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SA 836 Separation System

System Manual - English

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System Manual

English

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SA836

Separation

System

Only foreseeable conditions have been taken into consideration. No warnings are given for situations arising from unintended usage of the system components and tools.

Safety

System

Operating Instructions

Parameter List

Alarms and FauM Findifl^

Installation Syai tm Reference

Sarvice M a M H i Marine & Diesel Equipment

Printed Jan 2003

Book No. 1817285-02

Product No. 1010O3O<4>1, 1010031-01, 1010031-02

Spare Parts Catalogue 8

SA Separation System

Safety Printed Book No.

May 2002 1810737-02 V 1

Solutions beyond tßchnafagy

•3

Alfa Laval

SA SEPARATION SYSTEM SAFETY 1 SAFETY INSTRUCTIONS

# 1 Safety Instructions

Important - read this!

The centrifugal separator includes parts that rotate at very high speeds, generating huge forces. It is therefore essential for the safe operation of this separator system that you read and understand this manual, including the warning signs and safety precautions presented in this manual. Failure to do so may cause a fatal accident.

1.1 Key Factors for Safe Operation

The separation system is designed and supplied for a specific function (type of liquid, rotational speed, temperature, density, etc.). The system must be used for this function only, and strictly within Alfa Laval's specifications.

Incorrect operation or maintenance may result in a heavy unbalance, reduction of material strength, etc. that could lead to serious breakdown with fatal injury or damage to property.

For safe operation, strictly follow the instructions for installation, operation and maintenance in this manual.

• .

A DANGER

t A S K

1810737-02

1 SAFETY INSTRUCTIONS SA SEPARATION SYSTEM SAFETY

The following is compulsory for safe operation:

1 Never start up a separator before the bowl is completely assembled, and all fastenings securely tightened.

2 Never discharge a vibrating separator, Always stop with the emergency stop button.

3 Never begin to disassemble a separator before it has come to a complete standstill,

4 Always set the discharge intervals according to instructions in the instruction book.

5 Never ignore alarms. Always eliminate the cause before resuming operation.

6 Never use the separator for other liquids than those specified by Alfa Laval.

7 Never operate a separator with a different power supply frequency than stated on the machine plate.

8 Clean the operating system regularly to avoid sludge discharge malfunction.

9 Ensure that personnel are fully trained and competent in installation, operation, maintenance, and emergency procedures.

10 Use only Alfa Laval genuine spare parts and the special tools supplied.

1810737-02

SA SEPARATION SYSTEM SAFETY SAFETY INSTRUCTIONS

1.2 Warning Sign Definitions

Below are definitions of the warning signs used.

Danger - serious injury or death

This type of safety sign or instruction indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Example:

l ^ »ANGER

Entrapment hazard Make sure that rotating parts have come to a complete standstill before starting any dismantling worl<.

Warning - serious injury or death

This type of safety sign or instruction indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Example:

^ A R N I N G

Disintegration hazard If unusually strong vibration occurs, press the Emergency Stop button and leave the room. Do not enter the room after an emergency stop while the separator is still rotating.

Caution - minor or moderate injury

This type of safety sign or instruction indicates a situation which, if not avoided, could result in minor or moderate injury.

'CAUTION' used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result in equipment damage.

Example:

AcAOTlON

Bum hazard Various machine surfaces can be hot and cause burns.

1810737-02


1.3 Summary of Safety Hazards

Below follows a selection of the warnings which have been used in the text of this instruction manual to ensure safe installation, start-up, operation, stop, and maintenance. Further warnings are to be found in the appropriate places throughout the manual.

Start-up

Be especially observant during start-up. If there is any abnormal vibration, immediately stop the separator and investigate the cause. Clean the bowl if it contains sediment.

>VJIAR»*»**®

Breakdown hazard Assemble the separator completely before start. All couplings, covers, and guards must be in place and properly tightened. Failure to do so may lead to breakdown.

Continued on next page

1810737-02


j^fiSiHxno

Electrical hazard Follow local regulations for electrical installation and earthing (grounding).

Disintegration hazard if the system is operated from a position from which the separator is not visible, a vibration sensor must be fitted.

Breakdown hazard Check that the power frequency is in agreement with the machine plate. If incorrect, resulting overspeed may cause breakdown.

Breakdown hazard Use the separation system for the purpose, and within the limits, specified by Alfa Laval. Failure to do so could cause a violent breakdown.

Breakdown hazard Always observe the separator during start-up after assembly. If strong vibration occurs, stop by using the Emergency Stop button and evacuate the room.

50 Hz? 60 Hz?

If power cable polarity has been reversed, the separator will rotate in reverse, and vital rotating parts can loosen.

1810737-02


Operation

J^PXO*^^

Disintegration hazard If the system is operated from a position from which the separator is not visible, an unbalance sensor must be fitted.

^ A B t * " * * ^

Breakdown hazard If strong vibration occurs, press the emergency stop button and evacuate the room.

Never discharge a vibrating separator. Vibration may then become violent and result in breakdown.

^ « A ^ * ^

Noise hazard Use ear protection if noise levels are high.

^ÔlS«*»*'

Breakdown hazard Never reset an alarm without first finding and remedying the cause.

KpivUTlON

Bum hazard Avoid contact with hot surfaces. Process pipes, various machine surfaces, and processed liquid can be hot and cause burns.

^CAUTION

Slip hazard Check all connections for leakage. Oil leakage may make the floor slippery.

1810737-02

STl-1,/1 ÜAFETY 1 SAFETY INSTRUCTIONS

o t „ n *ho f.pof rstor by means of the control unit, and :iotor.

Never attempt to clean the bowl by manual discharge

V uLi'^

Disintegration hazard ^ J . i i , i^tiung vibration occurs, press the nergency Stop button and leave the room

'; -• i'f r the room after an emergency stop ufc i iiparator is still rotating.

, ffcs „^fiJIfi lG

«gc'rition hazard tjtrirt f ho c;øQarator after an emergency stop

ing the cause of the emergency. Mcttvki äiiie tnat tne bowl is clean before restart.

1810737-02


Maintenance

Entrapment hazard Make sure that rotating parts have come to a complete standstill before starting any dismantling work. The rotation indicator lamp, where applicable, must be off.

Disintegration hazards Always contact your Alfa Laval representative if you suspect that the depth of the corrosion damage exceeds 0.5 mm (0.2 mm for bowl body and bowl hood) or if cracks have been found. Do not continue to use the separator until it has been inspected and given clearance for operation by Alfa Laval.

Disintegration hazard Pits and spots forming a line may indicate cracks beneath the surface.

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

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

Disintegration hazard All forms of cracks are potentially dangerous as they reduce the strength and functional ability of components.

Always replace a part if cracks are present.

Disintegration hazard Erosion damage weakens parts by reducing the thickness of the material.

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

Replace parts If erosion is suspected of affecting strength or function.

Max. 0,2 mm

1810737-02


Ay""*"* ^

Entrapment hazard To avoid accidental start, switch off and lock power supply before starting any dismantling work.

Make sure that the separator has come to a complete standstill before starting any dismantling work.

Disintegration hazard Separator parts that are either missing, worn beyond their safe limits, or incorrectly assembled, may cause severe damage or fatal injury.

Disintegration hazard Do not weld nor heat parts that are subject to highspeed rotation.

Breaicdown hazard Assemble the separator completely before restart. All couplings, covers, and guards must be in place and properly tightened. Failure to do so may lead to breakdown.

1810737-02


10 1810737-02

SA Separation System

^ System Description Apr 2002

1810738-02 V 1

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Salutians beyond technology Alfa Laval

Contents

1 System Overview 1 1.1 Oil Flow 1 1.2 System Layout 2 1.3 System Components 4

2 The Process 5 2.1 Principle 5 2.2 Process Cycle Start 6 2.3 Discharge 8 2.4 Increased Water Content 9

1810738-02

1810738-02

SA SEPARATION SYSTEM SYSTEM DESCRIPTION 1 SYSTEM OVERVIEW

1 System Overview

The SA Separation System is designed for cleaning of fuel and lube oils for diesel engines, and fuel oil for gas turbine engines, in marine and power applications.

Heated oil is fed through the separator to clean the oil from solid particles and water.

The basic separation unit comprises:

• A separator.

• Ancillary equipment including control unit.

• Optional equipment such as, butterfly valve, vibration sensor, etc.

Cleaned oil leaves the separator through the oil outlet while separated water and sludge accumulate at the periphery of the rotating separator bowl.

The control unit supervises the entire operation of the separation system, performing monitoring, control, and alarm functions.

The process adapts automatically to certain changes in conditions, such as increased water content in the vuiprocessed oil, high or low oil feed temperature, etc.

1.1 Oil Flow

The unprocessed oil is fed through a heater by a feed pump, operating at a constant flow.

A change-over valve directs the oil to the separator. The cleaned oil is pumped from the separator to either the daily service tank (fuel oil), or back to the engine (lube oil).

During separator start and stop procedures, during alarm conditions, or if the oil temperature is outside the preset range, the oil is directed by the change-over valve to a return line back to the engine sump or settling tank.

Settling tank Change-over valve

Backpressure regulating valve

Pump Heater Separator Daily service tank

1810738-02

1 SYSTEM OVERVIEW SA SEPARATION SYSTEM SYSTEM DESCRIPTION

1.2 System Layout

Heater

Heats unprocessed oil to separation temperature.

Temperature transmitter (TT1, TT2)

Measures the oil temperature and signals the control unit.

Pressure transmitter, oil(PT1)

Measures the pressure in the oil inlet, and signals the control unit.

Pneumatically controlled Separator change-over valve (V1) _, L, ,,

' Cleans the oil by Directs the unprocessed oil to removing water the separator, or back to the and solid settling tank (recirculation - particles, fuel oil only).

Feed pump

Feeds unprocessed oil to the separator,

Unprocessed oil inlet

Oil return

Additional equipment not part of the SA System

Solenoid valve block, water

Distributes separator opening/ closing water, and conditioning water.

Sludge outlet

1810738-02

SA SEPARATION SYSTEM SYSTEM DESCRIPTION 1 SYSTEM OVERVIEW

Control unit

Supervises the separation system.

Pressure transmitter, oil (PT4)

Measures the pressure in the oil outlet, and signals the control unit.

Water transducer (MT50)

Measures change in water content in the cleaned oil, and signals the control unit.

Regulating valve (RV4)

To manually regulate the backpressure in the clean oil outlet.

Pneumatically controlled shut-off valve (V4)

Closes the clean oil outlet.

Clean oil outlet to service tank

Pressure transmitter, water (PT5)

Measures the pressure in the water drain outlet, and signals the control unit.

Drain valve (V5)

Opens to drain separated water from the separator.

1810738-02

1 SYSTEM OVERVIEW SA SEPARATION SYSTEM SYSTEM DESCRIPTION

1.3 System Components

Pressure transmitter, oil inlet (PT1)

Control unit EPC50

Combined regulating valve (RV4) and shut-off valve (V4)

Temperature transmitter (TT1TT2) Water transducer

(MT50)

Pressure transmitter, oil outlet {PT4)

Pressure transmitter, water (PT5)

Drain valve (V5)

1810738-02

SA SEPARATION SYSTEM SYSTEM DESCRIPTION 2 THE PROCESS

2 The Process

2.1 Principle

During the separation process, sludge and water accumulate at the periphery of the separator bowl.

Sludge and water

Sludge and water are discharged at preset time intervals. During discharge, the oil inlet is closed.

Excessive water can also be drained from the separator bowl between discharges.

The cleaned oil leaving the separator is tested for traces of water. Any increase in water is detected by the water transducer. Disc stack

Water Vt. ^

1 /~V_ I C T " Water R \ \ ^ transducer

m y

The signal from the water transducer is continuously transmitted to the control unit, in which a reference value is stored. The control unit compares the transducer signal with the reference value. A significant deviation from the reference value will cause draining of water.

EPC-50

• • • : • • - .

1810738-02

2 THE PROCESS SA SEPARATION SYSTEM SYSTEM DESCRIPTION

2.2 Process Cycle Start

First the oil pump, separator, and heater are started.

The temperature transmitter (TT) and the speed transmitter (ST) signal the EPC-50 control unit continuously. When the correct separator speed and the correct temperature are reached, a sludge discharge is carried out to ensure the bowl is empty. The control unit then starts the process cycle.

The change-over valve directs the oil to the recirculation line. Conditioning water is added to the separator bowl until the pressure sensor in the oil outlet senses pressure and signals the control unit.

The control unit registers the time taken for water addition. This water flow reference value is later used to calculate the correct amount of conditioning water and displacement water to be added.

EPC-50

>..

3 The separator discharges. EPC-50

S

f

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Using the flow rate calculated in paragraph 2 above, the control unit signals the solenoid valve to open so that the correct amount of conditioning water is added to the separator bowl.

EPC-50

— ^\j ty}»——^ ,'•"

«IXjBa*»^

The change-over valve opens so that oil is directed to the separator bowl. When pressure in the oil outlet is sensed, the pressure sensor (PT) signals the control unit. The control unit calculates and stores the time taken to add oil to the bowl.

EPC-50

- ^ •"^ttHMcstiar-^ fXf? -OO*'^

Cxj™

The cleaning process is now running. Unprocessed oil is fed to the separator, and clean oil is pumped from the separator.

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2.3 Discharge

The separator discharges after a preset time has elapsed. The following sequence takes place:

1 The change-over valve changes to oil recirculation,

Using the flow rate calculated in paragraph 2 under 2.2 Process Cycle Start, page 6, the control unit signals the solenoid valve to open so that displacement water is added to push the oil towards the disc stack.

EPC-50

^ ^ ^ ^

^ X J Q M O I M B S ,

3 After the calculated time for displacement water addition has elapsed, the separator discharges.

4 Conditioning water is then added, and a new separation cycle begins.

1810738-02


2.4 Increased Water Content

If the water transducer senses increased water content in the oil, the following takes place:

1 The water drain valve (V5) opens for a number of seconds.

2 The water drain valve closes again, and the transducer signal is evaluated,

3 If there is still an increase in water content, the drain valve opens again. If the water content is still high after the drain valve has opened five times, a discharge is initiated.

4 If the water content has decreased, the separation cycle returns to normal.

1810738-02


10 1810738-02

5>l Separation System

Operating Instructions Apr 2002

1810739-02 V 1

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Solutions beyond technology Alfa Laval

Contents

Operating 2 1.1 Before Startup 2 1.2 Operators Panel 5 1.3 Startup 7 1.4 Manual Startup 8 1.5 During operation 12 1.6 Stop 15 1.7 Emergency Stop 16 1.8 After Emergency Stop 17 1.9 Cleaning In Place 19 1.10 Automatic Operation 20 1.11 Remote Operation 22 1.12 Emergency Operation 23 1.12,1 Manual Operation of the Separation

System 23

1810739-02

1 OPERATING SA SEPARATION SYSTEM OPERATING INSTRUCTIONS

1 Operating

1.1 Before Startup

1 Check that the separator is correctly assembled and connected to power supply of correct voltage and frequency. The EPC 50 Control Unit must be ON.

AÂRl*»»«^

Breakdown hazard Assemble the separator completely before start. All couplings, covers, and guards must be in place and properly tightened. Failure to do so may lead to breakdown.

^ A R M I N G

Electrical hazard Follow local regulations for electrical installation and earthing (grounding).

AANAB»*^®

Breakdown hazard Check that the power frequency is in agreement with the machine plate. If incorrect, resulting overspeed may cause breakdown.

50 Hz? 60 Hz?

^ A R » » » » * * ^

Use the separation system for the purpose, and within the limits, specified by Alfa Laval. Failure to do so could cause a violent breakdown.

1810739-02

SA SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

2 Check the oil sump level, If necessary, top up until oil starts to run from the oil-filling hole.

NOTE

Too much or too little oil can damage the separator bearings.

Rotat ion Direct ion

To check the rotation of the bowl, do a quick start/stop. The motor fan must rotate in a clockwise direction.

A' ;AÜtlOt*

If power cable polarity has been reversed, the separator will rotate in reverse, and vital rotating parts can loosen.

NOTE

To make this check, the Mode Selector Switch should be In the CIP position.

1810739-02


Air Valve Block

Use the pressure gauge situated in the air valve block to check that the air supply is correct (500 - 700 kPa or 5 - 7 Bar).

For further information concerning air, see chapter 7 Technical Data in the Installation System Reference booklet.

Operating Water Pressure

Check that the operating water pressure is sufficient (200 - 600 kPa or 2 - 6 Bar).

For further information concerning water, see chapter 7 Technical Data in the Installation System Reference booklet.

1810739-02


1.2 Operators Panel

The operators panel (local) is positioned on the control unit.

A duplicate operators panel (remote) may be connected for fully functional operation from a remote location e.g. control room.

By using the REMIND ™ software (see the REMIND™ User's Manual) it is possible to operate the control cabinet from a remote position with the aid of a PC.

For ftu-ther information concerning communication alternatives using REMIND '^^ and the Remote Operators Panel, see the Remote Operation Systems the Installation System Reference booklet.

1810739-02


General principle for changing control parameters

The 'Enter' button is used to;

- enter into a parameter list

- enter into a parameter

- accept/store a new parameter value.

The '+' or the ' - ' buttons are used to change the value flashing in the display window.

Process parameters

Set the process parameters to suit the installation as follows:

1 Push 'Enter'. Parameter no. 1 in the process parameter list is shown. You have now come to the process parameter list. Go through the list and set parameters.

2 When the parameters have been set, 'End I/O' (flashing) shows. Push '+', 'Standst.' now shows in the display.

For information on how to set discharge intervals, see chapter 3 Process Parameters in the Parameter list booklet.

NOTE

Make sure that the operators panel is 'active' (LED green) before operating.

1810739-02


1.3 Startup

The control panel mode switch has three positions: 'MANUAL', 'AUTO', and 'CIF.

The 'MANUAL' mode is for use on all Separation Systems.

AUT

The 'AUTO' mode is for use on systems supplied for fully automatic control and/or fully automatic remote control. The following general rules apply for use of the 'AUTO' mode:

e The EPC 50 must have control of the oil feed pump,

• The EPC 50 must have control of the heater.

• The EPC 50 must have control of vibration monitoring.

• The cover interlock must be fitted.

The 'CIP' mode is for use with Cleaning in Place equipment. See "Cleaning In Place" on page 19.

1810739-02


1.4 Manual Startup

The first startup must always be carried out manually.

Before startup make sure that all the main supply valves for air, oil, and water are open. Open heating media supply valve if applicable. Switch on the power supplies. Make sure the mode selection switch is in the 'MANUAL' position.

1 Start the oil feed pump from the pump starter. The oil flow/ can be read on the display (parameter In 32). If applicable, set the desired flow using regulating valve RV4.

2 If necessary, vent air from the heater through the relief valve (if applicable). Switch on the heater from the operator panel (if applicable).

MOTE

The operators panel must be' active' to allow operation.

3 Press the 'SEPARATION' button to activate the EPC-50.

1810739-02


Before the separator can be started, a number of questions scroll across the display which have to be answered:

'Has the bowl been dismantled? + = YES, - = NO'

4 If the bowl has been dismantled press the '+' button.

If no work has been carried out on the bowl, press the '-' button, The start sequence begins and the text 'Start' appears in the display.

NOTE

If this is the first start, answer 'YES'.

'Assembled according to manual? + = YES, - = NO'

5 If the bowl has been dismantled and assembled according to the instructions in the Service Manual, press the '+' button.

r + ] ^^H

:^^^^^

'Bowl cleaned? + = YES, - = NO'

6 If the bowl has been cleaned press the '+' button.

An automatic calibration of the system is carried out. See display.

1810739-02


8 Listen and observe.

Vibration may occur during start up, when passing critical speeds,This is normal and should pass without danger.

If vibration increases, or continues at full speed, press the emergency stop button and stand clear until the vibration stops. The separator, feed pump, and heater are stopped when the emergency stop button is pushed.

The emergency stop will only reset when the speed sensor indicates zero speed.

Once the zero speed signal has been received, the alarm reset button can be pushed. The message ' Switch power on/off.' will be displayed. This refers to the EPC 50 power indside the control cabinet.

The cause of vibration must be determined and corrected before starting again!

See the Alarms and Fault Finding booklet.

AÂ^*»»*^

Breakdown hazard Always observe the separator during start-up after assembly. If strong vibration occurs, stop by using the Emergency Stop button and evacuate the room.

i*olL If the system is equipped with a vibration sensor, and has control of heater and feed pump, the Auto Start can be used.

10 1810739-02


9 The separator speed, and 'Start.' are shown alternately in the display until the separator is at full speed. When the separator is at full speed, 'Standby' is shown on the display.

1 0 Check the oil feed temperature by pressing the '+' button until 'TT1' is shown on the display,

1 1 Wait until the oil feed temperature is correct:

Heavy fuel mode 98 "C

Lube oil mode 95 °C (trunk engines), or 90 °C (cross-head engines)

Diesel oil mode 40 °C

1 2 When the separator has reached the correct speed, and the oil is at the correct temperature, press the process start/stop button on the operator panel to start the separation process.

1 3 Adjust the backpressure to the normal running value. Normal running backpressure is determined at commissioning. See the Installation System Reference booklet.

1810739-02 11


1.5 During operation

Operator panel information

Observe the operator panel information:

• Heater operation LED lit (green)

• Separator system operation LED lit (green)

• Activated valve LED lit (green)

During normal operation, the ALCAP trigger signal is shown on the left of the display, and the time to next sludge discharge is shown on the right.

Any alarm is indicated on the display. For further information see the Alarms and Fault Finding booklet.

NOTE,

Regularly check connections. Tighten if necessary.

12 1810739-02


NOTE

The values displayed in the examples below are not recommendations.

More operational information may be read as required, by pressing the '+' button repeatedly.

To return to normal display, i.e. the trigger value, and time to next sludge discharge, continue pressing the '+' button.

i i s ° M

*

B HEATGR

j J SEPARATION

i 5 STOP

DISCHARGE '

OP ACTIVE

o

Oil feed temperature. For the correct separation temperature see the Installation System Reference bool<let,

TT1 98 °C

Oil pressure, oil inlet

PT1

Oil pressure, oil outlet

PT4

Pressure, water outlet

PT5

• Water transducer value

Speed

Rpm 10300

Accumulated operating time in hours

Run time 5 hours

1810739-02 13


h^pso»^^

Noise hazard Use ear protection if noise levels are high.

^ M U A R N I N G


A' AÜTION

Bum hazard Avoid contact with hot surfaces. Process pipes, various machine surfaces, and processed liquid can be hot and cause burns.

Slip hazard Check all connections for leakage. Oil leakage may make the floor slippery.

14 1810739-02


1.6 Stop

To stop t h e system:

1 Stop the system by pushing the 'SEPARATION' button on the operators panel.

The yellow LED for separator stop sequence starts to flash.

A sludge discharge is initiated.

The stop sequence LED changes to steady yellow, and the green LED for separation system operation goes out, when the sludge discharge is completed,

'Stop' is displayed,

If the heater is controlled by the EPC 50, it is switched off automatically.

When the oil feed temperature has started to drop, the oil feed pump is switched off automatically.

The separator comes to a complete standstill after about 20 minutes. 'Standst.' is then displayed.

Breakdown hazard Stop the separator by means of the control unit, and not by turning off the motor.

AcAirno*^

Never attempt to clean the bowl by manual discharge in connection with stop.

1810739-02 15


If the system is switched off for reasons other than high vibration, it is not necessary to wait for the separator to slow down before restarting the process.

^ W A R » * » ^ ' '

Breakdown hazard The system must not be restarted with the separator rotating if high vibration alarm has been given.

1.7 Emergency Stop

If an emergency situation occurs, press the emergency stop button and evacuate the room. Do not return until the separator has come to a complete standstill.

^ A R N I N G

Disintegration hazard If unusually strong vibration occurs, press the Emergency Stop button and leave the room

Do not enter the room after an emergency stop while the separator is still rotating.

NOTE

In order to be able to restart, the system must be at standstill, and then the ERC power switched off - on.

16 1810739-02


1.8 After Emergency Stop

Separator standstill

Dismantling work must not be started before all rotating parts have come to a complete standstill.

ÔAW®^*^

Entrapment hazard Make sure that rotating parts have come to a complete standstill before starting any dismantling work. The rotation indicator lamp, where applicable, must be off.

Avoid accidental start

^P^^^^^

Entrapment hazard To avoid accidental start, switch off and lock power supply before starting any dismantling work.

Make sure that separator has come to a complete standstill before starting any dismantling work

1810739-02 17


R e m e d y the c a u s e

The cause of the emergency must be remedied before attempting to restart the separator.

If the cause is not found, an overhaul must be performed on the separator, and all moving parts thoroughly checked

AÂRt*»»*®

Disintegration hazard Do not start the separator after an emergency stop without first remedying the cause of the emergency.

lUlaice sure that the bowl is clean before restart.

Separator reassembled

The separator must be fully reassembled with all covers and guards in place and tightened before unlocking the power supply and starting the system.

^PXOf^

Breakdown hazard Assemble the separator completely before restart. All couplings, covers, and guards must be in place and properly tightened. Failure to do so may lead to breakdown.

18 1810739-02


H 1.9 Cleaning In Place

The use of Cleaning In Place (CIP) equipment is recommended for best separation results. For further information on the CIP equipment, see the CIP booklet, bookno. 1817261.

Before connecting the CIP equipment to the Separation Unit, the switch on the control cabinet must be turned to the CIP position. This is to avoid accidental pumping of oil when the pipeline is opened up.

For instructions on how to connect the CIP equipment to the Separation Unit, see the Service Manual booklet.

For recommended CIP intervals see chapter 1 m^ Technical Data in the Installation System

Reference booklet.

1810739-02 19


1.10 Automatic Operation

For automatic operation, the system must be equipped for automatic start. Make sure the mode selection switch is in the 'AUTO' position and Pr3 has the correct setting.

NOTE

If local control is needed (for example in an emergency situation), turn the switch to manual mode. This will automatically override the Pr3 setting.

NOTE

The first startup must always be carried out manually. The system can thereafter be run automatically as long as no changes are made to it between runs.

Before the separator can be started, a number of questions scroll across the display which have to be answered:

'Has the bowl been dismantled? + = YES, - = NO'

2 If the bowl has been dismantled press the '+' button.

If no work has been carried out on the bowl, press the '-' button. The start sequence begins and the text 'Start' appears in the display.

20 1810739-02


'Assembled according to manual? + = YES, - = NO'

3 If the bowl has been dismantled and assembled according to the instructions in the Service Manual, press the '+' button.

'Bowl cleaned? + = YES, - = NO'

4 If the bowl has been cleaned press the'+' button.

An automatic calibration of the system is carried out. See display.

f

^

+

^ ^ ^ F ^

To stop the process, press the 'SEPARATION' button (see 1.6 Stop, page 15.)

If the system is to be restarted, the system valves can remain in operating positions.

1810739-02 21


1.11 Remote Operation

Remind/Remote Operation

NOTE

After maintenance, the system must be started locally. If in Remote, and '+' Is pushed in answer to the question 'Has the bowl been dismantled?', the system reverts to local control.

Follow the instructions in chapter 1.10 Automatic Operation, page 20.

22 1810739-02


1.12 Emergency Operation

In the event of a water transducer failure, the system can still be operated by setting parameter Pr 4 in the EPC to standby mode (see the Parameter List booklet). The transducer is then disabled and the time to discharge automatically changes to 15 minutes. 'Nc' (not connected) is shown on the display. All Alcap functions are disabled. Water is removed only during a discharge. A reminder alarm is activated after 24 hours.

If the system oil contains plenty of water, and the oil density is less than 991 kg/m^, emergency operation as described below is possible.

1.12.1 Manual Operation of the Separation System

In the event of extemely high water content, the system can be run manually by a competent engineer using the following instructions:

1 Ensure all oil system manual valves are in the correct position.

2 Set the selection switch on the control unit to the MANUAL position.

3 Fit a jumper between terminals X9: l , and X9:2 in the EPC.

4 Start the feed pump.

5 Start the separator.

6 Heat the oil to the correct separating temperature. Where there is a Heatpac® EHM electric heater, usejumpers in the power unit to bridge terminals XI2.11 -X12.6, X12.11 -X12.9, andX12.11 - XI 2.7. Switch on the heater and use the switch to regulate the temperature.

NOTE

Remove the jumpers after emergency operation.

1810739-02 23

http://X12.11


7 When the separator is up to speed and the correct oil flow and temperature are achieved, close the bowl. Open SVl 5 for 5 seconds, Wait 15 seconds. Open SVl 6 fori 5 seconds. The bowl is now closed.

8 Temperature, flow, and backpressure must remain constant throughout.

9 Screw C (see illustration on the right), should be in the outermost position (12 on the scale). Screw C is fixed by stop B.

1 0 Remove the water outlet pipe at D.

24 1810739-02


1 1 Screw in screw A to move the paring tube to its innermost position,

1 2 Open SV10 as follows:

•^Sjms'^M'&m SA835

|s|B|iii:3i||i SA855

';||il|ilil?|i| SA875

'siieigiliill

Time (sees.)

iÄllii 40

WSeål 30

lliiii 40

Biili

Amount bowl filled (litre)

l&ååSSmåM 1,1

msåmmB 3.0

•mmmmiå 7.0

illllilllliiii

1 3 Open SVI to open oil feed V I ,

1 4 Open SV5. This will open the water outlet valve V5.

1 5 Carefully screw out screw A until water starts to come from D or E.

1 6 Lock screw A in position.

h^psom^

Breakdown hazard During operation open SV16 for about 5 seconds every 15 minutes to ensure that the bowl remains closed.

1810739-02 25


Discharge

1 Close oil feed VI using SV1.

2 Close water outlet V5 using SV5.

3 Open SV10 to add displacement water as follows:

SA826

SA835

SA845

SA855

SA865

SA875

SA885

Time (sees.)

60

49

79

44

59

47

84

Amount b o w l f i l led (litre)

0.9-

1.3

2.1

4.0

5.4

8.4

15.0

4 Open SV15 until a discharge is heard (within 5 seconds).

5 Wait 15 seconds.

6 Open SV16 for 15 seconds.

26 1810739-02


7 Open SVI O as follows:

SA825

SA835

SA845

SA855

SA865 ,

SA875

SA885

Time (sees.)

40

40

70

30

50

40

45

Amount bowl filled (litre)

0.7

1,1

1.9

3.0

4.5

7.0

11.0

8 Open V I .

9 OpenV5.

1 0 Maintain backpressure at normal setting

throughout.

^yiAR«*»«**^

Breakdown hazard Discharging of the bowl, and supervision of the operation, is now completely manual and under the direct responsibility of the engineer who has placed the separation system in the manual control mode.

1810739-02 27


28 1810739-02

S-type Separation System

Parameter List ir^vy^L

Printed

Book No.

Jun 2004

1810572-02 V 10

Contents

1 Parameter Setting 2

2 Installation Parameters 5

3 Process Parameters 8

4 Factory Set Parameters 11

5 Sequence Diagram 24 5.1 Separation Sequence 26

1810572-02

1 PARAMETER SETTING S-TYPE SEPARATION SYSTEM PARAMETER LIST

1 Parameter Setting

The parameters are set in the operator panel for the different separator systems, and for different conditions within the systems.

There are three parameter types: Installation, Process, and Factory Set parameters.

The parameters are initially set at installation. The process parameters can also be set as required during operation.

Parameters not in use are not displayed.

The parameter list in this booklet is valid for Separation Units (SU) and SA systems.

General principle

The 'ENTER' button is used to:

- enter into a parameter list

- enter into a parameter

- accept/store a new parameter value.

The '+' or t h e ' - ' buttons are used to change the value flashing in the display window.

1810572-02

S-TYPE SEPARATION SYSTEM PARAMETER LIST 1 PARAMETER SETTING

To change parameters, proceed as follows:

1 Push the 'ENTER' button.

'Time to discharge P1 60' is shown. 'P1 is the parameter, and '60' is the set value.

The'1 'of the'P1' is flashing.

2 Push the'+' button until the number of the parameter you wish to program appears in the display window.

The chosen parameter number is now flashing.

3 Push the 'ENTER' button.

The chosen parameter number is now shown on the left side in the display The parameter value is shown flashing on the right side of the display.

4 Push the '+' or'-' button to change the parameter value.

5 Push the 'ENTER' button. The new value is stored.

The parameter number is now flashing.

6 Push the'+' or'-' button to go to the next parameter to be changed.

7 To leave the list, push the '+' and the '-' buttons at the same time. The display shows 'Standst.' or, when in operation, the trigger value to the left, and time remaining to discharge on the right.

Schematic diagram with position LEDP

LED for heater (green)

Heater on/off push-button

LED for control program running (green)

Control program on/off push-button

LED for stop sequence running (yellow)

Sludge discharge pushbutton

Display window - pushbutton

+ pushbutton

Enter Alarm reset LED for common LED showing pyg|-i. main alarm (red) this panel button active

1810572-02

1 PARAMETER SETTING S-TYPE SEPARATION SYSTEM PARAMETER LIST

Tlie following lists are available for viewing from a menu in tiie EPC-50 control unit:

• Install (parameters)

• Factory (parameters)

• Alarms

• Test

For detailed information see each list.

To open the menu and select a list, proceed as follows:

1 Push the 'ENTER' button. The process parameter list is now open.

2 Push the'+' button until 'End' is displayed.

3 Push the 'ENTER' button and the '+' button at the same time. 'Install' will show flashing on the display. -

4 Use the '+' button to select a list.

5 Use the 'Enter' button to enter into the selected list.

6 To leave the list, push the '+' and the '-' buttons at the same time.

7 To leave the menu, press the '+' button repeatedly until 'Exit' is displayed. Push the 'ENTER'button.

1810572-02

rVr'E SEPARATION SYSTEM PARAMETER LIST 2 INSTALLATION PARAMETERS

2 instal lat ion Parameters

' ''a+ ion parameters must be set before i urt iip and before process

• ' ' -• i- '< "^heso parameters rarely . . '' ! " f'W parameter

LU o^ ütoi OU, IL Ib iiecessary to go through ile whoie list, and confirm at the end.

»ÔfE

Aita Laval caniiot be held responsible for injuries and damage caused by usage of parameter values vhioh are not in proximity to the factory values set oy Alfa Laval.

^^•'Bmef&F Factory set value

Plant set value

Range

en [i F f] h

|p G-f nan

f'b - far ^fiiS"''

fr = French

Description

Lrin }in \\ ml t I r I ( VL I I n tht j[ )i t p n 11 «.»I'lAn <ii 1 IL sLm::lL i idn ]urj i

' l , • •

in i

. ' - -'^

In 5

,. , - ' .

^ , .

Alcap

8304«: ; ^ -î J~

1

It ^ Italian

pt = Portuguese

fi = Finnish

se - Swedish

A! dp

811 816

?0C 820 821

300 eJO ?l^

IOC 840 841

snr flTi 81 1

uOO «360 661

700 f'70 871

"00 R°C 8*11

1 - 9

B?5 826

8J5 836

845 fa4b

o5'j Ö56

865 b(}U

47'i '?7i»

IS'-, nur,

If more than one EPC on same Sattbus

Ser dial r t , _

Sopardto' si^ö

Paranielofb t.p..ndin i n separator •size aie bat aut jnat i . . illv aciorJirg t n i t e «Liiupin 1

Separator identity

If more than one separator system is connected to the internal Sattbus communication, each system must be given its own identity (1 or 2 or 3 etc.).

1810572-02

2 INSTALLATION PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST

Parameter

in 6

In 7

In 8

In 9

In 15

In 16

In 17

In 18

In 19

In 20

Factory set value

Yes

No

No

Yes

No

No

°C

No

16

120

Plant set value

Range

No

Yes

No

Yes

No

Yes

No

Yes

No

Ye-

No

Yes

°C

No (no heater)

El. (electrical heater)

Steam (steam heater)

7 d 14 16 U e.', jc 10 50 56 m 72 84 QG 98 100 110 1-2 IPC ICc" 131 44 kw

0 - 999 seconds

Description

Speed sensor

Vibration sensor

OP remote

Water transducer

"^ludqppumi. uspd

I/O expansion board used

Celsius or Fahrenheit

Heater type

El he-iler size

Activated when El is selected in In 18

Steam-valve run time

Activated when Steam is selected in In 18

1810572-02

S-TYPE SEPARATION SYSTEM PARAMETER LIST 2 INSTALLATION PARAMETERS

P a r a m e t e r

in 22

In 23

In 24

In 25

In 26

In 27

In 28

In 29

in 30

In 31

Factory set va lue

Plant se t va lue

J5 15

No

Yes

No

0

0

0

0

No

Range

0 - 30 seconds

0 - 240 seconds

Nr

Ves

No

Yes

No

ExtPC = Fieldbus

l-Net = Internet

0-255

0-255

0-255

0-255

No

Yes

Description

.•Afarm delay time

Change-over valve VI temp, alarm delay

Prevents false alarm due to any fluctuations in temperature caused by valve actions.

Chdngp over valve V1 dctr >T\ at ex*rd dlcirm

When the extra alarm ir put is Lsed action at alarm can be none (Nc^ c' feed off (ye<\

Power fall alarm used

If this alarm is not required, set the parameter to 'No*.

Type of computer communication board used

Internet IP address, part 1




Feed pump controlled

Feed pump has to be connected by EPC when running In auto mode.

In 32 r h m h

Ui^Gh

Fi|->* latti in m^h per hcur o US gallons per hour

T'-e feed flow measurement Lds^d on inlet pressure cdn be displaye I in one nf the«!" ways

1810572-02

3 PROCESS PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST

3 Process Parameters

The process parameters can be adjusted easily and as often as required, even during operation, to meet changes in the operating conditions, e.g. time between sludge discharges, oil temperature, alarm points.

note

Regularly check the condition of the bowl. If there is no noticeable amount of hard sludge in the sludge space, the discharge interval may be increased by 30 minutes at a time. The total discharge interval must not exceed three times the factory set value in order to avoid an uneven build-up of sludge.

Parameter Factory set va lue

Plant set va lue

Range Descript ion

P r i

Pr2

Pr3

Pr5

120

HF380

OPIoc

•ii^m-

1 - 999 minutes

MDO = Marine Diesel Oil GO = Gas Oil IFxxx = Intermediate Fuel Oil HFxxx = Heavy Fuel Oil LO TP = Lubricating Oil for Trunk Piston Engines LO OH = Lubricating Oil for Cross Head Engines

OPIoc = Local OP in control

X)Pn8m-=. Remote OP c5s;- .

• ' ' • ' • . " • . •

, , . ' - - . . • . . • • .

##E' Pr4

.:-^tf - ; .• : " * - V

'..•..'••• '•::••'.

• .-i' : . .J

On

00

ExtPß''=-,ExtBrnCoraputer ß ö l r ä ^ " ' ^ " ••-:'•'::•' >'•'¥ •'•••'

F|en[iS.vv,=. Reracfte switches

On

Stb.

0 0 - Not used

0 1 to 10 0x1000 hours

Time to discharge

Oil type

(xxx represents viscosity in Ost at 50 °C)

Control iocation'>^.

Ateap On/Standby

MT-50 function disabled when in standby (Stb.). Discharge every 15 minutes (overrides Pr1). No displacement water added.

Countnojvn servirp timer

Action lb to be taken when thr timer reaches 0

1810572-02

s Tvpi: SEPARATION SYSTEM PARAMETER LIST 3 PROCESS PARAMETERS

aâmete r i Factory se t value

!'6 0

f ,

' - • , " > ' . : - - -

- '\

Plant set value

Range

0 = service time elapsed

1 - 9 = Servicetext 1...9

Infnrriirition

1 - l i i i trs t ic f tn

? = '^crvri' mode

0.0 - 6.0 bar 0.0 = oil pressure sensor disabled

Descript ion

Type of service

When service timer Pr5 reaches 0, an alarm is given and a message shown

Keystospcridl fuHLtntiou- J hy servLw«' üpg le^r

When Pr7 is set to 1 durinq normal opunaticn the actudi timer is displayed rf the + button i<; pressed once

High oil pressure limit

(cleaned oil outlet)

cr : '

Pr13

P n 4

1.0

5.5

0.2

3.0

••r 1 6 0.2

p.-If. 105°C

85 °C

0.0-6.0 bar

0.0-6.0 bar 0.0 = water pressure sensor disabled

0.0-6.0 bar

0.0 - 6.0 bar 0.0 = feed pressure sensor disabled

I) 0 - e 0 bdr

0-115°Cor

0 - 255 °F

0 = Temp sensor disabled

0 - f . Cwi

0 iL— >-

Low oil pressure limit

High water pressure limit

(water outlet)

Low water pressure limit

High feed pressure limit

LOA f«- -1 lotJ I limit

Low pv^suie iridiCrit b •n''.flirienl fiow Th» I JW preisurt limit rnu'jt be mghef 'han ciny static pre s .ure- CUKI lower than normal prpssurc

HFO/LO high temp, limit

HFO LO Ijvi temp limit

1810572-02

3 PROCESS PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST

Parameter Factory set value

Plant set value

Range Description

Pr18

Pr19

Pr20

Pr21

95 °C

4Ü'C

20 °C

10 C

0-110°Cor

0-240°F

0 = Temp sensor disabled

0-115=Cor

0-255°F

0-115°Cor

0-255°F

Ü - 1 - . C j r

0-240 =

HFO/LO setpolnt^)

Setpoint for feed temperature is valid only when a temperature controller is installed in the ERC.

DO high temp limit

DO low temp, limit

DO sptpoint

Setpoint for feed tsmpprature is valid only when a temperature controlle' is instdlled in the EPC

Pr22

Pr23

Pr24

Pr25

Pr40

Pr41

40

1.2

0

2

60

15

10-500%

0.1 -10 0 minutes

0 - 9

0 = disabled or heater controlled from EPC x

0-240 seconds r

0-100 discharges

0 - 1 0 0 %

P-constant ^

Preset value based on experience with Alfa Laval Heatpac heaters. i

l-constant''

Preset value based on experience with Alfa Laval Heatpac heaters

Heater control location

To be set when more than one EPC temperature controller can be used for one heater.

Sludge tank alarm delay (during Ti 68)

Test of sludge in bowl

Max decrease of displacement water

) Parameter appears only when heater board installed.

10 1810572-02

S-TYPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS

# 4 Factory Set Parameters

Parameter

Fa 3

Fa 6

Fa 10

1

i 1

F a l l

Fa 12

Fa 16

Fa 17

Fa 18

Fa 20

•;:

Fa 21

Fa 22

Fa 23

Factory set va lue

See table on page 22

0.2

Plant se t value


1

Range

0 1 - 99 99 litre

0.0 - 9.9 bar

0 -14000rpm

0 = sensor disabled

1 Is set depending on separator size


300

0-14000 rpm

Is set depending on separator size

0 - 2000 rpm

See table on , 0 0 - 2.5 mm page 22


0.5

3 0 if Pr 2 = fuel Oil

0 6 if Pr 2 = lube oil

100

100

120 if Pr 2 = fuel oil

90 if Pr 2 = lube oil

0.0 = sensor disabled

0 0 - 2.5 mm

0.0-2.5 mm

0 01- IOOpF

0 - 250 %

0 - 250 %

0 - 999.9 pF

0 = water transducer disabled

Description

Conditioning water volume to be fed j after discharge

PT4 pressure increase or decrease. (Test during Tl 59, Ti 64, Ti 70, Ti 71, Ti 82) Signal that the bowl is filled.

High speed

Low speed

Speed decrease during discharge

Shutdown limit for separator spindle amplitude

Vibration alarm prewarning

Vibration sensor adjustment zero point. Zero point should be within 1.5 mm ± Fa 18

Alcap trigger factor

This IS the amplification factor for the transducer signal so that the proper tngger range is achieved

Trigger limit HFO

Trigger limit LO/DO

Alarm limit for high water transducer value.

1810572-02 11

4 FACTORY SET PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST

Parameter

Fa 24

Fa 25

Fa 26

Fa 27

Fa 28

Fa 29

Fa 30

Fa 31

Factory set va lue

70

25

5

70

5

5

250

2

P lant set v a l u e

Range

0 - 999 9 pF

0 - 250 secondfa

0 - 3 0 seconds

0 - 1 0 0 %

0 .0

0 -100

0 = disabled

0 - 9 0 0 %

0 - 4

0 = No reduction

1 = Reduction after every trigg

2 = Reduction after 2 consecutive trlggs

3 = Reduction after 2 trlggs within 3 discharges

4 = Reduction after 2 triggs within 4 discharges

Description

Alarm limit for tow water transducer value

Pulse time for open dram valve

Dram pause lime With the valve closed, the system waits for the result of the drainmg

The limit below which the trigger value must be to interrupt draining.

Limit for number of HFO drdininqs 1' the trigger alup has not tdllen benw the vaiue of fa 27 after F j AH an dinrm i<> given

Test of water transducer trigger signal every x discharge. (x = 0-100)

Trigger level during Ti 64 - Ti 65

Reduction of Ti 72 due to trigger signals during Ti 64, Ti 65,

12 1810572-02


Parameter

Fa 32

Fa 33

Fa 34

Fa 35

Fa 36

Fa 37

Fa 41

Factory set value

1.0

2

Plant set value

Range

0 0 - 1 0

0 - 1 0

+0 00 J L ^ 1

+0.00

+0 00

0 - 20^

200 = - 00

100-•'2 11

1 1

1

i

1

20

5

-2.00-+2.00

0 = -2.00

200 = 0.00

400 = +2.00

-2.00 - +2.00

0 = -2.00

200 = 0.00

400 = +2.00

0-100

1-30 minutes

Description

Reduction of Ti 7? in DO mode

Timer Ti 72 is reduced by Fa 32

Limit for number of LO drainings. If a iiigher no. of drainings than Fa 33 talæs place within one separation period (Ti 68), an alarm will be given.

HhO temperature ddjuslmcnt MT JO

Tbmperatü & corrperaatiur fo th«-water Iransducer HFO mode

LO temperature adjustment, MT 50

Temperature compensation for the water transducer, LO mode.'')

DO temperature adjustment, MT 50

Temperature compensation for the water transducer. DO mode.^'

Flush water every x disch

Closing water pulse time

Time between closing water pulses

' The transducer value can be influenced by temperature variations. This can be compensated for by using this parameter. Proceed as follows:

Note the transducer value. N.B. The transducer value must be steady (no water in oil) in order to do this test. At normal stable running temperature, decrease the temperature by 10 °C. At stable new temperature, read the temperature and transducer value. Example: Temperature decrease = 10 °C Transducer value change = + 1 (from 82.6 to 83.6) Since the transducer value increased, this must be compensated by making Fa34 negative. Fa34 = (1.0xlO)/10°C = -1 .0

1810572-02 13


Parameter

Fa 42

Fa 44

Fa 45

Fa 46

Fa 47

Fa 48

Fa 49

Factory set va lue

No


See table on pagti 22

1.0

3.0

1 0

5

Plant set value

Range

No

Yes

0 -15 seconds

1 0-1'' '!fi , i jrid!.

0 - 4 bar

0 - 4 bar

0 - 4 bar

0 - 1 0

Description

V4 activated in Ti 64

To get a faster pressure response when oil feed fills the bowl (see Ti 64) valve V4 could be closed = Yes.

Delay for close of V4 at leak test. Automatically adjusted during test. (Ti 66)

Delay of P^4 pressure referenc c value registration durina the automatic adjustment of pressure range for leakage test (SPP TJ 66)

Acceptable PT4 decrease during leakage test

Alarm for leaking bowl If the pressure decreases more than Fa 46 during leakage test.

PT4 liigh limit dunng leakage test

PT4 low limit during leakage test

Max no of leakage tests to establish the test pressure within high-low limits

For piarameters Fa 90 - Fa 95, see page 2 1 .

14 1810572-02

3 fvPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS

TJjvê SöcâaEscts ParÄisäselei-s ( s e p a r a t i o n

; tart, sludge discharge, stop)

.'"arameters for timers are listed under Factory, but are called Ti' .

• '? ; . O .ijßcied feedback from a timer is given, ihc vw]cv i; ii:'terrupted and the next timer

'I feedback is not received within the preset

time, an alarm is given.

Timers for start are 50 - 59.

""ixiiers .for operation are 60 - 69.

'"imeTS tor discharge are 70 - 79.

Timers for stop are 80 - 89.

Timers 50, 51, 52 and 87 are intended for the ;|):'j autoiiiaiic' system (Auto mode) with pump and heater controlled by EPC 50.

' MT( -ir' and heater are started independent of ,nu .il>u iâval starter, X6:4 - X40 must be

' ; ' ''ree closing contact at the ,...j;xi.u jjump contactor. Increasing

temperature is the only process condition needed for timers 51 and 52. The program skips directly so timer 55 when not 'fully automatic'.

1810572-02 15


Parameter

Ti50

Ti 51

Ti52

Ti53

Tl55

Ti56

Ti57

Ti58

Factory set va lue

60

15

4

15

Plant set value

Range

2 - 300 seconds

0 - 3 0 seconds

0 - 6 0 minutes

0 - 6 0 minutes

u 0 - 3 0 mrrii.te=

3 = nu standL\ 1 1

1 1 1

3.0

15


0.1 -5 .0 seconds

0 - 3 0 seconds

0 - 6 0 seconds

Description

Feed pump on |

Feed pressure feedback

Separator slart-up (Speed feedback)

Speed above low limit (Fa 11) expected Condition of belt, coupling, motor beanngs, height adjustment, and speed sensor supervised

Heater on (temp, feedback)

Temperature above low limit (Pr 17, Pr 20) expected to confirm that the heater works normally.

Max time for'Standby mode Durina Standby mode the system is waiting for an order to btart the procps«! sequence The proccso sequf ii>p IS Ltaitud w.itl' d |. j ^h * the stirt button

When Ti ••£: "• t' > 11 /.r-is tt r ' -witlnufdtldv

Discharge if Ti 59 has expired after alarm.

Pause = Draining of operating system

Close bowl

16 1810572-02


Parameter

Ti 59

r

T \

Ti 60

Ti 61

Ti 62

Factory set va lue

Plant set value

170 1


15


Range

0 - 300 seconds

4»

1

0.1 -30.0 seconds

0 - 3 0 seconds

0 - 6 0 seconds

Description

Water flow rate calibration

At start three questions are displayed

• Bowl dismantled'?

• Assembled according to manual'

• Bowl cleaned'?

When the answer to the third {]uestion IS Yes, calibration of the water flow rate through SV 10 takes place. SV 10 IS open until pressure in the water outlet increases (Fa 6) THé water volume is defined for each separator size Based on this and the time taken to fill the bowl, the EPC calculates the water f lowrate

When the answer is No, this means that stored calibration data will be used and consequently the program performs Ti 63

Discharge

- when starting, the operating system needs some extra water to support the operating slide before closing the bowl. (This is not a proper discharge, since the bowl is empty.),

- after a power failure to prevent a period between discharges greater thanPrl .

Pause = Draining of operating system

Close bowl

1810572-02 17



Plant set value

Range Description

Ti63 120 ' becond-i calculated I

Ti64

Ti65 ^<^

t s n Is

0 - V) «.erjo IS

TI66

Ti67


60

0 - 3 0 seconds

0 - JOO S^CO ids»

Conditioning water addsd

Based on the calibration of the water flow rate the EPC calculate«; the time to which Ti 63 is set so that the correal volume of condrtionirrg watc r IS add«>d to the bowl Data concerning the bowl is activated when size of bcparator is chooben (In 4j The preset value <b just for Stat After thu calculation *he corroLt value for Ti 63 is set autr nidtically

Oil ff ff* mi Mix bO «• •• '

Wati r tranbdui er puisp on itrol tini>^

Test of 'he siqndl from the Wiiter trdnbclucLr If this shov b wjter in the. Uli ttie displdLement time pnor tn next dioch-irqe mil be rpduo d

Bowl leakage check

(See also Fa 44 - 49)

Time for stabilisation of the transducer signal When the time has elapsed the EPC stores the actual transducer value as a reference 'or changes n wate' content

•

18 1810572-02

i YPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS

i Parameter

1 Ti 68

1

1 ! 1

! Ti 70

1 Ti71

i 1 1 Ti 72

I Ti73 i 1 j Ti 74

Factory set value

120( = Pr1)

Plant set value

15

-15 .

150

10

3.0

Range

0 - 300 minutes

0 - 3 0 seconds

0-120 seconds

Seconds, calculated (max. 300 seconds)

0 - 3 0 seconds

I 0.1 -5.0 seconds

Description

Time between discharges This is the same as Pr 1 If one is changed, the other one is automatically changed

During Ti 68 the water transducer supervises changes of the water content in the clean oil If the tngger value IS greater than 100, the dram valve (V5)opens For details see Fa 25-28

Oil feed off. Oil outlet pressure below low limit (Pr 11) expected.

Displacement of oil During Ti 71, V4 ts closed until increasing pressure is sensed, indicating displacement water has entered the bowl

Displacement water (SV 10) continues for the calculated time.

Opening of the drain valve to wash out any oil from the paring tube and piping.

Discharge

1810572-02 19



Plant set value

Range Description

Ti75

Ti81

TiB2

Ti83

Ti85

T 0 - 3J a"«!- Jnj"!


150

0 -60 seconds

0 - 300 «icconas

10

I S

0 -30 seconds

n - iO IT M ite

Pausij = Draining of u|:eiatiiig system

Discharge feedback (ds shonn by decreased soeed Fa 111

If the speed sensor is out of ordbi disabled feedback is autorndticalk taken over by time' Ti 64 (If time, close to 0 there was no discharge)

Draininq of operdting svstem tdkes place dunng Ti 75

After " 175 the program rbturns to T I B? rrcvided stop is not ordered

If however dny value or timer mrluencing tne wator c ^librdtion h is been chdnged the progrdrn returns to Ti 58

[ When stop is ordered the d suharnp precede« the btop sequence

Close bowl

Heater oft

Addition of water until 80°r o' boA' volume or inci eased pressure is sensed in the oil outlet (Fa 6) This is to keep the bowl filled dunng stop sequence

Opening of the drain valve to wash out any oil from the paring tube and the pipe.

Temperature dec rtdsc

The EPC switchPb tfie separator motor off

Decreasing oil fded temperature greater than 5 C expected

f TI 85 = 0 no temperature control

20 1810572-02

4 FACTORY SET PARAMETERS

S-TYPE SEPARATION SYSTEM PARAMETER LIST

' Decreasing speed expectea (Fa11)

Pump off In Auto mode, the ERC switches the feed pump off. By doing so after switching off the separator, further oil

is fed to the heater (which is already switched off) to help cooling. _ _ The EFC IS waiting for ze'o sp»ed As long as the separator <s rotatii n at a speed greater thin 6 revs i r n

.1 puis, rev) tne speed is displayeJ alternating wrtb Stop Speed Jpss than 6 rerfb-nr is displayed ds 0

When speeo J fids beer. di-P'^yi '1 '->rlmPJt dtern-stnAt'i '- 'rp, t-fonls« l - < ' i f ' / '

Set runtime, ÖÖB oiidpit' ^ o,.-/.»-of Circuit Board in the Alarms and

Fault Findmg booklet.

Break point, cold start

The temperature up to which gam factor Fa92 IS active Above this temperature normal gam (Pr 22) is

active.

Gam factor, cold start

This factor is usea to increase the normal P-band(Pr 22) w hen temperature is below that defined

Fa 91. Ex.NormalP-band = 30, Fa92 = gives an actual P-band below Fa of 0.40x30 = 12

in

40 91

1810572-02 21


Parameter

Fa 93

Fa 94

Fa 95,

Fa 96

Factory se t value

SBSU

9.6

No

3.0 if Pr 2 = fuel oil

0.6 if Pr 2 = lube oil

Plant set value

Range

SBSU (Sattbus on RS232)

ASCII (ASCII protocol)

PRINT (Printer output)

1.2, 2.4, 4.8, 9.6, 19.2, or 38.4

(4.8 = 4800)

No

Odd

Even

0.1 - l O . O p F

Description

Communication type

1

Serial communication Baudrate channel A

Communication parity channel A

Alcap trigger range during discharge

Parameters depending on separator size

Separator size

S A A # ^ s 2 g U S Æ 2 1 . S 626

S 820, S 825, S 300, S 830, S 831,

S 835, S 836

S 400, S 840. S 841. S 845 S 846

S s 1 c ^ Ci<-1 V j - ;j oe^^

s f OO s 'leo s «1C1 s d65 S 866

S ) "- ^ s -»-1 - « i - c br t7u

S GOO ^ •'•'u fa 881 £ 885 S 886

F a 3

p j ß '

0.3

0 4

-

0 9

1 3

. 5

Fa to

i 3 , 300 --^•

11.000

9 600

Cl r o

7 8üiJ

üÔ

5 800

F a l l

SliÖOO-^.-,

9.900

8 600

7 400

6 400

5 500

4.700

Fa16

0:3

0.3

0 5

0 5

0 5

0 5

0 5

Fa17

0.2

0 2

0 3

0 3

0 3

0 3

0 3

Fa44

2

2

4

6

8

10

10

Fa45

5

5

10

10

10

10

10

Separator size

S 811, S 816, S 200, S 821, S826

S 820, S 825, S 300, S 830, S 831, S 835,

S 836

S 400 S 840 S 841 S 845 S 84i>

=. 1 00 S asr ^ sfî b p «5 - 8 i

S 600 S 860 S8b1 S 865 S 866

S "OC S 870 fa 8^1 & 8 " = «•'i

S 800 S 880 S 881 S 865 S 8Bo

T i 5 8

15

15

3

25

i

U)

Ti60

5

5

5

^

15

r

«

Ti62

15

15

15

-i"^

«

3-

60

Ti66

10

10

?n

2";

3

TIBI

15

15

15

1

?

• )

bO

22 1810572-02


1810572-02 23

5 SEQUENCE DIAGRAM S-TYPE SEPARATION SYSTEM PARAMETER LIST

5 Sequence Diagram

Activity Feed pump motor on Flow stabilized

Separator motor on Heater on temp increase Heater max. start time

Discharge, ' I S V I S ^ ' Drain of operating water orösjfrg'water;

?»"•' -«: Calibration of water flow rate SV10 Condifioning water SV10 Feed on VI

Oil outlet closed, V4 Leak test

Ref time

Separation

Drain of water, V5 Feed off |[)>splacement water

syio Water SV10

Autostart TI50 60s

v

Ti51 15s

1 "^î

- -

'!K**STW sgsssi.

TI52TTI53 TI55

4m 15m 30m

1)

i

«.»... -

i n

1)

*

IKUr it^tterla.

,

i •

1

Start

Ti56 |Ti57 3s 15s

I'- -

1

^

>'

.Toiiwe'P' -

TI58 TJ59

15s 170s

1

Ti60 5s

1

1

sj ...-i--

' .'. -

1)

1)

S

• . iC-*» * * .« * i fS

^f< • . ^ , ^ -

•m

Ti61 Ti62 15s 15s

Ti63 Calc

w»n*«» fM -.-f"

ii/fi •;;]:{•;'• •

*

"

<

'•rV- - !•*

Separation Tl64 60s

5^,

£

••**• J* • H '

Ti65 IT166 15s

p

10s

•i ^ '

- •

Ti67 IT168 60s 60m

i

•«•Ml

3)

1

10) •-

1)

2) 3)

Interrupted by feedback signal Pulse 1 sec. every 5 min. Activated when needed

4) Interrupted by decreasing temperature

HOTE;

5) Interrupted by decreasing speed 6) Interrupted by pump off feedback 7) Intermpted by O-speed during 1 min. 8) Interrupted by calculated time

or trigger signal

9) 1 sec. pulse at 4000 rpm 10) 5 sec. every 30 minutes 11) 15 sec. only

Note! This diagram is valid for normal operation only. See the flow chart on page 30 for a more detailed sequence description.

24 1810572-02

PE SEPARATION SYSTEM PARAMETER LIST 5 SEQUENCE DIAGRAM

' , • . - : « ni iJ 'g&

, 1 7 i i , / 2 i Ti73|TI74 1 {

TI75

15s

Ti62

158 1

i

i T ^ !

t

f 1 1

i 1

I 1 S

!

\ ,

i 1)

s !

i i

''•^4

'- r

1

1 1

1

1» '

' i 'Å'al

T

• ü ^

11)

Tf63

Caic

TI64

60s

'-;,.:

T(65 l'ss

* 4^

Ti66

lOs - , • "

J'67:; 60s

i

-'• '

1 1

"'

If 'Stop' after Ti62 skip'to

Ti81 1 1

S t o p

T i 8 l

15s • •

Ti82 iTi83

150$ ' lOs

-

:-

• • • • J

1 i 1

1)

Ti85

5m

4)

Ti86

3m

5)

]

9)<

Ti87

60s

6)

'

1

Ti89 |

30m 1

7)

Activity

Feed pump motor on

Flow stabilized

Separator motor on

Heater on temp increase

Heater max. start time

discfiarge, ' SV15 -

Drain of operating water

Closing water; " SV16

Calibration of water flow rate

SV10

Conditioning water SV 10

Feed on V I

Oil outlet closed, V4

Leak test

Ref time

Separation

Dram of water, V5

Feed off

Displacement water

SV10

Water

SV10

Optional sludge pump

Flow rates for Flow rates for Flow rates for Flow rates for Flow rates for S811,S816, S200, S820, S825, S300 S500, S850, S851, S700,S870, S871, S800, S880, S881, S821, S826 S830, S831, S835, S855, S856, S600, S875, S876 S885, S886

S836, S400, S840, S860, S861, S865, S841,S845, S846 S866

SV10:0.9l/rn SV10:1.6l /m SV10:5.5l/m SV10:11 l/m SV10:15l /m

SVI 5:11.0 l/m SVI 5:11 l/m SV15:11 l/m SVI5:11 l/m SVI 5:11 l/m

SV16: 2.8 l/m SV16; 2.8 l/m SV16: 2.8 l/m SVI6: 2.8 l/m SV16: 2.8 l/m

1 8105 72-02 25


5.1 Separation Sequence

IF*

T imer

Ti 56 = 3 sec.

SV15

Ti 57 = 15 sec.

Ti 58 = See table chapter 4.

SV16

Ti 59 = calculated

V 4, SV 10


SV15

Ti 61 = 15 sec.


SV16

Ti 63 = calculated

SV10

Act ion

Discharge

To ensure that the operating system gets sufficient water before closing.

Draining of operating water

Bowl closing

Calibration of water flow

Bowl filled with water until pressure is indicated in the oil outlet (Parameter Fa6 = 0.2 bar). Flow rate is calculated based on the known bowl volume and time taken to fill with water.

Discharge

Normal start begins here. There are two reasons for this: 1. To ensure that the operating system gets sufficient water before closing. 2. To empty the bowl before start after power failure.

Pause

During this timer, water is drained from the operating system.

Bowl closing

Filling of conditioning water

The time (volume) is based on the calibrated flow rate and bowl volume.

A. A l a r m s

'NO PT4 PRESSURE FEEDBACK DURING Ti 59'

Ti 59 has a max. value of 170 sec. Alarm is given if no pressure response within this time.

Max. 120 sec.

26 1810572-02

S-TYPE SEPARATION SYSTEM PARAMETER LIST 5 SEQUENCE DIAGRAM

Timer Action A Aiarms

Ti 64 = 60 sec. V 1, (V 4 automatic selection)

Feed on to separator 'Oil bacltpressure PT4 - LOW

Alarm is given if no pressure response in oil outlet within Ti64.

Ti 65 = 15 sec.

VI

Test of water content in oil outlet

If traces of water are detected in the oil outlet, the time for displacement {Ti 72) will be reduced before next discharge. After calibration start, the oil outlet pipe is filled with oil and the system now skips to Ti 70 to perform a discharge. Ti 72 max 90 sec interrupted by transducer response.


V4

Bowl leaking test

With the feed off and the oil outlet closed, a decreasing pressure indicates that the bowl is leaking. In order to find a suitable pressure range ( 1 - 2 bar) for test, Ti 65 and Ti 66 may be repeated (see Fa 49).

•OIL LEAKING FROM BOWL'

Alarm is given if the pressure falls by more than 1.0 bar.

; Ti 67 = 60 sec.

V1

Reference time

After the process has stabilized, the transducer (MT 50) reference value is stored.

Ti 68 = 120 min.

V1 (V5)

Separation.

When necessary, the drain valve (V5) in the water outlet opens for a short while. The trigger value is then checked during a few seconds. Draining stops when the trigger value is lower than 70. Draining can continue max. 5 openings. After 5 openings, skip to Ti74.

Water drain - INSUFFICIENT'

During separation all necessary functions are supervised. Alarm given if more than 5 openings and trigger value not less than 70.

1810572-02 27


Timer

Ti 70 = 15 sec.

Ti 71 = 15 sec.

V4, SV10

Ti 72 = 0 -150 sec.

SV10

Ti 73 = 10 sec

V5

Ti 74 = 3 sec.

SV15

Ti 75 = 15 sec.

TI 62 to 67

repeated.

orT iSI

Action

Feed off.

Oil outlet pressure decreases.

Displacement water.

Oil outlet pressure increase more than 0.5 bar indicates that water is fed. The timer is then interrupted.

Displacement water.

Water pumped out through the water outlet to wash out any remaining oil. Sludge pump in operation.

Discharge.

Discharge feedback and draining of operating system

After'bowl cleaned' at start, the program continues with Ti 58 - 68. Once Ti 68 has elapsed, the program skips from Ti 75 to Ti 62 after every discharge, or to Ti 81 if stop is ordered.

A Alarms

'OIL PRESSURE PT4 HIGH DURING Ti70'.

Alarm given if no pressure feedback.

'NO PT4 PRESSURE FEEDBACK DURING Ti71'.

Alarm given if no pressure feedback. Max. 15 sec.

Max. to calibrated value.

'Discharge feedback -ERROR'.

Alarm is given if bowl speed after discharge is not below Fa 11 minus Fa 12.

28 1810572-02


! i

ÉHHHI

®M

j Timer

Ti 81 = See table

I T . - . "•"• sec,

1 V'+i bv lU hlcateroft

1 Ti S;-; --- ')0 sec

I V5

1 Separate)!' motoi off

1 Ti 86 = 3 min.

1 Ti 87 = 60 sec.

1 Feed pump off

1 Ti 89 = 30 - 60 min.

Action

Bowl closing

Water to the bowl.

Timer interrupted when 80% of bowl volume is filled, or when pressure in oil outlet is increased by more than 0.2 bar.

Water pumped out through the water outlet to wash out any remaining oil from the paring tube and pipes.

Waiting for oil feed temp. decrease-Timer is interrupted when temp, decrease below low limit.

Waiting for speed decrease.

Time for cooling of heater

Timer is interrupted by pump off feedback.

Waiting for zero speed

When speed = 0, timer is interrupted and 'Standst' is indicated.

A Alarms

Max. 300 sec.

'Temperature - NOT DECREASING'

If temp, not decreased within Ti 85.

'Bowl speed - HIGH xxxxx'

If speed not decreased within timer.

Max. 60 min.

1810572-02 29


Process Start Start With Calibration

Calibration

Ti50-54 Feed, speed,and temp check

Ti55 Standby. Push

'Separation' to continue

i Ti 60 Discharge

I Ti 61 Pause

T Ti62 Bowl closing

i Ti64 Feed on

T Ti65 Stabilizing

T Ti70 Feed off

T Ti71 Displ.

water check

I Ti72

Displacement

J Ti 73 Water

outlet flushing.

J Ti74 Discharge

T Ti75 Pause and

discharge feedback

30 1810572-02


Start Without Calibration

Discharge Stop

Ti50-54 Feed, speed, and temp

check

T Ti55 Standby.

Push 'Separation' to continue

i Ti 60 Discharge

Ti71 Displ. water check

I Ti 72

Displacement

T Ti 73 Water

outlet flushing.

T Ti74 Discharge

T Ti75 Pause and

discharge feedback

Stop

Ti81 Bowl closing

Ti82 Water into bowl.Heater off

J Ti83 Water outlet

flushing

Ti85 Sep. motor off. Check

decreasing temp

Ti86 Heater cooling. Check

decreasing speed

Ti87 Pump off

Ti89 Waiting for 0-speed

1810572-02 31


32 1810572-02

S-type Separation System

^ Alarms and Fault Finding ^^'^\y^'^

Printed

Book No.

Mar 2005

1810573-02 V 10

S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

1 Alarms 2 1.1 Alarm Functions 2 1.2 Reading Alarm History List 2 1.2.1 Alarm message explanation: 3 1.3 Alarm Reset 3 1.4 Abnormalities not displayed 4

2 Display Alarms and Actions 5

3 Alarm Tests 19

1810573-02

I ALARMS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

1 Alarms

1.1 Alarm Functions The alarm system is designed to ensure a safe •epai-.'ition system.

All alarms are shown on the operator panel display, and most of them are complemented by light emitting diodes (LEDs).

The alarms are displayed in order of occurrence.

1.2 Reading Alarm History List

To read the stored list of aleirms, do as follows:

Push 'Enter'.

Push '+' until 'End' is shown on the display.

Push 'Enter' and '+' at the same time.

Push '+' repeatedly until 'AL list' shows on the display.

Push 'Enter'.

Go through the list using the '+' pushbutton until 'End' shows on the display.

Push 'Enter'.

Push '+' repeatedly until 'Exit' shows on the display.

Push 'Enter' to return to normal display.

H0T6

The texts 'Aicap Pr4 = On/ Standby', and 'Discharge Repeated' are reminders to the operator, and not alarms.

1810573-02

S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 1 ALARMS

1.2.1 Alarm message explanation;

The display shows:

Alarm no. 5

0:13

Feed pressure low

PI 60

00:02:13

Alarm number

This alarm occvired 13 minutes ago.

Type of alarm

Parameter Pr 1 was set to 60 minutes.

The alarm was reset after 2 minutes 13 seconds.

1.3 Alarm Reset

^ ; ^ Ö H 6


1 Acknowledge the alarm signal by pressing the alarm pushbutton. The flashing LED then changes to steady shine.

2 Remedy the cause.

3 Reset the alarm function by pressing the alarm pushbutton a second time.

The LED will go out.

^ ^^z^

\ ALARM

It is possible to reset the system without remedying the cause, but the alarm signal wül be repeated.

HOTE

The STOP sequence is automatically initiated if an alarm is not remedied within 30 minutes.

1810573-02

1 ALARMS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

M fÄÜtlOI*

Risk of injury Never return to the operator panel to acknowledge or reset an alarm if doing so is by any means hazardous.

1.4 Abnormalities not displayed

There are some abnormalities not shown on the display. Below are listed the most common:

Why? What to do

Smell Normal occurrence during start while the friction biocids are slipping.

Oil level in oil sump too low.

None.

Check oil level and add oil if necessary.

Noise Height position of paring disc is incorrect.

Bearing(s) damaged or worn.

Improper bowl assembly

Stop the separator, measure and adjust the height.

Renew all bearings

Check and reassemble.

Unsatisfactory separation result • Incorrect separation temperature.

Adjust.

• Throughput too high.

• Disc stack is clogged.

• Sludge space in bowl is filled.

Adjust.

Clean disc stack.

Clean and reduce the time

Bowl speed too low. Examine the motor and power transmission for correct frequency parts.

Check belt and coupling pads.

Bowl rotates in wrong direction Check the electncal connections to the motor.

1810573-02

S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 2 DISPLAY ALARMS AND ACTIONS

2 Display Alarms and Actions

on page The display

shows

Alcap in standby - MORE THAN 24 HOURS

xxxxx board - ERROR

Bowl speed - HIGH xxxxx

Bowl speed - LOW xxxxx

Bowl speed sensor - ERROR

Communication - ERROR xxxxx

Computer communication board - ERROR

Discharge feedback - ERROR

Emergency stop - BUTTON PUSHED

Feed flow PT1 - ERROR DURING Tixx

Feed pressure PT1 - HIGH

Feed pressure PT1 - LOW

Feed pressure sensor PT1 - ERROR

Heater - FAULT

Heater board - ERROR

Heater connection - ERROR

High vibration - SHUTDOWN

High vibration - WARNING

HIGH WATER CONTENT

HIGH WATER CONTENT IN OIL

17

18

11

12

13

la

18

17

9

11

15

15

15

16

18

18

7

8

16

17

The display shows

10 expansion board - ERROR

IP address-FAULT

Level switch - DISABLED

Local OP in control

Lockswitch - FAILURE

NO PT5 DRAIN FEEDBACK DURING Tixx

NO PT4 PRESSURE FEEDBACK DURING Tixx

NO SIGNAL FROM EXTRA INPUT X6:8

Oil backpressure PT4 - HIGH

Oil backpressure PT4 - LOW

Oil feed temperature - HIGHxxxxx

Oil feed temperature - LOWxxxxx

OIL LEAKING FROM BOWL

OIL PRESSURE PT4 HIGH DURING Ti70

Oil pressure sensor PT4 - ERROR

Parameter xx:xx - ILLEGAL

Parameter changes - LOCKED

POWER FAILURE

Pressure in water outlet PT5 - HIGH

Pressure in water outlet PT5 - LOW

on page

18

13

18

17

7

17

15

16

13

14

9

10

13

15

14

18

13

17

15

15

1810573-02

2 DISPLAY ALARMS AND ACTIONS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

on page The display

shows

Pump starter-FAILURE

Separator motor - FAILURE

Separator run-up time - TOO LOTslG

Service alarm

SLUDGE IN BOWL

Sludge tank level - HIGH

Switch power off/on

Temperature increase - TOO SLOW

Temperature - NOT DECREASING

Temperature alarm sensor - ERROR

Temperature control sensor - ERROR

Transducer - NO RESPONSE

WIT 50 board - ERROR

Transducer value ^ LOW

Vibration board ERROR

cition sensoi L H K I J H

Water drain pressure HIGH

Water pressure sensor PT5 - ERROR

15

13

16

18

13

13

17

18

18

10

11

17

16

16

16

18

8

17

15

1810573-02


The display shows

Why? What to do

Lockswitch - FAILURE

High vibration - SHUTDOWN

• Separator not mounted as Mount the separator according to described in the Service Manual the instructions in the Service booklet. Manua/booklet.

HOTE

The cause of this alarm must be remedied within 30 minutes. If not, the STOP sequence will begin.

Disintegration liazards If excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown.

The cause of the vibration must be identified and corrected before the separator is restarted.

Sludge remaining in part of the bowl

Dismantle, clean and check the bowl before restart. See Service Manual.

^ A B H « * »

Disintegration hazard The separator bowl must be manually cleaned before starting up again.

Bowl wrongly mounted

Disc stack compression incorrect

Bowl assembled with parts from

Check assembly See Service Manual.

other separators

Height position of paring disc is incorrect.

Stop the separator, measure and if necessary adjust the height.

Bowl spindle bent. Renew the bowl spindle.

• Bearing(s) damaged or worn. Renew all beanngs.

• The frame feet are worn out.

• SpindlS top bearing spflnig broken.

Renew the frame feet.

Renew all spnngs.

1810573-02


The display shows

Why? What to do

High vibration-WARNING

Vibration sensor - ERROR

• Sludge remaining in part of the ; Dismantle, dean and check the bowl bowl before restart.

Disintegration hazard The separator bowl must be manually cleaned before starting up again.

• Bowl wrongly mounted

• Disc stack compression incorrect

• Bowl assembled with parts from other separators

• Height position of paring disc is incorrect.

• Bowl spindle bent.

• Bearing(s) damaged or worn.

• The frame feet are worn out.

Check assembly. See Service Manual.

Stop the separator, measure and if necessary adjust the height.

Renew the bowl spindle.

Renew all bearings.

Renew the frame feet.

Spindle top bearing spring broken.

Renew all springs.

• Sensor or cable damaged Replace sensor. If no spare sensor available, set parameter Fa 16 = 0.0 to be able to run the system.

Note that it is not possible to run in AUTO mode.

1810573-02


The display shows

Why? WiiHt to do

Emergency stop - BUTTON PUSHED Emergency button pushed Remedy cause for pushing button.

Reset pushbutton.

Oil feed temperature - HIGHxxxxx Steam supply valve faulty Investigate cause and remedy.

• Faulty triac module(s) in the power unit or faulty controller in the control unit (electric heater).

If relay K11 is on:

Disconnect X12:10.

If the temperature is falling, replace the control module in the control unit.

If the temperature is not falling, replace the triac module(s).

If relay K11 is off. but contactor K12. K16. or K17 is on. and the temperature is not falling:

Check if power is supplied from the control unit to the contactor which is on (X12:6 - X12:12, X12:7 - X12:12. X12:9 - X12:12). If it is. replace the control module in the control unit.

Broken wiring or defective heater resistance, or faulty controller In the control unit.

Check adjustment of P and I functions in the control unit.

If contactor sequence correct:

Check wiring and heater resistance of each block or heater element. See EIHM heater component booklet.

If contactor sequence not correct:

Replace the control module in the control unit.

1810573-02

2 DISPLAY ALARMS AND ACTIONS S-TYPE SEPARATION SYSTEM AURMS AND FAULT FINDING

The display shows

Why? What to do

Oil feed temperature - LOWxxxxx • Heater clogged

• Steam supply insufficient

• Steam trap faulty

• Steam supply valve faulty

Investigate cause and remedy

Faulty fuses or burned contactors (electric heater)

Broken wiring or defective heater resistance (electric heater)

Temperature alarm sensor - ERROR Short circuit/ broken sensor or cable.

Check and renew broken fuses. Reset overcurrent protection (applicable for m - 24/22 kW power unit)

Check wiring and contactor coils.

Check wiring and heater resistance of each block or heater element. See the Service Manual booklet.

Disconnect cable at sensor. iVIeasure resistance between 1-3. Resistance shall be within 100-142 ohms 3 0-110 C / 32-230 F.

Test of EPC 50 Input:

• Disconnect cables from sensor, (terminal X 5:1-2-3).

• IIAove jumpers Xjl and Xj2 upwards - from Normal to Test (The jumpers can be found in the upper left corner of the I/O Board)

> Indication within 50-60 C when OK.

• If no spare sensor available set parameter Pr 16 = 0, or if control sensor free, move connection to that one

10 1810573-02


The display shows

Why? What to do

Temperature control sensor - ERROR Short Circuit / brol<en sensor or cable.

Disconnect cable at sensor. Measure resistance between 1-3. Resistance sliall be wittiin 100-142 oiims = 0-110 C / 32-230 F. If no spare sensor available set parameter Pr 18 = 0. Heater is tlien out of function.

Feed flow PT1 - ERROR DURING Tlxx • Pump not working

• Pressure in feed line too low

Bowl speed - HIGH xxxxx High power (net) frequency

Checic pump.

Checic feed line.

Checif power supply before restart.

Incorrect transmission parts (50 Hz belt pulley and belt for 60 Hz power supply).

Disintegration hazard Stop and change the belt transmission to suit the power supply frequency.

1810573-02 11


The display shows

Why? What to do

Bowl speed - LOW xxxxx Slipping belt Change belt.

Worn coupling pads Check / change pads.

Bowl not properly closed Check closing water supply (valve SV 16).

Check bowl operating system for leakage.

Check nozzle.

Bowl not properly assembled Check that the lock ring is in place.

• Low power net frequency

• Motor failure.

• Bearing(s) damaged.

Check power.

Repair the motor.

Renew all bearings.

Incorrect transmission parts (60 Hz belt pulley and belt for 50 Hz power supply).

Disintegration i iazard Stop and change the belt transmission to suit the power supply frequency.

12 1810573-02


The display shows

Why? What to do

Bowl speed sensor - ERROR • Sensor or cable damaged Replace sensor, if no spare sensor available set parameter In 6 = No to be able to run the system. Note that it is not possible to run in AUTO mode.

Separator motor - FAILURE Feedback signal from contactor K 2 missing

Check the contactor function. Input terminal X 6:5 in EPC 50.

OIL LEAKING FROM BOWL Bowl periphery sealing damaged

Change seal ring in bowl hood.

Check/change rubber rmgs and valve plugs.

Leakage somewhere in oil outlet Check for leakage.

Closing water leaking

SLUDGE IN BOWL Too much sludge in t)owl

Check/change sealings and plugs.

This alarm cannot be acknowledged. The separator will come to a stop Wait until EPC comes to 'Standstill. Investigate cause and remedy.

Sludge tank level -HIGH

Parameter changes - LOCKED

IP address - FAULT

• Pump has not drained the tank

• A code has been set to make parameter changes not possible

• Wrong IP address used in In 27-30

Check the pump function.

Unlock the code.

Check the setting.

Oil backpressure PT4 - HIGH Increased throughput Check. Reduce backpressure.

• Regulating valve too restricted Adjust valve

1810573-02 13


The display shows

Why? -What to do

Oil backpressure PT4 - LOW • Decreased throughput Check feed pump and adjust flow.

• Regulating valve open too much Adjust valve

• Change over valve V1 in recirculation position

Check air pressure, solenoid valve SV1 and output from EPC 50 terminal X 8:1-X 41

Bowl opens unintentionally during operation because:

Strainer in the operating water supply is clogged.

No water in the operating water system.

Hoses between the supply valves and separator are incorrectly fitted.

Clean the strainer.

Check the operating water system and make sure any supply valves are open

Fit correctly

• Nozzle in bowl body clogged Clean the nozzle

Rectangular ring in discharge slide is defective.

Renew the rectangular ring.

Valve plugs are defective. Renew all plugs.

Supply valve SV15 for opening water is leaking.

Rectify the leak.

Oil pressure sensor PT4 - ERROR • Sensor or cable damaged Replace sensor. If no spare sensor available set parameter Pr 10=0.0 to be able to run the system.

14 1810573-02


The display shows

Whyi What to do

OIL PRESSURE PT4 HIGH DURING Ti70 No decrease in oil pressure during this timer.

Check function of change-over valve V1.

NO PT4 PRESSURE FEEDBACK DURING No Increase in oil pressure during this timer

Check supply of displacement water. Valve SV 10.

Pressure In water outlet PT5 - HIGH Paring tube not moving correctly Check that movement is not impeded-by frKtion.

Pressure in water outlet PT5 - LOW Paring tube not moving correctly Check that movement is not impeded by friction.

Water pressure sensor PT5 - ERROR Sensor or cable damaged Check cable connections

Replace sensor. If no spare sensor available set parameter Pr 12=0.0 to be able to run the system.

Feed pressure sensor PT1 - ERROR Sensor or cable damaged Check cable connections

Replace sensor. If no spare sensor available set parameter Pr 14=0.0 to be able to run the system.

Feed pressure PT1 - HIGH Pipe restricted Check recirculation for restriction

Feed pressure PT1 - LOW Low flow Check pump and flow regulation.

Check heater for fouling.

Pump starter - FAILURE Feedback signal from contactor K 3 missing

Check the contactor function.

Check input terminal X 9:1 in the EPC.

1810573-02 15


The display shows

Why? What to do

NO SIGNAL FROM EXTRA INPUT X6:8 Depends on use of the input Depends on use of the input

Separator run-up time - TOO LONG Separator coupling slipping Check the coupling.

Heater - FAULT

• Belt slipping

• Height position of paring disc is incorrect.

• Motor failure

• Bearing(s) damaged or worn.

Check the belt.

Stop. Check and adjust the height.

Repair the motor.

Renew all bearings.

Separator start button not pushed.

Push start button.

• OV in cable heater X 12:3 to EPC 50X51:4 (electric heater)

Check the power supply to the heater.

High temp, switch released (electric heater)

Check temp setpoint in the control unit.

Check the heater and clean if necessary.

Reset temp, switch in power unit. Restart heater.

MT 50 board - ERROR Faulty board Change MT50 Board (see Change of Circuit Board in the Service Manua/booklet).

Transducer value - HIGH • Extremely high water content Check the dirty oil quality.

Fouling In the monitor MT 50 Dismantle and dean with detergent.

Transducer value - LOW • Too much air in oil outlet Check oil back pressure

HIGH WATER CONTENT For HFO and DO

• Too much water in oil

Much water in the feed

Investigate cause and remedy.

Check the dirty oil quality.

• Paring tube not moving properly Check that movement is not impeded by friction.

16 1810573-02


The display shows

Why? What to do

HIGH WATER CONTENT IN OIL ForLO

• Too much water in oil Investigate cause and remedy.

• Much water in the feed Check the dirty oil quality.

Paring tut» not moving properly Check that movement is not impeded iiy friction.

Alcap in standby - MORE THAN 24 HOUR! • Reminder Check the reason for stand by and try to get back to normal operation as soon as possible.

Water drain pressure - HIGH Water pressure has not decreased sufficiently though valve V5 open.

Check V5 function

NO PT5 DRAIN FEEDBACK DURING Tixx Restriction in water outlet causing no reduction in pressure

Clean the outlet pipe.

Transducer - NO RESPONSE Expected increase of trigger signal during Ti 64 and Ti 65 failed

Check water supply Valve SV 10.


Switch power off/on

Speed not decreased as discharge feedback (below Fa12) caused by:

• Strainer in the operating water supply is clogged.

Clean the strainer.

• Water flow too low. Check opening water. Valve SV 15.

Hoses between the supply valves and separator are incorrectly fitted.

Correct.

Rectangular ring in the operating slide is defective.

Renew the rectangular ring.

Local OP in control

POWER FAILURE

• Attempt to operate remote OP

• Black-out has occurred with EPC in operation

Not legal when local OP is active.

Check plant conditions and restart.

• Alarms comes at standstill after emergency or vibration shut down

Investigate the cause for the stop and switch the power off and then on to the EPC 50

1810573-02 17


The display shows

Why? . What to do

Parameter xx:xx - ILLEGAL If parameters are changed automatically by "thunderstorm" type influence, alarm is given to indicate out of range.

Switch EPC50 power off. IMove X J4 on I/O board to position right Switch power on. Parameters are now all set to default values. Move X J4 back to original position Adjust all parameter settings to correct value

Switch power off and on again.

10 expansion board - ERROR X71:2 and X71:3 are both set to Set X71:2 to X41 and jumper 0 or both set to 1 between X71.3 and X40

xxxxx board - ERROR Transducer board, operator panel board, or I/O board In EPC not working

Check cables to board or replace the board (see Change of Circuit Board in the Service Martual booklet)

Computer communication board - ERROR Bad connection Check connection

Board faulty Replace the board

Communication - ERROR xxxxx • Cable errors Check cables to board or replace the board (see Change of Circuit Board in the Service Manual booklet).

Heater board - ERROR Optional heater board in EPC not working

Check caliles to board or replace the board (see Change of Circuit Board in the Service Manual booklet).

Vibration board - ERROR Optional vibration board in EPC not working

Check cables to board or replace the board {see Change of Circuit Board in the Service Manual booklet)

Heater connection - ERROR • System cross-connection heater communication error

Check parameters and cable.

If Pr 25=0 the high level alarm is disabled

The atamw con»a«.Mjii|arotnB to operalUiü'ü*'

• If Pr 5 is used, the text in Pr 6 is displayed

Take action according to*what the text means (plant dependant).

TemperatLire increase - TOO SLOW Insufficient heating during start (Ti 53)

Check heater function.

Temperature - NOT DECREASING • Heating on during stop sequence Check heater function.

Recirculating oil not cooling Reset alarm to continue

18 1810573-02

S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 3 ALARM TESTS

3 Alarm Tests

note. If any parameter value is changed to activate an alarm, do not forget to reset to the original value before operation.

Alarm message

Siandiandi |uncitons

Bowl speed sensor - ERROR

POWER FÄJLÜRE

Feed pressure PT1 - HIGH

Feed pressure PT1 - LOW

Feed pressure sensor PT1 -ERROR

Pump starter - FAILURE

Oil feed - TEMPERATURE HIGH

Oil feed - TEMPERATURE LOW

Temperature alarm sensor -ERROR

Bowl speed -.HIGH

Bowl speed - LOW

Oil iDackpressure PT4 - HIGH

Oil backpressure PT4 - LOW

NO PT4 PRESSURE FEEDBACK DURING Tixx

Oil pressure sensor PT4 -ERROR

Red diode

PT1

PT1

PT1

Pump

TT

TT

TT

"

PT4

PT4

PT4

Sequence

, „ , • •

Standst.

Start

Start

Start

Start

Start

Start

Start

Start

Separation

Separation

Separation

Separation

timer Ti 71

Separation

Method

' ' ' • • " ' • ; . ' • •

Start separator with sensor disconnected.

Switch power off / on during operation

Decrease limit (Pr14)

Increase limit (Pr15)

Disconnect sensor

Switch punüp'off

Decrease limit (Pr16/Pr19)

Increase limit (Prt7/Pt20) or decrease Ti 53

Disconnect sensor

Decrease limit (Falb)

increase limit (Fa11)

Increase backpressure

Decrease backpressure

Disconnect V4

Disconnect sensor

Termin ai

X6:1

X5:4

X5:2

X8:3 [ 1

X5:6

Reaction

VI off.

Heating off.

V1 off

VI off

Heating off.

Stop sequence.

Stop sequence.

v i off

VI off

1810573-02 19

ALARM TESTS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

ll'.løit'm message Red diode

Sequence Method Termin al

Reaction

I Pressure in water outlet PT5 -i-liOfi

; • 'ressure in water outlet PT5 -

I Woier pressure sensor PT5 -

' FRROR

, !:cni,cijOt.;i vaiuu • HIGH

Tia- '>''ioet value - LOW

<3'.. •. , :d!-f .RHOR

HIGH WATER C O N T E N T IN

OIL


PT5

PT5

i PT5 !

MT

MT

MT

F.mergency stop - BUTTON PUSHED

I Optional funct ions

' roT.püid'ure control sensor -I ERROR

'-'< •>..• I " A I ' L T

i Sludge tank level - HIGH , ,

I Separator run-up - TOO LONG

TT

Heater

Tank

Separation

Separation

Separation

Separation

Separation

Separation

Separation

Discharge

Separation

Start

Start

Start

Start

Start

Force the paring tube outwards or decrease limit (Pr12)

Force the paring tube inwards or Increase limit (Pr13)

Disconnect sensor

Decrease limit (Fa23)

Increase limit (Fa24)

Disconnect X2 cable plug

Add much water to the feed and wait for 5 draining actions. Discharge. After another 5 drainings alarm is given.

Disconnect SV15

Push the button

Disconnect

Disconnect

Disconnect

Decrease Ti 52 to 1. Start the separator.

Start separator arKl_EPC but notTiSSelrTor'slärt s ys fem" ' with Ti 53 set to 1.

X5:8

X8:5

X51:3

X51:4

X201

V1 off

V I off

V1 off

A second attempt to discharge will take place before alarm and stop.

Sep.motor off, heater off, feed on for max.3 minutes. Feed stops when pressure reaches Pr11.

Sep. motor off.

20 1810573-02


ir^v^^L Installation System Reference Printed

Book No.

May 2005

1810965-02 V 2

Contents Technical Data 1 1.1 Demand Specification Water 1 1.2 Demand Specifications Air 1 1.3 System Data 2

Drawings 4 2.1 Flow Cliart 4 2.2 Drawings 5 2.2.1 SA 836 Separator Mounting Drawing,

DIN 5 2.2.2 SA 836 Separator Mounting Drawing,

JIS 6 2.2.3 S 836 Separator Basic Size Drawing 7 2.2.4 S 836 Separator Foundation Drawing ...8 2.2.5 Valve Block Oil, DN 25 Dimension

Drawing 9 2.2.6 Valve Block Oil, DN 25 Assembly

Drawing 10 2.2.7 Valve Block Water Assembly Drawing . 11 2.2.8 Valve Block Air, Assembly Drawing 12 2.2.9 Control Unit EPC 50 Dimension

Drawing 13 2.2.10 Starter Dimension Drawing 14 2.3 Electrical System Layout 15 2.4 Electrical Diagrams 16 2.4.1 Cable List 16 2.4.2 Interconnection Diagram, Starter 19 2.4.3 Interconnection Diagram, Starter,

cont 20 2.4.4 Interconnection Diagram, Transmitters 21 2.4.5 Interconnection Diagram, Solenoid

Valves 22 2.4.6 Interconnection Diagram, Solenoid

Valves cont 23 2.4.7 Interconnection Diagram, Optional

Equipment 24 2.4.8 Transformer Connection Diagram 25

2.4.9 Circuit Diagram, Power Circuits 26 2.4.10 Circuit Diagram, Separator Starter and

Feed Pump 27 2.4.11 Circuit Diagram, Remote Start Interlock

(optional) 28 2.4.12 Circuit Diagram, ESD-relay and Trip

Contacts (optional) 29

3 Remote Operation Systems 31

4 Specifications 34 4.1 Cables 34 4.2 Cable Routing 35 4.3 Oil, Water, Steam, and

Condensate Piping 35 4.4 Ambient Temperature

Limitation 36 4.5 Sludge Tanit 36 4.6 Sludge Piping 38

5 Commissioning and Initial Start 40 5.1 Completion Checic List 40 5.2 initial Start-up 42 5.2.1 Calculating Operating Pressure 44

6 Shut-down and Storage 45 6.1 Shut-down after Use 45 6.2 Protection and Storage 46 6.3 Reassembly and Start up 47

1810965-02

1810965-02

SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE 1 TECHNICAL DATA

1 Technical Data

1.1 Demand Specification Water Altø Laval ret 574487 rev. O

Poor quality of the operating water may with time cause erosion, corrosion and I or operating problems. The water shall be treated to meet certain demands.

The following requirements are of fundamental importance:

1 Turbidity-free water, solids content <0,001 % by volume. Max. particle size 50 pm. Deposits shall not be allowed to form in certain areas in the system.

2 Total hardness less than 180 mg CaCOs per litre, which corresponds to 10 °dH or 12,5 °E. Hard water may with time form deposits in the operating mechanism. The precipitation rate is accelerated with increased operating temperature and low discharge frequency. These effects become more severe the harder the water is.

3 Chloride content max. 100 ppm NaCI (equivalent to 60 mg Cl/I). Chloride ions contribute to corrosion on surfaces in contact with the operating water.Corrosion is a process that is accelerated by increased separating temperature, low pH, and high chloride ion concentration,

4 6,5 < pH < 9 Bicarbonate content (HC03) min. 70mg HCO3 per litre, which corresponds to 3,2 °dKH.

H ^

Alfa Laval accepts no liability for consequences arising from unsatisfactorily purified operating water supplied by the customer.

1.2 Demand Specifications Air Specif ic requirements regarding t h e quality of air

1 Pressure 500 - 700 kPa ( 5 - 7 bar). Electrical interconnections must be made by qualified electricians.

2 Free from oil. IMechanical interconnections must be made by _ ,.. .,, , . ^ . j ^ n ^ i I qualified mechanical technicians. 3 Dry, with dew point mm. 10 °C below

ambient temperature.

1810965-02

1 TECHNICAL DATA SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE

1.3 System Data

Media

Feed density, max

Viscosity max

Pressure:

oil inlet

oil outlet

sludge outlet from separator

Feed temperature

Ambient temperature

Discharge volume

Operating water pressure

Operating water temp

Operating water consumption (without make-up water)

Make up water

Operating water flow

" -

Airquallty " ,'• '" •••

Air pressure

Drain-connectiorisize ' •-'-"•','•. ' • . " , " '

Mains supply voltage

ERG supply vöjtage (fram/starterj' •-'' V;.'',"

Control voltage, operating

Power consumption, startup '"^ •:.. . .•••'•'.:

Power consumption idling/max. capacity

Frequéricy • • • - - ^:' '.^'-V^/.;/;.:'i^Vi;'•'.,•'.'.• • . •

Enclosure class

Storage time before use (with bow| removed)

Storage tDm^

Stojage humidity v ' • i •

Se'Vice interva :>

Note! Cleaning In Place (CIP) Is recommended to avoid manual internal cleaning of the bowl. The following intervals are recommended:

Fuel oil and lube oils for diesel engines

lOIOkg/mâtlS C

55cStat100''C 700 :&t a*'•lO C)

Max. 200 kPa (2 bar) at separator inlet

Max. delivery head 250 kPa (2.5 bar)

open outlet

98 °C ± 2 °C

Mm +5°C max +55'C

2 4 litre/discharge

Mm 200 kPa (2 bar) max 600kPa(6bar)

Mm +5 "C max +55 °C (unheated water)

3 7 litre/discharge

1 11rtre/hour

fromSV10:1.6l/m

from SV 15:11.0 l/m

fromSV16:2.8l/m

Instrument: air" ' - • - ' • , - •

Min. 500 kPa (5 bar), max. 700 kPa (7 bar)

^x1':(interriåily threaded). - -•'•;?; '-' ••

3x230/400/440/480/575/690 V ± 10%

' 230 W1.lÖy/i 15 V/10ÖV± iq%,-max..fus6;iÖ A'-" ' '- •

24 VAC

i l kVV; . ' ' . • - • . , > • • "*- v-.-;.- : ...

2.3 kW/6.2 kW

50 or 60 Hz ± max. 5% ' •••..•;.••"•• -i-., ">•;" '•• '• .•'"'' •'•..' "

Min. IP 54

max 6 monthb -- . , .

Mm +1 C max -7C C

,pelativä humidity (RH) 10% - 95 % Non Condensing

Note' RegjIarlv chev,k connections Tighten if necessary

OvertiaCi! every 12000 hours or 16 monthVoteralion' * ' * 1 • I

Prior to inspection and overhaul

HFO 1 - 2 months depending on oil quality

LO (Cross-head engines) 1 - 2 months depending on oil quality and engine condition.

LO (Trunk engines) 1 month

1810965-02

SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE 1 TECHNICAL DATA

Hours

1000

Separat ion System Pianned Ma in tenance Kits

Period Separator Ancillary Equipment

2000

4000 6 months InspeJior

12000

24000

As rit- essirv

With delivery

18 months

3 years

Overhaul

Overhaul

Inspection

Tools

Rpp-ii

n| - '

1810965-02

DD 2, Üi 03 00

o CD

00

o (O O) Ul 6 to

AK

MCFR Flow Control

FC Flow Control

Lo-application

H© i

Alt

II II

'I 'I { , ..Il

^__Æ

" I

Feedpump

•f^^H-€> u::::f7_:

GH>'Ö+H<2ÖT]

Control unit

Starter

I'..

201

?06

209

220

221

222

371

3/5

462

501

Oli Inlet

WatPr for water sea and displacement

Oll ReciFCulataon to tank

Clean oil outlet

Water outlet

Sludge disc tiargp outlet

Operating water

Opening/closing walPr

Dram

Operating air

= =-^= = _ Optional Alfa Laval delivery

Block mounted

10 10

•n 0

t o tt

0 & )

t 3

tf)

s. Ol o> æ o - j c» 33 CD

The EPC-50 Control Unit must be postioned close to the separator. It must be possible to see the separator from the EPC-50 Control Unit position.

i

00

o CO 05 CJI I o

l>0

901

<06

E09

?20

221

02

371

•»75

SOI

709

79$

0 1 Fnle*

WitPr for cor dilion na displacement

Oil ReciiEulalian to lank

Clein Oil outlPl

Water outlet

Sludge discharge outlet

OpeiBhns water-we 11 Demand Spläncdlah Water Piéabré ZOO QO kpa (2-« bar)

" i m p mn-tS'C max -iSS'C

Oppping water/closing wpfor

Opdraling air Insfrument air jDrouura Sto-TI» kPa (5-7 bar)

Mams supply 3x23Qi4C0 440 48 575/690 V

EPC SO supply voltage 230 V 11Ci nsvor loovAC

882

C o n n e c t i o n s

A

B

C

D

F

—

*

DIN Flange DN25 P M 6 DIN2633

DIN Fhnge DN50 PN16 DIN2')4T

ISO G 1/8

ISO G 1 2

Range DN2S-PN16-DIN2633

" " ~ " ~ Optional

InternalflexiblecorinetAon (enclosed with delivery)

If there is more than one separator system in the same installation, the EPC-50 Control Units and their corresponding separators must be clearly marked

oi

ro 1» •

> 00

0>

w 9 tt

10 10

D • 1 fi) ^ • • • 3 (fi W

tt

o c 3

3 (O O S I. 5'

O)

00

o CO

Ü 1

o

J3

2, Ol

~< CD 0 0 C35 33 CD

<

The EPC-50 Control Unit must be postioned close to the separator. It must be possible to see the separator from the EPC-50 Control Unit position.

§

m?^W

v ^ •

EPC 50

Starter

^ ^

201

21b

209

220

.221

222

371

375

501

709

799

Oil iniei

W-ater to cond 1 o ng^d piace MT 1

OIIFMdfCLAatlonlDtank

Cle?n 01 outlet

Water outlet

Sludge d scha ge c tiel

Opefatina water-see 11 Demand S|ic(i(eaHan Water

0Pri&sui«'20frS0O kPa f 2 6 t)ar) Ttaw nAi +5°C max +55 C

Open ng water clos ng v t«4r

, OdKAMB air Instrument air . pi|M[it»EDO-700kPa (5 7 bar)

Mains supply 3x<!''0 410 •l l i f 57'i/69C V

EPC-SO supply voltage 230V 110/ l lbVorlOOV AC

10 io io (A > OB

u

w 9 tt

o • I

o c 3

5' 03

I Connections

A

B

C

D

Welding connecbon 0 34.5 •

Flange 50A-10K-JISB2222

ISO G1/8

ISO G 1/2

7" " * " - " " Ofillonal

If there is more than one separator system in the same installation, the EPC-50 Control Units and their corresponding separators must be clearly marked

•

00 —j> .

o CO o> U1 I o

ISi

835

Maximum horizontal displacement at the inlet/outlet connections during operation ±5 mm

Maximum vertical displacement at the sludge connection during operation ±2 mm

CE (ß

m

028, depth 45

Connection house with connections 201,220, and 221, turnable in 60 ° steps all round.

All connections to be installed non-loaded and flexible.

All dimensions are nominal. Reservation for Individual deviations due to tolerances.

M10, depth 30.

/J-®U. 022, depth 45 / ^

to 10 •

u OB u 0> w 9 V a S

a (0 5' in N'

D S I. 5'

CO 3) (D

Ol C3>

-vi N) 05 J3

<

00

O (O o> Ol

ö IV3

Min. lifting capacity required when doing service: 300 kg

Max. height of largest component incl. lifting tool.

T'

800

'/v^////////''A}//////// •"—^ hy)>/////]^m

"~\

Service side.

-^r?^""! ^ > ^ _

Centre of sepeuator bowl

<S)S

jijm 7 T

Foundation bolt

Installation ace. to stated foundation forces

Centre of motor

8 holes for foundation bolts

Recommended free floor space for unloading when doing service.

No fixed installation within this area

0^ Centre of gravity (complete machine)

1 i T Vertical force not exceeding 10 kN/foot

A A Horizontal force not exceeding 10 kN/foof

Total static load max. 4 kN

10 io •

(A 0»

u 0> M •o

T1 O c 3 a

O

3' (fi

SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.2.5 Valve Block Oil, DN 25 Dimension Drawing

Ref. 568054 Rev. O

1810965-02

2 DRAWINGS SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE

2.2.6 Valve Block Oil, DN 25 Assembly Drawing

Cable 19

Water transducer

* Angular coupling

Non-return valve

Connection Pressure transmitter

Needle valve

Temperature sensor

Nipple

Pneumatic change-over valve l4f3^\Y'

Non-return valve

Connection kit

Connection

Pressure transmitter

Needle valve

Nipple

Elbow *

Pressure^ gauge

Valve block

Nipple

Needle valve

Shut-off valve *

Pressure transmitter

Connection

Nipple

Screw Washer Hexagon plug Elbow Silencer Flexible connection -*

* To be sealed with locking liquid

Ref. 567802 Rev. 2

10 1810965-02


2.2.7 Valve Block Water Assembly Drawing

Connection for solenoid valve

Valve block.

Flexible connection

Flow valve for SV 10



Flexible connection

^ Quick coupling

Non return valve kit

Ref. 567940 Rev 0

1810965-02 11


2.2.8 Valve Block Air, Assembly Drawing

Spade connection

Valve block

EOS

Ref. 568048 Rev. 0

12 1810965-02


2.2.9 Control Unit EPC 50 Dimension Drawing

Operating panel

Separator interlock Iridication (optional)

Sludge valve interlock indication (optional)

PC connection

481 »9 lt»l

»25 12«!

Emergency stop, separator

On-off, feed pump

On-off, separator

Ä a Plugged holes for extra cable glands

Technical Data

"AmMsnttempetature

Protection class

Mstenat in cabinet

Power supply

Oparatng voltage

Power consi-mption

Weight ' . - ' ' , • ' *

— Optional

IWax. 55 'C

IP 65

Sheet steel

100,115 or 230 V AC 50/60 Hz

24vAC«VeOHz' ,

70 VA (+200 VA for I/O)

•sBfia \x'^'• ".'"

Ref. 568304 Rev. 3

1810965-02 13


2.2.10 Starter Dimension Drawing

5$^

PoTl

A

01^

P2

600 3 l l

•o

08.5x15

Ref. 568025 Rev. 1

14 1810965-02


2.3 Electrical System Layout

Aiddns suiBW

S

< ir m

n "rö 1 o c D

U-

I I

4) ^ 4 (i) (^

Ref. 568029 Rev. 0

1810965-02 15


2.4 Electrical Diagrams

2.4.1 Cable List

N o . type Connect ion point A

Instruction Connect ion point B

Power cables (currents according to order)

2

3

3

3

3

3

3

3

71

4

4

72

MPRXCX

MPRXCX

MPRXCX

MPRXCX

MPRXCX

MPRXCX

MPRXCX

MPRXCX

.MPRXCX

MPRXCX

>»PRXCX

MPRXCX

MPRXCX

MPRXCX

MPRXCX

MPRXCX

MPRXCX

3x4

3x10

3x16

3x25

3x35

2x1 5

3x1 5

3x2 5

3x4

3x6

3x10

3x16

3x25

2x15

3x1 5

3x2 5

2x1.5

Mams supply

Mams supply

'Mams supply

Mams supply

Mains supply

Starter

Starter

Starter

Starter

Starter

Starter

Starter

Starter

Starter

Starter

Starter

J w* ft * *

starter

. Starter

Starter

Starter

starter

Starter

EPC50

Separator motor

Separator motor

Separator motor

Separator motor

Separator motor

Separator motor

Separator motor

Separator motor

Feed pump

Feed pump

Feed pump

R e m a r k s

1

Fuse 20 A

Fuse 35 A

Fuse 50 A

Fuse 63 A

Fuse 80 A

2 5 - 6 3 A

6 3 - 1 6 A

1 6 - 2 0 A

20 - 25 A

2 5 - 3 2 A

32 - 45 A

4 5 - 6 3 A

0 4 - 6 3 A

6 3 - 1 6 A

* 4 * ''

Ref. 568031 Rev. 0

16 1810965-02


No. Type

Signal cables

11 1 RFE-HF

12

13

14

15

16

17

18

19

20

21

22

23

50

51

52

Options

31

32

33

34

35

38

40

45

41

44

RFE-HF

RFE-HF

RFE-HF

RFE-HF

RFE-HF

RFE-HF

RFE-HF

PUR-cable

RFE-HF

RFE-HF

RFE-HF

RFE-HF

RFE-HF

RFE-HF

RFE-HF

(as ordered)

RFE-HF

RFE-HF

MPRXCX

RFE-HF

RFE-HF

MPRXCX

RFE-HF

RFE-HF

RFE-HF

RFE-HF

li.CJx'' ^ E

1x2x0 75

1x2x0 75

1x2x0 75

1x2x0.75

1x2x0 75

1x2x075

1x2x0 75

4x0 34

4x2x0 50

1x2x0 75

1x2x0 75

4x2x0 75

4x2x0 75

4x2x0 75

1x4x0 75

1x4x0 75

1x4x0 75

5x1 5

1x4x075

1x4x0.75

4x1 5

4x2x0 75

1x2x0 75

1x4x0 75

1x2x0 75

Connection point A

E-'C -n

EPC50

EPC50

EPC50

EPC50

EPC50

EPC50

EPC50

EPC50

EPC50

EPC50

EPC50

EPC50

EPC50

EPC50

EPC50

Instruction

ssc ssc ssc + EMC

SSC + EMC

SSC

SSC + EMC

SSC + EMC

Connection point B

SV1

SV4

SV5

SV10

SV15

SV16

PT1

PT4

MT

ST (YT SS)

PT5

SUM Alarm

TT1/TT2

Starter

Starter

Starter

Rem OP unit

Rem Temp al

Rem Start/Stop

Comm module

GS Valve switch

Syst Emergency

Power unit

Power unit

Steam reg valve

Shut-off valve

Remarks '

2)

1)

^ This cable cannot be longer than 25 m to avoid voltage drop. ^ Cable with moulded connector included in Alfa Laval delivery.

Ref. 568031 Rev. 0

1810965-02 17


Other equivalent and approved cables may be used.

Cable areas are calculated with correction factor 0.7.

Cables used are Shipboard Cables, designed according to IEC 92-3.

Flame retardant according to IEC 332-3/A.

Halogen-free according to IEC 754-1

Code designations for cables obtainable through cable producers Helkama, Finland, and Acatel, France.

Where SSC is indicated it should be a Signal Shielded Cable with the shield properly connected to earth as shown in the electrical drawings.

For other connections, an armoured cable may be used provided the armour is connected to earth, as shown in the electrical drawings, and gives sufficient EMI protection. Copper wire armouring is normally used.

•

18 1810965-02


2.4.2 Interconnection Diagram, Starter

Mains suppy

3x230,400, 440, 480, 575 or 690 V AC

Select correct voltage on transformer T8

Separator motor

-^J >

Space heater 230 VAC Separator motor optional

.11 J

Contactor response, separator

Potential free contacts, max. 250 V 0.5 A

Feed pump motor optional

Space heater 230 VAC Separator motor optional

Contactor response, separator

J

J

n x i 72-1 -" •-] 72-2 I d -.11 1

J2>-

Potential free contacts, max. 250 V 0.5 A

Systems emergency stop (Control voltage off)

Power supply to EPC 50 (Sheet 5)

230 V AC, 50/60 Hz

IU-i-1 JL.,-2 i - 1 - 3

- 3 - 1 • • 3 - 2 •

- 3 - 3 •

£

£ _

.J

Ji

Jl 62 ! 61

; ^ 7 i - 2 > 4 ^ '' 72 I 71

i

II

H -

I L - 4 - 1 , 11- - 4 -2 . " 4 \ 11- - 4-3 •

4:; £ _

!!- 72-1 -

J

J

---(ZBy-A-

<5>

72-2

62 I 61

72 I 71

""63-;^5i

r» ml I ^cn I

- - h -11-38-1

Jl

l 3

L

*[[ 2 - - I - - M xiTT

P •2-1 •2-2

Ä i , ni±.

CO

DD — I m 3}

Ref. 568030 Sheet 1, Rev. 1

1810965-02 19


2.4.3 Interconnection Diagram, Starter, cent.

* = Replaces jumper in terminals ** = Internal connections

To EPC 50 (sheet 5)

To EPC 50 (sheet 5)

Separator emergency stop (optional, external)

Sludge valve interlock switch optional

^1 II

— I I -_1 ^r

,-T

J

, 35-1--J1 •-- jfO-- 35-2-^l / C ^ u i

'-•»•^<^-35-4--II

Feed pump Remote stop

Remote start

f- * T " 0 - -

Feed pump interlock

" I I --II - - i f _ j i

_ j i it--

-"11

Heater interlock

Potential free contact, max. 250 V 0.5 A (Feed pump running = contact closed) Tripped motor^circjj|t J)£eaJ<ersJoptjonal)_ Potential free NC contacts, max. 250 V 0.5 A

Emergency Shut Down (ESD) signal (optional)

Emergency Shut Down (ESD) feedback

-50-1 -- 5 0 - 2 -- 5 0 - 3 -- 5 0 - 4 -

- 5 0 - 5 -- 5 0 - 6 -- 5 0 - 7 -- 5 0 - 8 -

-51-1 --51-2 --51-3--51-4 -

-51-5--51-6 --51-7--51-8-

X1:101 X1:102 X1:103 X1:1Q4

X1:105 X1;106 XI : 107 X1:108

X1:109 X1;11Q X1:111 X1:112

- H -

J

- h -

- (45h-4

J

J -¥-u - h -

J

To EPC 50 (sheet 3)

. 1-

-52-2 -

I L . -II i r -r-

i l - - 3 5 - 1 - -J L - 3 5 - 2 -I P - 3 5 - 3 - -I I - - 3 5 - 4 - -

X1:113 X1.-1H X1:115 X1;116

Xl:117

X1:118 X1:119 X1:120 X1:121

X1:122 X1:123

• fX1;124 X1:125 X1:126 X1:127

J

X1:128

i r -I I - -

~ i i - -I L .

•f XI : 129 X1:130

I L . -II i r -. L . « - 1 .

r-- - 4 5 - 2 - -

•II l u ll

I f -1l

X1:131 X1:132

X1;133 XI: 134

XI: 135 XI: 136

XI: 137 XI: 138

XI: 139 XI: 140

XI; 141

XI; 142

-X I : 143

XI: 144 XI; 145

05

-H

m J3

K112

'ATOMI

'-i\^

X40 MI

X41 X41 X41


20 1810965-02

SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE 2 -DRAWINGS

2.4.4 Interconnection Diagram, IVansmitters

MT Water transducer

* Termination jumper. Only at sattbus end units.

Remote OP unit

* Termination jumper. Only at sattbus end units.

Temp, sensor, 2xPT 100

IT 1 (Alarm)

TT 2 (Control)

PT1

PT4

PT5

Speed transmitter (Cable included in separator delivery)

Vibration transmitter (Factory mounted when used)

Separator interlock switch optional

O O

J3 O I — c z H m O en O

From starter (sheet 2)


1810965-02 21


2.4.5 Interconnection Diagram, Solenoid Valves

Signal to alarm panel. Pot. free contact, opens at alarm

Max. 50VAC/DC, 1.0A

SV1 Oil feed

SV4 Oil outlet

SV5 Water outlet

SV10 Water seal

SV15 Opening water

SV16 Closing water

. jp i i - i - ]

--)p 13-1-

-<Sy

^ ^ i : : : ] t — &

®-• 13-2-11 ^-^

x ^ : : : ; i i — ^

, ^ ' • 2 2 - 1 •

• 2 2 - 2 •

fl xzu_-X 7 L 2 .

X2ii XZil .

X7:5 ÔLL

,_y t^:z:

.ji: lpi2-2 ^ i

,-1

,jr

t:3:

.-jr J|-15-l ] | - 15-2 1 i

,jr 11- 16-1 | |- 16-2 11

X8:2

MlL

m i

XM.

m i

XSii

m i JSiZ.

Ä i

o o z H XI

o

m - 0 O en o


22 1810965-02


2.4.6 Interconnection Diagram, Solenoid Valves cent.

Systems emergency stop (Control voltage off)

38-1 — • ^ - 3 8 - 2 - j

38-3—I - - - f38 }

From starter'(sheet 2)

<I> c 3 x> CD

O O

< > O

MM X43:2 Mil X43:4 Mil X43:6 Mil Ml.

C—

c

•a CD

Ol

<

2- o

^X43:1 -X43:2

X43:3 ^X43:4 f X43:5

X43:6 -X43:7 ^X43;8

3 CD O Ö' D CO

o "

CD

Ä < •

CD



^ Replaces jumper in terminals

-H

r 38-1 •

38-2 •

38-3 •

38-4 .

X40 X40 X40 X4n X40 X40 X40 X4n X40 X40

1 7 7> 4 5 f> 7 R 9 10

hi -1

•o

SB <n CD

F5 I H

.jr

.J

,J

X40:11 l

X41 Ml Ml

X41:16 X41:17 X41:1f

it'-' r—2-2

c 3 CD

< > o

^ M i X43;? X43:3 X43:4 X43:5 MM. X43:7 X43:8

•50-1 •50-2 •50-3 •50-4

•50-5 -50-6 -50-7 -50-8

•51-1 51-2

-51-3 •51-4

-51-7 -51-8

-20-7 -20-8

X45:1 X45:? X45:3 X45:4

X45:5 X45:6 X45:7 X45:8

X45;9 X45:1Q X45;11 X45:12

X45:13 X45:14 X45:15 X45:ie

AZ}

Sheet 6

O O Z H J3 O

m

O en o


1810965-02 23


2.4.7 Interconnection Diagram, Optional Equipment

Remote alarm indication

High temp, indication

Low temp, indication Pot. free contacts Max. 50 V AC/DC, 1.0 A Contact closes at alarm.

Riqmntfi nperatinn

Remote mode selected (output 24 V< AC) Sep. status indication (output 24 V AC) Separation Start/Stop

Note Jumper X71:1 toX71:3to avoid false alarm v\/hen not used.

— 32-1 -— 3 2 - 2 -

— 3 2 - 3 -— 3 2 - 4 -

Start top

-33-1 -

-33-2-

-33-3-

33-4-33-5-

Data communication C-34-1 9usGNC|-34-2'

34-3-JneA .IneB Shield

34-4-

-51-5--51-6-

r i -20-3-}-

-20-4-j--20-5-|-

XfiOll XfiO;? WQ:^ X60;4

m-^ X60;6

II

I J

J

3 4 - 1 -34-2-34-3-

• 34-4-

3 3 - 3 - -

1 1

_L

L

r

L

X50:l X5n;? x?^n-,^ X50:4 X.'in;S X50:6

X51:l X.-il;? X51:3 Xfi1;4 XS1;5 XS1;6

X7n;l X/O;?

X70;4

X70;.'

X70:6

X71:1 X71:2 X71n^ X71;4 X71:5 X71;6

I

>i

P

D

„ - 1 r" 1

? 3 Z CO

O z CD O %

Mill mki mi^ MM mi^ ISÖ1

o o z H 33 O

m t J O en O

8 s

I


24 1810965-02


2.4.8 Transformer Connection Diagram

r n n -65 - -^

r f

—Q— © - e - -©- —© I

'h

L _ 1 1 r -r -

1

J

E

? ^

A—A 4-

o o

0 0 X zfi)é-c!)—

X X

A—Â— A- £ é

V-

— CO

Ref. 31830-6337-0 Rev. 2

1810965-02 25


2.4.9 Circuit Diagram, Power Circuits

Mains supply

Separator

Space heater (optional)

Feed pump (optional)

Space heater (optional)

c r T ^ "-^^ ' V ^

::::::::::::::'v^ vr Ol I y

I

r C i : ] ;ô<r-L r ôo^

V^Ci Vf-^ * I

I I

rCII] ^°4^ L f ' i o j ^

0'

eV s ; -r,

%v

Ais-^l

3

O.J ho - *

Cont.


26 1810965-02


2.4.10 Circuit Diagram, Separator Starter and Feed Pump

mmf t-ht-PPI=R=l=

Åi- — IfO I ^ Im Itci

y f^ f io U - t o ^ U o U o r —

Æ - *

xmrn xmoi

a H

\J

. i -


1810965-02 27


2.4.11 Circuit Diagram, Remote Start Interlock (optional)

• ' •

z > ^

> CM

§rr m

• « ^ ^ . ^

o CJ

>-CO gj

>< D <

ic

>< r" • ;„" i ^ 1 m i ^ • ,

! ; ^ I ! o

3 <

— ^ m _ lO >z: x » ^ X » : ;

. - t n ID i n (O j '*" 5»"" S«*" j

1 j

i s 1 ! i

! iS ^ i !

1 i CO U i = ! 1 i 1 Q . ~ l a 1 i ! i 0) 5 (-) i • 1 !co wfci. ! 1 • 1 r r . - i 1 i ») ' „ 1

I T i a j

>

rr j » :

m r O o m Q

B

S- 2 § t o CO ••=

^ l | X 0) ^ 3 C/D . £ <

<

-|

£<S i

^ «N

o f

>< i

fM !

. . .J

(N

>c<

r i r i ic i iO 1 !--=T3 I \^ CO 1 IrQ O Q

L, L>cD. i

S a

s

ro ^ • ^ X )

s i tn X

a

, ^

1

"1 i

»*o J i

. . . . .J

Ref. 568028 Sheet 3, Rev. O

28 1810965-02


2.4.12 Circuit Diagram, ESD-relay and IVip Contacts (optional)

j < :

o

c W o c

•r^ f ^

x o f ^

i n

L O

in tn

^ 00 xtf^

to

sr to

5-

^ O) X U f O

to in

ill

„ o X l l ^

to CO

s/ CO

9-Q-

I I

•—

•—

CN

1 i i l

< 1 1 <

i S CO <D c

o

L . . . l . - " . ^ J

Ref. 568028 Sheet 4, Rev. O

1810965-02 29


30 1810965-02

SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE 3 REMOTE OPERATION SYSTEMS

0 3 Remote Operation Systems

y^VJABWlHO^

Disintegration liazard If the system is operated from a position from which the separator is not visible, a Remote Operation System must be installed, including vibration sensor and frame cover interlock switch.

PC connection witii REMIND™

The cable supphed is used for communication between the EPC 50 Control Unit and the PC. This is connected between the contact at the front of the operator panel, and a COM gate on the PC. Communication is via an RS232 interface. Only one operator panel can be connected to ihe PC.

Connection to PC or steering system via PROFIBUS or MODBUS fieldbus systems.

PROFIBUS or MODBUS communication protocol can be used to connect an EPC 50 Control Unit to a central steering system. The EPC 50 Control Unit uses a PROFIBUS DP or MODBUS RTU. Every node, or EPC 50 Control Unit, on the bus has a unique address, and can use 200 bytes for data exchange. An interface board is needed to connect an EPC 50 Control Unit to the respective fieldbus system. This is mounted on the I/O card.

Remote fieldbus connection for EPC 50 Control Unit is for use in those cases where the user wants access to data and operation information from the control cabinet, and supervision and/ or remote control from his own steering system.

REMIND^M via PROFIBUS or MODBUS is not available. If a user wants to have a REMIND^"*" window on his monitor, a programme is needed to make the information accessable in REMIND^M.

1810965-02 31

3 REMOTE OPERATION SYSTEMS SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE

Alternative REMIND™ EPC 50 Basic (via RS232)

31830.6409-1

"REMIND™ installation discs included in delivery.

Part no. 31830-6415-1 included in delivery.

Included in delivery.

Part no. 4931142-11

PROFIBUS MODBUS

User interface

Cable

! Mariua;

Board

To be arranged b>' customer.

Cable for PROFIBUS aquired and installed by customer.

Hardware and softwaie instructions exist.

Tc be arranged by customer.

Cable for MODBUS aquired and installed by customer.

Hardware and software instructions exist.

Part no. 31830-6559-1 Part no. 31830-6558-1

32 1810965-02

SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE 3 REMOTE OPERATION SYSTEMS

1810965-02 33

4 SPECIFICATIONS SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE

4 Specifications

4.1 Cables

Cable Identification

All cables are to be marked to simplify identification and fault finding.

Specifications

The following specifications apply to cables connected to and fi*om Alfa Laval equipment. Follow the instructions given in the cable list. Examples of cable types that can be used:

• Steel armoured cable.

Copper armoured cable with a separate earth core.

Steel armoured and shielded signal cable; pair twisted or parallel.

Shielded signal cable; pair twisted or parallel.

< m

34 1810965-02

SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS

4.2 Cable Routing

Recommendations Power cables carry the power supply to motors, heaters, etc. Any distance between signal and power cables reduces electrical noise transfer.

Examples of recommended routing of various cable tjrpes.

• Power cables and signal cables routed on a cable rack should be separated.

• Sattbus cables should be routed away from power cables.

If the space is limited, cables can be routed in tubes.

i(SXS)(S> ®®®l

Power Signal Cables Cable

4.3 Oil, Water, Steam, and Condensate Piping For piping to and from Alfa Laval equipment, see the specifications below.

Specifications

• The correct pipe size must be used in the oil systerh.

• The number of bends in the oil pipes must be minimized.

• The suction height must be as low as possible.

• The oil feed pump must be of positive displacement type.

• The pump must be positioned close to the oil tank.

• The heater must be installed close to the separation system to maintain correct feed oil temperature.

• The recirculation line should be connected either directly to the settling tank (HFO) or to the oil dutlet line from the separator (LO).

• The oil outlet line from the separator must be connected to the system tank for lube oil, or the service tank for fuel oil.

1810965-02 35


4.4 Ambient Temperature Limitation

SpecKication Leading classification societies state in their regulations for engine room equipment that the maximum ambient temperature permissible is +55 ° C. To meet this regulation, it is essential that electrical and electronic components have good ventilation, and temperature control.

4.5 Sludge Tanic

Sludge tank volume per separation system should cover approximately up to 2 days storage at a discharge interval of 2 hours (for discharge volumes see technical data).

A manhole should be installed for inspection and cleaning.

The tank should be fitted with a sounding pipe.

The tank floor, or most of it, should have a slope (B) of minimum 15°.

The sludge outlet pump connection should be positioned in the lowest part of the tank.

A high-level alarm switch, connected to the sludge pump, should be installed.

A heating coil should be used to keep the sludge warm and fluid while being pumped out.

Tank ventilation must follow the classification rules for evacuation of gases.

There should be a ventilation pipe to fresh air

The ventilation pipe should be straight. If this is not possible, any bends must be gradual.

The ventilation pipe must not extend below the tank top.

A sludge tank with partition walls must have ventilation pipes in all compartments, or cutouts in the upper edge, to allow vapours to travel through the tank.

Ventilation pipe

Sludge pipe connection

Sludge outlet pump connection

l^ln. height 400 mm

Min. slope 15°

Bowl casing drain IManhole connection

IHigh level alarm switch

Heating coil

36 1810965-02


The number of ventilation pipes, and their minimum dimension, depend on the size and number of separators connected to the same tank. See table below.

Type

SA811,SA816

S A : 8 2 1 , S A 8 2 6

SA831,SA836

S A ; 8 4 1 , S A 8 4 6

SA%51, SA856

SA861,SA866

SA871,SA876

SA881,SA886

1 system

1 X 050mm

1 X 075mm

1 X 0100mm

1 X 0100mm

2 systems

1 X 050mm

1 X 075mm

1 X 0100mm

1 X 0125mm

The separation system generates almost no air during operation. At any discharge, the maximum volume of air produced is the same as the bowl volume (see technical data).

1810965-02 37


4.6 Sludge Piping

Specification

• The sludge pipe from the separator to the sludge tank should be vertical.

If a vertical pipe is not possible, the deviation (A) from the vertical line must not exceed 30°.

• The sludge pipe must not extend below the tank top.

An extended sludge pipe will obstruct ventilation and create back pressure that could cause separator problems.

^ ^ ^ ^ L n

'~~~~~~ZÆF

/

jj J^^^f

^»

\

38 1810965-02


If more than one separator is connected to the same sludge tank, a butterfly valve should be installed in each sludge pipe.

note If a butterfly valve Is not used, the bowl and the operating system may be affected.

If a butterfly valve is used, it should be equipped with an interlocking switch (connected to the separator starter) to prevent the separator from being started when the valve is not fully open.

1810965-02 39

5 COMMISSIONING AND INITIAL START SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE

5 Commissioning and Initial Start

5.1 Completion Check List It is essential before starting up the separation system that all units are in good operating condition and that all pipelines and control equipment are properly connected to assure correct operation.

Use this check list as a guide for completing the system installation;

.urmz Breakdown hazard Check that the power frequency is in agreement with the machine piate. If incorrect, resulting overspeed may cause breakdown.

1 Check that transport seals are removed from all pipes.

2 Use flushing filters to prevent pipe work debris from being pumped into the separation system

MOTE

The flushing filters must be removed after initial flushing.

3 Check that all separators are in proper working condition. Follow the manufacturer's instructions.

4 Make sure that separators are lubricated in accordance with instructions.

M O ^ -

Make sure that the spindle bearings are prelubricated

5 Separators are delivered without oil in the oil sump. For information on oil filling and oil type, see the Service Manual booklet.

40 1810965-02

SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE 5 COMMISSIONING AND INITIAL START

note Too much, or too little oil may result in damage the separator bearings. Neglecting an oil change may result in damage to separator bearings.

6 Power on.

7 With the mode selector switch in the CIP postion, check that the separator rotation direction corresponds with the arrow on the frame by doing a quick start/stop (1-2 seconds.) and looking at the motor fan rotation.

KcftOTlOl*

If power cables have been installed incorrectly, the separator will rotate in reverse, and vital rotating parts can unscrew.

8 Check the pump function and direction.

1810965-02 41


5.2 Initial Start-up

Use this check Hst for initial system start up:

1 Check that there is oil in the feed oil tank.

2 Check water and air supply. See "System Data"on page 2.

3 Check power supplies to the control unit and that the voltage is in accordance with data in "System Data"on page 2.

4 Check all parameter settings in the control unit. See Installation Parameters in the Parameter List booklet.

note The Control Unit is supplied with standard configuration parameters. You may have to make some changes to suit your installation.

5 Start the separation system as described in the Operating Instructions booklet.

6 Start up step by step, checking that the machine and units function properly.

7 Establish system pressures.

The|delivery height pressure is the pressure in the ON pipe work down stream from the separation system, due to the pipe bends and the height (head) to the cleaned oN tank. If the cleaned oil tank is below the separation system the delivery height pressure may be very low; The oil paring disc pressure will have to be greater than the delivery height pressure for any oil to flow. Proceed as follows:

• Ensure the valves in the oil system are in the correct positions.

• The oil should be at separation temperature. Cent.

42 1810965-02

SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE 5 COMMISSIONING AND INITIAL START

The 2 adjustment screws for the water paring tube should be in their outer positions. The paring tube should be able to move freely. Ensure that V5 is closed. Fully open the back pressure regulating valve RV4. The shut off valve V4 should be open. Open SV15 for 3 seconds to prime the operating slide. Open SV16 for 15 seconds to close the bowl. Open SV10 for 30 seconds to put water into the bowl. Feed oil to the separator at the normal flow rate by opening SV1. Note the pressure in the oil outlet PT4, both on the pressure gauge and in the EPC50 display. This pressure is P min. Gradually close the back pressure regulating valve RV4. The pressure on PT4 will increase. The water pressure (PT5) decreases slightly as the paring tube moves inwards. The water pressure will suddenly drop when oil passes from the oil paring chamber to the water paring chamber. Note the pressure of PT4 both on the pressure gauge and in the EPC50 display. This pressure is P max. Open RV4. Stop the oil feed to the separator and note the pressure in the oil outlet. This is the delivery height pressure P del. Stop the heater. Stop the separator. Stop the feed pump when the heater has cooled.

1810965-02 43


5.2.1 Calculating Operating Pressure

• Calculate the normal back pressure level during operation as follows:

"min ••• "max = P, normal

• Calculate the value for low pressure alarm setting (Pr 11) as follows:

"mln "*• "normal — "low press.

2

• Calculate the value for high pressure alarnn (Pr 10) as follows:

^normal ••• "max 7 ~ "high press.

Adjust the back pressure to Ppormai

Set Pr 11 to give alarm at pressure decreasing below the P|ow press, value.

Set Pr 10 to give alarm at pressure increasing above the P jgh press, value.

44 1810965-02

!ÜÜÜ:^^SV5TEK„NSTA.UT,ON SYSTEM REFERENCE

Shut-down and Storage ^ f ^ D O W N AND STORAGE

Storage bo,ore|„sta.,a.io„

Ä C : r X ^ - - t o r e d befor, taken: ' ^'^''^^«^^^^ safeguard s must be

> Storage period Action

>-> t I ^ ' ' . " II t ,

liSDe"tiop

1 - 6 months > 6 months S e p

"•• •i» chapter

6-1 Shut-down after Use

»"St be taken: ' ^ ™""™« safeguards

Shut>down period

Action

1 - 6 months

(stand-by) 6 - 1 8

months

t 1 i" i p t-

I P o»bct «I h an* rj<,t Oil ' •'Ot t ,

> 1 8 months

Service manual

See

1 I I n <•

aju

1810965-02

45

6 SHUT-DOWN AND STORAGE SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE

6.2 Protection and Storage

All system equipment, both the separator and the ancillary equipment, must be stored indoors at 5 - SS'C, if not delivered in water-resistant box for outdoor storage.

If there is a risk for condensation of water, the equipment must be protected by ventilation and heating above dew point.

The following protection products are recommended:

• Anti-rust oil (Dinitrol 112 or equivalent) with long lasting effective treatment for external surfaces. The oil should prevent corrosion attacks and give a waxy surface.

• Anti-rust oil (Dinitrol 40 or equivalent) thin and lubricating for inside protection. It gives a lubricating transparent oil film.

• Solvent, e.g. white spirit, to remove the anti-rust oil after the shut-down.

• Moist remover to be packed together with separator equipment.

• If the storage time exceeds 12 months, the equipment must be inspected every 6 months and, if necessary, the protection be renewed.

Rubber Parts • Gaskets, O-rings and other rubber parts

should not be stored for more than two years. After this time, they should be replaced.

Separator

Dismantle the separator bowl and take out the O-rings. Clean the bowl with oil and reassemble without the O-rings. Place in a plastic bag with silica dessicant bags and seal the plastic bag.

Grease the spindle.

46 1810965-02

SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE 6 SHUT-DOWN AND STORAGE

Valves, Pipes and Similar Equipment

• Components such as valves need to be cleaned with solvent and treated with anti-rust oil (type 112).

• Water pipes should be drained and treated with anti-rust oil (type 112).

• Articles made of rubber or plastics (e.g. seals) must not be treated with anti-rust oil.

6.3 Reassembly and Start up

• Clean away the anti-rust oil with white spirit.

• Remove all silica gel bags.

• Pre-lubricate the separator spindle bearings

• If stored for 6 months or longer, perform an inspection service (including change of oil in the separator sump).

• Follow all relevant instructions in the Service Manual and Operating Instructions.

Always lubricate the separator bearings before startup.

1810965-02 47

6 SHUT-DOWN AND STORAGE SA 836 SEPARATION SYSTEM INSTALLATION SYSTEM REFERENCE

48 1810965-02


Service Manual i^^î^

Printed

Book No.

Sep 2004

1810993-02 V 1

» • \

^

Contents Separator Design 1 1.1 Overview 1 1.2 The Drive Section 3 1.3 The Process Section 4 1.4 Sensors 8 1.5 Separating Function 9 1.5.1 The liquid balance in the bowl 9 1.5.2 Liquid flow 10 1.5.3 Discharge of sludge and water 10 1.5.4 ALCAP™ concept 11

Technical Reference 13 2.1 Product description 13 2.2 Technical Data 14 2.3 Connection List 15 2.4 Interface Description 17 2.4.1 Scope 17 2.4.2 References 17 2.4.3 Definitions 18 2.4.4 Goal 18 2.4.5 Description of separator modes 19 2.4.6 Remote start 20 2.4.7 Handling of connection interfaces 20 2.5 Demand Specification Water 27 2.6 Drawings 28 2.6.1 Basic size drawing 28 2.6.2 Foundation drawing 29 2.6.3 Interconnection diagram 30 2.6.4 Electric motor 31

Separator Service, Dismantling, Assembly 33 3.1 Periodic Maintenance 33 3.1.1 Maintenance intervals 33 3.1.2 Maintenance procedures 34 3.1.3 Tightening of screws 35 3.1.4 Service kits.... 35 3.1.5 Cleaning 36 3.2 Maintenance Log 37 3.3 Dismantling 39 3.3.1 Introduction 39 3.3.2 Tools 40 3.3.3 Frame hood 42 3.3.4 Bowl 44 3.3.5 Driving device 54

3.3,6 Centrifugal clutch 66 3.4 Actions Before Assembly 73 3.4.1 Cleaning 73 3.4.2 Inspection for corrosion 75 3.4.3 Inspection for cracks 76 3.4.4 Inspection for erosion 77 3.4.5 Exchange of frame feet 79 3.4.6 Lubrication of bowl parts 80 3.4.7 How to lubricate bowl parts with slide

laquer 81 3.4.8 Check for galling on operating slide

and bowl body 82 3.5 Assembly 83 3.5.1 Centrifugal clutch 83 3.5.2 Driving device 90 3.5.3 Bowl 102

3.5.4 Frame hood 115 3.5.5 Unbalance sensor (option) 119 3.5.6 Speed sensor 121 3.6 Actions After Assembly 122 3.6.1 Control of machine plates and safety

labels 122 3.7 Oil Change 124 3.7.1 Lubricating oil 124 3.7.2 Check oil level 125 3.7.3 Oil change procedure 125 3.7.4 Lubrication chart 126 3.7.5 Lubricants 127 3.7.6 Lubricating oils 129 3.8 Lifting instructions 130 3.8.1 Lifting the separator 130 3.8.2 Lifting the bowl 131

C h a n g e of C i r c u i t B o a r d 1 3 2

4.1 Circuit Board Temperatures 134

Cleaning in P lace 135 5.1 Cleaning in Place, Separator... 135 5.2 Cleaning in Place,

Heatpac® CBM Heater 136 5.3 Cleaning in Place, Separator

and Heater 138

1810993-02

1810993-02

SA 836 SEPARATION SYSTEM SERVICE MANUAL 1 SEPARATOR DESIGN

• 1 Separator Design

Process section

The feed inlet and o u t l e t s \ r are situated at the top of the separator.

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

Sensors

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

Frame feet

The separator rests on vibration damping frame feet.

Electric motor

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

Drive section

The rotating separator n bowl is driven by a flat 1 belt transmission.

Sludge outlet

Separated solids are discharged at preset intervals.

1.1 Overview The separator comprises a process section and a drive section powered by an electric motor.

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

The bottom part of the separator contains a flat belt transmission, a centrifugal clutch and a vertical spindle. The lower body also contains an oil bath for lubrication of spindle bearings.

1810993-02

1 SEPARATOR DESIGN SA 836 SEPARATION SYSTEM SERVICE MANUAL

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

The process liquid is cleaned in the separator bowl. The bowl is fitted on the upper part of a vertical spindle and rotates at high speed inside the frame hood. The bowl also contains the discharge mechanism which empties the sludge during operation.

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

1810993-02


1.2 The Drive Section

The separator howl is driven by an electric motor via a belt transmission. The belt pulley on the motor shaft includes a centrifugal clutch.

Flat belt

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

To reduce bearing wear and the transmission of bowl vibrations to the frame and foundation, the top bearing of the bowl spindle is mounted in a spring dampened bearing seat.

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

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

1810993-02


1.3 The Process Section The separation process takes place inside the rotating separator bowl. The feed and outlet of process liquid takes place in the in and outlet unit on top of the separator frame hood.

Inlet and outlet

The inlet and outlet unit consists of the following parts:

A connection house for pipe connections.

A pipe with a paring disc and a paring tube is located inside the connection house. The pipe has channels for incoming and outgoing process liquid.

The paring disc and paring tube pump the cleaned oil and water respectively out of the bowl.

The paring tube can move radially. During separation it surfs on the liquid surface. It is balanced by a spring.

Under certain operating conditions, the paring tube radial position can be locked in place by two adjustable screws on the connection house.

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

The inlet and outlet device is held together against the frame hood by a nut on the end of the inlet pipe.

Height adjusting rings determine the height position of the paring disc and paring tube relative to the bowl.

1810993-02


- - ' - ( i r • ' • ' • -

1810993-02


Separator bowl

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

The bowl body and bowl hood are held together by a lock ring (Centrilock). Inside the bowl are the distributor and the disc stack. The disc stack is kept compressed by the bowl hood. The discharge slide forms a separate bottom in the bowl body.

The upper space between the bowl hood and the top disc forms the water paring chamber and contains the paring tube, which pumps the separated water out of the bowl. The oil paring chamber, with its paring disc, is located inside the top of the distributor. From here the cleaned oil is pumped out of the bowl.

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

At fixed intervals, decided by the operator, the discharge slide drops down to empty the bowl of sludge.

The sludge discharge mechanism, which controls the movement of the discharge slide, is comprised of an operating slide and an operating water device. Passive parts are: nozzle and valve plugs. The operating water cover, beneath the bowl, supplies operating water to the discharge mechanism via the operating water ring.

1810993-02


Water paring chamber

Bowl hood

Top disc

Oil paring chamber

Disc stacl<

Lock ring

Seal ring

Discharge slide

Operating slide

Sludge space

Nozzle

Holder Operating water ring

1810993-02


1.4 Sensors The separator is equipped with a speed sensor. As options, an unbalance sensor and an interlocking kit can be fitted.

speed sensor

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

Monitoring kit (option)

For indication of any abnormal unbalance, the separator can be equipped with a sensor monitoring the radial position of the bowl spindle.

Cover interlocking kit (option)

When the cover Is closed the Interlocking circuit In the control system is closed which makes It possible to start the separator.

Cover interlocking switch

Unbalance sensor

Speed sensor

1810993-02


1.5 Separating Function

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

1.5.1 The liquid balance in the bowl

The liquid levels in the bowl depend on many factors (bowl geometry, liquid densities, flow rates etc.). To get a picture of how the liquids are distributed in the bowl, imagine that the bowl is at standstill and turned 90° (only influenced by gravity). The bowl can now be compared with a settling tank:

SEPARATOR BOWL TURNED 90°

i T

Y

Unseparated oi!

Separated oi!

Water

Distributor

Unseparated oil

Separated oil

Water

SETTLING TANK

1810993-02


1.5.2 Liquid flow

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

When the oil reaches slots in the distributor, it rises through the channels formed by the disc stack, where it is evenly distributed.

The oil is continuously cleaned as it travels towards the centre of the bowl. When the cleaned oil leaves the disc stack, it flows through a number of holes in the distributor and enters the oil paring chamber. From here it is pumped by the oil paring disc, and leaves the bowl through the oil outlet. Separated water, sludge and solid particles, which are heavier than the oil, are forced towards the periphery of the bowl and collect in the sludge space.

The space between the bowl hood and top disc, as well as the water paring chamber, is filled with oil, which is distributed over the entire circumference via the grooves in the top disc.

During normal operation, the water drain valve in the water outlet is closed.

1.5.3 Disciiarge of sludge and water

As the sludge space fills up and water enters the disc stack, traces of water will escape with the cleaned oil. The increase of water content in the cleaned oil is the sign of reduced separation efficiency.

This condition is monitored by the process control system, and water is removed from the bowl when minimal levels are recorded.

The water is removed by either of two ways:

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

• Through the sludge ports at sludge discharge.

Which way is decided by the process control system.

10 1810993-02


1.5.4 ALCAP™ concept

When the sludge space is filled up and water enters the disc stack, traces of water will escape with the cleaned oil. The increase of water content in the cleaned oil is the sign of reduced separation efficiency.

This condition is monitored by the process control system, and water is removed from the bowl when minimal levels are recorded.

1810993-02 11


DISCHARGE OF WATER THROUGH WATER OUTLET

Bowl hood

Oil paring disc

Oil paring chamber

Oil/water interface

Unseparated oil

Separated oil

Water

Water paring tube

Water paring channber

Holes in distributor

Top disc

Sludge space

Uncleaned oil

Cleaned oil

Water

12 1810993-02

SA 836 SEPARATION SYSTEM SERVICE MANUAL 2 TECHNICAL REFERENCE

2 Technical Reference

2.1 Product description Alfa Laval ret 57447Z, rev. 0

MOTE

The separator is a component operating in an integrated system including a monitoring system.

If the technical data in the system description does not agree with the technical data in this instruction manual, the data in the system description is the valid one.

Product number. 881202-02-03

Separator type. S 836

Application. Cleaning of fuel and lube oil. Not to be used for liquids with flashpoint below 60 °C.

Technical design. Intended for marine- and land installations. Total discharge. Centrilock® lock ring

Designed in accordance with standards:

98/37EC

89/336EEC

EN 12547

The Directive of the European Parliament and Council relating to machinery.

EMC and amendments related to said directive.

Centrifuges - Common safety requirements.

Operational limits:

Feed temperature: 0°C to-i-100°C

Ambient temperature -h5°C to +55°C

Discharge intervals: min. 2 minutes max. 4 hours.

Maximum allowed density of operating liquid: 1000 kg/m^.

Viscosity max. 700 cSt at 50°C.

Not to be used for liquids with flashpoint below 60°C.

Remote restart allowed under certain conditions, see Interface description.

1810993-02 13

2 TECHNICAL REFERENCE SA 836 SEPARATION SYSTEM SERVICE MANUAL

2.2 Technical Data Alfa Laval ref. 561760, rev. 5

•

Subject

General technical data:

Motor power

Gear ratio

Gear ratio

Alarrn levels for vibration monitor connection 752; 1st/2nd

Bowl max. inner diameter

Discharge interval; min./max.

IVIax. density of operating liquid, max.

Max. density of feed/sediment

Feed temperature, min./max.

Max. running time without flow,

- empty bowl

- filled bowl

Bowl body material

Operating data:

Bowl speed, synchronous

Motor speed synchronous

Power consumption at start-up, max.

Power consumption idling/max.

Value

7,5

292/82

243 / 82

0,2/0,3

237

2/240

1000

1100 72659

0/100

60

60

AL 111 2377-02

10683/10668

3000/3000

11

Unit

l<W

50Hz

60Hz

mm

mm

minutes

kg/m=

kg/m3

'C

minutes

minutes

r/minute 50Hz/60Hz

r/minute 50Hz/60Hz

kW

^ --;-:- - ' - , ' - 3 ' '

- " ~-

capacity:

Starting time, min./max

Stopping time min./max.

Stopping time without brake, avprage

Sound power

Sound pressure

Vibrations, separator in use

Volume and capacity data:

I Max. hydraulic capacity, bowl i

> Bowl liquid volume

I Fixed discharge volume

Sludge volume, efficient'total

Lubricating oil volume

Weight information:

Motor drive

Bowl

Separator total

2,3/5,4

1,5 2

18/25

22

9,2

78

9,1

8,5

kW

minutes

minutes

minutes

Bel(A)

dB(A)

mm/second

m3/h

2,6

2,4

0,35/1,1

2,2

112

! 48

I 371

litres

litres

litres

litres

kg

kg

kg

14 1810993-02


2.3 Connection List

Alia Laval ret 561759 rev. 4

No. Description Requirements/limits

201 iniet for process liquid

• Allowed temperature

• Max allowed density

• Allowed flow

Min. 0°C, max. 100°C

See demand specification

Max 6,3 m /h

206 Inlet for conditioning and displacement liquid

• Instantaneous flow

Fresfi water

1,6 litres/minute

220 Outlet for light phase, clarified liquid

• Counter pressure 0 - 250 kPa

221 Outlet for heavy phase No counter pressure.

222 Outlet for solid phase

• Small discharge

• Large discharge

• Discharge frequency

Total discharge

Max 24 discharge/h.

The outlet from the cyclone must always be arranged to prevent the cyclone from being filled up with sludge. Solids are discharged by gravity.

375 Inlet for discharge and make-up liquid

• Quality requirements

• Max density

• Pressure

Make-up liquid

• Flow (momentary)

• Consumption

• Interval

• Time

Discharge liquid

• Flow

• Consumption

• Time

Closing liquid

• Flow

• Consumption

• Time

Start up closing liquid

• Flow

• Time

See page 27.

Max. 1000 kg/m^

min. 150 kPa

2,8 litre/minute

1.7 litres/hour

5 minutes

3 seconds

11 litre/minute

0,55 litre/discharge

3 seconds

2.8 litre/minute

0,7 litre/discharge

15 seconds

11 litres/minute

5 seconds

1810993-02 15


462

701

740

752

760

Drain of frame top section, lower

Motor for separator

Allowed frequency variation: (momentarily during 5 seconds

Speed sensor for bowl spindle

• Type

• Supply voltage, nominal

• With sensor activated (near metal)

• With sensor not activated (far from metal)

• Number of pulses per revolution

Position transducer for bearing holder

• Type

• Supply voltage

• Operation range (mild steel)

• Output voltage within sensing range

• Load resistance, RL

Cover interlocking switch

• Type

• Switch rating, resistive load max.

± 5 % ±10%

See page 21.

Inductive promixly switch

8V

Less or equal to 1 mA.

More or equal to 3 mA.

1

See page 22.

Inductive analogue sensor

18to30VDC

0,5 to 2,5 mm

4 to 20 mA

400 Ohm

Mechanical limit switch

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

16 1810993-02


2.4 Interface Description

Alfa Laval ref. 564834 rev. 2

2.4.1 Scope

This document gives information, requirements, and recommendations about operational procedures and signal processing for safe and reliable operation of the separator. It is intended to be used for designing auxiliary equipment and control systems for the separator

2.4.2 References

This Interface Description is one complementary document to the separator. Other such documents that contain necessary information and are referred to here are:

• Interconnection Diagram

• Connection List

• Technical Data

Standards referred to are:

• EN 418 Safety of machinery - Emergency stop equipment, functional aspects - Principles of design

• EN 1037 Safety of machinery - Prevention of unexpected start-up

• EN 954-1 Safety of machinery - Safety related parts of control systems - Part 1 General principles for design.

1810993-02 17


2.4.3 Definitions

For the purpose of this document, the following definitions apply:

• Synchronous speed: The speed the machine will attain when it is driven by a three phase squirrel-cage induction motor and there is no slip in the motor and the drive system.

• Full speed: The synchronous speed minus normal slip.

2.4.4 Goal

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

Situation

Unbalance caused by uneven sediment accumulation in the bowl.

Too high bowl speed.

Access to moving parts.

Insufficient cleaning of separator.

Bowl leakage.

Effect

Too high stress on bowl and bearing system which might cause harm.

Too high stress on bowl which might cause harm.

Can cause injury to person who accidentally touches these parts.

Unsatisfactory product quality.

Product losses.

Information and instructions given in this document aim at preventing these situations.

Control and supervision can be more or less comprehensive depending on the type of used control equipment. When a simple control unit is used it would be impossible or too expensive to include many of the functions specified here while these functions could be included at nearly no extra cost when a more advanced control unit is used. For this reasons functions that are indispensable or needed for safety reasons to protect the machine and/or personnel are denoted with shall while other functions are denoted with should.

18 1810993-02


2.4.5 Description of separator modes

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

The normally used modes are described below but other modes might exist.

It is assumed that:

• The separator is correctly assembled.

• All connections are made according to Connection List, Interconnection Diagram and Interface Description.

• The separator control system is activated.

If above conditions are not fulfilled the separator will be in SERVICE mode.

Stand still means:

• The power to the separator motor is off

• The bowl is not rotating.

Starting means:

• The power to the separator motor is on.

• The bowl is rotating and accelerating

Running means:

• The power to the separator motor is on.

• The bowl is rotating at full speed.

• RUNNING is a collective denomination for a number of sub modes which e.g. can be;

- STAND BY. Separator is in a waiting mode and not producing.

- PRODUCTION: Separator is fed with product and producing.

- CLEANING: Separator is fed with cleaning liquids with the intention to clean the separator.

1810993-02 19


Stopping means:

• The power to the separator motor is off.

• The bowl is rotating and decelerating.

• STOPPING is a collective denonnination for a number of sub modes which e.g. can be:

- NORMAL STOP. A manually or automatically initiated stop.

- SAFETY STOP: An automatically initiated stop at too high vibrations.

- EMERGENCY STOP: A manually initiated stop at emergency situations. This stop will be in effect until it is manually reset.

2.4.6 Remote start

This machine may be started from a remote location under the following conditions;

• First start after any kind of service or manual cleaning must be supervised locally in order to ensure that no mistakes has been made during assembly

• The unbalance sensor is mandatory for remote start.

• The installation must include equipment to prevent unintentional start-up from remote location when the machine is disassembled.

• The installation must include equipment to prevent unintentional start of process flow from remote location when the machine is not properly connected to the piping.

2.4.7 Handling of connect ion interfaces

Electrical connections

701 Separator motor.

The separator is equipped with a 3-phase DOL -(direct on line) started motor. The separator can also be started by a Y/D starter, but then the time in Y-position must be maximized to 5 seconds.

20 1810993-02


There shall be an emergency stop circuit designed according to EN 418 and a power isolation device according to EN 1037.

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

There should be a counter to count number of running hours.

There should be a current transformer to give an analogue signal to the control unit about the motor current.

740 Speed sensor

A proximity sensor of inductive type according to DIN 19234 (Namur) standard is giving a number of pulses per revolution of the bowl (see Connection List).

Signal processing in STARTING:

• The separator should be stopped automatically according to NORMAL STOP procedure and an alarnn should be given when the accumulated time for acceleration is longer than the maximum time specified in Technical Data. An abnormal start time indicates some malfunction of the separator equipment and should be investigated.

• If the speed exceeds "Bowl speed, synchronous" in Technical Data with more than 5% the separator shall be stopped automatically by NORMAL STOP and a high speed alarm shall be given.

• The speed monitoring system shall be checked continuously (e.g by checking that pulses are coming). In case of failure indication the separator shall be stopped automatically by NORMAL STOP with a timer controlled stop sequence and an alarm for speed monitoring system failure shall be given.

• The acceleration should be supervised to ensure that a certain speed (e.g 250r/min.) has been reached within a certain time (e.g 30 seconds).

1810993-02 21


Signal processing in RUNNING:

• If the speed exceeds "Bowl speed, synchronous" in Technical Data with more than 5% for a period longer than 1 minute or momentarily during maximum 5 seconds more than 10% the separator shall be stopped automatically by NORMAL STOP ana a high speed alarm shall be given.

• If the speed falls more than 10% below the synchronous speed for a period longer than 1 minute or 15% during more than 5 seconds a low speed alarm should be given. Low speed indicates some malfunction of the separator equipment and shall be investigated.

• The speed monitoring system shall be checked continuously (e.g. by checking that pulses are coming), in case of a failure indication an alarm for speed monitoring system failure shall be given. If there is a risk of too high speed the separator shall be stopped by NORMAL STOR

• The speed drop during DISCHARGE. compared to the measured speed immediately before, should be between 3-8% which will indicate a proper discharge.

Signal processing in STOPPING:

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

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

752 Unbalance sensor (option).

For indication of any abnormal unbalance and to be able to perform appropriate countermeasures, the separator has been equipped with a vibration velocity transducer on the separator frame. The signal from the transducer shall be monitored and two alarm levels according to the vibration alarm levels in Technical Data should be set.

22 1810993-02


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

The vibration monitor shall include self check function to be performed at least at initiation of STARTING.

If vibrations exceed the second alarm level the separator shall be stopped the quickest way possible and it shall not been restarted until the reasons for the unbalance have been found and measures to remove them have been taken.


If vibrations exceed the second alarm level the separator shall be stopped automatically by SAFETY STOP.

If the self check system triggers, an alarm shall be given and an automatic stop by NORMAL STOP shall be initiated.

Signal processing in RUNNING:

• If vibrations exceed the first alarm level an alarm sinould be given. Vibrations of this magnitude will reduce the expected life time of the bearings and should therefore be eliminated.

• If vibrations exceed the second alarm level the separator shall be stopped automatically by SAFETY STOP.

• If the self check system triggers, an alarm shall be given.

Signal processing in STOPPING:

• If the self check system triggers, an alarm shall be given.

Signal processing in NORMAL STOP:

• If vibrations exceed the second level the system shall turn over automatically to SAFETY STOP.

1810993-02 23


760 Cover interlocking switch (option)

The separator is equipped with a interlocking switch to detect if the cover is mounted.

Signal processing in STAND STILL:

• The circuit is closed wlien the cover of the separator is mounted.

• The interlocl<ing sw/itch should be connected in such a way that starting of the motor is prevented when the separator cover is not mounted.

Signal processing in STARTING, RUNNING and CLEANING:

• If the circuit is broken the separator should be stopped automatically by NORMAL STOP. This is to minimise the risk of having access to moving parts.

Fluid connections

Complementary information is given in the document Connection List.

201 Inlet

Processing in STAND STILL:

• Shall be closed.

Processing in STARTING:

• Should be closed. Bowl will be open and empty or closed and filled depending on if start is done from STAND STILL or STOPPING.

Processing in RUNNING:

• Could be closed or open.

Processing in CLEANING:

• A sequence of cleaning liquids should be fed to the separator. The flow rate should be as high as possible and preferably not less than the production flow rate.

Processing in NORMAL STOP or EMERGENCY STOP:

24 1810993-02


• Could be closed or open but the bowl should be filled unless the stop is initiated in STARTING.

Processing in SAFETY STOP:

• Could be closed or open but the bowl shall be filled unless the stop is initiated in STARTING.

206 Inlet for conditioning and displacement liquid

• According to process

220, 221 and 222 Outlets

Processing in STAND STILL:

• Could be closed or open.

Processing in other modes:

• Shall be open.

375 Inlet for discharge and make-up liquid

Processing in all modes:

• It is recommendable to supervise the supply pressure. If pressure is too low (see Connection List), start should be interlocked and if it happens in PRODUCTION or CLEANING turn over to STAND BY should take place.


• Below 85% of synchronous bowl speed no water supply may be made.

• When coming from PRODUCTION a discharge shall be initiated to remove sediments from bowl to avoid problems due to solidification, see Connection List.

Signal processing in PRODUCTION:

• Automatic discharges shall be initiated by timer or ALCAP system.

1810993-02 25


Signal processing in CLEANING:

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

Signal processing in NORMAL STOP:

• Discharges should not be made.

Signal processing in SAFETY STOP and EMERGENCY STOP:

» Discharges should not be made,

26 1810993-02


2.5 Demand Specification Water


Poor quality of the operating water may with time cause erosion, corrosion and/or operating problems. The water shall be treated to meet certain demands.

The following requirements are of fundamental importance:

1 Turbidity-free water, solids content <0,001 % by volume. Max. particle size 50 pm. Deposits shall not be allowed to form in certain areas in the system.

2 Total hardness less than 180 mg CaCOs per litre, which corresponds to 10 °dH or 12,5 °E. Hard water may with time form deposits in the operating mechanism. The precipitation rate is accelerated with increased operating temperature and low discharge frequency. These effects become more severe the harder the water is.

3 Chloride content max. 100 ppm NaCI (equivalent to 60 mg Cl/I). Chloride ions contribute to corrosion on surfaces in contact with the operating water.Corrosion is a process that is accelerated by increased separating temperature, low pH, and high chloride ion concentration.

4 6 ,5<pH<9 Bicarbonate content (HC03) min. 70mg HCO3 per litre, which corresponds to 3,2 °dKH.

MOTE

Alfa Laval accepts no liability for consequences arising from unsatisfactorily purified operating water supplied by the customer.

1810993-02 27


2.6 Drawings

2.6.1 Basic size drawing

Atta Laval ret. 561693 rev. 5

^ I X f

'-ISO-G 1/2

• -0(7

"X-U Connection house, with connections 201, 220 and 221, turnable in 60° steps all around. All connections to be installed non-loaded and flexible All dimensions are nominal. Reservation for individual deviations due to tolerances. Data for connection, see 2.3 Connection List, page 15.

A Tightening torque 160 Nm, B Maximum horizontal displacement at the inlet and outlet

connections during operation ± 5 mm. C Maximum vertical displacement at the sludge connection

during operation ± 2 mm. D 4 holes MIO E MIO depth 30 F 028, depth 45 G 022, depth 45

28 1810993-02


2.6.2 Foundation drawing


4> D

^77777777777777777777777

-424 _ .^13,5

20O0

1750

^Ül^M-pJ—Jjpi

I J

® K

g L <H) IM

Total static load max. 4 kN.

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

service. J No fixed installation witliin this area. K Centre of gravity (complete machine). L Vertical force not exceeding 10 kN/foot. M Horizontal force not exceeding 10 kN/foot.

1810993-02 29


2.6.3 Interconnection diagram

Alfa Laval ret 561786 rev. 5

Interlocking switch (frame top part)

Unbalance sensor (position trans for bearing holder).

Speed sensor (bowl speed).

V\/iring without junction box

I r I I I I

• • • J I I I

( W ) (W) {760]

Junction box

Wiring of connector "X":

RD=A BU=B GN=C YW=D WT=E BK=F BN=G PU=H

Wire colour codes:

BK=Black BN=Brown BU=Blüe RD=Red GN=Green PU=Purple YW=Yellow WT=White

Demand specification wire Approval: UL 1007/1569

CSA TR-64 Area ace. to AWG 18

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

30 1810993-02


2.6.4 Electric motor


W h9 U12x28 Knockout openings for M25+M20 cable glands Cast lifting lugs on both on both sides. sides.

4 holes M10x18

External earthing bolt var. code 067

Note: Drain holes with closable plugs to be Note: The motor positioned at lowest bearings have point. permanent lubrication

Metal fan cover var. code 053

Manufacturer

iUlanuf. drawing

Standards

Size

Type

Weiglit

Poies

Insuiation class

Bearings

Method of cooling

Spec.

ABB UoXors

Cat. GB 08-2001

IEC 34-serles, 72, 79 and 85

132SB

M3AA132SB

42 kg

2

F

D-end 6208-2Z/C3

N-end 6206-2Z/C3

IC411 (IEC 34-6)

Totally enclosed three-phase motor for marine service '

Motor with feet and small flange.

Type of mounting

g IM 2111

Protection

class

IP 55

The rotor balanced with half-key Max. vibration velocity 1,8 mm/second (rms) Cast iron bearing shield at N-end Factory test certificate to be enclosed at the delivery. Rated output (kW) valid for temp-rise max. 90 °C. The motors can be provided with space heaters for 110 V or 220 V, 25 W as option.

1810993-02 31


Art ic le No.

561356-17

561356-16

561356-15

561356-14

561356-13

561356-12

561356-11

561356-10

561356-9

561356-8

561356-7

561356-6

561356-5

. 561356-4

561356-3

561356-2

561356-1

Output kW

8;6

8;6

8;6

8;6

8;6

8;6

8;6

8;6

7,5

7,5

7,5

7,5

7,5

7,5

7,5

7,5

7,5

Speed r/min

3430

3430

3430

3430

3430

3430

3430

3430

2830

2830

2830

2830

2830

2830

2830

2830

2830

Freq Hz

60

60

60

60

60

60

60

60

50

50

50

50

50

50

50

50

50

Vol tage V

690D

380D

230 D

220 D

575D

480D

460D

440 D

230 D

220 D

690 D

660D

500 D

440 D

415D

400 D

380 D

Current A

9,3

16,9

28,0

29,0

11,2

13,4

14,0

14,6

24,5

25,5

8,1

8,5

11,2

12,7

13,5

14,0

14,7

Pow.fac cos (p

0,92

1 s t / p )

7,1

Note

-

CSA- plated

-

-

-

-

-

-

-

-

-

-

-

-

1st /l=starting current /rated current at direction line starting.

Ttie motors can be designed to fulfil requirements of following Classification Societies (Essential Service, If required).

Lloyds Register of Shipping (LRS)

Det Norske Veritas (DnV)

Germanischer Lloyd (GL)

Bureau Veritas (BV)

American Bureau of Shipping (ABS)

Registro Italiano Navale (RINA)

Nippon Kaiyi Kyokai (NK)

Korean Register of Shipping (KR)

Polski Rejester Statkow (PRS)

China Classification Societies (ZG)

Indian Register of Shipping (IRS)

Maritime Register of Shipping (IRS)

Required classification society must always be specified when ordering.

32 1810993-02

SA 836 SEPARATION SYSTEM SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3 Separator Service, Dismantling, Assembly

3.1 Periodic A/laintenance Periodic (preventive) maintenance reduces the risk of unexpected stoppages and breakdowns. Follow the maintenance log in this chapter in order to facilitate the periodic maintenance.

3.1.1 Maintenance intervals

The following directions for periodic maintenance give a brief description of parts to be cleaned, checked and renewed at different maintenance intervals.

The maintenance log for each maintenance interval on page 37 gives a detailed list of actions to be performed.

Inspection An Inspection consists of an overhaul of the separator bowl, inlet/outlet and operating water device every 6 months or 4000 operating hours.

Seals in bowl and gaskets in inlet/outlet device are renewed.

OverKaul Q^

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

Oil cliange

The oil should be changed every 4000 hours, or at least once every year if the total number of operating hours is less than 4000 hours I year.

1810993-02 33

3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SA 836 SEPARATION SYSTEM SERVICE MANUAL

3.1.2 Maintenance procedures

At each Inspection and/or Overhaul, take a copy of the maintenance log and use it to make notes during the service.

An inspection and overhaul should be carried out as follows:

1 Dismantle the parts as described in 3.3 Dismantling, page 39.

Place the separator parts on clean, soft surfaces such as pallets.

2 Inspect and clean the dismantled separator parts according to the maintenance log and description in 3.4 Actions Before Assembly, page 73.

3 Fit all the parts delivered in the service kit while assembling the separator as described in chapter 3.5 Assembly, page 83.

4 When the separator is assembled, make final checks described in 3.6 Actions After Assembly, page 122.

^ ^ m

Disintegration Hazards Separator parts that are either missing, worn beyond their safe limits or incorrectly assembled, may cause severe damage or fatal injury.

^CMlT»OI*

Bum and Corrode Hazards Escaping hot and/or corroding process material, which can be hazardous, may still remain in the separator after stop.

The use of serv ice symbols in the

dismantling/assembly instructions

Parts that have to be renewed from the service kits (see below) are marked Q ^ and/or Ejj^ in the assembly instructions.

34 1810993-02


Example: a Fit the 0-ring ^ ^ .

When dismantling and assembling between the service periods, some procedures do not have to be carried out. These procedures are marked Qjr and/or Q ^ .

Example:

5 Renew/ the valve plugs on the operating slide

All symbols used in the instructions refer to activities mentioned in the maintenance logs.

3.1.3 Tightening of screws

Tightening all screws with the correct torque value is important.

These figures apply unless otherwise stated:

Torque

Metric thread

M4

M5

M6

M8

M10

M12

M16

M20

M24

Stainless steel

Nm

1,7

3,4

7

17

33

57

140

270

470

kpm

0,17

0,34

0,7

1,7

3,4

5,8

14

28

48

Ib.ft

1,2

2,5

5

13

24

42

100

200

340

Carbon steel

Nm

2,25

4,9

8

20

39

68

155

325

570

kpm

0,25

0,49

0,8

2

3,9

6,9

15,8

33

58

Ib.ft

1,8

3,6

5,9

14,7

28,7

50

114

239

420

The figures apply to lubricated screws tightened with a torque wrench.

3.1.4 Service kits

Special service kits are available for Inspection and Overhaul.

1810993-02 35


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

Note that the parts for Inspection a r e included in the Overhaul kit.

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

MOTE

Always use Alfa Laval genuine parts as otherwise the warranty may become Invalid.

Alfa Laval takes no responsibility for the safe operation of the equipment if non-genuine spare parts are used.

ÂBt»»«*<^

Disintegration iiazards Use of imitation spare parts may cause severe damage.

3.1.5 Cleaning

CIP (Cleaning In Place)

To prolong the intervals between manual cleaning of the separator the use of CIP together with repeated discharges can be used.

Some CIP liquids can be corrosive to brass- and aluminium alloy parts which are included in the separator.

^cAirrioi*

Use only Alfa Laval recommended CIP liquids.

36 1810993-02

SA 836 SEPARATION SYSTEM SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING. ASSEMBLY

3.2 Maintenance Log

Name of ship/plant:

Separator: S 836

Total running hours:

Date:

Local identification:

Manufacture No./Year:

Product No.: 881202-02-03

Signature:

Part i 5_

3 IS r « > O E» 1

Action Page Note

Frame hood

- All parts

- All parts

- All parts

- Connecting housing

- Frame hood

- All parts

- All parts

- All parts

- All parts

- Bowl body

- Operating slide

- Discharge slide

- In and outlet pipe

- Paring tube

- Bowl hood

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

1 X

X

X

X

X

X

X

X

X

X

X

X

X

X

Clean

Check for corrosion

Check for cracks

Check for erosion damages

Renew O-ring

Control measure of paring disc height

Check height adjusting rings

Clean

Check for corrosion

Check for cracks

Check for erosion damages

Check for impact marks and corrosion

Renew rectangular ring

X Renew O-rlngs

X

X

X

X

X

Renew rectangular nng

jRenew valve plugs

Renew rectangular nng

Renew O-rings

Renew 0-rings and beanngs

X Renew seal nng

1 X Renew 0-ring

73

75

76

77

115

116

116

73

75

76

77 -

102

103

104, 107

103

1 102

107

110

110

1 112

112

Framo foet

Drain and oil filling holes

Oil pin

X , X

X I X

Renew frame feel (including washers } 79 land screws)

Renew washers ' 101

Renew 0-nng I 101

Has to be ordered separately

1810993-02 37

3 SEPARATOR SERVICE, DISMANTLING. ASSEMBLY SA 836 SEPARATION SYSTEM SERVICE MANUAL

Part

e 'S 0 tt a M C m

s £ a» >

O

E» 1

Action Page Note

Driving device All parts

All partb

All parts

Bottom bearing housing

Labyrinth ring holder

Top bearing housing

Flat belt

Bowl spindle

Neck bearing cover

Deflector nng

Water Inlet pipe

Operating water cover

Fan

Coupling

All parts

All parts

All parts

Coupling hub

Friction blocks

Electr ical motor

- Electncal motor

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

I X

X

X

X

X

Clean

Check for corrosion

Check for cracks

Renew 0-nng

Renew labyrinth nng

Renew 0-ring

Renew springs

Renew flat belt

Pre-lubricate and renew ball bearing

Pre-lubricate and renew self-aligning roller bearing

Measure the radial wobble

Lubricate the spindle

Renew O-nng

Renew O-nng

Renew O-nng

Renew seal nng and O-nng

Renew the O-nng

Clean

Check for corrosion

Check for cracks

Renew single row ball beanngs

Renew friction pads (if they are worn) or clean the pads if they are oily

Lubncate if nipples are fitted See sign on motor - •• _^,

73

7;.

76

90

91

91

93

97-

92

94

100

99

99

100

^00

96

• 73

75

83

Signs and labels on separator - Machine plate

- Power supply frequency

- Lifting instructions

1 1" Check attachment and legibility

' x Check attachment and legibility t

X

- Safety labels ' x

Check attachment and legibility

Check attachment and legibility

- Name plate ' \ x Check attachment and legibility

- Representative label |x ICheck attachment and legibility

1 122

122

122

1 1

1

122 ]

122

122 1

38 1810993-02


3.3 Dismantling

3.3.1 Introduction

To disconnect the oil inlet, oil outlet, and water outlet, undo the two screws on the connection plate. Hook the plate, together with the three hoses, to the edge of the small work table to avoid oil draining from the hoses.

The frame hood and heavy bowl parts must be lifted by means of a hoist. Position the hoist exactly above the bowl centre. Use a lifting sling and lifting hooks with safety catches.

The parts must be handled carefully. Don't place parts directly on the floor, but on a clean rubber mat, ftbreboard or a suitable pallet.

NOTt

For safety reasons, it is essential that all personnel who work with the separator read this manual thoroughly and completely. Do not allow personnel to clean, assemble, operate or maintain the separator until they have read and fully understood this manual. Ensure that all personnel who operate and service the separator are well-trained and knowledgeable concerning the separator and the work to be carried out.

1810993-02 39


3.3.2 Tools

Special tools from the tool kit must be used for dismantling and assembly, as well as Standard tools (not included). The special tools are specified in the Spare Parts Catalogue and are illustrated at the beginning of each dismantling section.

y^VTABWlWO^

Entrapment hazard To avoid accidental start, switcli off and lock-out power supply before starting any dismantling work.

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

40 1810993-02


Standard Tools

"1 Screwdriver

2 Torque wrencln (capacity 0-200 Nm)

3 Drift ( 0 4 mm)

4 Dial indicator witli magnetic base

5 Spanner for clutch

6 Heating equipment for bearings

7 Sliding calliper

8 Hammers (standard and soft-faced)

9 Pliers for internal snap rings

1 0 Pliers for external snap rings

1 1 T-handle with extension rod, sockets (13, 16, 17, 18, 19,27,30 mm)

1 2 Spanners (various sizes)

1 3 Adjustable spanner

1 4 Shackle

1810993-02 41


3.3.3 Frame hood

1 Hook spanner (lock nut)

^VlAflHW*^

Entrapment hazard To avoid accidental start, switch off and lock-out the power supply before starting any dismantling work.

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

Lock nut

Washer

Connecting housing

Frame hood

Height adjusting rings

Support ring

1 Removing the connecting Inousing.

a Remove the lock nut using the hook spanner.

KvÂBMWj®

The nut must not be removed before the separator has stopped.

Remove the washer

"SoTt

Right hand thread.

HOTE

Remove connections before starting dismantling.

b Press the pipe down to loosen the connecting housing.

c Remove the connecting housing

42 1810993-02


2 Removing the spring and arm.

c Turn the paring tube so that the frame hood can be removed upwards.

IIOT6

Paring tube

To avoid the paring tube from being damaged and preventing the inlet pipe from sticking to the frame hood when lifting the hood, always turn the paring tube towards the pipe before lifting.

'A:-X

3 Removing the frame hood.

a Remove the screws holding the frame hood.

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

NOTE

Do not place the hood upside down.

c Lift off the frame hood.

1810993-02 43


3.3.4 Bowi Lock ring

Bowl hood

- ••0«.j(|t'.-,;t,J::>

1 » * ^ ' » . * • ' • - ^

• » V XC

1 Compressing tool (lock ring) 2 Lifting eyes 3 Spanner for nut (nut/discharge slide) 4 Puller (discharge slide) 5 Lifting tool (distributor, spindle) 6 Puller (Bowl body) 7 Screw (lock ring) (M5) 8 Hexagon head key 9 Chisel (seal ring) 10 Pin (distributor/lifting tool)

Inlet and outlet pipe Paring tube

Axial support.

Splash sealing

Bowl disc (without caulks)

Bowl discs

Distributor

•

Cap nut

Nut

Discharge slide

Rectangular ring

0-ring

Bowl body

Rectangular ring

0-ring

Valve plugs

Operating slide

Rectangular ring

0-ring Holder Nozzle Operating water ring s

<D CD

Ring ^

44 1810993-02


i Removing tine lock ring

a Fit the compressing tool.

b Fit the clamps and the

screws to stop. c Compress the disc stack by

alternately tightening the inner screws on the compressing tool to a maximum of 60 Nm.

Fit the dismantling s c r e w s ^ to the bowl body and press out the loci< ring by tightening the screws successively going counter-clocl<;wise. Start with the screw nearest the locl< ring end (the one without the guide pin). The locl< ring can be removed when it has passed the edge of the groove.

e Remove the lock ring from the groove.

f Remove the dismantling screws.

1810993-02 45


2 Removing the bowl hood.

a Remove the compressing screws.

Loosen the screws on the clamp tool. Remove the tool. Remove the lock -ring. note

The bowl hood must be pulled off straight up, in order not to get stuck.

Recommendation: Take measurements with a calliper around the bowl, between the upper edge of the bowl body and the bowl hood, to check that the bowl hood is being pulled off straight up.

c Fit the compressing tool and the puller screws. Pull the bowl hood off by screwing the screws alternately (max. 1/2 turn) and gradually increase the momentum evenly until the bowl hood come loose.

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

^ ^ l * e

Crush hazard The top disc can adhere to the bowl hood when lifting. Be careful not to accidentally drop it.

46 1810993-02


3 Removing the seal ring.

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

Seal ring

A ^ ^ * ^

b Turn the bowl hood upside down and rennove the seal ring by carefully knock pieces of the seal ring out of the groove, using the special tool: chisel.

MOTE

It is very important not to damage the bottom of the groove!

Risk for eye iiûry from flying seal ring parts or f rom splashing fluid The seal ring breaks when removed from the bowl hood and may cause trapped fluid to splash. Wear safety goggles.

4 Removing the inlet/outlet pipe and top disc.

Lift out the in- and outlet pipe together with the top disc.

Crush hazard The distributor and disc stack can adhere to the top disc. Separate them from the top disc so that they do not accidentally drop.

1810993-02 47


5 Removing the paring tube.

a Remove the top disc from the inlet and outlet pipe.

To avoid damaging the paring tube, turn it towards the centre of the pipe.

b Remove the splash sealing.

c Remove the screws ^ and the axial support

d Lift up and remove the paring tube.

MOTE

Turn the paring tube upwards.

If the paring tube sticlcs, use a drift to carefully tap it out from the pipe.

Be careful not to damage the paring tube.

^

48 1810993-02


6 Removing the disc stacl< and distributor.

Assemble the lifting tool with the pin. c Carefully lift off the

disc stack assembly.

b Fit the assembled tool into the distributor and ease off the djsc stack using a spanner or wrench.

^ C A U T I O H

Cut hazard Sharp edges on the separator discs may cause cuts

7 Removing the nut

b Use the spanner for nut to remove the nut.

Screw

Clamp

To prevent the bowl body from rotating when removing the nut; Fit one of the clamps (see page 45) to the bowl body and one of the screws for the frame hood in the frame. Fasten a sling between the clamp and the screw around the bowl body.

1810993-02 49


8 Removing the discharge slide.

a Fit the lifting tool by pressing the puller rods towards each other and position them into the two slots on the bowl bottom. Slide metal ring down over bowl nave.

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

If discharge slide is difficult to remove, tap lightly on outside edge with a soft

\ faced hammer.

Crush hazard The ring on the lifting tool must be pushed down against the discharge slide, otherwise the discharge slide may come loose from the tool.

50 1810993-02


9 Removing the cap nut.

^

a Remove the cap nut

Left-hand thread!

10 Removing the bowl body

a Fit the lifting tool to the bowl body.

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

c Lift off the bowl body

1810993-02 51


11 Turn the bowl body upside down.

Crush hazard Support the bowl body when turning to prevent it from rolling.

12 Removing the holder.

a Remove the screws.

b Lift off the holder

If the ring sticks, use two M8 screws in threaded holes to raise the operating slide holder up and away from the bowl body.

52 1810993-02


13 Removing the operating slide.

a Lift off the operating slide.

MOtE

If the ring sticks, use two IMS screws in threaded holes to raise the operating slide holder up and away from the bowl body.

1 4 Removing the operating water r ing.

Loosen and remove ttie screws (13 mm socket).

b Lift off ttie ring.

If the ring sticks, use two M8 screws in threaded holes to raise the operating slide holder up and away from the bowl body.

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

1810993-02 53


3.3.5 Driving device

Seal ring

Operating water cover

0-ring

0-ring ' -Deflector ring

Seal ring

Neck bearing cover

0-ring

0-ring

Fan

Snap ring

Bowl spindle

Bail bearing

Bearing seat

Spring

Top bearing housing

Compression spring

Plug

•

1 Puller (spindle pulley, ball bearing).

2 Tool (bearing housing). 3 Cover puller

(neck bearing cover).

4 Lifting tool (spindle assembly)

5 Drift (bottom bearing). 6 Sleeve (ball bearing in

top bearing seat 7 Pin spanner (oil fan).

Air deflector

Spindle pulley

Belt

Self-aligning roller bearing Lubrication oil orifice

0-ring

Oil pump

Labyrinth ring holder

O-ring

Labyrinth ring

Wing insert

0-ring

Bottom bearing holder

Screw

- O-ring

Strainer

54 1810993-02


1 Empty the oil sump.

Unscrew the oil plug and empty the oil sump.

2 Removing the clutch cover.

a Remove the screws

b Remove the clutch cover

1810993-02 55


3 Loosen the flat belt, by tilting the motor.

a Loosen, but do not remove, the screws holding the motor. Start with the two screws at the bottom. Do not loosen more than shown in the illustration.

Motor

Separator frame

Screw

b Loosen the two upper screws a little bit more so that the motor can be tilted. Do not loosen more than shown in the illustration.

^yiABWH*o^

c Remove the flat belt from the motor pulley. Crush hazard The motor will come off if tlie screws are unscrewed.

56 1810993-02


4 Removing the operating w/ater cover

a Remove the screws.

b Lift off the operating water cover.

If the cover sticks, fit two M10 screws to the threaded holes and tighten.

5 Removing the neck bearing cover and deflector ring.

a Attach the tools

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

c Ease off the cover by tightening the screw.

Frame

b Fasten the tool to the cover.

Cover

1810993-02 57


6 Prepare for removal of spindle assembly.

HOTE

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

b Remove the screw/s

If the cover sticks, fit two IVI10 screws to tlie threaded holes and tighten.

58 1810993-02


7 Lifting the spindle assembly from the frame.

a Fit the lifting tool to the spindle end.

b Slowly raise and lift out the spindle assembly.

Crush hazard Do not rotate the spindle assembly during lifting. The spindle assembly may otherwise come loose from the lifting tool.

H0T6

Take care not to damage the oil pump.

1810993-02 59


8 Place the spindle assembly upside dov/n on a support.

r\

d h

-3 ,0 mm free space

Make a support

-130 mm

-174 mm

9 Removing the air deflector

a

Remove the screws and the air deflector.

60 1810993-02


"10 Removing the fan.

a Turn the spindle assembly the right way up.

c Fit the pin spanner and remove the fan.

NOTE,

Left-hand thread!

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

. Key-grip

11 Removing the bottom bearing assembly.

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

Puller tool

b Pull off the belt pulley and the self-aligning roller bearing using the puller tool.

Always discard a used bearing.

Lubrication oil orifice

Compressed air

c Cover the the oil orifice and blow compressed air through the bottom hole of the oil pump and

Å slowly ease out the lubrication oil orifice.

1810993-02 61


12 Removing the top bearing housing.

a Turn the spindle assembly over. Compression

springs b Remove the plugs

and the compression springs.

c Carefully remove the spindle from the top bearing seat.

HOTE

Be careful not to damage the vibration indicator.

62 1810993-02


13 Removing the ball bearing.

NOTE

Do not damage threads on spindle.

a Remove the snap ring.

A^Âfll«»»*G

Risk for eye injury from flying snap ring Use the correct pliers for dismantling of snap ring to avoid accidental release.

b Fit the cap nut on the spindle to protect the threads.

c Use the puller tool to remove the top bearing seat from the spindle.

HOTE

Tal<e care not to damage the vibration indicator when separating the top bearing seat from the spindle.

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

Piece of wood to • protect the spindle threads.

Always discard used bearings.

1810993-02 63


14 Removing the labyrinth ring holder

If the holder sticks, fit two screws M8 to the threaded holes and tighten.

64 1810993-02


"15 Removing the bottom bearing holder

a Fit the tool into the bottom bearing holder and attach the socl<;et, extension rod and T-handie.

T-handle

Extension rod

Socket

^ ^ b Loosen the bottom bearing T ^ holder by turning it counter

clockwise. Remove it by hand.

c Remove the strainer.

1810993-02 65


3.3.6 Centrifugal clutch

Spacing ring

• • ^ ' " • ' s ^ ^ . tøf. ' f'

AÂBMIWG

Entrapment hazard To avoid accidental start, switch off and lock-out power supply before starting any dismantling work.

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

Belt pulley

Parallel pin

Friction blocks (3=60 Hz)

Cover

Snap ring

MOTE

50 Hz = 5 Friction blocks 60 Hz = 3 Friction blocks

The illustration shows 60 Hz

i-Ji-^Äf^:

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

66 1810993-02


1 Removing the clutch cover.

s Loosen and remove the screws

b Remove the clutch cover

2 Loosen the flat belt, by tilting the motor,

a Loosen, but do not remove, the screws holding the motor. Start with the two screws at the bottom. Do not loosen more than shown in the illustration.

c Remove the flat belt from the motor pulley.

Motor

Separator frame

Screw

b Loosen the two upper screws a little bit more so that the motor can be tilted. Do not loosen more than shown in the illustration.

M Vi ABHIN®

Crush hazard The motor will come off if the screws are unscrewed.

1810993-02 67


3 Removing the motor.

a Disconnect the electrical cables.

^^MARM»»*®

Electrical hazard If the cables are not disconnected during lifting procedures, they may become damaged.

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

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

^ ^ ^ H G

Crush hazard If not supported, the motor with coupling will drop when removing the screws.

d Lower the motor onto a suitable pallet.

4 Removing the friction blocks.

KciVUTlOH

Inhalation hazard When handling friction blocks/pads wear a mask to avoid inhalation of dust. Do not use compressed air to remove dust. Remove dust using vacuum or a damp cloth

a Remove the snap ring, cover and friction blocks.

Friction blocks (3=60 Hz)

Cover

Snap ring


68 1810993-02


5 Checl<ing the condition of the friction blocl<s E ^

ACAJ^JOH

Inhalation hazard When handling friction blocks/pads wear a mask to avoid inhalation of dust. Do not use compressed air to remove dust. Remove dust using vacuum or a damp cloth.

If the blocks are worn:

Fit new friction biocids.

HOTE

Replace all blocks, even if only one is worn.

a Clean the pins of coupling hub and apply a thin film of lubricating paste to the pins.

»»22. Make sure that there is no oil on the pads.

Be sure that the pins on the back of the blocks project into the grooves in the clutch hub.

b If only friction block service is to be done, proceed to "Assembly of friction blocks" on page 86,

1810993-02 69


Complete dismantling of centrifugal clutch

6 Removing ttie coupling from tlie motor

a Remove the screw, spring washer and washer

Washer

Spring washer

Screw

Attach a socket with extension rod and handle to the screw. Place a piece of wood according to the illustration. Push the handle to start the rotor moving, when the handle hits the piece of wood, the weight and movement of the rotor loosens the screw. Repeat until screw is loose.

Piece of wood

b Check that the brass plug is mounted on the puller tool. Fit the tool to the friction clutch.

c Ease off the friction coupling.

Flat areas for spanner

y^VlABHiWG_

HOT6

Crush hazard The centrifugal clutch is heavy and can fail, causing injury, when loosened from the motor shaft.

See dismantling with optional hydraulic puller tool (if purchased) on next page.

70 1810993-02


7 Removing the coupling from the motor using the optional hydraulic tool.

"MOTE

First remove the screw, spring washer and washer according to instructions a -b, on previous page.

a Fit the sleeve to the stud bolt.

Fit the stud bolt with sleeve to the motor shaft.

b Fit the holder to the coupling nave. e Fit nut and sleeve to the

stud bolt as shown.

f Fit hydraulic cylinder as shown.

Motor shaft

Hydraulic oil inlet

g Fit the plate and fasten with screws through plate and holder

Coupling nave

Sleeve Holder

e Attach the hose from the hand pump to the hydraulic oil inlet.

Ease off the friction coupling by pumping the handle on the pump until stop. Release pressure on the hand pump and adjust the nut on the stud bolt.

Repeat until coupling is loose.

y >WiVBMlWG^

Crush hazard The centrifugal clutch is heavy and can fall, causing injury, when loosened from the motor shaft.

1810993-02 71


8 Dismantling of tlie coupling assembly.

a Remove the snap rings.

b Drive out the coupling hub.

Wooden support

. Support

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

• S o «

Always discard used bearings.

72 1810993-02


3.4 Actions Before Assembly

3.4.1 Cleaning

Clean the separator parts according to the diagram below. Afterwards, protect all cleaned carbon steel parts against corrosion by oiling.

Part

Frame and motor

Procedure

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

Electrical hazard Never wash down a separator with a direct water stream.

Never play a water jet on the motor. Totally enclosed motors can be damaged by direct hosing to the same extent as open motors, resulting in short-circuit and internal corrosion.

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

Cleaning agents

Water and de-greasing agent.

1810993-02 73


Part

Bowl

Inlet/ outlet

Driving device

Centrifugal clutch

Belt pulley

Procedure

Cleaning of bowl discs

Handle the bowl discs carefully in order to avoid damage to the surfaces during cleaning

1 Remove the bowl discs from the distributor and place them individually in the cleaning agent.

2 Allow the discs to remain in the cleaning agent until the deposits have been dissolved. This will normally take between two and four hours.

3 Lastly, clean the discs with a soft brush.

Cleaning of holder for operating slide, operating water ring and operating slide with nozzle.

Use 10% acetic acid solution to dissolve lime deposits. The acid should be heated to 80 °C.

Clean the nozzle on the operating slide using a soft iron wire or a similar object.

Use a sponge or a soft brush and clean the oil orifice, bearing holder and oil pump thoroughly

Use a sponge or a soft brush.

Use a a steel brush.

Cleaning agents

A chemical cleaning agent must dissolve the deposits quickly without attacking the material of the separator parts.

Fuel 0/7 sludge mainly consists of complex organic substances such as asphaltenes. The most important property of a cleaning liquid for the removal of fuel oil sludge is the ability to dissolve these asphaltenes.

Cut hazard Sharp edges on the separator discs may cause cuts.

White spirit, cleaning-grade kerosene or diesel oil.

White spirit, cleaning-grade kerosene or diesel oil.

Solvent

74 1810993-02


3.4.2 Inspection for corrosion

Inspect the separator parts for corrosion. Evidence of corrosion attacks should be looked for and rectified each time the separator is dismantled.

^ ^ ^

Max. 0,2 mm

Disintegration iiazards Always contact your Alfa Laval representative if you suspect that the depth of the corrosion damage exceeds 0,2 mm for bowl body and bowl hood (0,5 for other parts) or if cracks have been found. Do not continue to use the separator until it has been inspected and given clearance for operation by Alfa Laval.

Material

Non-stainless steel and cast iron parts

Stainless steel

Other metal parts

Type of corrosive environment

Water or dampness

Ctilorides or acidic solutions

"Aggressive" environment

Appearance

Rust

Acidic solutions cause general corrosion.

Chloride corrosion begins as small dark spots that can be difficult to detect, and goes on to local damage such as pitting, grooves or cracks.

Possible corrosion damage can be in the form of pits and/or cracks.

Measure

If damage exceeds 0,5 mm, contact Alfa Laval.

Polish dark-coloured spots and other corrosion marks with a fine grain emery cloth. This may prevent further damage.

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

If damage exceeds 0,5 mm, contact Alfa Laval.

A ^ V ^ A W ^

Disintegration hazard Pits and spots forming a line may indicate cracks beneath the surface.

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

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

1810993-02 75


3.4.3 Inspection for cracks Ql^ 01^

Check the separator parts for cracks. It is particularly important to inspect for cracks in rotating parts, and especially the pillars between the sludge ports in the bowl wall.

ys,v»ABWiwo^

Disintegration iiazard All forms of cracks are potentially dangerous as they reduce the strength and functional ability of components.

Always replace a part if cracks are present.

Cracks can occur from cyclic material stresses and corrosion. Keeping the separator and its parts clean and free from deposits will help to prevent corrosion attacks.

y^QWABW«^

Disintegration iiazards Always contact your Alfa Laval representative if you suspect that the depth of the damage exceeds 0,2 mm for bowl body and bowl hood (0,5 for other parts).

Do not continue to use the separator until it has been inspected and given clearance for operation by Alfa Laval.

76 1810993-02


3.4.4 Inspection for erosion u j p ^w

Erosion may occur when particles suspended in the process liquid slide along or strike against a surface.

Surfaces particularly subjected to erosion are:

The sealing edge of the discharge slide.

Bowl body and holder.

Holder and operating slide

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

Erosion is characterised by:

1 Burnished traces in the material.

2 Dents and pits having a granular and shiny surface.

Paring disc and paring tube

Lock ring

Pillars between the sludge ports in the bowl wall

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

1 Inspect the bowl and intet/outiet parts for erosion damages.

HOTE

Always contact your Alfa Laval representative if you suspect that the depth of the damage exceeds 0,2 mm for bowl body and bowl hood (0,5 for other parts). Do not continue to use the separator until it has been inspected and cleared for operation by Alfa Laval.

1810993-02 77


2 Replace parts if erosion is suspected.

y^VtfABWlW^

Disintegration hazard Erosion damage weakens parts by reducing the thickness of the material.

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

Replace parts if erosion is suspected of affecting strength or function.

78 1810993-02


3.4.5 Exchange of frame feet

The frame feet have to be changed occasionally due to rubber deterioration fromage.

When replacing the frame feet, the separator must be lifted. Follow 3.8.1 Lifting the separator, page 130.

M21 Discard the old frame feet, screws and washers.

a Loosen the bolts and prepare to remove ttie separator frame

b Lift the separator. See "Lifting tiie separator" on page 130

c Remove the existing frame feet.

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

e Place the separator in its original position and

fasten the mounting bolts.

1810993-02 79


3.4.6 Lubrication of bowl parts

a Apply a thin layer of Molykote 1000, or equivalent lubrication, on all the following contact surfaces. Apply D321 on the operating slide and the bowl body, guide pin and bowl hood.

/ ~ > = Molykote 1000

r~j = D321 + Molykote 1000

80 1810993-02


3.4.7 How to lubricate bowl parts with slide laquer

HOTE

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

a Carefully clean the contact surfaces (1) on bowl body and bowl hood.

b Apply Molykote D321 Ron surfaces.

c Air-cure for 15 minutes.

d Use a smooth fibre brush to polish to an even and homogenous contact film.

e Apply a second layer slide laquer.

f Air-cure for 15 minutes.

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

h Finish the treatment by lubricating the contact surfaces with Alfa Laval lubricating paste or Molykote 1000 paste. Use a well cleaned brush and rub it into the surface, do not leave any excessive paste.

1810993-02 81


3.4.8 Check for galling on operating slide and bowl body

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

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

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

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

d Apply Molykote D321R on surfaces.

e Air-cure for 15 minutes.

f Polish to an even, homogenous surface.

g Apply a second layer.

h Air-cure for 15 minutes.

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

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

WOTE

To avoid the risk of galling, the guiding surface of the operating slide should be primed with a slide lacquer at every inspection service.

82 1810993-02


3.5 Assembly

3.5.1 Centrifugal clutch

1 Assembly of the coupling.

a Slip the belt pulley over the coupling hub and place them on a firm and level foundation.

AÂB»»»»®

Disintegration Hazard If the belt pulley must be renewed, check that the new pulley has the correct diameter. An incorrect pulley will cause the separator bowl to run at either an excessive or insufficient speed.

d=292 mm 50 Hz d=243 mm 60 Hz

Remove rust from the belt pulley using a steel brush.

b Apply a thin film of oil onto the external and internal surfaces of the ball bearings Q ^ .

c Press the ball bearings down one at a time into the coupling hub, preferably using a hydraulic press. Place the spacing ring between them.

Mounting tool

MOTE

Never re-fit used ball bearings. The ball bearings must not be heated as they are

packed with grease and sealed with plastic membranes.

Fit the snap rings.

1810993-02 83


2 Fitting the coupling to the motor.

a Clean the motor shaft and apply a thin oil film.

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

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

MOTE

See mounting with optional hydraulic puller tool (if purchased) on next page.

Remove the brass plug.

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

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

f Install and tighten the washer, spring washer and screw.

Attach a socket with extension rod and handle to the screw. Place a piece of wood according to the illustration. Push the handle to start the rotor moving, when the handle hits the piece of wood, the weight and movement of the rotor tightens the screw. Repeat until screw is fastened.

Piece of wood

84 1810993-02


3 Fitting the coupling to the motor with optional hydraulic tool.

a Clean the motor shaft and apply a thin oil film. HOTE

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

b Fit the sleeve to the stud bolt.

Fit the stud bolt with sleeve to the motor shaft.

c Screw the holder to the coupling nave.

Hydraulic oil inlet.

Motor shaft

d Fit hydraulic cylinder as shown.

e Fit the sleeve and secure with the nut.

Sleeve Hydraulic cylinder

f Attach the hose from the hand pump to the hydraulic oil inlet. Fit the friction coupling by pumping the handle on the pump until stop. Release pressure on the hand pump and adjust the nut on the stud bolt.

Repeat procedure until coupling is mounted. Note! The pressure on the hand pump should not exceed 200 bar

g Remove the hydraulic tool.

h Install and tighten the washer, spring washer and screw.

Piece of wood

Attach a socket with extension rod and handle to the screw. Place a piece of wood according to the illustration.

Push the handle to start the rotor moving, when the handle hits the piece of wood, the weight and movement of the rotor tightens the screw.

Repeat until screw is fastened.

1810993-02 85


Assembly of friction bloci(s

4 Fitting the friction blocl<s.

Be sure that the pins on the back of the blocks project into the grooves in the clutch hub.

Guide pin

a Fit the friction blocl s onto the guide pins

HOTE


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

Snap ring

Cover

86 1810993-02


5 Fitting tine motor.

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

b Lower the motor (while supported) on to the separator frame. It will set on the ledge.

y^VliVBHlWG^

m ©

Crush hazard If not supported, the motor with coupling may drop when lifted.

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

d Connect the electrical cables.

»OTE

If carrying out change of friction blocks only, continue with steps 6 to 7. If carrying out a complete machine assembly, continue with the driving device instructions on page 90.

1810993-02 87


6 Fitting the flat belt.

MOTE

Clean the inside of the frame before fitting the flat belt, and make sure that there is no oil on the belt.

a Lift up the belt to the middle (centre) of the spindle pulley.

MOTE

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

Clearance

b Fit the flat belt to the motor belt pulley.

c Tighten the two upper screws.

d Tighten all motor attachment screws.

MOTE

Do not turn the spindle until the motor is tightened properly to the frame.

88 1810993-02


7 Fitting the clutch cover.

b Tighten the screws.

a Fit the clutch cover.

1810993-02 89


3.5.2 Driving device

1 Fitting the bottom bearing holder.

MOtE

Clean the strainer and bearing holder thoroughly before fitting

c To secure the bottom bearing holder into the frame, apply Loctite 222 on the surfaces directly above and below the upper 0-ring.

a Fit the wing insert, 0-rings and strainer.

b Secure the wing insert with the screw secured <* thread the bottom bearing

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

e Tighten the holder to a torque of 200 Nm.

90 1810993-02


2 Fitting the labyrinth ring liolder.

i^ tr«: C H

Spread oil film on the 0-ring and fit it Q ^ .

b Lubricate and fit the labyrinth ring Q ^ .

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

^ V

1810993-02 91


3 Fitting the ball bearing and top bearing seat Q^ to the spindle.

a Heat the top bearing seat in oil to maximum 125 °C. ^v«ABt*»»*e

b Fit the ball bearing.

HOTE

c Fit the snap ring.

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

MOTE

Bum hazard Use protective gloves when handling any heated parts.

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

^ M l H l M G

Risk for eye injury from flying snap ring Use the correct pliers for assembly of snap ring to avoid accidental release.

Puller

e Wipe off the spindle and fit the top bearing seat to the spindle using the sleeve and puller.

Make sure to fit the bearing seat correctly or it might get stuckl

92 1810993-02


4 Fitting the top bearing housing.

a Fit the axial springs Q ^ to the top bearing housing.

Axiai springs

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

d Fit the compression springs E ^ and plugs to the top bearing housing. Do not tighten the plugs. Make sure that the springs enter the recesses in the top bearing seat. The plugs should be tightened when the spindle assembly is mounted into the frame.

1810993-02 93


5 Fitting the spindle pulley.

s Turn the spindle assembly upside down.

b Wipe off tlie spindle pulley seat on the spindle and nave bore in the spindle pulley with a dry cloth.

TJöTE

c Fit the spindle pulley firmly on the bowl spindle.

At least 1 mm free space between support and spindle assembly to protect the bearing.

Mount the cap nut to protect the threads and support the spindle.

6 Fitting the self-aligning roller bearing EJ

a Heat the bearing in oil to maximum 125 "C.

MOTE

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

M V«M*»*»»*®

Bum hazard Use protective gloves when handling the heated bearing.

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

94 1810993-02


7 Fitting Vne oil pump.

a Fit O-ring onto lubrication oil orifice. Spread oil film on 0-ring.

b Push lubrication oil orifice into oil pump. Be sure to line up tabs on orifice with slots in pump.

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

HOTE

Clean the oil pump and make sure that the bottom hole is not clogged.

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

1810993-02 95


8 Fitting the fan

A a Turn the spindle assembly up-side down.

HOTE

Ensure that the spindle is seated against the inner ring of the ball bearing.

b Spread oil film on the 0-ring [Jj^ and fit it into the fan.

HOTt

Key-grip •

IVIake sure that the bearing is pre lubricated before fitting the fan.

c Place a spanner (or similar) on the spindle pulley key-grip, as holder-up and fit the fan. Tighten firmly, by hand, with the pin spanner.

9 Fitting tlie air deflector.

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

96 1810993-02


10 Lowering the spindle assembly into the frame.

a Turn the assembly and remove the cap nut from the spindle. Fit the lifting tool to the spindle assembly and lift it.

^V«ABMll*G

Crush hazard Do not rotate the spindle assembly during lifting. The spindle assembly may otherwise come loose from the lifting tool.

MOTE

Check that the hole at the bottom of the oil pump is clean before lowering the assembly down.

Check the bottom hole.

b Position the flat belt Q ^ so that the spindle assembly can pass through when lowering. See note below.

c Carefully lower the spindle assembly and position the bolt holes over the threaded frame holes. Make sure that the bottom bearing, enters the bottom bearing holder correctly Do not use force.

- ^ ^ * G

Cut hazard Do not put fingers between the frame and air deflector while lowering the assembly.

d Fit and tighten the screws.

Space

HOTE

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

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

e Tighten the plugs firmly.

1810993-02 97


11 Fitting the flat belt,

HOTE

Clean the Inside of the frame before fitting the flat belt, and make sure that there is no oil on the belt.

a Lift up the belt to the middle (centre) of the spindle pulley.

HOTE

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

Clearance

b Fit the flat belt to the motor belt pulley.

c Tighten the two upper screws.

d Tighten all motor attachment screws.

"MSTE

Do not turn the spindle until the motor is tightened properly to the frame.

98 1810993-02


12 Fitting the necl<: bearing cover and deflector ring.

a Apply a thin layer of oil and fit the 0-rings and seal ring in the lower groove Ejjj .

b Fit the neck bearing cover.

note

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

Deflector rinq

Neck bearing cover

c Push the deflector down until it stops.

1810993-02 99


13 Fitting the operating water cover.

a Lubricate with oil and fit the seal ring and 0-ring Q ^ into the operating water cover

Renew the 0-ring b Fit the operating water cover. Fit and

tighten the screws.

MOTE

The water pipe in the frame should enter the hole in the cover.

14 Measuring the radial wobble of the bowl spindle.

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

HOTE

Permissible radial wobble: max. 0,04 mm. If the spindle wobble exceeds this value, contact an Alfa Laval representative.

Max. 0,04 mm

100 1810993-02


15 Fitting the clutch cover.

b Tighten the screws.

a Fit the clutch cover.

16 Fill oil in the oil sump.

HOT6

a Remove the oil pin, plug and washer. The separator should be level and at standstill when oil Is filled.

d Fit new 0-ring Q ^ onto the oil pin.

e Refit the plug with new washer Qjj

f Fit the oil pin.

b Fit new washer ^ ^ and refit the drain plug,

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

HOTE

For grade and quality of oil see 3.7.6 Lubricating oils, page 129

1810993-02 101


3.5.3 Bowl

1 Check for impact marks and corrosion in bowl body nave and on spindle taper Qjj 0 ^ •

KpAtfTlOH a Remove any impact marks using

a scraper and/or a wlietstone.

Disintegration hazard Impact marks may cause the separator to vibrate while running.

b Rust can be removed by using a fine-grain emery cloth (e.g. No. 320).

c Finish with polishing paper (e.g. No. 600).

d Lubricate to prevent further corrosion.

2 Fitting new valve plugs on the operating slide

a Remove the valve plugs using

JL ^ ' '''''' Drift

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

note

IVIake sure that the plugs are fitted as described in the illustration.

102 1810993-02


3 Fitting the operating slide.

a Apply a thin layer of silicone grease and fit the rectangular ring on the operating slide and the rectangular ring and 0-ring on the bowl body

mf3

b Fit the operating slide.

HOTE

The guide pin in tlie bowl body should enter the hole in the operating slide (this hole is marked with a drill mark).

Nozzle secured with Loctite 222

Alignment hole - ^ i ^ >^Wk

Operating slide — tJSÅ

Bowl body -

Guide pin . 1 : ^

4 Fitting the operating slide holder.

a Fit the holder over the operating slide. b Apply a thin layer of molykote grease

and fit and tighten the screws to a torque of m\n. 15 Nm and max. 20 Nm.

1810993-02 103


5 Fitting the operating water ring.

a Fit the ring |

^^^^t^îXsristÉrf^

MOTE

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

Apply a thin layer of silicone grease and fit the 0-ring QI^

c Fit the operating water ring.

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

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

104 1810993-02


6 Lifting the bov\/l body onto the spindle taper,

a Put a drop of oil on the spindle taper.

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

c Turn the bowl body over.

y^viMiH»*Q^

Crush hazard Support the bowl body when turning to prevent it from rolling.

©Carefully lower the bowl body onto the spindle taper.

d Fit the lifting tool and lift the bowl body.

f Remove the lifting tool.

1810993-02 105


7 Fitting and tightening the cap nut.

a To prevent the bowl body from rotating when fitting the cap nut; Fit one of the clamps (see page 45) to the bowl body and one of the screws for the frame hood in the frame. Fasten a sling between the clamp and the screw around the bowl body.

b Apply a thin layer of molykote grease. Fit and tighten the cap nut to a torque of 50 Nm.

Left-hand thread!

Sling Screw

Clamp

Cap nut

106 1810993-02


8 Fitting tine discharge slide.

,a Apply a thin layer of silicone grease and fit the rectangular ring Qjjj D ^ •

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

d Remove the tiffing tool.

Crush hazard The ring on the lifting tool must be pushed home against the discharge slide, otherwise it may come loose from the tool.

e Fit the nut.

f Fit the spanner for nut and tighten the nut with a torque wrench to a torque of min. 200 Nm.

g Remove the spanner for nut.

1810993-02 107


9 Assembly of the disc stack.

a Fit the discs one by one onto the distributor. The distributor has a guide rib for the correct positioning of the bowl discs. Always end with the disc without caulks.

^V*IVBH»HG

The number of discs may have to be increased to adjust the disc stack pressure. Always check before operating the separator. See "Checking the disc stack pressure" on page 114

lîø^ Cut hazard Sharp edges on the bowl discs may cause cuts.

Recess on bowl disc

Guide rib on distributor

108 1810993-02


10 Fitting the disc stack assembly to the bow/I body

a Fit the lifting tool into the distributor.

b Lower the disc stack into the bowl.

MOTE

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

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

Guide pin on bowl body

Quide rib on distributor

Guide ribs inside the distributor.

Recesses on the bowl body nave.

1810993-02 109


11 Assembling the paring tube |

^

-Tolerance ring

a Fit the 0-rings Qjl^ bearings 01^ and tolerance ring to the paring tube.

12 Mounting the paring tube and fitting the inlet and outlet pipe.

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

b Mount the splash sealing

c Apply a thin layer of silicone grease and fit the 0-rings B I^

d Carefully lower the inlet and outlet pipe assembly into the top of the distributor.

110 1810993-02


13 Fitting the top disc,

b Lower the top disc

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

'

a Move the paring tube to the centre.

MOtE

To avoid damaging the paring tube, turn it towards tlie centre of the pipe.

1810993-02 111


14 Fitting tine bowl hood.

a Apply a thin layer of silicone grease and fit the 0-ring Qjjj E>

b Fit the seal ring Q p | 3 ^ Press the ring down evenly until bulges appear

c Carefully tap down the bulges crosswise with a soft rubber nnallet, until the ring is completely fitted.

d Fit the connpressing tool and attach lifting eyes. Lower the bowl hood so that its recess fits into the guide pin in the bowl body.

Recess on bowl hood

e Remove the compressing tool

Guide pin on bowl body

112 1810993-02


15 Fitting the loGi< ring.

Place the lock ring on the bowl hood with its guide pin close to the corresponding hole in the bowl body.

note

Make sure that the groove in the bowl body which retains the lock ring is clean.

Fit the complete compressing tool and compress the disc stack by alternately turning the screws a maximum of 40 Nm at a time until the lock ring fits into the bowl body. The lock ring is correctly fitted when the lock ring ends are facing each other.

For correct disc stack pressure see page 114

MOti

Check that the lock ring is correctly positioned all way around!

Never remove any material from the lock ring. A hazardous situation could result.

) \

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

Lock ring

Bowl hood

Bowl body

Before compressing Lock ring in position

1810993-02 113


16 Checking the disc stack pressure |

a Remove bowi hood, top disc and inlet and outlet pipe.

b Add one disc to the disc stack.

c Refit the disc without caulks, the top disc and bowl hood.

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

MOTE

Do not use more power than 50 A/m/screw at a time, alternately.

Always refit the disc without caulks on top of the disc stack!

e If the lock ring enters the groove, repeat a-d until the lock ring does not enter the groove.

f Dismantle the bowl and remove one disc to get the correct disc stack pressure.

g Assemble the bowl with inlet and outlet pipe.

114 1810993-02


3.5.4 Frame hood

1 Fitting tlie frame hood Ql^ B^

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

b Apply a thin layer of siiicone grease and fit the 0-ring onto the frame hood

c Lower the frame hood.

Make sure that the frame hood is mounted in its correct position according to the piping arrangement.

d Fit and tighten the screws.

IVIal<e sure to fit the frame hood groove and the projection of the pipe.

1810993-02 115

3 SEPARATOR SERVICE. DISMANTLING, ASSEMBLY SA 836 SEPARATION SYSTEM SERVICE MANUAL

2 Control measurement of paring disc height f^

Remove the safety screw.

b Measure the distance A. Add or remove height adjusting rings and washers according to the table.

A

mm

26 ± 0 , 5

25 ± 0,5

24 ± 0,5

Quantity washers

1

2

3

Quantity heigtit adjusting rings

3

2

1

Frame hood

Bowl hood

Height adjusting rings

Support ring

m

116 1810993-02


3 Fitting the spring Q ^ and arm.

a Fit the spring on ttie arm and fit the arm to the top of the paring tube end.

Paring tube Arm

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

1810993-02 1 1 7


4 Fitting tlie connection housing.

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

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

Make sure that the screw, on top of the frame hood, enters the guide hole at the underside of the connecting housing.

118 1810993-02


3.5.5 Unbalance sensor (option)

1 Fitting the unbalance sensor holder.

a Remove the cover.

Sensor arm

Sensor holder.

Frame

Screw M8

M10

V_ 0-ring

b Fit the 0-ring on the holder. Fit the screw into the holder and mount the holder into the separator frame.

note

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

»OtE

See next page for fitting and correct adjustment of the sensor.

1810993-02 119


2 Adjusting the unbalance sensor

/ j ( . .* •-;

——

* - c

'. - ' • "

Sensor

Nut,

a Fit the sensor into the holder Do not forget the nut.

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

Nut

- + = brown or red

- J = black or white

- OV = blue

( G ) 2 4 V D C

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

Adjustment value for the sensor is; 12 mA ± 1 mA. For more details see 2.3 Connecf/on L/sf, page 75and 752 Unbalance sensor (option)., page 22.

•

120 1810993-02


3.5.6 Speed sensor

1 Adjusting the speed sensor

a Adjust the speed sensor according to the illustration.

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

rf " l y - - • -^n H n

102 ±0,1

IT-T 1\]\ IJ-J U L

1810993-02 121


3.6 Actions After Assembly

3.6.1 Control of machine plates and safety labels Qj^

Alta Laval ref. 561498 rev. 3

1 Check that the following signs are attached.

Machine plate

ä _ • 2 äl äni. £. ^ £

Lifting instructions

Space for additional label as specified.

Space for label indicating representative.

Oil type plate

Indicating direction of rotation of tiorizontal driving device.

Safety label.

50Hz

60Hz

122 1810993-02


2 Check legibility. Following texts should be read on the labels.

Separator

Manufacturing serial No. / Year

Product No.

In and outlet device

Bowl

Machine bottom part

Max. speed (bowl)

Direction of rotation (bowl)

Speed motor shaft

El. current frequency

Recommended motor power

Max. density of feed

Max. density of sediment

Max. density of operating liquid

Process temperature min./max.

xxxxxxxxxxxxxxxxx

XXXXJOOtXX.

T K x x x x x x x x x x x x x x x X x x x x XXX.

XXX XXX X XXXXXX XXXXXXXXXXXXXXX XXXXXXXX,

XKXXKXX/XXX XX

ÂJtaLnri

m 9

• O

« 9

2.—. o

m k

» &.— • »— s— "-=""

WARNING

Read the instruction manuals before installation, operation and maintenance. Consider inspection inten/als.

Failure to strictly follow instructions can lead to fatal injury.

If excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown.

Out of balance vibration will become worse if bowl is not full.

Separator must stop rotating before any dismantling work is started.

Read instruction manual before lifting.

1810993-02 123


3.7 Oil Change

The separator should be level and at standstill when oil is filled or the oil level is checked.

3.7.1 Lubricating oil

Do not mix different oil brands.

Always use clean vessels when handling lubricating oil.

Great attention must be paid not to contaminate the lubricating oil. Of particular importance is to avoid mixing of different types of oil. Even a few drops of motor oil mixed into a synthetic oil may result in severe foaming.

Any presence of black deposits in a mineral type oil is an indication that the oil base has deteriorated seriously or that some of the oil additives have precipitated. Always investigate why black deposits occurs.

If changing from one oil brand to another it is recommended to do this in connection with an overhaul of the separator. Clean the gear housing and the spindle parts thoroughly and remove all deposits before filling the new oil.

HOT6

Always clean and dry parts (also tools) before lubricants are applied.

KCAOTIOH

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

It is of utmost importance to use the lubricants recommended in our documentation.

This does not exclude, however, the use of other brands, provided they have equivalently high quality properties as the brands recommended. The use of oilbrands and other lubricants than recommended, is done on the exclusive responsibility of the user or oil supplier.

Applying, handling and storing of lubricants

Always be sure to follow lubricants manufacturer's instructions.

124 1810993-02


3.7.2 Check oil level

•f Remove the oil pin and make sure that the oil level is above the lower hole in the oil pin.

3.7.3 Oil change procedure

1 Remove the oil pin, plug and washer.

2 Place a vessel under the drain plug.

3 Remove the drain plug.

y^CjVUTlOW^

Bum hazard The lubricating oil and various machine surfaces can be sufficiently hot to cause burns.

4 Collect the oil in the vessel.

5 Fit and tighten the drain plug.

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

MOTE

See 3.7.6 Lubricating oils, page 129.

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

8 Fit the oil pin.

Oil fill

Plug and washer

Oil drain plug

HOTE

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

1810993-02 125


3.7.4 Lubrication chart

Alfa Laval ret 567329-01, rev. 1

Bowl (3), Rubber seal rings (4)

Bowl spindle taper (2)

Buffers (3)

Bowl spindle and bearings (1)

Electric motor (6)

Friction clutch bearings (5)

1

2

3

4

5

6

Lubricating-points

The oil bath. Bowl spindle bearings are lubricated by oil mist from the oil bath.

Bowl spindle taper.

Bowl: Sliding contact surfaces, thread of lock nut and cap nut.

Rubber seal rings.

Friction clutch bearings.

Electric motor.

Type of lubricant

See 3.7.1 Lubricating oil, page 124 Volume: 2.2 Technical Data, page 14 Ambient temperature 0 to +55°C

Lubricating oil, only a few drops for rust protection.

Pastes specified in 3.7.5Lubricants, page 127

Grease as specified in 3.7.5 Lubricants, page 127

The bearings are pre-lubricated with grease.

Follow the manufacturer's instructions.

Interval

Oil change:

1. Continous operation: 4000 hours 2. Seasonal operation:

before every operating period 3. Short periods operation:

12 months even if total numbers of operating hours is less than stated above

At assembling

At assembling.

At assembling

No need for extra lubrication.

Follow the manufacturer's instructions.

»OTE

Check and pre lubricate new spindle bearings and those that have been out of service for one month or longer. If not otherwise specified, follow the suppliers instructions about applying, handling and storing of lubricants.

^CAUTlOt*

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

126 1810993-02


3.7.5 Lubricants Alia Laval rei. 553217-01 rev. 8

Pastes for non-food applications:

note

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

Brands with Alfa Laval article numbers are approved and recommended for use.

Manufacturer

Fuchs Lubritech

Dow Corning

Rocol

Kluber

Designation

Gleitmo 805 K Gleitmo 705 K

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

Antiscuffing (ASP) (Paste)

Wolfracoat C (Paste)

Alfa Laval No.

537086-02 (1000 g) 535586-01 (too g) 535586-02 (50 g)

Bonded coatings

Manufacturer

Fuchs Lubritech

Dow Corning

Designation

Gleitmo 900 (Varnish or spray)

Molykote D321R (Spray) Molykote D321R (Varnish)

Alfa Laval No.

535586-01 (300 ml) 535586-02 (60 ml)

1810993-02 127


Silicone grease for rubber rings

Manufacturer

Dow Corning

Fuchs Lubritech

Kluber

Wacker

Designation

Molykote 111 (Compound) Molykote 111 (Compound)

Gleitmo 750

Unisilkon L 250 L

Silicone P (Paste)

Alfa Laval No.

539474-02 (100 g) 539474-03 (25 g)

Greases for ball and roller bearings:

HOTE

Always follow the specific recommendation for lubrication as advised by the manufacturer.

Manufacturer

BP

Castro!

Chevron

Elf

Esso/Exxon

Mobil

Gulf

Q8/Kuwait Petroleum

Shell

SKF

Texaco

Designation

Energrease MM-EP2 Energrease LS2

APS 2 Grease

EPL2

Duralith grease EP2

Epexa 2

Beacon EP2 Unirex N2

Mobilith SHC 460 iVIobilux EP2

Gulf lex MP2

Rembrandt EP2

Albida Grease EP2 Alvania EP Grease 2

LGEP2orLGIVIT2

Multitak AFB 2

128 1810993-02


3.7.6 Lubricating oils

Alfa Laval ref. 567330-01, rev. 1

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

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

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

Standard

DIN 51524 part 2 (German standard)

ISO 11158 (International standard)

Designation

DIN51524-HLPorHVLP68

ISO-L-HM or HV 68

The following is the list of recommended oil brands. Trade names and designations might vary from country to country. Please contact your local oil supplier for more information.

Manufacturer

Alfa Laval

BP

Castrol

Chevron

Esse / Exxon

Mobil

Shell

Statoil

Total Fina Elf

Designation

567334-01

567334-02

Bartran 68 Bartran HV 68

Hyspin AWS 68 Hyspin AWH 68

Hydraulic oil AW 68

Nuto H 68 Univis N 68

DTE 26 (ISO VG 68) DTE 16 (ISO VG 68) DTE16M(ISOVG68)

TellusOil 68 Tellus Oil S 68 Tellus Oil T 68

HydraWay HMA 68 Hydra Way HVX 68

Azolla ZS 68 Lubmarine Visga 68

1 litre

4 litres

The list of recommended oil brands is not complete. Other oil brands may be used as long as the follow the above standards and have equivalent high quality as the brands recommended. The use of other lubricants than recommended is done on the exclusive responsibility of the user or oil supplier.

1810993-02 129


3.8 Lifting instructions

3.8.1 Lifting the separator

Weight to lift 320 kg

Fasten all four bolts. Tightening torque 35 - 45 Nm

Sling length: Min. 750 mm

1 Remove the inlet and outlet device, the frame hood and the bowl according to the instructions in 3.3 Dismantling, page 39.

»OTE

Never lift or transport the separator with the bowl still inside.

2 Disconnect all connections.

3 Fit the lifting tool (not included in set of tools). All four bolts on the lifting tool must be fastened to the frame.

4 Unscrew the foundation bolts.

5 Use two lifting slings to lift the separator. Total length of each loop: minimum 1,5 metres.

130 1810993-02


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

KWABHIHG

Crush hazards A falling separator can cause accidents resulting

in serious injury and damage. Never lift the separator by any other method than

described in this manual.

note

When lifting parts without weight specifications, always use lifting straps with the capacity of at least 500 kg.

3.8.2 Lifting the bowl

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

1 Fit the lifting tool with lifting eyes to the bowl assembly.

2 Check that the lock ring is mounted correctly before lifting the complete bowl.

3 Lift the bowl using a sling with the proper rating.

HOtE

Weight to lift 50 kg

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

Tightening torque 35 - 45 Nm

Make sure that lock ring is fitted.

1810993-02 131

4 CHANGE OF CIRCUIT BOARD SA 836 SEPARATION SYSTEM SERVICE MANUAL

4 Change of Circuit Board

If a circuit board has to be changed, proceed as follows:

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

Change the board according to the instructions below.

Go to parameter Fa 90, and insert the run time.

OP-Board

• Switch power off.

• Remove the snap-in transparent cover.

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

• Disconnect the flatcable connector at the top.

• Unscrew the five hexagon nuts.

• Mount the new board, and connect in reverse order.

I/O-Board


If there is no optional board installed:

• Disconnect all the cable plugs on the large board (do not remove the cables from the plugs).

• Unscrew the hexagon nuts. Take care to note where the special nuts for optional board(s) are located.

• Mount the new board, and connect in reverse order.

132 1810993-02

SA 836 SEPARATION SYSTEM SERVICE MANUAL 4 CHANGE OF CIRCUIT BOARD

If one or more optional board is installed:


• Disconnect the cable plug(s) on the optional board (do not remove the cables from the plug(s)).

• Disconnect the flatcable connector at the top.

• Unscrew the three hexagon nuts.

• Note the position of the board and remove the board.

• Disconnect all the cable plugs on the large board (do not remove the cables from the plugs).

• Unscrew the hexagon nuts. Take care to note where the special nuts for optional board(s) are located.

• Mount the new board in the same position as the old, and connect in reverse order.

MT-Board

Switch power off.

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

Disconnect the centrally connected cable.

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

Mount the new board, and connect in reverse order.

Check that the central hexagon nut is properly tightened.

1810993-02 133

4 CHANGE OF CIRCUIT BOARD SA 836 SEPARATION SYSTEM SERVICE MANUAL

4.1 Circuit Board Temperatures

Circuit board temperature information can be read as follows:

• Set Pr 7 = 2.

• Push '+' and '-' at the same time ('Standst.' now shows on the display).

• Push '-'

The actual temperature, max. temperature, and the number of times the temperature has been above 70 °C for the transducer scrolls across the display.

• For further circuit board temperatures, push the '-' button.

• To leave the list push the'+' and the '-' buttons at the same time.

• Reset Pr 7 = 0.

134 1810993-02

SA 836 SEPARATION SYSTEM SERVICE MANUAL 5 CLEANING IN PLACE

5 Cleaning in Place

The use of Cleaning In Place (CIP) equipment is recommended for best separation results. For further information concerning the CIP equipment, see the CIP booklet, bookno. 1817261.

Before connecting the CIP equipment to the Separation Unit, the switch on the control cabinet must be turned to the CIP position. This is so that oil is not accidentally pumped when the pipeline is opened up.

5.1 Cleaning in Place, Separator

1 Remove the pipe connecting plate with pipes from the separator.

2 Attach the CIP equipment as shown in the illustration.

HOTL

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

1810993-02 135

5 CLEANING IN PLACE SA 836 SEPARATION SYSTEM SERVICE MANUAL

5.2 Cleaning in Place, Heatpac® CBM Heater

For systems including a Heatpac® CBM heater, cleaning in place of the heater should be carried out circa every 6 months, or according to experience. Cleaning in place of the heater should also be carried out in the event of a pressure drop increase greater than 0.3 - 0.5 bar (which indicates that the heater is beginning to clog).

We recommend that you use Alfa Laval cleaning liquids. These are specially suitable for the materials used in the Heatpac® CBM heater. Liquids that are corrosive to copper or stainless steel, for example hydrochloric acid, phosphoric acid, or nitric acid, must not be used.

y ^ ^ M W » ^

Bum hazard Shut off the oil flow and the heating medium flow before starting maintenance work.

^^WABMWIG

Corrosion hazard Pay strict attention to the safety instructions for the cleaning liquid used.

HOTE

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

136 1810993-02

SA 836 SEPARATION SYSTEM SERVICE MANUAL 5 CLEANING IN PLACE

Proceed as follows:

1 Close the valves before and after the heater,

2 Open the heater drain valve until oil remaining in the heater has drained.

3 Close the drain valve.

4 Loosen the turnable connections before and after the heater. Turn the connections 90 ° so that the'special CIP connections can be connected.

5 Connect the CIP equipment. The top inlet on the CIP unit should be connected to the oil outlet on the heater. The hose from the heater inlet should be inserted into the tank and secured with the help of the cover.

MOTE

The middle and lower CIP unit outlets must be closed.

6 Clean with CIP fluid.

7 Flush with water

After cleaning:

1 Open the heater drain valve until the flushing water has drained.

2 Close the drain valve.

3 Remove the CIP connections.

4 Return the turnable connections to their former positions and re-tighten.

5 Re-open the valves before and after the heater.

1810993-02 137

5 CLEANING IN PLACE SA 836 SEPARATION SYSTEM SERVICE MANUAL

5.3 Cleaning in Place, Separator and Heater

Connect the CIP equipment as shown in the illustration. Proceed with cleaning as described above.

Oil outlet Water outlet

138 1810993-02


Spare Parts Catalogue ^^K7^^^

Product No.

Book No.

Separator Part No.

Printed

567889-03

1811025-02 V 1

881202-02-03

Sep 2004

Spare Parts Catalogue

Reservdel skatal og

Ersatzteilkatalog

Catalogue de pieces de rechange

Catalogue de piezas de recambio

Kaia/ior sanacHbix Hacren

Catalogo parti di ncambio

Catalogo de pecas sobressalentes

Varaosaluettelo

KaTaÅoyoQ avTaA.Ä.aKTLKü)v

Reserveonderdelen-catalogus

Reservedelskatalog

Contents Separator 8 1.1 Machine bottom part 8 1.2 Driving device vertical 10 1.3 Separator bowl 12 1.4 Inlet and outlet device 14 1.5 Belt driving device 16 1.6 Centrifugal clutch 18 1.7 Set of plates 20 1.8 Monitoring kit 22 1.9 Cover interlocking kit 24 1.10 Set of tools 26 1.11 Lifting tool 28 1.12 Inspection kit 30 1.13 Overhaul kit .32 1.14 Support kit 34 1.15 Hydraulic tool kit 36 1.16 Hydraulic components 38 1.17 Hydraulic tool 40

Ancillary Equipment 42 2.1 Valve block water 42 2.2 Spare parts kit, valve block

water 44 2.3 Valve block air 46 2.4 Spare parts kit, valve block

air 48 2.5 Valve block oil 50 2.6 Water transducer 52 2.7 Spare parts kit, pneumatic

3-way valve 54 2.8 Connection kit, oil 56 2.9 Sludge outlet kit 58 2.10 Butterfly valve 60 2.11 Spare parts, EPC 50 Control

Unit 62 2.12 EPC 50 Control unit 64 2.13 Starters 64 2.14 Separator starter kits, basic

a n d 4 A - 3 2 A 65 2.15 Separator starter kits,

32A - 63A 66 2.16 Pump starter kits,

0.4A - 16.0A 66 2.17 ESD-relay kit 67 2.18 Motor trip contact kit 67

Index 70

1811025-02

1811025-02

Read this first

en

sv

de

fr

es

ru

it

pt

f i

Gi ni

da

Check the machine unit number on the name-plate before using this catalogue

Kontrollera maskinenhetens nummer på maskinskylten innan du använder katalogen

Das Typenschild - ein Hinweis zur korrekten Ersatzteilnummer

La plaque de la machine, un guide pour trouver le numéro de piece de rechange correct

La placa-marca de la maquina - gui'a del nümero correcto del repuesto

ctJupMeHHafi laöJiMHKa MamuHbi - yKasaienb npasmiHoro HOMepa sanacHoii sacTH

La targhetta della macchina - guida al corretto numero del ricambi

A placa do fabricante da mäquina - um guia do nümero correto das partes sobressalentes

Konekilpi - opastin oikeaan varaosanumeroon

H nivoKiSa xriq [irixaviiq sivai o oSriYöq TOU acoaxou avTctAXaKTiKoü

Het gegevensplaatje - een wegwijzer naar het juiste onderdeelnummer

Typeskiltet - en guide til det rette reservedelsnummer

en

Safeguard your commitment to quality by always using genuine Alfa Laval spare parts.

Remember, Alfa Laval cannot accept responsibility for the failure of a separator equipped with non-original spare parts. We guarantee the quality and reliability of our products.

Följ ditt kvalitetstänkande genom att endast använda Alfa Laval originalreservdelar.

Kom ihåg att Alfa Laval inte tar något ansvar for fei på en separator, som innehåller icke-originaldelar. Vi garanterar kvaliteten och driftsäkerheten endast hos vara egna produkter.

de

Aus Rücksicht auf Ihr Bestreben um beste Qualität sollten Sie nur Alfa Laval Originalersatzteile benutzen.

Vergessen Sie nicht, Alfa Laval kann keine Verantwortung für das Versagen eines Separators übernehmen, der nicht mit Originalersatzteilen versehen ist. Wir garantieren Qualität und Zuverlässigkeit unserer Produkte.

Préservez la qualité de vos equipments en n'employant que des pieces de rechange Alfa Laval.

N'oubliez pas q'Alfa Laval decline toute responsabilité en cas de panne d'un séparateur non équipé de pieces de rechange d'origine. Nous garantissons la qualité et la fiabilité de nos produits.

B Mantenga su compromiso con la calidad, al usar siempre piezas de repuesto Alfa Laval auténticas.

Recuerde que Alfa Laval no acepta responsabilidad por el fallo de una separadora equipada con piezas de repuesto no originales. Garantizamos la calidad y fiabilidad de nuestros productos.

B FapaHTupyMTe HaflexHOCTb KanecTBa Bcerfla ncnonbaypi noAHMHHbie aanacHbie nacTn c|DnpMbi Alfa Laval.

3anoMHMTe, HTO Alfa Laval He Hecei oTBercTBeHHOCTn aa noBpexfleHne cenaparopa, ocHameHHoro HenofljinHHbiMH aannacTaMM. Mbi rapaHTnpyeM Kanecibo M HaAe)KHOCTb naiunx \A3Renm.

Salvaguardate la vostra garanzia di qualitå facendo sempre uso di parti di ricambio Alfa Laval autentiche.

Tenete presente che la Alfa Laval non puo accettare responsabilita per avaria ad un separatore attrezzato con parti di ricambio non originali. Nol garantiamo la qualitå l'affidabilitä del nostri prodotti.

Proteja o seu cometimento a qualidade usando sempre pegas sobressalentes genuinas Alfa Laval.

Näo esquega que Alfa Laval näo aceita responsabilidade por falha de uma separadora equipada com pefas sobressalentes näo genuinas. NÖS garantimos a qualidade e a confianga dos nossos produtos.

ra Varmistakaa vastuunne laadusta käyttämällä aina alkuperäisiä Alfa Laval varaosia.

Muistakaa, Alfa Laval ei vol hyväksyä vastuuta ei-alkuperäsillä varaosilla varustetun separaattorin vaurioista. Me takaamme tuotteidemme laadun ja käyttövarmuuden.

E aacpaXCoTC uiiJtiArj noiöxriTa xPICfiponoiüvTac; pövo yvnaia avTaWcKTiKä xn«; Alfa Lava!.

'ExETE unöipriv öxi ri Alfa Laval 5EV avaXaiaßcivEi Koppiä EuSüvri yia ßÄäßEQ ßouxupoprixavTiq, oxr|v onoia éxouv scpapnoaxEi [ir\ yviiaia avxaWQKxiKÖ. EvYuöpaaxE noiöxnxa KQI KoAri AEixoupyia pövo yia xa ÖIKÖ paq npoiövxa.

s Street naar een zo hoog mogelijke kwaliteit en gebruik uitsluitend originele Alfa Laval reserveonderdelen. Street naar een zo hoog mogelijke kwaliteit en gebruik uitsluitend originele Alfa Laval reserveonderdelen.

Vergeet niet dat Alfa Laval niet verantwoordelijk is voor een defecte separator die niet-originele onderdelen bevat. Wij garanderen de kwaliteit en betrouwbaarheid van onze eigen Produkten.

da

Hold Dem til den kvalitet, De har valgt at satse på, ved altid at anvende ægte Alfa Laval reservedele.

Husk, at Alfa Laval ikke kan påtage sig noget ansvar for fejl på en separator, som indeholder uoriginale dele. Vi kan kun garantere kvalitet og driftsikkerhed på vore egne produkter.

Translation list

Översättningslista Überzetsungsliste Liste de traduction Lista de traducciones

[ e n ] 1 [ s v j

Part.no. i Reservdelsnummer

Qty Antal

Description Benämning

1

Notes Anmärkningar

Machine type | Maskintyp

Product no. ' Produktnr

Machine unit Maskinblocksbenämning description 1

Machine unit no. Maskinblocksnr

Subassembly ' Undergruppsbenämning description

Subassembly no. Undergruppsnr

1 See page

Fig. ref.

Product name

Exchange necessitates rebalancing of bowl

See separate spare parts list

Not delivered as spare part

Se sidan

Figurhanvisning

Produktnamn

Utbyte nödvändiggör ombalansering av kulan

Se separat reservdelslista

Levereras ej som reservdel

® Teil-Nr.

Anzahl

Bezeichnung

Anmerkungen

Maschinentyp

Produktnummer

Bezeichnung des Maschinenblocks

Maschinenblock Nr.

Bezeichung der Untergruppe

Untergruppe Nr.

Siehe Seite

Bildhinweise

Produktname

Austasch erfordert Wiederauswuchtung der Trommel

Siehe separate Ersatzteilliste

Nicht als Ersatzteil geliefert

E Numero de piece

Quantité

Denomination

Remarques

Type de machine

Numero de produit

Denomination de partie de machine

Partie de machine n

Denomination de sous-ensemble

N' de sous-ensemble

Voir page

Réf. de fig.

Nom du produit

Le remplacement nécessite le rééquilibrage du bol

Voir liste séparée des pieces de rechange

Non livre comme piece de rechange

S Pieza No.

Cantidad

Descripcion

Notas

Tipo de måquina

Nijmero de producto

Descripcion de seccion de la måquina

No. de seccion de måquina

Descripcion de subconjunto

Numero de subconjunto

Véase la pagina

Referenda de figura

Nombre del producto

El racmbio requiere el reequilibrado del rotor

Véase la lista de piezas se parada

No se entrega como pieza de recambio

http://Part.no

Translation list

C/iOBapb nepesAa Lista traduzioni Lista para tradu9äo Käännösluttelo

B Part no.

Qty

Description

Notes

iMachine type

Product no.

lUiachine unit description

iUlachine unit no.

Subassembiy description

Subassembly no.

See page

Fig. ret.

Product name




S fleranb Ne

KO/l-BO

HanMeHOBaHne

npuMenaHUH

MaiuMHa THna

ApiMKyji Ms

HanMeHOBaHne 5noKa MaUJklHbl

E/10K MaiuviHbi Ns

HanMeHOBaHne rpynnw

rpynna Ns

CM. cTpaHMuy

CcbmKa Ha 3CKI/I3

HakiMeHOBBHMe apTMKyna

SaMBHa Tpe6yeT 6a/iaHCMpoBKM 5apa6aHa

C M . OTflenbHbiki nepeneHb sanacHbix nacTeü

He nocTBBneHa BMecre c sanacHbiMbi MacTnMki

3 Nr.parte.

Quantita

Descrizione

Note

Tipo macchina

Nr.produtto

Nr. unita macchina

Descrizione sottogruppo

Descrizione unita macchina

Nr. sottogruppo.

Vedi pagina

Rif. fig.

Nome prodotto

La sostituzione comporta la iequilibratura del tamburo

Vedi lista separata delle parti dl ricambio

Non fornito come parte di ricambio

S Numero de peca

Quantidade

Descricao

Notas

Tipo de maquina

No. do produto

Descricao da unidade da maquina

Numero de unidade da maquina

Descriao do subconjunto

Ntimero de subconjunto

Véase la pagina

Referencia de figura

Nombre del producto

El racmbio requiere el reequilibrado del rotor

Véase la lista de piezas separada

No se entrega como pieza de recambio

m Varaosanumero

Lukumäärä

Nimitys

Huomautuksia

Konetyyppi

Tuotteen no

Koneenosan nimitys

Koneenosan no

Alaryhmän nimitys

Alaryhmän no

Kssivu

Kuvavilte

Tuotteen nimi

Vaihdettaessa kuula tasapainoitettava uudelleen

Katso erillistä varaosaluetteloa

Ei toimiteta varaosana

Translation list

rAQZZAPI Vertaallijst Oversættelseliste

® 1

1 Part no.

Qty

Description

Notes

1 Machine type

Product no.

Machine unit description ,

Machine unit no.

Subassembly description

Subassembly no.

See page

Fig. ref.

Product name




S ApiØôc; avxaXXaKTiKOiJ

lüvoXo

riepiYpacpTi

napatriptiaeic;

Tünoc; MnxavrjiJaToc;

Api9p6c; npoiovToq

nepLYpacpii cuYKpoTiinaToc; lr Xavl c;

Api6|j6q øuYKpoTiiiJaToc; Mnxaviic;

nepiYpatpii unoauYKpoTiinaToc;

AptØnoq unoouyKpoTiipaToc;

BXéne aeMöa

riapanount^ ae ELKOVQ

OvoiaaaCa npotövroc;

AvTaXXoYn anaiTEi enavappüöniari laopponCaq xou Tunnavou

BXéne EIÖIKI^ Xiøxa avTaXXaKTiKcjv

Aev napaSiSetai wq aviaXXaKTiKÖ

ra Onderdeelnr.

Hoeveelheid

Beschrijving

Opmerkingen

Machinetype

Produktnr.

Machineblokbenaming

Machineblokbenamning

Subgroepbenamning

Subgroepnr.

Zie biz.

Afb. ref.

Produktnaam

Vervangning vereist lierbalanceren van de kogel

Vervangning vereist van de kogel

Niet geleverd als reserveonderdeel

® Reservedelsnummer

Antal

Betegnelse

Bemaerkninger

Maskintype

Produktnr.

Masklnbetegnelse

Maskinnr.

Undergruppsbetegnelse

Undergruppenr.

Se side

Figurhenvisning

Produktnavn

Udskriftning kraever ny afbalcering at kuglen

Se spaat reservedelsliste

Levereres ikke som reservedel

1 SEPARATOR SA 836 SEPARATION SYSTEM SPARE PARTS CATALOGUE

1 Separator

1.1 Machine bottom part

R e f

1 1A 2 3 4 5 6 7. . 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 22 A 23 24 25 26 27 28 29 30 31 32 33, . 34 , . , 35 36 S?" , ,.37X,,,-37 AA " 37 AB 37B ' -37'C:w • 37 D 38 '39 ---40, •' ' 4 1 ' 42 43 44 45

Part No

562993 80 2522302 09

560131 02 70490

2210462 32 552766 07

. '52635004 -565378 01 223404 05 571743 80 562992 01

2234121 38 562091 01 562092 02

' 221706 01 2234121 40

562094 01 562095 02

• 22S4.12 23 . 2217:16 23

572703 80 221721 24 57i406 80 22;i7t1'18 223412 46 566788 21 56^773 02

^223406, 28 '560202 01 223404 20 539418 02 528352 06 564493 02 566788 05 223412 46 - 4V45e - •' 221040 46 221040 08 566718 81

- 562902 80 562903*02 552042 01 55287Ö 41

-.- 556416 i \ 566692 80 223404 22

•-221716-23 -17812 • 561773'03 74067

221716 23 563007 02 221716 02

Description

Frame bottom part Square plug

Frame support Washer Screw Washer pitjg ; Plug O-ring Oil pin Bottom bearing holder O-ring Strainer Wing Insert Screw O-ring Labyrinth ring holder Labyrinth ring O-ring;. Screw Driving device vertical Screw Neck bearing cover Sorevy -

O-ring Seal ring Deflector ring O-ring , Pipe O-rIng Elbow ~ - . ' Bushing -, - -Operating water cover Seal ring O-ring • ,• Waslief Screw Screw Monltorir^Mt. Seasor wrtth support

Sensor support Inductive sensor

Tube gtand, angle 90° iProteotwe tube - • . -

Junction box O-ring Bcrevy • '_ ' / - ' ' ' : Screw " Plug' O-ring Screw Front casing Screw

Machine unit number or Subassembly description

572704 -01

Quantity 1 2

• 4

4 4 2

2 ^ 2

-' i

t

-

'

' • .

\

•

•

':

-

\

Notes

• •

Seepage 10

' 1 - -

'"

'"' • -\

• ' . u' '%-' -

-r'"

1811025-02

SA 836 SEPARATION SYSTEM SPARE PARTS CATALOGUE 1 SEPARATOR

1811025-02


1.2 Driving device vertical

Ref

1 2 3 4 5 6 ^ -"1 a -g

10 11 12 13 14 15 16 17

Part No

560134 01 548747 08 .562277' 80 22364ia 36 560191 02 562109 03

"; 5621.10-02 , 560406 .01 564129 01 548744 03 563677:02 223404 20 562995 01 571453 02 223406 30 562997 01 221040 41

Description

Bowl spindle Ball bearing Tt^^ bearing seat Snap ring Top bearing housing Helical spring cbrnposjte spring ' P l t ^ , ' . • : % - •

Spindle pulley Self-align roller bearing Lubrication oB orifice O-ring Oil pump Fan O-ring Air deflector Screw


572703 •80

Quantity

3 4

4

3

, "

Notes

10 1811025-02


1811025-02 11


1.3 Separator bowl Slotted disk stack, caulks 0,5 mm

Ref

1 1 A I B 2 . " " 3 4 5 6 7 8 9"

10 11 12 13 14 15 16 16.1 17 19 20 21 22 23 24 25 26

Part No

560634 80 560637 01

- . r 64416-;. 1'560638' O'l '560é39 01 545869 03

.T5Ö0638501' *564478^)1 565217 01 221036 01 22Sto6 39 572223.01 260104 05 574226 01 565295 01 560649 01 563081 80 563089 80 563089 80 563067' 02 564401 01 564403 01 260247 02 560661 80

'" 561298 01 566788 15 ,223403 61 563089 01

Description

Bowl body Guide lug

,Qy|ndriQalpin, , Reotangufar ring Operating slide Nozzle 0 1,5 mm Rectanglifar ring Valve plug' Holder Screw 0-Jfihg Operatir)g water rjng 0-ring Discharge slide Rectangular ring Nut Distributor Bowl disc complete Bowl disc complete Top disc Bowl hood Seal ring O-riiig Lock ring Cap nut Seal ring O-ring Bowl disc

IVIachine unit number or Subassembly description

560626 -03

Quantity

12

82

"

, •

'

' --.'

-

Notes

"

" ~

' ' '"'

12 1811025-02


•

1811025-02 13


1.4 Inlet and outlet device

Ref

1 3 4 4A 4B 4C 7 8 9

10 10 A 10B IOC 10D 11 12 13 14 15 16 17' 18 19 20 24 25 26-.' 27

Part No

563367 80 223403 55 566642 80 566642 02 566408 02 561386 01 563316 01 562583 01 561957 01 562751 80 '562587~'0t 56'1^Ö Ot 221711 13 221716 09 221036 01

• 561966* 01 221716 13 562582 80 56é407 02

,223406 27 74067

562584 80 ' . 561965 01

562343'02 561389 82 521127 05

, '41456 ' 221040 05

Description

Inlet and outlet pipe complete 0-ring Paring tube _ -Paring tube Plain bearing bushing Tolerance ring

Splash sealing Support ring Heigiit adjusting ring Frame liood Spring holder. Support sleeve Screw Screw

Screw Washer Screw Arm complete Spring O-ring 0-ring Connecting housing Wash'er Looking nut Purifier screw 0-rlng Washer Screw

l\/lachine unit number or Subassembly description

563041 -01

Quantity 1 2

3

. 2 " 2

. 6 6 .'

Notes

14 1811025-02


1811025-02 15


1.5 Belt driving device

Ref

,1 -'2 -' 3 3

; 4v "i . 5

6 7 8 9

10 11 12 13 13

Part No

, -560208.02 581114 01 564095 80 564095 81

: . '221045. 60. -;• 223107 35

547837 01 221040 42 41456 .

.221721" 37 41456

221040 58 35120

563464 01 563467 01

Description

50 Hz 60 Hz CMch cover , Cover support Centrifugal clutch Centrifugal clutch Screw Spring washer .. Washer Screw VVasher Screw Washer Screw Nut Flat belt Flat belt


561118 .01 .02

Quantity

i

1 1

1 ,1 1 1 3 3 4 8 4 4 1

4. . 1 - 1

1

1 1 1 3 3 4 8 4 4

1

'

. " 1 -"- .

Notes

--'----,' '' ,

See page 18 See page 18

'-^ I,~ ' '.' , ' ' • } - • - -"- '

16 1811025-02


1811025-02 17


1.6 Centrifugal clutch

Ref

1 1 2 J

A 5 5 6 8 9

10

Part No

560426 02 560426 04 548051 49

Description

50 Hz 60 Hz Motor belt pulley Motor belt pulley Ball bearing

547833 01 Spacing ring 66251

564089 80 564100 80 223641 18 564075-80' 549325 Ot 223641 20

Snap ring Coupling hub Coupling hub Snap ring Friction block Cover Snap ring


564095 -81 -80

Quantity

i

' l 2

5

i ' 1

2 1 1 '1

1 3 1 1

-

,

Notes

''',•"

'

18 1811025-02


1811025-02 19


1.7 Set of plates

R e f

3 3A 3B 3C 3D 3E 3'F,-'" ' 3G --3H 31 3J •' 3K . 3L 3M 3N 3 0 3P 3Q 3R 3S 6 6 7 8 9

Part No

1270019 1270018 01

'. ,1270018 .02. 1270018 03, 1270018 04 1270018 05 127GÖ18 06

•;:;.i27ooi8.07^ 1270018 08 1270018 09

. •-1270018.10 1270018 t1 1270018 12 1270018 13 1270018 14 1270018 15 1270018 16 1270018 17

,1270018 18 •,. 1270018 19

553171 01 553272 01

, 555529 01 ' 1270001*

554214 02

Description

Set of safety labels Safety label sv

.SafetyJab.efen -Safety label de Safety label fr Safety label es Safety &)éni,.

-Safét/lébéltt:- -" Safety label pt Safety label pi Säfei^Jäbeker Safety label f i , " Safety label zfi Safety label da Safety label ar Safety label nl Safety label cs Safety label ja Safety labet ko Safety label no

Label 50 Hz Label 60 Hz Plate with arrow Lifting instruction Cable tie

Machine unit number or 1 Subassembly description

549572 -84

Quantity

.-

~ * -

Notes

--

20 1811025-02


3,3A-S

•HMK

A DANGER 4 ^

50 Hz

60 Hz

tT'vxÛ

ecKMadb rrc B ( x r ^ e i I»

[[j3HBBB

1811025-02 21


1.8 Monitoring icit

Ref

1 2 4 6

Part No

570142 01 561773 04 552870 21 556416 17

Description

Inductive analogue sensor Sensor holder Tube gland, straight Protective tube


566727 -02

1 1 1 1

Quantity

-

Notes

22 1811025-02


1811025-02 23


1.9 Cover interlocking kit

Ref

1 2 3

Part No

552870 21 566054 01

• 556416 24

Description

Tube gland, straight Limit switch Pro^ctiyetube


570819 -02

1 1 1

Quantity Notes

24 1811025-02


1811025-02 25


1.10 Set of tools

Ref

1 1A

.2-, 3 3A SB

,;3C" ,3D/ 3E 4 5 5A 6 6A 6B 7 8 9 9A

10 11 12 13 13A 13B 14 15 16 17 18 19

Part No

561593 80 561829 01

"• .561360, eg-i ' . 575055 Br

575055 80 575083 02

'f57B0&a'M: " 22t<Ä5;52,

561551 02 561584 80

. •57273ÖC80, .260121'66 561607 éo 561610 01 221040 '43 260154 01 221706 05 548457 80 223406 13 567008 80 561439 01 564679 01

, 563084 80 221040 05 221035 46 548043 01 527395: I t 66414' _

566441 6l 566614 01 567009 01

Description

Puller Screw

Spanner for nut . -- . . . -Cotnpresslng tool Compressing tool Clamp

;• Screw - Screw

Screw Puller Pin spanner '. Cylindrical pin Puller Support ring Screw

UftSng eye bolt Screw Tool for belt pulley 0-ring

Lifting tool Drift Key Puller Screw Screw

Mounting tool Hook spanner Hexagon socket tiead key Sleeve Chisel Pin


561614 -14

Quantity 1 1

-1 . ' 1

1 3

. 3 .3 3

- 2

2

, " * ••

'•

Notes

Spindle pulley/ Neck bearing

Nuy Discharge slide Disc stack

"'-'.-• ".-" " ' . ; ' " ' •

Bowl tiody Fan ;"-_ -

" _ ' - - " ' - • .

Discharge slide

'^ Lock ring/ Bowl body Motor/ Coupling

Distributor/ Bowl spindle Bottom bearing Bottom bearing housing Neck bearing cover

Coupling bearing Nut/ Inlet and outlet pipe Look ring/ Bowl body Neck bearing Seal ring Distributor

26 1811025-02


10 11 12

13 14 15

16 17 18

19

u 20 21

1811025-02 27


1.11 Lifting tool Lifting of separator

Ref

6

Part No

260236 03

Description

Shackle


563453 -80

Quantity

2| 1 1 1 1 1 1

Notes

28 1811025-02


1811025-02 29


1.12 Inspection kit

Ref

1 2 3 4 5 6 8 9

10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Part No

560638 01 560638 01

. , ) 564478 01 '•223406 39 • 260104 05

565295 01 -r564403 01 ' 260247 02

223403 55 223406 27 •74067/ -52it27*05 552766 07 537086 06 539474 03 223404 05 221706 05 66414

566408 02 •566788 15

" 223403 61 563316 01

.561386 01 260104 22 223404 51

Description

Rectangular ring Rectangular ring Valvß.plug Ö-ring O-ring Rectangular ring Seal ring 0-rinig O-ring O-ring 0-rlng p-ring Washer Lubricating paste Silicone grease O-ring Screw Hexagon socket head key Plain bearing bushing Seal ring O-ring Splash sealing Tolerance ring O-ring O-ring


563859 -01

Quantity 1 1 3 1 1 1 1 1 2 2 2

- 1 2 1 1 1 6 1 2 1 1 1 1 4 2

•-

1

-

Notes

Bowl body/ Operating slide Operating slide/ Holder Operating^lide/, Bowl body . Bowl body/Operating water ring Bowl body/ Discharge slide Discharge slide/ Bowl body Bowl hood/ Discharge sfide BbWl hood/Bcwi twdy Paring tube/ Inlet and outlet pipe Inlet and outlet pipe/ Connecting housing tnlet and outlet pipe/ Connecting housing Frame hood/ Frame bottom part Frame bottom part/ Plug

Oil pin/ Plug Lock ring Lock ring Paring tube Operating water cover Bowl body/ Holder Inlet pipe Paring tube/ Arm Oil pipe/ Connecting housing Water pipe/ Connecting housing

30 1811025-02


LO

LO 1 - O CM CM -,-

1811025-02 31


1.13 Overhaul kit

Ref

1 2 3 4

, 5 - •

6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23' 24 25 26 27 28 29 30 31 31

Part No

563859. 01 2234121 Vs 2234121 40

562095 02 • -223412'23

; 203412 '46, 566788' 21 223406 28 223404 20 223412 46 566788 05 544465 10 223404 22 74067

548747 08 223642 36 562109 03 562110 02 548744 03 223404 20 223406 30 545869 03 221036 01 566407 02 548051 49 66251

223641 18 564075 80 223641 20 223107 35 563464 01 563467 01

Description

50 Hz 60 Hz Inspection l<it O-ring O-ring Labyrinth ring O-ring O-ring Seal ring O-rIng O-ring O-ring Seal ring Locking liquid O-ring 0-rlng Ball bearing Snap ring Helical spring Compositaspring Self-align roller bearing O-ring O-rtng Nozzle 0 1,5 mm Screw Spring BatI bearing Snap ring Snap ring Friction block Snap ring Spring washer Flat belt Flat belt


563869 -03 -04

Quantity i

12

2

5

i

12

2

3

1

Notes

Seepage 30 , Strainer/ Bottom bearing housing Bottom bearing housing/ Frame bottom part Labyrinth ring holder/ Spindle pulley Labyrinth ring HoWer/ Frame bottom "part Neck bearing cover/ Frame bottom part Neck bearing cover/ Fan Deflector ring/ Bowl spindle Pipe/Operating water cover Operating water cover/ Frame bottom part Bowl spindle/ Operating water cover Bottom bearing holder Frame bottom part/ Sensor support Plug/ Frame bottom part Bowl spindle/ Top bearing seat Top bearing seaV Ball bearing Top bearing seat/ Top bearing housing Top bearing seat/ Plug Bowl spindle/ Bottom bottom housing Lubrication oil orifice/ Oil pump Bowl spindle/ Fan Operating slide Bowl body/ Operating water ring Arm Coupling hub/ Motor belt pulley Motor belt pulley/ Ball bearing Coupling hub/ Ball bearing Coupling hub/ Motor belt pulley coupling hub/ Cover Motor shaft/ Screw Motor belt pulley/ Spindle puley Motor belt pulley/ Spindle puley

32 1811025-02


•^COCVI CM CviCMOJ CM

CO 05 C3>

•«tm

CD IS.

i-sjl|j:t3

CO 00 (O

1811025-02 33


1.14 Support kit Spare part not included in service kit

Ref

1 2 3 . 4 5 6 7 _ 8 8A 8B 9

10 13 15 16 19 20 21 22 23 24 25 26 27 28 29 30 , 31 32 33 34 35 36

Part No

526350 04 221716 23

, .221721-24 ' 221711.18

564773 02 41456

'•• 221040 ,46 '-562902'80

5é2903 02 552042 01 221716-23 221716 23 221040 41 560661 80 561298 01 562586 02 221701 15 561957 01 562587 01

. 221036 01 562582 80 561962 01 562343 02 41456

221040 05 547833 01 - iftse -

221040 58 35120

565378 01 57^743 80 563677 02 561369 02

Description

Plug Screw Screw Screw Deflector ring Washer Screw -Sensor with support

Sensor support Inductive sensor

Screw Screw Screw Lock ring Cap nut Axiat support Screw Height adjusting ring Spring holder Screw Arm complete Washer Locking nut Washer Screw Spacing ring Washer Screw Nut Plug Oil pin Lubrication oil orifice Spanner fornut


563877 -01

Quantity 1 2 3 1 1 3 3 1 1 1 1 1 3 1 1 1 2 3 1 4 1 1 1 6 6 1 8 4 4 1 1 1 1

. '-'

"

Notes

Frame bottom part Labyrinth ring holder Top bearjng,housing/ Frame bottom Neck bearing cover Bowl spindle Screw/ Operating water cover Cêrattrtg water cover Frame tjottom part

Frame bottom part/ Sensor support Frame bottom part/ Plug Top bearing housing/ Air deflector Bowl body/ Bowl hood Bowl spindle/ Bowl body In-and outlet device/ Pipe In-and outlet device/ Axial support Frame hood/ Support ring Frame hood Frame hood/ Height adjusting ring Frame hood/ Paring tube Inlet pipe/ Connecting housing inlet pipe/ Connecting housing Frame hood/ Frame bottom part Frame hood/ Frame bottom part Ball bearing/ Ball bearing Motor/ Frame bottom part Motor/ Frame bottom part Motor/ Frame bottom part Frame bottom part Frame bottom part/ Plug Oil pump Nut/ Discharge slide

34 1811025-02


00 r^ CVICM

com CM CM

1811025-02 35


1.15 Hydraulic tool kit

Ref

1 2

Part No

574618 80 574626 82

Description

Hydraulic components Hydraulic tool


574986 -04

1 1

Quantity Notes

See page 38 See page 40

36 1811025-02


CM

9 ccjo:

1811025-02 37


1.16 Hydraulic components

Ref

1 2

Part No

574618 01 574618 02

Description

Pump with hose Hydraulic cylinder


574618 .80

1 1

Quantity

i Notes

38 1811025-02


3 4

cn>

1811025-02 39


1.17 Hydraulic tool

Ref

1 2 3 4 5 6 7

Part No

571628 01 574627 03 571627 01

''221803 35 574954 01 571620 01

• 571622 01

Description

stud bolt Sleeve Holder Nut " Sleeve Plate Screw • , ' •

Maciiine unit number or Subassembly description

574626 -82

Quantity

3

Notes

40 1811025-02


#

toi

erfi 1 ^

1811025-02 41

2 ANCILLARY EQUIPMENT SA 836 SEPARATION SYSTEM SPARE PARTS CATALOGUE

2 Ancillary Equipment •

2.1 Valve block water

Ref

1 2 3

• 4 ,-

5 6 6A 6B 7 8 9

Part No

176592701 176603707

^176603702 176603703 56971201

176707180 176616201' 176183409 176615701 176593601 176593701

Description

Valve block, water Flow valve, 1.6 l/min ülow vah/el 11.0 ftin Flow vatve, 2.8 tfinip Rectangular connector Non return valve kit Non return valve Washer

Quick coupling Flexible connection Flexible connection

Machine unit nunnber or Subassembly description

567940 -02

Quantity

3

, '- - ;

Notes

SV10 SV15 SV16

42 1811025-02

SA 836 SEPARATION SYSTEM SPARE PARTS CATALOGUE 2 ANCILLARY EQUIPMENT

1811025-02 43


2.2 Spare parts kit, valve block water

Ref

1 2

. 3 4 5 6 7 8 9

10 11 12 13 14 15

Part No

176599301 176599302 176599303 1765^9304 176599305 176599306 176599307 176599308-176599309 176599310 176599311 -176600407_ 176600408 176599313 176599316

Description

Retaining clip Spring Core Spring washer O-ring Piston Valve Non-return vatve 0-nng 0-nng Coll Washer adhesive tape Indicator Drain valve Strainer


1765993 -83

Quantity

- -

Notes

44 1811025-02


1811025-02 45


2.3 Valve block air

Ref

1 2

4 .,

Part No

176592801 176391102 1763ä1-(04 -56971203

Description

Valve block Flexible connection Flexible connéctfon " Rectangular connector


568048 •01

1 1 2 3

Quantity Notes

46 1811025-02


•

1811025-02 47


2.4 Spare parts kit, valve block air •

Ref

1 2 3 ' 4 ,. 5 6 7 •;

8 9

Part No

176600401 176600402 176600403' 176600404 176600405 176600406 176600407 176600408 176600409

Description

Retaining clip Spring O-n'ng 0-ring Screw Coil Washer adhesive tape Indicator Manometer


1766004 -82

Quantity

'

.i

•

Notes

48 1811025-02


1811025-02 49


2.5 Valve block oil

Ref

1 2 3 4 6 7 8 9

10 11 12 13-14 15 16 ^ 17 17A 17B 19 22 23 24 25 ' 26 28 29 30 31 32 33 34 35 36 37 38 39 40 41

Part No

176587701 176476086 176644401 -'56971201 176610201 176473301 176462101 176401101 • 176349201 176378003 176508209 -" 176390303 17é589701 176591101 54305405

176443980 176439101 176181480

" • ' - - •

176590801 5350047202

176593401 -22104546 '•

. 223J0149 22180333 22104529

1761834Ö3 22104528 ~ 22104551

176183406 56971201 ;

176589701 176390303 176183406 176508209 176183403•

5355171602 5355171602

1

Description

Valve block Water transducer Valve Rectangular connector Non-return valve Pneumatic 3-way valv Shul-off valve ' Silencer Elbow Nipple Nfppje Needle valve Pressure transmitter Elbow Pressure gauge temperature sensor

Temperature sensor Spring pocl<et

Connection kit, oil Gasket Cable 19 Flexible connection Screw Wastier Nut Screw Cu-washer Screw . Screw Washer Rectangular connector Pressure transmitter Needle valve Washer Nipple Cu-washer Washer Washer


567802 -06

Quantity 1 1 1 2 2 1 1 1 1 2 2 2 2 2 2 1 1 1 1 8 1 1 8

40 16 4 1 4 4 2

4 2

_ -

• ;

'-'-•

' f

-

,'' ,- ._

'-

.

Notes

See page 52

See page 54 -" -,"

2xPt-100

See page 56

• / " _

.

50 1811025-02


*) To be seolod with locking liquid.

1811025-02 51


2.6 Water transducer

Ref

1 2

'.3

4 5

ß 7 8 9

10- ._ 11 12 14 15 16 18 19 23 24 25 27

Part No

176475884 176476901

:;'176476é80 376476701 176521682 22340470

f'-'"26ÖV04,i9

•176513Ö01 176476103 176476601 ' 26750.-:.• 22104008 22310706 22103010 22310725

176476202 3183045474

? 22112106 490167322

22170113 490122209 492036801

Description

Valve body Distance rod-Electrode - •"' '. " . tnsulatot ' -Spare parts kit including: 0-ring 0-ring : . .

Gasltet Cover Bushing Spring washer Screw Spring washer Screw Spring washer Junction box Circuit board Screw Spacing sleeve Screw Connector Product tabel


1764760 •86

Quantity 1 2

2 4 4 4 4

Notes

-

- -„

/

52 1811025-02


Z u E

A-A

25X26) B- B ^

1811025-02 53


2.7 Spare parts kit, pneumatic 3-way valve

Ref

1 1A IB -, 1C

Part No

176473482 176473404 -176473405 176473406

Description

Spare parts kit including: Diaphragm Stuffing box kit Stem/disc kit


1 1 1 1

Quantity Notes

54 1811025-02


1811025-02 55


2.8 Connection kit, oil

Ref

1 2 3 " 4 5 6 7: ' -

' '8, . 9

10 11 12 13 14

Part No

176598801 176598901

' . " I7669yi0r - • 1765,97201 ^

2601Ö422 ' 22340451

'*'22364"ir4-223641Ö3 22104008 22172618 22310149

-176^97102 176635602 176635601

Description

Connecting plate Connecting plate, valve b Flexltjfe'ôonnecäion Flexible connection 0-ring 0-ring jSnap'Tlrig _ Retaining rtng - ~. Screw Screw Wastier Flexible connection Support Support

1 1 1 1 6 3

' 4 2 2 1 1 1 4 2


Quantity

• ' -

'

; '^ S,

Notes

• - " ' "

: " t .

' , " . ; ' : - : •

56 1811025-02


1811025-02 57


2.9 Sludge outlet kit

Ref

1 1 1A 2 3 4

Part No

176598080 176598081 176609601 66133901 41456

22104008

Description

Sludge outlet DIN Sludge outlet JIS Ptug

Gasket Washer Screw

1 1 1 1 4 4


Quantity

''

Notes

"*

58 1811025-02


1811025-02 59


2.10 Butterfly valve

Ref

1 2

Part No

176600701 56830403

176616101 176616105

Description

Butterfly valve Sludge valve interlock Seat' Limit switch


1 1

- 1 1

Quantity

-

Notes

Mounted in Control Unit

60 1811025-02


1811025-02 61


2.11 Spare parts, EPC 50 Control Unit

Ref

5 6 7 "

Part No

3183045511 3183045492 31rø04584t

Description

EPC 50 Vibration Board EPC 50 Heater Board EPC W1/0 B^mnston Board


1 1

•'1

Quantity Notes

.

Ref

1 2 3 4 9

10 11 • 12 15 16 17 18 21

Part No

3183062451 3183045486 3183063461 3183062411 5350046201 5350020103 5350020110 5350020111 5350048901 5350048902 5350048903 5350045102

3183063731

Description

EPC 50 OP front module EPC 50 I/O board Cable EPC 50 transformer Pusti button Switcfi Sealing Led bulb, white, 24 V AC Switch body Switch actuator Legend plate . Pilot lamp Fuse kit

tVlachine unit number or Subassembly description

568452 -01

Quantity

'•1

" -

Notes

62 1811025-02


1811025-02 63


2.12EPC 50 Control unit

Ref

.,.

Part No

56830401 3183064091

Description

Control Unit ERC ERC 50 REMIND 8-pole corweotor'


568303 -01 -02

1 1

'1

1|

- • i ;

Quantity Notes

Mounted on separator

2.13 Starters

Ref Part No Description


Notes

568022 568022 ,568022 • 568022 568022 568022 "568022 568022 568022 568022 '568022 568022 568022 568022 568022

•:568022. ' 568Ö22 568022 568022 568022 568022 568022 56^022. 568022 568022

Basic Icil for starter Sep. starter, 2.5-4A Sep. starter, 4-6.3A Sep. starter, 6.3-10A •Sep. starter, 10-16A Sep. starter, 16-20A Sep..starter, 20-25A Sep, starter, 25-32A Sep. starter, 32-45A Sep. starter, 45-63A Sep. start., 690v,6.3-10v Sep. start.; 690v,10-16A Sep. start., 690v,16-20A Sep. start., 690v,20-25A Sep. start,, 690v,25-32A Sep. start.-, 690v,32-45A Pump starter, 0,4-0,63A Pump starter, 0.63-1 A Pijmp starter, 1-1.6A Punip starter, 1;6-2.5A Pump starter, 2.5-4A Pump starter, 4-6.3A Pump starter, 6.3-1 OA Pump starter, 10-16A Pump starter, 690V, 6.3-1 OA

Quantity See page 65 See page 65 See page 65 See page 65 See page 65 See page 65 See page 65 See page 65 See page 66 See page 66 See page 66 See page 66 See page 66 See page 66 See page 66 See page: 66 See page 66 See page 66 See page'66' See page 66 See page 66 See page 66 See page 66-See page 66 See page 66

64 1811025-02


2.14 Separator starter kits, basic and 4A - 32A

Reff

2 3 4 6 8"

F8 K2 K2 K2 K2

K2.1 K2.2 P2 P2 P2 P2 P2 Q1 Q2 Q2 Q2 Q2 Q2 Q2 , Q8 T8

TA2 .' • TA2.1,:. X1 XF8

Part No

568026 02 1764728 01

'1761990 02 53500'447 01 53500453 01 53500167 02 53500460 02 53500460 04

Description

Wall mounting kit Label Prödüct-fäbel' ' Diagram pocket' Ground connection Fuse Contactor " Corilactor

53500460 05 Contactor 53500460 08 53500461 01 53S()p461 02 53500006 01 53500006 02 53500006 03 53500006 04 53500Ö06 06

1764712 05 53500098 28 53500098 29 53500098 30 53500098 31 53500098 32 5350Ö098 33 53500098 Sé

568027 01 53500503 01 53500503 03 53500402 11 53500402 18

Contactor Aux.- contact bk>ck Äüx.; contact blook • Ammeter Ammeter Ammeter Ammeter Ammeter, 50/5A Switch Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaKjer Circuit breaker , Circuit breaker Transformer Cun-erttttarisformér Mounting kit Terminal Fuse terminal


568022 -01 -10-11 -12 -13 -14 -15 -16

Quantity

- ' 1

1

1 1

1 1

1

1

1

i

1

1

,

1

1 1

1

., 1

1

1 1

, 1

1

1

1 1 1

1

1

1 1 1

1

-1

,1 1

1

1

-

1

'•-• - 1

t

1

1 .1

Notes

' - " • ' - :

for door

' " " '

/"" -

torTA2

1811025-02 65


2.1 S Separator starter kits, 32A - 63A

Ref

K2 K2 K2 K2

K2.1 K2.2 P2 P2 P2 P2 P2 02 Q2 Q2 Q2 Q2 TA2 TA2 TA2.1

Part No

53500460 04 53500460 05 535CIÖ46"0"08-53500460.09 53500461 01 53500461 02 53500b06, 01 53500{X)6 03 53500006 04 53500006 06 53500006 07-53500098 30 53500098 31 53500098 32 53500098 33 5350009S 37 53500503 01 53500503 02 53600503 03

Description

Contactor Contactor Contactor Contactor Aux. contact block Aux. contact block Ammeter Ammeter Ammeter Ammeter, 50/5A Ammeter, 75/5A Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Current transformer Current transformer IVtoimting kit

t /lachine unit number o Subassembly description

568022 -17 -18-32-33 -34-35

Quantity

1

1 1

1

1

1

1 1 1

1

1

1 1

1

1 1

1

1

1

1 1 1

1

1 1 1

1

1

1 1

1

1

,.

-36-37

1

1 1

1

1

1

1 1 1

1

1

1

Notes

- - •

forTA2

2.16 Pump starter kits, 0.4A - 16.0A

Ref

K2 K2

K2.i K2.2. Q3 Q3 Q3. Q3 Q3 Q3 Q3 03 ;

Part No

53500460 02 53500460 04 53500461 01

-535Q0461;02 53500098 24 53500098 25

•63500098 26 53500098 27 53500098 28 53500098 29 53500098 30 53500098 31

Description

Contactor Contactor Aux, contact btock Attx< üontact btock Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker ' "

l\4achine unit number or Subassembly description

568022 -20 -21 -22 -23 -24 -25 -26 -27 -30

Quantity 1

1 1 1

1

1 1

1

1

1 , 1

1

1

1 1

1

1

1 1

1

1

• 1

1

1

1

1 1

1

1 1 1

1

1 1 1

1

Notes

'.

•':.••- . .- .

66 1811025-02


2.17ESD-relay kit

Ref

K112 Kl 12.1

Part No

5350002809 5350002808

Description

Relay Relay socket


568022 -53

1 1

Quantity

Notes

2.18 Motor trip contact kit

Ref

02.1 Q3.1

Part No

5350009838 5350009838

Description

Trip contact block Trip contact block

Machine unit number or

Subassembly description

568022 -51

1 1

Quantity

Notes

1811025-02 67


-0-

IS

0

m

A

1 1 1 1 1 ! 1 1

P2

• « -

Sh

IS

J Q2 Q3 08

K20 Kn2 YT

nmm uuu F8

[TÄ2

K3

X2

XI

68 1811025-02


1811025-02 69

3 INDEX SA 836 SEPARATION SYSTEM SPARE PARTS CATALOGUE

3 Index 1270001

1270018 01

1270018 02

1270018 03

1270018 04

12/0C18 05

12/C018 06

127X18 07

1?7C018 08

1^7C018 0D

1270018 10

1270018 11

1270018 12

1270018 13

1270018 14

1270018 15

1270018 16

1270018 17

1270018 18

1270018 19

1270019

1761814 80

1761834 03

1761834 03

1761834 06

1751834 06

1761834 09

1751990 0?

175349:? 01

1/63780 03

1763903 03

1763903 03

1763911 02

1763911 04

1764011 01

17G4391 CI

1764439 80

17646^1 Ü1

•;764712 05

1764728 01

1764733 01

1764734 04

1764734 05

1764734 06

1764734 82

1754758 84

1764760 86

17647G1 03

1764762 02

1764766 01

1 1764767 01

20

20

20

20

20

20

20

20

20

20

20

20

20

20

20

20

20

20

20

20

20

50

50

50

50

50

42

65

50

50

50

50

46

46

50

50

50

öO

65

65

50

54

54

54

54

52

50

52

52

52

52

70

1764768 80

1764769 01

1765082 09

1765082 09

1765130 01

1765216 82

1765877.01

1765897''01

1765897 01 "

1765908 01

1765911 01

1765927 01

1765928 01

1765934 01

1765936 01

1765937 01

1765972 01

1765980 80

1765980 81

1765988 01

1765989 01

1765993 01

1765993 02

1765993 03

1765993 04

1765993 05

1765993 06

1765993 07

1765993 08

1765993 09

1765993 10

1765993 11

1765993 13

1765993 16

1766004 01

1766004 02

1766004 03

1766004 04

1766004 05

1766004 06

1766004 07

1766004 07

1766004 08

1766004 08

1766004 09

1766007 01

1766037 02

1766037 03

1766037 07

1766096 01

1766102 01

52

52

50

50

52

52

50

50

50

50

50

42

46

50

42

42

56

58

58

56

56

44

44

44

44

44

44

44

44

44

44

44

44

44

48

48

48

48

48

48

44

48

44

48

48

60

42

42

42

56

5C

1811025-C D2

1766157 01

1766161 01

1766161 05

1766162 01

1766356 01

.1766356 02

-1766444 01

1766971 01

1766971 02

1767071 80

1767199 80

17812

221030 10

221035 46

221036.01

221036 01

221036 01

221036 01

221040 05

221040 05

221040 05

221040 08

221040 08

221040 08

221040 08

221040 41

221040 41

221040 42

221040 43

221040 46

221040 46

221040 58

221040 58

221045 28

221045 29

'221045 46

221045 51

. 221045 52

221045 60

2210462 32

221121 06

221701 13

221701 15

221706 01 .

221706 05

221706 05

- 221711 13

221711 18

221711 18

221716 02

221716 09

42

60

60

42

56

56

50

56

56

42

64

8

52

26

12

14

32

34

14

26

34

8

52

56

58

10

34

16

26

8

34

16

34

50

50

50

50

26

16

8

52

52

34

8

26

•30

14

8

34

8

14

SA 836 SEPARATION SYSTEM SPARE PARTS CATALOGUE 3 INDEX

221716 13

221716 23

221716 23

221716 23

221716 23

221716 23

221716 23

221721 24

221721 24

221721 37

221726 18

221803 33

221n03 35

223101 49

223101 49

22'i\i>7 06

??31Ü7 25

223107 35

223107 35

223403 55

223403 55

223403 61

223403 61

223404 05

223404 05

223404 20

223404 20

223404 20

223404 20

223404 22

223404 22

223404 51

223404 51

223404 70

223406 13

223406 27

223406 27

223406 i:&

223406 28

223406 30

223406 30

223406 39

223406 39

223412 23

223412 23

223412 46

223412 46

2?3412 46

223412 46

2234121 38

2234121 38

2234121 40

1 2234121 40

1 223641 O'ö

14

8

8

8

34

34

34

8

34

16

56

50

40

50

56

52

52

16

32

14

30

12

30

8

30

8

10

32

32

8

32

30

56

52|

26'

14

30

8

32

10

32

12

30

8

32

8

S

32

32

8

32

8

32

56

223641 14

223641 18

223641 18

223641 20

223641 20

223642 36

223642 36

2522302 09

260104 05

260104 05

260104 19

260104 22

260104 22

260121 56

260154 01

260236 03

260247 02

260247 02

26750

35120

35120

41456

41456

41456

41456

41456

41456

4145C

41456

490122209

490167322

492636801

521127 05

521127 05

526350 04

526350 04

526352 06

; y-'y^\j ' 1

D3:J00CCG 01

53500G06 01

53;)000CG 02

53500006 03

53J00ÜC6 03

53500006 04

53500006 04

53500006 06

53500006 06

53500006 07

53500028 OB

53500028 09

53500098 24

53500008 25

53500098 26

53500098 27

56

18

32

18

32

10

32

8

12i

30'

52|

3o! 56|

26

26

28

12

30

52

16

34

8

14

16

16

34

34

34

58i

52

52

52

14

30

8

34

8

26

65

66

65

65

66

65

66

65

66

6€

67

67

66

6f

6(

6«

1811025-(

.

D2

53500098 28

53500098 28

53500098 29

53500098 29

53500098 30

53500098 30

53500098 30

53^0098 31

53500098 31.

53500098 31

53500098 32

53500098 32

53500098 33

53500098 33

65

66

65

66

65

66

66

65

66

66

65

66

65

66

53500098 36

53500098 37

b3;)00093 38

b.J;)00098 33

53500167 02

53500201 03

53500201 10

53500201 11

53500402 11

53500402 18

53500447 01

53500451 02

53500453 01 -

535Ö0460 02

53500460 02

53500460 04

53500460 04

53500460 04

53500460 05

53500460 05

535Ö0460 08

53500460 08

53500460 09

53500461 01

53500461 01

53500461 01

53500461 02

53500461 02

53500461 02

53500462 01

53500472 02

53500480 01

53500489 02

53500480 03

53500503 C1

53500503 01

53500503 02

53500503 03

53500503 03

53551716 02

65

66

67

67

65

62

62

62

65

65

65

62

65

65

66

65

66

66

65

66

65

66

66

65

66

66

65

66

66

62

50j

62

62

62

65

66

66

65

66

50

71


53551716 02

537086 06

539418 02

539474 03

543054 05

544465 10

545869 03

545869 03

547833 01

?4~833 C1

547837 CI

548043 01

548051 49

548051 49

548457 80

548744 03

548744 03

548747 08

548747 08

549325 01

552042 01

552042 01

552766 07.'

552766 07 .

552870 21 '

552870 21

552870 41

553171 01

553272 01

554214 02

555529 01

555416 11

556416 17

555416 24

560131 02

560134 01

560191 02

560202 01

560208 02

560406 01

56042C 02

560426 04

560634 80

560637 01

560638 01

560638 01

560638 01

560638 01

560639 01

560649 01

560661 80

56C661 80

=;RIII4 01

561293 01

50

30

8

30

50

32

12

32

18

34

16

26

18

32

26

10

32

10

32

18

8

34

8

^ "30

,22

24

8

20

20

20

20

8

22

24

8

10

10

8

16

10

18

18

12

12

12

12

30

30

12

12

12

34

16

12

561298 01.

581339 01

561369 02

561369 02

561386 01

561386 01

5013Ö3 32

551459 01

561551 02

561584 80

561593 80

561607 80

561610 01

561773 03

561773 04

561829 01

561957 01

561957 01

561960 01

561962 01

561962 01

561966 01

562091 01

562092 02

552094 01

562095 02

562095 02

562109 03

562109 03

562110 02

562110 02

562277 80

562343 02

562343 02

562582 80

562582 80

562583 01

562584 80

562586 02

562587 01

562587 01

562751 80

562902 80

562902 80

562903 02

5G2=>03 02

34

58

26

34

14

30

14

26

28

26

26

26

26

8

22

26

14

34

14

14

34

14

8

8

8

8

32

10

32

10

32

10

14

34

14

34

14

14

• 34

14

34

14

8

34

8

34

562992 01

562093 80

562995 01

562997 01

563007 02

5G3C07 02

563081 80

563084 80

8

8

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74 1811025-02

Date post:	17-Jul-2016
Category:	Documents
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