Alfa Laval FOPX 610TFD Manual
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Alfa Laval FOPX 610TFD Manual

Alfa Laval FOPX 610TFD Manual

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Summary of Contents for Alfa Laval FOPX 610TFD

  • Page 1 > 7@AI'"!E75#% DVaRcRe`c>R_fR] ?a^SdRc=^ '' !##$ 1^^Z=^ !&##&!E...
  • Page 2 Telephone: +46 8 53 06 50 00 Telefax: +46 8 53 03 10 40 Printed in Sweden, 98-10 © Alfa Laval Separation AB 1998 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 6.6 Vertical driving device (MS) 6.7 Horizontal driving device (MS) 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 Connection list 8.3 Interface description 8.4 Water quality 8.5 Lubricants 8.6 Drawings 8.7 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 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 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 16: Basic Principles Of Separation

    3.1 Basic principles of separation 3 Separator Basics 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 17 3 Separator Basics 3.1 Basic principles of separation 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 18 3.1 Basic principles of separation 3 Separator Basics Density difference (specific gravity ratio) The greater the density difference between the two liquids, the easier the separation. The density difference can be increased by heating. High density (with low temperature) Low density (with high temperature)

  • 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 needed to achieve the best separating results and for reasons of safety. The number of revolutions on the revolution counter for correct speed is shown in chapter ‘‘8 Technical Reference”...
  • 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 Connection list” on page 180. Increasing back pressure in the clean oil outlet can be caused by: •...
  • Page 23 3 Separator Basics 3.2 Design and function...
  • Page 24 3.2 Design and function 3 Separator Basics 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 25 3 Separator Basics 3.2 Design and function 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 26 3.2 Design and function 3 Separator Basics 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. Passive parts are: the dosing ring (17), nozzles (15, 16) and drain valve plugs (25).
  • Page 27 3 Separator Basics 3.2 Design and function 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 of the distributor, it will rise through the channels formed by the disc stack (8) where it is evenly distributed.
  • Page 28 3.2 Design and function 3 Separator Basics 3.2.6 Sludge discharge cycle An interface (1) is formed between the oil and water in the bowl. In order to achieve optimum separation of the oil, the interface must be maintained in the correct position, that is outside the disc stack.
  • Page 29 3 Separator Basics 3.2 Design and function 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 30: Definitions

    3.3 Definitions 3 Separator Basics 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. Clarifier disc An optional disc, which replaces the gravity disc in the separator bowl, in the case of clarifier operation.

  • 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 describe routine procedures to follow before and during the start, running and stopping sequences of the separator. If there is a System Manual, always follow the operating instructions of the System Manual. If there is no System Manual the instructions below are to be followed.

  • 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 consumption of the motor starter to ensure that the separator has reached full speed. During start, the current reaches a peak and then drops slowly. When the friction coupling engages, the current slowly increases again before decreasing to a low and stable level, which is the normal current during running.

  • 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 7(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 5.1.3 Maintenance procedure body nave 5.1.4 Service kits 5.4.3 Bowl spindle; height position 5.4.4 Bowl spindle;...
  • 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 teeth 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 spare 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: Oil Change

    5.2 Maintenance Logs 5 Service Instructions 5.2.2 Oil change The oil change and check of worm gear should be carried out every 1000 hours of operation. NOTE: In a new installation, or after replacement of gear, change the oil after 200 operating hours. Main component and activity Part Page...

  • Page 45: Intermediate Service (Is)

    5 Service Instructions 5.2 Maintenance Logs 5.2.3 Intermediate Service (IS) Name of plant: Local identification: Separator: FOPX 610TFD-24 Manufacture No./Year: Total running hours: Product No: 881244-05-01 Date: Signature: Main component and activity Part Page Notes Inlet and outlet Clean and inspect...
  • Page 46 5.2 Maintenance Logs 5 Service Instructions Main component and activity Part Page Notes Check Corrosion Cracks Erosion Galling of guide surface Disc stack pressure Operating device Clean and check Operating paring disc – Horizontal driving device Worm wheel shaft and gear housing Check Worm wheel and worm Renew...
  • Page 47 5 Service Instructions 5.2 Maintenance Logs 5.2.4 Major Service (MS) Name of plant: Local identification: Separator: FOPX 610TFD-24 Manufacture No./Year: Total running hours: Product No: 881244-05-01 Date: Signature: Main component and activity Part Page Notes Inlet and outlet Clean and inspect...
  • Page 48 5.2 Maintenance Logs 5 Service Instructions Main component and activity Part Page Notes Check Corrosion Cracks Erosion Galling of guide surface Disc stack pressure Height position of oil paring disc Operating device Clean and check Operating paring disc – Check Height position of operating paring disc Vertical driving device...
  • Page 49 5 Service Instructions 5.2 Maintenance Logs 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 50: 3-Year Service (3S)

    5.2 Maintenance Logs 5 Service Instructions 5.2.5 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 the parts included in the 3-year Service kit (3S).

  • Page 51: Check Points At Intermediate Service (Is)

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 52: Bowl Spindle Cone And Bowl Body Nave

    5.3 Check points at Intermediate Service (IS) 5 Service Instructions 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 53 5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 54 5.3 Check points at Intermediate Service (IS) 5 Service Instructions 1. Inspect closely for all types of damage by corrosion and record these observations carefully. 2. Polish dark-coloured spots and other corrosion marks with a fine grain emery cloth. This may prevent further damage. Polish corrosion marks to prevent further damage DANGER Disintegration hazard...

  • Page 55: 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 56: Disc Stack Pressure

    5.3 Check points at Intermediate Service (IS) 5 Service Instructions 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 57 5 Service Instructions 5.3 Check points at Intermediate Service (IS) Complementary check using the compressing tool With the large lock ring correctly tighten and the compressing tool mounted on the separator bowl, turn the switch to position 1 for compression. Compress the disc stack by pumping the lever arm until the oil pressure is released through the relief valve.

  • Page 58: 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 59 5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 60: 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 and 2). Apply Alfa Laval lubricating paste or Molykote 1000 Paste with a well-cleaned brush on surfaces (1 and 2).
  • Page 61 5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 62: 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 76. Apply Alfa Laval lubricating paste or Molykote 1000 Paste to the surface after priming. 5.3.9 Inlet pipe and oil paring disc...

  • Page 63: Lock Ring; Wear And Damage

    610TFD-24), an Alfa Laval representative must be contacted immediately. (MAX 25 ) If the marks become illegible, an Alfa Laval representative should be contacted immediately The φ -mark on the lock ring must not pass the φ -mark to inspect thread wear and for determining the on the bowl body by more than 25°...

  • Page 64: Operating Mechanism

    5.3 Check points at Intermediate Service (IS) 5 Service Instructions 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 65: Operating Slide

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 66: Springs For Operating Mechanism

    5.3 Check points at Intermediate Service (IS) 5 Service Instructions If the seal ring for the sliding bowl bottom is to be replaced, 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.

  • Page 67: Cover Interlocking Switch (Option)

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 out-of-circuit. Check also the reverse when the button not pressed.

  • Page 68: Check Points At Major Service 7(Ms)

    5.4 Check points at Major Service (MS) 5 Service Instructions Check points at Major Service (MS) 5.4.1 Bowl hood seal ring Same as described in ‘‘5.3.1 Bowl hood seal ring” on page 51. 5.4.2 Bowl spindle cone and bowl body nave Same as described in ‘‘5.3.2 Bowl spindle cone and bowl body nave”...

  • Page 69: Bowl Spindle; Radial Wobble

    5 Service Instructions 5.4 Check points at Major Service (MS) 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 run. This leads to vibration and reduces lifetime of ball bearings.

  • Page 70: Buffer Springs And Ball Bearing Housing

    5.4 Check points at Major Service (MS) 5 Service Instructions If the lining is oily: • Clean the lining and the coupling drum with a suitable degreasing agent. • Roughen the friction surface of the lining with a coarse file. NOTE Identify the cause of oily lining.
  • Page 71 5 Service Instructions 5.4 Check points at Major Service (MS) Top bearing springs In case of spring fracture, the complete set of springs should be replaced, even if only one spring is broken. Ball bearing housing Radial buffer Buffer spring Screw plug Ball bearing housing Examine the contact surface for the buffers on the...

  • Page 72: Coupling Friction Pads

    5.4 Check points at Major Service (MS) 5 Service Instructions 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 the bowl lose speed during operation, the friction pads of the coupling may be worn or oily.

  • Page 73: Corrosion

    5 Service Instructions 5.4 Check points at Major Service (MS) Different friction blocks for different power supply frequencies If mounting new friction blocks, check that the blocks are correct for the power supply frequency. The measure A is different for 50 and 60 Hz separators 50 Hz: A = 20 mm...

  • Page 74: Flexible Plate In Coupling

    5.4 Check points at Major Service (MS) 5 Service Instructions 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 75: Guide Surfaces

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

  • Page 76: Level Ring

    5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.16 Level ring Same as described in section ‘‘5.3.10 Level ring” on page 62. 5.4.17 Lock ring; priming The arrows indicate positions of threads, guide and contact surfaces to be primed. Recommended agents for priming procedure: •...
  • Page 77 5 Service Instructions 5.4 Check points at Major Service (MS) 3. Use a fibre brush to polish the slide lacquer into the surface. The black spray will look like well-polished leather when properly done. 4. Spray the lock ring a second time and let it dry for about 20 minutes.

  • Page 78: Lock Ring; Wear And Damage

    5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.18 Lock ring; wear and damage Same as described in section ‘‘5.3.11 Lock ring; wear and damage” on page 63. 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 79: Operating Slide

    5 Service Instructions 5.4 Check points at Major Service (MS) 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.

  • Page 80: Springs For Operating Mechanism

    5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.24 Springs for operating mechanism Same as described in ‘‘5.3.15 Springs for operating mechanism” on page 66. 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.

  • Page 81: Worm Wheel Shaft; Radial Wobble

    Maximum permissible radial wobble is 0,10 mm. If the wobble is larger, 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 replaced.

  • Page 82: Lifting Instructions

    5.5 Lifting instructions 5 Service Instructions Lifting instructions Attach three endless slings or cables to the lifting eyes (the screws must be tightened with spanner). Length of each sling must be min. 2 metres. NOTE Machine weight without frame hood and bowl is approx.

  • Page 83: Cleaning

    5 Service Instructions 5.6 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.
  • Page 84 The most important property of a cleaning liquid for the removal of fuel oil sludge is the Alfa Laval cleaning liquid for fuel oil separators ability to dissolve these asphaltenes. Alfa Laval cleaning liquid for fuel oil separators has been developed for this purpose.
  • Page 85 5 Service Instructions 5.6 Cleaning 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 Cleaning 5 Service Instructions 5.6.3 Cleaning of bowl discs Handle the bowl discs carefully so as to avoid damage to the surfaces during cleaning. NOTE Mechanical cleaning is likely to scratch the disc surfaces causing deposits to form quicker and adhere more firmly. A gentle chemical cleaning is therefore preferable to mechanical cleaning.
  • Page 87 5 Service Instructions 5.6 Cleaning 5.6.4 CIP-system Alfa Laval has developed a CIP (Cleaning-In- Place) system specifically designed for cleaning the bowl and with the inlet and outlets of lube and fuel oil separators without the need of dismantling. CIP Unit connected to separator...

  • Page 88: When Changing Oil

    5.7 When changing oil 5 Service Instructions 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 90.
  • Page 89 5 Service Instructions 5.7 When changing oil 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 90 5.7 When changing oil 5 Service Instructions 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 91 5 Service Instructions 5.7 When changing oil 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 ‘‘8.5 Lubricants” on page 187 must be well known.

  • Page 92: Vibration

    5.8 Vibration 5 Service Instructions 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.
  • Page 93 5 Service Instructions 5.8 Vibration 5.8.2 Vibration switch (option) Adjustment of setpoint The vibration switch is adjusted by a simple procedure with the separator in operation. In making this adjustment, the cover must be removed to gain access to the setpoint adjusting screw (1).

  • Page 94: Common Maintenance Directions

    The bearings used for the bowl spindle are special 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 in appearance looks equivalent to...
  • Page 95 5 Service Instructions 5.9 Common 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 or in some other way.
  • Page 96 5.9 Common maintenance directions 5 Service Instructions • 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 97 5 Service Instructions 5.9 Common maintenance directions 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 98 5.9 Common maintenance directions 5 Service Instructions...

  • Page 99: 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 100: Introduction

    6.1 Introduction 6 Dismantling/Assembly 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 101: Tools

    6 Dismantling/Assembly 6.1 Introduction 6.1.3 Tools Special tools from the tool box must be used for dismantling and assembly. The special tools are specified in the Spare Parts Catalogue and are shown as illustrations together with the dismantling/assembly instructions. NOTE When lifting parts without weight specifications, always use lifting straps with the capacity of at least 500 kg.

  • Page 102: Inlet/Outlet, Frame Hood (Is)

    6.2 Inlet/outlet, frame hood (IS) 6 Dismantling/Assembly 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 103: Dismantling

    6 Dismantling/Assembly 6.2 Inlet/outlet, frame hood (IS) 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.
  • Page 104 6.2 Inlet/outlet, frame hood (IS) 6 Dismantling/Assembly 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 105: Assembly

    6 Dismantling/Assembly 6.2 Inlet/outlet, frame hood (IS) 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.
  • Page 106 6.2 Inlet/outlet, frame hood (IS) 6 Dismantling/Assembly 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.

  • Page 107: Bowl Hood And Disc Stack (Is)

    6 Dismantling/Assembly 6.3 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.

  • Page 108: Dismantling

    To facilitate unscrewing the large lock ring, reduce shocks to bearings and keep thread wear to a minimum, the disc stack should be compressed using an Alfa Laval compressing tool (optional) as described below. Unscrewing lock ring without using a compressing tool a.
  • Page 109 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 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 lever.
  • Page 110 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly 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 slightest distortion could make it impossible to refit.
  • Page 111 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 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 lever.
  • Page 112 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly 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 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 9. Fit the lifting tool into the distributor and lift the distributor with disc stack out of the bowl body using hoist. 10. Remove deposits and clean all parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning”...

  • Page 114: Assembly

    6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly 6.3.3 Assembly Check point ‘‘5.3.3 Corrosion” on page 52, ‘‘5.3.4 Cracks” on page 55, ‘‘5.3.7 Erosion” on page 58, ‘‘5.3.11 Lock ring; wear and damage” on page 1. Assemble the discs one by one on the distributor.
  • Page 115 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) Check point ‘‘5.3.10 Level ring” on page 62. 3. Check that the small hole (1) in the top disc is not clogged. Fit the oil paring disc and level ring with O-ring into the top disc.
  • Page 116 To facilitate tightening of the lock ring, reduce shocks to bearings and keep the thread wear to a minimum, the disc stack should be compressed using an Alfa Laval compressing tool (optional) as described below. Tightening of lock ring without using a compressing tool a.
  • Page 117 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) b. Tighten until the assembly marks are in line. Check point ‘‘5.3.5 Disc stack pressure” on page 56. NOTE The assembly marks must never pass each other more than 25° which corresponds to A=100 mm.
  • Page 118 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly d. Tighten the lock ring using the spanner for lock ring. Left-hand thread! e. Tighten until the assembly marks are in line. Check point ‘‘5.3.5 Disc stack pressure” on page 56. NOTE The assembly marks must never pass each other more than 25 °...
  • Page 119 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 11. Fit and tighten the paring chamber cover by using the spanner. Left-hand thread!

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

    6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 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.

  • Page 121: Dismantling

    6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 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 hoist.
  • Page 122 6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 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.
  • Page 123 6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 7. Thread a strap through two sludge ports and turn the bowl body upside down using hoist. WARNING Crush hazards Support the bowl body when turning to prevent it from rolling. 8.
  • Page 124 6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 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.
  • Page 125 6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 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

    6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 14. Place the operating slide with the valve plugs facing upwards. Remove any thick deposits in the bowl hood and clean all other parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning”...
  • Page 127 6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 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.
  • Page 128 6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 5. Lubricate the guide surfaces of the spring support. See chapter ‘‘8.5 Lubricants” on page 187. 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 6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 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.
  • Page 130 6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 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)

    6 Dismantling/Assembly 6.5 Operating water device (IS) Operating water device (IS) 6.5.1 Exploded view O-ring Distributing ring Control paring disc O-ring Cover Gasket Distributing cover Height adjusting ring...

  • Page 132: Dismantling

    6.5 Operating water device (IS) 6 Dismantling/Assembly 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 133 6 Dismantling/Assembly 6.5 Operating water device (IS) 3. Loosen and pull out the operating water inlet pipes. 4. Lift out the distributing cover.
  • Page 134 6.5 Operating water device (IS) 6 Dismantling/Assembly 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”...

  • Page 135: Assembly

    6 Dismantling/Assembly 6.5 Operating water device (IS) 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.
  • Page 136 6.5 Operating water device (IS) 6 Dismantling/Assembly 3. Fasten the distributing cover. 4. Assemble the paring disc device. Do not forget the gasket on its underside.
  • Page 137 6 Dismantling/Assembly 6.5 Operating water device (IS) 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 138 6.5 Operating water device (IS) 6 Dismantling/Assembly 7. Tighten the screws of the paring disc. Check point ‘‘5.4.21 Operating paring disc; height position” on page 79. Only at Major Service (MS).
  • Page 139 6 Dismantling/Assembly 6.5 Operating water device (IS)

  • Page 140: Vertical Driving Device (Ms)

    6.6 Vertical driving device (MS) 6 Dismantling/Assembly Vertical driving device (MS) 6.6.1 Exploded view...
  • Page 141 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 1. Protecting plate 2. O-ring 3. Protecting collar 4. Guard 5. O-ring 6. Ball bearing housing 7. Spring casing 8. Gasket 9. Oil fan 10. Ball bearing 11. Screw 12. Screw 13. Screw 14.

  • Page 142: Dismantling

    6.6 Vertical driving device (MS) 6 Dismantling/Assembly 6.6.2 Dismantling 1. Unscrew the six screws and remove the hood and O-ring. 2. Unscrew the three screws and remove the protecting plate, O-ring and protecting collar. 3. Unscrew the six screws and remove the guard and O-ring.
  • Page 143 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 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.
  • Page 144 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 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 145 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 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 hoist.
  • Page 146 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 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.

  • Page 147: Assembly

    6 Dismantling/Assembly 6.6 Vertical driving device (MS) 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.
  • Page 148 6.6 Vertical driving device (MS) 6 Dismantling/Assembly Check point ‘‘5.4.25 Worm; wear of groove” on page 80. 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 149 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 9. Carefully lower the spindle into the frame and guide the spindle into the right 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 tin hammer.
  • Page 150 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 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 151 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 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.
  • Page 152 6.6 Vertical driving device (MS) 6 Dismantling/Assembly Check point ‘‘5.4.5 Brake lining” on page 69. 20. Fit the brake cover and revolution counter cap and their gaskets.
  • Page 153 6 Dismantling/Assembly 6.6 Vertical driving device (MS)

  • Page 154: Horizontal Driving Device (Ms)

    6.7 Horizontal driving device (MS) 6 Dismantling/Assembly Horizontal driving device (MS) 6.7.1 Exploded view...
  • Page 155 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 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.

  • Page 156: Dismantling

    6.7 Horizontal driving device (MS) 6 Dismantling/Assembly 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.
  • Page 157 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 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.
  • Page 158 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly 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 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 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 electrical motor using hoist. 13. Remove the flexible plate and unscrew the six screws for the coupling disc and remove 14.
  • Page 160 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly 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.

  • Page 161: Assembly

    6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 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.
  • Page 162 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly Check point ‘‘5.7.1 Worm wheel and worm; wear of teeth” on page 88. 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 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 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. 11. Fit the bearing shield together with the oil shield.
  • Page 164 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly 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. If necessary, use the driving- on sleeve. 14. Fit the flexible plate. Check point ‘‘5.4.13 Flexible plate in coupling”...
  • Page 165 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) The remaining description in this section implies that the bowl spindle is mounted in the frame. If not, proceed with the assembly instruction for the vertical driving device in chapter ‘‘6.6.3 Assembly” on page 147. 16.
  • Page 166 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly...

  • 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

    7.1 FOPX mechanical functions 7 Trouble-tracing 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 speed. DANGER Disintegration hazards When excessive vibration occurs, keep liquid feed on and stop separator. The cause of the vibration must be identified and corrected before the separator is restarted.

  • Page 169: Smell

    7 Trouble-tracing 7.1 FOPX mechanical functions 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 too low. Check oil level and add oil if necessary. 7.1.3 Noise Cause...

  • Page 170: Starting Power Too High

    7.1 FOPX mechanical functions 7 Trouble-tracing 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.

  • Page 171: Water In Worm Gear Housing

    7 Trouble-tracing 7.1 FOPX mechanical functions 7.1.9 Water in worm gear housing Cause Corrective actions Page Bowl casing drain obstructed. Clean worm gear housing and change oil. Leakage at top bearing. Renew seal ring and change oil. 140, 91 Condensation. Clean worm gear housing and change oil.

  • Page 172: Fopx Separating Functions

    7.2 FOPX separating functions 7 Trouble-tracing 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 Trouble-tracing 7.2 FOPX separating functions 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 –...

  • Page 174: Unsatisfactory Sludge Discharge

    7.2 FOPX separating functions 7 Trouble-tracing 7.2.4 Unsatisfactory sludge discharge Cause Corrective actions Page Dosing ring too firmly tightened. Check the tightening torque. Valve plugs in the operating slide too Renew with correct valve plugs. high. Sludge deposits in the operating system. Check and clean the operating system.

  • Page 175: Vibration Switch (Option)

    Cause Corrective actions Page Dirt or iron chips on magnets. Clean magnets. – Leaf spring broken. Return to Alfa Laval for repair. – Reset coil open. Check for continuity and proper coil – resistance. 7.3.2 Impossible to adjust setpoint setting to obtain...
  • Page 176 7.3 Vibration switch (option) 7 Trouble-tracing...

  • Page 177: Technical Reference

    8 Technical Reference Contents 8.1 Technical data 8.2 Connection list 8.3 Interface description 8.3.1 General 8.3.2 Definitions 8.3.3 Component description and signal processing 8.3.4 Function graph and running limitations 8.4 Water quality 8.5 Lubricants 8.5.1 Lubrication chart, general 8.5.2 Recommended lubricating oils 8.5.3 Recommended oil brands 8.5.4...

  • Page 178: Technical Data

    8.1 Technical data 8 Technical Reference 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 does not agree with the technical data in this instruction manual, the data in the system description is the valid one.
  • Page 179 8 Technical Reference 8.1 Technical data Bowl speed, max. 5175/5148 r/min, 50/60 Hz Motor shaft speed, max. 1500/1800 r/min, 50/60 Hz Gear ratio, 50 Hz 3,45:1 Gear ratio, 60 Hz 2,86:1 No. of teeth; - on worm, 50 Hz - on worm, 60 Hz - on worm wheel, 50 Hz - on worm wheel, 60 Hz Friction blocks for coupling, thickness...

  • Page 180: Connection List

    8.2 Connection list 8 Technical Reference Connection list Alfa Laval ref. 554904 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. Outlet for light phase (oil).
  • Page 181 8 Technical Reference 8.2 Connection list Connection No. Description Requirements/limits Motor for separator. - Max. deviation from nominal frequency. ± 5% (momentarily 10% during a period of maximum 5 seconds). Vibration sensor (delivered as option). See ‘‘8.3 Interface Mechanical switch. description’’.

  • Page 182: Interface Description

    8.3 Interface description 8 Technical Reference Interface description Alfa Laval ref. 557138 8.3.1 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 183: Component Description And Signal Processing

    8 Technical Reference 8.3 Interface description 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. −...
  • Page 184 8.3 Interface description 8 Technical Reference Signal Processing The vibration sensor gives an open contact when the vibration exceeds the preset value. If too high vibration occurs the separator must be stopped with automatic Safety Stop. Cover interlocking switch 760 (option) The cover of the separator can be equipped with an interlocking switch as option.

  • Page 185: Function Graph And Running Limitations

    8 Technical Reference 8.3 Interface description 8.3.4 Function graph and running limitations A. Stand still B. Starting mode C. Running mode D. Stop mode E. Safety stop mode...

  • Page 186: Water Quality

    For test methods, contact an Alfa Laval representative. If these demands cannot be met, the water should be pre-treated in accordance with Alfa Laval’s recommendations. Alfa Laval accepts no liability for consequences arising from unsatisfactory purified operating water supplied by the customer. Suspended particles Content of suspend substances: Less than 0,001 percentage of volume.

  • Page 187: Lubricants

    The bearings are packed with grease and sealed and need no extra lubrication. Electric motor ( if nipples are fitted). Follow manufacturer’s instructions. Alfa Laval Lubricating Oil Groups: • Group A oil: a high quality gear oil on paraffin base with stable AW (anti wear) additives.
  • Page 188 8.5 Lubricants 8 Technical Reference 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 189: Recommended Lubricating Oils

    Alfa Laval ref. 553216-01 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. The corresponding commercial oil brands are found in chapter ‘‘8.5.3 Recommended oil...

  • Page 190: Recommended Oil Brands

    8.5 Lubricants 8 Technical Reference 8.5.3 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...
  • Page 191 8 Technical Reference 8.5 Lubricants Alfa Laval lubricating oil group D/220 Alfa Laval ref. 553218-08 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...
  • Page 192 8.5 Lubricants 8 Technical Reference 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...

  • Page 193: Recommended Lubricants

    8 Technical Reference 8.5 Lubricants 8.5.4 Recommended lubricants Pastes and bonded coatings for non-food applications Alfa Laval ref. 553217-01 Manufacturer Designation Alfa Laval No. Application Gleitmolybdän Gleitmo 805 K or 805 K varnish 901 Gleitmo Paste G rapid 537086-04 All pressure...
  • Page 194 8.5 Lubricants 8 Technical Reference Greases for ball and roller bearings Alfa Laval ref. 554900-01 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...
  • Page 195 8 Technical Reference 8.5 Lubricants...

  • Page 196: Drawings

    8.6 Drawings 8 Technical Reference Drawings 8.6.1 Basic size drawing Alfa Laval ref. 558527 Maximum vertical displacement Maximum horizontal displacement at the sludge connection during at the in/outlet connections during operation ± 10 mm. operation ± 15 mm.

  • Page 197: Dimensions Of Connections

    8 Technical Reference 8.6 Drawings 8.6.2 Dimensions of connections Alfa Laval ref. 558527 Data for connections, see chapter All connections to be installed non-loaded ‘‘8.2 Connection list” on page 180. and flexible.

  • Page 198: Foundations

    8.6 Drawings 8 Technical Reference 8.6.3 Foundations Alfa Laval ref. 554896 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 199: Electric Motor

    8 Technical Reference 8.6 Drawings 8.6.4 Electric motor 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...
  • Page 200 8.6 Drawings 8 Technical Reference Alfa Laval ref. 552813 4xPg29, max. cable diameter 29 mm Manufacturer ABB Motors Manuf. drawing MK20-92S Standards IEC 34-1, IEC 72 Size 160M Type MBT 160M Weight 72 kg Poles Insulation class Bearings DE 6209-Z/C3 – NDE 6209-Z/C3 Method of cooling IC 41 (IEC 34-6) Spec.
  • Page 201 8 Technical Reference 8.6 Drawings Article No Output Speed Freq Voltage Current Pow.fac Therm Note cos ϕ °C 552813-01 1445 200 D 0,85 552813-02 1445 220 D 0,85 552813-03 1445 380 D 0,85 552813-04 1445 415 D 0,85 552813-05 1445 440 D 0,85 552813-06...

  • Page 202: Machine Plates And Safety Labels

    8.6 Drawings 8 Technical Reference 8.6.5 Machine plates and safety labels Alfa Laval ref. 554651 1. Machine plate Separator FOPX 610TFD-24 Manufacturing serial No./ Year XXXX Product No. 881244-05-01 Machine top part 557057-02 Inlet and outlet 547331-81 Bowl 554048-02 Machine bottom part 540225-09/10 (50/60 Hz) Max.
  • Page 203 8 Technical Reference 8.6 Drawings 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.

  • Page 204: Vibration Sensor (Option)

    8.6 Drawings 8 Technical Reference 8.6.6 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 1-2 Reset coil ‘‘8.2 Connection list”...

  • Page 205: Storage And Installation

    8 Technical Reference 8.7 Storage and installation Storage and installation 8.7.1 Storage and transport of goods Storage Specification Upon arrival to the store, check all components and keep them: 1. Well stored and protected from mechanical damage and theft. 2. Dry and protected from rain and humidity. 3.
  • Page 206 8.7 Storage and installation 8 Technical Reference 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.

  • Page 207: Planning Of Installation

    8 Technical Reference 8.7 Storage and 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”...
  • Page 208 8.7 Storage and installation 8 Technical Reference 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 209 8 Technical Reference 8.7 Storage and installation 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.

  • Page 210: Foundations

    8.7 Storage and installation 8 Technical Reference 8.7.3 Foundation NOTE When lifting a separator it must always be hung securely. See chapter ‘‘5.5 Lifting instructions” on page 82.. Specification • The separator should be installed at floor level, see chapter ‘‘8.6.3 Foundations” on page 198.
  • Page 211 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. SKEL, S-147 80 Tumba, Sweden. Fax: +46 8 53031040.
  • Page 213 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 215: Index

    Index Erosion External cleaning Assembly Flexible plate in coupling Bowl body and operating mechanism Guide surfaces Bowl hood and disc stack Inlet pipe and oil paring disc General directions Level ring Horizontal driving device Lifting instructions Inlet/outlet, frame hood Lock ring - priming Operating water device Lock ring - wear and damage Tools (special)
  • Page 216 Repair of galling Daily checks Density of feed Disc Horizontal driving device Disc stack pressure Assembly Dismantling Dismantling Bowl body and operating mechanism Bowl hood and disc stack General directions Installation Horizontal driving device Interface Inlet/outlet, frame hood Definition Operating water device Description Tools Interface description...
  • Page 217 Major service Safety stop Materials Sensors and indicators Metal surfaces Separating function Cleaning and cleaning agents Sludge discharge cycle Corrosion Start Cracks Storage and transportation Erosion Technical data Motor Service instructions. See Check points Cleaning Service kits Coupling Shutdown Drawing Start Power consumption Stopping procedure...
  • Page 218 Warning signs Water Water quality specifications Weight Worm gear Function and description Number of teeth Wear of teeth...

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