricating oils, page 138
d Fit new O-ring i
onto the oil pin.
e Refit the plug with new washer i
f Fit the oil pin.
108
G 08 6 87 G 1
a Remove the oil pin, plug and washer.
6 SERVICE, DISMANTLING, ASSEMBLY
6.5 ASSEMBLY
6.5.3 Bowl
1
Check for impact marks and corrosion in bowl
o .
body nave and on spindle taper i
!
a Remove any impact marks using
a scraper and/or a whetstone.
ON
CAUTI
Disintegration hazard
Impact marks may cause the separator to
vibrate while running.
b Rust can be removed by using a
fine-grain emery cloth (e.g. No. 320).
c Finish with polishing paper (e.g. No. 600).
G 0 87 4 61 1
d Lubricate to prevent further corrosion.
Fitting new valve plugs on the operating slide i i .
b Carefully tap in new valve plugs, using a
clean, soft-faced hammer.
NOTE
Make sure that the plugs are fitted as
described in the illustration.
G 0 87 4 87 1
2
109
6.5 ASSEMBLY
3
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting the operating slide.
a Apply a thin layer of silicone grease and fit the
rectangular ring on the operating slide and the
rectangular ring and O-ring on the bowl body.
o .
i
b Fit the operating slide.
NOTE
The guide pin in the bowl body
should enter the hole in the
operating slide (this hole is
marked with a drill mark).
Nozzle secured with Loctite 222
Alignment hole
Operating slide
Guide pin
Fitting the operating slide holder.
a Fit the holder over the
operating slide.
b Apply a thin layer of molykote grease and
fit and tighten new screws and washers
o to a torque of 30 Nm + 2 Nm.
i
NOTE
It is very important not to refit used screws
and washers. Always fit new ones included
in the Inspection kit!
110
G 0 8 61 34 1
4
G 0 86 12 41
Bowl body
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting the operating water ring.
NOTE
a Fit the ring and screws i
o
.
It is very important not to refit used screws.
Always fit new ones included in the
Inspection kit!
b Apply a thin layer of silicone grease
o
and fit the O-ring i
c Fit the operating water ring.
NOTE
The drilled assembly mark on the water ring should
face the corresponding mark on the bowl body.
d Grease, fit and tighten the screws to a torque of
30 Nm + 2 Nm.
G 08 61 44 1
5
6.5 ASSEMBLY
111
6.5 ASSEMBLY
6
6 SERVICE, DISMANTLING, ASSEMBLY
Lifting the bowl body onto the spindle taper.
a Put a drop of oil on the spindle taper.
b Wipe off the spindle taper and
nave bore with a dry cloth.
c Turn the bowl body over.
!
ING
WARN
Crush hazard
Support the bowl body when turning to
prevent it from rolling.
d Fit the lifting
tool and lift the
bowl body.
e Carefully lower the bowl body
onto the spindle taper.
G 08 6 17 31
f Remove the lifting tool.
112
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting and tightening the cap nut.
a To prevent the bowl body from rotating
when fitting the cap nut; Fit one of the
clamps (see page 51) to the bowl body
and one of the screws for the frame
hood in the frame. Fasten a sling
between the clamp and the screw
around the bowl body.
b Apply a thin layer of
molykote grease. Fit and
tighten the cap nut to a
torque of 50 Nm.
NOTE
Left-hand thread!
Sling
Screw
Clamp
G 0 86 18 6 1
7
6.5 ASSEMBLY
Cap nut
113
6.5 ASSEMBLY
8
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting the discharge slide.
a Apply a thin layer of silicone grease and
o .
fit the rectangular ring i
O-ring
b Apply a thin layer of silicone grease
o
and fit the O-ring i
!
c Fit the lifting tool and
lower the discharge
slide into the bowl.
ING
WARN
Crush hazard
d Remove the lifting tool.
The ring on the lifting tool must be
pushed home against the discharge
slide, otherwise it may come loose
from the tool.
e Fit the nut.
g Remove the spanner for nut.
114
G 0 86 19 6 1
f Fit the spanner for nut and
tighten the nut with a torque
wrench to a torque of min.
200 Nm.
6 SERVICE, DISMANTLING, ASSEMBLY
Assembly of the disc stack.
a Fit the discs one by one onto the distributor.
The distributor has a guide rib for the correct
positioning of the bowl discs. Always end with
the disc without caulks.
ING
WARN
!
The number of discs may have to be increased
to adjust the disc stack pressure. Always check
before operating the separator. See ‘‘Checking
the disc stack pressure” on page 121
!
ON
CAUTI
Cut hazard
Sharp edges on the bowl discs may cause
cuts.
Recess on bowl disc
Guide rib on distributor
G 0 8 62 05 1
9
6.5 ASSEMBLY
115
6.5 ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
10 Fitting the disc stack assembly to the bowl body.
a Fit the lifting tool into the
distributor.
b Lower the disc stack into the bowl.
Guide pin on bowl
body
NOTE
The guide pin on the bowl body should face
the guide rib on the distributor.
The guide ribs inside the distributor then
enter the recesses on the bowl body nave.
Guide rib on
distributor
Guide ribs inside the distributor.
G 08 62 1 71
Recesses on the bowl body nave.
116
6 SERVICE, DISMANTLING, ASSEMBLY
6.5 ASSEMBLY
11 Assembling the paring tube and bearing holder
i
.
a Apply a thin layer of silicone grease to the
o and bearing
O-ring. Fit the O-ring i
o to the paring tube.
bushing i
Bearing bushing
O-ring
b Fit the flanged
o
bushing i
to the bearing
holder.
Flanged bushing
c Mount the bearing holder with
the flanged bushing into the
paring tube.
G 0 98 49 31
Bearing holder
12 Mounting the paring tube and fitting the inlet and outlet pipe.
b Apply a thin layer of silicone grease
and mount the splash sealing i
c Apply a thin layer of
silicone grease and fit
the O-rings
o to the pipe.
i
d Carefully lower the inlet and
outlet pipe assembly into the
top of the distributor.
G 0 86 22 M 1
a Insert the
paring tube
and mount
the axial
support to
the inlet and
outlet pipe.
117
6.5 ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
13 Fitting the top disc.
a Move the paring tube
to the centre.
b Lower the top disc.
The guide rib on the
distributor should enter
one of the two larger
recesses on the top disc.
NOTE
G 08 6 23 51
To avoid damaging
the paring tube, turn
it towards the centre
of the pipe.
118
6 SERVICE, DISMANTLING, ASSEMBLY
6.5 ASSEMBLY
14 Fitting the bowl hood.
a Apply a thin layer of silicone grease and fit the
o
O-ring i
o
b Fit the seal ring i
Press
the ring down evenly until bulges
appear.
c Carefully tap down the bulges crosswise with a soft
rubber mallet, until the ring is completely fitted.
d Fit the compressing tool and attach
lifting eyes. Lower the bowl hood so that
its recess fits into the guide pin in the
bowl body.
Recess on bowl hood
Guide pin on bowl body
G 08 62 48 1
e Remove the compressing tool.
119
6.5 ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
15 Fitting the lock ring.
a Place the lock ring on the bowl hood
with its guide pin close to the
corresponding hole in the bowl
body.
NOTE
Make sure that the groove in
the bowl body which retains
the lock ring is clean.
b Fit the complete compressing
tool and compress the disc stack
by alternately turning the screws
a maximum of 40 Nm at a time
until the lock ring fits into the
bowl body. The lock ring is
correctly fitted when the lock ring
ends are facing each other.
NOTE
Check that the lock ring is
correctly positioned all way
around!
For correct disc stack pressure
see page 121
c Release the
pressure on the
compressing
tool and
remove it.
NOTE
Never remove
any material
from the lock
ring. A
hazardous
situation could
result.
Lock ring
Bowl hood
Before compressing
120
Lock ring in position
G 08 62 5 61
Bowl body
6 SERVICE, DISMANTLING, ASSEMBLY
6.5 ASSEMBLY
16 Checking the disc stack pressure i i
a Remove bowl hood, top disc and inlet and outlet pipe.
b Add one disc to the disc stack.
c Refit the disc without caulks, the top disc
and bowl hood.
d Fit the lock ring and fully compress
the disc stack with the compressing
tool.
NOTE
Do not use more power than 50
Nm/screw at a time, alternately.
NOTE
Always refit the disc
without caulks on top
of the disc stack!
e If the lock ring enters the groove,
repeat a-d until the lock ring does
not enter the groove.
G 0 87 49 71
f Dismantle the bowl and remove
one disc to get the correct disc
stack pressure.
g Assemble the bowl with
inlet and outlet pipe.
121
6.5 ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
6.5.4 Frame hood
1
Fitting the frame hood i
o
.
a Turn the paring tube so that
the frame hood can pass.
Paring tube.
NOTE
b Apply a thin layer of silicone grease and
fit the O-ring onto the frame hood
o
i
c Lower the frame hood.
Make sure that the frame
hood is mounted in its
correct position
according to the piping
arrangement.
d Fit and tighten the
screws.
Make sure to fit the frame hood
groove and the projection of the
pipe.
122
G 0 86 3 79 1
NOTE
6 SERVICE, DISMANTLING, ASSEMBLY
Control measurement of paring disc height o
.
a Remove the guide screw (A).
b Measure the distance D.
Assemble the correct
number of height
adjusting rings (B).
c Refit the guide screw (A).
Support ring
Height adjusting rings
Guide screw
Frame hood
Bowl hood
Paring disc
Distributor
G 0 91 15 Q 1
2
6.5 ASSEMBLY
Alfa Laval ref. 574285, rev. 1
123
6.5 ASSEMBLY
3
Fitting the spring o
6 SERVICE, DISMANTLING, ASSEMBLY
and arm.
Spring
a Fit the spring on the arm
and fit the arm to the top
of the paring tube end
and fit the screw.
Screw
Pin
Arm
Paring tube
G 08 63 7 A1
b Fit the spring to the pin
on the frame hood and
make sure that it is
properly attached on
both ends.
124
6 SERVICE, DISMANTLING, ASSEMBLY
Fitting the connection housing.
a Fit the connection housing over
the inlet/outlet pipe.
b Fit the washer and the lock
nut using the hook spanner.
NOTE
Make sure that the screw, on top of
the frame hood, enters the guide
hole at the underside of the
connecting housing.
G 0 86 35 91
4
6.5 ASSEMBLY
125
6.5 ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
6.5.5 Unbalance sensor (optional)
1
Fitting the unbalance sensor holder.
a Remove the cover.
Sensor holder.
Sensor arm
Frame
Screw M8
M10
b Fit the O-ring on the holder.
Fit the screw into the holder and
mount the holder into the
separator frame.
Sensor
holder
O-ring
NOTE
If removing the sensor holder;
use a M10 screw as a puller.
NOTE
G 0 87 34 8 1
See next page for fitting and
correct adjustment of the sensor.
126
6 SERVICE, DISMANTLING, ASSEMBLY
2
6.5 ASSEMBLY
Adjusting the unbalance sensor
a Fit the sensor into the holder. Do not forget the nut.
b Adjust the sensor so that a value of 1,5 appears on the display.
Nut
Sensor
Nut.
+ = brown or red
J = black or white
A
G 24 V DC
0V = blue
Adjustment value for the sensor is; 12 mA ± 1mA.
For more details see 8.3 Connection List, page 149 and
752 Unbalance sensor (optional)., page 156.
G 0 87 3 4A 1
c When correct distance is achieved tighten the nut
against the holder.
Fit the cover (see previous page).
127
6.5 ASSEMBLY
6 SERVICE, DISMANTLING, ASSEMBLY
6.5.6 Speed sensor
1
Adjusting the speed sensor
a Adjust the speed sensor. Distance A = 73 + 0,1 mm.
NOTE
G 08 73 4 E1
b Fit the sensor to the frame, see 4.4 Sensors, page 24.
If the sensor does not work
properly, check the distance
between the sensor and the
spindle belt pulley.
Adjust the sensor to achieve
measure (B) shown below.
G 08 58 8O 1
Spindle belt pulley
NOTE
The distance (B) between the
sensor and the spindle belt
pulley must be 2,5 + 0,5 mm
128
6 SERVICE, DISMANTLING, ASSEMBLY
6.6 ACTIONS AFTER ASSEMBLY
6.6 Actions After
Assembly
6.6.1 Control of machine plates and
safety labels o
Alfa Laval ref. 561498 rev. 3
1
Check that the following signs are attached.
Machine plate
Space for label indicating representative.
Safety label.
Lifting instructions
Space for
additional label as
specified.
S 00 50 1D 1
Oil type plate
Indicating direction of rotation of horizontal driving device.
129
6.6 ACTIONS AFTER ASSEMBLY
2
6 SERVICE, DISMANTLING, ASSEMBLY
Check legibility. Following texts should be read on the labels.
Separator
Manufacturing serial No. / Year
Product No.
In and outlet device
Bowl
Machine bottom part
Bowl speed synchronous
Direction of rotation (bowl)
Speed motor shaft
El. current frequency
Recommended motor power
Max. density of feed
Max. density of sediment
Max. density of operating liquid
Process temperature min./max.
! WA R N I N G
XXXXXXXXXXXXXXXXX
XXXX XXXX XXXX
XXXXXXXXXXXX XXX
XXXXXXX XXXXX XX
XXXXX XXXXXXX
XXXXXXXXX.
XXX XXX X XXX XX XXXX
XXXX XX X X XXXXX XXX
X XXX XXXX XXX XX XX X
X XXX X XXX.
XX X XXXXX XX X XXXX
XXX XXX X XXXXXX
XXX XXX XXX X XXXXX
XXX X XXXX .
XXXXX XXX XXXX XXX
XXXXX XXXX X XXXX XXX XXXXX X XXXXX XX X
XXX XX XXX XXX XX X.
XX.
XXXXXXX/XX,X XX
WARNING
Read the instruction manuals before installation, operation and maintenance.
Consider inspection intervals.
Failure to strictly follow instructions can lead to fatal injury.
If excessive vibration occurs, stop separator and keep bowl filled with liquid
during rundown.
Out of balance vibration will become worse if bowl is not full.
Separator must stop rotating before any dismantling work is started.
Read instruction manual before lifting.
130
6 SERVICE, DISMANTLING, ASSEMBLY
6.7 OIL CHANGE
6.7 Oil Change
The separator should be level and at
standstill when oil is filled or the oil level is
checked.
6.7.1 Lubricating oil
Do not mix different oil brands.
Always use clean vessels when handling lubricating oil.
Great attention must be paid not to contaminate the lubricating oil. Of
particular importance is to avoid mixing of different types of oil. Even a
few drops of motor oil mixed into a synthetic oil may result in severe
foaming.
Any presence of black deposits in a mineral type oil is an indication that
the oil base has deteriorated seriously or that some of the oil additives
have precipitated. Always investigate why black deposits occurs.
If changing from one oil brand to another it is recommended to do this
in connection with an overhaul of the separator. Clean the gear housing
and the spindle parts thoroughly and remove all deposits before filling
the new oil.
NOTE
Always clean and dry parts (also tools) before lubricants are applied.
!
ON
CAUTI
Check the oil level before start. Top up when necessary.
Oil volume = see “Technical Data”.
It is of utmost importance to use the lubricants recommended in our
documentation.
This does not exclude, however, the use of other brands, provided they
have equivalently high quality properties as the brands recommended.
The use of oilbrands and other lubricants than recommended, is done
on the exclusive responsibility of the user or oil supplier.
Applying, handling and storing of lubricants
Always be sure to follow lubricants manufacturer's instructions.
131
6.7 OIL CHANGE
6 SERVICE, DISMANTLING, ASSEMBLY
6.7.2 Check oil level
1
Remove the oil pin and make sure that the oil
level is above the lower end of the pin.
6.7.3 Oil change procedure
1
Remove the oil pin, plug and washer.
2
Place a vessel under the drain plug.
3
Remove the drain plug.
!
ON
CAUTI
Burn hazard
Oil fill
Plug and washer
The lubricating oil and various machine surfaces can
be sufficiently hot to cause burns.
Oil drain plug
Collect the oil in a vessel.
5
Fit and tighten the drain plug.
6
Fill with new oil until oil flows out of oil filler
hole.
Max.
Min.
G 08 68 7H 1
4
NOTE
See 6.7.6 Lubricating oils, page 138.
NOTE
7
Fit the washer and the oil filling plug. Tighten
the plug.
8
Fit the oil pin.
132
For Inspection service procedures; See
“Fill oil in the oil sump.” on page 108.
6 SERVICE, DISMANTLING, ASSEMBLY
6.7 OIL CHANGE
6.7.4 Lubrication chart
Alfa Laval ref. 567329-01, rev. 2
Bowl (3), Rubber seal rings (4)
Electric motor (6)
Bowl spindle taper (2)
Buffers (3)
Plug thread (7)
Bowl spindle and bearings (1)
G 0 8 75 44 1
Friction clutch bearings (5)
Lubricating points
Type of lubricant
Interval
The oil bath. Bowl spindle bearings
are lubricated by oil mist from the oil
bath.
See 6.7.1 Lubricating oil, page 131
Volume: 8.2 Technical Data, page 148
Ambient temperature 0 to +55°C
Oil change:
2
Bowl spindle taper.
Lubricating oil, only a few drops for
rust protection.
At assembling
3
Bowl: Sliding contact surfaces, thread
of lock nut and cap nut.
Pastes specified in 6.7.5 Lubricants,
page 134
At assembling.
4
Rubber seal rings.
Grease as specified in 6.7.5
Lubricants, page 134
At assembling
5
Friction clutch bearings.
The bearings are pre-lubricated with
grease.
No need for extra lubrication.
6
Electric motor.
Follow the manufacturer’s instructions.
Follow the manufacturer’s instructions.
7
Plug thread
(neck bearing assembly)
Lubricating oil.
At assembly.
1
NOTE
!
Check and pre lubricate new spindle bearings and
those that have been out of service for one month or
longer.
If not otherwise specified, follow the suppliers
instructions about applying, handling and storing of
lubricants.
1. Continous operation: 4000 hours
2. Seasonal operation:
before every operating period
3. Short periods operation:
12 months even if total numbers of
operating hours is less than stated
above
ON
CAUTI
Check the oil level before start.
Top up when necessary.
Do not overfill.
133
6.7 OIL CHANGE
6 SERVICE, DISMANTLING, ASSEMBLY
6.7.5 Lubricants
Alfa Laval ref. 553217-01 rev. 10
NOTE
The data in below tables is based on supplier
information in regards to lubrication properties.
Trade names and designations might vary from
country to country, contact your local supplier for
more information.
Brands with Alfa Laval article numbers are
approved and recommended for use.
Pastes for non-food applications:
Manufacturer
Designation
Fuchs Lubritech
Gleitmo 805K
Alfa Laval No
Gleitmo 705
Dow Corning
Molykote 1000 (Paste)
537086-02(1000 g)
Molykote 1000 (Paste)
537086-03 (100 g)
Molykote G-rapid plus (Paste)
537086-04 (50 g)
Rocol
Dry Moly Paste
MT-LM
Klüber
Wolfracoat C (Paste)
Bonded coatings:
Manufacturer
Designation
Fuchs Lubritech
Gleitmo 900 (Varnish or spray)
Dow Corning
Molykote D321R (Spray)
535586-01(400 ml)
Molykote D321R (Varnish)
535586-02 (60 ml)
Molykote D321R (Paste)
535586-80 (25 ml)
134
Alfa Laval No
6 SERVICE, DISMANTLING, ASSEMBLY
6.7 OIL CHANGE
Pastes for hygienic applications
(NSF registered H1 is prefered):
Manufacturer Designation
Hygienic Comment
Fuchs Lubritech
Gleitmo 805
DVGW (KTW) approval for
drinking water
(TZW prüfzeugnis)
Geralyn 2
NSF Registered H1
(3 sep 2004)
Bremer & Leguil,
Fuchs Lubritech
Rivolta F.L.A
NSF Registered H1
(15 Feb 2003)
German §5 Absatz 1 LMBG
approved
Dow Corning
Molykote TP 42
Alfa Laval No
561764-01 (50 g)
Molykote D
Klüber
Rocol
Molykote P1900
NSF Registered H1
(7 Jan 2004)
Klüberpaste 46 MR 401
White; contains no lead,
cadmium, nickel, sulphur nor
halogens.
Klüberpaste UH1 96-402
NSF Registered H1
(25 Feb 2004)
Foodlube Multi Paste
NSF Registered H1
(13 Apr 2001)
135
6.7 OIL CHANGE
6 SERVICE, DISMANTLING, ASSEMBLY
Silicone grease for rubber rings:
Manufacturer
Designation
Follows according. to
Manufacturer
Dow Corning
Molykote 111
(Compound)
Conform to the FDA regulations (21 539474-02 (100 g)
CFR 178.3570) for occasional food
contact. Certified: National Water
539474-03 (25 g)
Council UK and WRC, UK.
Certified: food industry as per
Chemical Testing Laboratory Dr.
Böhm, Munich.
Molykote 111
(Compound)
Fuchs Lubritech
Molykote Foodslip SR
grease
Former USDA H1 approved.
Chemplex 750
DVGW approved according to the
German KTW-recomendations for
drinking water.
Bremer & Leguil Rivolta NSF Registered H1
F.L.G MD2
(15 Feb 2003)
Klüber
Unisilkon L 250 L
Complies with German
Environmental Agency on hygiene
requirements for tap water.
Certified by DVGW-KTW, WRC,
AS4020, ACS.
Paraliq GTE 703
NSF Registered H1 (25 Feb 2004)
Complies with LMBG and the
European standard EN 1672,
part2.
Bel-Ray
No-Tox Silicone valve
seal
NSF Registered H1
(19 June 2002)
MMCC
ALCO 220
NSF Registered H1
(25 March 2002)
Rocol
Foodlube Hi-Temp
NSF Registered H1
(18 April 2001)
136
Alfa Laval No
569415-01 (50 g)
6 SERVICE, DISMANTLING, ASSEMBLY
6.7 OIL CHANGE
Greases for ball and roller bearings:
NOTE
Always follow the specific recommendation for
lubrication as advised by the manufacturer.
Manufacturer
Designation
BP
Energrease MP-MG2
Alfa Laval No
Energrease LS2
Energrease LS-EP2
Castrol
APS 2
Spheerol EPL 2
Chevron Texaco
Chevron Dura-Lith Grease EP2
Texaco Multifak AFB 2
Dow Corning
Molykote G-0101
Molykote Multilub
ExxonMobil
Beacon EP2
Unirex N2
Mobilith SHC 460
Mobilux EP2
Fuchs Lubritech
Lagermeister EP2
Q8/Kuwait Petroleum
Rembrandt EP2
Shell
Alvania EP 2
Albida EP2
SKF
LGEP 2
LGMT 2
Total
Multis EP2
137
6.7 OIL CHANGE
6 SERVICE, DISMANTLING, ASSEMBLY
6.7.6 Lubricating oils
Alfa Laval ref. 567330-01, rev. 2
Paraffinic mineral lubricating oil,
category (ISO-L-) HM 68.
Viscosity grade (ISO-3448/3104) VG 68.
The oil shall follow the requirements in one of
the standards below.
Standard
Designation
DIN 51524 part 2 or 3* (German standard)
DIN 51524-HLP or HVLP* 68
ISO 11158 (International standard)
ISO-L-HM or HV* 68
Viscosity index (ISO 2909) VI>95
The following is the list of recommended oil
brands. Trade names and designations might
vary from country to country. Please contact
your local oil supplier for more information.
Manufacturer
Designation
Alfa Laval
567334-01
1 litre
567334-02
4 litres
BP
Bartran 68
Bartran HV 68*
Castrol
Hyspin AWS 68
Hyspin AWH(-M) 68*
ChevronTexaco / FAMM
Hydraulic oil AW 68
Rando HD 68 (H2)
Rando HDZ 68 (H2)*
Rykon Premium 68 (H2)*
ExxonMobil
Nuto H 68
Univis N 68*
Mobil DTE 16 (ISO VG 68)
Mobil DTE 16M (ISO VG 68)*
Q8/Kuwait Petroleum
Haydn 68
Shell
Tellus Oil 68
Tellus Oil S 68
Tellus Oil T 68*
Statoil
HydraWay HMA 68
Hydra Way HVXA 68*
Total
Azolla ZS 68
Elf Lubmarine Visga 68*
* These oils should be used at cold start, i.e. when the ambient temperature is
below 20 oC.
The list of recommended oil brands is not complete. Other oil brands may be
used as long as the follow the above standards and have equivalent high quality
as the brands recommended. The use of other lubricants than recommended is
done on the exclusive responsibility of the user or oil supplier.
138
6 SERVICE, DISMANTLING, ASSEMBLY
6.8 LIFTING INSTRUCTIONS
6.8 Lifting instructions
Alfa Laval ref. 567319, rev. 1
6.8.1 Lifting the separator
Weight to lift 275 kg
Sling length: Min. 750 mm
G 08 68 4 51
Fasten all four bolts. Tightening
torque 35 - 40 Nm
1
Remove the inlet and outlet device, the
frame hood and the bowl according to the
instructions in 6.3 Dismantling, page 46.
NOTE
Never lift or transport the separator with the bowl
still inside.
2
Disconnect all connections.
3
Fit the lifting tool (not included in set of tools).
All four bolts on the lifting tool must be
fastened to the frame.
4
Use two lifting slings to lift the separator.
Total length of each loop: minimum 1,5
metres.
139
6.8 LIFTING INSTRUCTIONS
5
Unscrew the foundation bolts.
6
When lifting and moving the separator, follow
normal safety precautions for lifting large
heavy objects.
!
6 SERVICE, DISMANTLING, ASSEMBLY
ING
WARN
Crush hazards
A falling separator can cause accidents resulting
in serious injury and damage.
Never lift the separator by any other method than
described in this manual.
NOTE
When lifting parts without weight specifications,
always use lifting straps with the capacity of at
least 500 kg.
6.8.2 Lifting the bowl
When lifting and moving an assembled
bowl, always follow these instructions.
Weight to lift 37 kg
1
Fit the lifting tool with lifting eyes to the bowl
assembly.
2
Check that the lock ring is mounted correctly
before lifting the complete bowl.
3
Lift the bowl using a sling with the proper
rating.
Tightening torque 35 - 45 Nm
NOTE
Never try to lift the bowl while it is still in the frame.
The bowl body is fastened to the frame with the
cap nut.
Lock ring
G 08 68 4 71
Make sure that
lock ring is fitted.
140
SEPARATOR MANUAL
7 FAULT FINDING
7 Fault Finding
These fault finding instructions are for the
separator only.
If a fault occurs, study the System
Documentation fault finding section (if
applicable).
7.1 Mechanical Functions
7.1.1 Separator vibration
!
ING
WARN
Disintegration hazards
NOTE
If excessive vibration occurs, stop separator and
keep bowl filled with liquid during rundown.
The cause of the vibration must be identified and
corrected before the separator is restarted.
Some vibration is normal during the starting and
stopping sequences when the separator passes
through its critical speed.
Cause
Corrective action
Bowl out of balance due to:
Dismantle the separator and check the assembly
and cleaning.
- poor cleaning
- incorrect assembly
- incorrect disc stack compression
- bowl assembled with parts from other separators
Uneven sludge deposits in the sludge space.
Dismantle and clean the separator bowl.
Height position of paring disc is incorrect.
Stop the separator, measure, and if necessary,
adjust the height.
Bowl spindle bent.
Renew the bowl spindle.
Bearing(s) damaged or worn.
Renew all bearings.
The frame feet are worn out.
Renew the frame feet.
Spindle top bearing spring broken.
Renew all springs.
578701-02
141
7.1 MECHANICAL FUNCTIONS
7 FAULT FINDING
7.1.2 Smell
Cause
Corrective action
Normal occurrence during start while the friction
blocks are slipping.
None.
If smell continues when separator is at full speed,
stop the separator and replace friction blocks.
Oil level in oil sump too low.
Check oil level and add oil if necessary.
7.1.3 Noise
Cause
Corrective action
Height position of paring disc is incorrect.
Stop the separator, measure and adjust the height.
Bearing(s) damaged or worn.
Renew all bearings.
7.1.4 Speed too low
Cause
Corrective action
Friction blocks are oily or worn.
Clean or renew friction blocks.
Bowl is not closed or leaking.
Dismantle the bowl and check.
Motor failure.
Repair the motor.
Bearing(s) damaged.
Renew all bearings.
Incorrect transmission parts (60 Hz belt pulley for
50 Hz power supply).
!
ING
WARN
Stop and change the belt transmission to
suit the power supply frequency.
7.1.5 Speed too high
Cause
Corrective action
Incorrect transmission parts (50 Hz belt pulley for
60 Hz power supply).
!
ING
WARN
Stop and change the belt transmission to
suit the power supply frequency.
142
7 FAULT FINDING
7.1 MECHANICAL FUNCTIONS
7.1.6 Starting power too high
Cause
Corrective action
Incorrect transmission parts (60 Hz belt pulley for
50 Hz power supply).
!
ING
WARN
Stop and change the belt transmission to
suit the power supply frequency.
Wrong direction of rotation.
Change electrical phase connections to the motor.
7.1.7 Starting power too low
Cause
Corrective action
Incorrect transmission parts (50 Hz belt pulley for
60 Hz power supply).
!
ING
WARN
Stop and change the belt transmission to
suit the power supply frequency.
Friction blocks are oily or worn.
Clean or renew friction blocks.
Motor failure.
Repair the motor.
7.1.8 Starting time too long
Cause
Corrective action
Friction blocks are oily or worn.
Renew or clean friction blocks.
Height position of paring disc is incorrect.
Stop, check and adjust the height.
Motor failure.
Repair the motor.
Bearing(s) damaged or worn.
Renew all bearings.
143
7.2 SEPARATING FUNCTIONS
7 FAULT FINDING
7.2 Separating Functions
7.2.1 Bowl opens accidentally
during operation
Cause
Corrective action
Strainer in the operating water supply is clogged.
Clean the strainer.
No water in the operating water system.
Check the operating water system and make sure
the valve(s) are open.
Hoses between the supply valves and separator are
incorrectly fitted.
Correct.
Nozzle in operating slide clogged.
Clean the nozzle.
Rectangular ring in discharge slide is defective.
Renew the rectangular ring.
Valve plugs are defective.
Renew all plugs.
Supply valve for opening water is leaking.
Rectify the leak.
7.2.2 Bowl fails to open for sludge
discharge
Cause
Corrective action
Strainer in the operating water supply is clogged.
Clean the strainer.
Water flow too low.
Check the water flow
Hoses between the supply valves and separator are
incorrectly fitted.
Correct.
Nozzle in operating slide missing.
Fit the nozzle.
Rectangular ring in the operating slide or bowl body
is defective.
Renew the rectangular rings.
7.2.3 Unsatisfactory separation
result
Cause
Corrective action
Incorrect separation temperature.
Adjust.
Throughput too high.
Adjust.
Disc stack is clogged.
Clean disc stack.
Sludge space in bowl is filled.
Clean and reduce the time between sludge
discharges.
Bowl speed too low.
Examine the motor and power transmission including
the belt transmission (clutch).
Bowl rotates i wrong direction
Check the electrical connections to the motor.
144
7 FAULT FINDING
7.2 SEPARATING FUNCTIONS
7.2.4 Bowl fails to close
Cause
Corrective action
Nozzle in operating slide clogged.
Clean nozzle.
Hoses reversed.
Adjust.
Rectangular ring in discharge slide is defective
Renew rectangular ring.
Valve plugs in operating slide missing or defective.
Renew valve plugs.
No water.
Turn on water supply.
145
7.2 SEPARATING FUNCTIONS
146
7 FAULT FINDING
8 Technical Reference
8.1 Product description
Alfa Laval ref. 574276, rev. 2 & 574277, rev. 2
NOTE
The separator is a component operating in an
integrated system including a monitoring system.
If the technical data in the system description does
not agree with the technical data in this instruction
manual, the data in the system description is the
valid one.
Product number. 881201-05-01/2 & 881201-06-01/3
Separator type. S 821 & S 826
Application. Cleaning of fuel oil and lube oil.
Intended for marine- and land installations.
Total discharge.
Centrilock® lock ring
Designed in accordance with standards:
98/37EC
The Directive of the European Parliament and Council relating to
machinery.
89/336EEC
EMC and amendments related to said directive.
EN 12547
Centrifuges - Common safety requirements.
Operational limits:
Feed temperature: 0°C to 100°C
Ambient temperature: 5°C to 55°C
Discharge intervals: min. 2 minutes max. 4 hours.
Maximum allowed density of operating liquid:
1000 kg/m3.
Viscosity max. 700 cSt at 50°C.
Not to be used for liquids with flashpoint below
60°C.
Risk for corrosion and erosion have to be
investigated in each case.
Remote restart allowed under certain conditions,
see Interface description.
147
8.2 TECHNICAL DATA
8 TECHNICAL REFERENCE
8.2 Technical Data
Alfa Laval ref. 574297, rev. 1
NOTE
The separator is a component operating in an
integrated system including a monitoring system.
If the technical data in the system description does
not agree with the technical data in this instruction
manual, the data in the system description is the
valid one.
Subject
Value
Unit
Motor power: 50 Hz / 60 Hz
5,5 / 6,4
kW
Gear ratio
283 / 70
50Hz
Gear ratio
235 / 70
60Hz
Alarm levels for vibration monitor,
connection 752, 1st/2nd
0,2 / 0,3
mm
Bowl max. inner diameter
208,5
mm
Discharge interval, min./max.
2 / 240
minutes
Max. density of operating liquid
1000
kg/m³
Max. density of feed/sediment
1100 / 2327
kg/m³
Feed temperature, min./max.
0 / 100
°C
- empty bowl
30
minutes
- filled bowl
30
minutes
Bowl body material
AL 111 2377-02
General technical data:
Max. running time without flow,
Operating data:
Bowl speed, synchronous
12129/12086
r/min 50Hz/60Hz
Motor speed synchronous
3000 / 3600
r/min 50Hz/60Hz
Power consumption at start-up, max.
6,4
kW
Power consumption idling/max.
capacity:
2,6 / 6,3
kW
Starting time, min./max.
100 / 120
seconds
Stopping time min./max.
18 / 22
minutes
Sound power
9
Bel(A)
Sound pressure
76
dB(A)
Vibrations, separator in use
9,1
mm/s
Max. hydraulic capacity, bowl
5,5
m³/h (water at 3,5 bar)
Bowl liquid volume
1,8
litres
Fixed discharge volume
1,6
litres
Sludge volume, efficient/total
0,23 / 0,74
litres
Lubricating oil volume
1,7
litres
Motor drive
58
kg
Bowl
35
kg
Separator total
315
kg
Volume and capacity data:
Weight information:
148
8 TECHNICAL REFERENCE
8.3 CONNECTION LIST
8.3 Connection List
Alfa Laval ref. 567321 rev. 0
No.
Description
201
Inlet for process liquid
206
220
Requirements/limits
• Allowed temperature
Min. 0 °C, max. 100 °C
• Max allowed density
See ‘‘Technical Data” on page 148
• Allowed flow
Max 4,5 m3/h
Inlet for conditioning and displacement liquid
Fresh water
• Instantaneous flow
0,9 litres/minute
Outlet for light phase, clarified liquid
• Counter pressure
0 - 250 kPa
221
Outlet for heavy phase
No counter pressure.
222
Outlet for solid phase
• Small discharge
• Large discharge
Total discharge
• Discharge frequency
Max 24 discharge/h.
The outlet from the cyclone must always be
arranged to prevent the cyclone from being
filled up with sludge. Solids are discharged
by gravity.
375
Inlet for discharge and make-up liquid
• Quality requirements
See page 161.
• Max density
Max. 1000 kg/m3
• Pressure
Min. 150 kPa
Make-up liquid
• Flow (momentary)
2,8 litres/minute
• Consumption
1,7 litres/hour
• Interval
5 minutes
• Time
3 seconds
Discharge liquid
• Flow
11 litres/minute
• Consumption
0,55 litres/discharge
• Time
3 seconds
Closing liquid
• Flow
2,8 litres/minute
• Consumption
0,7 litres/discharge
• Time
15 seconds
Start up closing liquid
• Flow
11 litres/minute
• Time
5 seconds
149
8.3 CONNECTION LIST
462
Drain of frame top section, lower
701
Motor for separator
(momentarily during 5 seconds)
± 5%
± 10%
Speed sensor for bowl spindle
See page 155.
• Type
Inductive promixly switch
• Supply voltage, nominal
8V
• With sensor activated (near metal)
Less or equal to 1 mA.
• With sensor not activated (far from metal)
More or equal to 3 mA.
• Number of pulses per revolution
1
Position transducer for bearing holder
See page 156.
• Type
Inductive analogue sensor
• Supply voltage
18 to 30 V DC
• Operation range (mild steel)
0,5 to 2,5 mm
• Output voltage within sensing range
4 to 20 mA
• Load resistance, RL
400 Ohm
Allowed frequency variation:
740
752
760
150
8 TECHNICAL REFERENCE
Cover interlocking switch
• Type
Mechanical limit switch
• Switch rating, resistive load max.
3 A (at 48 V DC)
1 A (at 220 V AC)
8 TECHNICAL REFERENCE
8.4 INTERFACE DESCRIPTION
8.4 Interface Description
Alfa Laval ref. 564834 rev. 2
8.4.1 Scope
This document gives information,
requirements, and recommendations about
operational procedures and signal
processing for safe and reliable operation of
the separator. It is intended to be used for
designing auxiliary equipment and control
systems for the separator.
8.4.2 References
This Interface Description is one
complementary document to the separator.
Other such documents that contain necessary
information and are referred to here are:
•
Interconnection diagram
•
Connection List
•
Technical Data
Standards referred to are:
•
EN 418 Safety of machinery - Emergency
stop equipment, functional aspects Principles of design
•
EN 1037 Safety of machinery - Prevention of
unexpected start-up
•
EN 954-1 Safety of machinery - Safety
related parts of control systems - Part 1
General principles for design.
151
8.4 INTERFACE DESCRIPTION
8 TECHNICAL REFERENCE
8.4.3 Definitions
For the purpose of this document, the following
definitions apply:
•
Synchronous speed: The speed the machine
will attain when it is driven by a three phase
squirrel-cage induction motor and there is no
slip in the motor and the drive system.
•
Full speed: The synchronous speed minus
normal slip.
8.4.4 Goal
To eliminate situations that can cause harm,
i.e. injury, damage to health or property and
unsatisfactory process result are e.g.:
Situation
Effect
Unbalance caused by uneven sediment
accumulation in the bowl.
Too high stress on bowl and bearing
system which might cause harm.
Too high bowl speed.
Too high stress on bowl which might
cause harm.
Access to moving parts.
Can cause injury to person who
accidentally touches these parts.
Insufficient cleaning of separator.
Unsatisfactory product quality.
Bowl leakage.
Product losses.
Information and instructions given in this
document aim at preventing these situations.
Control and supervision can be more or less
comprehensive depending on the type of used
control equipment. When a simple control unit
is used it would be impossible or too expensive
to include many of the functions specified here
while these functions could be included at
nearly no extra cost when a more advanced
control unit is used. For this reasons functions
that are indispensable or needed for safety
reasons to protect the machine and/or
personnel are denoted with shall while other
functions are denoted with should.
152
8 TECHNICAL REFERENCE
8.4 INTERFACE DESCRIPTION
8.4.5 Description of separator
modes
For control purposes the operation of the
separator should be divided into different
modes.
The normally used modes are described below
but other modes might exist.
It is assumed that:
•
The separator is correctly assembled.
•
All connections are made according to
Connection List, Interconnection Diagram
and Interface Description.
•
The separator control system is activated.
If above conditions are not fulfilled the
separator will be in SERVICE mode.
Stand still means:
•
The power to the separator motor is off
•
The bowl is not rotating.
Starting means:
•
The power to the separator motor is on.
•
The bowl is rotating and accelerating
Running means:
•
The power to the separator motor is on.
•
The bowl is rotating at full speed.
•
RUNNING is a collective denomination for a
number of sub modes which e.g. can be:
– STAND BY: Separator is in a waiting mode
and not producing.
– PRODUCTION: Separator is fed with
product and producing.
– CLEANING: Separator is fed with cleaning
liquids with the intention to clean the
separator.
153
8.4 INTERFACE DESCRIPTION
Stopping means:
•
The power to the separator motor is off.
•
The bowl is rotating and decelerating.
•
STOPPING is a collective denomination for a
number of sub modes which e.g. can be:
– NORMAL STOP: A manually or
automatically initiated stop.
– SAFETY STOP: An automatically initiated
stop at too high vibrations.
– EMERGENCY STOP: A manually initiated
stop at emergency situations. This stop
will be in effect until it is manually reset.
8.4.6 Remote start
This machine may be started from a remote
location under the following conditions;
•
First start after any kind of service or manual
cleaning must be supervised locally in order
to ensure that no mistakes has been made
during assembly.
•
The unbalance sensor is mandatory for
remote start.
•
The installation must include equipment to
prevent unintentional start-up from remote
location when the machine is disassembled.
•
The installation must include equipment to
prevent unintentional start of process flow
from remote location when the machine is
not properly connected to the piping.
8.4.7 Handling of connection
interfaces
Electrical connections
701 Separator motor.
The separator is equipped with a 3-phase DOL
- (direct on line) started motor. The separator
can also be started by a Y/D starter, but then
the time in Y-position must be maximized to 5
seconds.
154
8 TECHNICAL REFERENCE
8 TECHNICAL REFERENCE
8.4 INTERFACE DESCRIPTION
There shall be an emergency stop circuit
designed according to EN 418 and a power
isolation device according to EN 1037.
There shall be a start button close to the
separator that shall be used for first start after
assembly of the separator.
There should be a counter to count number of
running hours.
There should be a current transformer to give
an analogue signal to the control unit about the
motor current.
740 Speed sensor
A proximity sensor of inductive type according
to DIN 19234 (Namur) standard is giving a
number of pulses per revolution of the bowl (see
Connection List).
Signal processing in STARTING:
•
The separator should be stopped
automatically according to NORMAL STOP
procedure and an alarm should be given
when the accumulated time for acceleration
is longer than the maximum time specified in
Technical Data. An abnormal start time
indicates some malfunction of the separator
equipment and should be investigated.
•
If the speed exceeds “Bowl speed,
synchronous” in Technical Data with more
than 5% the separator shall be stopped
automatically by NORMAL STOP and a high
speed alarm shall be given.
•
The speed monitoring system shall be
checked continuously (e.g by checking that
pulses are coming). In case of failure
indication the separator shall be stopped
automatically by NORMAL STOP with a timer
controlled stop sequence and an alarm for
speed monitoring system failure shall be
given.
•
The acceleration should be supervised to
ensure that a certain speed (e.g 250r/min.)
has been reached within a certain time (e.g
30 seconds).
155
8.4 INTERFACE DESCRIPTION
Signal processing in RUNNING:
•
If the speed exceeds “Bowl speed,
synchronous” in Technical Data with more
than 5% for a period longer than 1 minute or
momentarily during maximum 5 seconds
more than 10% the separator shall be
stopped automatically by NORMAL STOP
and a high speed alarm shall be given.
•
If the speed falls more than 10% below the
synchronous speed for a period longer than
1 minute or 15% during more than 5 seconds
a low speed alarm should be given. Low
speed indicates some malfunction of the
separator equipment and shall be
investigated.
•
The speed monitoring system shall be
checked continuously (e.g. by checking that
pulses are coming). In case of a failure
indication an alarm for speed monitoring
system failure shall be given. If there is a risk
of too high speed the separator shall be
stopped by NORMAL STOP.
•
The speed drop during DISCHARGE.
compared to the measured speed
immediately before, should be between 38% which will indicate a proper discharge.
Signal processing in STOPPING:
•
STAND STILL shall be indicated when no
pulses are detected within 30 seconds.
•
Stopping the separator when alarm for
speed monitoring system failure is active,
shall cause a timer controlled stop. (See
“Stop time” in Technical Data.)
752 Unbalance sensor (optional).
For indication of any abnormal unbalance and
to be able to perform appropriate
countermeasures, the separator has been
equipped with a vibration velocity transducer
on the separator frame. The signal from the
transducer shall be monitored and two alarm
levels according to the vibration alarm levels in
Technical Data should be set.
156
8 TECHNICAL REFERENCE
8 TECHNICAL REFERENCE
8.4 INTERFACE DESCRIPTION
The vibration level shall be high for 3 seconds
to generate an alarm. The first level is only
used to generate an alarm while the second
level shall stop the machine.
The vibration monitor shall include self check
function to be performed at least at initiation of
STARTING.
If vibrations exceed the second alarm level the
separator shall be stopped the quickest way
possible and it shall not been restarted until
the reasons for the unbalance have been found
and measures to remove them have been taken.
Signal processing in STARTING:
If vibrations exceed the second alarm level the
separator shall be stopped automatically by
SAFETY STOP.
If the self check system triggers, an alarm shall
be given and an automatic stop by NORMAL
STOP shall be initiated.
Signal processing in RUNNING:
•
If vibrations exceed the first alarm level an
alarm should be given. Vibrations of this
magnitude will reduce the expected life time
of the bearings and should therefore be
eliminated.
•
If vibrations exceed the second alarm level
the separator shall be stopped automatically
by SAFETY STOP.
•
If the self check system triggers, an alarm
shall be given.
Signal processing in STOPPING:
•
If the self check system triggers, an alarm
shall be given.
Signal processing in NORMAL STOP:
•
If vibrations exceed the second level the
system shall turn over automatically to
SAFETY STOP.
157
8.4 INTERFACE DESCRIPTION
760 Cover interlocking switch (optional)
The separator is equipped with a interlocking
switch to detect if the cover is mounted.
Signal processing in STAND STILL:
•
The circuit is closed when the cover of the
separator is mounted.
•
The interlocking switch should be connected
in such a way that starting of the motor is
prevented when the separator cover is not
mounted.
Signal processing in STARTING, RUNNING
and CLEANING:
•
If the circuit is broken the separator should
be stopped automatically by NORMAL
STOP. This is to minimise the risk of having
access to moving parts.
Fluid connections
Complementary information is given in the
document Connection List.
201 Inlet
Processing in STAND STILL:
•
Shall be closed.
Processing in STARTING:
•
Should be closed. Bowl will be open and
empty or closed and filled depending on if
start is done from STAND STILL or
STOPPING.
Processing in RUNNING:
•
Could be closed or open.
Processing in CLEANING:
•
A sequence of cleaning liquids should be
fed to the separator. The flow rate should be
as high as possible and preferably not less
than the production flow rate.
Processing in NORMAL STOP or
EMERGENCY STOP:
158
8 TECHNICAL REFERENCE
8 TECHNICAL REFERENCE
•
8.4 INTERFACE DESCRIPTION
Could be closed or open but the bowl should
be filled unless the stop is initiated in
STARTING.
Processing in SAFETY STOP:
•
Could be closed or open but the bowl shall
be filled unless the stop is initiated in
STARTING.
206 Inlet for conditioning and displacement
liquid
•
According to process
220, 221 and 222 Outlets
Processing in STAND STILL:
•
Could be closed or open.
Processing in other modes:
•
Shall be open.
375 Inlet for discharge and make-up liquid
Processing in all modes:
•
It is recommendable to supervise the supply
pressure. If pressure is too low (see
Connection List), start should be interlocked
and if it happens in PRODUCTION or
CLEANING turn over to STAND BY should
take place.
Signal processing in STARTING:
•
Below 85% of synchronous bowl speed no
water supply may be made.
•
When coming from PRODUCTION a
discharge shall be initiated to remove
sediments from bowl to avoid problems due
to solidification, see Connection List.
Signal processing in PRODUCTION:
•
Automatic discharges shall be initiated by
timer or ALCAP system.
Signal processing in CLEANING:
•
Automatic discharges shall be initiated by
timer or CIP-control system.
Signal processing in NORMAL STOP:
159
8.4 INTERFACE DESCRIPTION
•
Discharges should not be made.
Signal processing in SAFETY STOP and
EMERGENCY STOP:
•
160
Discharges should not be made.
8 TECHNICAL REFERENCE
8 TECHNICAL REFERENCE
8.5 DEMAND SPECIFICATION WATER
8.5 Demand Specification
Water
Alfa Laval ref. 574487 rev. 0
Poor quality of the operating water may with time cause erosion,
corrosion and/or operating problems. The water shall be treated
to meet certain demands.
The following requirements are of fundamental importance:
1
Turbidity-free water, solids content <0,001% by volume.
Max. particle size 50 µm.
Deposits shall not be allowed to form in certain areas in the system.
2
Total hardness less than 180 mg CaCO3 per litre, which corresponds
to 10 °dH or 12,5 °E. Hard water may with time form deposits in the
operating mechanism. The precipitation rate is accelerated with
increased operating temperature and low discharge frequency.
These effects become more severe the harder the water is.
3
Chloride content max. 100 ppm NaCl (equivalent to 60 mg Cl/l).
Chloride ions contribute to corrosion on surfaces in contact with the
operating water.Corrosion is a process that is accelerated by
increased separating temperature, low pH, and high chloride ion
concentration.
4
6,5 < pH < 9
Bicarbonate content (HCO3) min. 70mg HCO3 per litre, which
corresponds to 3,2 °dKH.
NOTE
Alfa Laval accepts no liability for consequences
arising from unsatisfactorily purified operating
water supplied by the customer.
161
8.6 DRAWINGS
8 TECHNICAL REFERENCE
8.6 Drawings
8.6.1 Basic size drawing
Connection house, with connections 201, 220 and 221, turnable in 60° steps all around.
All connections to be installed non-loaded and flexible
All dimensions are nominal. Reservation for individual deviations due to tolerances.
Data for connection, see 8.3 Connection List, page 149.
A Tightening torque 160 Nm.
B Maximum horizontal displacement at the inlet and outlet
connections during operation ± 5 mm.
C Maximum vertical displacement at the sludge connection
during operation ± 2 mm.
D 4 holes M10, depth 30
162
G 0 8 67 6H 1
Alfa Laval ref. 574283 rev. 0
8 TECHNICAL REFERENCE
8.6 DRAWINGS
8.6.2 Foundation drawing
Alfa Laval ref. 574284 rev. 1
D
E
F
I
J
K
B
G
L
M
A
A
B
C
D
E
F
G
H
I
J
K
L
M
G 0 97 76 A 1
H
C
Centre of separator bowl.
Holes for foundation bolts (8x).
Centre of motor.
Min. lifting capacity required during service: 300 kg.
Max. height of largest component incl. lifting tool.
Service side.
Foundation bolts.
Installation according to stated foundation force.
Foundation turnable 360o
Recommended free floor space for unloading when
doing service.
No fixed installation within this area.
Centre of gravity (complete machine).
Dynamic forces (static force excluded)
From separator do not exceed;
Force in any separator foot;
Vertical ± 8 kN
Horizontal ± 8 kN
Total foundation force (sum of all feet)
Vertical ± 8 kN
Horizontal ± 8 kN
163
8.6 DRAWINGS
8 TECHNICAL REFERENCE
8.6.3 Interconnection diagram
Alfa Laval ref. 561786 rev. 5
Interlocking switch (frame top part)
Unbalance sensor (position trans.
for bearing holder).
Speed sensor (bowl speed).
Junction box
Wiring without
junction box
Wire colour codes:
RD=A
BU=B
GN=C
YW=D
WT=E
BK=F
BN=G
PU=H
BK=Black
BN=Brown
BU=Blue
RD=Red
GN=Green
PU=Purple
YW=Yellow
WT=White
G 0 86 75 61
Wiring of connector “X”:
Demand specification wire
Approval: UL 1007/1569
CSA TR-64
Area acc. to AWG 18
164
Items showed in this document are not included in all
separators. See product specification.
SEPARATOR MANUAL
8 TECHNICAL REFERENCE
8.6.4 Electric motor
Alfa Laval ref. 565595 rev. 7
Knockout openings for
M25 + M20 cable glands
on both sides.
Casted lifting lugs on
both sides.
Shaft dimensions
External
earthing bolt
G 0 9 38 26 1
depth 20
Open
Closed
Note: Drain holes with closable
plugs to be positioned at lowest
point for IM2111 mounting
position.
Manufacturer
ABB Motors
Manuf. drawing
Cat. BA/Marine mot./GB 082001
Standards
IEC 34-series, 72, 79 and 85
Size
IEC 112MB
Type
M3AA 112 MB
Weight
33 kg
Poles
2
Insulation class
F
Bearings
D-end 6206-2Z/C3
Metal fan cover acc.
to variant code 053
Note: The motor
bearings have
permanent
lubrication
Type of mounting
Degree of
protection
IEC 34-7
IEC 34-5
IM 2111
IP 55
Rated output (kW) valid for temp. rise max.
90o.
Cast iron bearing shield at N-end.
The motors can be provided with space heaters
for 110V or 220V, 25W as option.
NOTE
N-end 6206-2Z/C3
Method of cooling
IC 411 (IEC 34-6)
Spec.
Totally enclosed three-phase
motor for marine service 2)
For complete information about motor variants, please
contact your Alfa Laval representative.
Motor with feet and small flange.
578701-02
165
8.6 DRAWINGS
166
8 TECHNICAL REFERENCE
9 Installation
9.1 Introduction
These installation specifications are valid
for the S 821 & S 826 separator.
The installation instructions are specifications,
which are compulsory requirements.
Any specific requirements from classification
societies or other local authorities must be
followed.
NOTE
If the specifications are not followed, Alfa Laval can
not be held responsible for any malfunctions related
to the installation.
167
9.2 UPON ARRIVAL AT THE STORAGE AREA
9 INSTALLATION
9.2 Upon Arrival At The
Storage Area
Ensure that the separator delivered is
suitable for the application.
9.2.1 Transport
a When lifting the separator, make sure that tools and lifting
devices are fastened securely. See chapter 6.8.1 Lifting
the separator, page 139.
!
ING
WARN
Crush hazards
Use correct lifting tools and follow lifting
instructions.
b When lifting the bowl see 6.8.2 Lifting the bowl, page 140
G 08 7 35 31
c During transport of the separator, the inand outlet device, frame hood and bowl
must always be removed.
168
9 INSTALLATION
9.2 UPON ARRIVAL AT THE STORAGE AREA
9.2.2 Protection and storage of gods
a The separator must be stored indoors at 5 55 °C, if not delivered in a water-resistant
box, designated for outdoor storage.
1 Anti-rust oil (Dinitrol 112 or equivalent) with long
lasting effective treatment for external surfaces.
The oil should prevent corrosion attacks and
leaves a waxy surface.
2 Anti-rust oil (Dinitrol 40 or equivalent) is a thin
lubricant for inside protection. It gives a
lubricating transparent oil film.
3 Solvent, e.g. white spirit, to remove the anti-rust
oil after the storage period.
4 Moist remover to be packed together with the
separator equipment.
b If there is a risk for water condensation, the
equipment must stand well ventilated and at
a temperature above dew point.
c If the storage time exceeds 12 months, the
equipment must be inspected every 6
months and, if necessary, the protection be
renewed.
G 0 87 3 61 1
The following protection products are
recommended:
169
9.3 PLANNING OF INSTALLATION
9 INSTALLATION
9.3 Planning of
Installation
G 08 73 71 1
9.3.1 Important measurements
Important measurements are:
-
minimum lifting height for lifting bowl parts
shortest distance between driving motor and wall
space for control and operation
free passage for dismantling and assembly
space for maintenance work
space on floor for machine parts during maintenance
work
For more detailed information, see 8.6.1 Basic size drawing,
page 162 and 8.6.2 Foundation drawing, page 163.
170
9 INSTALLATION
9.3 PLANNING OF INSTALLATION
9.3.2 Maintenance service
A work bench should be installed in the separator room.
Hot water, compressed air and diesel oil should be available
near the work bench to make maintenance work easier.
An overhead hoist with capacity of 300 kg is required for
transport of bowl parts to the working bench. Lifting point should
be above the centre of the separator.
NOTE
G 0 8 73 84 1
When two or more separators are installed, the
lifting height should be increased to enable bowl
parts from one separator to be lifted and moved over
an adjoining separator.
See 8.6.2 Foundation drawing, page 163
171
9.3 PLANNING OF INSTALLATION
9 INSTALLATION
9.3.3 Connections to surrounding
equipment
If the local safety regulations prescribe that the
installation has to be inspected and approved by
responsible authorities before the plant is put
into service, consult with such authorities before
installing the equipment and have the projected
plant design approved by them.
G 0 8 73 91 1
Local safety regulations
Service media
G 0 8 74 02 1
Ensure that all service media (electric power,
operating and safety liquids etc.) required for the
separator have the correct quality and capacity.
Sludge discharge tank
If the sediment from the separator is discharged
into a tank, this tank must be sufficiently
ventilated. The connection between the
separator and the tank must be of the size and
configuration specified.
G 0 87 4 31 1
If the solids are discharged from the separator
bowl casing into a closed system, ensure that
this system cannot be overfilled or closed in such
a way that the solids cannot leave the bowl
casing. This could cause a hazardous situation.
172
9 INSTALLATION
9.4 STORAGE AT OUT OF OPERATION
9.4 Storage at out of
operation
If the separator is out of operation for more
than 1 month:
1
Lift out the bowl.
2
Protect the spindle taper from corrosion by
lubricating it with oil.
3
Keep the separator and bowl well stored, dry
and protected from mechanical damage.
For details see 9.2.2 Protection and storage of
gods, page 169
9.5 Before start-up
If the separator has been out of operation for:
1 months or longer
•
Pre-lubricate the spindle bearings.
•
Perform an Inspection service i i and make
sure to pre-lubricate the spindle bearings.
•
Change the oil before starting.
G 08 68 74 1
6 months or longer
18 months or longer
•
Perform an Overhaul service o and make
sure to pre-lubricate the spindle bearings.
•
Change the oil before starting.
173
9.5 BEFORE START-UP
174
9 INSTALLATION
SA/PA Purifier System
Service Manual
Printed
Aug 2006
Book No.
577190-02 V2
Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by:
Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2006.
Contents
1
Change of Circuit Board.................................................................................... 5
1.1
2
Circuit Board Temperatures ........................................................................... 7
Cleaning in Place (SA only) ............................................................................ 9
2.1
2.2
2.3
Cleaning in Place, Separator.......................................................................... 9
Cleaning in Place, Heatpac® CBM Heater ............................................... 10
Cleaning in Place, Separator and Heater................................................. 12
577190-02
577190-02
SA/PA PURIFIER SYSTEM SERVICE MANUAL
1 CHANGE OF CIRCUIT BOARD
1 Change of Circuit Board
If a circuit board has to be changed, proceed as
follows:
Note down the run time (days only) as shown in
the function list of the EPC 50.
Change the board according to the instructions
below.
Go to parameter Fa 90, and insert the run time.
OP-Board
•
Switch power off.
•
Remove the snap-in transparent cover.
•
Disconnect the two cable plugs (do not
remove the cables from the plugs).
•
Disconnect the flatcable connector at the top.
•
Unscrew the five hexagon nuts.
•
Mount the new board, and connect in reverse
order.
I/O-Board
•
Switch power off.
If there is no optional board installed:
•
Disconnect all the cable plugs on the large
board (do not remove the cables from the
plugs).
•
Unscrew the hexagon nuts. Take care to note
where the special nuts for optional board(s)
are located.
•
Mount the new board, and connect in reverse
order.
577190-02
5
1 CHANGE OF CIRCUIT BOARD
SA/PA PURIFIER SYSTEM SERVICE MANUAL
If one or more optional board is installed:
•
Switch power off.
•
Disconnect the cable plug(s) on the optional
board (do not remove the cables from the
plug(s)).
•
Disconnect the flatcable connector at the top.
•
Unscrew the three hexagon nuts.
•
Note the position of the board and remove the
board.
•
Disconnect all the cable plugs on the large
board (do not remove the cables from the
plugs).
•
Unscrew the hexagon nuts. Take care to note
where the special nuts for optional board(s)
are located.
•
Mount the new board in the same position as
the old, and connect in reverse order.
6
577190-02
SA/PA PURIFIER SYSTEM SERVICE MANUAL
1 CHANGE OF CIRCUIT BOARD
1.1 Circuit Board
Temperatures
Circuit board temperature information can be
read as follows:
•
Set Pr 7 = 2.
•
Push ‘+’ and ‘–’ at the same time (‘Standst.’
now shows on the display).
•
Push ‘–’
The actual temperature, max. temperature, and
the number of times the temperature has been
above 70 °C for the transducer scrolls across the
display.
•
For further circuit board temperatures, push
the ‘–’ button.
•
To leave the list push the ‘+’ and the ‘–’ buttons
at the same time.
•
Reset Pr 7 = 0.
577190-02
7
1 CHANGE OF CIRCUIT BOARD
8
SA/PA PURIFIER SYSTEM SERVICE MANUAL
577190-02
SA/PA PURIFIER SYSTEM SERVICE MANUAL
2 CLEANING IN PLACE (SA ONLY)
2 Cleaning in Place (SA only)
The use of Cleaning In Place (CIP)
equipment is recommended for best
separation results. For further information
concerning the CIP equipment, see the CIP
booklet, bookno. 1817261.
Before connecting the CIP equipment to the
Separation Unit, the switch on the control
cabinet must be turned to the CIP position.
This is so that oil is not accidentally pumped
when the pipeline is opened up.
2.1 Cleaning in Place,
Separator
1
Remove the pipe connecting plate with pipes
from the separator.
2
Attach the CIP equipment as shown in the
illustration.
NOTE
577190-02
G065054A
The top outlet on the CIP unit should be connected to
the top inlet on the separator.
The middle inlet on the CIP unit should be connected
to the middle oil outlet on the separator.
The lower CIP inlet should be connected to the lower
water outlet on the separator.
9
2 CLEANING IN PLACE (SA ONLY)
SA/PA PURIFIER SYSTEM SERVICE MANUAL
2.2 Cleaning in Place,
Heatpac® CBM Heater
For systems including a Heatpac® CBM heater,
cleaning in place of the heater should be carried
out circa every 6 months, or according to
experience. Cleaning in place of the heater
should also be carried out in the event of a
pressure drop increase greater than 0.3 – 0.5 bar
(which indicates that the heater is beginning to
clog).
We recommend that you use Alfa Laval cleaning
liquids. These are specially suitable for the
materials used in the Heatpac® CBM heater.
Liquids that are corrosive to copper or stainless
steel, for example hydrochloric acid, phosphoric
acid, or nitric acid, must not be used.
!
ING
WARN
Burn hazard
Shut off the oil flow and the heating medium flow
before starting maintenance work.
!
ING
WARN
Corrosion hazard
Pay strict attention to the safety instructions for the
cleaning liquid used.
NOTE
Use only specified cleaning liquids. Other cleaning
agents may corrode the metal surfaces.
10
577190-02
SA/PA PURIFIER SYSTEM SERVICE MANUAL
2 CLEANING IN PLACE (SA ONLY)
1
Close the valves before and after the heater.
2
Open the heater drain valve until oil remaining
in the heater has drained.
3
Close the drain valve.
4
Loosen the turnable connections before and
after the heater. Turn the connections 90 ° so
that the special CIP connections can be
connected.
5
Connect the CIP equipment. The top inlet on
the CIP unit should be connected to the oil
outlet on the heater. The hose from the heater
inlet should be inserted into the tank and
secured with the help of the cover.
G065053A
Proceed as follows:
NOTE
The middle and lower CIP unit outlets must be
closed.
6
Clean with CIP fluid.
7
Flush with water.
After cleaning:
1
Open the heater drain valve until the flushing
water has drained.
2
Close the drain valve.
3
Remove the CIP connections.
4
Return the turnable connections to their
former positions and re-tighten.
5
Re-open the valves before and after the
heater.
577190-02
11
2 CLEANING IN PLACE (SA ONLY)
SA/PA PURIFIER SYSTEM SERVICE MANUAL
2.3 Cleaning in Place,
Separator and Heater
Oil outlet
Water outlet
G065062A
Connect the CIP equipment as shown in the
illustration. Proceed with cleaning as described
above.
12
577190-02
Spare parts catalogue, Reservdelskatalog, Ersatzteilkatalog, Catalogue de piéces de rechange, Varaosaluettelo,
Catalogue de piezas de recambio, Êàòàëîã çàïàñíûõ ÷àñòåè, Catalogo parti di ricambio, Reservedelskatalog,
Catalogo de pecas sobressalentes, Êáôáëïãïó áíôáëëáêôéêùí, Reserveonderdelen-catalogus
S 821
Product No.
Book No.
881201-05-01/2
574322-02 Rev. 4
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:
+46 8 530 310 40
© Alfa Laval Tumba AB July 2006
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of
Alfa Laval Tumba AB.
Contents
1
Read this first
2
Machine bottom part
12
2.1
14
Driving device vertical
5
3
Monitoring kit for speed
16
4
Separator bowl
18
5
Inlet and outlet device
20
6
Belt driving device
22
6.1
24
Centrifugal clutch
7
Set of plates
26
8
Commissioning kit
28
9
Monitoring kit for vibration
30
10
Cover interlocking kit
32
11
Set of tools
34
12
Inspection kit
36
13
Overhaul kit
38
14
Support kit
40
15
Lifting tool
42
16
Hydraulic tool kit
44
16.1 Hydraulic components
46
16.2 Hydraulic tool
48
Cross reference list
51
17
3
4
1 Read this first
Read this first
S0023731
1
Check the machine unit number on the name-plate before using this catalogue
Kontrollera maskinenhetens nummer på maskinskylten innan du använder katalogen
Das Typenschild - ein Hinweis zur korrekten Ersatzteilnummer
La plaque de la machine, un guide pour trouver le numéro de piéce de rechange correct
La placa-marca de la máquina - guía del número correcto del repuesto
Ôèðìåííàÿ òàáëè÷êà ìàøèíû — óêàçàòåëü ïðàâèëíîãî íîìåðà çàïàñíîé ÷àñòè
La targhetta della macchina - guida al corretto numero dei ricambi
A placa do fabricante da máquina - um guia do número correto das partes sobressalentes
Konekilpi - opastin oikeaan varaosanumeroon
Ç ðéíáêßäá ôçò ìç÷áíÞò åßíáé ï ïäçãüò ôïõ óùóôïý áíôáëëáêôéêïý
Het gegevensplaatje - een wegwijzer naar het juiste onderdeelnummer
Typeskiltet - en guide til det rette reservedelsnummer
5
S 821
Remember, Alfa Laval cannot accept responsibility for the failure of a
separator equipped with non-original spare parts. We guarantee the
quality and reliability of our products.
Följ ditt kvalitetstänkande genom att endast använda Alfa Laval
originalreservdelar.
Kom ihåg att Alfa Laval inte tar något ansvar för fel på en separator,
som innehåller icke-originaldelar. Vi garanterar kvaliteten och
driftsäkerheten endast hos våra egna produkter.
Aus Rücksicht auf Ihr Bestreben um beste Qualität sollten Sie nur Alfa
Laval Originalersatzteile benutzen.
Vergessen Sie nicht, Alfa Laval kann keine Verantwortung für das
Versagen eines Separators übernehmen, der nicht mit
Originalersatzteilen versehen ist. Wir garantieren Qualität und
Zuverlässigkeit unserer Produkte.
Préservez la qualité de vos équipments en n‘employant que des
pièces de rechange Alfa Laval.
N'oubliez pas q'Alfa Laval décline toute responsabilité en cas de
panne d'un séparateur non équipé de pièces de rechange d'origine.
Nous garantissons la qualité et la fiabilité de nos produits.
Mantenga su compromiso con la calidad, al usar siempre piezas de
repuesto Alfa Laval auténticas.
Recuerde que Alfa Laval no acepta responsabilidad por el fallo de una
separadora equipada con piezas de repuesto no originales.
Garantizamos la calidad y fiabilidad de nuestros productos.
6
S0023621
Safeguard your commitment to quality by always using genuine Alfa
Laval spare parts.
1 Read this first
Ãàðàíòèðóéòå íàäåæíîñòü êà÷åñòâà âñåãäà èñïîëüçóÿ
ïîäëèííûå çàïàñíûå ÷àñòè ôèðìû Alfa Laval.
S0023621
Çàïîìíèòå, ÷òî Alfa Laval íå íåñåò îòâåòñòâåííîñòè çà
ïîâðåæäåíèå ñåïàðàòîðà, îñíàùåííîãî íåïîäëèííûìè
çàï÷àñòàìè. Ìû ãàðàíòèðóåì êà÷åñòüî è íàäåæíîñòü íàøèõ
èçäåëèé.
Salvaguardate la vostra garanzia di qualità facendo sempre uso di
parti di ricambio Alfa Laval autentiche.
Tenete presente che la Alfa Laval non può accettare responsabilità
per avaria ad un separatore attrezzato con parti di ricambio non
originali. Noi garantiamo la qualità l'affidabilità dei nostri prodotti.
Proteja o seu cometimento a qualidade usando sempre peças
sobressalentes genuinas Alfa Laval.
Não esqueça que Alfa Laval não aceita responsabilidade por falha de
uma separadora equipada com peças sobressalentes não genuinas.
Nós garantimos a qualidade e a confiança dos nossos produtos.
Varmistakaa vastuunne laadusta käyttämällä aina alkuperäisiä Alfa
Laval varaosia.
Muistakaa, Alfa Laval ei voi hyväksyä vastuuta ei-alkuperäsillä
varaosilla varustetun separaattorin vaurioista. Me takaamme
tuotteidemme laadun ja käyttövarmuuden.
Åîáóöáëßïôå õøçëÞ ðïéüôçôá ÷ñçóéìïðïéþíôáò ìüíï ãíÞóéá
áíôáëëáêôéêÜ ôçò Alfa Laval.
¸÷åôå õðüøçí üôé ç Alfa Laval äåí áíáëáìâÜíåé êáììéÜ åõèýíç ãéá
âëÜâåò âïõôõñïìç÷áíÞò, ïôçí ïðïßá Ý÷ïõí åöáñìïóôåß ìÞ ãíÞóéá
áíôáëëáêôéêÜ. Åããõüìáóôå ðïéüôçôá êáé êáëÞ ëåéôïõñãßá ìüíï
ãéá ôá äéêÜ ìáò ðñïúüíôá.
7
S 821
Vergeet niet dat Alfa Laval niet verantwoordelijk is voor een defecte
separator die niet-originele onderdelen bevat. Wij garanderen de
kwaliteit en betrouwbaarheid van onze eigen produkten.
Hold Dem til den kvalitet, De har valgt at satse på, ved altid at
anvende ægte Alfa Laval reservedele.
Husk, at Alfa Laval ikke kan påtage sig noget ansvar for fejl på en
separator, som indeholder uoriginale dele. Vi kan kun garantere
kvalitet og driftsikkerhed på vore egne produkter.
8
S0023621
Streef naar een zo hoog mogelijke kwaliteit en gebruik uitsluitend
originele Alfa Laval reserveonderdelen. Streef naar een zo hoog
mogelijke kwaliteit en gebruik uitsluitend originele Alfa Laval
reserveonderdelen.
1 Read this first
Translation list
Översättningslista
Überzetsungsliste
Liste de traduction
Lista de traducciones
Part no.
Reservdelsnummer
Teil-Nr.
Numéro de pièce
Pieza No.
Qty
Antal
Anzahl
Quantité
Cantidad
Description
Benämning
Bezeichnung
Dénomination
Descripción
Notes
Anmärkningar
Anmerkungen
Remarques
Notas
Machine type
Maskintyp
Maschinentyp
Type de machine
Tipo de máquina
Product no.
Produktnr
Produktnummer
Numéro de produit
Número de producto
Machine unit
description
Maskinblocksbenämning
Bezeichnung des
Maschinenblocks
Dénomination de partie
de machine
Descripción de sección
de la máquina
Machine unit no.
Maskinblocksnr
Maschinenblock Nr.
Partie de machine nº
No. de sección de
máquina
Subassembly
description
Undergruppsbenämning
Bezeichung der
Untergruppe
Dénomination de
sous-ensemble
Descripción de
subconjunto
Subassembly no.
Undergruppsnr
Untergruppe Nr.
Nº de sous-ensemble
Número de subconjunto
See page
Se sidan
Siehe Seite
Vòir page
Véase la página
Fig. ref.
Figurhänvisning
Bildhinweise
Réf. de fig.
Referencia de figura
Product name
Produktnamn
Produktname
Nom du produit
Nombre del producto
Exchange necessitates
rebalancing of bowl
Utbyte nödvändiggör
ombalansering av kulan
Austasch erfordert
Wiederauswuchtung der
Trommel
Le remplacement
nécessite le
rééquilibrage du bol
El racmbio requiere el
reequilibrado del rotor
See separate spare
parts list
Se separat
reservdelslista
Siehe separate
Ersatzteilliste
Voir liste séparée des
pièces de rechange
Véase la lista de piezas
separada
Not delivered as spare
part
Levereras ej som
reservdel
Nicht als Ersatzteil
geliefert
Non livré comme piéce
de rechange
No se entrega como
pieza de recambio
9
S 821
Translation list
Ñëîâàðü ïåðåâäà
Lista traduzioni
Lista para tradução
Käännösluttelo
Part no.
Äåòàëü ¹
Nr.parte.
Numero de peca
Varaosanumero
Qty
Êîë—âî
Quantita
Quantidade
Lukumäärä
Description
Íàèìåíîâàíèå
Descrizione
Descricao
Nimitys
Notes
Ïðèìå÷àíèÿ
Note
Notas
Huomautuksia
Machine type
Ìàøèíà òíïà
Tipo macchina
Tipo de maquina
Konetyyppi
Product no.
Àðòèêóë ¹
Nr.produtto
No. do produto
Tuotteen no
Machine unit
description
Íàèìåíîâàíèå áëîêà
ìàøèíû
Nr. unita macchina
Descricao da unidade da
maquina
Koneenosan nimitys
Machine unit no.
Áëîê ìàøèíû ¹
Descrizione sottogruppo
Numero de unidade da
maquina
Koneenosan no
Subassembly
description
Íàèìåíîâàíèå ãðóïïû
Descrizione unita
macchina
Descriao do subconjunto
Alaryhmän nimitys
Subassembly no.
Ãðóïïà ¹
Nr. sottogruppo.
Número de subconjunto
Alaryhmän no
See page
Ñì. ñòðàíèöó
Vedi pagina
Véase la página
Ks sivu
Fig. ref.
Ññûëêà íà çñêèç
Rif. fig.
Referencia de figura
Kuvaviite
Product name
Íàèìåíîâàíèå
àðòèêóëà
Nome prodotto
Nombre del producto
Tuotteen nimi
Exchange necessitates
rebalancing of bowl
Çàìåíà òðåáóåò
áàëàíñèðîâêè áàðàáàíà
La sostituzione comporta
la iequilibratura del
tamburo
El racmbio requiere el
reequilibrado del rotor
Vaihdettaessa kuula
tasapainoitettava
uudelleen
See separate spare
parts list
Ñì. îòäåëüíûé
ïåðå÷åíü çàïàñíûõ
÷àñòåé
Vedi lista separata delle
parti di ricambio
Véase la lista de piezas
separada
Katso erillistä
varaosaluetteloa
Not delivered as spare
part
Íå ïîñòàâëåíà âìåñòå ñ
çàïàñíûìè ÷àñòÿìè
Non fornito come parte di
ricambio
No se entrega como
pieza de recambio
Ei toimiteta varaosana
10
1 Read this first
Translation list
ÃËÙÓÓÁÑÉ
Vertaallijst
Oversættelseliste
Part no.
Ëñéèìüò áíôáëëáêôéêïý
Onderdeelnr.
Reservedelsnummer
Qty
Óýíïëï
Hoeveelheid
Antal
Description
ÐåñéãñáöÞ
Beschrijving
Betegnelse
Notes
ÐáñáôçñÞóåéò
Opmerkingen
Bemaerkninger
Machine type
Ôýðïò ìç÷áíÞìáôïò
Machinetype
Maskintype
Product no.
Áñéèìüò ðñïúüíôïò
Produktnr.
Produktnr.
Machine unit
description
ÐåñéãñáöÞ
óõãêñïôÞìáôïò ìç÷áíÞò
Machineblokbenaming
Maskinbetegnelse
Machine unit no.
Áñéèìüò óõãêñïôÞìáôïò
ìç÷áíÞò
Machineblokbenamning
Maskinnr.
Subassembly
description
ÐåñéãñáöÞ
õðïóõãêñïôÞìáôïò
Subgroepbenamning
Undergruppsbetegnelse
Subassembly no.
Áñéèìüò
õðïóõãêñïôÞìáôïò
Subgroepnr.
Undergruppenr.
See page
ÂëÝðå óåëßäá
Zie blz.
Se side
Fig. ref.
ÐáñáðïìðÞ óå åéêüíá
Afb. ref.
Figurhenvisning
Product name
Ïíïìáóßá ðñïúüíôïò
Produktnaam
Produktnavn
Exchange necessitates
rebalancing of bowl
ÁíôáëëáãÞ áðáéôåß
åðáíáññýèìéóç
éóïññïðßáò ôïõ
ôýìðáíïõ
Vervangning vereist
herbalanceren van de
kogel
Udskriftning kraever ny
afbalcering af kuglen
See separate spare
parts list
ÂëÝðå åéäéêÞ ëßóôá
áíôáëëáêôéêþí
Vervangning vereist van
de kogel
Se spaat reservedelsliste
Not delivered as spare
part
Äåí ðáñáäßäåôáé ùò
áíôáëëáêôéêü
Niet geleverd als
reserveonderdeel
Levereres ikke som
reservedel
11
S 821
2
Machine bottom part
Machine unit number or
Subassembly description
564504Ref
Part No
Description
-01
Notes
Quantity
1
1A
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
33
34
35
36
37
37 A
37 B
37 C
37 D
40
41
42
12
564505
2522302
560131
70490
2210462
552766
526350
221035
565657
2234121
562091
564507
221706
2234121
566788
565694
566788
223412
564508
221716
565484
223412
565682
223406
560202
223404
539418
526352
565619
70560
221035
221716
565696
223406
221716
574914
574907
574914
221716
221721
223404
565378
571743
80 Frame bottom part
09 Square plug
01 Frame support
Washer
32 Screw
07 Washer
04 Plug
45 Screw
01 Bottom bearing holder
38 O-ring
01 Strainer
02 Wing insert
01 Screw
40 O-ring
11 Seal ring
02 Labyrinth ring
10 Seal ring
06 O-ring
80 Driving device vertical
02 Screw
02 Neck bearing cover
06 O-ring
02 Deflector ring
26 O-ring
01 Pipe
20 O-ring
02 Elbow
06 Bushing
02 Operating water cover
Washer
51 Screw
23 Screw
02 Plug
25 O-ring
23 Screw
80 Front casing
02 Holder
01 Front casing
22 Screw
37 Screw
05 O-ring
01 Plug
80 Oil pin
1
2
4
4
4
2
1
2
1
1
1
1
1
1
2
1
1
1
1
3
1
1
1
2
1
1
1
1
1
3
3
1
1
1
1
1
1
1
4
4
1
1
1
See page 14
2 Machine bottom part
13
S 821
2.1 Driving device vertical
Machine unit number or
Subassembly description
564508Ref
Part No
Description
-80
Notes
Quantity
1
2
3
3A
3B
4
5
6
7
8
9
10
11
12
13
14
15
16
17
14
564509
548747
564510
568972
557085
73049
564511
562109
573603
565875
564512
548744
567904
223404
565608
565522
223406
565700
221716
01 Bowl spindle
01 Ball bearing
80 Top bearing seat
01 Sensor arm
01 Hexagon hole screw
Snap ring
02 Top bearing housing
12 Helical spring
01 Composite spring
01 Plug
01 Spindle pulley
03 Self-alig. roller bearing
01 Lubrication oil orifice
20 O-ring
01 Oil pump
02 Fan
26 O-ring
01 Air deflector
27 Screw
1
1
1
1
2
1
1
3
4
4
1
1
1
1
1
1
1
1
3
2.1 Driving device vertical
2 Machine bottom part
15
14
4
1
3B
3A
2
3
6
7
8
5
17
16
9
10
11
12
13
15
S 821
3
Monitoring kit for speed
Machine unit number or
Subassembly description
566718Ref
Part No
Description
-88 -80
Notes
Quantity
1
1
3
5
5
6
7
16
565691
565691
552870
556416
556416
566692
17812
80
81
41
10
30
80
Speed sensor only
Speed sensor and junction box
Sensor with support
Sensor with support
Tube gland, angle 900
Protective tube
Protective tube
Junction box
Screw
↓
↓
1
1
1
1
1
1
1
2
Alternative
3 Monitoring kit for speed
17
S 821
4
Separator bowl
Slotted disk stack, caulks 0,55 mm
Machine unit number or
Subassembly description
564214Ref
Part No
Description
-02
Notes
Quantity
1
1A
1B
2
3
4
5
6
7
8
8.1
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
18
563977
560637
64416
560638
563978
545869
560638
564478
563895
576173
576279
223406
579223
223406
574239
565295
564140
563735
564094
564094
563897
563814
564134
223406
564136
564142
223403
566788
564094
80 Bowl body
01 Guide lug
Cylindrical pin
16 Rectangular ring
01 Operating slide
03 Nozzle Ø 1,5 mm
16 Rectangular ring
01 Valve plug
01 Holder
01 Hexagon head screw
01 Lock washer
38 O-ring
02 Operating water ring
06 O-ring
01 Discharge slide
03 Rectangular ring
01 Nut
80 Distributor
81 Bowl disc
81 Bowl disc
02 Top disc
01 Bowl hood
02 Seal ring
99 O-ring
80 Lock ring
01 Cap nut
62 O-ring
14 Seal ring
02 Bowl disc
1
1
1
1
1
1
1
3
1
12
6
1
1
1
1
1
1
1
62
2
1
1
1
1
1
1
1
1
1
4 Separator bowl
22
19
20
21
18
26
16
17
15
23
14
1A
1B
6
8.1
12
13
11
1
2
9
3
4
5
24
7
8
10
8
25
19
S 821
5
Inlet and outlet device
Machine unit number or
Subassembly description
574261Ref
Part No
Description
-01
Notes
Quantity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18 A
19
20
21
22
23
20
574247
574253
566940
573828
566408
223403
574258
564187
574137
574213
565636
221031
574012
221701
566407
223406
223406
574099
64416
561962
562343
521127
41456
221040
80
01
02
02
08
67
01
01
80
01
03
03
02
11
01
26
20
80
01
02
10
05
Inlet and outlet pipe
Bearing holder
Flanged bushing
Paring tube
Plain bearing bushing
O-ring
Screw
Splash sealing
Support ring
Height adjusting ring
Frame hood
Screw
Arm
Screw
Spring
O-ring
O-ring
Connecting housing
Cylindrical pin
Washer
Locking nut
O-ring
Washer
Screw
1
1
1
1
1
1
1
1
1
3
1
4
1
1
1
2
1
1
1
1
1
1
6
6
5 Inlet and outlet device
20
19
18
18A
15
12
14
13
11
23
22
21
10
6
9
5
4
3
2
17
16
8
7
1
21
S 821
6
Belt driving device
Machine unit number or
Subassembly description
565455Ref
Part No
Description
-01 -02
Notes
Quantity
1
2
3
3
4
5
6
7
8
9
10
11
12
13
13
22
576603
565561
574532
574532
221040
223107
565574
221040
41456
221716
41456
221040
35120
565552
565553
80
01
80
81
55
06
01
42
23
58
01
01
50 Hz
60 Hz
Clutch cover
Cover support
Centrifugal clutch
Centrifugal clutch
Screw
Spring washer
Washer
Screw
Washer
Screw
Washer
Screw
Nut
Flat belt
Flat belt
↓
↓
1
1
1
1
1
1
3
3
3
8
4
4
1
1
1
1
1
1
1
3
3
3
8
4
4
1
See page 24
See page 24
6 Belt driving device
23
S 821
6.1 Centrifugal clutch
Machine unit number or
Subassembly description
574532Ref
Part No
Description
573949
573950
548051
574068
223642
573947
573948
549552
66252
565576
565568
223641
50 Hz
60 Hz
Motor belt pulley
Motor belt pulley
Ball bearing
Spacing ring
Snap ring
Coupling hub
Coupling hub
Parallel pin
Lock ring
Friction block
Cover
Snap ring
-80 -81
Notes
Quantity
1
1
2
3
4
5
5
5A
6
7
8
9
24
02
02
50
01
38
80
80
01
80
01
19
↓
↓
1
2
1
1
1
5
1
5
1
1
1
2
1
1
1
3
1
3
1
1
6.1 Centrifugal clutch
6 Belt driving device
6
4
2
3
2
1
5
5A
7
8
9
25
S 821
7
Set of plates
Machine unit number or
Subassembly description
549572Ref
Part No
Description
3
3A
3B
3C
3D
3E
3F
3G
3H
3I
3J
3K
3L
3M
3N
3O
3P
3Q
3R
3S
4
6
6
7
8
9
1270019
1270018
1270018
1270018
1270018
1270018
1270018
1270018
1270018
1270018
1270018
1270018
1270018
1270018
1270018
1270018
1270018
1270018
1270018
1270018
577802
553171
553272
555529
1270001
554214
Set of safety labels
Safety label sv
Safety label en
Safety label de
Safety label fr
Safety label es
Safety label ru
Safety label it
Safety label pt
Safety label pl
Safety label el
Safety label fi
Safety label zh
Safety label da
Safety label ar
Safety label nl
Safety label cs
Safety label ja
Safety label ko
Safety label no
Name sign
Label 50 Hz
Label 60 Hz
Plate with arrow
Lifting instruction
Cable tie
-84
Notes
Quantity
26
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
01
01
01
01
02
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
7 Set of plates
27
S 821
8
Commissioning kit
Machine unit number or
Subassembly description
576452Ref
Part No
Description
223404
223404
223406
223406
564187
O-ring
O-ring
O-ring
O-ring
Splash sealing
-01
Notes
Quantity
1
2
3
4
5
28
51
51
20
26
01
4
2
1
2
1
Oil pipe/ Connecting housing
Water pipe/ Connecting housing
Inlet and outlet pipe/ Connecting housing
Inlet and outlet pipe/ Connecting housing
Inlet and outlet pipe
8 Commissioning kit
29
S 821
9
Monitoring kit for vibration
Machine unit number or
Subassembly description
566727Ref
Part No
Description
-01
Notes
Quantity
1
2
4
6
30
570142
565696
552870
556416
01
03
21
13
Inductive analogue sensor
Sensor holder
Tube gland, straight
Protective tube
1
1
1
1
9 Monitoring kit for vibration
31
S 821
10 Cover interlocking kit
Machine unit number or
Subassembly description
570819Ref
Part No
Description
-01
Notes
Quantity
1
2
3
32
552870 21 Tube gland, straight
566054 01 Limit switch
556416 23 Protective tube
1
1
1
10 Cover interlocking kit
33
S 821
11 Set of tools
Machine unit number or
Subassembly description
561614Ref
Part No
Description
-13
Notes
Quantity
1
1A
2
3
3A
3B
3C
3D
3E
4
5
6
6A
6B
7
8
9
9A
9B
9C
9D
10
11
12
13
13 A
13 B
14
15
16
17
18
19
34
565879
561829
564358
575125
575125
575083
575098
221045
561551
561584
565857
561607
564360
221040
260154
527395
574348
574346
574347
565889
223404
567010
561439
569695
563084
221040
221035
221706
66414
566458
566646
566897
567011
80
01
02
81
80
02
01
52
02
85
80
85
01
43
01
11
80
01
01
01
13
80
06
01
80
05
46
05
01
01
01
01
Puller
Screw
Spanner for nut
Compressing tool
Compressing tool
Clamp
Screw
Screw
Screw
Puller
Pin spanner
Puller
Support ring
Screw
Lifting eye bolt
Hook spanner
Tool for coupling
Screw
Nut
Plug
O-ring
Lifting tool
Drift
Key
Puller
Screw
Screw
Screw
Hexagon socket head key
Sleeve
Chisel
Mounting tool
Pin
1
1
1
1
1
3
3
3
3
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
6
1
1
1
1
1
Spindle pulley/ Top bearing
Nut/ Discharge Slide
Disc stack
Bowl body
Fan
Discharge slide/ Bowl body
Nut/ Inlet and outlet pipe
Motor/ Coupling
Distributor/ Bowl Spindle
Bottom bearing
Bottom bearing housing
Neck bearing cover
Lock ring/ Bowl body
Lock ring/ Bowl body
Neck bearing
Seal ring
Coupling bearing
Distributor
11 Set of tools
35
S 821
12 Inspection kit
Machine unit number or
Subassembly description
567020Ref
Part No
Description
-02
Notes
Quantity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
99
36
560638
564478
560638
223403
223406
566788
223406
565295
564134
223406
566940
566408
223403
564187
223406
223406
521127
223404
552766
223404
221706
66414
537086
539474
576279
576173
535586
574747
16
01
16
62
38
14
06
03
02
99
02
08
67
01
26
20
10
51
07
05
05
06
03
01
01
80
Rectangular ring
Valve plug
Rectangular ring
O-ring
O-ring
Seal ring
O-ring
Rectangular ring
Seal ring
O-ring
Flanged bushing
Plain bearing bushing
O-ring
Splash sealing
O-ring
O-ring
O-ring
O-ring
Washer
O-ring
Screw
Hexagon socket head key
Lubricating paste
Silicone grease
Lock washer
Hexagon head screw
Anti-friction coating
Exploded view
1
3
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
6
2
1
6
1
1
1
6
12
1
1
Bowl body/ Operating slide
Operating slide/ Bowl body
Operating slide/ Holder
Bowl body/ Holder
Bowl body/ Operating water ring
Operating water ring
Bowl body/ Discharge slide
Discharge slide/ Bowl body
Bowl hood/ Discharge slide
Bowl hood/ Bowl body
Bearing holder/ Paring tube
Paring tube
Paring tube/ Inlet and outlet pipe
Inlet and outlet pipe
Inlet and outlet pipe/ Connecting housing
In. and outlet pipe/ Connecting housing
Frame hood/ Frame bottom part
Oil and water pipe/ Connecting housing
Frame bottom part/ Plug
Oil pin/ Plug
Lock ring/ Bowl body
Lock ring/ Bowl body
Bowl body/ Holder
Bowl body/ Holder operating water ring
C01956J1
15
16
18
14
18
18
11
12
13
17
2
6
26
21
26
25
3
4
5
1
22
7
8
10
9
20
19
19
12 Inspection kit
37
S 821
13 Overhaul kit
Machine unit number or
Subassembly description
567021Ref
Part No
Description
567020
2234121
2234121
565694
223412
566788
223406
223404
223412
566788
223406
548747
73049
562109
573603
548744
223404
223406
545869
566407
548051
223642
66252
565576
223641
223107
565552
565553
544465
572507
50 Hz
60 Hz
Inspection kit
O-ring
O-ring
Labyrinth ring
O-ring
Seal ring
O-ring
O-ring
O-ring
Seal ring
O-ring
Ball bearing
Snap ring
Helical spring
Composite spring
Self-align roller bearing
O-ring
O-ring
Nozzle
Spring
Ball bearing
Snap ring
Lock ring
Friction block
Snap ring
Spring washer
Flat belt
Flat belt
Locking liquid
Exploded view
-03 -04
Notes
Quantity
1
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
29
30
99
38
02
38
40
02
06
11
26
20
06
10
25
01
12
01
03
20
26
03
01
50
38
80
19
06
01
01
10
↓
↓
1
1
1
1
1
2
2
1
1
1
1
1
1
3
4
1
1
1
1
1
2
1
1
5
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
3
4
1
1
1
1
1
2
1
1
3
1
1
1
1
1
See page 36
Strainer/ Bottom bearing holder
Bottom bearing holder/ Frame bottom part
Frame bottom part/ Spindle pulley
Neck bearing cover/ Frame bottom part
Fan/ Neck bearing cover
Deflector ring/ Bowl spindle
Pipe/ Operating water cover
Neck bearing cover/ Frame bottom part
Operating water cover/ Bowl spindle
Plug/ Frame bottom part
Bowl spindle/ Top bearing seat
Top bearing seat/ Ball bearing
Top bearing seat/ Top bearing housing
Top bearing housing/Plug
Bowl spindle/ Bottom bearing holder
Lubrication oil orifice/ Oil pump
Bowl spindle/ Fan
Operating slide
Arm
Coupling hub/ Motor belt pulley
Ball bearing/ Motor belt pulley
Coupling hub/ Ball bearing
Coupling hub/ Motor belt pulley
Coupling hub/ Cover
Motor shaft/ Screw
Motor belt pulley/ Spindle pulley
Motor belt pulley/ Spindle pulley
Bottom bearing holder
C01958J1
8
10
12
2
3
4
9
6
5
7
18
17
13
14
19
15
16
22
20
29
28
27
26
25
24
23
23
1
13 Overhaul kit
39
S 821
14 Support kit
Machine unit number or
Subassembly description
567022Ref
Part No
Description
-02
Notes
Quantity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
21
22
23
24
25
26
28
29
30
99
40
526350
565378
571743
565691
221716
221716
221716
567904
221716
565682
70560
221035
564136
564142
564358
574253
574258
574213
221031
574012
221701
41456
221040
561962
562343
41456
221040
35120
574874
04
01
80
80
23
23
02
01
27
02
26
80
01
02
01
01
01
03
02
11
05
01
02
58
Plug
Plug
Oil pin
Sensor with support
Screw
Screw
Screw
Lubrication oil orifice
Screw
Deflector ring
Washer
Screw
Lock ring
Cap nut
Spanner for nut
Bearing holder
Screw
Height adjusting ring
Screw
Arm
Screw
Washer
Screw
Washer
Locking nut
Washer
Screw
Nut
Exploded view
1
1
1
1
1
1
3
1
3
1
3
3
1
1
1
1
1
3
4
1
1
6
6
1
1
8
4
4
1
Frame bottom part
Frame bottom part
Frame bottom part/ Plug
Frame bottom part
Frame bottom part/ Sensor support
Frame bottom part/Plug
Top bearing housing/ Frame bottom part
Oil pump
Top bearing housing/ Air deflector
Bowl spindle
Screw/ Operating water cover
Operating water cover
Bowl body/ Bowl hood
Bowl spindle/ Bowl body
Nut/ Discharge slide
Inlet and outlet pipe/ Paring tube
Inlet and outlet pipe/ Bearing holder
Frame hood/ Support ring
Frame hood/ Support ring
Paring tube
Arm/ Paring tube
Frame hood/ Frame bottom part
Frame hood/ Frame bottom part
Inlet and outlet pipe/ Connecting housing
Inlet and outlet pipe/ Connecting housing
Motor/ Frame bottom part
Motor/ Frame bottom part
Motor/ Frame bottom part
7
10
4
6
12
11
5
9
1
3
8
2
17
19
21
16
18
22
26
25
24
23
30
28
14
13
15
29
14 Support kit
41
S 821
15 Lifting tool
Machine unit number or
Subassembly description
563453Ref
Part No
Description
-81
Notes
Quantity
2
3
5
6
42
566079 01 Lug
221035 29 Screw
27345
Nut
260236 03 Shackle
4
4
4
2
15 Lifting tool
43
S 821
16 Hydraulic tool kit
Machine unit number or
Subassembly description
574986Ref
Part No
Description
-05
Notes
Quantity
1
2
44
574618 80 Hydraulic components
574626 83 Hydraulic tool
1
1
See page 46
See page 48 For coupling
1
2
16 Hydraulic tool kit
45
S 821
16.1 Hydraulic components
Machine unit number or
Subassembly description
574618Ref
Part No
Description
-80
Notes
Quantity
1
2
46
574618 01 Pump with hose
574618 02 Hydraulic cylinder
1
1
16.1 Hydraulic components
16 Hydraulic tool kit
47
S 821
16.2 Hydraulic tool
Machine unit number or
Subassembly description
574626Ref
Part No
Description
-83
Notes
Quantity
1
2
3
4
5
6
7
48
574632
574627
574631
221803
574954
571620
571622
01
04
01
35
01
01
01
Stud bolt
Sleeve
Holder
Nut
Sleeve
Plate
Screw
1
1
1
1
1
1
3
16.2 Hydraulic tool
16 Hydraulic tool kit
49
S 821
50
17 Cross reference list
Part No
Page
Ref.
Part No
Page
Ref.
Part No
Page
17812
16
7
221716 27
14
17
526350 04
12
6
27345
42
5
221721 37
12
37 D
526352 06
12
27
35120
22
12
221803 35
48
4
527395 11
34
8
35120
40
30
223107 06
22
5
535586 80
36
27
41456
22
8
223107 06
38
28
537086 06
36
23
41456
22
10
223403 62
36
4
539418 02
12
26
41456
20
22
223403 62
18
24
539474 03
36
24
41456
40
23
223403 67
20
6
544465 10
38
30
41456
40
28
223403 67
36
13
545869 03
18
4
64416
18
1B
223404 05
36
20
545869 03
38
20
64416
20
18 A
223404 05
12
40
548051 50
24
2
66252
24
6
223404 13
34
9D
548051 50
38
23
66252
38
25
223404 20
38
8
548744 03
14
10
66414
34
15
223404 20
14
12
548744 03
38
17
66414
36
22
223404 20
38
18
548747 01
14
2
70490
12
3
223404 20
12
25
548747 01
38
13
70560
40
11
223404 51
28
1
549552 01
24
70560
12
29
223404 51
28
2
552766 07
12
5
73049
14
4
223404 51
36
18
552766 07
36
19
73049
Ref.
5A
38
14
223406 06
36
7
552870 21
32
1
221031 03
20
12
223406 06
18
11
552870 21
30
4
221031 03
40
19
223406 20
28
3
552870 41
16
3
221035 26
40
12
223406 20
36
16
553171 01
26
6
221035 29
42
3
223406 20
20
17
553272 01
26
6
221035 45
12
7
223406 25
38
12
554214 02
26
9
221035 46
34
13 B
223406 25
12
35
555529 01
26
7
221035 51
12
30
223406 26
28
4
556416 10
16
5
221040 05
34
13 A
223406 26
38
7
556416 13
30
6
221040 05
20
23
223406 26
14
15
556416 23
32
3
221040 05
40
24
223406 26
36
15
556416 30
16
5
221040 42
22
7
223406 26
20
16
557085 01
14
3B
221040 43
34
6B
223406 26
38
19
560131 01
12
2
221040 55
22
4
223406 26
12
23
560202 01
12
24
221040 58
22
11
223406 38
36
5
560637 01
18
1A
221040 58
40
29
223406 38
18
9
560638 16
36
1
221045 52
34
223406 99
36
10
560638 16
18
2
221701 11
20
14
223406 99
18
21
560638 16
36
3
221701 11
40
22
223412 06
38
5
560638 16
18
5
221706 01
12
12
223412 06
38
9
561439 06
34
11
221706 05
34
14
223412 06
12
17
561551 02
34
3E
221706 05
36
21
223412 06
12
21
561584 85
34
4
221716 02
40
7
223641 19
24
9
561607 85
34
6
221716 02
12
19
223641 19
38
27
561829 01
34
1A
221716 22
12
37 C
223642 38
24
4
561962 01
20
19
221716 23
40
5
223642 38
38
24
561962 01
40
25
221716 23
40
6
260154 01
34
7
562091 01
12
10
221716 23
22
9
260236 03
42
6
562109 12
14
6
221716 23
12
33
521127 10
36
17
562109 12
38
15
221716 23
12
36
521127 10
20
21
562343 02
20
20
221716 27
40
9
526350 04
40
1
562343 02
40
26
3D
51
S 821
52
Part No
Page
Ref.
Part No
Page
Ref.
Part No
Page
Ref.
563084 80
34
13
565657 01
563735 80
18
15
565682 02
12
8
573948 80
24
5
40
10
573949 02
24
563814 01
18
19
1
565682 02
12
22
573950 02
24
1
563895 01
18
563897 02
18
7
565691 80
16
1
574012 02
20
13
18
565691 80
40
4
574012 02
40
563977 80
18
21
1
565691 81
16
1
574068 01
24
563978 01
3
18
3
565694 02
38
4
574099 80
20
18
564094 02
18
26
565694 02
12
15
574137 80
20
9
564094 81
18
16
565696 02
12
34
574213 01
20
10
564094 81
18
17
565696 03
30
2
574213 01
40
18
564134 02
36
9
565700 01
14
16
574239 01
18
12
564134 02
18
20
565857 80
34
5
574247 80
20
1
564136 80
40
13
565875 01
14
8
574253 01
20
2
564136 80
18
22
565879 80
34
1
574253 01
40
16
564140 01
18
14
565889 01
34
9C
574258 01
20
7
564142 01
40
14
566054 01
32
2
574258 01
40
17
564142 01
18
23
566079 01
42
2
574346 01
34
9A
564187 01
28
5
566407 01
20
15
574347 01
34
9B
564187 01
20
8
566407 01
38
22
574348 80
34
9
564187 01
36
14
566408 08
20
5
574532 80
22
3
564358 02
34
2
566408 08
36
12
574532 81
22
3
564358 02
40
15
566458 01
34
16
574618 01
46
1
564360 01
34
6A
566646 01
34
17
574618 02
46
2
564478 01
36
2
566692 80
16
6
574618 80
44
1
564478 01
18
6
566788 10
38
10
574626 83
44
2
564505 80
12
1
566788 10
12
16
574627 04
48
2
564507 02
12
11
566788 11
38
6
574631 01
48
3
564508 80
12
18
566788 11
12
14
574632 01
48
1
564509 01
14
1
566788 14
36
6
574747
36
99
564510 80
14
3
566788 14
18
25
574874
40
99
564511 02
14
5
566897 01
34
18
574907 02
12
37 A
564512 01
14
9
566940 02
20
3
574914 01
12
37 B
565295 03
36
8
566940 02
36
11
574914 80
12
37
565295 03
18
13
567010 80
34
10
574954 01
48
5
565378 01
40
2
567011 01
34
19
575083 02
34
3B
565378 01
12
41
567020 02
38
1
575098 01
34
3C
565484 02
12
20
567904 01
40
8
575125 80
34
3A
565522 02
14
14
567904 01
14
11
575125 81
34
3
565552 01
22
13
568972 01
14
576173 01
18
8
565552 01
38
29
569695 01
34
12
576173 01
36
26
565553 01
22
13
570142 01
30
1
576279 01
36
25
565553 01
38
29
571620 01
48
6
576279 01
18
8.1
565561 01
22
2
571622 01
48
7
576603 80
22
1
565568 01
24
8
571743 80
40
3
577802 01
26
4
565574 01
22
6
571743 80
12
42
579223 02
18
10
565576 80
24
7
572507
38
99
1270001
26
8
565576 80
38
26
573603 01
14
7
1270018 01
26
3A
565608 01
14
13
573603 01
38
16
1270018 02
26
3B
565619 02
12
28
573828 02
20
4
1270018 03
26
3C
565636 03
20
11
573947 80
24
5
1270018 04
26
3D
3A
17 Cross reference list
Part No
Page
Ref.
1270018 05
26
3E
1270018 06
26
3F
1270018 07
26
3G
1270018 08
26
3H
1270018 09
26
3I
1270018 10
26
3J
1270018 11
26
3K
1270018 12
26
3L
1270018 13
26
3M
1270018 14
26
3N
1270018 15
26
3O
1270018 16
26
3P
1270018 17
26
3Q
1270018 18
26
3R
1270018 19
26
3S
1270019
26
3
2210462 32
12
4
2234121 38
38
2
2234121 38
12
9
2234121 40
38
3
2234121 40
12
13
2522302 09
12
1A
53
S 821
54
SA 821 Separation System
Spare Parts Catalogue
Product No.
569587-02
Book No.
579616-02 Rev. 2
Separator Part No.
881201-05-01
Spare Parts Catalogue
Catalogo parti di ricambio
Reservdelskatalog
Catalogo de pecas
sobressalentes
Ersatzteilkatalog
Catalogue de piéces de
rechange
Catalogue de piezas de
recambio
Êàòàëîã çàïàñíûõ
÷àñòåè
Varaosaluettelo
Êáôáëïãïó
áíôáëëáêôéêùí
Reserveonderdelencatalogus
Reservedelskatalog
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gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by:
Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB March 2006.
Contents
2
Ancillary Equipment ......................................................................................... 12
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
2.20
3
Valve block water ............................................................................................ 12
Spare parts kit, valve block water ............................................................. 14
Valve block air .................................................................................................. 16
Spare parts kit, valve block air ................................................................... 18
Sludge removal kit .......................................................................................... 20
Sludge pump ..................................................................................................... 22
Valve block oil................................................................................................... 24
Water transducer ............................................................................................. 26
Spare parts kit, pneumatic 3-way valve ................................................... 28
Connection kit, oil............................................................................................ 30
Sludge outlet kit ............................................................................................... 32
Butterfly valve ................................................................................................... 34
Spare parts, EPC 50 Control Unit................................................................ 36
EPC 50 Control unit ......................................................................................... 38
Starters................................................................................................................ 38
Separator starter kits, basic and 4A – 32A.............................................. 39
Separator starter kits, 32A – 63A ............................................................... 40
Pump starter kits, 0.4A – 16.0A ................................................................... 41
ESD-relay kit ...................................................................................................... 42
Motor trip contact kit ..................................................................................... 42
Index .......................................................................................................................... 44
579616-02
579616-02
1 Read this first
Read this first
S0023731
1
Check the machine unit number on the name-plate before using this catalogue
Kontrollera maskinenhetens nummer på maskinskylten innan du använder katalogen
Das Typenschild - ein Hinweis zur korrekten Ersatzteilnummer
La plaque de la machine, un guide pour trouver le numéro de piéce de rechange correct
La placa-marca de la máquina - guía del número correcto del repuesto
Ôèðìåííàÿ òàáëè÷êà ìàøèíû — óêàçàòåëü ïðàâèëíîãî íîìåðà çàïàñíîé ÷àñòè
La targhetta della macchina - guida al corretto numero dei ricambi
A placa do fabricante da máquina - um guia do número correto das partes sobressalentes
Konekilpi - opastin oikeaan varaosanumeroon
Ç ðéíáêßäá ôçò ìç÷áíÞò åßíáé ï ïäçãüò ôïõ óùóôïý áíôáëëáêôéêïý
Het gegevensplaatje - een wegwijzer naar het juiste onderdeelnummer
Typeskiltet - en guide til det rette reservedelsnummer
5
1 Read this first
Remember, Alfa Laval cannot accept responsibility for the failure of a
separator equipped with non-original spare parts. We guarantee the
quality and reliability of our products.
Följ ditt kvalitetstänkande genom att endast använda Alfa Laval
originalreservdelar.
Kom ihåg att Alfa Laval inte tar något ansvar för fel på en separator,
som innehåller icke-originaldelar. Vi garanterar kvaliteten och
driftsäkerheten endast hos våra egna produkter.
Aus Rücksicht auf Ihr Bestreben um beste Qualität sollten Sie nur Alfa
Laval Originalersatzteile benutzen.
Vergessen Sie nicht, Alfa Laval kann keine Verantwortung für das
Versagen eines Separators übernehmen, der nicht mit
Originalersatzteilen versehen ist. Wir garantieren Qualität und
Zuverlässigkeit unserer Produkte.
Préservez la qualité de vos équipments en n‘employant que des
pièces de rechange Alfa Laval.
N'oubliez pas q'Alfa Laval décline toute responsabilité en cas de
panne d'un séparateur non équipé de pièces de rechange d'origine.
Nous garantissons la qualité et la fiabilité de nos produits.
Mantenga su compromiso con la calidad, al usar siempre piezas de
repuesto Alfa Laval auténticas.
Recuerde que Alfa Laval no acepta responsabilidad por el fallo de una
separadora equipada con piezas de repuesto no originales.
Garantizamos la calidad y fiabilidad de nuestros productos.
6
S0023621
Safeguard your commitment to quality by always using genuine Alfa
Laval spare parts.
1 Read this first
Ãàðàíòèðóéòå íàäåæíîñòü êà÷åñòâà âñåãäà èñïîëüçóÿ
ïîäëèííûå çàïàñíûå ÷àñòè ôèðìû Alfa Laval.
S0023621
Çàïîìíèòå, ÷òî Alfa Laval íå íåñåò îòâåòñòâåííîñòè çà
ïîâðåæäåíèå ñåïàðàòîðà, îñíàùåííîãî íåïîäëèííûìè
çàï÷àñòàìè. Ìû ãàðàíòèðóåì êà÷åñòüî è íàäåæíîñòü íàøèõ
èçäåëèé.
Salvaguardate la vostra garanzia di qualità facendo sempre uso di
parti di ricambio Alfa Laval autentiche.
Tenete presente che la Alfa Laval non può accettare responsabilità
per avaria ad un separatore attrezzato con parti di ricambio non
originali. Noi garantiamo la qualità l'affidabilità dei nostri prodotti.
Proteja o seu cometimento a qualidade usando sempre peças
sobressalentes genuinas Alfa Laval.
Não esqueça que Alfa Laval não aceita responsabilidade por falha de
uma separadora equipada com peças sobressalentes não genuinas.
Nós garantimos a qualidade e a confiança dos nossos produtos.
Varmistakaa vastuunne laadusta käyttämällä aina alkuperäisiä Alfa
Laval varaosia.
Muistakaa, Alfa Laval ei voi hyväksyä vastuuta ei-alkuperäsillä
varaosilla varustetun separaattorin vaurioista. Me takaamme
tuotteidemme laadun ja käyttövarmuuden.
Åîáóöáëßïôå õøçëÞ ðïéüôçôá ÷ñçóéìïðïéþíôáò ìüíï ãíÞóéá
áíôáëëáêôéêÜ ôçò Alfa Laval.
¸÷åôå õðüøçí üôé ç Alfa Laval äåí áíáëáìâÜíåé êáììéÜ åõèýíç ãéá
âëÜâåò âïõôõñïìç÷áíÞò, ïôçí ïðïßá Ý÷ïõí åöáñìïóôåß ìÞ ãíÞóéá
áíôáëëáêôéêÜ. Åããõüìáóôå ðïéüôçôá êáé êáëÞ ëåéôïõñãßá ìüíï
ãéá ôá äéêÜ ìáò ðñïúüíôá.
7
1 Read this first
Vergeet niet dat Alfa Laval niet verantwoordelijk is voor een defecte
separator die niet-originele onderdelen bevat. Wij garanderen de
kwaliteit en betrouwbaarheid van onze eigen produkten.
Hold Dem til den kvalitet, De har valgt at satse på, ved altid at
anvende ægte Alfa Laval reservedele.
Husk, at Alfa Laval ikke kan påtage sig noget ansvar for fejl på en
separator, som indeholder uoriginale dele. Vi kan kun garantere
kvalitet og driftsikkerhed på vore egne produkter.
8
S0023621
Streef naar een zo hoog mogelijke kwaliteit en gebruik uitsluitend
originele Alfa Laval reserveonderdelen. Streef naar een zo hoog
mogelijke kwaliteit en gebruik uitsluitend originele Alfa Laval
reserveonderdelen.
1 Read this first
Translation list
Översättningslista
Überzetsungsliste
Liste de traduction
Lista de traducciones
Part no.
Reservdelsnummer
Teil-Nr.
Numéro de pièce
Pieza No.
Qty
Antal
Anzahl
Quantité
Cantidad
Description
Benämning
Bezeichnung
Dénomination
Descripción
Notes
Anmärkningar
Anmerkungen
Remarques
Notas
Machine type
Maskintyp
Maschinentyp
Type de machine
Tipo de máquina
Product no.
Produktnr
Produktnummer
Numéro de produit
Número de producto
Machine unit
description
Maskinblocksbenämning
Bezeichnung des
Maschinenblocks
Dénomination de partie
de machine
Descripción de sección
de la máquina
Machine unit no.
Maskinblocksnr
Maschinenblock Nr.
Partie de machine nº
No. de sección de
máquina
Subassembly
description
Undergruppsbenämning
Bezeichung der
Untergruppe
Dénomination de
sous-ensemble
Descripción de
subconjunto
Subassembly no.
Undergruppsnr
Untergruppe Nr.
Nº de sous-ensemble
Número de subconjunto
See page
Se sidan
Siehe Seite
Vòir page
Véase la página
Fig. ref.
Figurhänvisning
Bildhinweise
Réf. de fig.
Referencia de figura
Product name
Produktnamn
Produktname
Nom du produit
Nombre del producto
Exchange necessitates
rebalancing of bowl
Utbyte nödvändiggör
ombalansering av kulan
Austasch erfordert
Wiederauswuchtung der
Trommel
Le remplacement
nécessite le
rééquilibrage du bol
El racmbio requiere el
reequilibrado del rotor
See separate spare
parts list
Se separat
reservdelslista
Siehe separate
Ersatzteilliste
Voir liste séparée des
pièces de rechange
Véase la lista de piezas
separada
Not delivered as spare
part
Levereras ej som
reservdel
Nicht als Ersatzteil
geliefert
Non livré comme piéce
de rechange
No se entrega como
pieza de recambio
9
1 Read this first
Translation list
Ñëîâàðü ïåðåâäà
Lista traduzioni
Lista para tradução
Käännösluttelo
Part no.
Äåòàëü ¹
Nr.parte.
Numero de peca
Varaosanumero
Qty
Êîë—âî
Quantita
Quantidade
Lukumäärä
Description
Íàèìåíîâàíèå
Descrizione
Descricao
Nimitys
Notes
Ïðèìå÷àíèÿ
Note
Notas
Huomautuksia
Machine type
Ìàøèíà òíïà
Tipo macchina
Tipo de maquina
Konetyyppi
Product no.
Àðòèêóë ¹
Nr.produtto
No. do produto
Tuotteen no
Machine unit
description
Íàèìåíîâàíèå áëîêà
ìàøèíû
Nr. unita macchina
Descricao da unidade da
maquina
Koneenosan nimitys
Machine unit no.
Áëîê ìàøèíû ¹
Descrizione sottogruppo
Numero de unidade da
maquina
Koneenosan no
Subassembly
description
Íàèìåíîâàíèå ãðóïïû
Descrizione unita
macchina
Descriao do subconjunto
Alaryhmän nimitys
Subassembly no.
Ãðóïïà ¹
Nr. sottogruppo.
Número de subconjunto
Alaryhmän no
See page
Ñì. ñòðàíèöó
Vedi pagina
Véase la página
Ks sivu
Fig. ref.
Ññûëêà íà çñêèç
Rif. fig.
Referencia de figura
Kuvaviite
Product name
Íàèìåíîâàíèå
àðòèêóëà
Nome prodotto
Nombre del producto
Tuotteen nimi
Exchange necessitates
rebalancing of bowl
Çàìåíà òðåáóåò
áàëàíñèðîâêè áàðàáàíà
La sostituzione comporta
la iequilibratura del
tamburo
El racmbio requiere el
reequilibrado del rotor
Vaihdettaessa kuula
tasapainoitettava
uudelleen
See separate spare
parts list
Ñì. îòäåëüíûé
ïåðå÷åíü çàïàñíûõ
÷àñòåé
Vedi lista separata delle
parti di ricambio
Véase la lista de piezas
separada
Katso erillistä
varaosaluetteloa
Not delivered as spare
part
Íå ïîñòàâëåíà âìåñòå ñ
çàïàñíûìè ÷àñòÿìè
Non fornito come parte di
ricambio
No se entrega como
pieza de recambio
Ei toimiteta varaosana
10
1 Read this first
Translation list
ÃËÙÓÓÁÑÉ
Vertaallijst
Oversættelseliste
Part no.
Ëñéèìüò áíôáëëáêôéêïý
Onderdeelnr.
Reservedelsnummer
Qty
Óýíïëï
Hoeveelheid
Antal
Description
ÐåñéãñáöÞ
Beschrijving
Betegnelse
Notes
ÐáñáôçñÞóåéò
Opmerkingen
Bemaerkninger
Machine type
Ôýðïò ìç÷áíÞìáôïò
Machinetype
Maskintype
Product no.
Áñéèìüò ðñïúüíôïò
Produktnr.
Produktnr.
Machine unit
description
ÐåñéãñáöÞ
óõãêñïôÞìáôïò ìç÷áíÞò
Machineblokbenaming
Maskinbetegnelse
Machine unit no.
Áñéèìüò óõãêñïôÞìáôïò
ìç÷áíÞò
Machineblokbenamning
Maskinnr.
Subassembly
description
ÐåñéãñáöÞ
õðïóõãêñïôÞìáôïò
Subgroepbenamning
Undergruppsbetegnelse
Subassembly no.
Áñéèìüò
õðïóõãêñïôÞìáôïò
Subgroepnr.
Undergruppenr.
See page
ÂëÝðå óåëßäá
Zie blz.
Se side
Fig. ref.
ÐáñáðïìðÞ óå åéêüíá
Afb. ref.
Figurhenvisning
Product name
Ïíïìáóßá ðñïúüíôïò
Produktnaam
Produktnavn
Exchange necessitates
rebalancing of bowl
ÁíôáëëáãÞ áðáéôåß
åðáíáññýèìéóç
éóïññïðßáò ôïõ
ôýìðáíïõ
Vervangning vereist
herbalanceren van de
kogel
Udskriftning kraever ny
afbalcering af kuglen
See separate spare
parts list
ÂëÝðå åéäéêÞ ëßóôá
áíôáëëáêôéêþí
Vervangning vereist van
de kogel
Se spaat reservedelsliste
Not delivered as spare
part
Äåí ðáñáäßäåôáé ùò
áíôáëëáêôéêü
Niet geleverd als
reserveonderdeel
Levereres ikke som
reservedel
11
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 Ancillary Equipment
2.1 Valve block water
Machine unit number or
Subassembly description
Ref
Part No
Description
567940
-01
Notes
Quantity
1
2
3
4
5
6
6A
6B
7
8
9
12
176592701
176603704
176603702
176603703
56971201
176707180
176616201
176019105
176615701
176593603
176593701
Valve block, water
Flow valve, 0.9 l/min
Flow valve, 11.0 l/min
Flow valve, 2.8 l/min
Rectangular connector
Non return valve kit
Non return valve
Washer
Quick coupling
Flexible connection
Flexible connection
1
1
1
1
3
1
1
1
1
1
1
579616-02
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
579616-02
13
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.2 Spare parts kit, valve block water
Machine unit number or
Subassembly description
Ref
Part No
Description
1765993
-83
Notes
Quantity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
14
176599301
176599302
176599303
176599304
176599305
176599306
176599307
176599308
176599309
176599310
176599311
176600407
176600408
176599313
176599316
Retaining clip
Spring
Core
Spring washer
O-ring
Piston
Valve
Non-return valve
O-ring
O-ring
Coil
Washer adhesive tape
Indicator
Drain valve
Strainer
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
579616-02
2 ANCILLARY EQUIPMENT
X018351D
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
579616-02
15
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.3 Valve block air
Machine unit number or
Subassembly description
Ref
Part No
Description
568048
-01
Notes
Quantity
1
2
3
4
16
176592801
176391102
176391104
56971203
Valve block
Flexible connection
Flexible connection
Rectangular connector
1
1
2
3
579616-02
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
579616-02
17
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.4 Spare parts kit, valve block air
Machine unit number or
Subassembly description
Ref
Part No
Description
1766004
-82
Notes
Quantity
1
2
3
4
5
6
7
8
9
18
176600401
176600402
176600403
176600404
176600405
176600406
176600407
176600408
176600409
Retaining clip
Spring
O-ring
O-ring
Screw
Coil
Washer adhesive tape
Indicator
Manometer
1
1
1
1
1
1
1
1
1
579616-02
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
9
579616-02
19
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.5 Sludge removal kit
Ref
Part No.
Description
577837-01 DIN
577837-02 JIS
-01 -02
Notes
Quantity
1
2
3
1766869 80 Tank
1766704 01 Level switch
1766699 01 Sludge pump
1
1
1
1
1
1
4
5
6
7
8
9
10
11
11
13
15
17
19
20
21
23
24
25
26
27
30
38
39
40
41
42
43
574409
1763491
1763911
1765974
1763780
574351
1766002
1765962
1765962
1762672
221035
70560
1766080
526352
1766308
1766789
1766788
1766715
1761482
1766081
1766893
574386
1761834
577830
561339
41456
221040
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
81
02
03
01
02
01
01
80
81
01
07
01
01
02
80
01
01
06
01
01
01
11
01
01
08
1766702 80
Solenoid valve
Nipple R1/8-R1/8
Flexible connection, air
Elbow pipe R1/8-R1/8
Nipple G3/4-G3/4
Flexible connection, L = 480
Non return valve conn. G3/4
Sludge outlet flange
Sludge outlet flange
Hexagon plug G1/2
Screw
Washer
Distance nipple G1/8-G1/8
Bushing R1/4-R1/8
Packing
Cover
Gasket
Inlet pipe
O-ring
Regulating valve
Plug G11/2
Extension pipe
Coppar washer
Sludge outlet
Gasket
Washer
Screw
Optional:equipment including:
Sludge pump T70 spare parts
1
4
4
1
1
1
1
1
1
1
1
2
1
1
1
1
4
4
1
1
4
4
1
1
1
1
1
1
1
1
2
1
1
1
1
4
4
See 2.6 Sludge pump, page
22
See 2.6 Sludge pump, page
22
1766702 81 Spare parts kit
20
See 2.6 Sludge pump, page
22.
579616-02
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
579616-02
21
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.6 Sludge pump
Ref
Part No.
Description
1766699-01
Quantity
1
2
3
1
2
3
4
5
22
1766702
1766702
1766702
1766702
1766702
1766702
1766702
1766702
1766702
1766702
81
01
02
03
80
01
02
03
04
05
Spare parts kit including:
O-ring/packing kit
Diaphagm
O-ring
Sludge pump spare parts
O-ring/packing kit
Diaphagm
O-ring
Air valve
Muffler
4
2
6
4
2
6
1
1
579616-02
Notes
2 ANCILLARY EQUIPMENT
X0 1 8 3 8 2 A
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
579616-02
23
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.7 Valve block oil
Machine unit number or
Subassembly description
Ref
Part No
Description
567802
-08 -09
Notes
Quantity
1
2
3
4
6
7
8
9
10
11
12
13
14
15
16
17
17A
17B
19
22
23
24
25
26
28
29
30
31
32
33
34
35
36
37
38
39
40
41
24
176587701
176476086
176644401
56971201
176610201
176473301
176462101
176401101
176349201
176378003
176508209
176390303
176589701
176591101
54305405
176443980
176439101
176181480
176590801
5350047202
176593401
22104546
22310149
22180333
22104529
176183403
22104528
22104551
176183406
56971201
176589701
176390303
176183406
176508209
176183403
5355171602
5355171602
Valve block
Water transducer
Valve
Rectangular connector
Non-return valve
Pneumatic 3-way valv
Shut-off valve
Silencer
Elbow
Nipple
Nipple
Needle valve
Pressure transmitter
Elbow
Pressure gauge
Temperature sensor
Temperature sensor
Spring pocket
Connection kit, oil
Gasket
Cable 19
Flexible connection
Screw
Washer
Nut
Screw
Cu-washer
Screw
Screw
Washer
Rectangular connector
Pressure transmitter
Needle valve
Washer
Nipple
Cu-washer
Washer
Washer
1
1
1
2
2
1
1
1
1
2
2
2
2
2
2
1
1
1
1
8
1
1
8
40
16
4
1
4
4
2
1
1
1
1
1
1
4
2
579616-02
1
1
1
2
2
1
1
1
1
2
2
2
2
2
2
1
1
1
1
8
1
1
8
40
16
4
1
4
4
2
1
1
1
1
1
1
4
2
See page 26
See page 28
2xPt-100
See page 30
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
579616-02
25
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.8 Water transducer
Machine unit number or
Subassembly description
Ref
Part No
Description
1764760
-86
Notes
Quantity
1
2
3
4
5
6
176475884
176476901
176476880
176476701
176521682
22340470
26010419
7
8
9
10
11
12
14
15
16
18
19
23
24
25
27
176513001
176476103
176476601
26750
22104008
22310706
22103010
22310725
176476202
3183045474
22112106
490167322
22170113
490122209
492636801
26
Valve body
Distance rod
Electrode
Insulator
Spare parts kit including:
O-ring
O-ring
1
2
1
1
1
1
1
Gasket
Cover
Bushing
Spring washer
Screw
Spring washer
Screw
Spring washer
Junction box
Circuit board
Screw
Spacing sleeve
Screw
Connector
Product label
1
1
1
2
4
4
4
4
1
1
1
1
1
1
1
579616-02
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
579616-02
27
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.9 Spare parts kit, pneumatic 3-way valve
Machine unit number or
Subassembly description
Ref
Part No
Description
Notes
Quantity
1
1A
1B
1C
28
176473482
176473404
176473405
176473406
Spare parts kit including:
Diaphragm
Stuffing box kit
Stem/disc kit
1
1
1
1
579616-02
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
1A
1B
1C
579616-02
29
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.10 Connection kit, oil
Machine unit number or
Subassembly description
Ref
Part No
Description
Notes
Quantity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
30
176598901
57433380
57429980
57429880
22340451
22340451
26010422
22104509
22310149
22364114
22364103
22103506
70560
22103506
70560
Connecting plate
Flexible hose
Flexible hose
Flexible hose
O-ring
O-ring
O-ring
Screw
Washer
Snap ring
Retaining ring
Screw
Washer
Screw
Washer
1
1
1
1
6
1
2
1
1
2
1
2
2
2
2
579616-02
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
579616-02
31
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.11 Sludge outlet kit
Machine unit number or
Subassembly description
Ref
Part No
Description
Notes
Quantity
1
1
1A
2
3
4
32
176684780
176684781
176609601
56133901
41456
22104008
Sludge outlet DIN
Sludge outlet JIS
Plug
Gasket
Washer
Screw
1
1
1
1
4
4
579616-02
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
579616-02
33
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.12 Butterfly valve
Machine unit number or
Subassembly description
Ref
Part No
Description
Notes
Quantity
1
2
34
176600701
56830403
176616101
176616105
Butterfly valve
Sludge valve interlock
Seat
Limit switch
1
1
1
1
579616-02
Mounted in Control Unit
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
2
579616-02
35
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.13 Spare parts, EPC 50 Control Unit
Machine unit number or
Subassembly description
Ref
Part No
Description
Notes
Quantity
5
6
7
8
8
3183045511
3183045492
3183045841
3183065591
3183065581
EPC 50 Vibration Board
EPC 50 Heater Board
EPC 50 I/O Expansion Board
Profibus board
Modbus board
1
1
1
1
1
Optional
Optional
Optional
Optional
Optional
Machine unit number or
Subassembly description
Ref
Part No
Description
568452
-01
Notes
Quantity
1
2
3
4
9
10
11
12
15
16
17
18
21
22
23
36
3183062451
3183045486
3183063461
3183062411
5350046201
5350020103
5350020110
5350020111
5350048901
5350048902
5350048903
5350045102
3183063731
3183063721
5350046203
EPC 50 OP front module
EPC 50 I/O board
Cable
EPC 50 transformer
Push button
Switch
Sealing
Led bulb, white, 24 V AC
Switch body
Switch actuator
Legend plate
Pilot lamp
Fuse kit
EPC 50 Board mounting kit
Protector
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
579616-02
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
579616-02
37
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.14 EPC 50 Control unit
Machine unit number or
Subassembly description
Ref
Part No
Description
568303
-01 -02
Notes
Quantity
56830401
176719980
Control unit epc
8-pole connector
1
1
1
1
Mounted on separator
2.15 Starters
Machine unit number or
Subassembly description
Ref
Part No
Description
Notes
Quantity
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
568022
38
01
10
11
12
13
14
15
16
17
18
32
33
34
35
36
37
20
21
22
23
24
25
26
27
30
Basic kit for starter
Sep. starter, 2.5-4A
Sep. starter, 4-6.3A
Sep. starter, 6.3-10A
Sep. starter, 10-16A
Sep. starter, 16-20A
Sep. starter, 20-25A
Sep. starter, 25-32A
Sep. starter, 32-45A
Sep. starter, 45-63A
Sep. start., 690v,6.3-10v
Sep. start., 690v,10-16A
Sep. start., 690v,16-20A
Sep. start., 690v,20-25A
Sep. start., 690v,25-32A
Sep. start., 690v,32-45A
Pump starter, 0,4-0,63A
Pump starter, 0.63-1A
Pump starter, 1-1.6A
Pump starter, 1.6-2.5A
Pump starter, 2.5-4A
Pump starter, 4-6.3A
Pump starter, 6.3-10A
Pump starter, 10-16A
Pump starter, 690V, 6.3-10A
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
579616-02
See page 39
See page 39
See page 39
See page 39
See page 39
See page 39
See page 39
See page 39
See page 40
See page 40
See page 40
See page 40
See page 40
See page 40
See page 40
See page 40
See page 41
See page 41
See page 41
See page 41
See page 41
See page 41
See page 41
See page 41
See page 41
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
2.16 Separator starter kits, basic and 4A – 32A
Machine unit number or
Subassembly description
Ref
Part No
2
3
4
6
8
F8
K2
K2
K2
K2
K2.1
K2.2
P2
P2
P2
P2
P2
Q1
Q2
Q2
Q2
Q2
Q2
Q2
Q8
T8
TA2
TA2.1
X1
XF8
568026
1764728
1761990
53500447
53500453
53500167
53500460
53500460
53500460
53500460
53500461
53500461
53500006
53500006
53500006
53500006
53500006
1764712
53500098
53500098
53500098
53500098
53500098
53500098
53500098
568027
53500503
53500503
53500402
53500402
Description
568022
-01 -10 -11 -12 -13 -14 -15 -16 Notes
Quantity
02
01
02
01
01
02
02
04
05
08
01
02
01
02
03
04
06
05
28
29
30
31
32
33
36
01
01
03
11
18
Wall mounting kit
Label
Product label
Diagram pocket
Ground connection
Fuse
Contactor
Contactor
Contactor
Contactor
Aux. contact block
Aux. contact block
Ammeter
Ammeter
Ammeter
Ammeter
Ammeter, 50/5A
Switch
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
Transformer
Current transformer
Mounting kit
Terminal
Fuse terminal
1
1
1
1
1
1
for door
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 for TA2
1
1
579616-02
39
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.17 Separator starter kits, 32A – 63A
Machine unit number or
Subassembly description
Ref
Part No
K2
K2
K2
K2
K2.1
K2.2
P2
P2
P2
P2
P2
Q2
Q2
Q2
Q2
Q2
TA2
TA2
TA2.1
53500460
53500460
53500460
53500460
53500461
53500461
53500006
53500006
53500006
53500006
53500006
53500098
53500098
53500098
53500098
53500098
53500503
53500503
53500503
Description
568022
-17 -18 -32 -33 -34 -35 -36 -37 Notes
Quantity
40
04
05
08
09
01
02
01
03
04
06
07
30
31
32
33
37
01
02
03
Contactor
Contactor
Contactor
Contactor
Aux. contact block
Aux. contact block
Ammeter
Ammeter
Ammeter
Ammeter, 50/5A
Ammeter, 75/5A
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
Current transformer
Current transformer
Mounting kit
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 for TA2
1
1
1
1
1
1
1
1
1
1
1
1
1
579616-02
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
2.18 Pump starter kits, 0.4A – 16.0A
Machine unit number or
Subassembly description
Ref
Part No
K2
K2
K2.1
K2.2
Q3
Q3
Q3
Q3
Q3
Q3
Q3
Q3
53500460
53500460
53500461
53500461
53500098
53500098
53500098
53500098
53500098
53500098
53500098
53500098
Description
02
04
01
02
24
25
26
27
28
29
30
31
Contactor
Contactor
Aux. contact block
Aux. contact block
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
568022
-20 -21 -22 -23 -24 -25 -26 -27 -30 Notes
1
1
1
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
579616-02
41
2 ANCILLARY EQUIPMENT
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2.19 ESD-relay kit
Machine unit number or
Subassembly description
Ref
Part No
Description
568022
-53
Notes
Quantity
K112
K112.1
5350002809
5350002808
Relay
Relay socket
1
1
2.20 Motor trip contact kit
Machine unit number or
Subassembly description
Ref
Part No
Description
568022
-51
Notes
Quantity
Q2.1
Q3.1
42
5350009838
5350009838
Trip contact block
Trip contact block
1
1
579616-02
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
2 ANCILLARY EQUIPMENT
579616-02
43
3 INDEX
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
3 Index
44
1760191 05
12
1765937 01
12
1766702 04
22
1761482 06
20
1765962 80
20
1766702 05
22
1761814 80
24
1765962 81
20
1766702 80
20
1761834 03
24
1765974 01
20
1766702 80
22
1761834 03
24
1765989 01
30
1766702 81
20
1761834 06
24
1765993 01
14
1766702 81
22
1761834 06
24
1765993 02
14
1766704 01
20
1761834 11
20
1765993 03
14
1766715 01
20
1761990 02
39
1765993 04
14
1766788 01
20
1762672 01
20
1765993 05
14
1766789 80
20
1763491 02
20
1765993 06
14
1766847 80
32
1763492 01
24
1765993 07
14
1766847 81
32
1763780 02
20
1765993 08
14
1766869 80
20
1763780 03
24
1765993 09
14
1766893 01
20
1763903 03
24
1765993 10
14
1767071 80
12
1763903 03
24
1765993 11
14
1767199 80
38
1763911 02
16
1765993 13
14
221030 10
26
1763911 03
20
1765993 16
14
221035 06
30
1763911 04
16
1766002 01
20
221035 06
30
1764011 01
24
1766004 01
18
221035 07
20
1764391 01
24
1766004 02
18
221040 08
20
1764439 80
24
1766004 03
18
221040 08
26
1764621 01
24
1766004 04
18
221040 08
32
1764712 05
39
1766004 05
18
221045 09
30
1764728 01
39
1766004 06
18
221045 28
24
1764733 01
24
1766004 07
14
221045 29
24
1764734 04
28
1766004 07
18
221045 46
24
1764734 05
28
1766004 08
14
221045 51
24
1764734 06
28
1766004 08
18
221121 06
26
1764734 82
28
1766004 09
18
221701 13
26
1764758 84
26
1766007 01
34
221803 33
24
1764760 86
24
1766037 02
12
223101 49
24
1764761 03
26
1766037 03
12
223101 49
30
1764762 02
26
1766037 04
12
223107 06
26
1764766 01
26
1766080 01
20
223107 25
26
1764767 01
26
1766081 01
20
223404 51
30
1764768 80
26
1766096 01
32
223404 51
30
1764769 01
26
1766102 01
24
223404 70
26
1765082 09
24
1766157 01
12
223641 03
30
1765082 09
24
1766161 01
34
223641 14
30
1765130 01
26
1766161 05
34
260104 19
26
1765216 82
26
1766162 01
12
260104 22
30
1765877 01
24
1766308 02
20
26750
26
1765897 01
24
1766444 01
24
41456
20
1765897 01
24
1766699 01
20
41456
32
1765908 01
24
1766702 01
22
490122209
26
1765911 01
24
1766702 01
22
490167322
26
1765927 01
12
1766702 02
22
492636801
26
1765928 01
16
1766702 02
22
526352 01
20
1765934 01
24
1766702 03
22
53500006 01
39
1765936 03
12
1766702 03
22
53500006 01
40
579616-02
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
3 INDEX
53500006 02
39
53500461 02
39
574333 80
30
53500006 03
39
53500461 02
40
574351 01
20
53500006 03
40
53500461 02
41
574386 01
20
53500006 04
39
53500462 01
36
574409 81
20
53500006 04
40
53500462 03
36
577830 01
20
53500006 06
39
53500472 02
24
70560
20
53500006 06
40
53500489 01
36
70560
30
53500006 07
40
53500489 02
36
70560
30
53500028 08
42
53500489 03
36
31830 4547 4
26
53500028 09
42
53500503 01
39
31830 4548 6
36
53500098 24
41
53500503 01
40
31830 4549 2
36
53500098 25
41
53500503 02
40
31830 4551 1
36
53500098 26
41
53500503 03
39
31830 4584 1
36
53500098 27
41
53500503 03
40
31830 6241 1
36
53500098 28
39
53551716 02
24
31830 6245 1
36
53500098 28
41
53551716 02
24
31830 6346 1
36
53500098 29
39
543054 05
24
31830 6372 1
36
53500098 29
41
561339 01
20
31830 6373 1
36
53500098 30
39
561339 01
32
31830 6558 1
36
53500098 30
40
568022 01
38
31830 6559 1
36
53500098 30
41
568022 10
38
53500098 31
39
568022 11
38
53500098 31
40
568022 12
38
53500098 31
41
568022 13
38
53500098 32
39
568022 14
38
53500098 32
40
568022 15
38
53500098 33
39
568022 16
38
53500098 33
40
568022 17
38
53500098 36
39
568022 18
38
53500098 37
40
568022 20
38
53500098 38
42
568022 21
38
53500098 38
42
568022 22
38
53500167 02
39
568022 23
38
53500201 03
36
568022 24
38
53500201 10
36
568022 25
38
53500201 11
36
568022 26
38
53500402 11
39
568022 27
38
53500402 18
39
568022 30
38
53500447 01
39
568022 32
38
53500451 02
36
568022 33
38
53500453 01
39
568022 34
38
53500460 02
39
568022 35
38
53500460 02
41
568022 36
38
53500460 04
39
568022 37
38
53500460 04
40
568026 02
39
53500460 04
41
568027 01
39
53500460 05
39
568304 01
38
53500460 05
40
568304 03
34
53500460 08
39
569712 01
12
53500460 08
40
569712 01
24
53500460 09
40
569712 01
24
53500461 01
39
569712 03
16
53500461 01
40
574298 80
30
53500461 01
41
574299 80
30
579616-02
45
3 INDEX
46
SA 821 SEPARATION SYSTEM SPARE PARTS CATALOGUE
579616-02