Alfa Laval AFPX 617XGV-14/74CG Instruction Manual
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Alfa Laval AFPX 617XGV-14/74CG Instruction Manual

Alfa Laval AFPX 617XGV-14/74CG Instruction Manual

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Summary of Contents for Alfa Laval AFPX 617XGV-14/74CG

  • Page 1 DVcgZTV>RZ_eV_R_TV>R_fR] DVaRcRe`c 27AI'"(I8G"% (%48 ?a^SdRc=^ ! '   1^^Z=^ !& %#(!ATe...
  • Page 2 Telephone: +46 8 530 650 00 Telefax: +46 8 530 310 40 Printed in Sweden, 01-04 © Alfa Laval Tumba AB 2001 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 Safety Instructions Maintenance Directions 2.1 Periodic maintenance 2.1.1 Introduction 2.1.2 Maintenance intervals 2.1.3 Maintenance procedure 2.1.4 Service kits 2.2 Maintenance Logs 2.2.1 Daily checks 2.2.2 Lubrication of electric motor 2.2.3 Oil change 2.2.4 Intermediate Service (IS) 2.2.5 Major Service (MS) 2.2.6 3-year Service (3S) 2.3 Cleaning...
  • Page 4 Dismantling/Assembly 3.1 Introduction 3.1.1 General directions 3.1.2 References to check points 3.1.3 Tools 3.1.4 Tightening of screws 3.2 Intermediate Service (IS), dismantling 3.2.1 Inlet/outlet, frame hood 3.2.2 Bowl hood and disc stack 3.2.3 Bowl body and operating mechanism 3.2.4 Operating liquid device 3.3 Intermediate Service (IS), check points 3.3.1 Introduction...
  • Page 5 3.4.5 Bowl hood and disc stack 3.4.6 Inlet/outlet, frame hood 3.5 Major Service (MS), dismantling 3.5.1 Introduction 3.5.2 Vertical driving device 3.5.3 Horizontal driving device 3.6 Major Service (MS), check points 3.6.1 Introduction 3.6.2 Lock ring; priming 3.6.3 Brake 3.7 Major Service (MS), assembly 3.7.1 Introduction 3.7.2...
  • Page 7 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 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 1 Safety Instructions DANGER Disintegration hazards • Use the separator only for the purpose and parameter range specified by Alfa Laval. • If excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown. • When power cables are connected, always check direction of motor rotation.
  • Page 11 1 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 1 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 1 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 1 Safety Instructions...

  • Page 15: Maintenance Directions

    2 Maintenance Directions Periodic maintenance 2.1.1 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 16 2.1 Periodic maintenance 2 Maintenance Directions Intermediate Service (IS) Intermediate Service consists of an overhaul of the separator bowl, inlet/outlet and operating liquid device every 3 months or 2000 operating hours. Seals in bowl and gaskets in inlet and outlet devices are renewed. Major Service (MS) Major Service consists of an overhaul of the complete separator and includes an Intermediate...

  • Page 17: Maintenance Procedure

    2 Maintenance Directions 2.1 Periodic maintenance 2.1.3 Maintenance procedure At each Intermediate and Major Service, take a copy of the maintenance log and use it for notations during the service. The Intermediate and Major Services should be carried out in the following manner: 1.

  • Page 18: 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 19: Maintenance Logs

    2 Maintenance Directions 2.2 Maintenance Logs Maintenance Logs 2.2.1 Daily checks The necessary daily checks to be carried out for a safe operation are enumerated in chapter Running in the Operator´s Manual . 2.2.2 Lubrication of electric motor The bearings of the electric motor shall be greased with intervals that is dependent of the motor speed (50 or 60 Hz), ambient temperature and if the bearing is located on the driving end or...

  • Page 20: Intermediate Service (Is)

    2.2 Maintenance Logs 2 Maintenance Directions 2.2.4 Intermediate Service (IS) Name of plant: Local identification: Separator: AFPX 617XGV-14/74CG Manufacture No./Year: Total running hours: Product No: 881218-01-01 Date: Signature: Main component and activity Part Page Notes Inlet and outlet Clean and inspect Outlet housing –...
  • Page 21 2 Maintenance Directions 2.2 Maintenance Logs Main component and activity Part Page Notes Operating liquid device Clean and check Operating liquid device – Renew O-rings – Horizontal driving device Worm wheel shaft and gear housing Check Worm wheel and worm Renew Oil in gear housing Signs and labels on separator...

  • Page 22: Major Service (Ms)

    2.2 Maintenance Logs 2 Maintenance Directions 2.2.5 Major Service (MS) Name of plant: Local identification: Separator: AFPX 617XGV-14/74CG Manufacture No./Year: Total running hours: Product No: 881218-01-01 Date: Signature: Main component and activity Part Page Notes Inlet and outlet Clean and inspect Outlet housing –...
  • Page 23 2 Maintenance Directions 2.2 Maintenance Logs Main component and activity Part Page Notes Operating liquid device Clean and check Operating liquid device – Check Height position Renew O-rings and throttling ring – Vertical driving device Clean and check Bowl spindle –...

  • Page 24: 3-Year Service (3S)

    2.2 Maintenance Logs 2 Maintenance Directions 2.2.6 3-year Service (3S) Renew the frame feet as described below. 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 the parts included in the 3-year service kit (3S).
  • Page 25 2 Maintenance Directions 2.2 Maintenance Logs 8. Tighten the set screws (9), first by hand (or by a hand tool, if necessary) until all of them are in contact with the frame feet (2). Then tighten the set screws with 100 Nm. NOTE Tighten the set screws before mounting the bowl or cyclone.

  • Page 26: Cleaning

    2.3 Cleaning 2 Maintenance Directions Cleaning 2.3.1 Cleaning agents When using chemical cleaning agents, make sure you follow the general rules and suppliers’ recommendations regarding ventilation, protection of personnel, etc. For separator bowl, inlet and outlet A chemical cleaning agent must dissolve the deposits quickly without attacking the material of the separator parts.

  • Page 27: Cleaning Of Bowl Discs

    2 Maintenance Directions 2.3 Cleaning 2.3.2 Cleaning of bowl discs When the discs are to be removed from the distributor, use the special tool included in the tool kit. Handle the bowl discs carefully to avoid damage to the surfaces during cleaning. CAUTION When removing discs, use the special tool Cut hazard...

  • Page 28: External Cleaning

    2.3 Cleaning 2 Maintenance Directions 2.3.3 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.

  • Page 29: When Changing Oil

    2 Maintenance Directions 2.4 When changing oil When changing oil 2.4.1 Worm wheel and worm; wear of teeth To check at each oil change Check the teeth of both the worm wheel and worm for wear. Examine the contact surfaces and compare the tooth profiles with the ‘‘...
  • Page 30 2.4 When changing oil 2 Maintenance Directions 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 31 2 Maintenance Directions 2.4 When changing oil 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...

  • Page 32: Oil Change Procedure

    2.4 When changing oil 2 Maintenance Directions 2.4.2 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 must be well ‘‘2.5 Lubricants”...

  • Page 33: Lubricants

    2 Maintenance Directions 2.5 Lubricants Lubricants 2.5.1 Lubrication chart, general Alfa Laval ref. 553216-01, rev. 6 Lubricating points Lubricants Bowl spindle ball bearings and buffers are Lubricating oil as specified in ‘‘2.5.2 lubricated by oil mist. Recommended lubricating oils” on page Bowl spindle taper.
  • Page 34 2.5 Lubricants 2 Maintenance Directions Always use clean vessels when handling lubricating oil. Great attention must be paid not to contaminate the lubricating oil. Of particular importance is to avoid mixing of different types of oil. Even a few drops of motor oil mixed into a synthetic oil may result in severe foaming.

  • Page 35: Recommended Lubricating Oils

    Recommended lubricating oils Alfa Laval ref. 553219-05, rev. 1 One group of lubricating oil is approved for this separator. It is designated as Alfa Laval lubricating oil group B. The numerical value after the letter states the viscosity grade. The corresponding commercial oil brands are found in chapter ‘‘2.5.3 Recommended oil...

  • Page 36: Recommended Oil Brands

    2.5 Lubricants 2 Maintenance Directions 2.5.3 Recommended oil brands Alfa Laval ref. 553218-05, rev. 2 NOTE The data in below tables is based on supplier information in regards to lubrication properties. Trade names and designations might vary from country to country, contact your local supplier for more information.

  • Page 37: Recommended Lubricants

    The data in below tables is based on supplier information in regards to lubrication properties. Trade names and designations might vary from country to country, contact your local supplier for more information. Brands with Alfa Laval article number are approved and recommended for use. Pastes for food applications: Manufacturer...
  • Page 38 2.5 Lubricants 2 Maintenance Directions Bonded coatings: Manufacturer Designation Alfa Laval No. Fuchs Lubritech Gleitmo 900 (Varnish or spray) Dow Corning Molykote D321R (Spray) 535586-01 (300 ml) Molykote D321R (Varnish) 535586-02 (60 ml) Silicone grease for rubber rings: Manufacturer Designation Alfa Laval No.
  • Page 39 2.5 Lubricants Greases for ball and roller bearings: NOTE Always follow the specific recommendation for lubrication as advised by the manufacturer. Manufacturer Designation Alfa Laval No. Energrease MM-EP2 Energrease LS2 Castrol APS 2 Grease EPL 2 Chevron Dura-Lith Grease EP2...

  • Page 40: Vibration

    2.6 Vibration 2 Maintenance Directions Vibration 2.6.1 Vibration analysis Excessive vibration or noise indicates a malfunction. 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 9,0 mm/s at full speed.

  • Page 41: 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 that appears equivalent to the genuine...
  • Page 42 2.7 Common maintenance directions 2 Maintenance Directions 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 43 2 Maintenance Directions 2.7 Common maintenance directions • When assembling ball bearings without seals, the bearings must be heated in oil to max. 125 °C. NOTE Heat the bearing in a clean container. Use only clean oil with a flash point above 250 °C.
  • Page 44 2.7 Common maintenance directions 2 Maintenance Directions Angular contact ball bearings Always fit single-row angular contact ball bearings with the wide shoulder of the inner race facing the axial load (upwards on a bowl spindle). The wide shoulder of the inner race must face the axial load Lubrication NOTE...

  • Page 45: Before Shutdowns

    2 Maintenance Directions 2.7 Common maintenance directions 2.7.2 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 ‘‘3 Dismantling/Assembly” on page NOTE The bowl must not be left on the spindle during standstill for more than one week.
  • Page 46 2.7 Common maintenance directions 2 Maintenance Directions...

  • Page 47: Introduction

    3 Dismantling/Assembly Introduction 3.1.1 General directions The separator must be dismantled regularly for cleaning and inspection. The recommended intervals are stated in chapter ‘‘2.1.2 Maintenance intervals” on page DANGER Entrapment hazard 1. Make sure that rotating parts have come to a complete standstill before starting any dismantling work.

  • Page 48: References To Check Points

    3.1 Introduction 3 Dismantling/Assembly NOTE Never interchange bowl parts To prevent mixing of parts, e.g. in an installation comprising several machines of the same type, the major bowl parts carry the machine manufacturing number or its last three digits. 3.1.2 References to check points In the beginning of each sub-chapter describing the assembly you will find references to the check...

  • Page 49: Tightening Of Screws

    3 Dismantling/Assembly 3.1 Introduction 3.1.4 Tightening of screws When tightening screws, use the torques stated in the table below unless otherwise stated. The figures apply to oiled, stainless screws tightened with a torque wrench. METRIC THREAD Torque in Nm Stainless Carbon steel steel...

  • Page 50: Intermediate Service (Is), Dismantling

    3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly Intermediate Service (IS), dismantling 3.2.1 Inlet/outlet, frame hood Coupling nut Pipes for feed/cleaned liquid outlet Rectangular ring Inlet bend Rectangular ring Nozzle (Ø20, 25, 30 mm) Rectangular ring Seal ring Inlet pipe 10. Screw 11.
  • Page 51 3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling 1. Disconnect and remove the in and outlet pipe connections (1-2) and the inlet bend (4). 2. Unscrew the inlet pipe (9). Left-hand thread! 3. Unscrew the four screws (10) and remove the discharge cover (11).

  • Page 52: Bowl Hood And Disc Stack

    3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly 3.2.2 Bowl hood and disc stack...
  • Page 53 3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling Small lock ring Bowl 545247-12, purifier Paring chamber top part Bowl 545247-10, purifier Gasket Bowl 545247-14, purifier with wing insert Paring disc Bowl 545247-11, concentrator Gasket Bowl 545247-13 / -09, concentrator (Bowl -13, pos. 15: Caulks = 0,6 mm) Gravity disc (Bowl -09, pos.
  • Page 54 3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly 1. Unscrew the small lock ring using the special spanner. Left-hand thread! 2. Remove: - paring chamber top part, - gasket, - paring disc - gasket - gravity disc. 3. Unscrew the large lock ring with the compressing tool as described below.
  • Page 55 3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling 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. Turn the control lever to position 1 for compression.
  • Page 56 3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly e. Release the pressure in the compressing tool and remove it from the lifting tool. 4. Fit two eye bolts and remove the large lock ring by a hoist. NOTE The lock ring must be kept lying horizontally or it may become distorted.
  • Page 57 3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling e. Remove the lifting tool and the compressing tool. Then refit the lifting tool. 6. Lift off the bowl hood using a hoist. Be careful not to scratch the bowl hood seal ring. CAUTION Crush hazards If the top disc is stuck into the bowl hood,...

  • Page 58: Bowl Body And Operating Mechanism

    3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly 3.2.3 Bowl body and operating mechanism Cap nut Gasket Distributing cone A. Purifier bowl B. Concentrator bowl Wear lining * O-ring * Rectangular ring Sliding bowl bottom Rectangular ring O-ring 10. Wear protection * 11.
  • Page 59 3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling 1. Unscrew and remove the cap nut. Place the heel of the special tool into one of the holes, not on a wing. Left-hand thread! 2. Remove the gasket from the cap nut contact surface on the distributing cone.
  • Page 60 3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly 6. 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 61 3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling 9. Protect the nave bore in bowl body with a rag. 10. Loosen the screws for the spring support successively a little at a time. 11. Remove the spring support (1) and the springs (2).

  • Page 62: Operating Liquid Device

    3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly 3.2.4 Operating liquid device O-ring Control paring disc Distributing ring Throttling ring Holder O-ring Screw O-ring Screw 10. Distributing cover 11. Height adjusting ring...
  • Page 63 3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling 1. Tap the control paring disc (1) carefully with a soft hammer, so that the upper O-ring is unloaded. 2. Remove the O-ring with a small screw driver or similar tool. 3. Remove the control paring disc by lifting up the distributing ring (2).
  • Page 64 3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly 6. Lift off the distributing cover. Remove the height adjusting rings. Note the number. After dismantled all parts for Intermediate Service, remove any thick deposits in the frame top part and clean all other parts Guide pin thoroughly in a suitable cleaning agent.

  • Page 65: Intermediate Service (Is), Check Points

    Inspect frequently if the process liquid is Main bowl parts to check for corrosion corrosive. 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 66 3.3 Intermediate Service (IS), check points 3 Dismantling/Assembly Stainless steel Stainless steel parts corrode when in contact with either chlorides or acidic solutions. Acidic solutions cause general corrosion. The chloride corrosion is characterised by local damage such as pitting, grooves or cracks. The risk of chloride corrosion is higher if the surface is: •...

  • Page 67: 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 68: Erosion And Wear Linings

    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 or if the chromed surface of the sliding bowl bottom shows any sign of damage.
  • Page 69 3 Dismantling/Assembly 3.3 Intermediate Service (IS), check points Look carefully for any signs of erosion damage. Erosion damage can deepen rapidly and consequently weaken parts by reducing the thickness of the metal. DANGER Disintegration hazard Erosion damage can weaken parts by reducing the thickness of the metal.
  • Page 70 3.3 Intermediate Service (IS), check points 3 Dismantling/Assembly 1. Remove the old lining and place the new lining blank in the wall pillar. 2. Fasten the mounting tool between the wall pillars as shown in the illustration. Clamp the wear lining with the tool. 3.
  • Page 71 3 Dismantling/Assembly 3.3 Intermediate Service (IS), check points 8. Remove the tool and check that the wear lining is well attached and that the shank (1) does not protrude beyond the bowl periphery. Fit the other linings as described above. Wear liner in sliding bowl bottom When removing the old wear liner (1) from the sliding bowl bottom, it can preferably be pressed...

  • Page 72: Guide Surfaces

    3.3 Intermediate Service (IS), check points 3 Dismantling/Assembly 3.3.5 Guide surfaces Check surfaces indicated (A) for burrs or galling. Rectify when necessary. Repair of galling on guide surfaces; see following pages. Clean the indicated surfaces and apply lubricating paste with a well-cleaned brush. Sliding bowl bottom Bowl body Lubricate the O-rings and the seal rings with...
  • Page 73 3 Dismantling/Assembly 3.3 Intermediate Service (IS), check points 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 74: Bowl Hood Seal Ring

    3.3 Intermediate Service (IS), check points 3 Dismantling/Assembly 3. An emery cloth of 240 grade should be used to smooth the edges and to remove any burnt-in foreign matter. 4. Finish off by polishing the damaged spot with the fibre brushes and brush wax. It is recommended that the whole area where galling may occur is polished.

  • Page 75: Bowl Spindle Taper And Bowl Body Nave Taper

    3 Dismantling/Assembly 3.3 Intermediate Service (IS), check points Fit the new ring as follows: Press the ring into the groove with a straight wooden board placed across the ring. NOTE If the new ring is too narrow, place it in hot water (70-80 °C) for about 5 minutes.

  • Page 76: 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=150 mm), an Alfa Laval representative must be contacted immediately. If the marks become illegible, an Alfa Laval...
  • Page 77 3 Dismantling/Assembly 3.3 Intermediate Service (IS), check points 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, see chapter ‘‘2.3.1 Cleaning agents” on page Check for burrs and protrusions caused by impact.

  • Page 78: Operating Mechanism

    3.3 Intermediate Service (IS), check points 3 Dismantling/Assembly 3.3.9 Operating mechanism Dirt and lime deposits in the operating mechanism may cause poor discharge function or no function at all. Clean all ducts in the control paring disc with a soft iron wire or similar. Remove deposits on other surfaces with steel wool.

  • Page 79: 3.3.10 Sliding Bowl Bottom

    3 Dismantling/Assembly 3.3 Intermediate Service (IS), check points 3.3.10 Sliding bowl bottom Poor sealing between the bowl hood seal ring and the sealing edge of the wear lining fitted in the sliding bowl bottom will cause a leakage of process liquid from the bowl. Check the sealing edge of the wear lining.

  • Page 80: 3.3.12 Valve Plugs

    3.3 Intermediate Service (IS), check points 3 Dismantling/Assembly 3.3.12 Valve plugs Poor sealing between the valve plugs (1) in the operating slide and bowl body may prevent complete closing of the bowl. Examine the sealing surfaces (2) of the bowl body in contact with the valve plugs.

  • Page 81: 3.3.15 Vibration Sensor

    3 Dismantling/Assembly 3.3 Intermediate Service (IS), check points 3.3.15 Vibration sensor • Check that the electrical cables and connections are not damaged. • Check that the sensor is well attached to the frame. If the sensor has to be tightened, see below.

  • Page 82: Cover Interlocking Switch (Option)

    3.3 Intermediate Service (IS), check points 3 Dismantling/Assembly 3.3.17 Cover interlocking switch (option) • Check that the electrical cables and connections are not damaged. • Check that the screws fixing the switch to the frame are tightened. Position of cover interlocking switch •...

  • Page 83: Intermediate Service (Is), Assembly

    3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly Intermediate Service (IS), assembly 3.4.1 Introduction Before starting the assembly first carry out the Intermediate Service check points starting on page 65. NOTE Renew all parts included in the IS-kit. The O-rings and other sealing rings should be lubricated with grease of silicone type.

  • Page 84: Operating Liquid Device

    3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly 3.4.3 Operating liquid device Check point ‘‘3.3.9 Operating mechanism” on page An exploded view of the operating water device can be found on page 62. 1. Replace the height adjusting rings, the same number as were removed.
  • Page 85 3.4 Intermediate Service (IS), assembly 5. Check the height position of the operating liquid device relative to the bowl spindle in following way: Alfa Laval ref. 529692, rev. 0 • Use two steel rules or a depth gauge for measuring.

  • Page 86: Bowl Body And Operating Mechanism

    3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly 3.4.4 Bowl body and operating mechanism Check point ‘‘3.3.2 Corrosion” on page ‘‘3.3.3 Cracks” on page ‘‘3.3.4 Erosion and wear linings” on page ‘‘3.3.5 Guide surfaces” on page ‘‘3.3.7 Bowl spindle taper and bowl body nave taper”...
  • Page 87 3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly 5. Fit a new gasket (4) and the sleeve with wings (3) onto the operating slide. Turn the gasket in the right way. A gasket turned in the wrong way could block the ducts for operating water.
  • Page 88 3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly 8. Wipe off the spindle top and nave bore in the bowl body. For rust protection, lubricate the tapered end of the spindle with a few drops of oil (no other lubricant shall be used). Spread it over the surface carefully.
  • Page 89 3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly 11. 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. 12. Lower the bowl body slowly using a hoist until the central screw rests on the spindle top.
  • Page 90 3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly 15. Lubricate and fit a new rectangular ring in the sliding bowl bottom groove. Make sure the ring is well recessed in the groove. 16. Except lubrication of the parts mentioned in chapter ‘‘3.3.5 Guide surfaces”...
  • Page 91 3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly 21. Replace gasket underneath the centre screw. Fit and tighten the centre screw. Left-hand thread!

  • Page 92: Bowl Hood And Disc Stack

    3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly 3.4.5 Bowl hood and disc stack Check point ‘‘3.3.2 Corrosion” on page ‘‘3.3.3 Cracks” on page ‘‘3.3.4 Erosion and wear linings” on page ‘‘3.3.6 Bowl hood seal ring” on page ‘‘3.3.8 Lock ring; wear and damage” on page ‘‘3.3.14 Inlet pipe and outlet paring disc”...
  • Page 93 3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly 14. Bowl discs, top (have thinner caulks than Bowl 545247-12, purifier other discs in the disc stack) Bowl 545247-10, purifier 15. Bowl discs Bowl 545247-14, purifier with wing insert 16. Bottom bowl disc (has caulks also on its Bowl 545247-11, concentrator underside) Bowl 545247-13 / -09, concentrator...
  • Page 94 3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly 2. Fit the lifting tool to the distributor and lift the distributor with disc stack into the sliding bowl bottom using a hoist. Check that the drill mark (A) on the distributor is in line with the guide key (B) on the bowl body.
  • Page 95 3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly 5. Check that the O-ring and the seal ring of the bowl hood are properly fitted and lubricated. Make certain that the so-called dovetail slot (1) is well cleaned. 6. Lower the bowl hood straight down onto the disc stack, otherwise it may get stuck.
  • Page 96 3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly 9. Lift the lock ring by using eye bolts and a hoist. Tighten the lock ring by hand. 10. Tighten the lock ring using the compressing tool as described below. a. Fit the lifting tool onto the bowl hood. b.
  • Page 97 3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly d. Fit the lock ring spanner and tighten the large lock ring, first by hand. Then advance the lock ring by giving the spanner handle some blows until the φ-marks are in line or passed. Left-hand thread! Check of disc stack pressure •...
  • Page 98 The vertical height of a disc with 2,0 mm caulk is 3,8 mm. e. If the assembly marks have passed each other by more than 25° after tightening the lock ring, contact your Alfa Laval representative. NOTE The assembly marks must never pass each other more than 25°...
  • Page 99 0 and then remove the compressing and lifting tools. Control of height position Alfa Laval ref. 538596, rev. 0 The height position should normally not be checked at Intermediate Service but when the bowl spindle has been removed (each Major Service) or when the bowl has been replaced.
  • Page 100 3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly 11. Fit: - O-ring, - gravity disc, - gasket, - paring disc, - gasket, - paring chamber top part. Some of the above parts have guide pins. Check that these guide pins enter corresponding holes for correct assembly.

  • Page 101: Inlet/Outlet, Frame Hood

    3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly 3.4.6 Inlet/outlet, frame hood The figures within brackets below refer to the exploded view on page 50. 1. Renew and lubricate with silicone grease the rectangular rings (3, 5, 7) and seal ring (8) which are included in the IS-kit.

  • Page 102: Major Service (Ms), Dismantling

    3.5 Major Service (MS), dismantling 3 Dismantling/Assembly Major Service (MS), dismantling 3.5.1 Introduction When carry out a Major Service an Intermediate Service is always included. By that reason it is assumed that the dismantling for Intermediate Service starting on page is already done.
  • Page 103 3 Dismantling/Assembly 3.5 Major Service (MS), dismantling...

  • Page 104: Vertical Driving Device

    3.5 Major Service (MS), dismantling 3 Dismantling/Assembly 3.5.2 Vertical driving device...
  • Page 105 3 Dismantling/Assembly 3.5 Major Service (MS), dismantling Screw Protecting plate O-ring Protecting collar O-ring Seal ring Guard Rectangular ring Oil fan 10. Bowl spindle 11. Screw 12. Seal ring 13. Screw 14. Top bearing cover 15. Rubber buffer 16. Snap ring 17.
  • Page 106 3.5 Major Service (MS), dismantling 3 Dismantling/Assembly 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. 1. Place a collecting tray under the oil drain hole.
  • Page 107 3 Dismantling/Assembly 3.5 Major Service (MS), dismantling 4. Pull off the protecting collar. Note! No threads. 5. Unscrew the three screws and remove the guard. 6. Remove the seal ring fitted in the guard. 7. Remove the oil fan by hitting with light blows on the wings.
  • Page 108 3.5 Major Service (MS), dismantling 3 Dismantling/Assembly 8. On the horizontal driving device, loosen the screws in the clamping element uniformly and successively in the order shown in the illustration. In the first step, do not loosen the screws more than ¼ turn to avoid distortion in the clamping element.
  • Page 109 3 Dismantling/Assembly 3.5 Major Service (MS), dismantling 15. Pull off the worm together with the roller bearing. Now and then hit on the head of the centre screw. 16. Remove the snap ring. 17. Pull off the sleeve. Note! No thread. 18.
  • Page 110 3.5 Major Service (MS), dismantling 3 Dismantling/Assembly 21. Remove the upper rubber buffer (not provided with springs). 22. Lift the spindle out of the spring support. 23. Remove the lower rubber buffer (provided with springs) from the top bearing support.
  • Page 111 3 Dismantling/Assembly 3.5 Major Service (MS), dismantling 24. Remove the springs from the top bearing support. 25. Then remove the top bearing support from the mounting tube.
  • Page 112 3.5 Major Service (MS), dismantling 3 Dismantling/Assembly Tube End tube Compressing tool Dismantling and assembly tool 4A.* Ring 4B. Plate, lower 4C. Sleeve 4D. Bar 4E. Support ring 4F. Intermediate part 4G. Snap ring (normally mounted on the bar) 4H. Washer Plate, upper 4J.
  • Page 113 3 Dismantling/Assembly 3.5 Major Service (MS), dismantling 26. Dismantle the top bearing support from the spindle in the following way: a. Arrange the tube (1) on a firm support. Fill the tube with rags to protect the spindle from damage when pressing out. b.
  • Page 114 3.5 Major Service (MS), dismantling 3 Dismantling/Assembly 27. The parts pressed off the spindle are the upper and lower ball bearing housings and the spacing sleeve. 28. Force out the ball bearing from the lower ball bearing housing. 29. Check the guide pins. Replace any damaged pins but do not loosen the others.

  • Page 115: Horizontal Driving Device

    3 Dismantling/Assembly 3.5 Major Service (MS), dismantling 3.5.3 Horizontal driving device Worm gear end Round nut Clamp element 15. Worm wheel shaft Frame bottom part Small ball bearing 16. Cooling coil Bearing housing 10. O-ring 17. Washer Round nut 11. Gasket 18.
  • Page 116 3.5 Major Service (MS), dismantling 3 Dismantling/Assembly 1. Remove the guard covering the bearing shield. 2. Shut off the water supply and disconnect the cooling water connections to the cooling coil in the worm gear housing. 3. Remove the nuts and washers fixing the cooling coil to the bearing shield and press the two tube ends up into the bearing shield.
  • Page 117 3 Dismantling/Assembly 3.5 Major Service (MS), dismantling 6. Fit the puller tool and pull off the ball bearing from the worm wheel shaft. 7. Remove the worm wheel and clamping element. CAUTION Crush hazard The worm wheel is quite heavy. Hold it firmly when dismantling.
  • Page 118 3.5 Major Service (MS), dismantling 3 Dismantling/Assembly 14. To remove the coupling disc from the horizontal driving shaft, unscrew the centre screw (A) and remove the plain washer (B). Then tighten the screw (A) again to protect the worm wheel shaft during next operation. 15.
  • Page 119 3 Dismantling/Assembly 3.5 Major Service (MS), dismantling 18. Unscrew the round nut fixing the ball bearing. 19. Remove the ball bearing. Put some cotton twist into the tool to avoid damage to the shaft. The pressure should be applied to the inner race of the ball bearing.

  • Page 120: Major Service (Ms), Check Points

    3.6 Major Service (MS), check points 3 Dismantling/Assembly Major Service (MS), check points 3.6.1 Introduction This chapter consists of check points that can be done when the separator has been dismantled for Major Service but before it is assembled. Other check points that can be done only in conjunction with the assembly are described in the assembly sections.
  • Page 121 3 Dismantling/Assembly 3.6 Major Service (MS), check points 1. Clean the lock ring thoroughly with a degreasing agent and wipe it off. 2. Spray the threads, guide and contact surfaces with slide lacquer Molykote D321R. Let the lacquer air-cure for about 15 minutes. 3.

  • Page 122: Brake

    3.6 Major Service (MS), check points 3 Dismantling/Assembly 5. Polish the slide lacquer to a black shiny surface which will now last about a year. Proceed in the same way with the threads of the bowl body and with the guide surfaces of the bowl hood and bowl body.
  • Page 123 3 Dismantling/Assembly 3.6 Major Service (MS), check points 4. Note that the screws (10) are slotted at both ends. 5. Remove any rust and brake dust from the surface of the brake shoe (7) and the corresponding guiding surface in the cover (1).

  • Page 124: Major Service (Ms), Assembly

    3.7 Major Service (MS), assembly 3 Dismantling/Assembly Major Service (MS), assembly 3.7.1 Introduction Before starting the assembly first carry out the Intermediate Service check points starting on page and Major Service check points starting on page 120. NOTE Renew all parts included in the IS- and MS- kits.

  • Page 125: Horizontal Driving Device

    3 Dismantling/Assembly 3.7 Major Service (MS), assembly NOTE Since roller bearings are normally treated only with rust protection oil from the factory, an initial lubrication of new bearings must always be performed whenever bearings are replaced. The initial lubrication implies adding a few drops of lube oil to the bearings.
  • Page 126 3.7 Major Service (MS), assembly 3 Dismantling/Assembly 4. Clean the ball bearing housing in the frame and oil the outer race of the ball bearing. NOTE The bearing must cool down before fitting the worm wheel shaft into the frame. Otherwise the tolerance between the outer diameter of the bearing and the bearing housing will be too narrow.
  • Page 127 3 Dismantling/Assembly 3.7 Major Service (MS), assembly 8. If the brake pulley has been removed, first lubricate the motor shaft with Molykote Paste 1000. Then knock the disc on to the motor shaft as far as possible using a piece of wood and a hammer.
  • Page 128 3.7 Major Service (MS), assembly 3 Dismantling/Assembly 13. Clean the worm wheel shaft and the inner surface of the worm wheel nave thoroughly with a clean cloth. Then oil the surfaces. The oil must be of the same quality as used in the worm gear housing.
  • Page 129 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. NOTE Excessive wobble on the worm wheel shaft may cause vibration and noise.

  • Page 130: Vertical Driving Device

    3.7 Major Service (MS), assembly 3 Dismantling/Assembly 3.7.3 Vertical driving device Check point ‘‘2.4.1 Worm wheel and worm; wear of teeth” on page An exploded view of the vertical driving device can be found on page 104. All three bearings on the bowl spindle are off different types as follows: A.
  • Page 131 3 Dismantling/Assembly 3.7 Major Service (MS), assembly 2. Fit the cold deep groove ball bearing into the heated upper housing using the special mounting tool included in the set of tools. 3. Lock the bearing with a snap ring. WARNING Risk for eye injury Use the correct pliers for the snap ring to avoid accidental release.
  • Page 132 3.7 Major Service (MS), assembly 3 Dismantling/Assembly Tube End tube Compressing tool Dismantling and assembly tool 4A. Ring 4B. Plate, lower 4C.* Sleeve 4D. Bar 4E.* Support ring 4F. Intermediate part 4G. Snap ring (normally mounted on the bar) 4H. Washer Plate, upper 4J.
  • Page 133 3 Dismantling/Assembly 3.7 Major Service (MS), assembly 6. Assemble the top bearing support on the spindle in the following way: a. Arrange the tube (1) on a firm support. b. Fit the bottom plate (4B) on the tube (1). Fit the ring (4A) with inside diameter Ø77 mm in the bottom plate (4B).
  • Page 134 3.7 Major Service (MS), assembly 3 Dismantling/Assembly 7. Remove the spindle from the tube and instead fit the top bearing support in the tube. 8. Fit the top bearing support in the tube and put the springs in place. 9. Fit the rubber buffer with springs. 10.
  • Page 135 3 Dismantling/Assembly 3.7 Major Service (MS), assembly 12. Fit the rubber buffer without springs. 13. Fit the cover and tighten its screws alternately, a little at a time. Final tightening torque: 60 Nm 14. Fit the oil fan. Hit with light blows on the wings.
  • Page 136 3.7 Major Service (MS), assembly 3 Dismantling/Assembly 15. Lay down the spindle, fit the sleeve and lock it with the snap ring. 16. Make sure that the conical surfaces inside the worm and on the spindle are clean and free from oil before fitting the worm.
  • Page 137 3 Dismantling/Assembly 3.7 Major Service (MS), assembly 19. Fit the spacing washer, the lock washer and the round nut. 20. Fasten the hole assembly with the round nut and lock it with the lock washer. 21. Wipe off the contact surfaces for frame and spindle assembly.
  • Page 138 3.7 Major Service (MS), assembly 3 Dismantling/Assembly 24. Fit the rectangular ring into the frame. 25. Fit the guard into position. 26. Fit new seal rings under the screw heads. Tighten the screws alternately, a little at a time. Final tightening torque: 40 Nm 27.
  • Page 139 3 Dismantling/Assembly 3.7 Major Service (MS), assembly 28. Fit the protecting collar and push it firmly down against the oil fan. NOTE Check that the protecting collar is in the bottom position (resting against the oil fan) before tightening the protecting plate. 29.
  • Page 140 3.7 Major Service (MS), assembly 3 Dismantling/Assembly 31. Clean and oil the worm wheel shaft, the nave of the clamping element and the nave and outer surface of the worm wheel. The oil must be of the same quality as used in the worm gear housing.
  • Page 141 3 Dismantling/Assembly 3.7 Major Service (MS), assembly 36. Check the radial wobble of the bowl spindle. NOTE Spindle wobble will cause rough bowl running. This leads to vibration and reduces lifetime of ball bearings. • Set up a dial indicator on a magnetic stand. Use the key for the large lock ring as a support for the stand, see the illustration.

  • Page 142: Operating Water Module Compact (Owmc)

    3.8 Operating water module compact (OWMC) 3 Dismantling/Assembly Operating water module compact (OWMC) 3.8.1 Exploded view...
  • Page 143 3 Dismantling/Assembly 3.8 Operating water module compact (OWMC) Cylinder Locking wire, upper Garter strap O-ring O-ring Outlet Turcon variseal “M” Nozzle 10. Screw 11. Two-pulse adapter 12. Turcon AQ-seal (3 pieces) 13. Piston 14. Turcite slidering 15. O-ring 16. Air tank 17.

  • Page 144: Dismantling (Ms Service)

    2. Remove the connections for operating water. NOTE The Air tank (16) must only be dismantled by Alfa Laval personel. 3. Turn the cylinder (2) anti-clockwise relative to the air tank (16). The upper locking wire is thereby forced out.

  • Page 145: Check Points

    3 Dismantling/Assembly 3.8 Operating water module compact (OWMC) 4. Pull off the cylinder (2) 5. Carefully press the piston (13) out of the cylinder using a soft rod or similar. 3.8.3 Check points Clean and check the condition of the dismantled parts.

  • Page 146: Assembly (Ms Service)

    506c.Inlet for activating a large discharge 3.8.5 Air tank If the air tank has to be dismantled (i.e. repair) it is removed by removing the nuts (19). NOTE If problems are related to the Air tank (16), always contact Alfa Laval representative.
  • Page 147 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 Tumba AB, Separator Manuals, dept. PPDM, SE-147 80 Tumba, Sweden. Fax: +46 8 530 310 40.
  • Page 149 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 151: Index

    Index Cover interlocking switch Cracks Air tank Disc stack pressure Assembly Elastic plates in coupling Bowl body and operating mechanism Erosion Bowl hood and disc stack External cleaning General directions Guide surfaces Horizontal driving device Inlet pipe and outlet paring discs Inlet/outlet, frame hood Lock ring - priming Operating water device...
  • Page 152 Erosion Maintenance intervals Exploded views Maintenance logs Bowl body and operarting mechanism 3-year Service (3S) Bowl hood and disc stack Daily checks Horizontal driving device Intermediate Service (IS) Inlet/outlet, frame hood Major Service (MS) Operating liquid device Oil change Operating water module (OWMC) Maintenance, general information Vertical driving device Ball and roller bearings...
  • Page 153 Tightening torques Bowl body - distributing ring Bowl body - operating slide Bowl spindle, bearing support Bowl spindle, guard Frame feet Large lock ring Screws, common Speed sensor Vibration sensor Worm wheel assembly Worm wheel clamping ring Vertical driving device Assembly Check point Dismantling...

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