Alfa Laval FOPX 609TFD-24 Manual
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Alfa Laval FOPX 609TFD-24 Manual

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Product No.
881244-02-03
Book No.
1270843-02 V1
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Summary of Contents for Alfa Laval FOPX 609TFD-24

  • Page 1 Product No. 881244-02-03 Book No. 1270843-02 V1...
  • Page 2 Telephone: +46 8 53 06 50 00 Telefax: +46 8 53 06 50 29 Printed in Sweden, 97-08 © Alfa Laval Separation AB 1997 This publication or any part thereof may not be reproduced or transmitted by any process or means without prior written permission of...

  • Page 3: Table Of Contents

    Contents Read this first Safety Instructions Separator Basics 3.1 Basic principles of separation 3.2 Design and function 3.3 Definitions Operating Instructions 4.1 Operating routine Service Instructions 5.1 Periodic maintenance 5.2 Maintenance Logs 5.3 Check points at Intermediate Service (IS) 5.4 Check points at Major Service (MS) 5.5 Lifting instructions 5.6 Cleaning 5.7 When changing oil...
  • Page 4 Trouble-tracing 7.1 FOPX mechanical functions 7.2 FOPX separating functions 7.3 Vibration switch (option) Technical Reference 8.1 Technical data 8.2 Basic size drawing 8.3 Water quality 8.4 Lubricants 8.5 Drawings 8.6 Storage and installation Index...
  • Page 5 Study instruction manuals and observe the warnings before installation, operation, service and maintenance. Not following the instructions can result in serious accidents. In order to make the information clear only foreseeable conditions have been considered. No warnings are given, therefore, for situations arising from the unintended usage of the machine and its tools.

  • Page 7: Read This First

    15 and chapter ‘‘8 Technical Reference” on page 177. If the separator has been delivered and installed by Alfa Laval as part of a processing system, this manual is a part of the system documentation. In this case, study carefully all the instructions in the system documentation.
  • Page 8 1 Read this first Service Instructions This chapter gives instructions for daily checks, cleaning, oil changes, servicing and check points. Dismantling / Assembly This chapter contains step-by-step instructions for dismantling and assembly of the separator for service and repair. Trouble-tracing Refer to this chapter if the separator functions abnormally.

  • Page 9: Safety Instructions

    Strictly follow the instructions for installation, operation and maintenance. • Ensure that personnel are competent and have sufficient knowledge of maintenance and operation, especially concerning emergency stopping procedures. • Use only Alfa Laval genuine spare parts and the special tools supplied.
  • Page 10 2 Safety Instructions DANGER Disintegration hazards • Use the separator only for the purpose m /h and parameter range specified by Alfa Laval. kg/m • If excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown. •...
  • Page 11 2 Safety Instructions DANGER Entrapment hazards • Make sure that rotating parts have come to a complete standstill before starting any dismantling work. • To avoid accidental start, switch off and lock power supply before starting any dismantling work. • Assemble the machine completely before start.
  • Page 12 2 Safety Instructions CAUTION Burn hazards • Lubrication oil and various machine surfaces can be hot and cause burns. Cut hazards • Sharp edges on separator discs and lock ring threads can cause cuts.
  • Page 13 2 Safety Instructions Warning signs in the text Pay attention to the safety instructions in this manual. Below are definitions of the three grades of warning signs used in the text where there is a risk for injury to personnel. DANGER Type of hazard This type of safety instruction indicates a...
  • Page 14 2 Safety Instructions...

  • Page 15: Separator Basics

    3 Separator Basics Contents 3.1 Basic principles of separation 3.2 Design and function 3.2.1 Overview 3.2.2 Mechanical power transmission 3.2.3 Sensors and indicators 3.2.4 Process main parts 3.2.5 Separating function 3.2.6 Sludge discharge cycle 3.3 Definitions...

  • Page 17: Basic Principles Of Separation

    3 Separator Basics 3.1 Basic principles of separation Basic principles of separation The purpose of separation can be: • to free a liquid of solid particles, • to separate two mutually insoluble liquids with different densities while removing any solids presents at the same time, •...
  • Page 18 3.1 Basic principles of separation 3 Separator Basics Separating temperatures For some types of process liquids (e.g. mineral oils) a high separating temperature will normally increase the separation capacity. The temperature influences oil viscosity and density and should be kept constant throughout the separation.

  • Page 19: Design And Function

    3 Separator Basics 3.2 Design and function Design and function 3.2.1 Overview The separator comprises a processing part and a driving part. It is driven by an electric motor (9). Mechanically, the separator machine frame is composed of a bottom part, a top part and a frame hood.
  • Page 20 3.2 Design and function 3 Separator Basics 3.2.2 Mechanical power transmission The main parts of the power transmission between motor and bowl are illustrated in the figure. The friction coupling ensures a gentle start and acceleration and at the same time prevents overloading of the worm gear and motor.
  • Page 21 3 Separator Basics 3.2 Design and function 3.2.3 Sensors and indicators Revolution counter (1) A revolution counter indicates the speed of the separator and is driven from the worm wheel shaft. The correct speed is essential to achieve the best separating results and for safety of operation.
  • Page 22 3.2 Design and function 3 Separator Basics Back pressure gauge (5) Correct limits for the back pressure in the clean oil outlet can be found in chapter ‘‘8.2.2 Connection list” on page 183. Increasing back pressure in the clean oil outlet can be caused by: •...
  • Page 23 3 Separator Basics 3.2 Design and function 3.2.4 Process main parts Upper paring camber Flow control disc Oil paring chamber Small lock ring (with paring chamber cover) Level ring Distributor Top disc Bowl hood Bowl disc stack 10. Large lock ring 11.
  • Page 24 3.2 Design and function 3 Separator Basics Inlet and outlet device The inlet and outlet device consists of the following parts: • The inlet (201). This comprises the pipe bend and the long inlet pipe (22) which extends into the middle of the bowl. •...
  • Page 25 3 Separator Basics 3.2 Design and function Sludge discharge mechanism At intervals decided by the operator, the sliding bowl bottom drops to empty the bowl of sludge. The sludge discharge mechanism, which controls the sliding bowl bottom, comprises an operating slide (14) and an operating water device.
  • Page 26 3.2 Design and function 3 Separator Basics 3.2.5 Separating function Unseparated oil is fed into the bowl through the inlet pipe (6) and is pumped via the distributor (7) towards the periphery of the bowl. When the oil reaches slots in the base of the distributor, it will rise through the channels formed by the disc stack (8) where it is evenly distributed.
  • Page 27 3 Separator Basics 3.2 Design and function 3.2.6 Sludge discharge cycle When the sludge space is filled up and water approaches the disc stack, some droplets of water start to escape with the cleaned oil. The small increase of the water content in the cleaned oil must be detected and initiate a short opening of the water drain valve or initiate a sludge discharge cycle.
  • Page 28 3.2 Design and function 3 Separator Basics Closed bowl (normal operation) The sliding bowl bottom (6) is pressed upwards by force of the closing water in the closing water space (8) under the sliding bowl bottom which is greater than the force of the process liquid above the sliding bowl bottom.

  • Page 29: Definitions

    3 Separator Basics 3.3 Definitions Definitions Back pressure Pressure in the separator outlet. Clarification Liquid/solids separation with the intention of separating particles, normally solids, from a liquid (oil) having a lower density than the particles. Counter pressure See Back pressure. Density Mass per unit volume.
  • Page 30 3.3 Definitions 3 Separator Basics...

  • Page 31: Operating Instructions

    4 Operating Instructions Contents 4.1 Operating routine 4.1.1 Ready for start 4.1.2 Start 4.1.3 Running 4.1.4 Normal stop 4.1.5 Safety stop...

  • Page 32: Operating Routine

    4.1 Operating routine 4 Operating Instructions Operating routine These operating instructions are related only to the separator itself. If the separator is a part of a system or module follow also the instructions for the system. 4.1.1 Ready for start To achieve the best separation results the bowl should be in a clean condition.

  • Page 33: Start

    4 Operating Instructions 4.1 Operating routine 4. Make sure that the brake is released. 4.1.2 Start Release the brake 1. Start the separator. 2. Check the direction of rotation of the bowl. The revolution counter should turn clockwise. DANGER Disintegration hazards When power cables have been connected, always check direction of rotation.

  • Page 34: Running

    4.1 Operating routine 4 Operating Instructions 4. Check, if possible, the current drawn by of the motor starter to ensure that the separator has reached full speed. At full speed the starter ammeter reading has decreased from a high starting value to a low steady value.

  • Page 35: Normal Stop

    4 Operating Instructions 4.1 Operating routine 4.1.4 Normal stop 1. Carry out a sludge discharge before stopping the separator. Otherwise the bowl must be cleaned manually before the next start up. The volume of the discharged sludge must be compensated for by additional feed. 2.

  • Page 36: Safety Stop

    Out-of-balance vibration can become worse if only part of the sediment is discharged. CAUTION Disintegration hazards After a safety stop the cause of the fault must be identified. If all parts have been checked and the cause remains unclear, contact Alfa Laval for advice.

  • Page 37: Service Instructions

    5 Service Instructions Contents 5.1 Periodic maintenance 5.4 Check points at Major Service (MS) 5.1.1 Introduction 5.4.1 Bowl hood seal ring 5.1.2 Maintenance intervals 5.4.2 Bowl spindle cone and bowl body nave 5.1.3 Maintenance procedure 5.4.3 Bowl spindle; height position 5.1.4 Service kits 5.4.4...
  • Page 38 5 Service Instructions 5.5 Lifting instructions 5.6 Cleaning 5.6.1 External cleaning 5.6.2 Cleaning agents 5.6.3 Cleaning of bowl discs 5.6.4 CIP-system 5.7 When changing oil 5.7.1 Worm wheel and worm; wear of teeth87 5.7.2 Oil change procedure 5.8 Vibration 5.8.1 Vibration analysis 5.8.2 Vibration switch (option)

  • Page 39: Periodic Maintenance

    5 Service Instructions 5.1 Periodic maintenance Periodic maintenance 5.1.1 Introduction Periodic (preventive) maintenance reduces the risk of unexpected stoppages and breakdowns. Follow the maintenance logs on the following pages in order to facilitate the periodic maintenance. DANGER Disintegration hazards Separator parts that are either worn beyond their safe limits or incorrectly assembled may cause severe damage or fatal injury.
  • Page 40 5.1 Periodic maintenance 5 Service Instructions Intermediate Service (IS) Intermediate Service consists of an overhaul of the separator bowl, inlet/outlet and operating device every 3 months or 2000 operating hours. Seals in bowl and gaskets in inlet/outlet device are renewed. Major Service (MS) Major Service consists of an overhaul of the complete separator and includes an Intermediate...

  • Page 41: Maintenance Procedure

    5 Service Instructions 5.1 Periodic maintenance 5.1.3 Maintenance procedure At each Intermediate and Major Service, take a copy of the maintenance log and use it for notations during the service. An Intermediate and Major Service should be carried out in the following manner: 1.

  • Page 42: Service Kits

    Spare Parts Catalogue . NOTE Always use Alfa Laval genuine parts as otherwise the warranty will become invalid. Alfa Laval takes no responsibility for the safe operation of the equipment if non-genuine spare parts are used. DANGER Disintegration hazards Use of imitation parts may cause severe damage.

  • Page 43: Maintenance Logs

    5 Service Instructions 5.2 Maintenance Logs Maintenance Logs 5.2.1 Daily checks The following steps should be carried out daily. Main component and activity Part Page Notes Inlet and outlet Check for leakage Connecting housing – Separator bowl Check for vibration and noise Horizontal driving device Worm wheel shaft and gear casing Check for vibration and noise...

  • Page 44: Intermediate Service (Is)

    5.2 Maintenance Logs 5 Service Instructions 5.2.3 Intermediate Service (IS) Name of plant: Local identification: Separator: FOPX 609TFD-24 Manufacture No./Year: Total running hours: Product No: 881244-02-03 Date: Signature: Main component and activity Part Page Notes Inlet and outlet Clean and inspect...
  • Page 45 5 Service Instructions 5.2 Maintenance Logs Main component and activity Part Page Notes Check Corrosion Cracks Erosion Galling of guide surface Disc stack pressure Renew O-rings and sealings Operating device Clean and check Operating paring disc – Renew O-rings Horizontal driving device Worm wheel shaft and gear housing Check Worm wheel and worm...

  • Page 46: Major Service (Ms)

    5.2 Maintenance Logs 5 Service Instructions 5.2.4 Major Service (MS) Name of plant: Local identification: Separator: FOPX 609TFD-24 Manufacture No./Year: Total running hours: Product No: 881244-02-03 Date: Signature: Main component and activity Part Page Notes Inlet and outlet Clean and inspect...
  • Page 47 5 Service Instructions 5.2 Maintenance Logs Main component and activity Part Page Notes Check Corrosion Cracks Erosion Galling of guide surface Disc stack pressure Height position of oil paring disc Renew O-rings and sealings Operating device Clean and check Operating paring disc –...
  • Page 48 5.2 Maintenance Logs 5 Service Instructions Main component and activity Part Page Notes Friction coupling Clean and check Worm wheel coupling – Renew (if necessary) Friction pads Electrical motor Lubrication (if nipples are fitted) See sign on motor – Signs and labels on separator Check attachment and legibility Safety label on hood Direction of rotation arrow...

  • Page 49: 3-Year Service (3S)

    5 Service Instructions 5.2 Maintenance Logs 5.2.5 3-year Service (3S) The 3-year service should be carried out in conjunction with a Major Service (MS). The extent of the 3-year service is the same as for a major service plus renewing of parts included in the 3-year Service kit (3S).

  • Page 50: Check Points At Intermediate Service (Is)

    5.3 Check points at Intermediate Service (IS) 5 Service Instructions Check points at Intermediate Service (IS) 5.3.1 Bowl hood seal ring Poor sealing between the bowl hood seal ring and the sealing edge of the sliding bowl bottom will cause a leakage of process liquid from the bowl. Renew the bowl hood seal ring at each Intermediate Service (IS).

  • Page 51: Bowl Spindle Cone And Bowl Body Nave

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) 5.3.2 Bowl spindle cone and bowl body nave Impact marks on the spindle cone or in the bowl body nave may cause poor fit and out-of-balance vibrations. The bowl spindle and the nave should also be checked if the bowl spindle has been dismantled or if the bowl runs roughly.
  • Page 52 5.3 Check points at Intermediate Service (IS) 5 Service Instructions Always contact your Alfa Laval representative if you suspect that the largest depth of the corrosion damage exceeds 1,0 mm or if cracks have been found. Do not continue to use the separator until it has been inspected and given clearance for operation by Alfa Laval.
  • Page 53 5 Service Instructions 5.3 Check points at Intermediate Service (IS) Corrosion damage caused by chlorides on stainless steel begins as small dark spots that can be difficult to detect. 1. Inspect closely for all types of damage by corrosion and record these observations carefully.

  • Page 54: Cracks

    It is particularly important to inspect for cracks in rotating parts and especially the pillars between the sludge ports in the bowl wall. Always contact your Alfa Laval representative if you suspect that the largest depth of the damage exceeds 1,0 mm. Do not continue to use the separator until it has been inspected and cleared for operation by Alfa Laval.

  • Page 55: Disc Stack Pressure

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) 5.3.5 Disc stack pressure NOTE Ensure that the disc stack pressure is sufficient to maintain bowl balance. Insufficient pressure in the disc stack can cause vibration and reduce lifetime of ball bearings.
  • Page 56 5.3 Check points at Intermediate Service (IS) 5 Service Instructions Complementary check using the compressing tool With the large lock ring correctly tightened and the compressing tool mounted on the separator bowl, turn the lever to position 1 for compression. Compress the disc stack by pumping the horizontal handle arm until the oil pressure is released through the relief valve.

  • Page 57: Dosing Ring

    Disintegration hazard Inspect regularly for erosion damage. Inspect frequently if the process liquid is erosive. Always contact your Alfa Laval representative if the largest depth of any erosion damage exceeds 1,0 mm. Valuable information as to the nature of the damage can be recorded using photographs, plaster impressions or hammered-in lead.
  • Page 58 5.3 Check points at Intermediate Service (IS) 5 Service Instructions Surfaces particularly subjected to erosion are: 1. The upper paring disc. 2. The top disc. 3. The pillars between the sludge ports in the bowl wall. 4. The sealing edge of the sliding bowl bottom. 5.

  • Page 59: Guide Surfaces

    Repair of galling on guide surfaces; see following pages. Before fitting the sliding bowl bottom, clean (do not degrease) the contact surfaces (1). Apply Alfa Laval lubricating paste or Molykote 1000 Paste with a well-cleaned brush on surfaces (1 and 2).
  • Page 60 5.3 Check points at Intermediate Service (IS) 5 Service Instructions Repair of galling on guide surfaces Galling (friction marks) may appear on guide surfaces in the operating system, the bowl body and the sliding bowl bottom. Surfaces subject to repair are indicated by an arrow. The example below describes the repair of the lower guide surface of the bowl body nave.

  • Page 61: Inlet Pipe And Oil Paring Disc

    Prime the repaired area with lubricating spray Molykote 321 R. Read the correct procedure under checkpoint ‘‘5.4.17 Lock ring; priming” on page 75. Apply Alfa Laval lubricating paste or Molykote 1000 Paste to the surface after priming. 5.3.9 Inlet pipe and oil paring disc...

  • Page 62: Lock Ring; Wear And Damage

    If the original φ−mark on the lock ring passes the φ−mark on the bowl body by more than 25° (which corresponds to A=100 mm, an Alfa Laval representative must be contacted immediately. If the marks become illegible, an Alfa Laval...

  • Page 63: Operating Mechanism

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) Damage The position of the threads, contact and guide surfaces are indicated by arrows in the illustration. Clean the threads, contact and guide surfaces with a suitable degreasing agent. Check for burrs and protrusions caused by impact.

  • Page 64: Operating Slide

    5.3 Check points at Intermediate Service (IS) 5 Service Instructions 5.3.13 Operating slide Poor sealing between the valve plugs on the operating slide and bowl body may prevent complete closing of the bowl. Examine the sealing surfaces (1) of the bowl body in contact with the valve plugs.

  • Page 65: Springs For Operating Mechanism

    If the seal ring for the sliding bowl bottom is to be renewed, turn the sliding bowl bottom upside down and inject compressed air through the hole on the underside. This will press the ring outwards far enough to be gripped easily. WARNING Risk for eye injury Wear safety goggles.

  • Page 66: Vibration Switch (Option)

    5.3.17 Cover interlocking switch (option) When the button is pushed, check that the brown and blue wires are short-circuited and the two black wires are open circuit. Check also the reverse when the button not pressed. See the illustration for exact measurement when the button is operated.

  • Page 67: Check Points At Major Service (Ms)

    Check points at Major Service (MS) 5.4.1 Bowl hood seal ring Described in ‘‘5.3.1 Bowl hood seal ring” on page 5.4.2 Bowl spindle cone and bowl body nave Described in ‘‘5.3.2 Bowl spindle cone and bowl body nave” on page 51. 5.4.3 Bowl spindle;...

  • Page 68: Bowl Spindle; Radial Wobble

    5.4.4 Bowl spindle; radial wobble The bowl spindle wobble should be checked if the bowl spindle has been dismantled or if rough bowl running (vibration) occurs. NOTE Spindle wobble will cause rough bowl running. This leads to vibration and reduces lifetime of ball bearings.
  • Page 69 f the friction pad is oily: • Clean the friction pad and the coupling drum with a suitable degreasing agent. • Roughen the friction surface of the friction pad with a coarse file. NOTE Identify the cause of oily friction pad. If oil is leaking from the gear housing, renew the sealing ring between the two parts.
  • Page 70 Top bearing springs In case of spring failure, the complete set of springs should be renewed, even if only one spring is affected. Ball bearing housing Radial buffer Buffer spring Screw plug Ball bearing housing Examine the contact surface for the buffers on the ball bearing housing.

  • Page 71: Coupling Friction Pads

    5.4.7 Coupling friction pads Worn or oily pads in the coupling will cause a long acceleration period. If the separator does not attain full speed within about 10 minutes or if the bowl loses speed during operation, the friction pads of the coupling may be worn or oily.

  • Page 72: Corrosion

    Different friction blocks for different power supply frequencies If fitting new friction blocks, check that the blocks are correct for the power supply frequency. The dimension A is different for 50 and 60 Hz separators. 50 Hz: A = 20 mm 60 Hz: A = 5,5 mm Dimension A is different for 50 and 60 Hz installations...

  • Page 73: Flexible Plate In Coupling

    5.4.13 Flexible plate in coupling The axial play (1) of the flexible plate should be approximately 2 mm. Location of the axial play (1) in the flexible coupling Check the play as follows: Measure the distance from the frame ring to the coupling disc of the separator.

  • Page 74: Guide Surfaces

    Bowl body 9. Finish the treatment by lubricating the contact surfaces (A) with Alfa Laval lubricating paste or Molykote 1000 Paste. Use a well-cleaned brush. Rub it into the surface, do not leave any excess paste.

  • Page 75: Level Ring

    5.4.16 Level ring Described in section ‘‘5.3.10 Level ring” on page 5.4.17 Lock ring; priming The arrows indicate positions of threads, guide and contact surfaces to be primed. Recommended agents for priming procedure: • Degreasing agent • Lubricating spray Molykote 321 R •...
  • Page 76 3. Use a fibre brush to polish the slide lacquer into the surface. The black spray will look like well-polished leather when properly finished. 4. Spray the lock ring a second time and let it dry for about 15 minutes. 5.

  • Page 77: Lock Ring; Wear And Damage

    5.4.18 Lock ring; wear and damage Described in section ‘‘5.3.11 Lock ring; wear and damage” on page 62. 5.4.19 Oil paring disc; height position The height position of the oil paring disc (1) should be checked if the bowl spindle has been removed or the bowl has been replaced.

  • Page 78: Sliding Bowl Bottom

    5.4.21 Operating paring disc; height position If the bowl spindle has been removed or the bowl has been replaced, the height position of the operating device relative to the bowl spindle top must be checked. • The operating paring disc device should be assembled and fitted.

  • Page 79: Springs For Operating Mechanism

    5.4.24 Springs for operating mechanism Described in ‘‘5.3.15 Springs for operating mechanism” on page 65. 5.4.25 Worm; wear of groove Renew the worm if the wear in the groove (1) which receives the conveyor exceeds 3-4 mm. If renewing the worm, it is recommended to renew also the worm wheel, see ‘‘5.7.1 Worm wheel and worm;...

  • Page 80: Cover Interlocking Switch (Option)

    Permissible radial wobble is maximum 0,10 mm. If the wobble is greater, the worm wheel shaft must be removed from the frame for closer examination. Get in touch with your Alfa Laval representative as the worm wheel shaft may need to be renewed.

  • Page 81: Lifting Instructions

    Lifting instructions Attach three endless slings or cables to the lifting eyes (the screws must be tightened with spanner). The circumferense of each sling must be min. 2 metres. NOTE Machine weight without frame hood and bowl is approx. 850 kg. Do not lift the separator unless the frame hood and bowl have been removed.
  • Page 82 When lifting the bowl, use the special lifting tool fastened on the bowl hood. NOTE Check that the lock ring is properly tightened. The height of the lock ring above the bowl body must not exceed 12 mm, see illustration. Weight to lift is approx.

  • Page 83: Cleaning

    Cleaning 5.6.1 External cleaning The external cleaning of the frame and motor should be restricted to brushing, sponging or wiping while the motor is running or is still hot. Never wash down a separator with a direct water stream. Totally enclosed motors can be damaged by direct hosing to the same extent as open motors and even more than those, because: •...
  • Page 84 The most important property of a cleaning liquid for the removal of fuel oil sludge is the Alfa Laval cleaning liquid for lube and fuel oil ability to dissolve these asphaltenes. separators Alfa Laval cleaning liquid for fuel oil separators has been developed for this purpose.
  • Page 85 For parts of the driving devices Use white spirit, cleaning-grade kerosene or diesel oil. Oiling (protect surfaces against corrosion) Protect cleaned carbon steel parts against corrosion by oiling. Separator parts that are not assembled after cleaning must be wiped and coated with a thin layer of clean oil and protected from dust and dirt.
  • Page 86 5.6.4 CIP-system Alfa Laval has developed a CIP (Cleaning-In- Place) system specifically designed for cleaning the bowl and without the need of dismantling. CIP unit connected to separator...

  • Page 87: When Changing Oil

    When changing oil 5.7.1 Worm wheel and worm; wear of teeth Check at each oil change. Check the teeth of both the worm wheel and worm for wear. See the ‘‘ Tooth appearance examples” on page 89. Examine the contact surfaces and compare the tooth profiles.
  • Page 88 NOTE Presence of metal chips in the oil bath is an indication that the gear is wearing abnormally. Important! When using mineral-type oil in the worm gear housing, the presence of black deposits on the spindle parts is an indication that the oil base has deteriorated seriously or that some of the oil additives have precipitated.
  • Page 89 Tooth appearance examples Satisfactory teeth: Uniform wear of contact surfaces. Surfaces are smooth. Good contact surfaces will form on the teeth when the gear is subjected to only moderate load during its running-in period. Satisfactory teeth Worn teeth: Permissible wear is as a rule 1/3 of the thickness of the upper part of a tooth, provided that •...
  • Page 90 5.7.2 Oil change procedure NOTE Before adding or renewing lubricating oil in the worm gear housing, the information concerning different oil groups, handling of oils, oil change intervals etc. given in chapter ‘‘8.4 Lubricants” on page 190 must be well known.

  • Page 91: Vibration

    Vibration 5.8.1 Vibration analysis Excessive vibration or noise indicates that something is incorrect. Stop the separator and identify the cause. Use vibration analysis instrument to periodically check and record the level of vibration. See the illustration where to take measurements. NOTE The level of vibration should not exceed 11,2 mm/s at full speed.
  • Page 92 5.8.2 Vibration switch (option) Adjustment of setpoint The vibration switch is adjusted with the separator in operation. The cover must be removed to gain access to the setpoint adjusting screw (1). 1. Back-off the setpoint adjusting screw counter- clockwise (A) two or three turns. Press the reset button.

  • Page 93: Common Maintenance Directions

    The bearings used for the bowl spindle are specified to withstand the speed, vibration, temperature and load characteristics of high- speed separators. Only Alfa Laval genuine spare parts should be used. Outer race A bearing appears equivalent to the genuine may...
  • Page 94 Cleaning and inspection Check shaft (spindle) end and/or bearing seat in the housing for damage indicating that the bearing has rotated on the shaft (spindle) and/or in the housing respectively. Replace the damaged part(s), if the faults cannot be remedied by polishing.
  • Page 95 WARNING Burn hazards Use protective gloves when handling the heated bearings. • There are several basic rules for assembling cylindrical bore bearings: - Never directly strike a bearing’s rings, cage or rolling elements while assembling. A ring may crack or metal fragments break off. - Never apply pressure to one ring in order to assemble the other.
  • Page 96 5.9.2 Before shutdowns Before the separator is shut-down for a period of time, the following must be carried out: • Remove the bowl, according to instructions in chapter ‘‘6 Dismantling/Assembly” on page NOTE The bowl must not be left on the spindle during standstill for more than one week.

  • Page 97: Dismantling/Assembly

    6 Dismantling/Assembly Contents 6.1 Introduction 6.7 Horizontal driving device (MS) 6.1.1 General directions 6.7.1 Exploded view 6.1.2 References to check points 6.7.2 Dismantling 6.1.3 Tools 6.7.3 Assembly 6.2 Inlet/outlet, frame hood (IS) 6.2.1 Exploded view 6.2.2 Dismantling 6.2.3 Assembly 6.3 Bowl hood and disc stack (IS) 6.3.1 Exploded view 6.3.2...

  • Page 99: Introduction

    Introduction 6.1.1 General directions The separator must be dismantled regularly for cleaning and inspection. The recommended intervals are stated in chapter ‘‘5.1.2 Maintenance intervals” on page 39. DANGER Entrapment hazard Make sure that rotating parts have come to a complete standstill before starting any dismantling work.

  • Page 100: References To Check Points Dismantling

    6.1.2 References to check points In the text you will find references to the Check Point instructions in chapter 5. The references appear in the text as in the following example: Check point ‘‘5.4.10 Disc stack pressure” on page 72. In this example, look up check point Disc stack pressure in chapter 5 for further instructions.

  • Page 101: Inlet/Outlet, Frame Hood (Is)

    Inlet/outlet, frame hood (IS) 6.2.1 Exploded view Plug O-ring Support Square-sectioned ring Inlet pipe Support Connecting housing O-ring Frame hood...

  • Page 102: Dismantling

    6.2.2 Dismantling DANGER Entrapment hazards 1. Make sure that rotating parts have come to a complete standstill before starting any dismantling work. The revolution counter and the motor fan indicates if separator parts are rotating or not. 2. To avoid accidental start, switch off and lock power supply before starting any dismantling work.
  • Page 103 3. Unscrew the inlet pipe using the special pin spanner. Left-hand thread! 4. Remove the inlet pipe. 5. Swing aside the oil outlet pipe. Loosen the coupling nut of the connection housing.

  • Page 104: Assembly

    6. Remove the connection housing. 7. Remove the six screws holding the frame hood at lift it off. 6.2.3 Assembly 1. Put the frame hood in place and tighten it with the six screws. 2. Fit the connection housing. Note its angular position on the upper paring disc.
  • Page 105 7. Fit the feed pipe and plug and tighten the clamp screw properly. 8. Tighten the coupling nuts of inlet and outlet piping at the pipe support. DANGER Disintegration hazards When power cables have been connected, always check direction of rotation. If incorrect, vital rotating parts could unscrew causing disintegration of the machine.

  • Page 106: Bowl Hood And Disc Stack (Is)

    Bowl hood and disc stack (IS) 6.3.1 Exploded view Paring chamber cover (small lock ring) 10. Bowl hood O-ring 11. O-ring O-ring 12. Seal ring Upper paring disc 13. Top disc O-ring 14. Oil paring disc Gasket 15. Level ring Flow control disc 16.

  • Page 107: Dismantling

    3. Apply the brake and unscrew the lock ring as described below. NOTE Use an Alfa Laval compressing tool (optional) to reduce shocks to bearings and keep thread wear minimized when unscrewing the large lock ring. Unscrewing lock ring without using a compressing tool a.
  • Page 108 Unscrewing lock ring by using a compressing tool a. Fit the lifting tool on the bowl hood. b. Fit the compressing tool by screwing the pillar of the tool into the threads of the distributor using the horizontal handle. The control lever on the compressing tool should be in position 0.
  • Page 109 e. Release the pressure in the compressing tool and remove it from the lifting tool. 4. Remove the lock ring. NOTE The lock ring must be kept lying horizontally or it may become distorted. Even the slightest distortion could make it impossible to refit.
  • Page 110 b. Screw the spindle plate into the lifting tool. Unscrew the spindle a few turns if the plate is not in contact with the lifting tool. c. Screw home the spindle until the bowl hood loosens from the bowl body. d.
  • Page 111 Separating bowl hood by using a compressing tool a. Remove the lifting tool from the bowl hood. b. Fit the compressing tool by screwing the pole of the tool into the threads of the distributor using the horizontal handle. The control lever on the compressing tool should be in position 0.
  • Page 112 7. Remove the top disc. 8. Screw the inlet pipe into the paring disc located above the level ring inside the top disc. Left-hand thread! Place the top disc onto wooden blocks to act as protection for the top disc edge and for falling level ring.
  • Page 113 9. Fit the lifting tool into the distributor and lift the distributor with disc stack out of the bowl body using a hoist. 10. Remove deposits and clean all parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning” on page 83.

  • Page 114: Assembly

    6.3.3 Assembly Check point ‘‘5.3.3 Corrosion” on page 51, ‘‘5.3.4 Cracks” on page 54, ‘‘5.3.7 Erosion” on page 57, ‘‘5.3.11 Lock ring; wear and damage” on page 1. Assemble the discs one by one on the distributor. The distributor has one guide rib for the correct positioning of the discs.
  • Page 115 Check point ‘‘5.3.10 Level ring” on page 61. 3. Fit the oil paring disc and level ring with the O-ring into the top disc. Make sure that the paring disc is positioned in the right direction. 4. Fit the top disc onto the distributor. The drilled assembly mark on the top disc must face the guide lug on the bowl body.
  • Page 116 ‘‘5.4.17 Lock ring; priming” on page 75 (only when Major Service). 9. Tighten the lock ring. NOTE Use an Alfa Laval compressing tool (optional) to reduce shocks to bearings and keep thread wear minimized when unscrewing the large lock ring.
  • Page 117 b. Tighten until the assembly marks are at least in line. Check point ‘‘5.3.5 Disc stack pressure” on page 55. NOTE The assembly marks must never pass each other more than 25 ° which corresponds to A=100 mm. (MAX 25 ) Tightening of lock ring using a compressing tool a.
  • Page 118 d. Tighten the lock ring using the spanner for lock ring. Left-hand thread! e. Tighten until the assembly marks areat least in line. Check point ‘‘5.3.5 Disc stack pressure” on page 55. NOTE The assembly marks must never pass each other more than 25°...
  • Page 119 11. Fit and tighten the paring chamber cover by using the spanner. Left-hand thread!

  • Page 120: Bowl Body And Operating Mechanism (Is)

    Bowl body and operating mechanism (IS) 6.4.1 Exploded view 1. Cap nut 2. Distributing cone 3. O-ring 4. Sliding bowl bottom 5. Rectangular ring 6. Cylindrical pin 7. Bowl body 8. Guide lug 9. O-ring 10. Cylindrical pin 11. O-ring 12.

  • Page 121: Dismantling

    6.4.2 Dismantling 1. Unscrew and remove the cap nut. Left-hand thread! 2. Fit the lifting tool into the distributing cone and lift it out. 3. Fit the lifting tool onto the sliding bowl bottom and lift it out by a hoist.
  • Page 122 4. Unscrew the three screws in the bottom of the bowl body. 5. Fit the lifting tool into the bowl body bottom with the three screws. Release the bowl body from the spindle by using the lifting tool as a puller. Turn the handle at top of the lifting tool until the bowl body comes loose from the spindle taper.
  • Page 123 7. Thread a strap through two sludge ports and turn the bowl body upside down using a hoist. WARNING Crush hazards Support the bowl body when turning to prevent it from rolling. 8. Loosen the screws for the spring support successively a little at a time.
  • Page 124 10. Unscrew the screws for the dosing ring. 11. Dismantle the dosing ring from the bowl body with the special puller. Proceed in the following way: a. Screw the nuts against the heads of the screws. b. Place the puller on the operating slide and screw the screws into the dosing ring.
  • Page 125 12. Fit two lifting eyes (M10) or two screws from the puller into the dosing ring and lift it off from the bowl body. 13. Fit two lifting eyes (M10) or two screws from the puller into the operating slide and lift it off from the bowl body.

  • Page 126: Assembly

    14. Place the operating slide with the valve plugs facing upwards. 15. Remove any thick deposits in the bowl hood and clean all other parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning” on page 83. 6.4.3 Assembly Check point ‘‘5.3.3 Corrosion”...
  • Page 127 3. Fit the dosing ring. Check that the guide pin in the bowl body enters the hole in the dosing ring. 4. Apply only a thin film of lubricating paste on the screws for the dosing ring. NOTE If there is too much lubrication paste applied, the surplus will collect between the operating slide and bowl body with risk of malfunction.
  • Page 128 5. Lubricate the guide surfaces of the spring support. See chapter ‘‘8.4 Lubricants” on page 190. Fit springs and support. 6. Tighten the three screws for the spring support successively by hand a little at a time. Finally tighten the screws to a torque of 25 Nm.
  • Page 129 9. Fit the lifting tool into the bowl body bottom with the three screws. Turn the handle at the top of the lifting tool so that the central screw is home. 10. Lower the bowl body using a hoist until the central screw rests on the spindle top.
  • Page 130 15. Fit the distributing cone onto the sliding bowl bottom. Check that the guide pins on the underside of the distributing cone enter the recess in the sliding bowl bottom. 16. Tighten the cap nut firmly. Left-hand thread!

  • Page 131: Operating Water Device (Is)

    Operating water device (IS) 6.5.1 Exploded view O-ring Distributing ring Operating paring disc O-ring Cover Gasket Distributing cover Height adjusting ring...

  • Page 133: Dismantling

    6.5.2 Dismantling 1. Slacken the screws of the paring disc with a hexagon wrench and unscrew with a suitable screw driver. 2. Lift out the paring disc device.
  • Page 134 3. Loosen and pull out the operating water inlet pipes. 4. Loosen the screws and lift out the distributing cover.
  • Page 135 5. To dismantle the paring disc device turn it upside down and remove the screws. 6. Remove deposits and clean all parts thoroughly in a suitable cleaning agent. Pay special attention to the channels. See chapter ‘‘5.6 Cleaning” on page 83. 7.

  • Page 136: Assembly

    6.5.3 Assembly 1. Put the distributing cover in place. Do not tighten the screws (this will make it easier to fit the operating water inlet tubes). 2. Fit the operating water inlet pipes into the distributing cover and connect the water hoses.
  • Page 137 3. Fasten the distributing cover. 4. Assemble the paring disc device. Do not forget the gasket on its underside.
  • Page 138 5. Align the three holes (1) in the paring disc with the three holes (2) in the distributing cover. 6. Fit the paring disc device in its place.
  • Page 139 7. Tighten the screws of the paring disc. Check point ‘‘5.4.21 Operating paring disc; height position” on page 78. Only at Major Service (MS).

  • Page 140: Vertical Driving Device (Ms)

    Vertical driving device (MS) 6.6.1 Exploded view...
  • Page 141 Protecting plate O-ring Protecting collar Guard O-ring Ball bearing housing Spring casing Gasket Oil fan Ball bearing Screw Screw Screw Spring washer Buffer Spring Buffer plug Bowl spindle Stop sleeve Ball bearing Worm Ball bearing Conveyor Ball bearing Spacing washer Ball bearing Washer Ball...

  • Page 143: Dismantling

    6.6.2 Dismantling 1. Unscrew the six screws and remove the hood and O-ring. NOTE Clean the space in the bowl casing thoroughly before starting to dismantle the bowl spindle to prevent contaminations falling down into the oil gear housing. 2. Unscrew the three screws and remove the protecting plate, O-ring and protecting collar.
  • Page 144 4. Loosen (but do not remove) the six screw plugs for the buffers with a spanner and a hammer. 5. Unscrew the six screw plugs and remove the springs. Move the spindle top a few turns in a circle while pressing outwards. This will disengage buffers from the ball bearing housing.
  • Page 145 8. Prize out the ball bearing housing from the spring casing with a screw driver. 9. Remove the spring casing and gasket. 10. Drain the oil from the worm gear housing. CAUTION Burn hazards Lubricating oil and various machine surfaces can be hot and cause burns.
  • Page 146 13. Push the worm wheel to one side before removing the spindle. If worm wheel is stuck use a piece of wood to loosen it. 14. Fit the lifting tool onto the spindle and lift out using the a hoist. 15.
  • Page 147 19. Drive off the top ball bearing from the sleeve spindle with the driving-off sleeve. Use a wooden plank or similar as a soft base for the spindle top. 20. Lift out the axial bottom ball bearing and the washer beneath using the lifting pin. 21.

  • Page 148: Assembly

    6.6.3 Assembly 1. Fit the bottom sleeve with mounted parts (rings and sleeve) into the bottom bearing housing. Use the lifting pin. Check that one ball is fitted both on top and bottom of the bottom sleeve. 2. Fit the washer and the ball bearing onto the bottom sleeve.
  • Page 149 Check point ‘‘5.4.25 Worm; wear of groove” on page 79. ‘‘5.7.1 Worm wheel and worm; wear of teeth” on page 87. 4. Heat the two ball bearings and fit them on the worm. 5. Fit the stop sleeve (1) and the worm (2) on the spindle.
  • Page 150 9. Carefully lower the spindle into the frame and guide the spindle into the correct position in the bottom bearing housing so the ball bearings enter their seats. If the ball bearings do not completely enter their seats, tap the spindle top gently with a soft hammer.
  • Page 151 13. Tighten the six screw plugs. 14. Fit the guard with O-ring and tighten the six screws. 15. Fit the protecting collar with O-ring and protecting plate. NOTE Check that the protecting collar is in the bottom position before tightening the protecting plate.
  • Page 152 16. Fit the hood with O-ring and tighten the six screws. Check point ‘‘5.4.3 Bowl spindle; height position” on page 17. Match the worm wheel with the teeth in the worm of the bowl spindle. Knock the taper pin into the worm wheel stop ring. Check points ‘‘5.4.27 Worm wheel shaft;...
  • Page 153 Check point ‘‘5.4.5 Brake” on page 68. 20. Fit the brake cover and revolution counter cap and their gaskets.

  • Page 154: Horizontal Driving Device (Ms)

    Horizontal driving device (MS) 6.7.1 Exploded view...
  • Page 155 1. Ball bearing 2. Screw 3. Spring washer 4. Round nut 5. Lock washer 6. Bearing shield 7. Spring washer 8. Nut 9. Oil shield 10. Taper pin 11. Stop ring 12. Worm wheel 13. Ball bearing 14. Sealing ring 15.
  • Page 156 6.7.2 Dismantling DANGER Entrapment hazards 1. Make sure that rotating parts have come to a complete standstill before starting any dismantling work. The revolution counter and the motor fan indicates if separator parts are rotating or not. 2. To avoid accidental start, switch off and lock power supply before starting any dismantling work.
  • Page 157 3. Knock out the taper pin from the worm wheel stop ring. 4. Remove the protecting cover with gasket. 5. Unscrew the two nuts holding the oil shield. The shield can not be removed from the housing before the bearing shield is moved. 6.
  • Page 158 7. Unscrew and remove the round nut and lock washer. 8. Remove the ball bearing. 9. Remove the stop ring and worm wheel with ball bearing. 10. Pull off the ball bearing from the worm wheel. Use a washer as a support for the puller.
  • Page 159 11. Disconnect the motor cables. Note the positions of cables in the terminal box to re- connect correctly (for correct direction of rotation). 12. Remove the electric motor using a hoist. 13. Remove the flexible plate and unscrew the six screws for the coupling disc and remove 14.
  • Page 160 15. To dismantle the nave, unscrew the round nut with the pin spanner and remove the lock washer. 16. Pull off the nave with the puller and remove the friction blocks. 17. Remove the sealing washer using two screws with 1/4”-20 UNC threads. 18.
  • Page 161 6.7.3 Assembly 1. Lubricate the O-ring on the sealing washer periphery and the sealing ring with silicone grease. Fit the sealing washer in frame and check that the sealing ring is fitted in the correct direction, as illustrated. Check point ‘‘5.4.7 Coupling friction pads”...
  • Page 162 Check point ‘‘5.7.1 Worm wheel and worm; wear of teeth” on page 87. ‘‘5.7.1 Worm wheel and worm; wear of teeth” on page 87. 6. Heat the ball bearing and fit it on the worm wheel. When mounting the ball bearings on the worm wheel and shaft, the bearings must be heated in oil to max.
  • Page 163 8. Fit the ball bearing. 9. Knock the ball bearing into its seat with the driving-on sleeve tool. 10. Tighten the round nut with the pin spanner and secure it with the lock washer.
  • Page 164 11. Fit the bearing shield together with the oil shield. Tighten the four screws for the bearing shield. 12. Tighten the two nuts holding the oil shield in the bearing shield. 13. Fit the coupling disc with gasket and tighten the six screws.
  • Page 165 15. Fit the electric motor. DANGER Disintegration hazards When power cables have been connected and the separator is completely assembled see‘‘4.1.1 Ready for start” on page 32, always check direction of rotation. If incorrect, vital rotating parts could unscrew causing disintegration of the machine. The remaining description in this section implies that the bowl spindle is mounted in the frame.
  • Page 166 18. Pour oil into worm gear housing. The oil level should be exactly in the middle of the sight glass. For correct oil volume and recommended oil brands see chapter ‘‘8.4 Lubricants” on page 190. Check point ‘‘5.4.5 Brake” on page 68. 19.

  • Page 167: Trouble-Tracing

    7 Trouble-tracing Contents 7.1 FOPX mechanical functions 7.1.1 Separator vibrates 7.1.2 Smell 7.1.3 Noise 7.1.4 Speed too low 7.1.5 Starting power too high 7.1.6 Starting power too low 7.1.7 Starting time too long 7.1.8 Retardation time too long 7.1.9 Water in worm gear housing 7.2 FOPX separating functions 7.2.1 Liquid flows through the bowl casing...

  • Page 168: Fopx Mechanical Functions

    FOPX mechanical functions 7.1.1 Separator vibrates NOTE Some vibration is normal during the starting and stopping sequences when the separator passes through its critical speeds. DANGER Disintegration hazards When excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown.

  • Page 169: Smell

    7.1.2 Smell Cause Corrective actions Page Normal occurrence during start while the None – friction blocks are slipping Brake is applied Release the brake – Oil level in gear housing is too low Check oil level and add oil if necessary 7.1.3 Noise Cause...

  • Page 170: Starting Power Too High

    7.1.5 Starting power too high Cause Corrective actions Page Incorrect friction blocks (50 Hz blocks for 60 Hz power supply) DANGER Stop immediately and change the friction blocks to suit the power supply frequency Wrong direction of rotation Change electrical phase connections to the –...

  • Page 171: Water In Worm Gear Housing

    7.1.9 Water in worm gear housing Cause Corrective actions Page Bowl casing drain is obstructed. Clean the casing and the drains properly. The drains have connection Nos. 462 and 463 on the Basic size drawing . Solve the reason for obstruction. Clean worm gear housing and change oil.

  • Page 172: Fopx Separating Functions

    FOPX separating functions 7.2.1 Liquid flows through the bowl casing drain and/or sludge outlet Cause Corrective actions Page Sludge discharge or water draining in None (normal) – progress Strainer in operating water line is clogged Clean the strainer and check water –...

  • Page 173: Bowl Opens Accidentally During Operation

    7.2.2 Bowl opens accidentally during operation Cause Corrective actions Page Strainer in the operating water supply is Clean the strainer – clogged No water in the operating water system Check the operating water system and – make sure the valve(s) are open Water connections to the separator are Rectify –...

  • Page 174: Unsatisfactory Sludge Discharge

    7.2.4 Unsatisfactory sludge discharge Cause Corrective actions Page Dosing ring is too firmly tightened Check the tightening torque Valve plugs in the operating slide too are Renew with correct valve plugs high Sludge deposits in the operating system Check and clean the operating system 120, 131 7.2.5 Unsatisfactory separation...

  • Page 175: Vibration Switch (Option)

    Cause Corrective actions Page Dirt or iron particles on magnets Clean magnets – Leaf spring is broken Return to Alfa Laval for repair – Reset coil is open Check for continuity and proper coil – resistance 7.3.2 Impossible to adjust...

  • Page 177: Technical Reference

    8 Technical Reference Contents 8.1 Technical data 8.2 Basic size drawing 8.2.1 Dimensions of connections 8.2.2 Connection list 8.2.3 Interface description 8.2.4 General 8.2.5 Definitions 8.2.6 Component description and signal processing 8.2.7 Function graph and running limitations 8.3 Water quality 8.4 Lubricants 8.4.1 Lubrication chart, general...

  • Page 179: Technical Data

    Technical data Alfa Laval ref. 555051 NOTE The separator is a component operating in an integrated system including a monitoring system. If the technical data in the system description do not agree with the technical data in this instruction manual, the data in the system description shall apply.
  • Page 180 Motor power rating 12/14 kW, 50/60 Hz Power consumption, max. kW (at starting up) Power consumption, normal 4,5/9 kW (idling/at max. capacity) Discharge volume, nominal litres fixed discharge volume Discharge interval, min./max. 1/240 minutes Bowl volume litres Sediment space litres Starting time minutes Stopping time with brake, min./max.

  • Page 181: Basic Size Drawing

    Basic size drawing Alfa Laval ref. 554900 rev. 2 Maximum vertical displacement Maximum horizontal displacement at the sludge connection during at the in/outlet connections during operation ± 10 mm. operation ± 15 mm.

  • Page 182: Dimensions Of Connections

    8.2.1 Dimensions of connections Alfa Laval ref. 554900 rev. 2 Data for connections, see chapter All connections to be installed non-loaded ‘‘8.2.2 Connection list” on page 183. and flexible.

  • Page 183: Connection List

    8.2.2 Connection list Alfa Laval ref. 554904 rev. 3 Connection No. Description Requirements/limits Inlet for product − Allowed temperature Min. 0 °C, max. 100 °C Inlet to liquid seal or displacement liquid, water. Fresh water − Instantaneous flow 2,8 litre/minute −...
  • Page 184 Connection No. Description Requirements/limits Outlet for operating liquid (discharge and make-up liquid) (463) Drain of frame top part, upper. Drain of frame top part, lower Motor for separator. − Max. deviation from nominal frequency. ± 5% (momentarily 10% during a period of maximum 5 seconds).

  • Page 185: Interface Description

    8.2.3 Interface description Alfa Laval ref. 557138 rev. 3 8.2.4 General In addition to the Connection List this document describes limitations and conditions for safe control, monitoring and reliable operation. At the end of the document a function graph and running limitations are found.

  • Page 186: Component Description And Signal Processing

    Safety stop means: The machine must be stopped in the quickest and safest way due to vibrations or process reasons. Comply to following conditions: • The bowl must be kept filled. • Sludge ejection must not be made. • The machine must not be restarted before the reason for the safety stop has been investigated and action has been taken.
  • Page 187 Signal Processing The circuit is closed when the frame hood of the separator is closed. The interlocking switch should be connected so that starting of the motor is prevented when the separator hood is not closed. Discharge signal processing The control system shall contain a memory function for registration of the number of initiated discharges.

  • Page 188: Function Graph And Running Limitations

    8.2.7 Function graph and running limitations Stand still Starting mode Running mode Stop mode Safety stop mode...

  • Page 189: Water Quality

    For test methods, contact any Alfa Laval representative. If these demands cannot be met, the water should be pretreated according to Alfa Laval's recommendations. Alfa Laval accepts no liability for consequences arising from unsatisfactorily purified water supplied by the customer.

  • Page 190: Lubricants

    Lubricants 8.4.1 Lubrication chart, general Alfa Laval ref. 553216-01 rev. 5 Lubricating points Lubricants Bowl spindle ball bearings and buffers are Lubricating oil as specified in ‘‘8.4.2 lubricated by oil mist Recommended lubricating oils” on page 192 Bowl spindle taper...
  • Page 191 Great attention must be paid not to contaminate the lubricating oil. Of particular importance is to avoid mixing of different types of oil. Even a few drops of motor oil mixed into a synthetic oil may result in severe foaming. Any presence of black deposits in a mineral type oil is an indication that the oil base has deteriorated seriously or that some of the oil...

  • Page 192: Recommended Lubricating Oils

    Alfa Laval ref. 553219-15 rev. 0 Two different groups of lubricating oils are approved for this separator. They are designated as Alfa Laval lubricating oil groups A and D. The numerical value after the letter states the viscosity grade.

  • Page 193: Recommended Oil Brands

    8.4.3 Recommended oil brands Alfa Laval lubricating oil group A/320 Alfa Laval ref. 553218-11 Viscosity grade VG (ISO 3448/3104) Viscosity index VI (ISO 2909) >95 Manufacturer Designation Alfa Laval 546099-80 20 litres 546099-81 4 litres 546099-82 208 litres 546099-83 1 litre...
  • Page 194 Alfa Laval lubricating oil group D/220 Alfa Laval ref. 553218-08 rev. 0 Viscosity grade VG (ISO 3448/3104) Viscosity index VI (ISO 2909) > 130 Manufacturer Designation Alfa Laval 542690-80 20 litres 542690-81 4 litres 542690-82 208 litres 542690-83 1 litres...
  • Page 195 Alfa Laval lubricating oil group D/320 Alfa Laval ref. 553218-06 Viscosity grade VG (ISO 3448/3104) Viscosity index VI (ISO 2909) >130 Manufacturer Designation Alfa Laval 542690 Separation AB - blue Castrol Alpha Syn T 320 Lubmarine/Beijer Epona SA 320 (ELF Brand designation according to ELF) Optimol Ölwerke...

  • Page 196: Recommended Lubricants

    8.4.4 Recommended lubricants Pastes and bonded coatings for non-food applications Alfa Laval ref. 553217-01 rev. 2 Manufacturer Designation Alfa Laval No. Application Gleitmolybdän Gleitmo 805 K or 805 K varnish 901 Gleitmo Paste G rapid 537086-04 All pressure Dow Corning...
  • Page 197 Greases for ball and roller bearings Alfa Laval ref. 553217-01 rev.2 Manufacturer Designation Alfa Laval No. Energrease MMEP2 Energrease LS2 Castrol Spheerol SW2 EP Spheerol EPL2 Chevron Duralith grease EP2 Exxon Beacon EP2 Mobil Mobilith SHC 460 Mobilux EP2 Gulf...

  • Page 199: Drawings

    Drawings 8.5.1 Foundations Alfa Laval ref. 554895 Min. lifting capacity 1000 kg Recommended free floor space for unloading Max. height of largest when doing service component incl. lifting tool Min. access area for overhead hoist Center of separator bowl (no fixed piping within this area) 4 holes Ø...

  • Page 200: Electric Motor

    8.5.2 Electric motor Alfa Laval ref. 552813 rev. 2 4xPg29, max. cable diameter 29 mm Manufacturer ABB Motors Manuf. drawing 3GZV 1000 007-4 Standards IEC 34-series, 72,79 and 85 Size 160M Type M2AA 160M-4 Weight 62 kg Poles Insulation class Bearings DE 6209-2Z/C3 –...
  • Page 201 Article No Output Speed Freq Voltage Current Pow.fac Therm Note cos ϕ °C 552813-01 11,5 1445 200 D 44,5 0,85 552813-02 11,5 1445 220 D 40,5 0,85 552813-03 11,5 1445 380 D 23,5 0,85 552813-04 11,5 1445 415 D 21,5 0,85 552813-05 11,5...
  • Page 202 Alfa Laval ref. 552943 Manufacturer WEG, Brazil Poles Manuf. drawing 003.10/03 1990 Insulation class Standards IEC 34-1, IEC 72 Bearings DE 6308-Z – NDE 6207-Z Size IEC 132 M Method of cooling IC 41 (IEC 34-6) Type WEG132 M Spec.

  • Page 203: Machine Plates And Safety Labels

    8.5.3 Machine plates and safety labels Alfa Laval ref. 554651 1. Machine plate Separator FOPX 609TFD-24 Manufacturing serial No / Year XXXX Product No 881244-02-03 Machine top part 561012-01 Bowl 554048-05 Machine bottom part 540225-09/10 (50/60 Hz) Max. speed (bowl) 5175 r.p.m.(50 Hz), 5148 r.p.m.
  • Page 204 3. Safety label Text on label: DANGER Read the instruction manuals before installation, operation and maintenance. Consider inspection intervals. Failure to strictly follow instructions can lead to fatal injury. If excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown. Out of balance vibration will become worse if bowl is not full.

  • Page 205: Vibration Sensor (Option)

    8.5.4 Vibration sensor (option) Alfa Laval ref. 536498-80 Type: Mechanical velocity Switch rating, voltage: Max. 460 V AC Reset coil: 24 V DC, 48 V DC, 117 V AC 60 Hz Interconnection diagram For other technical information see chapter ‘‘8.2.2 1-2 Reset coil Connection list”...

  • Page 206: Storage And Installation

    Storage and installation 8.6.1 Introduction Most of the instructions are specifications, which are compulsory requirements. These specifications are sometimes completed with non-compulsory recommendations, which could improve the installation quality. Additional installation information, such as drawings and component installation instructions, can be found previous in this chapter. 8.6.2 Storage and transport of goods...
  • Page 207 A separator can be delivered with different types of protection: • Fixed on a pallet. The separator must be stored in a storage room well protected from mechanical damage and theft and also dry and protected from rain and humidity. Fixed on a pallet •...

  • Page 208: Planning Of Installation

    Transport Specification • During transport of the separator, the frame hood and bowl must always be removed from the machine. • When lifting a separator it must always be hung securely. See chapter ‘‘5.5 Lifting instructions” on page 81. WARNING Crush hazards Use correct lifting tools and follow lifting instructions.
  • Page 209 Important measurements Important measurements are the minimum lifting height for lifting tackle, shortest distance between driving motor and wall, free passage for dismantling and assembly, maintenance and operation. Plan your installation with sufficient room for the controls and operation so that instruments are easily visible.
  • Page 210 Space for oil changing Specification The plug for gearbox oil draining must not be blocked by floor plate arrangement, etc. Recommendation • It should be possible to place a portable collecting tray under the gearbox drain plug for changing oil. Place the separator in such a way that makes the oil change easy...

  • Page 211: Foundation

    8.6.4 Foundation NOTE When lifting a separator it must always be hung securely. See chapter ‘‘5.5 Lifting instructions” on page 81.. Specification • The separator should be installed at floor level, see chapter ‘‘8.5.1 Foundations” on page 199. • When a separator is installed on a ship, the separator should be installed in such a way that the centre line of the electric motor is parallel with the centre line of the ship.
  • Page 213 You can do this by copying this page and sending it by fax, or you could mail it, or hand it over to your local Alfa Laval representative. Alfa Laval Separation AB, Separator Manuals, dept. SKL, S-147 80 Tumba, Sweden. Fax: +46 8 53065029.
  • Page 215 If you wish to order extra copies of this manual, please copy this page and give it to your local Alfa Laval representative, who will advise you of current prices. Your local Alfa Laval representative will also be able to help you with information regarding any other manuals.

  • Page 217: Index

    Index Disc stack pressure Dosing ring Assembly Erosion Bowl body and operating mechanism External cleaning Bowl hood and disc stack Flexible plate in coupling General directions Guide surfaces Horizontal driving device Inlet pipe and oil paring disc Inlet/outlet, frame hood Level ring Operating water device Lifting instructions...
  • Page 218 Daily checks Horizontal driving device Density of feed Assembly Disc Dismantling Disc stack pressure Dismantling Bowl body and operating mechanism Installation Bowl hood and disc stack Interface General directions Definition Horizontal driving device Description Inlet/outlet, frame hood Interface description Operating water device Intermediate service Tools Vertical driving device...
  • Page 219 Metal surfaces Ready for start Cleaning and cleaning agents Running Corrosion Safety stop Cracks Sensors and indicators Erosion Separating function Motor Sludge discharge cycle Cleaning Start Coupling Storage and transportation Drawing Technical data Power consumption Service instructions. See Check points Service kits Shutdown Start...
  • Page 220 Warning signs Weight Worm gear Function and description Number of teeth Wear of teeth...

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