Alfa Laval

Separation Unit 840

Service ManualPrintedBook No.

Jan 20031810828-02 V 1

Alfa Laval reserves the right to make changes at any time withoutprior notice.

Any comments regarding possible errors and omissions orsuggestions for improvement of this publication would begratefully appreciated.

Copies of this publication can be ordered from your localAlfa Laval company.

Published by: Alfa Laval Tumba ABMarine & Diesel EquipmentSE - 147 80 TumbaSweden

© Copyright Alfa Laval Tumba AB 2003.

Contents
1 Separator Design .................................1
1.1 Overview .............................................1

1.2 The Drive Section.............................3

1.3 The Process Section .......................41.4 Sensors ................................................8

1.5 Separating Function ........................91.5.1 The liquid balance in the bowl ...............9

1.5.2 Liquid flow ............................................10

1.5.3 Discharge of sludge and water ............101.5.4 ALCAPTM concept................................11

2 Technical Reference ......................132.1 Technical Data ................................132.2 Connection List...............................15

2.3 Interface Description ....................17

2.3.1 Scope ...................................................172.3.2 References ...........................................17

2.3.3 Definitions.............................................182.3.4 Goal ......................................................18

2.3.5 Description of separator modes...........19

2.3.6 Remote start .........................................202.3.7 Handling of connection interfaces .......20

2.4 Drawings ...........................................27

2.4.1 Basic size drawing ...............................272.4.2 Foundation drawing..............................28

2.4.3 Interconnection diagram ......................292.4.4 Electric motor .......................................30

2.5 Nomogram paring tube.................32

3 Separator Service, Dismantling, Assembly .................353.1 Periodic Maintenance ...................35

3.1.1 Maintenance intervals ..........................35

3.1.2 Maintenance procedures .....................363.1.3 Tightening of screws ............................37

3.1.4 Service kits ...........................................37

3.1.5 Cleaning ...............................................383.2 Maintenance Log ............................39

3.3 Dismantling ......................................413.3.1 Introduction...........................................41

3.3.2 Tools .....................................................42

3.3.3 Frame hood ..........................................443.3.4 Bowl......................................................46

3.3.5 Driving device ......................................56

3.3.6 Centrifugal clutch .................................68

3.4 Actions Before Assembly ............743.4.1 Cleaning .............................................74

3.4.2 Inspection for corrosion ......................76

3.4.3 Inspection for cracks ..........................773.4.4 Inspection for erosion .........................78

3.4.5 Exchange of frame feet ........................803.4.6 Lubrication of bowl parts ......................81

3.4.7 How to lubricate bowl parts with slide laquer....................................................82

3.4.8 Check for galling on operating slide and bowl body .....................................83

3.5 Assembly ...........................................84

3.5.1 Centrifugal clutch .................................84

3.5.2 Driving device.......................................903.5.3 Bowl ....................................................102

3.5.4 Frame hood ........................................1153.5.5 Unbalance sensor (option) .................119

3.5.6 Speed sensor .....................................120

3.6 Actions After Assembly..............1213.6.1 Control of machine plates and safety

labels .................................................121

3.7 Oil Change ......................................123

3.7.1 Lubricating oil .....................................1233.7.2 Check oil level ....................................124

3.7.3 Oil change procedure.........................124

3.7.4 Lubrication chart.................................1253.7.5 Lubricants...........................................126

3.7.6 Lubricating oils ...................................1283.8 Lifting instructions ......................129

3.8.1 Lifting the separator............................129

3.8.2 Lifting the bowl ...................................131

4 Change of Circuit Board............1324.1 Circuit Board Temperatures .....134

5 Cleaning in Place ...........................1355.1 Cleaning in Place, Separator ....135

5.2 Cleaning in Place, Heatpac® CBM Heater ....................................136

5.3 Cleaning in Place, Separator and Heater ......................................138

6 Heatpac® CBM Heater (Optional).............................................1396.1 Technical Data .............................1396.1.1 Manual Cleaning.................................139

1810828-02

7 Heatpac® EHM Electric Heater (Optional) ...........................1417.1 Technical Data ............................ 141

7.2 Dismantling and Cleaning......... 142

7.2.1 Replacing Heater Element................. 1437.2.2 Insulation Resistance Megger Test ... 144

7.2.3 Measuring of Heater Block Resistance ........................................ 146

8 Heatpac® Power Unit (Optional) .............................................1498.1 Technical Data ............................ 149

8.2 Working principle ........................ 1508.3 Electric Heater Function ......... 150

8.4 Heating Performance Principle ........................................ 151

8.5 Load Control and Functions..... 1528.5.1 Variable Part Load ............................ 152

8.5.2 Fixed Part Load ................................ 152

8.5.3 External Safety Stop ......................... 1538.5.4 Start and Reset Functions ................ 153

1810828-02

SEPARATION UNIT 840 SERVICE MANUAL 1 SEPARATOR DESIGN

1 Separator Design

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41

Drive section

The rotating separator bowl is driven by a flat belt transmission.

Sludge outlet

Separated solids are discharged at preset intervals.

Electric motor

The rotating bowl is driven by the electric motor via a belt transmission.

1.1 OverviewThe separator comprises a process section and adrive section powered by an electric motor.

The separator frame comprises a lower body anda frame hood. The motor is attached to theframe. The frame feet dampen vibration.

The bottom part of the separator contains a flatbelt transmission, a centrifugal clutch and avertical spindle. The lower body also contains anoil bath for lubrication of spindle bearings.

Process section

The feed inlet and outlets are situated at the top of the separator.

The liquid is cleaned in the rotating separator bowl inside the frame hood.

Frame feet

The separator rests on vibration damping frame feet.

Sensors

The separator is monitored by a speed sensor. An unbalance sensor is optional.

1810828-02 1

1 SEPARATOR DESIGN SEPARATION UNIT 840 SERVICE MANUAL

The frame hood contains the processing parts ofthe separator; the inlets, outlets and piping.

The process liquid is cleaned in the separatorbowl. The bowl is fitted on the upper part of avertical spindle and rotates at high speed insidethe frame hood. The bowl also contains thedischarge mechanism which empties the sludgeduring operation.

A speed sensor and an unbalance sensor (option)are part of the equipment for monitoring theseparator functions.

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41

The centrifugal clutch ensures a gentle start and smooth acceleration, and at the same time prevents overloading of the belt and motor.

Flat belt

The flat belt transmission has a ratio which increases the bowl speed several times compared with the motor speed.

1.2 The Drive Section

The separator bowl is driven by an electricmotor via a belt transmission. The belt pulleyon the motor shaft includes a centrifugalclutch.

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 bearings on the spindle are lubricated by the oil spray produced by an oil pump mounted on the lower end of the spindle.

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1.3 The Process SectionThe separation process takes place insidethe rotating separator bowl. The feed andoutlet of process liquid takes place in the inand outlet unit on top of the separatorframe hood.

Inlet and outlet

The inlet and outlet unit consists of thefollowing parts:

A connection house for pipe connections.

A pipe with a paring disc and a paring tube islocated inside the connection house. The pipehas channels for incoming and outgoingprocess liquid.

The paring disc and paring tube pump thecleaned oil and water respectively out of thebowl.

The paring tube can move radially. Duringseparation it surfs on the liquid surface. It isbalanced by a spring.

Under certain operating conditions, the paringtube radial position can be locked in place bytwo adjustable screws on the connection house.

The paring disc and tube are located inside andat the top of the separator bowl.

The inlet and outlet device is held togetheragainst the frame hood by a nut on the end ofthe inlet pipe.

Height adjusting rings determine the heightposition of the paring disc and paring tuberelative to the bowl.

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41

Uncleaned oil

Cleaned oil

Water

Pipe

Paring disc

Paring tube

Connection house

Spring

Arm

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Separator bowl

The separator bowl, with its sludge dischargemechanism, is built-up as follows:

The bowl body and bowl hood are held togetherby a lock ring (Centrilock). Inside the bowl arethe distributor and the disc stack. The disc stackis kept compressed by the bowl hood. Thedischarge slide forms a separate bottom in thebowl body.

The upper space between the bowl hood and thetop disc forms the water paring chamber andcontains the paring tube, which pumps theseparated water out of the bowl. The oil paringchamber, with its paring disc, is located insidethe top of the distributor. From here the cleanedoil is pumped out of the bowl.

The sludge space is in the bowl periphery. Thebowl is kept closed by the discharge slide, whichseals against a seal ring in the bowl hood.

At fixed intervals, decided by the operator, thedischarge slide drops down to empty the bowl ofsludge.

The sludge discharge mechanism, which controlsthe movement of the discharge slide, iscomprised of an operating slide and an operatingwater device. Passive parts are: nozzle and valveplugs. The operating water cover, beneath thebowl, supplies operating water to the dischargemechanism via the operating water ring.

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51

Lock ring

Nozzle

Holder Operating water ring

Sludge space

Discharge slide

Seal ring

Disc stack

Oil paring chamber

Top disc

Water paring chamber

Bowl hood

Bowl body

Operating slide

1810828-02 7


onitoring kit (option)

r indication of any abnormal unbalance, the separator can equipped with a sensor monitoring the radial position of

e bowl spindle.

ver interlocking kit (option)

hen the cover is closed the interlocking circuit in the control stem is closed which makes it possible to start the parator.

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71

Unbalance sensor

Speed sensor

Cover interlocking switch

1.4 SensorsThe separator is equipped with a speedsensor. As options, an unbalance sensor andan interlocking kit can be fitted.

Speed sensor

A speed sensor indicates the speed of the separator. The correct speed is needed to achieve the best separating results and for reasons of safety. Refer to name plate for speed particulars.

M

Fobeth

Co

Wsyse

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31

1.5 Separating Function

The separator separates water and solids from the uncleaned oil. Water normally leavesthe separator through the water outlet. During sludge discharge, solids (sludge) and waterare removed through the discharge ports.

1.5.1 The liquid balance in the bowl

The liquid levels in the bowl depend on manyfactors (bowl geometry, liquid densities, flowrates etc.). To get a picture of how the liquidsare distributed in the bowl, imagine that thebowl is at standstill and turned 90° (onlyinfluenced by gravity). The bowl can now becompared with a settling tank:

Unseparated oil

Separated oil

Water

Distributor

Oil/water interface

Top disc

Unseparated oil

Separated oil

Water

SETTLING TANK

SEPARATOR BOWL TURNED 90°

G

R

A

V

I

T

Y

1810828-02 9


1.5.2 Liquid flow

Unseparated oil is fed into the bowl through theinlet pipe and travels via the distributor towardsthe periphery of the bowl.

When the oil reaches slots in the distributor, itrises through the channels formed by the discstack, where it is evenly distributed.

The oil is continuously cleaned as it travelstowards the centre of the bowl. When the cleanedoil leaves the disc stack, it flows through anumber of holes in the distributor and enters theoil paring chamber. From here it is pumped bythe oil paring disc, and leaves the bowl throughthe oil outlet. Separated water, sludge and solidparticles, which are heavier than the oil, areforced towards the periphery of the bowl andcollect in the sludge space.

The space between the bowl hood and top disc, aswell as the water paring chamber, is filled withoil, which is distributed over the entirecircumference via the grooves in the top disc.

During normal operation, the water drain valvein the water outlet is closed.

1.5.3 Discharge of sludge and water

As the sludge space fills up and water enters thedisc stack, traces of water will escape with thecleaned oil. The increase of water content in thecleaned oil is the sign of reduced separationefficiency.

This condition is monitored by the processcontrol system, and water is removed from thebowl when minimal levels are recorded.

The water is removed by either of two ways:

• The water drain valve opens and the waterleaves the bowl through the water outlet.

• Through the sludge ports at sludgedischarge.

Which way is decided by the process controlsystem.

10 1810828-02


1.5.4 ALCAPTM concept

When the sludge space is filled up and waterenters the disc stack, traces of water will escapewith the cleaned oil. The increase of watercontent in the cleaned oil is the sign of reducedseparation efficiency.

This condition is monitored by the processcontrol system, and water is removed from thebowl when minimal levels are recorded.

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Unseparated oil

Separated oil

Water

Water paring tube

Water paring chamber

Holes in distributor

Top disc

Sludge space

R THROUGH WATER OUTLET

Uncleaned oil

Cleaned oil

Water

Oil/water interface

Oil paring chamber

Oil paring disc

DISCHARGE OF WATE

Bowl hood

12 1810828-02

SEPARATION UNIT 840 SERVICE MANUAL 2 TECHNICAL REFERENCE

2 Technical Reference

xcept for the council

tive.

pplications subject toleaning program.

2.1 Technical DataAlfa Laval ref. 569604 rev. 2

Product number: 881203-03-01

Separator type: S 840

Application: Cleaning of fuel and lube oil.

Technical design: Intended for marine- and land installations. Total discharge.

Designed in accordance with standards:

Restrictions:

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.

Remote restart allowed under certain conditions, see Interface description.

NOTE

The separator is a component operating in anintegrated system including a monitoring system.

If the technical data in the system description doesnot agree with the technical data in this instructionmanual, the data in the system description is thevalid one.

98/37EC The Directive of the European Parliament erelating to the machinery.

89/336EEC EMC and amendments related to said direc

EN 292-2 Safety of machines. Use of the machine in ahygienic demands requires a well adapted c

1810828-02 13

2 TECHNICAL REFERENCE SEPARATION UNIT 840 SERVICE MANUAL

nit

W

0Hz

0Hz

m/s

m

inutes

g/m³

g/m³

C

inutes

inutes

/min 50Hz/60Hz

/min 50Hz/60Hz

W (at starting up) (50Hz/60 Hz)

W (idling/at max. capacity)

inutes

inutes

el(A)

B(A)

m/sec (new sep./sep. in use)

³/h

tres

tres

tres

tres

g

g

g

Alfa Laval ref. 562576 rev. 3

Subject Value U

General technical data:

Motor power 9,5 k

Gear ratio 292 / 82 5

Gear ratio 243 / 82 6

Alarm levels for vibration monitor,connection 752, 1st/2nd 0,3 / 0,45 m

Bowl max. inner diameter 279 m

Discharge interval, min./max. 2/240 m

Max. density of operating liquid, max. 1000 k

Max. density of feed/sediment 1100 / 2425 k

Feed temperature, min./max. 0 / 100 °

Max. running time without flow,

- empty bowl 60 m

- filled bowl 60 m

Bowl body material AL 111 2377-02

Operating data:

Bowl speed, synchronous 9220/9220 r

Motor speed synchronous 3000 / 3600 r

Max. power consumption 12 k

Power consumption 3 / 7,5 k

Starting time, min./max. 1,7 / 2,3 m

Stopping time min./max. 25 / 30 m

Sound power 9,1 B

Sound pressure 76 d

Vibration level, max. 5,6 / 9,1 m

Volume and capacity data:

Max. hydraulic capacity, bowl 12 m

Bowl liquid volume 4,3 li

Fixed discharge volume 4 li

Sludge volume, efficient/total 0,65 / 1,8 li

Lubricating oil volume 2,7 li

Weight information:

Motor drive 84 k

Bowl 74 k

Separator total 445 k

14 1810828-02


Requirements/limits

Min. 0 °C, max. 100 °C

See demand specification

Max 9 m3/h

1,6 litres/minute

0 - 250 kPa

No counter pressure.

Total discharge

Max 24 discharge/h.

The outlet from the cyclone must always bearranged to prevent the cyclone from beingfilled up with sludge. Solids are dischargedby gravity.

See ‘Technical Data’ in the InstallationSystem Reference.

Max. 1000 kg/m3

min. 150 kPa

2,8 litres/minute

1,7 litres/hour

5 minutes

3 seconds

11 litres/minute

0,55 litres/discharge

3 seconds

2,8 litres/minute

0,7 litres/discharge

15 seconds

2.2 Connection List


No. Description

201 Inlet for process liquid

• Allowed temperature

• Max allowed density

• Allowed flow

206 Inlet for conditioning and displacement liquid

• Instantaneous flow

220 Outlet for light phase, clarified liquid

• Counter pressure

221 Outlet for heavy phase

222 Outlet for solid phase

• Small discharge

• Large discharge

• Discharge frequency

375 Inlet for discharge and make-up liquid

• Quality requirements

• Max density

• Pressure

Make-up liquid

• Flow (momentary)

• Consumption

• Interval

• Time

Discharge liquid

• Flow

• Consumption

• Time

Closing liquid

• Flow

• Consumption

• Time

462 Drain of frame top section, lower

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± 5%

± 10%

See page 21.

Inductive promixly switch

8 V

Less or equal to 1 mA.

More or equal to 3 mA.

1

See page 22.

Inductive analogue sensor

18 to 30 V DC

0,5 to 2,5 mm

1 to 9 mA

400 Ohm

Mechanical limit switch

3 A (at 48 V DC)1 A (at 220 V AC)

701 Motor for separator

Allowed frequency variation:

(momentarily during 5 seconds)

740 Speed sensor for bowl spindle

• Type

• Supply voltage, nominal

• With sensor activated (near metal)

• With sensor not activated (far from metal)

• Number of pulses per revolution

752 Position transducer for bearing holder

• Type

• Supply voltage

• Operation range (mild steel)

• Output voltage within sensing range

• Load resistance, RL

760 Cover interlocking switch

• Type

• Switch rating, resistive load max.

16 1810828-02


2.3 Interface Description


2.3.1 Scope

This document gives information,requirements, and recommendations aboutoperational procedures and signal processingfor safe and reliable operation of theseparator. It is intended to be used fordesigning auxiliary equipment and controlsystems for the separator.

2.3.2 References

This Interface Description is one complementarydocument to the separator. Other suchdocuments that contain necessary informationand 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.

1810828-02 17


h stress on bowl and bearingwhich might cause harm.

h stress on bowl which mightarm.

use injury to person whotally touches these parts.

sfactory product quality.

t losses.

2.3.3 Definitions

For the purpose of this document, the followingdefinitions 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.

2.3.4 Goal

To eliminate situations that can cause harm, i.e.injury, damage to health or property andunsatisfactory process result are e.g.:

Information and instructions given in thisdocument aim at preventing these situations.

Control and supervision can be more or lesscomprehensive depending on the type of usedcontrol equipment. When a simple control unit isused it would be impossible or too expensive toinclude many of the functions specified herewhile these functions could be included at nearlyno extra cost when a more advanced control unitis used. For this reasons functions that areindispensable or needed for safety reasons toprotect the machine and/or personnel aredenoted with shall while other functions aredenoted with should.

Situation Effect

Unbalance caused by uneven sedimentaccumulation in the bowl.

Too higsystem

Too high bowl speed. Too higcause h

Access to moving parts. Can caacciden

Insufficient cleaning of separator. Unsati

Bowl leakage. Produc

18 1810828-02


2.3.5 Description of separator modes

For control purposes the operation of theseparator should be divided into different modes.

The normally used modes are described belowbut 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 separatorwill 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.

1810828-02 19


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.

2.3.6 Remote start

This machine may be started from a remotelocation 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.

2.3.7 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 canalso be started by a Y/D starter, but then thetime in Y-position must be maximized to 5seconds.

20 1810828-02


There shall be an emergency stop circuitdesigned according to EN 418 and a powerisolation device according to EN 1037.

There shall be a start button close to theseparator that shall be used for first start afterassembly of the separator.

There should be a counter to count number ofrunning hours.

There should be a current transformer to give ananalogue signal to the control unit about themotor current.

740 Speed sensor

A proximity sensor of inductive type according toDIN 19234 (Namur) standard is giving a numberof pulses per revolution of the bowl (seeConnection 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).

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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 3-8% which will indicate a proper discharge.

Signal processing in STOPPING:

• STAND STILL shall be indicated when no pulses are detected within 30 seconds.

• Stopping the separator when alarm for speed monitoring system failure is active, shall cause a timer controlled stop. (See “Stop time” in Technical Data.)

752 Unbalance sensor (option).

For indication of any abnormal unbalance and tobe able to perform appropriate countermeasures,the separator has been equipped with a vibrationvelocity transducer on the separator frame. Thesignal from the transducer shall be monitoredand two alarm levels according to the vibrationalarm levels in Technical Data should be set.

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The vibration level shall be high for 3 seconds togenerate an alarm. The first level is only used togenerate an alarm while the second level shallstop the machine.

The vibration monitor shall include self checkfunction to be performed at least at initiation ofSTARTING.

If vibrations exceed the second alarm level theseparator shall be stopped the quickest waypossible and it shall not been restarted until thereasons for the unbalance have been found andmeasures to remove them have been taken.


If vibrations exceed the second alarm level theseparator shall be stopped automatically bySAFETY STOP.

If the self check system triggers, an alarm shallbe given and an automatic stop by NORMALSTOP 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.

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760 Cover interlocking switch (option)

The separator is equipped with a interlockingswitch 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, RUNNINGand 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 thedocument 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.

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Processing in NORMAL STOP or EMERGENCYSTOP:

• 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 displacementliquid

• 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.


• 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.

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Signal processing in CLEANING:

• Automatic discharges shall be initiated by timer or CIP-control system.

Signal processing in NORMAL STOP:

• Discharges should not be made.

Signal processing in SAFETY STOP andEMERGENCY STOP:

• Discharges should not be made.

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10

4

28

32

25

ISO-G 1/2

ISO-G 1/2O 17

O 113

45 O

O

90

899

201

46

2

375

20

6

221

220

975

38

20

6

380

222

222

752

167

740

EFF

E

G

B

C

D

O75

25min.

222

G0

86

76

D1

rnable in 60° steps all around.

iations due to tolerances.

2.4 Drawings

2.4.1 Basic size drawing


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 M10E M10 depth 30F ø28, depth 45G ø22, depth 45

28

46

2

330

875932

291

300 629

221

201220

760

158

85

88,5

37

5

701

A

Connection house, with connections 201, 220 and 221, tuAll connections to be installed non-loaded and flexibleAll dimensions are nominal. Reservation for individual devData for connection, see 2.2 Connection List, page 15.

1810828-02 27


G0

97

76

11

F

G

IJ

KL

M

Total static load max. 4,5 kN.

2.4.2 Foundation drawingAlfa Laval ref. 562553 rev. 1

A Centre of separator bowl.B Holes for foundation bolts (8x).C Centre of motor.D Min. lifting capacity required during service: 300 kg.E Max. height of largest component incl. lifting tool.F Service side.G Foundation bolts.H Installation according to stated foundation force.I Recommended free floor space for unloading when doing

service.J No fixed installation within this area.K Centre of gravity (complete machine).L Dynamic forces (static force excluded)

From separator do not exceed;Force in any separator feet;Vertical ± 12 kNHorizontal ± 12 kN

M Total foundation force (sum of all feet)Vertical ± 12 kNHorizontal ± 12 kN

A

B C

D

E

H

28 1810828-02


G0

86

75

41

Wire colour codes:

BK=BlackBN=BrownBU=BlueRD=RedGN=GreenPU=PurpleYW=YellowWT=White

tion box

“X”:

2.4.3 Interconnection diagramAlfa Laval ref. 561786 rev. 4

Speed sensor (bowl speed).

Unbalance sensor (position trans. for bearing holder).

Interlocking switch (frame top part)

Junc

Wiring of connector

RD=ABU=BGN=CYW=DWT=EBK=FBN=GPU=H

Items showed in this document are not included in all separators. See product specification.

Demand specification wireApproval: UL 1007/1569

CSA TR-64Area acc. to AWG 18

1810828-02 29


2.4.4 Electric motorAlfa Laval ref. 562534 rev.2

G0

97

75

11

Knockout openings for cable glands on both sides.

Metal fan cover

Cast lifting lugs on both side.

4 holes M10x18

Note: The motor bearings have permanent lubrication

External earthing bolt

Manufacturer ABB Motors

Manuf. drawing Cat. GB 96-10

Standards IEC 34-series, 72, 79 and 85

Size 132 SC

Type M2AA 132 SC

Weight 56 kg

Poles

Insulation class

2

F

Bearings D-end 6208-2Z/C3

N-end 6206-2Z/C3

Method of cooling IC 411 (IEC 34-6)

Spec. Totally enclosed three-phasemotor for marine service 2)

Motor with feet and small flange.

Type of mountingProtection

class

IM 1001

IM 2101 IP 55

IM 2111 IP 55

IM 2131 IP 55

30 1810828-02


Article No.

OutputkW

Speed rpm

FreqHz

Voltage V

CurrentA

Pow.fac cos j

| st / |1) Note

562534-17 11 3455 60 690D 11,2 0,93 9,1

562534-16 11 3455 60 380D 20,3 0,93 9,1

562534-15 11 3455 60 230 D 33,5 0,93 9,1 -

562534-14 11 3455 60 220 D 35,0 0,93 9,1

562534-13 11 3455 60 575D 13,4 0,93 9,1 CSA- plated

562534-12 11 3455 60 480D 16,0 0,93 9,1 -

562534-11 11 3455 60 460D 16,7 0,93 9,1 -

562534-10 11 3455 60 440 D 17,5 0,93 9,1 -

562534-9 9,5 2855 50 230 D 29,1 0,94 8,8 -

562534-8 9,5 2855 50 220 D 30,4 0,94 8,8 -

562534-7 9,5 2855 50 690 D 9,7 0,94 8,8 -

562534-6 9,5 2855 50 660D 10,1 0,94 8,8 -

562534-5 9,5 2855 50 500 D 13,4 0,94 8,8 -

562534-4 9,5 2855 50 440 D 15,2 0,94 8,8 -

562534-3 9,5 2855 50 415 D 16,1 0,94 8,8 -

562534-2 9,5 2855 50 400 D 16,7 0,94 8,8 -

562534-1 9,5 2855 50 380 D 17,6 0,94 8,8 -

1) lst /l=starting current /rated current at direction line starting.

2) The motors can be designed to fulfil requirements of following ClassificationSocieties (Essential Service, if required).

Lloyds Register of Shipping (LRS)

Det Norske Veritas (DnV)

Germanischer Lloyd (GL)

Bureau Veritas (BV)

American Bureau of Shipping (ABS)

Registro Italiano Navale (RINA)

Nippon Kaiyi Kyokai (NK)

Korean Register of Shipping (KR)

Polski Rejester Statkow (PRS)

China Classification Societies (ZC)

Indian Register of Shipping (IRS)

Maritime Register of Shipping (IRS)

Required classification society must always be specified when ordering.Factory test certificate to be enclosed at the delivery.

Rated output (kW) valid for temp-rise max. 90 °C.

The motors can be provided with space heaters for 110 V or 220 V, 25 W asoption.

1810828-02 31


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93

80

51

2.5 Nomogram paring tubeAlfa Laval ref. 566504, rev. 0

Calculated level ring ø 80

A Density ratio

32 1810828-02


G0

93

81

51

A Paring radiusB Position of adjusting screw

1810828-02 33


34 1810828-02

SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3 Separator Service, Dismantling, Assembly

3.1 Periodic MaintenancePeriodic (preventive) maintenance reducesthe risk of unexpected stoppages andbreakdowns. Follow the maintenance log inthis chapter in order to facilitate the periodicmaintenance.

3.1.1 Maintenance intervals

The following directions for periodicmaintenance give a brief description of parts tobe cleaned, checked and renewed at differentmaintenance intervals.

The maintenance log for each maintenanceinterval on page 39 gives a detailed list of actionsto be performed.

Inspection

An Inspection consists of an overhaul of theseparator bowl, inlet/outlet and operating waterdevice every 6 months or 4000 operating hours.

Seals in bowl and gaskets in inlet/outlet deviceare renewed.

Overhaul

An Overhaul consists of an overhaul of thecomplete separator (including separator bowl,inlet/outlet and operating device) every 18months or 12000 operating hours. Seals,bearings, friction blocks and flat belt in theseparator are renewed.

Oil change

The oil should be changed every 4000 hours, orat least once every year if the total number ofoperating hours is less than 4000 hours/year.

ii

o

1810828-02 35

3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL

3.1.2 Maintenance procedures

At each Inspection and/or Overhaul, take a copyof the maintenance log and use it to make notesduring the service.

An inspection and overhaul should be carried outas follows:

1 Dismantle the parts as described in 3.3 Dismantling, page 41.

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 3.4 Actions Before Assembly, page 74.

3 Fit all the parts delivered in the service kit while assembling the separator as described in chapter 3.5 Assembly, page 84.

4 When the separator is assembled, make final checks described in 3.6 Actions After Assembly, page 121.

The use of service symbols in the dismantling/assembly instructions

Parts that have to be renewed from the servicekits (see below) are marked and/or inthe assembly instructions.

DANGER!

Disintegration HazardsSeparator parts that are either missing, wornbeyond their safe limits or incorrectly assembled,may cause severe damage or fatal injury.

CAUTION!

Burn and Corrode HazardsEscaping hot and/or corroding process material,which can be hazardous, may still remain in theseparator after stop.

ii o

36 1810828-02


Example:

a Fit the O-ring .

When dismantling and assembling between theservice periods, some procedures do not have tobe carried out. These procedures are marked

and/or .

Example:

5 Renew the valve plugs on the operating slide .

All symbols used in the instructions refer toactivities mentioned in the maintenance logs.

3.1.3 Tightening of screws

Tightening all screws with the correct torquevalue is important.

These figures apply unless otherwise stated:

The figures apply to lubricated screws tightenedwith a torque wrench.

3.1.4 Service kits

Special service kits are available for Inspectionand Overhaul.

Torque

Metricthread

Stainless steel Carbon steel

Nm kpm Ib.ft Nm kpm Ib.ft

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

ii

ii o

ii

1810828-02 37


For other services, a Support kit is available.Spare parts not included in the Support kit haveto be ordered separately.

Note that the parts for Inspection are includedin the Overhaul kit.

The contents of the kits are described in theSpare Parts Catalogue.

3.1.5 Cleaning

CIP (Cleaning In Place)

To prolong the intervals between manualcleaning of the separator the use of CIP togetherwith repeated discharges can be used.

Some CIP liquids can be corrosive to brass- andaluminium alloy parts which are included in theseparator.

CAUTION!

Use only Alfa Laval recommended CIP liquids.

NOTE

Always use Alfa Laval genuine parts as otherwisethe warranty may become invalid.

Alfa Laval takes no responsibility for the safeoperation of the equipment if non-genuine spareparts are used.

WARNING!

Disintegration hazardsUse of imitation spare parts may cause severedamage.

38 1810828-02


identification:

acture No./Year:

ct No.: 881203-03-01

ure:

Page Note

74

76

77

ages 78

aring disc height

g rings

115

116

116

74

76

77

ages 78

ks and corrosion

g

102

103

104, 107

g 103

102

g 107

110

earings 110

112

112

luding washers 80 Has to be orderedseparately

101

101

3.2 Maintenance Log

Name of ship/plant: Local

Separator: S 840 Manuf

Total running hours: Produ

Date: SignatIn

spec

tio

n

Ove

rha

ul

Che

ck

Part Action

Frame hood

- All parts x x Clean

- All parts x x Check for corrosion

- All parts x x Check for cracks

- Connecting housing x x Check for erosion dam

- Frame hood x x

x

x

Renew O-ring

Control measure of p

Check height adjustin

Bowl

- All parts x x Clean

- All parts x x Check for corrosion

- All parts x x Check for cracks

- All parts x x Check for erosion dam

- Bowl body x

x

x

x

x

x

Check for impact mar

Renew rectangular rin

Renew O-rings

- Operating slide x

x

x

x

Renew rectangular rin

Renew valve plugs

- Discharge slide x x Renew rectangular rin

- In and outlet pipe x x Renew O-rings

- Paring tube x x Renew O-rings and b

- Bowl hood x

x

x

x

Renew seal ring

Renew O-ring

Frame

- Frame feet Renew frame feet (incand screws)

- Drain and oil filling holes x x Renew washers

- Oil pin x x Renew O-ring

i o

1810828-02 39


74

76

77

90

91

91

93

97

ew ball bearing

ew self-aligning

obble

92

94

100

99

99

100

O-ring 100

96

74

76

77

ll bearings

if they are worn)ey are oily

84

e fitted. See sign ---

d legibility 121

d legibility 121

d legibility 121

d legibility 121

d legibility 121

d legibility 121

Page Note

Driving device

- All parts x Clean

- All parts x Check for corrosion

- All parts x Check for cracks

- Bottom bearing housing x Renew O-ring

- Labyrinth ring holder x

x

Renew labyrinth ring

Renew O-ring

- Top bearing housing x Renew springs

- Flat belt x Renew flat belt

- Bowl spindle x

x

x

Pre-lubricate and ren

Pre-lubricate and renroller bearing

Measure the radial w

- Neck bearing cover x Renew O-ring

- Deflector ring x Renew O-ring

- Water inlet pipe x Renew O-ring

- Operating water cover x Renew seal ring and

- Fan x Renew the O-ring

Coupling

- All parts x Clean

- All parts x Check for corrosion

- All parts x Check for cracks

- Coupling hub x Renew single row ba

- Friction blocks x Renew friction pads (or clean the pads if th

Electrical motor

- Electrical motor x Lubricate if nipples aron motor

Signs and labels on separator

- Machine plate x Check attachment an

- Power supply frequency x Check attachment an

- Lifting instructions x Check attachment an

- Safety labels x Check attachment an

- Name plate x Check attachment an

- Representative label x Check attachment an

Insp

ec

tio

n

Ove

rhau

l

Ch

ec

k

Part Actioni o

40 1810828-02


3.3 Dismantling

3.3.1 Introduction

To disconnect the oil inlet, oil outlet, andwater outlet, undo the two screws on theconnection plate. Hook the plate, togetherwith the three hoses, to the edge of the smallwork table to avoid oil draining from thehoses.

The frame hood and heavy bowl parts mustbe lifted by means of a hoist. Position thehoist exactly above the bowl centre. Use alifting sling and lifting hooks with safetycatches.

The parts must be handled carefully. Don’tplace parts directly on the floor, but on aclean rubber mat, fibreboard or a suitablepallet.

NOTE

For safety reasons, it is essential that all personnelwho work with the separator read this manualthoroughly and completely.Do not allow personnel to clean, assemble, operateor maintain the separator until they have read andfully understood this manual.Ensure that all personnel who operate and servicethe separator are well-trained and knowledgeableconcerning the separator and the work to be carriedout.

1810828-02 41


3.3.2 Tools

Special tools from the tool kit must be used fordismantling and assembly, as well as Standardtools (not included). The special tools arespecified in the Spare Parts Catalogue and areillustrated at the beginning of each dismantlingsection.

WARNING!

Entrapment hazardTo avoid accidental start, switch off and lock-outpower supply before starting any dismantling work.

Make sure that machine has come to a completestandstill before starting any dismantling work(takes about 30 minutes from switch off).

42 1810828-02


G0

91

16

41

45

6

11

12

13

14

Standard Tools

1 Screwdriver

2 Torque wrench (capacity 0-200 Nm)

3 Drift (Ø 4 mm)

4 Dial indicator with magnetic base

5 Spanner for clutch (55 mm)

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

12

3

7

8

9 10

1810828-02 43


G0

86

34

41

Spring

Arm

Height adjusting rings

Frame hood

Lock nut

Connecting housing

Washer

Support ring

Screws

O-ring

G0

86

35

31

b Press the pipe down to loosen the connecting housing.

c Remove the connecting housing

NOTE

Remove connections beforestarting dismantling.

3.3.3 Frame hood

WARNING!

Entrapment hazardTo avoid accidental start, switch off and lock-out thepower supply before starting any dismantling work.

Make sure that machine has come to a completestandstill before starting any dismantling work(after about 30 minutes from switch off).

1 Removing the connecting housing.

G0

86

33

31

G0

86

05

31

1 Hook spanner (lock nut)

1

a Remove the lock nut using the hook spanner.

WARNING!

The nut must not beremoved before theseparator has stopped.

Remove the washer

NOTE

.

Right hand thread.

44 1810828-02


G0

86

36

61

the spring from n the hood.

b Remove the arm together with the spring.

he paring tube so that the frame hood can be ed upwards.

TE

avoid the paring tube from being damagedpreventing the inlet pipe from sticking toframe hood when lifting the hood, always

n the paring tube towards the pipe beforeing.

G0

86

36

71

ot placeoode down.

c Lift off the frame hood.

2 Removing the spring and arm.

3 Removing the frame hood.

a Remove the pin o

c Turn tremov

Paring tube

NO

Toandtheturlift

NOTE

Do nthe hupsid

b Loosen the hood by bending with a screwdriver in all grooves in the hood.

a Remove the screws holding the frame hood.

1810828-02 45


G0

86

26

81

Lock ring

O-ring

Bowl body

Rectangular ring

Discharge slide

Nut

Cap nut

Top disc

O-rings

Inlet and outlet pipe

Paring tube

Distributor

Bowl discs

Rectangular ring

Operating slide

Rectangular ring

Holder

Operating water ring

O-ring

O-ring

Axial support.

Splash sealing

Bowl hood

Seal ring

Valve plugs

Ring

O-ring

Nozzle

Bowl disc(without caulks)

G0

86

16

21

3.3.4 Bowl

G0

86

05

71

1 Compressing tool (lock ring).2 Lifting eyes. 3 Bowl hood puller.4 Spanner for nut (nut/discharge slide).5 Puller (discharge slide).6 Lifting tool (distributor, spindle).7 Puller (Bowl body)8 Screw (lock ring) (M5)9 Hexagon head key10 Chisel (seal ring)11 Pin (distributor/lifting tool)

1

2

3

4

6

5

7

8

9

11

10

46 1810828-02


G0

86

27

51

d Fit the dismantling screws to the bowl body and press out the lock ring by tightening the screws successively going counter-clockwise. Start with the screw nearest the lock ring end (the one without the guide pin). The lock ring can be removed when it has passed the edge of the groove.

c Compress the disc stack by alternately tightening the screws on the compressing tool a maximum of 40 Nm at a time.

e Remove the lock ring from the groove.

1 Removing the lock ring.

a Fit the compressing tool.

b Screw in the screws to stop.

NOTE

Be sure not tocover the threadedholes.

f Remove the dismantling screws.

1810828-02 47


G0

86

28

61

b Fit the puller.

ompressing tool. the screws (de-ss) on the ssing tool. Pull the od off by continuing to the screws.

d Remove the compressing tool and attach the lifting eyes to the puller and lift off the bowl hood.

2 Removing the bowl hood.

a Loosen the screws on the compressing tool.Remove the tool.Remove the lock ring.

WARNING!

Crush hazardThe top disc can adhere to the bowlhood when lifting. Be careful not toaccidentally drop it.

c Fit the cLoosencomprecomprebowl hounscrew

48 1810828-02


G0

86

24

41

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 todamage the bottom of thegroove!

rts

G0

86

29

51

- and outlet pipe together with the top disc.

G

zardbutor and disc stack can adhere to theeparate them from the top disc so that

ot accidentally drop.

3 Removing the seal ring.

4 Removing the inlet/outlet pipe and top disc.

a Place the bowl hood on a support and tap out a piece of the seal ring using a drift in the holes.

Seal ring

WARNING!

Risk for eye injury from flying seal ring paor from splashing fluidThe seal ring breaks when removed from the bowlhood and may cause trapped fluid to splash. Wearsafety goggles.

a Lift out the in

WARNIN!

Crush haThe distritop disc. Sthey do n

1810828-02 49


G0

86

30

51

m .

c Remove the screws and the axial support

the parings the

d Lift up and remove the paring tube.

b Remove the splash sealing.

Turn the paring tube upwards.

5 Removing the paring tube.

a Remove the top disc frothe inlet and outlet pipe

NOTE

To avoid damagingtube, turn it towardcentre of the pipe.

NOTE

If the paring tube sticks, use a driftto carefully tap it out from the pipe.

Be careful not to damage theparing tube.

50 1810828-02


G0

86

31

71

nto the the disc stack nch.

c Carefully lift off the disc stack assembly.

ION

azardedges on the separator

ay cause cuts

G0

92

38

41

a To prevent the bowl body from rotating when removing the nut; Fit the compression tool to the bowl body and fit a screw together with a socket into the frame, as shown in the illustration.

Socket (or similar)

Screw

Compressing tool

6 Removing the disc stack and distributor.

7 Removing the nut

b Fit the assembled tool idistributor and ease offusing a spanner or wre

CAUT!

Cut hSharpdiscs m

a Assemble the lifting tool with the pin.

b Use the spanner for nut to remove the nut.

Nut

1810828-02 51


G0

86

32

51

Puller rod

Discharge slide

b Ease off the discharge slide by turning the central screw.

c Lift out the discharge slide.

WARNING!

Crush hazardThe ring on the lifting tool must be pusheddown against the discharge slide, otherwise thedischarge slide may come loose from the tool.

Bowl body

Ring on tool

NOTE

If discharge slide isdifficult to remove,tap lightly on outsideedge with a softfaced hammer.

8 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.

52 1810828-02


G0

86

06

51

NOTE

Left-hand thread!

a Remove the cap nut

b Remove the compressing tool.

G0

86

07

31

a Fit the lifting tool to the bowl body.

ody

9 Removing the cap nut.

10 Removing the bowl body

b Raise the bowl body off the spindle taper by turning the lifting eye clock-wise.

c Lift off the bowl b

1810828-02 53


G0

86

08

21

to prevent it from rolling.

G0

86

09

21

e the screws.

b Lift off the holder.

11 Turn the bowl body upside down.

12 Removing the holder.

WARNING!

Crush hazardSupport the bowl body when turning

a Remov

NOTE

If the ring sticks, use two M8screws in threaded holes to raisethe operating slide holder up andaway from the bowl body.

54 1810828-02


G0

86

10

21

ide.

NOTE

If the ring sticks, use two M8 screws inthreaded holes to raise the operatingslide holder up and away from the bowlbody.

G0

86

11

21

Loosen and remove the screws .

b Lift off the ring.

NOTE

The discoloration on the ring is oxideprotection. Do not clean with abrasives.

13 Removing the operating slide.

14 Removing the operating water ring.

a Lift off the operating sl

a

NOTE

If the ring sticks, use two M8screws in threaded holes to raisethe operating slide holder up andaway from the bowl body.

1810828-02 55


G0

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71

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 seat7 Pin spanner (oil fan).

1

2

3 4 5

6

7

G0

85

78

21

G0

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80

61

Air deflector

Spindle pulley

Self-aligning roller bearingLubrication oil orifice

Oil pump

Labyrinth ring holder

O-ring

Labyrinth ring

Wing insert

O-ring

Bottom bearing holder

Strainer

O-ring

Screw

Belt

O-ring

3.3.5 Driving device

Operating water cover

Seal ring

Deflector ring

Neck bearing cover

O-ring

Fan

Snap ring

Bowl spindle

Ball bearing

Top bearing seat

Plugs

Composite springs

Top bearing housing

Springs

Seal ring

O-rings

O-ring

O-rings

56 1810828-02


G0

86

85

71

G0

85

81

31

.

1 Empty the oil sump.

2 Removing the clutch cover.

Unscrew the oil plug and empty the oil sump.

a Remove the screws.

b Remove the clutch cover.

1810828-02 57


G0

85

88

A1

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.

WARNING!

Crush hazardThe motor will come off if the screws areunscrewed.

Separator frame

Motor

Screw

Nut

3 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.

c Remove the flat belt from the motor pulley.

58 1810828-02


r ring.

G0

85

89

31

move the screws.

b Lift off the operating water cover.

G0

85

90

51

d Lift off the neck bearing cover together with the deflector ring.

r

tool to

4 Removing the operating water cover.

5 Removing the neck bearing cover and deflecto

NOTE

If the cover sticks, fit twoM10 screws to the threadedholes and tighten.

a Re

a Attach the tools.

Cove

b Fasten the the cover.c Ease off the

cover by tightening the screw.

Frame

1810828-02 59


G0

85

91

51

b Remove the screws

NOTE

If the cover sticks, fit twoM10 screws to the threadedholes and tighten.

6 Prepare for removal of spindle assembly.

NOTE

a To facilitate later removal of plugs, loosen (do not remove) the plugs on the bearing housing.

60 1810828-02


G0

90

78

31

b Slowly raise and lift out the spindle assembly.

WARNING!

Crush hazardDo not rotate the spindle assemblyduring lifting. The spindle assemblymay otherwise come loose from thelifting tool.

NOTE

Take care not to damage the oil pump.

7 Lifting the spindle assembly from the frame.

a Fit the lifting tool to the spindle end.

1810828-02 61


support.

G0

85

92

11

Make a support

~135 mm

~180 mm

G0

85

92

21

Remove the screws and the air deflector.

8 Place the spindle assembly upside down on a

9 Removing the air deflector.

~3,0 mm free space

62 1810828-02


G0

92

39

21

b Place a spanner (or similar) on the spindle pulley key-grip, as holder-up.

Key-grip

G0

86

59

81

ulley and the r bearing using

rd a used

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.

Puller tool

10 Removing the fan.

11 Removing the bottom bearing assembly.

c Fit the pin spanner and remove the fan.

NOTE

Left-hand thread!

a Turn the spindle assembly the right way up.

a Turn the spindle assembly up-side down and remove the oil pump by using spanners.

b Pull off the belt pself-aligning rollethe puller tool.

NOTE

Always discabearing.

Lubrication oil orifice

Compressed air

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lugs osite

c Carefully remove the spindle from the top bearing seat.

NOTE

Be careful not to damagethe vibration indicator.

12 Removing the top bearing housing.

b Remove the pand the compsprings.

Composite springs

d Collect the axial springs.

Plug

a Turn the spindle assembly over.

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snap ring.

NG

eye injury from flying snap ringorrect pliers for dismantling of snap ring toidental release.

nut on the spindle to threads.

not to damage thendicator when

the top bearingthe spindle.

NOTE

Always discardused bearings.

Vibration indicator

ller tool to remove the seat from the spindle.

ece of wood to otect the spindle reads.

13 Removing the ball bearing.

a Remove the

WARNI!

Risk forUse the cavoid acc

d Place the top bearing seat on a support to protect the vibration indicator.Remove the bearing. Use a drift in the two holes.

b Fit the capprotect the

NOTE

Do not damage threads onspindle. NOTE

Take carevibration iseparatingseat from

c Use the putop bearing

Piprth

1810828-02 65


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B1

NOTE

If the holder sticks, fit two screws M8to the threaded holes and tighten.

14 Removing the labyrinth ring holder.

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D1

he tool into the bottom bearing holder and attach the ket, extension rod and T-handle.

Loosen the bottom bearing holder by turning it counter clockwise.Remove it by hand.

Extension rod

l

T-handle

c Remove the strainer.

Socket

15 Removing the bottom bearing holder.

a Fit tsoc

b

Too

1810828-02 67


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41

Snap rings

Ball bearingsSpacing ring

Belt pulley

Coupling hub

Parallel pin

Friction blocks(3=60 Hz)

Cover

Snap ring

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3.3.6 Centrifugal clutch

WARNING!

Entrapment hazardTo avoid accidental start, switch off and lock-outpower supply before starting any dismantling work.

Make sure that machine has come to a completestandstill before starting any dismantling work(takes about 30 minutes from switch off).

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NOTE

50 Hz = 5 Friction blocks60 Hz = 3 Friction blocks

The illustration shows 60 Hz

1 Mounting /dismantling tool (centrifugal clutch).2 Mounting /dismantling tool (ball bearing).

1

2

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A1

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.

WARNING!

Crush hazardThe motor will come off if the screws areunscrewed.

Separator frame

Motor

Screw

Nut

1 Removing the clutch cover.

2 Loosen the flat belt, by tilting the motor.

a Loosen and remove the screws.

b Remove the clutch cover.

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.

c Remove the flat belt from the motor pulley.

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edures,

c Tense the lifting sling to support the motor and remove the screws. Lift the motor while supported.

WARNING!

Crush hazardIf not supported, the motor with couplingwill drop when removing the screws.

d Lower the motor onto a suitable pallet.

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Remove the snap ring, cover and friction blocks.

Friction blocks(3=60 Hz)

Cover

Snap ring

3 Removing the motor.

4 Removing the friction blocks.

b Fit a sling to the motor using a shackle on the upper part.Weight of motor with coupling: approx. 80 kg.

a Disconnect the electrical cables.

WARNING!

Electrical hazardIf the cables are not disconnected during lifting procthey may become damaged.

a

NOTE


CAUTION!

Inhalation hazardWhen handling frictionblocks/pads wear amask to avoid inhalationof dust.Do not use compressedair to remove dust.Remove dust usingvacuum or a damp cloth.

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.

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ks are worn:

tion blocks.

ce all blocks, even if only one is.

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.

If only friction block service is to be done, proceed to ‘‘Assembly of friction blocks” on page 86.

NOTE

Be sure that the pins on the back of theblocks project into the grooves in theclutch hub.

5 Checking the condition of the friction blocks o

If the bloc

Fit new fric

NOTE

Replaworn

a

b

CAUTION!

Inhalation hazardWhen handling frictionblocks/pads wear amask to avoid inhalationof dust.Do not use compressedair to remove dust.Remove dust usingvacuum or a damp cloth.

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ve the screw, spring washer and washer.

Washer

Spring washer

Screw

ck that the brass plug is mounted he puller tool.e tool to the friction clutch.

c Ease off the friction coupling.

WARNING!

Crush hazardThe centrifugal clutch is heavy andcan fall, causing injury, whenloosened from the motor shaft.

r tool

NOTE

Use a spanner (55 mm) on thecoupling hub to prevent rotationduring dismantling.

).

Complete dismantling of centrifugal clutch

6 Removing the coupling from the motor.

a Remo

b Cheon tFit th

Flat areas for spanner (55 mm).

Pulle

Flat areas for spanner (50 mm

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7 Dismantling of the coupling assembly.

a Remove the snap rings.

b Drive out the coupling hub.

c Turn the coupling the other way round and drive out the ball bearings using the mounting tool.

Support

Wooden support

NOTE

Always discard used bearings.

1810828-02 73


3.4 Actions Before Assembly

3.4.1 Cleaning

Clean the separator parts according to thediagram below. Afterwards, protect all cleanedcarbon steel parts against corrosion by oiling.

i o

Part Procedure Cleaning agents

Frame andmotor

The external cleaning of the frame and motor should berestricted to brushing, sponging or wiping while the motor isrunning or still is hot.

Clean the inside of the frame with a clean cloth and removevisible particles.

Water and de-greasing agent.

WARNING!

Electrical hazardNever wash down a separator with a direct waterstream.

Never play a water jet on the motor. Totallyenclosed motors can be damaged by direct hosingto the same extent as open motors, resulting inshort-circuit and internal corrosion.

74 1810828-02


Cleaning agents

id damage to

and place them

ent until themally take

rating water

deposits. The

a soft iron wire

A chemical cleaning agent mustdissolve the deposits quickly withoutattacking the material of the separatorparts.

Fuel oil sludge mainly consists ofcomplex organic substances such asasphaltenes. The most importantproperty of a cleaning liquid for theremoval of fuel oil sludge is the ability todissolve these asphaltenes.

CAUTION!

Cut hazardSharp edges on the separatordiscs may cause cuts.

orifice, bearing White spirit, cleaning-grade keroseneor diesel oil.

White spirit, cleaning-grade keroseneor diesel oil.

Solvent

Part Procedure

Bowl

Inlet/ outlet

Cleaning of bowl discs

Handle the bowl discs carefully in order to avothe surfaces during cleaning

1 Remove the bowl discs from the distributorindividually in the cleaning agent.

2 Allow the discs to remain in the cleaning agdeposits have been dissolved. This will norbetween two and four hours.

3 Lastly, clean the discs with a soft brush.

Cleaning of holder for operating slide, opering and operating slide with nozzle.

Use 10% acetic acid solution to dissolve limeacid should be heated to 80 °C.

Clean the nozzle on the operating slide usingor a similar object.

Driving device Use a sponge or a soft brush and clean the oilholder and oil pump thoroughly.

Centrifugalclutch

Use a sponge or a soft brush.

Belt pulley Use a a steel brush.

1810828-02 75


e Measure

If damage exceeds 0,5 mm, contactAlfa Laval.

s cause general

sion begins as smallt can be difficult toes on to local damage, grooves or cracks.

Polish dark-coloured spots andother corrosion marks with a finegrain emery cloth. This may preventfurther damage.

If damage exceeds 0,5 mm (0,2mm for bowl body and bowl hood)contact Alfa Laval.

sion damage can beits and/or cracks.

If damage exceeds 0,5 mm, contactAlfa Laval.

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Max. 0,2 mm

3.4.2 Inspection for corrosion

Inspect the separator parts for corrosion.Evidence of corrosion attacks should be lookedfor and rectified each time the separator isdismantled.

DANGER!

Disintegration hazardsAlways contact your Alfa Laval representative if yoususpect that the depth of the corrosion damageexceeds 0,2 mm for bowl body and bowl hood (0,5for other parts) or if cracks have been found. Do notcontinue to use the separator until it has beeninspected and given clearance for operation by AlfaLaval.

Material Type of corrosive environment

Appearanc

Non-stainless steeland cast iron parts

Water or dampness Rust

Stainless steel Chlorides or acidicsolutions

Acidic solutioncorrosion.

Chloride corrodark spots thadetect, and gosuch as pitting

Other metal parts “Aggressive”environment

Possible corroin the form of p

DANGER!

Disintegration hazardPits and spots forming a line may indicate cracksbeneath the surface.

All forms of cracks are a potential danger and aretotally unacceptable.

Replace any part where corrosion can besuspected of affecting its strength or function.

io

76 1810828-02


3.4.3 Inspection for cracks

Check the separator parts for cracks. It isparticularly important to inspect for cracks inrotating parts, and especially the pillars betweenthe sludge ports in the bowl wall.

Cracks can occur from cyclic material stressesand corrosion. Keeping the separator and itsparts clean and free from deposits will help toprevent corrosion attacks.

DANGER!

Disintegration hazardAll forms of cracks are potentially dangerous as theyreduce the strength and functional ability ofcomponents.

Always replace a part if cracks are present.

DANGER!

Disintegration hazardsAlways contact your Alfa Laval representative if yoususpect that the depth of the damage exceeds 0,2mm for bowl body and bowl hood (0,5 for otherparts).

Do not continue to use the separator until it hasbeen inspected and given clearance for operation byAlfa Laval.

i o

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Pillars between the sludge ports in the bowl wall

Paring disc and paring tube

Lock ring

osion are:

The sealing edge of the discharge slide for the seal ring in the bowl hood

Erosion is characterised by:

1 Burnished traces in the material.

2 Dents and pits having a granular and shiny surface.

3.4.4 Inspection for erosion

Erosion may occur when particles suspendedin the process liquid slide along or strikeagainst a surface.

1 Inspect the bowl and inlet/outlet parts for erosion damages.

NOTE

Always contact your Alfa Laval representative if yoususpect that the depth of the damage exceeds 0,2mm for bowl body and bowl hood (0,5 for otherparts). Do not continue to use the separator until ithas been inspected and cleared for operation byAlfa Laval.

i o

The underside of the distributor in the vicinity of the distribution holes and wings

The sealing edge of the discharge slide.

Surfaces particularly subjected to er

Bowl body and holder.

Holder and operating slide.

78 1810828-02


2 Replace parts if erosion is suspected.

DANGER!

Disintegration hazardErosion damage weakens parts by reducing thethickness of the material.

Pay special attention to the pillars between thesludge ports in the bowl wall.

Replace parts if erosion is suspected of affectingstrength or function.

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prepare to remove

the separator” on

frame feet.

Fit the new feet, screws and washers. Tightening torque: 160 Nm.

3.4.5 Exchange of frame feet

The frame feet have to be changedoccasionally due to rubber deterioration fromage.

When replacing the frame feet, the separatormust be lifted. Follow 3.8.1 Lifting theseparator, page 129.

NOTE

Discard the old frame feet, screws and washers.

a Loosen the bolts andthe separator frame

b Lift the separator. See ‘‘Liftingpage 129

c Remove the existing

d

e Place the separator in its original position and fasten the mounting bolts.

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21

Nut

000

3.4.6 Lubrication of bowl parts

Discharge slide

a Apply a thin layer of Molykote 1000, or equivalent lubrication, on all the following contact surfaces. Apply D3on the operating slide and the bowl body, guide pin and bowl hood.

Bowl body(also apply D321 on guide pin)

Operating slide( apply D321)

Holder

Operating water ring

= Molykote 1000

= D321 + Molykote 1

Bowl hood( apply D321)

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y

1

k

es

3.4.7 How to lubricate bowl parts with slide laquer

a Carefully clean the contact surfaces (1) on bowl bodand 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 Polish the film to a shiny surface, the film should loolike well-polished leather when properly done.

h Finish the treatment by lubricating the contact surfacwith 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.

1

1

NOTE

This instruction is also valid forthe operating slide and the holder.

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1

s

NOTE

To avoid the risk of galling, theguiding surface of the operatingslide should be primed with a slidelacquer at every inspectionservice.

3.4.8 Check for galling on operating slide and bowl body

a Clean the surface thoroughly with a degreasing agent, i.e. white spirit.This is important!

1

If any friction marks are found on the guide surfaces (1) of operating slide and bowl body, proceed as follows:

b Using an emory cloth (e.g. No. 320) to smooth the metal edges.

c Finish by polishing the damaged spots with polishing paper (e.g No. 600).

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.

i Polish to a shiny surface, the surface should look like well-polished leather when properly done.

j Finish the treatment by lubricating the guiding surfacewith Alfa Laval lubricating paste or Molykote 1000 paste. Use a well cleaned brush. Rub it into the surface, do not leave any excessive paste.

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em on a firm and level

new pulley has thee separator bowl to

of oil onto the ernal surfaces of the

.

Mounting tool

into the coupling lace the spacing

d as they arelastic

NOTE

Remove rust from thebelt pulley using a steelbrush.

3.5 Assembly

3.5.1 Centrifugal clutch

1 Assembly of the coupling.

a Slip the belt pulley over the coupling hub and place thfoundation.

WARNING!

Disintegration HazardIf the belt pulley must be renewed, check that thecorrect diameter. An incorrect pulley will cause thrun at either an excessive or insufficient speed.

d=253,5 mm 50 Hzd=211 mm 60 Hz

b Apply a thin filmexternal and intball bearings o

c Press the ball bearings down one at a timehub, preferably using a hydraulic press. Pring between them.

NOTE

Never re-fit used ball bearings.The ball bearings must not be heate

packed with grease and sealed with pmembranes.

d Fit the snap rings.

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D1

shaft and apply a

Apply lubricating paste to the tool threads (keep lubricated).

d Fasten the sleeve of the tool to the motor shaft with the same screw that normally holds the centrifugal clutch to the motor.

e Use a spanner to turn the nut on the tool. This will press the centrifugal clutch on to the shaft. Remove the tool.

c Remove the brass plug.

tighten the washer, spring d screw.

2 Fitting the coupling to the motor.

a Clean the motor thin oil film.

b

NOTE

Make sure that the key is in place onthe motor shaft.

f Install andwasher an

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51

Guide pin

b Place the cover in position and secure it with the snap ring.

er

Snap ring

a Fit the friction blocks onto the guide pins

NOTE


Assembly of friction blocks

3 Fitting the friction blocks.

Cov

NOTE

Be sure that the pins on theback of the blocks project intothe grooves in the clutch hub.

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41

c Fit the screws.Do not tighten until the belt has been mounted.

d Connect the electrical cables.

hile e

ge.

WARNING!

Crush hazardIf not supported, the motor withcoupling may drop when lifted.

4 Fitting the motor.

b Lower the motor (wsupported) on to thseparator frame.It will set on the led

a Fit a lifting sling to the motor.Use a shackle from the separator lifting tool.Weight of motor with coupling: approx. 80 kg.

NOTE

If carrying out change of friction blocks only,continue with steps 5 to 6.If carrying out a complete machine assembly,continue with the driving device instructions onpage 90.

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D1

t up the belt to the middle (centre) of the indle pulley.

two upper screws.

d Tighten all motor attachment screws.

ulley.

NOTE

Do not turn the spindle until themotor is tightened properly to theframe.

NOTE

For correct position,centre the belt on thespindle pulley camber.

Clearance

5 Fitting the flat belt.

a Lifsp

c Tighten the

b Fit the flat belt to the motor belt p

NOTE

Clean the inside of the frame before fittingthe flat belt, and make sure that there is nooil on the belt.

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b Tighten the screws.

6 Fitting the clutch cover.

a Fit the clutch cover.

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91

t the wing insert, O-rings d strainer.

d Thread the bottom bearing holder into the frame and fit the tool into the bottom bearing housing.

e Tighten the holder to a torque of 200 Nm.

ecure the wing insert ith the screw secured ith Loctite 222

3.5.2 Driving device

1 Fitting the bottom bearing holder.

a Fian

Tool

Bottom bearing holder

c To secure the bottom bearing holder into the frame, apply Loctite 222 on the surfaces directly above and below the upper O-ring.

b Sww

Socket

NOTE

Clean the strainer and bearingholder thoroughly before fitting.

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Fit the O-ring using silicone grease .o

b Lubricate and fit the labyrinth ring .o

c Fit and seal the holder with Loctite 222. Fit and tighten the screws.

2 Fitting the labyrinth ring holder.

a

1810828-02 91


to the spindle.

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b Fit the ball bearing.

NOTE

Always fit a new bearing.Pre-lubricate before fitting.

G

eye injury from flying snap ringrrect pliers for assembly of snap ring to

idental release.

de

heated

spindle p bearing pindle eve and

ring seatt stuck!

Puller

Sleeve

3 Fitting the ball bearing and top bearing seat o

a Heat the top bearing seat in oil to maximum 125 °C.

c Fit the snap ring.

WARNIN!

Risk for Use the coavoid acc

WARNING!

Burn hazarUse protectivgloves whenhandling anyparts.

e Wipe off theand fit the toseat to the susing the slepuller.

d Heat the top bearing seat together with the bearing in oil to maximum 125 °C.

NOTE

Make sure to fit the beacorrectly or it might ge

92 1810828-02


08

66

62

1

b Carefully lower the bowl spindle. Make sure that the springs enter the recesses on the top bearing seat.

posite springs and e top bearing housing.ten the plugs. that the springs enter the n the top bearing seat. should be tightened when assembly is mounted into

o

icate the threads before mbly.

4 Fitting the top bearing housing.

a Fit the axial springs to the top bearing housing.

o

d Fit the complugs to thDo not tighMake surerecesses iThe plugsthe spindlethe frame.

Axial springs

c Lubrasse

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assembly

ve ith

c Fit the spindle pulley firmly on the bowl spindle.

e betweenssembly to

rotect thee spindle.

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imum

g.

b Lower the bearing onto the spindle and press down onto the spindle pulley using the special mounting tool.

5 Fitting the spindle pulley.

6 Fitting the self-aligning roller bearing .

a Turn the spindleupside down.

b Wipe off the spindle pulleyseat on the spindle and nabore in the spindle pulley wa dry cloth.

NOTE

At least 1mm free spacsupport and spindle aprotect the bearing.

Mount the cap nut to pthreads and support th

o

a Heat the bearing in oil to max125 °C.

NOTE

Always fit a new bearing.Pre-lubricate before fittin

WARNING!

Burn hazardUse protective gloves whenhandling the heated bearing.

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c Lubricate all threads with a few drops of oil before assembly.

d Fit the oil pump (65 + 5 Nm) using spanners.

7 Fitting the oil pump.

NOTE

Clean the oil pump and makesure that the bottom hole is notclogged.

a Fit O-ring 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.

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61

b Apply a thin layer of silicone grease and fit the O-rings into the fan.o

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.

dle assembly up-side down.

at the spindle is seated againstring of the ball bearing.

NOTE

Make sure that the bearingis pre lubricated beforefitting the fan.

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8 Fitting the fan

9 Fitting the air deflector.

Key-grip

a Turn the spin

NOTE

Ensure ththe inner

a Turn the spindle assembly up-side down and fit the air deflector.

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71

osition the flat belt so hat the spindle assembly can ass through when lowering.ee note below.

o

dle. sembly and lift it.

embly during lifting. The spindlee loose from the lifting tool.

ttom of the oil pump is clean before.

NOTE

Check the direction arrows on the belt and themachine plate for correct position.

Make sure that the belt does not get smudgedwith oil or grease during handling.

Space

and position e holes.nters the

not use force.

rame and airembly.

10 Lowering the spindle assembly into the frame.

b PtpS

d Fit and tighten the screws.

a Remove the cap nut from the spinFit the lifting tool to the spindle as

WARNING!

Crush hazardDo not rotate the spindle assassembly may otherwise com

NOTE

Check that the hole at the bolowering the assembly down

e Tighten the plugs firmly.

Check the bottom hole.

Carefully blow compressed air through the hole in the bearing housing.

c Carefully lower the spindle assemblythe bolt holes over the threaded framMake sure that the bottom bearing, ebottom bearing holder correctly. Do

WARNING!

Cut hazardDo not put fingers between the fdeflector while lowering the ass

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B1

t up the belt to the middle (centre) of the indle pulley.

two upper screws.

d Tighten all motor attachment screws.

ulley.

NOTE

Do not turn the spindle until themotor is tightened properly to theframe.

NOTE

For correct position,centre the belt on thespindle pulley camber.

Clearance

11 Fitting the flat belt.

a Lifsp

c Tighten the

b Fit the flat belt to the motor belt p

NOTE

Clean the inside of the frame before fittingthe flat belt, and make sure that there is nooil on the belt.

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g.

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51

e O-

Deflector ring

c Push the deflector ring down until it stops.

Neck bearing cover

12 Fitting the neck bearing cover and deflector rin

a Apply a thin layer of silicone grease and fit thrings and the seal ring in the lower groove o

b Fit the neck bearing cover.

NOTE

The guide pin on the cover should enter one ofthe two holes in the bearing housing.

1810828-02 99


e.

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b Fit the operating water cover. Fit and tighten the screws.

NOTE

The water pipe in the frame shouldenter the hole in the cover.

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11

NOTE

Permissible radial wobble: max. 0,04mm. If the spindle wobble exceedsthis value, contact an Alfa Lavalrepresentative.

Max. 0,04 mm

13 Fitting the operating water cover.

14 Measuring the radial wobble of the bowl spindl

a Lubricate with oil and fit the seal ring and O-ring into the operating water cover.

o

Renew the O-ring o

O-ring

a Fit a dial indicator in a support and fasten it in position as illustrated. Use the flat belt to turn the spindle.

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b Tighten the screws.

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81

c Fill with new oil until oil flows out from the filler hole. For correct oil volume see ‘‘Lubricating oil volume” on page 14.

NOTE

For grade and quality of oil see3.7.6 Lubricating oils, page 128

NOTE

The separator should be level and atstandstill when oil is filled.

b Fit new washer and refit the drain plug.

i

15 Fitting the clutch cover.

16 Fill oil in the oil sump.

a Fit the clutch cover.

a Remove the oil pin, plug and washer.

f Fit the oil pin.

d Fit new O-ring onto the oil pin.i

e Refit the plug with new washer i

1810828-02 101


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11

Remove any impact marks using a scraper and/or a whetstone.

20).

600).

ion.

ii

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41

b Carefully tap in new valve plugs, using a clean, soft-faced hammer.

NOTE

Make sure that the plugs are fitted asdescribed in the illustration.

3.5.3 Bowl

1 Check for impact marks and corrosion in bowl body nave and on spindle taper .

2 Fitting new valve plugs on the operating slide

i o

a

b Rust can be removed by using afine-grain emery cloth (e.g. No. 3

c Finish with polishing paper (e.g. No.

CAUTION!

Disintegration hazardImpact marks may cause the separator tovibrate while running.

d Lubricate to prevent further corros

a Remove the valve plugs using a drift.

Drift

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41

b Fit the operating slide.

NOTE

The guide pin in the bowl bodyshould enter the hole in theoperating slide (this hole ismarked with a drill mark).

Guide pin

Alignment hole

Operating slide

Bowl body

Nozzle secured with Loctite 222

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b Apply a thin layer of molykote grease and fit and tighten the screws to a torque of min.15 Nm and max. 20 Nm.

3 Fitting the operating slide.

4 Fitting the operating slide holder.

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.

.i o

a Fit the holder over the operating slide.

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ly a thin layer of silicone grease fit the O-ring i o

Grease, fit and tighten the screws to a torque of min.15 Nm and max. 20 Nm.

c Fit the operating water ring.

OTE

The drilled assembly mark on the water ring shouldface the corresponding mark on the bowl body.

OTE

he discoloration on the ring is oxide protection.o not clean with abrasives.

5 Fitting the operating water ring.

b Appand

d

N

N

TD

a Fit the ring i

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b Wipe off the spindle taper and nave bore with a dry cloth.

d Fit the lifting tool and lift the bowl body.

f Remove the lifting tool.

6 Lifting the bowl body onto the spindle taper.

a Put a drop of oil on the spindle taper.

e Carefully lower the bowl body onto the spindle taper.

c Turn the bowl body over.

WARNING!

Crush hazardSupport the bowl body when turning toprevent it from rolling.

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Cap nut

a thin layer of ote grease. Fit and n the cap nut to a of 50 Nm.

TE

t-hand thread!

Socket (or similar)

Screw

Compressing tool

7 Fitting and tightening the cap nut.

b Applymolyktightetorque

NO

Lef

a To prevent the bowl body from rotating when fitting the cap nut; Fit the compressing tool to the bowl body and fit a screw together with a socket into the frame, as shown in the illustration.

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a thin layer of silicone grease and ectangular ring .i o

b Apply a thin layer of silicone grease and fit the O-ring i o

O-ring

f Fit the spanner for nut and tighten the nut with a torque wrench to a torque of min. 150 Nm.

ol.

WARNING!

Crush hazardThe ring on the lifting tool must bepushed home against the dischargeslide, otherwise it may come loosefrom the tool.

g Remove the compressing tool and the spanner for nut.

8 Fitting the discharge slide.

a Apply fit the r

c Fit the lifting tool and lower the discharge slide into the bowl.

e Fit the nut.

d Remove the lifting to

1810828-02 107


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CAUTION!

Cut hazardSharp edges on the bowl discs may causecuts.

n distributor

l disc

WARNING

The number of discs may have to be increasedto adjust the disc stack pressure. Always checkbefore operating the separator. See ‘‘Checkingthe disc stack pressure .” on page 114

9 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.

Guide rib o

Recess on bow

!

108 1810828-02


y.

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71

lifting tool into the tor.

Guide rib ondistributor

Guide pin on bowlbody

the distributor.

bowl body nave.

10 Fitting the disc stack assembly to the bowl bod

a Fit the distribu

b Lower the disc stack into the bowl.

NOTE

The guide pin on the bowl body should facethe guide rib on the distributor.

The guide ribs inside the distributor thenenter the recesses on the bowl body nave.

Guide ribs inside

Recesses on the

1810828-02 109


d outlet pipe.

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61

s bearings rance ring to the

i

ring

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91

of d fit

od Carefully lower the inlet and outlet

pipe assembly into the top of the distributor.

11 Assembling the paring tube .

12 Mounting the paring tube and fitting the inlet an

i

a Fit the O-ringand tole

paring tube.i

Tolerance

c Apply a thin layersilicone grease anthe O-rings i

a Insert the paring tube and mount the axial support to the inlet and outlet pipe.

b Mount the splash sealing

110 1810828-02


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a Move the paring tube to the centre.

NOTE

To avoid damagingthe paring tube, turnit towards the centreof the pipe.

13 Fitting the top disc.

The guide rib on thedistributor should enter one of the two larger recesses on the top disc.

b Lower the top disc.

1810828-02 111


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71

ayer of silicone grease and fit the

b Fit the seal ring Press the ring down evenly until bulges appear.

i o

he bowl to the guide

Recess on bowl hood

Guide pin on bowl body

e bulges crosswise with a soft he ring is completely fitted.

14 Fitting the bowl hood.

a Apply a thin lO-ring i o

d Fit the lifting tool and lower thood so that its recess fits inpin in the bowl body.

c Carefully tap down thrubber mallet, until t

e Remove the lifting tool.

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31

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 inthe bowl body which retainsthe lock ring is clean.

c Release the pressure on the compressing tool and remove it.

g in position

NOTE

Check that the lock ring iscorrectly positioned all wayaround!

NOTE

Never remove any materialfrom the lock ring. Ahazardous situation couldresult.

15 Fitting the lock ring.

a

b Fit the 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.

For correct disc stack pressuresee page 114

Before compressing Lock rin

Lock ring

Bowl hood

Bowl body

1810828-02 113


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61

g Assemble the bowl with inlet and outlet pipe.

od, top disc and inlet and outlet pipe.

the disc stack.

efit the disc without caulks, the top disc nd bowl hood.

ove isc

ove, does

d Fit the lock ring and fully compress the disc stack with the compressing tool.

NOTE

Do not use more power than40 Nm/screw at a time,alternately.

16 Checking the disc stack pressure .ii

a Remove bowl ho

b Add one disc to

c Ra

f Dismantle the bowl and remone disc to get the correct dstack pressure.

e If the lock ring enters the grorepeat a-d until the lock ringnot enter the groove.

NOTE

Always refit the discwithout caulks on topof the disc stack!

114 1810828-02


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hood can

e hood.

d Fit and tighten the screws.

NOTE

Make sure that the framehood is mounted in itscorrect positionaccording to the pipingarrangement.

yer of silicone grease and nto the frame hood

3.5.4 Frame hood

1 Fitting the frame hood .i o

a Turn the paring tube so that the frame pass the paring tube.

Paring tube.

c Lower the fram

b Apply a thin lafit the O-ring o

i o

NOTE

Make sure to fit the frame hoodgroove and the projection of thepipe.

1810828-02 115


.

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15

E1

port ring

Frame hood

Important!

D

mm

Quantity heightadjusting rings

29 ± 0,5 3

28 ± 0,5 2

27 ± 0,5 1

Guide screw

2 Control measurement of paring disc height o

Sup

Height adjusting rings

Bowl hood Paring discDistributor

b Measure the distance D. Assemble the correct number of height adjusting rings (B) according to the table.

a Remove the guide screw (A).

c Refit the guide screw (A)

Guide screw

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81

b Fit the spring to the pin on the frame hood and make sure that it is properly attached on both ends.

spring on the arm the arm to the top aring tube end.

ArmParing tube

Spring

Pin

3 Fitting the spring and arm.o

a Fit the and fit of the p

1810828-02 117


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41

a Fit the connection housing over the inlet/outlet pipe.

NOTE

Make sure that the screw, on top ofthe frame hood, enters the guidehole at the underside of theconnecting housing.

4 Fitting the connection housing.

b Fit the washer and the lock nut using the hook spanner.

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81

a Remove the cover.

b Fit the O-ring on the holder.Fit the screw into the holder and mount the holder into the separator frame.

Sensor holder.

NOTE

See next page for fitting andcorrect adjustment of the sensor.

NOTE

If removing the sensor holder;use a M10 screw as a puller.

3.5.5 Unbalance sensor (option)

1 Fitting the unbalance sensor holder.

Sensor holder

O-ring

Screw M8

FrameSensor arm

M10

1810828-02 119


A

G

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A1

sensor into the holder. Do not forget the nut.

the sensor so that a value of 1,5 appears on the .

djustment value for the sensor is; 12 mA ± 1mA.or more details see 2.2 Connection List, page 15 and 752 nbalance sensor (option)., page 22.

+ = brown or red

J = black or white

0V = blue

24 V DC

0,1+

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B1

3.5.6 Speed sensor

2 Adjusting the unbalance sensor

1 Adjusting the speed sensor

a Fit the

Sensor

Nut

b Adjust display

c When correct distance is achieved tighten the nut against the holder.Fit the cover (see previous page).

Nut.

AFU

102

a Adjust the speed sensor according to the illustration.

b Fit the sensor to the frame, see 1.4 Sensors, page 8.

120 1810828-02


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05

01

A1

Lifting instructions

Safety label.

3.6 Actions After Assembly

3.6.1 Control of machine plates and safety labels

Alfa Laval ref. 561498 rev.2

1 Check that the following signs are attached.

o

Space for label indicating representative.

Space for additional label as specified.

Indicating direction of rotation of horizontal driving device.

Machine plate

1810828-02 121


on the labels.

manuals before installation, operation and maintenance.intervals.

w instructions can lead to fatal injury.

occurs, stop separator and keep bowl filled with liquid

ion will become worse if bowl is not full.

rotating before any dismantling work is started.

ual before lifting.

o. / Year

owl)

power

ent

ing liquid

in./max.

S 840

881203-03-01

563094-01

561904-04

562967-01

9220 r/minute (50 Hz)9220 r/minute (60 Hz)

←

3000 r/min (50 Hz),3600 r/min (60 Hz)

50/60 Hz

9,5 kW

1100 kg/m3

2425 kg/m3

1000 kg/m3

0/100 °C

2 Check legibility. Following texts should be read

DANGER

Read the instructionConsider inspection

Failure to strictly follo

If excessive vibrationduring rundown.

Out of balance vibrat

Separator must stop

Read instruction man

Separator

Manufacturing serial N

Product No.

In and outlet device

Bowl

Machine bottom part

Max. speed (bowl)

Direction of rotation (b

Speed motor shaft

El. current frequency

Recommended motor

Max. density of feed

Max. density of sedim

Max. density of operat

Process temperature m

122 1810828-02


oil.

e lubricating oil. Oft types of oil. Even ay result in severe

is an indication thatof the oil additivesposits occurs.

mended to do thisan the gear housingposits before filling

s are applied.

mmended in our

nds, provided theyands recommended.mmended, is doneplier.

instructions.

3.7 Oil Change

The separator should be level and atstandstill when oil is filled or the oil level ischecked.

3.7.1 Lubricating oil

Do not mix different oil brands.

Always use clean vessels when handling lubricating

Great attention must be paid not to contaminate thparticular importance is to avoid mixing of differenfew drops of motor oil mixed into a synthetic oil mafoaming.

Any presence of black deposits in a mineral type oilthe oil base has deteriorated seriously or that somehave precipitated. Always investigate why black de

If changing from one oil brand to another it is recomin connection with an overhaul of the separator. Cleand the spindle parts thoroughly and remove all dethe new oil.

NOTE

Always clean and dry parts (also tools) before lubricant

CAUTION!

Check the oil level before start. Top up when necessary.Oil volume = see “Technical Data”.

It is of utmost importance to use the lubricants recodocumentation.

This does not exclude, however, the use of other brahave equivalently high quality properties as the brThe use of oilbrands and other lubricants than recoon the exclusive responsibility of the user or oil sup

Applying, handling and storing of lubricants

Always be sure to follow lubricants manufacturer's

1810828-02 123


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C1

Oil fill

Oil drain plug

Plug and washer

NOTE

For Inspection service procedures; See“Fill oil in the oil sump.” on page 101.

Max.Min.

3.7.2 Check oil level

1 Remove the oil pin and make sure that the oil level is above the lower end of the pin.

3.7.3 Oil change procedure

1 Remove the oil pin, plug and washer.

2 Remove the drain plug.

3 Collect the oil in a vessel.

4 Fit and tighten the drain plug.

5 Fill with new oil until oil flows out of oil filler hole.

6 Fit the washer and the oil filling plug. Tighten the plug.

7 Fit the oil pin.

CAUTION!

Burn hazardThe lubricating oil and various machine surfacescan be sufficiently hot to cause burns.

NOTE

See 3.7.6 Lubricating oils, page 128.

124 1810828-02


cant Interval

ting oil, page 123nical Data, page 13ture 0 to +55°C

Oil change:

1. Continous operation: 4000 hours2. Seasonal operation:

before every operating period3. Short periods operation:

12 months even if total numbers ofoperating hours is less than statedabove

ly a few drops for At assembling

in 3.7.5 Lubricants, At assembling.

ied in 3.7.5126

At assembling

pre-lubricated with No need for extra lubrication.

acturer’s instructions. Follow the manufacturer’s instructions.

CAUTION!

Check the oil level before start.Top up when necessary.Do not overfill.

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Friction clutch bearings (5)

Electric motor (6)

Bowl (3), Rubber seal rings (4)

3.7.4 Lubrication chartAlfa Laval ref. 567329-01, rev. 0

Lubricating points Type of lubri

1 The oil bath. Bowl spindle bearingsare lubricated by oil mist from the oilbath.

See 3.7.1 LubricaVolume: 2.1 TechAmbient tempera

2 Bowl spindle taper. Lubricating oil, onrust protection.

3 Bowl: Sliding contact surfaces, threadof lock nut and cap nut.

Pastes specifiedpage 126

4 Rubber seal rings. Grease as specifLubricants, page

5 Friction clutch bearings. The bearings aregrease.

6 Electric motor. Follow the manuf

NOTE

Check and pre lubricate new spindle bearings andthose that have been out of service for six months orlonger.If not otherwise specified, follow the suppliersinstructions about applying, handling and storing oflubricants.

Bowl spindle taper (2)

Bowl spindle and bearings (1)

Buffers (3)

1810828-02 125


No.

00 g)0 g)g)

No.

0 ml)ml)

3.7.5 LubricantsAlfa Laval ref. 553217-01 rev. 7

Pastes for non-food applications:

NOTE

The data in below tables is based on supplierinformation in regards to lubrication properties.Trade names and designations might vary fromcountry to country, contact your local supplier formore information.

Brands with Alfa Laval article numbers are approvedand recommended for use.

Bonded coatings

Manufacturer Designation Alfa Laval

Fuchs Lubritech Gleitmo 805 KGleitmo 705 K

Dow Corning Molykote 1000 (Paste)Molykote 1000 (Paste)Molykote G-rapid plus(Paste)

537086-02 (10535586-01 (10535586-02 (50

Rocol Antiscuffing (ASP) (Paste)

Kluber Wolfracoat C (Paste)

Manufacturer Designation Alfa Laval

Fuchs Lubritech Gleitmo 900 (Varnish orspray)

Dow Corning Molykote D321R (Spray)Molykote D321R (Varnish)

535586-01 (30535586-02 (60

126 1810828-02


l No.

00 g)5 g)

Silicone grease for rubber rings

Greases for ball and roller bearings:

NOTE

Always follow the specific recommendation forlubrication as advised by the manufacturer.

Manufacturer Designation Alfa Lava

Dow Corning Molykote 111 (Compound)Molykote 111 (Compound)

539474-02 (1539474-03 (2

Fuchs Lubritech Gleitmo 750

Kluber Unisilkon L 250 L

Wacker Silicone P (Paste)

Manufacturer Designation

BP Energrease MM-EP2Energrease LS2

Castrol APS 2 Grease

EPL 2

Chevron Duralith grease EP2

Elf Epexa 2

Esso/Exxon Beacon EP2Unirex N2

Mobil Mobilith SHC 460Mobilux EP2

Gulf Gulflex MP2

Q8/Kuwait Petroleum Rembrandt EP2

Shell Albida Grease EP2Alvania EP Grease 2

SKF LGEP2 or LGMT2

Texaco Multifak AFB 2

1810828-02 127


HVLP 68

1 litre

4 litres

))8)

Other oil brands maynd have equivalentf other lubricants

sibility of the user or

3.7.6 Lubricating oilsAlfa Laval ref. 567330-01, rev. 1

Paraffinic mineral lubricating oil, category(ISO-L-) HM 68.

Viscosity grade (ISO-3448/3104) VG 68.

The oil shall follow the requirements in one ofthe standards below.

The following is the list of recommended oilbrands. Trade names and designations mightvary from country to country. Please contactyour local oil supplier for more information.

Standard Designation

DIN 51524 part 2 (German standard) DIN 51524-HLP or

ISO 11158 (International standard) ISO-L-HM or HV 68

Manufacturer Designation

Alfa Laval 567334-01

567334-02

BP Bartran 68Bartran HV 68

Castrol Hyspin AWS 68Hyspin AWH 68

Chevron Hydraulic oil AW 68

Esso / Exxon Nuto H 68Univis N 68

Mobil DTE 26 (ISO VG 68DTE 16 (ISO VG 68DTE 16M (ISO VG 6

Shell Tellus Oil 68Tellus Oil S 68Tellus Oil T 68

Statoil HydraWay HMA 68Hydra Way HVX 68

Total Fina Elf Azolla ZS 68Lubmarine Visga 68

The list of recommended oil brands is not complete.be used as long as the follow the above standards ahigh quality as the brands recommended. The use othan recommended is done on the exclusive responoil supplier.

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350 kg

Sling length: Min. 750 mm

3.8 Lifting instructions

3.8.1 Lifting the separator

1 Remove the inlet and outlet device, the frame hood and the bowl according to the instructions in 3.3 Dismantling, page 41.

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.

5 Unscrew the foundation bolts.

NOTE

Never lift or transport the separator with the bowlstill inside.

Weight to lift

Fasten all four bolts. Tightening torque 35 - 45 Nm

1810828-02 129


6 When lifting and moving the separator, follow normal safety precautions for lifting large heavy objects.

WARNING!

Crush hazardsA 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 atleast 500 kg.

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Weight to lift 75 kg

Make sure that lock ring is fitted.

Lock ring

Tightening torque 35 - 45 Nm

3.8.2 Lifting the bowl

When lifting and moving an assembled bowl,always follow these instructions.

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.

NOTE

Never try to lift the bowl while it is still in the frame.The bowl body is fastened to the frame with thecap nut.

1810828-02 131

4 CHANGE OF CIRCUIT BOARD SEPARATION UNIT 840 SERVICE MANUAL

4 Change of Circuit Board

If a circuit board has to be changed, proceed asfollows:

Note down the run time (days only) as shown inthe function list of the EPC 50.

Change the board according to the instructionsbelow.

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


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.


132 1810828-02

SEPARATION UNIT 840 SERVICE MANUAL 4 CHANGE OF CIRCUIT BOARD

If one or more optional board is installed:


• 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.

MT-Board


• Disconnect the cable plug (do not remove the cables from the plug).

• Disconnect the centrally connected cable.

• Unscrew the four screws holding the board and lift out the board.


• Check that the central hexagon nut is properly tightened.

1810828-02 133

4 CHANGE OF CIRCUIT BOARD SEPARATION UNIT 840 SERVICE MANUAL

4.1 Circuit Board Temperatures

Circuit board temperature information can beread as follows:

• Set Pr 7 = 2.

• Push ‘+’ and ‘–’ at the same time (‘Standst.’ now shows on the display).

• Push ‘–’

The actual temperature, max. temperature, andthe number of times the temperature has beenabove 70 °C for the transducer scrolls across thedisplay.

• 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.

134 1810828-02

SEPARATION UNIT 840 SERVICE MANUAL 5 CLEANING IN PLACE

5 Cleaning in Place

G0

65

05

4A

The use of Cleaning In Place (CIP)equipment is recommended for bestseparation results. For further informationconcerning the CIP equipment, see the CIPbooklet, bookno. 1817261.

Before connecting the CIP equipment to theSeparation Unit, the switch on the controlcabinet must be turned to the CIP position.This is so that oil is not accidentally pumpedwhen the pipeline is opened up.

5.1 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

The top outlet on the CIP unit should be connected tothe top inlet on the separator.The middle inlet on the CIP unit should be connectedto the middle oil outlet on the separator.The lower CIP inlet should be connected to the lowerwater outlet on the separator.

1810828-02 135

5 CLEANING IN PLACE SEPARATION UNIT 840 SERVICE MANUAL

5.2 Cleaning in Place, Heatpac® CBM Heater

For systems including a Heatpac® CBM heater,cleaning in place of the heater should be carriedout circa every 6 months, or according toexperience. Cleaning in place of the heatershould also be carried out in the event of apressure drop increase greater than 0.3 – 0.5 bar(which indicates that the heater is beginning toclog).

We recommend that you use Alfa Laval cleaningliquids. These are specially suitable for thematerials used in the Heatpac® CBM heater.Liquids that are corrosive to copper or stainlesssteel, for example hydrochloric acid, phosphoricacid, or nitric acid, must not be used.

WARNING!

Burn hazardShut off the oil flow and the heating medium flowbefore starting maintenance work.

WARNING!

Corrosion hazardPay strict attention to the safety instructions for thecleaning liquid used.

NOTE

Use only specified cleaning liquids. Other cleaningagents may corrode the metal surfaces.

136 1810828-02

SEPARATION UNIT 840 SERVICE MANUAL 5 CLEANING IN PLACE

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05

3A

Proceed as follows:

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.

NOTE

The middle and lower CIP unit outlets must beclosed.

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.

1810828-02 137

5 CLEANING IN PLACE SEPARATION UNIT 840 SERVICE MANUAL

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06

2A

Oil outlet Water outlet

5.3 Cleaning in Place, Separator and Heater

Connect the CIP equipment as shown in theillustration. Proceed with cleaning as describedabove.

138 1810828-02

SEPARATION UNIT 840 SERVICE MANUAL 6 HEATPAC® CBM HEATER (OPTIONAL)

6 Heatpac® CBM Heater (Optional)

MPa (16 bar)

MPa (24 bar)

°C

eral oil

am, hot water, thermal oil

- 9.2

.01 mg/l

all be neutral to minimize corrosion risk

e thermal oil must be highly resistant to oxidation andrmal desintegration. It must also have good corrosiontection properties.

6.1 Technical Data

6.1.1 Manual Cleaning

Manual cleaning is carried out as follows:

1 Disconnect the heater.

2 Drain the heater.

3 Flush the heater through with fresh water.

4 Drain the heater from water.

5 Fill the heater with hot cleaning liquid (50-70 °C). Use the type and concentration required for the deposits present.

6 Let the liquid stay in the heater for at least 60 minutes. If possible, let the cleaning liquid circulate in the heater.

7 Drain the cleaning liquid.

8 Flush through with clean water.

9 Reconnect the heater using new gaskets.

NOTE

Take care to reinstall the heater the right way up.

Operating pressure, maximum 1.6

Test pressure 2.4

Operating temperature, maximum 225

Medium Min

Heating media Ste

The following shall apply to the heating media:

Steam:condensate pH

sodium in condensate

8.8

< 0

Water:pH value Sh

Thermal oil Ththepro

1810828-02 139

6 HEATPAC® CBM HEATER (OPTIONAL) SEPARATION UNIT 840 SERVICE MANUAL

140 1810828-02

SEPARATION UNIT 840 SERVICE MANUAL 7 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL)

7 Heatpac® EHM Electric Heater (Optional)

7.1 Technical Data

Tightening Torques

Media Mineral oil

Max. testing pressure 2.4 MPa (24 bar)

Operating pressure and media temp According to PN 16:

Max. 1.6 MPa (16 bar) up to 150 °C

Max. 1.5 MPa (15 bar) up to 160 °C

Material:

Heating element Aluminium

Pressure vessel Pressure vessel steel

Cover Aluminium

Insulation 20 mm mineral wool

Mounting style Vertically or horizontally

Voltage supply 230, 400, 440, 460/480/500, 690 V AC, 50/60 Hz

Connections Acc. to DIN standard 2633 or JIS standard B2213

Terminal box IP 65

Elements; resistance, surface load, output 400 V: 63 Ω, 1.3 W/cm2, 2.5 kW

440 V: 70 Ω, 1.4 W/cm2, 2.8 kW

460 V: 83 Ω, 1.3 W/cm2, 2.5 kW

480 V: 83 Ω, 1.4 W/cm2, 2.8 kW

500 V: 83 Ω, 1.5 W/cm2, 3.0 kW

690 V see 400 V (= Y-connected 400 V elements)

Flange bolts M16 240 Nm

Ground screw M8 21 Nm

Connections on elements M4 3 Nm

Element nut h = 9 M14 70 Nm

Element nut h = 5 M14 30-50 Nm

Relief valve G1/2 80 Nm

Spring pocket for Pt 100 and safety guard G1/2 30 Nm

Temperature sensors 80 Nm

1810828-02 141

7 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL) SEPARATION UNIT 840 SERVICE MANUAL

G00

3313

A

7.2 Dismantling and Cleaning

The electric heater requires regular opening forcleaning. The heater block resistance, and theinsulation resistance of the heating elementsshould be checked and an inspection of thegeneral condition carried out.

Any malfunctions of the heater are indicated inthe control unit. For further information see theAlarms and Fault Finding booklet.

As a general guideline, the heater should beopened up for cleaning whenever an excessivepressure drop occurs, or if capacity falls and oiltemperature is low.

Where heavy fuel is used, dismantle the heaterwhen warm as described below:

1 Lift off the junction box cover.

2 Loosen the cable nipples.

3 Mark the signal wires, disconnect them and pull out the cables.

4 Remove the flange bolts.

5 Remove the earth connections between the flanges and the junction box.

6 Lift off the heater insert. If cold heavy fuel has stiffened the heater insert, a couple of screwdrivers may be used to ease off the insert. Avoid using a sling.

7 Clean the insert in a bath using Alfa-Laval cleaning liquid part no. 1762852-01 for lube oil heater; part no. 1763500-02 alternatively diesel oil, white spirit, or equivalent for fuel oil heater. Blow all parts dry with compressed air.

8 Assemble the heater in reverse order.

9 Measure the heater block resistance and the insulation resistance to ground before reconnecting the wires.

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7.2.1 Replacing Heater Element

1 Place the heater insert on a work bench.

2 Use a box spanner to disconnect the wires and the connecting plates. A wiring diagram is placed on the inside of the junction box cover.

3 Disconnect the junction box by removing the nuts on the heater element connecting rods inside the the junction box, using a box spanner. Be careful not to damage the insulation sleeves.

4 Remove the junction box.

5 Remove the O-rings above the tightening nuts of the heater element connecting rods.

6 Remove the nuts using a box spanner.

7 Pull out the heater element.

8 When reassembling:

9 Use a new copper packing.

10 Screw fast the elements in the top counter flange.

11 Before refitting the junction box, change the O-rings.

For tightening torques, see page 141.

CAUTION!

It is very important that the appropriate heaterelement is installed.

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G00

3322

A

7.2.2 Insulation Resistance Megger Test

The heating elements are electrically insulatedby means of compact magnesium oxide. Undercertain conditions, e.g. during storage, transport,etc., magnesium oxide can attract damp whichlowers the insulation resistance. The insulationresistance between terminal and ground for eachheater block must therefore be measured beforethe heater is taken into use. This is done bymeans of a megger test.

Megger Test Procedure

• Disconnect the wires from the terminal in the heater junction box before starting measurement.

• Test the insulation resistance for the heater blocks by means of a megger connected between the heater terminals and ground in the heater junction box. The test voltage to use is 500 V DC.

The total insulation resistance for the heatershould be ≥1 MΩ.

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Action to Increase Insulation Resistance

If the insulation resistance is between 100 kΩ and 1 MΩ, the heater can be reconditioned inplace simply by taking it into use.

Please note that during the first period ofoperation the insulation resistance can besomewhat reduced before it starts to increase.This is due to the accumulation of moisture inthe element top during heating.

In the event the insulation resistance is below100 kΩ in any group of elements, the elements inthe group must be measured separately. Theinsulation resistance in a single element ismeasured between the connecting pin on theelement, with the closing links disconnected, andthe ground.

A single element with resistance below 100 kΩcan be reconditioned in place by indirectwarming. Do not connect the connecting pins viathe closing link to the terminal. Connect theremaining elements in the block to the terminaland allow the heater to be taken into operation.

New Megger Test

If the insulation resistance at start-up wasunder 1 MΩ, a new megger test should be carriedout after 14 days operation. The elements shouldnow have a resistance of over 1 MΩ. If this is notthe case, any element still below 1 MΩ should bereplaced.

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2 Part load 3 Part load 4

----

----

----

----

----

----

----

----

----

----

----

----

----

----

----

----

21

23

28

63

----

----

----

----

21

23

23

63

----

----

----

----

21

23

28

63

21

23

28

63

21

23

28

63

11

12

14

32

G0

03

17

1A

7.2.3 Measuring of Heater Block Resistance

Resistances of available heater sizes andapplicable voltage supply are given in thefollowing table:.

The heater block resistances are measured fromthe power unit. This ensures that the heaterelements and the heater blocks are correctlyconnected.

Heater Block Resistance (Ω)

Size Voltage (V) Part load 1 Part load

7 kW

8 kW

8 kW

7 kW

400

440

480

690 V

42

47

55

126

----

----

----

----

14 kW

16 kW

16 kW

14

400

440

480

690

21

23

28

63

----

----

----

----

22 kW

24 kW

24kW

22

400

440

480

690

21

23

28

63

42

47

55

126

36 kW

40 kW

40 kW

36

400

440

480

690

21

23

23

63

42

47

47

126

50 kW

56 kW

56

50

400

440

480

690

21

23

28

63

42

47

55

126

65 kW

72 kW

72kW

65

400

440

480

690

21

23

28

63

42

47

55

126

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2 Part load 3 Part load 4

X11:10-11 X11:13-14

X11:10-12 X11:14-15

X11:11-12 X11:13-15

---- ----

---- ----

---- ----

K21:2-4 K22:2-4

K21:4-6 K22:4-6

K21:2-6 K22:2-6

Terminals for Block Resistance Measuring

Power unit Part load 1 Part load

X11:4-5 X11:7-8

X11:4-6 X11:8-9

X11:5-6 X11:7-9

Control unit X11:4-5 X11:7-8

X11:4-6 X11:8-9

X11:5-6 X11:7-9

Contactor box ---- ----

---- ----

---- ----

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SEPARATION UNIT 840 SERVICE MANUAL 8 HEATPAC® POWER UNIT (OPTIONAL)

8 Heatpac® Power Unit (Optional)

, 440, 460/480/500 V AC +10% /-15% ,60 Hz ±5%

x. 35 A

ermal relays, 16-23 A/8.5-12.5 A

x. 23 A

)

, 440, 460/480/500 V AC +10% /-15% ,60 Hz ±5%

x. 100 A

es, 25 A, 16 A, 25 A, 63 A

x. 23 A

V AC +10% /-15% , 50/60 Hz ±5% (from externaltrol unit)

30-6356-1 Max. 120 VA/30 VA

30-6407-1 Max. 200 VA/55 VA

°C

65

el

kg

kg

ins supply

ntrol signals (24 V AC)

x. contact on contactor for pump

100 temp. sensor (to internal high temp. switch).

er to heater

fety alarm feedback to control unit

8.1 Technical Data Power circuits. Up to 24 kW (smaller cabinet )

31830-6356-1

Mains supply (3 phase) 40050/

External fuse Ma

Overcurrent protection Th

Triac circuit current Ma

Power circuits. 36 kW to 72 kW (larger cabinet

31830-6407-1

Mains supply (3 phase) 40050/

External fuse Ma

Overcurrent protection Fus

Triac circuit current Ma

Control circuits

Control voltage 24con

Power consumption (inrush/hold) 318

318

General

High voltage tested at 2000 V

Max. ambient temperature 55

Protection class IP

Material Ste

Weight

Smaller cabinet 40

Larger cabinet 54

External inputs and outputs

Inputs Ma

Co

Au

Pt

Outputs Pow

Sa

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8 HEATPAC® POWER UNIT (OPTIONAL) SEPARATION UNIT 840 SERVICE MANUAL

8.2 Working principle

Power for the electric heater is supplied from anexternal power source via the main switch andthe different contactors.

The contactor K11 supplies power to a variableheater load of 0-7/8 kW or0-14/16 kW, which is controlled from the triacmodules A1 and A2. This contactor is activatedat all times once the heater is started and as longas the control unit signals no function fault. Theremaining contactors (K12 and K16-K17, ifapplicable) supply power to fixed heater loads ason/off functions in accordance with the size of theheater. By combining the variable load and thefixed loads, an overall stepless heater isachieved.

8.3 Electric Heater Function

By using the proportional and integral (PI)functions in the EPC, it is possible to activate thepower unit load functions to feed the electricheater with variable and fixed power.

The power unit is equipped with the necessarycontactors, fuses and terminals.

The power unit also holds two triac modules (A1and A2) for regulating the variable load.

The electric heater requires an extratemperature sensor (on the heater) connected toa temperature switch (in the power unit) toprevent overheating.

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G02

5651

A

A Load (kW)B Size (kW)1. Part load #1 (variable 0 –16 kW)2. Part load #2 (fixed 8 kW)3. Part load #3 (fixed 16kW)4. Part load #4 (fixed 32kW)

Heating Performance Principle for 440 V

8.4 Heating Performance Principle

The oil temperature is regulated from the controlunit which gives the appropriate signals to thepower unit. The power unit feeds the electricheater with both variable and fixed power.

The fixed power is fed in steps as a constant partload. The variable load operates on top of thefixed part load for fine tuning of temperature.

Sequential switching of the fixed part load andregulation of the variable part load areautomatically controlled by the control unit, andresults in an overall smooth operation.

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8.5 Load Control and Functions

8.5.1 Variable Part Load

8.5.2 Fixed Part Load

Power for the variable part load (#1) is fed viacontactor K11 in the power unit and regulatedby means of the two triac modules A1 and A2.

Contactor K11 is activated provided that there isa closed circuit through the safety switch (TS)and that there are no function faults in thecontrol unit (see electrical diagram in SystemReference/Installation Instructions). The triacmodules are controlled from the control unit.

The required electric power is then supplied tothe heater in accordance with the present load.Contactor K11 is furnished with a variableoverload protection relay (F11).

Power to the fixed part loads (#2 – #4) is fed viacontactors K12, K16, and K17, and controlledfrom the control unit as on/off functions inaccordance with the present load.

The contactors are switched off by the heatersafety switch function (TS, K14) in the case ofexcessive temperature or low oil flow (pumpinterlocking).

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8.5.3 External Safety Stop

8.5.4 Start and Reset Functions

The contactor circuits for switching power on/offto the different part loads are interlocked bymeans of the external safety stop switch (whichis connected in series to the internaltemperature switch TS), to prevent the electricheater from overheating.

The contactors K11, K12, K16, and K17 in thepower unit are connected in series to the internaltemperature switch TS. Excessive temperatureor no oil flow (pump stopped) will deactivate thecontactors, thus switching off the heater.

Overload relays/fuses F11, F12, F16, and F17 inthe power unit are used for overload protection.

During normal operation, the contactors in thepower unit are activated from the Control Unitand interlocked by the pump starter andcontactor K14. Contactor K14 is interlocked bythe temperature switch.

• If the temperature switch has been released, the heater must be restarted using the Alarm Reset on the Control Unit after the cause has been remedied.

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Alfa Laval

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