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1. brown or red G 24 V DC J black or white Q 0V blue Adjustment value for the sensor is 12 mA 1mA For more details see 2 2 Connection List page 15and 752 Unbalance sensor option page 22 c When correct distance is achieved tighten the nut against the holder Fit the cover see previous page 3 5 6 Speed sensor 1 Adjusting the speed sensor a Adjust the soeed sensor according to the illustration b Fit the sensor to the frame see 1 4 Sensors page 8 120 1810828 02 G08734A1 G08734B1 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 3 6 Actions After Assembly 3 6 1 Control of machine plates and Safety labels LD Alfa Laval ref 561498 rev 2 i Check that the following signs are attached 3000 xx 2000 X00 xx 2000 xxx 100000 20000000 000000000000 00000000 31000000X X000 906900020 X00 Xx 200K XXX YOO 0K X00 XX 2000 XXX XOOGOK XO XXXXXXXX XX XXXXXXXX XXX X00 XX YOK XXX XXXXXX OOK XIIA XX XXNX XXX XXXXXX XXX xx 2000000 Xx XXXKDOO XX XXXX X00 000K XH XXIOOK 300K X00 XX IDOD XX XXIOOOK AOO XX OOK XXX X X00 XX X000 XXX 00000 XXX Xx 0 100000000 XXXXXX Xx XXXX XXX 20000 Xxxx xx Xoce xw 00000 x xox Lifting instructions Space for label indicating representative Safety label Space for additional label as specified Alfa Lav
2. 98 1810828 02 G08588B1 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 12 Fitting the neck bearing cover and deflector ring a Apply a thin layer of silicone grease and fit the O Deflector ring rings and the seal ring in the lower groove E gt b Fit the neck bearing cover The guide pin on the cover should enter one of the two holes in the bearing housing c Push the deflector ring down until it stops 1810828 02 99 G0868051 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 13 Fitting the operating water cover a Lubricate with oil and fit the seal ring and O ring E into the operating water cover Renew the O ring E gt b Fit the operating water cover Fit and tighten the screws The water pipe in the frame should enter the hole in the cover 14 Measuring the radial wobble of the bowl spindle a Fit adial indicator in a support and fasten it in position as illustrated Use the flat belt to turn the spindle Permissible radial wobble max 0 04 mm If the spindle wobble exceeds this value contact an Alfa Laval representative Max 0 04 mm 100 1810828 02 G0868141 G0858711 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 15 Fitting the clutch cover SEE
3. lt l in G a b z be l i a teem TA N r a Move the paring tube to the centre To avoid damaging the paring tube turn it towards the centre of the pipe 111 G0862341 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 14 Fitting the bowl hood a Apply a thin layer of silicone grease and fit the O ring gt ED b Fit the seal ring gt Press the ring down evenly until bulges appear c Carefully tap down the bulges crosswise with a soft rubber mallet until the ring is completely fitted d Fit the lifting tool and lower the bowl hood so that its recess fits into the guide pin in the bowl body Recess on bowl hood Guide pin on bowl body e Remove the lifting tool 112 1810828 02 G0862471 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 15 Fitting the lock ring a Place the lock ring on the bowl hood with its guide pin close to the corresponding hole in the bowl body u Make sure that the groove in the bowl body which retains the lock ring is clean b Fit the compressing tool and compress the disc stack by alternately turning the screws a maximum of 40 Nm at a time until the lock ring fits into the bowl body The lock ring is correctly fitted when the lock
4. 43 25 44 25 45 5 0 900 47 25 49 25 0 850 52 55 25 0 800 59 0 750 m h A Density ratio 32 1810828 02 G0938051 SEPARATION UNIT 840 SERVICE MANUAL 2 TECHNICAL REFERENCE A Paring radius A 64 tf a 580 NE ft ct lh T 57 i 1 T 56 IAT tT ET 55 V 54 XT Tt tT 3 i i tf 32 TN ET tT tT ST st AT tT 50 oee PN pf _ Lo 411 AT 40 tN a AT 3 SN 37 KR 3 ft fs 35 ft 34 ft o 3 ft tt 32 ft ft ft 0 1 2 34 567 8 9101112 B B Position of adjusting screw 1810828 02 33 G0938151 2 TECHNICAL REFERENCE SEPARATION UNIT 840 SERVICE MANUAL 34 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 3 Separator Service Dismantling Assembly 3 1 Periodic Maintenance Periodic preventive maintenance reduces the risk of unexpected stoppages and breakdowns Follow the maintenance log in this chapter in order to facilitate the periodic maint
5. gt 1810828 02 91 G0866361 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 Fitting the ball bearing and top bearing seat E to the spindle a Heat the top bearing seat in oil to b Fit the ball bearing maximum 125 Always fit a new bearing Bum hazard Pre lubricate before fitting Use protective gloves when handling any heated parts c Fit the snap ring Risk for eye injury from flying snap ring Use the correct pliers for assembly of snap ring to avoid accidental release d Heat the top bearing seat Puller together with the bearing in oil to maximum 125 Sleeve e Wipe off the spindle and fit the top bearing seat to the spindle Z2 using the sleeve and A puller Make sure to fit the bearing seat correctly or it might get stuck 92 1810828 02 G0984831 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 4 Fitting the top bearing housing a Fit the axial springs B to the top bearing housing Axial springs b Carefully lower the bowl spindle Make sure that the springs enter the recesses on the top bearing seat A wy d Fit the composite springs J and plugs to the top bearing housing a Do not tighten the plugs _ Em Make sure tha
6. g Soa J Take care not to damage the oil aa pump anek A 1810828 02 61 G0907831 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 8 Place the spindle assembly upside down on a support Make a support 3 0 mm free space 9 Removing the air deflector 62 Remove the screws and the air deflector 1810828 02 G0859211 G0859221 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 10 Removing the fan a Turn the spindle assembly the right way up b Place a spanner or similar on the spindle pulley key grip as holder up c Fit the pin spanner and remove the fan nore Key grip Left hand thread 11 Removing the bottom bearing assembly a Turn the spindle assembly up side down and Puller tool remove the oil pump by using spanners gt b Pull off the belt pulley and the self aligning roller bearing using the puller tool Always discard a used bearing bubreatomoiloriiice c Cover the the oil orifice and blow compressed air through the bottom hole of the oil pump and 4 slowly ease out the lubrication oil orifice Compressed air 1810828 02 63 G0923921 G0865981 3 SEPARATOR SERVICE DISMANTLIN
7. 78 3 4 5 Exchange of frame feet 80 3 4 6 Lubrication of bowl parts 81 3 4 7 How to lubricate bowl parts with slide VACUO GE a a e N 82 3 4 8 Check for galling on operating slide and DOW DO Y ss ce diehesnttcacielandndencs 83 3 5 sASSOCMDINY oxen es 84 3 5 1 Centrifugal clutch 84 3 5 2 Driving device 90 25 3 BOW gt lt 550xa50 ewt a0 darane Ke Wi beya eo d k asa 102 354 Frame hod ac Ai 454 55055 42 Sina Wek 115 3 5 5 Unbalance sensor option 119 9 0 0 Speed SENSO ieee 120 3 6 Actions After Assembly 121 3 6 1 Control of machine plates and safety es cy a aa 121 3 7 Oil Change 123 Sufi Lubricating Oil sc 4i524k 54i04 kena nak 123 3 7 2 Check oil level 124 3 7 3 Oil change procedure 124 3 7 4 Lubrication char 125 327 0 UDC elalo acreage Mace E E a 126 9 4 0 KUDNCALING ONS sis ya e nee dek veka 128 3 8 Lifting instructions 129 3 8 1 Lifting the separator 129 3 8 2 Lifting the bowl 131 Change of Circuit Board 132 4 1 Circuit Board Temperatures 134 Cleaning in Plaec e 135 5 1 Cleaning in Place Sep
8. 1810828 02 Always discard used bearings 65 G0858331 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 14 Removing the labyrinth ring holder 66 1810828 02 If the holder sticks fit two screws M8 to the threaded holes and tighten G08586B1 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 15 Removing the bottom bearing holder r TT a Fit the tool into the bottom bearing holder and attach the J socket extension rod and T handle T handle Extension rod Socket Tool b Loosen the bottom bearing holder by turning it counter clockwise Remove it by hand c Remove the strainer 1810828 02 67 GO8586D1 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 3 6 Centrifugal clutch Entrapment hazard G0864711 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 50 Hz 5 Friction blocks 60 Hz 3 Friction blocks The illustration shows 60 Hz i lt gt D 1 Mounting dismantling tool centrifugal clutch 2 Mounting dismantling tool ball bearing 68 G0865021 1810828 02 E gt FD SS Spacing ring SS Snap rings ss p ring
9. e 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 e For further circuit board temperatures push the button e To leave the list push the and the buttons at the same time e Reset Pr 7 0 134 1810828 02 SEPARATION UNIT 840 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 pipdineis opened up 5 1 Cleaning in Place Separator Remove the pipe connecting plate with pipes from the separator Attach the CIP equipment as shown in the illustration 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 1810828 02 135 G065054A 5 CLEANING IN PLACE SEPARATION UNIT 840 SERVICE MANUAL 5 2 Cleaning in Place Heatpac CBM Heater For systems including a Heatpac CBM heater cl
10. Frame hood Inspection g Overhaul Clean Check for corrosion Check for cracks Check for erosion damages Connecting housing 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 Renew O rings Operating slide Renew rectangular ring Renew valve plugs Discharge slide Renew rectangular ring In and outlet pipe Renew O rings Renew O rings and bearings Renew seal ring Renew O ring Frame feet Renew frame feet including washers 80 Has to be ordered and screws separately Drain and oil filling holes Renew washers 101 Oil pin Renew O ring 101 1810828 02 39 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY DIALA me AYL Bottom bearing housing Labyrinth ring holder Top bearing housing Neck bearing cover Deflector ring Water inlet pipe Operating water cover Coupling hub Friction blocks Electrical motor Check g Inspection g Overhaul Page Clean Check for corrosion Check for cracks Renew O ring Renew labyrinth ring Renew O ring Renew springs Renew flat belt Pre lubricate and renew ball bearing Pre lubricate and renew self aligning roller bearing Measure the radial wobble Renew O ring Renew O ring Renew O ring Renew seal ring and O ring Renew t
11. plugs e Unscrew the hexagon nuts Take care to note where the special nuts for optional board s are located e Mount the new board and connect in reverse order 132 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 4 CHANGE OF CIRCUIT BOARD If one or more optional board is installed switch power off 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 1810828 02 133 4 CHANGE OF CIRCUIT BOARD SEPARATION UNIT 840 SERVICE MANUAL 4 1 Circuit Board Temperatures Circuit board temperature information can be read as follows e Set Pr 7 2 e Push and at the same time Standst now shows on the display
12. wo sz aa a we sr j se af sz e lt The figures apply to lubricated screws tightened with a torque wrench 3 1 4 Service kits Special service kits are available for nspection and Overhaul 1810828 02 37 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL For other services a Support kit is available Spare parts not included in the Support kit have to be ordered separately N ote that the parts for Inspection are included in the Overhaul kit The contents of the kits are described in the Spare Parts Catalogue 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 Disintegration hazards 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 CI P 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 Use only Alfa Laval recommended CIP liquids 38 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 3 2 Maintenance Log Name of ship plant Local identification Separator S 840 Manufacture No Year Total running hours Product No 881203 03 01 Date Signature
13. 146 1810828 02 G003171A SEPARATION UNIT 840 SERVICE MANUAL 7 HEATPAC EHM ELECTRIC HEATER OPTIONAL Control unit X11 4 5 X11 7 8 l X11 4 6 X11 8 9 eS X11 5 6 X11 7 9 1810828 02 147 7 HEATPAC EHM ELECTRIC HEATER OPTIONAL SEPARATION UNIT 840 SERVICE MANUAL 148 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 8 HEATPAC POWER UNIT OPTIONAL 8 Heatpac Power Unit Optional 8 1 Technical Data Power circuits Up to 24 kW smaller cabinet 31830 6356 1 Mains supply 3 phase External fuse Overcurrent protection Triac circuit current 400 440 460 480 500 V AC 10 15 50 60 Hz 5 Max 35 A Thermal relays 16 23 A 8 5 12 5A Max 23 A Power circuits 36 kW to 72 kW larger cabinet 31830 6407 1 Mains supply 3 phase External fuse Overcurrent protection Triac circuit current Control circuits Control voltage Power consumption inrush hold General High voltage tested at 2000 V Max ambient temperature Protection class Material Weight Smaller cabinet Larger cabinet External inputs and outputs Inputs Outputs 400 440 460 480 500 V AC 10 15 50 60 Hz 5 Max 100 A Fuses 25 A 16 A 25 A 63 A Max 23 A 24 V AC 10 15 50 60 Hz 5 from external control unit 31830 6356 1 Max 120 VA 30 VA 31830 6407 1 Max 200 VA 55 VA 55 IP 65 Steel 40 kg 54 kg Mains supply Control signals 24 V AC Aux contact on contac
14. 27 30 mm 12 Spanners various sizes 13 Adjustable spanner 14 Shackle 1810828 02 43 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 3 3 Frame hood ee Lock nut ee Washer cd Connecting BAN housing G0863331 G0860531 YL 1 Hook spanner lock nut Frame hood O ring Height adjusting es ios lt gt Support ring 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 1 Removing the connecting housing a Remove the lock nut using the hook spanner Remove connections before SS starting dismantling The nut must not be b Press the pipe down to loosen removed before the Ea the connecting housing separator has stopped 0 Remove the washer 44 1810828 02 G0863441 G0863531 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 2 Removing the spring and arm a Remove the spring from the pin on the hood b Remove the arm together with the c Turn the paring tube so that the frame hood can be removed upwards To avoid the paring tube from being damaged and preventing the inlet pipe
15. Ball bearings Belt pulley Coupling hub Parallel pin Friction blocks 3 60 Hz Cover lt gt ne ring G0865141 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 1i Removing the clutch cover a 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 SEE c Remove the flat belt from the motor pulley 1810828 02 Separator frame 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 Crush hazard The motor will come off if the screws are unscrewed 69 G0858131 G08588A1 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 Removing the motor a Disconnect the electrical cables Electrical hazard If the cables are not disconnected during lifting procedures they may become damaged 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 sup
16. The use of other lubricants than recommended is done on the exclusive responsibility of the user or oil supplier 128 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 3 8 Lifting instructions 3 8 1 Lifting the separator Weight to lift 350 kg Sling length Min 750 mm Fasten all four bolts Tightening torque 35 45 Nm 1 Remove the inlet and outlet device the frame hood and the bowl according to the instructions in 3 3 Dismantling page 41 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 Use two lifting slings to lift the separator Total length of each loop minimum 1 5 metres 5 Unscrew the foundation bolts 1810828 02 G0868451 129 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 6 When lifting and moving the separator follow normal safety precautions for lifting large heavy objects 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 When lifting parts without weight specifications always use lifting straps with the capacity of at least 500 kg 130 1
17. 2 Foundation drawing Alfa Laval ref 562553 rev 1 A Centre of separator bowl B Holes for foundation bolts 8x C Centre of motor D Min lifting capacity required during service 300 kg E Max height of largest component incl lifting tool F Service side G Foundation bolts H Installation according to stated foundation force I Recommended free floor space for unloading when doing service J No fixed installation within this area K Centre of gravity complete machine L Dynamic forces static force excluded From separator do not exceed Force in any separator feet Vertical 12 KN Horizontal 12 kN M Total foundation force sum of all feet Vertical 12 kN Horizontal 12 kN 28 1810828 02 Total static load max 4 5 KN G0977611 SEPARATION UNIT 840 SERVICE MANUAL 2 TECHNICAL REFERENCE 2 4 3 Interconnection diagram Alfa Laval ref 561786 rev 4 Interlocking switch frame top part for bearing holder Unbalance sensor position trans P N Speed sensor bowl speed AII lT TT T I lt SER Fe ee MH wl 0 O IN BE Junction box mai am 8 e ER s Wiring of connector X Wire colour codes ez RD A BK Black BU B BN Brown GN C BU Blue YW D R
18. 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 3 7 4 Lubrication c hart Alfa Laval ref 567329 01 rev 0 Bowl 3 Rubber seal rings 4 S C Nise oe KT SE Electric motor 6 Bowl spindle taper 2 Buffers 3 Bowl spindle and bearings 1 g Friction clutch bearings 5 G0875441 n Lubricating points Type of lubricant Interval The oil bath Bowl spindle bearings See 3 7 1 Lubricating oil page 123 Oil change are lubricated by oil mist from the oil Volume 2 1 Technical Data page 13 1 Continous operation 4000 hours bath Ambient temperature 0 to 55 C 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 2 Bowl spindle taper Lubricating oil only a few drops for At assembling rust protection 3 Bowl Sliding contact surfaces thread Pastes specified in 3 7 5 Lubricants At assembling of lock nut and cap nut page 126 4 Rubber seal rings Grease as specified in 3 7 5 At assembling Lubricants page 126 Friction clutch bearings The bearings are pre lubricated with No need for extra lubrication grease Electric motor Follow the manufacturer s instructions Follow the manufacturer s instructions Check and pre lubricate new spindle bearings and those that have been out of service for six months or longer Check the oil level before sta
19. D321 J N Operating slide apply D321 Operating water ring O Molykote 1000 D321 Molykote 1000 1810828 02 Nut 81 G0911751 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 4 7 How to lubricate bowl parts with slide laquer 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 D321R on surfaces c Air cure for 15 minutes d Use a smooth fibre brush to polish to an even and homogenous contact film e Apply a second layer slide laquer f Air cure for 15 minutes g Polish the film to a shiny surface the film should 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 82 1810828 02 G0874861 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 3 4 8 Check for galling on operating slide and bowl body q i 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 degr
20. Holes in distributor Top disc Sludge space Oil water interface Uncleaned oil Cleaned oil E 12 1810828 02 G0886231 SEPARATION UNIT 840 SERVICE MANUAL 2 TECHNICAL REFERENCE 2 Technical Reference 2 1 Technical Data Alfa Laval ref 569604 rev 2 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 881203 03 01 Separator type S 840 Application Cleaning of fuel and lube oil Technical design Intended for marine and land installations Total discharge Designed in accordance with standards 98 37EC The Directive of the European Parliament except for the council relating to the machinery 89 336EEC EMC and amendments related to said directive EN 292 2 Safety of machines Use of the machine in applications subject to hygienic demands requires a well adapted cleaning program Restrictions Feed temperature 0 C to 100 C Ambient temperature 5 C to 55 C Discharge intervals min 2 minutes max 4 hours Maximum allowed density of operating liquid 1000 kg m Viscosity ma
21. K14 Contactor K 14 is interlocked by the temperature switch e lf the temperature switch has been released the heater must be restarted using the Alarm Reset on the Control Unit after the cause has been remedied 1810828 02 153 8 HEATPAC POWER UNIT OPTIONAL SEPARATION UNIT 840 SERVICE MANUAL 154 1810828 02
22. SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 2 Replace parts if erosion is suspected 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 1810828 02 79 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 4 5 Exchange of frame feet The frame feet have to be changed occasionally dueto rubber deterioration from age When replacing the frame feet the separator must be lifted Follow 3 8 1 Lifting the separator page 129 Discard the old frame feet screws and washers a Loosen the bolts and prepare to remove the separator frame b Lift the separator See Lifting the separator on page 129 c Remove the existing frame feet d Fit the new feet screws and washers Tightening torque 760 Nm e Place the separator in its original position and fasten the mounting bolts 80 1810828 02 G0874421 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 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 SS S2 Bowl hood apply
23. and tighten the screws to a torque of min 15 Nm and max 20 Nm 104 1810828 02 G0861441 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 6 Lifting the bowl body onto the spindle taper a Putadrop 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 ee eee 7 Crush hazard Support the bowl body when turning to prevent it from rolling d Fit the lifting tool and lift the bowl body e Carefully lower the bowl body onto the spindle taper f Remove the lifting tool 1810828 02 105 G0861731 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 7 Fitting and tightening the cap nut a To prevent the bowl body from rotating when fitting the cap nut Fit the compressing tool to the bowl b Apply a thin layer of body and fit a screw together with a molykote grease Fit and socket into the frame as shown in the tighten the cap nut toa illustration torque of 50 Nm Left hand thread Cap nut 106 1810828 02 G0861851 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 8 Fitting the discharge slide a Apply a thin layer of silicone grease and fit the rectangular ring E gt ED b Apply a thin layer of silicone grease a
24. for lubrication as advised by the manufacturer ae ee TT Energrease MM EP2 Energrease LS2 Castrol APS 2 Grease EPL 2 Esso Exxon Beacon EP2 Unirex N2 Albida Grease EP2 Alvania EP Grease 2 Mobil Mobilith SHC 460 Mobilux EP2 1810828 02 127 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 7 6 Lubricating oils Alfa Laval ref 567330 01 rev 1 Paraffinic mineral lubricating oil category ISO L HM 68 Viscosity grade SO 3448 3104 VG 68 The oil shall follow the requirements in one of the standards below DIN 51524 part 2 German standard DIN 51524 HLP or HVLP 68 ISO 11158 International standard 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 Menufacturer T Besignation Alfa Laval 567334 01 1 litre 567334 02 4 litres Bartran 68 Bartran HV 68 Casirol Hyspin AWS 68 Hyspin AWH 68 Esso Exxon Nuto H 68 Univis N 68 Mobil DTE 26 ISO VG 68 DTE 16 ISO VG 68 DTE 16M ISO VG 68 Shell Tellus Oil 68 Tellus Oil S 68 Tellus Oil T 68 Statoil HydraWay HMA 68 Hydra Way HVX 68 Total Fina Elf Azolla ZS 68 Lubmarine Visga 68 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
25. frame hood can pass the paring tube Paring tube b Apply a thin layer of silicone grease and fit the O ring onto the frame hood c Lower the frame hood Make sure to fit the frame hood groove and the projection of the pipe 1810828 02 Make sure that the frame hood is mounted in its correct position according to the piping arrangement d Fit and tighten the Screws 115 G0863771 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 2 Control measurement of paring disc height o a Remove the guide screw A b Measure the distance D Assemble the correct number of height adjusting rings B according to the table Guide screw c Refit the guide screw A Support ring Height adjusting rings Ni TES 959953 HEZAZ TT TI SYY I a Bowl hood Distributor Paring disc 116 1810828 02 coos TA FA DP 2 Guide screw Frame hood ra lt f Ah VL N N N N A N N SS lt gt G09115E1 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 3 Fitting the spring 5 and arm a Fit the spring on the arm and fit the arm to the top of the paring tube end Paring tube el b Fit the spring to the pin on the frame hood and make sure that it is properly attached on both ends 1810828 02 117 G0863781 3 SEPARATOR SERVICE DISMANTLI
26. help of the cover The middle and lower CIP unit outlets must be closed Clean with CIP fluid Flush with water After cleaning 1 Open the heater drain valve until the flushing water has drained Close the drain valve Remove the CIP connections Return the turnable connections to their former positions and re tighten Re open the valves before and after the heater 1810828 02 Me N AY F y 7 LA A Y ZAR y Av f j amp aa LAW oly U 2 T I E p Fi Iy N iF _ _ A 137 G065053A 5 CLEANING IN PLACE SEPARATION UNIT 840 SERVICE MANUAL 5 3 Cleaning in Place Separator and Heater Connect the CIP equipment as shown in the illustration Proceed with cleaning as described A Qil outer Water outlet above gt 138 1810828 02 G065062A SEPARATION UNIT 840 SERVICE MANUAL 6 HEATPAC CBM HEATER OPTIONAL 6 Heatpac CBM Heater Optional 6 1 Technical Data Operating pressure maximum 1 6 MPa 16 bar Test pressure 2 4 MPa 24 bar Operating temperature maximum 225 C Medium Mineral oil Heating media Steam hot water thermal oil The following shall apply to the heating media Steam condensate pH 8 8 9 2 sodium in condensate lt 0 01 mg l Water pH value Shall be neutral to minimize corrosion risk Thermal oil The thermal oil must be highly resistant to oxida
27. hole at the bottom of the oil pump is clean before lowering the assembly down Carefully blow compressed air Be through the hole in b Position the flat belt B so the bearing housing that the spindle assembly can pass through when lowering 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 Cut hazard Do not put fingers between the frame and air deflector while lowering the assembly d Fit and tighten the screws 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 1810828 02 97 G0867971 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 11 Fitting the flat belt 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 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 Do not turn the spindle until the motor is tightened properly to the frame
28. 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 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 2 TECHNICAL REFERENCE 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 Signal processing in STARTING 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
29. lt p gt Air deflector Spindle pulley Belt Self aligning roller bearing oe Lubrication oil orifice O ring Oil pump Labyrinth ring holder Labyrinth ring A gt li Wing insert lt gt O ring Bottom bearing holder a Screw O ring A _ Strainer 56 1810828 02 G0858061 G0857971 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 1 Empty the oil sump Unscrew the oil plug and empty the oil sump 2 Removing the clutch cover a Remove the screws Sy D E b Remove the clutch cover Le 4 SS 1810828 02 57 G0868571 G0858131 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 Loosen the flat belt by tilting the motor a Loosen but do not remove the screws holding the motor Start with the two screws at the bottom Do not loosen more than shown in the illustration c Remove the flat belt from the motor pulley 58 1810828 02 Separator frame 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 Crush hazard The motor will come o
30. ring ends are facing each other Check that the lock ring is correctly positioned all way around For correct disc stack pressure see page 114 Lock ring Bowl hood a L L lt pe Bowl body Never remove any material from the lock ring A hazardous situation could result Before compressing Lock ring in position 1810828 02 113 G0862531 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 16 Checking the disc stack pressure gt a Remove bowl 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 Do not use more power than 40 Nm 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 1810828 02 G0874961 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 3 5 4 Frame hood 1 Fitting the frame hood B ED a Turn the paring tube so that the
31. towards each other and position them into the two slots on the bowl b Ease off the discharge slide bottom by turning the central screw Slide metal ring down over bowl nave If discharge slide is difficult to remove tap lightly on outside edge with a soft faced hammer Ring on tool Puller rod It Discharge slide T Bowl body _ c Lift out the discharge slide 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 52 1810828 02 G0863251 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 9 Removing the cap nut a Remove the cap nut Left hand thread SIU A b Remove the compressing tool 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 1810828 02 53 G0860651 G0860731 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 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
32. 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 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 2 TECHNICAL REFERENCE There shall be an emergency stop circuit designed according toEN 418 and a power isolation device according toEN 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 alarm should be given when the accumulated time for acceleration is longer than the maximum time specified in Technical Data An abnormal start time indicates some malfunction of the separator equipment and should be investigated If the speed exceeds Bowl speed synchronous in Technical Data with more than 5 the separator shall be stopped automatically by NORMAL STOP and a high speed alarm shall be given The speed monitoring system shall be checked continuously e g by checki
33. 0 SERVICE MANUAL 8 HEATPAC POWER UNIT OPTIONAL 8 4 Heating Performance Principle The oil temperature is regulated from the control unit which gives the appropriate signals to the power unit The power unit feeds the electric heater with both variable and fixed power C 2 E 3G OMe O Y Thefixed power is fed in steps as a constant part load The variable load operates on top of the 4 N fixed part load for fine tuning of temperature automatically controlled by the control unit and results in an overall smooth operation 72 Load kW Size kW Part load 1 variable 0 16 kW Part load 2 fixed 8 kW Part load 3 fixed 16kW Part load 4 fixed 32kW Sequential switching of the fixed part load and regulation of the variable part load are N Heating Performance Principle for 440 V 1810828 02 151 G025651A 8 HEATPAC POWER UNIT OPTIONAL SEPARATION UNIT 840 SERVICE MANUAL 8 5 Load Control and Functions 8 5 1 Variable Part Load Power for the variable part load 1 is fed via contactor K11 in the power unit and regulated by means of the two triac modules Al and AZ Contactor K 11 is activated provided that there is a closed circuit through the safety switch TS and that there are no function faults in the control unit see electrical diagram in Systen Reference Installation Instructions The triac modules are co
34. 0828 02 15 2 TECHNICAL REFERENCE SEPARATION UNIT 840 SERVICE MANUAL 16 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 R Cover interlocking switch e Type e Switch rating resistive load max 1810828 02 See page 21 Inductive promixly switch 8 V Less or equal to 1 mA More or equal to 3 mA 1 See page 22 Inductive analogue sensor 18 to 30 V DC 0 5 to 2 5 mm 1to9mA 400 Ohm Mechanical limit switch 3 A at 48 V DC 1 A at 220 V AC SEPARATION UNIT 840 SERVICE MANUAL 2 TECHNICAL REFERENCE 2 3 Interface Description Alfa Laval ref 564834 rev 2 2 3 1 Scope This document gives information requirenents and recommendations about operational procedures and signal processing for safe and rdiable operation of the separator It is intended to be used for designing auxiliary equipment and control systems for the separator 2 3 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 e Interconnection Diagram e Co
35. 810828 02 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 3 8 2 Lifting the bowl When lifting and moving an assembled bowl Weight to lift 75 kg always follow theseinstructi ons 1 Fit the lifting tool with lifting eyes to the bowl assembly 2 Check that the lock ring is mounted correctly Tightening torque 35 45 Nm before lifting the complete bowl 3 Lift the bowl using a sling with the proper rating T Lock ring Make sure that Never try to lift the bowl while it is still in the frame lock ring is fitted The bowl body is fastened to the frame with the cap nut U 1810828 02 131 G0868441 4 CHANGE OF CIRCUIT BOARD SEPARATION UNIT 840 SERVICE MANUAL 4 Change of Circuit Board If a circuit board has to be changed proceed as follows N ote down the run time days only as shown in the function list of the EPC 50 Change the board according to the instructions bel ow Go to parameter Fa 90 and insert the run time OP Board e Switch power off e Remove the snap in transparent cover e Disconnect the two cable plugs do not remove the cables from the plugs e Disconnect the flatcable connector at the top e Unscrew the five hexagon nuts e Mount the new board and connect in reverse order 1 O Board e Switch power off If there is no optional board installed e Disconnect all the cable plugs on the large board do not remove the cables from the
36. D Red WT E GN Green BK F PU Purple BN G YW Yellow PU H WT White Items showed in this document are not included in all separators See product specification Demand specification wire Approval UL 1007 1569 CSA TR 64 Area acc to AWG 18 1810828 02 29 G0867541 2 TECHNICAL REFERENCE SEPARATION UNIT 840 SERVICE MANUAL 2 4 4 Electric motor Alfa Laval ref 562534 rev 2 Cast lifting lugs on both side 261 160 Knockout openings for cable glands on 22 8 both sides 29 5 4 holes LO z S Ss r NE N ae m Slo External earthing X ME mine M10x18 41 Note The motor NI bearings have 45 permanent 80_ _ 89 140js14 Metal fan cover za 216js14 lubrication 262 Manufacturer ABB Motors Protection Type of mounting Manuf drawing Cat GB 96 10 class Standards IEC 34 series 72 79 and 85 Type M2AA 132 SC Poles 2 Insulation class F Bearings Method of cooling D end 6208 2Z C3 N end 6206 22Z C3 IC 411 IEC 34 6 pa Bm a _ Spec Totally enclosed three phase motor for marine service 2 Motor with feet and small flange 30 1810828 02 G0977511 SEPARATION UNIT 840 SERVICE MANUAL 2 TECHNICAL REFERENCE a J ARO J HEB Pow fac st j cos j mes oes r amo ms om of saena oes fm amo mo fom saa ms a so a4 oa or Compas me oes aw wom o os sr presser oes aw wom er os ar sesso oss fm wo
37. G ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 12 Removing the top bearing housing a Turn the spindle assembly over Composite b Remove the plugs springs and the composite springs i f Plug d Collect the axial springs c Carefully remove the spindle from the top bearing seat Be careful not to damage the vibration indicator 64 1810828 02 G0858221 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 13 Removing the ball bearing Do not damage threads on spindle a Remove the snap ring 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 Take care not to damage the vibration indicator when separating the top bearing seat from the spindle Vibration indicator Piece of wood to protect the spindle threads d Place the top bearing seat on a support to protect the vibration indicator Remove the bearing Use a drift in the two holes
38. NG ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 4 Fitting the connection housing 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 b Fit the washer and the lock nut using the hook spanner 118 1810828 02 G0863941 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 3 5 5 Unbalance sensor option 1 Fitting the unbalance sensor holder a Remove the cover 4 1 A Sensor arm Frame KJ N 2a Screw M8 b Fit the O ring on the holder Fit the screw into the holder and mount the holder into the separator frame Sensor mm WA holder O ring U P If removing the sensor holder use a M10 screw as a puller See next page for fitting and correct adjustment of the sensor 1810828 02 119 G0873481 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 2 Adjusting the unbalance sensor 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 Sensor
39. NN b Tighten the screws a Fit the clutch cover 16 Fill oil in the oil sump The separator should be level and at standstill when oil is filled a Remove the oil pin plug and washer 6 PERR ke 2 b Fit new washer lll 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 d Fit new O ring B onto the oil pin e Refit the plug with new washer gt For grade and quality of oil see 3 7 6 Lubricating oils page 128 f Fit the oil pin 1810828 02 101 G0858141 G0868781 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 5 3 Bowl 1 2 102 Check for impact marks and corrosion in bowl body nave and on spindle taper gt ED a Remove any impact marks using a scraper and or a whetstone 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 Fitting new valve plugs on the operating slide E gt a Remove the valve plugs using b Carefully tap in new valve plugs using a a drift clean soft faced hammer e Make sure that the p
40. Separation Unit 840 Serv ce Manual Printed J an 2003 Book No 1810828 02 V 1 Alfa Laval reserves the right to make changes at any time without prior notice Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated Copies of this publication can be ordered from your local Alfa Laval company Published by Alfa Laval Tumba AB Marine amp Diesel Equipment SE 147 80 Tumba sweden Copyright Alfa Laval Tumba AB 2003 Contents 1 Separator Design 1 1 1 Overview UEULUE EEE 1 1 2 The Drive Section 3 1 3 The Process Section 4 LA S NSOMrS c kane ke Kral ee 8 1 5 Separating Function 9 1 5 1 The liquid balance in the bowl 9 1 5 2 Liquid flOW u LALE 10 1 5 3 Discharge of sludge and water 10 1 5 4 ALCAP c oncept 11 Technical Reference 13 2 1 Technical pData 13 2 2 Connection List 15 2 3 Interface Description 17 2O31 OCODE Serie a eared eel teach 17 2 3 2 References cccceeccccececceseeeeeeeseeeeeees 17 239 DEIININONS orrena dikara ak ke Wana ia 18 234 ec eian ee a a aaa 18 2 3 5 Description of separator modes 19 2 3 6 R
41. TION UNIT 840 SERVICE MANUAL Complete dismantling of centrifugal clutch 6 Removing the coupling from the motor a Remove the screw spring washer and washer Washer Spring washer Use a spanner 55 mm on the coupling hub to prevent rotation during dismantling b Check that the brass plug is mounted on the puller tool Fit the tool to the friction clutch Flat areas for spanner 55 mm c Ease off the friction coupling Crush hazard The centrifugal clutch is heavy and can fall causing injury when loosened from the motor shaft Puller tool Flat areas for spanner 50 mm 12 1810828 02 G0865421 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 7 Dismantling of the 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 Always discard used bearings 1810828 02 73 G0865511 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 4 Actions Before Assembly 3 4 1 Cleaning gt LL Clean the separator parts according to the diagram below Afterwards protect all cleaned carbon steel parts against corrosion by oiling Frame and The external cleaning of the frame and motor should be Water and de greasing agent motor restricted to brushing spon
42. al 7 ki gt 7 a nO meN lal TT ES bE ee 7g ij OCN V Pal SS n 7 7 T zy Tdi ALI 50Hz o Indicating direction of rotation of horizontal driving device 1810828 02 121 S00501A1 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 2 Check legibility Following texts should be read on the labels 122 amp Alfa Laval A DANGER Alfa Laval YHOO xx 20K xxx xxx XXXXXX XX XXXX XXX XXXXXX XX HOOK xx xxxx xxx HHH HOOK Xxx 0000000 Xxxxxx xx 200K xxx XH XXXX Xx Xxxxxxxx YOK xx Xxxxxx xx xxxx xxx XH 000K xxx xxxxx XXXXXX XX XXXX XXX XXXXXX XXXX 1000000000000000 XXX XX 2000000 XX XXXX 20000000000000000000X J00000000000000000000000X x 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 DANGER S 840 881203 03 01 963094 01 961904 04 962967 01 9220 r minute 50 Hz 9220 r minute 60 Hz 2 3000 r min 50 Hz 3600 r min 60 Hz 50 60 Hz 9 5 kW 1100 kg m 2425 kg m 1000 kg m 0 100 C Read the instruction manuals before installation operation and maintenan
43. al operation the water drain valve in the water outlet is closed 1 5 3 Discharge 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 e The water drain valve opens and the water leaves the bowl through the water outlet e Through the sludge ports at sludge discharge Which way is decided by the process control system 10 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 1 SEPARATOR DESIGN 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 1810828 02 11 1 SEPARATOR DESIGN SEPARATION UNIT 840 SERVICE MANUAL DISCHARGE OF WATER THROUGH WATER OUTLET Dr n Unseparated oil Bowl hood Separated oil M MEZ Water Water paring tube Oil paring disc Water paring chamber Oil paring chamber
44. ally 230 400 440 460 480 500 690 V AC 50 60 Hz Acc to DIN standard 2633 or JIS standard B2213 IP 65 400 V 63 Q 1 3 Wiem 2 5 kW 440 V 70 Q 1 4 W cm2 2 8 kW 460 V 83 Q 1 3 Wicm 2 5 kW 480 V 83 Q 1 4 Wicm 2 8 kW 500 V 83 Q 1 5 W cm2 3 0 kW 690 V see 400 V Y connected 400 V elements 240 Nm Connections on elements 3 Nm Element nut h 9 M14 Element nut h 5 M14 30 50 Nm Relief valve G1 2 80 Nm Spring pocket for Pt 100 and safety guard G1 2 1810828 02 141 7 HEATPAC EHM ELECTRIC HEATER OPTIONAL SEPARATION UNIT 840 SERVICE MANUAL 7 2 Dismantling and Cleaning The electric heater requires regular opening for cleaning The heater block resistance and the insulation resistance of the heating elements Should be checked and an inspection of the general condition carried out Any malfunctions of the heater are indicated in the control unit For further information see the Alarms and Fault Finding booklet As a general guideline the heater should be opened up for cleaning whenever an excessive pressure drop occurs or if capacity falls and oil temperature is low Where heavy fuel is used dismantle the heater when warm as described below Lift off the junction box cover Loosen the cable nipples Mark the signal wires disconnect them and pull out the cables Remove the flange bolts Remove the earth connections between the flanges and the junction box Lift off the he
45. an be somewhat reduced before it starts to increase This is due to the accumulation of moisture in the element top during heating In the event the insulation resistance is below 100 kQ in any group of elements the elements in the group must be measured separately The insulation resistance in a single element is measured between the connecting pin on the element with the closing links disconnected and the ground A single element with resistance below 100 kQ can be reconditioned in place by indirect warming Do not connect the connecting pins via the closing link to the terminal Connect the remaining elements in the block to the terminal and allow the heater to be taken into operation New Megger Test If the insulation resistance at start up was under 1 MQ anew megger test should be carried out after 14 days operation The elements should now havea resistance of over 1 MQ If this is not the case any element still below 1 MQ should be replaced 1810828 02 145 7 HEATPAC EHM ELECTRIC HEATER OPTIONAL SEPARATION UNIT 840 SERVICE MANUAL 7 2 3 Measuring of Heater Block Resistance The heater block resistances are measured from the power unit This ensures that the heater elements and the heater blocks are correctly connected Resistances of available heater sizes and applicable voltage supply are given in the following table Heater Block Resistance Q ke Part load 1 Part load 2 Part load 3 Part load 4
46. and remove the paring tube Turn the paring tube upwards If the paring tube sticks use a drift to carefully tap it out from the pipe Be careful not to damage the paring tube 50 1810828 02 G0863051 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 6 Removing the disc stack and distributor c Carefully lift off the disc stack assembly a Assemble the lifting tool with the pin ab Ke O 9 O O O Ww op Q a J LL Q x O V O 2 O Q Ke O ab e eb O Cc ha O gt 2 D O lt O D O D c Q dp D v 5 LZLE9809 E AA st Sa 2 eee ii NNN ZE SF Fit the compression tool to the bowl body and fit a screw together with a a To prevent the bowl body from rotating when removing the nut 4 Sharp edges on the separator discs may cause cuts Cut hazard f socket into the frame as shown in the illustration CR B 3 2 2 2 S 9 E r D Q 2 MN the nut Nu Compressing tool Screw Socket or similar Lr8ez609 51 1810828 02 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 8 Removing the discharge slide a Fit the lifting tool by pressing the puller rods
47. anism which empties the sludge during operation A speed sensor and an unbalance sensor option are part of the equipment for monitoring the separator functions 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 1 SEPARATOR DESIGN 1 2 The Drive Section The separator bowl is driven by an edectric motor via a belt transmission The bat 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 centrifugal clutch ensures a gentle start and smooth acceleration and at the same time prevents overloading of the belt and motor The bearings on the spindle are lubricated by the oil soray produced by an oil pump mounted on the lower end of the spindle G0870741 1810828 02 3 1 SEPARATOR DESIGN SEPARATION UNIT 840 SERVICE MANUAL 1 3 The Process Section Theseparation process takes place inside the rotating separator bowl The feed and outlet of process liquid takes placein thein 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 f
48. arator 135 5 2 Cleaning in Place Heatpac CBM HHater 136 5 3 Cleaning in Place Separator and Heater 138 Heatpac CBM Heater Optiona 139 6 1 Technical Data 139 6 1 1 Manual Cleaning 139 Heatpac EHM Electric Heater Optional 141 7 1 Technical Data 141 7 2 Dismantling and Cleaning 142 7 2 1 Replacing Heater Element 143 7 2 2 Insulation Resistance Megger Test 144 7 2 3 Measuring of Heater Block RESISTANCE k lSu EEE 146 Heatpac Power Unit Optiona 149 8 1 Technical Data 149 8 2 Working principle 150 8 3 Electric Heater Function 150 8 4 Heating Performance Pr nG ple iy sl cenan 151 8 5 Load Control and Functions 152 8 5 1 Variable Part Load 152 9 5 2 Fixed Parl Load enrarir 152 8 5 3 External Safety Stop 153 8 5 4 Start and Reset Functions 153 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 1 SEPARATOR DESIGN 1 Separator Design Process section The feed inlet and outlets Sr 4 are situated at the top of the separator E
49. ater insert If cold heavy fuel has stiffened the heater insert a couple of screwdrivers may be used to ease off the sol anal insert Avoid using a sling sete sk HEK is heal be s ss os Miya J Glean the insert in a bath using Alfa Laval Cleaning liquid part no 1762852 01 for lube oil heater part no 1763500 02 alternatively diesel oil white spirit or equivalent for fuel oil heater Blow all parts dry with compressed air Assemble the heater in reverse order Measure the heater block resistance and the insulation resistance to ground before reconnecting the wires 142 1810828 02 G003313A SEPARATION UNIT 840 SERVICE MANUAL 7 HEATPAC EHM ELECTRIC HEATER OPTIONAL 7 2 1 Replacing Heater Element 1 Place the heater insert on a work bench 2 Use a box spanner to disconnect the wires and the connecting plates A wiring diagram is placed on the inside of the junction box cover 3 Disconnect the junction box by removing the nuts on the heater element connecting rods inside the the junction box using a box spanner Be careful not to damage the insulation sleeves Remove the junction box 5 Remove the O rings above the tightening nuts of the heater element connecting rods 6 Remove the nuts using a box spanner 7 Pull out the heater element 8 When reassembling Use a new copper packing 10 Screw fast the elements in the top counter flange 11 Before refitt
50. ce Consider inspection intervals Failure to strictly follow instructions can lead to fatal injury If excessive vibration occurs stop separator and keep bowl filled with liquid during rundown Out of balance vibration will become worse if bowl is not full Separator must stop rotating before any dismantling work is started Read instruction manual before lifting 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 3 7 Oil Change Theseparator should belea and at standstill when oil is filled or the oil lea 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 Evena 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 Always clean and dry parts also tools before lubricants are applied Check the oil le
51. e and not producing PRODUCTION Separator is fed with product and producing CLEANING Separator is fed with cleaning liquids with the intention to clean the separator 1810828 02 19 2 TECHNICAL REFERENCE SEPARATION UNIT 840 SERVICE MANUAL Stopping means e The power to the separator motor is off e The bowl is rotating and decelerating e STOPPING is a collective denomination for a number of sub modes which e g can be NORMAL STOP A manually or automatically initiated stop SAFETY STOP An automatically initiated stop at too high vibrations EMERGENCY STOP A manually initiated stop at emergency situations This stop will be in effect until it is manually reset 2 3 6 Remote start This machine may be started from a remote location under the following conditions e 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 e The unbalance sensor is mandatory for remote start e The installation must include equipment to prevent unintentional start up from remote location when the machine is disassembled e The installation must include equipment to prevent unintentional start of process flow from remote location when the machine is not properly connected to the piping 2 3 7 Handling of connection interfaces Electrical connections 701 Separator motor The separator is equipped
52. e bowl 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 EZE OoOO R OU ES C d4 cS Se EN EA ji AW abs LZ S T SS i A uJ Recesses on the bowl body nave Q A Q SS 1810828 02 aft Guide ribs inside the distributor Guide pin on bowl body uide rib on distributor 109 G0862171 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 11 Assembling the paring tube gt Ea Tolerance ring a Fit the O rings lll bearings HI and tolerance ring to the paring tube 12 Mounting the paring tube and fitting the inlet and outlet pipe a Insert the b Mount the splash sealing paring tube and mount the axial support to 1 c Apply a thin layer of the inlet and onan silicone grease and fit d Carefully lower the inlet and outlet outlet pipe the O rings D gt E pipe assembly into the top of the distributor _ _ e_ _ a __ 110 1810828 02 G0984961 G0862291 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 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 1810828 02
53. eaning 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 Burn hazard Shut off the oil flow and the heating medium flow before starting maintenance work Corrosion hazard Pay strict attention to the safety instructions for the cleaning liquid used Use only specified cleaning liquids Other cleaning agents may corrode the metal surfaces 136 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 5 CLEANING IN PLACE Proceed as follows 1 2 Close the valves before and after the heater Open the heater drain valve until oil remaining in the heater has drained Close the drain valve Loosen the turnable connections before and after the heater Turn the connections 90 so that the special CIP connections can be connected 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
54. easing agent i e white spirit This is important b Using an emory cloth e g No 320 to smooth the metal edges c Finish by polishing the damaged spots with polishing paper e g No 600 d Apply Molykote D321R on surfaces e Air cure for 15 minutes f Polish to an even homogenous surface g Apply a second layer h Air cure for 15 minutes i Polish to a shiny surface the surface should look like well polished leather when properly done j Finish the treatment by lubricating the guiding 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 1810828 02 To avoid the risk of galling the guiding surface of the operating slide should be primed with a slide lacquer at every inspection service 83 G0874851 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 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 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 253 5 mm 50 Hz d 211 mm 60 Hz Remove rust from the belt pulley using a steel brush b Apply a thin film of oil onto the ex
55. emote Start 20 2 3 Handling of connection interfaces 20 2 4 Drawings EEEEEEEEEEEUEEE 27 2 4 1 Basic size drawing 27 2 4 2 Foundation drawing 28 2 4 3 Interconnection diagram 29 2 4 4 Electric motor cccecccsseeeeeseeeeeeeeeees 30 2 5 Nomogram paring tube 32 Separator Service Dismantling Assembly 35 3 1 Periodic Maintenance 35 3 1 1 Maintenance intervals 35 3 1 2 Maintenance procedures 36 3 1 3 Tightening of SCreWS U 37 3 1 4 Service Kits LEE 37 CUN SAM lt GICANING EN NE N n a 38 3 2 Maintenance Log 39 3 3 Dismantling 41 9 0 1 INMOCUCTION cisreke cay la kar et eee 41 Des TOO aah ces eta eee eee eba an G R We 42 99 0 Fame NOOO As4 lek ee Ne EN ite 44 9 02 BOW ls 5 5 xy arana ka na Ki Wad n pana ya Ni 46 3 3 5 Driving device A UEU 56 3 3 6 Centrifugal clutch 68 1810828 02 3 4 Actions Before Assembly 74 3 4 1 CICANING lt cxivitiinarastarsmarctiwkansvaveisaiiends 74 3 4 2 Inspection for corrosion 76 3 4 3 Inspection for crackS k kWk j 77 3 4 4 Inspection for erosion
56. enance 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 39 gives a detailed list of actions to be performed Inspection BB 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 Overhaul 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 change 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 year 1810828 02 35 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 1 2 Maintenance procedures At each Inspection and or Overhaul take a 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 41 Place the separator parts on clean soft surfaces such as pallets 2 Inspect and clean the dismantled separator parts according to
57. essing in STARTING e 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 e Could be closed or open Processing in CLEANING e Asequence 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 24 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 2 TECHNICAL REFERENCE Processing in NORMAL STOP or EMERGENCY STOP e Could be closed or open but the bowl should be filled unless the stop is initiated in STARTING Processing in SAFETY STOP e Could be closed or open but the bowl shall be filled unless the stop is initiated in STARTING 206 Inlet for conditioning and displacenent liquid e According to process 220 221 and 222 Outlets Processing in STAND STILL e Could be closed or open Processing in other modes e Shall be open 375 Inlet for discharge and make up liquid Processing in all modes e tis 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 Signal processing in STARTING e Below 85 of synchronous bowl speed no water supply may be made e When coming from PRODUCTION a discharge shall be initiated to remove sediments from bowl to avoid problems d
58. ff if the screws are unscrewed G08588A1 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 4 Removing the operating water cover If the cover sticks fit two a Remove the screws b Lift off the operating water cover M10 screws to the threaded holes and tighten 5 Removing the neck bearing cover and deflector ring a Attach the tools c Ease off the cover by tightening the screw Lift off the neck bearing cover together with the deflector ring b Fasten the tool to the cover 1810828 02 59 G0858931 G0859051 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 6 Prepare for removal of spindle assembly 60 To facilitate later removal of plugs loosen do not remove the plugs on the bearing housing 1810828 02 0 b Remove the screws If the cover sticks fit two M10 screws to the threaded holes and tighten G0859151 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 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 a 4 Crush hazard Do not rotate the spindle assembly during lifting The spindle assembly ma Cs v may otherwise come loose from the u lifting tool
59. from sticking to the frame hood when lifting the hood always turn the paring tube towards the pipe before lifting Paring tube 3 Removing the frame hood a Remove the screws holding the frame hood c Lift off the frame hood i Do not place by bending with the hood a screwdriver in upside down all grooves in the hood b Loosen the hood 1810828 02 45 G0863661 G0863671 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 3 4 Bowl i Lock ring Bowl hood Seal ring O ring Top disc O rings Inlet and outlet pipe G0861621 Paring tube Axial support Splash sealing Bowl disc without caulks Co A al Bowl discs YY TT DD D I NN f H Bl Distributor Cap nut Nut Discharge slide Rectangular ring O ring G0860571 Compressing tool lock ring Lifting eyes Bowl hood puller Spanner for nut nut discharge slide Puller discharge slide Lifting tool distributor spindle Puller Bowl body Screw lock ring M5 Hexagon head key 10 Chisel seal ring 11 Pin distributor lifting tool Rectangular ring O ring OON QI amp UU N 4 Operating water ring Ring 46 1810828 02 G0862681 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 1i Removing the lock ring a Fit the compressing
60. ging 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 74 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY Bowl Cleaning of bowl discs A chemical cleaning agent must dissolve the deposits quickly without attacking the material of the separator parts 1 Remove the bowl discs from the distributor and place them individually in the cleaning agent Inlet outlet Handle the bowl discs carefully in order to avoid damage to the surfaces during cleaning Fuel oil 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 3 Lastly clean the discs with a soft brush dissolve these asphaltenes 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 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 Cut hazard Sharp edge
61. he O ring Clean Check for corrosion Check for cracks Renew single row ball bearings Renew friction pads if they are worn or clean the pads if they are oily Electrical motor X Lubricate if nipples are fitted See sign on motor Signs and labels on separator Machine plate Power supply frequency Lifting instructions Safety labels Name plate Representative label 40 Check attachment and legibility Check attachment and legibility Check attachment and legibility Check attachment and legibility Check attachment and legibility Check attachment and legibility 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 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 tableto avoid oil draining from the hoses Theframe hood and heavy bowl parts must be lifted by means of a hoist Position the hoist exactly above the bowl centre Usea 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 fibreboard or a suitable pallet For safety reasons it is essential that all personnel who work with the separator read this manual thoroughly and co
62. in threaded holes to raise the operating slide holder up and away from the bowl body 54 1810828 02 G0860821 G0860921 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 13 Removing the operating slide a Lift off the operating slide If the ring sticks use two M8 screws in threaded holes to raise the operating slide holder up and away from the bowl body a Loosen and remove the screws If the ring sticks use two M8 screws in threaded holes to raise the operating slide holder up and away from the bowl body 1810828 02 The discoloration on the ring is oxide protection Do not clean with abrasives 55 G0861021 G0861121 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 3 5 Driving device G0857821 Seal ring Operating water cover O ring O rings Seal ring Neck bearing cover O ring O rings Fan Snap ring Bowl spindle Ball bearing Top bearing seat Springs Top bearing housing Composite springs Plugs L N 1 Puller spindle pulley 4 Lifting tool ball bearing spindle assembly 2 Tool bearing housing 5 Drift bottom bearing 3 Cover puller 6 Sleeve ball bearing in neck bearing cover top bearing seat 7 Pin spanner oil fan
63. ing the junction box change the O rings For tightening torques see page 141 It is very important that the appropriate heater element is installed 1810828 02 143 7 HEATPAC EHM ELECTRIC HEATER OPTIONAL SEPARATION UNIT 840 SERVICE MANUAL 7 2 2 Insulation Resistance Megger Test The heating elements are electrically insulated by means of compact magnesium oxide Under certain conditions e g during storage transport etc magnesium oxide can attract damp which lowers the insulation resistance The insulation resistance between terminal and ground for each heater block must therefore be measured before the heater is taken into use This is done by means of a megger test Megger Test Procedure e Disconnect the wires from the terminal in the heater junction box before starting measurement Test the insulation resistance for the heater blocks by means of a megger connected between the heater terminals and ground in the heater junction box The test voltage to use is 500 V DC The total insulation resistance for the heater Should be gt 1 MQ 144 1810828 02 G003322A SEPARATION UNIT 840 SERVICE MANUAL 7 HEATPAC EHM ELECTRIC HEATER OPTIONAL Action to Increase Insulation Resistance If the insulation resistance is between 100 kQ and 1 MQ the heater can be reconditioned in place simply by taking it into use Please note that during the first period of operation the insulation resistance c
64. initiated Signal processing in RUNNING e If vibrations exceed the first alarm level an alarm should be given Vibrations of this magnitude will reduce the expected life time of the bearings and should therefore be eliminated e If vibrations exceed the second alarm level the separator shall be stopped automatically by SAFETY STOP e Ifthe self check system triggers an alarm shall be given Signal processing in STOPPING e Ifthe self check system triggers an alarm shall be given Signal processing in NORMAL STOP e lf vibrations exceed the second level the system shall turn over automatically to SAFETY STOP 1810828 02 23 2 TECHNICAL REFERENCE SEPARATION UNIT 840 SERVICE MANUAL 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 e The circuit is closed when the cover of the separator is mounted e The interlocking switch should be connected in such a way that starting of the motor is prevented when the separator cover is not mounted Signal processing in STARTING RUNNING and CLEANING e lf 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 e Shall be closed Proc
65. lectric motor The rotating bowl is driven by the electric motor via a The liquid is cleaned in the belt transmission rotating separator bowl inside the frame hood Sensors Drive section J The rotating separator bowl is driven by a flat belt transmission The separator is monitored by a speed sensor An unbalance sensor is optional Frame feet Ni eee el Sludge outlet The separator rests l on vibration damping Separated solids are discharged at frame feet preset intervals G0870641 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 1810828 02 1 1 SEPARATOR DESIGN SEPARATION UNIT 840 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 mech
66. lugs are fitted as described in the illustration 1810828 02 G0874611 G0874841 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 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 O ring on the bowl body 4 Fitting the operating slide holder a Fit the holder over the operating slide 1810828 02 b Fit the operating slide The guide pin in the 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 Operating slide N Bowl body Pa Guide pin a b Apply a thin layer of molykote grease and fit and tighten the screws to a torque of min 15 Nm and max 20 103 G0861241 G0861331 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 5 Fitting the operating water ring a Fit the ring ll not The discoloration on the ring is oxide protection Do not clean with abrasives b Apply a thin layer of silicone grease and fit the O ring IB EP 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
67. ly drop it 1810828 02 G0862861 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 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 b Turn the bowl hood upside down and remove the seal ring by carefully knock pieces of the seal ring out of the groove using the special tool chisel Seal ring It is very important not to damage the bottom of the groove Risk for eye injury from flying seal ring parts or from 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 a 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 1810828 02 49 G0862441 G0862951 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 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 RN j d Lift up
68. mpletely 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 1810828 02 41 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 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 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 42 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY Standard Tools 13 2e Cw gt oD G0911641 Screwdriver Torque wrench capacity 0 200 Nm Drift 4 mm Dial indicator with magnetic base Spanner for clutch 55 mm Heating equipment for bearings sliding calliper Hammers standard and soft faced O AN QI RP WN fF Pliers for internal snap rings 10 Pliers for external snap rings 11 T handle with extension rod sockets 13 16 17 18 19
69. nd fit the O ring BB Bb c Fit the lifting tool and lower the discharge slide into the bowl Crush hazard The ring on the lifting tool must be pushed home against the discharge d Remove the lifting tool 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 150 Nm g Remove the compressing tool and the spanner for nut 1810828 02 107 G0861951 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 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 108 Recess on bowl disc pore 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 Cut hazard Sharp edges on the bowl discs may cause cuts Guide rib on distributor 1810828 02 G0862051 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 10 Fitting the disc stack assembly to the bowl body a Fit the lifting tool into the distributor T yee Bd f gt A AEZ A Z amp S J Z gt QS SS Ee 0 0 UA i A 1 b b Lower the disc stack into th
70. ng 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 1810828 02 21 2 TECHNICAL REFERENCE SEPARATION UNIT 840 SERVICE MANUAL Signal processing in RUNNING If the speed exceeds Bowl speed synchronous in Technical Data with more than 5 for a period longer than 1 minute or momentarily during maximum 5 seconds more than 10 the separator shall be stopped automatically by NORMAL STOP and a high speed alarm shall be given If the speed falls more than 10 below the synchronous speed for a period longer than 1 minute or 15 during more than 5 seconds a low speed alarm should be given Low speed indicates some malfunction of the separator equipment and shall be investigated The speed monitoring system shall be checked continuously e g by checking that pulses are coming In case of a failure indication an alarm for soeed monitoring system failure shall be given If there is a risk of too high speed the separator shall be stopped by NORMAL STOP The speed drop during DISCHAAGE compared to the measured speed immediately before should be between 3 8 which will indicate a proper discharge Signal processing
71. nnection List e Technical Data Standards referred to are e EN 418 Safety of machinery Emergency stop equipment functional aspects Principles of design e EN 1037 Safety of machinery Prevention of unexpected start up e EN 954 1 Safety of machinery Safety related parts of control systems Part 1 General principles for design 1810828 02 17 2 TECHNICAL REFERENCE SEPARATION UNIT 840 SERVICE MANUAL 2 3 3 Definitions For the purpose of this document the following definitions apply e 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 e Full soeed The synchronous speed minus normal slip 2 3 4 Goal To eliminate situations that can cause harm i e injury damage to health or property and unsatisfactory process result are e g Unbalance caused by uneven sediment Too high stress on bowl and bearing accumulation in the bowl system which might cause harm Too high bowl speed Too high stress on bowl which might cause harm Access to moving parts Can cause injury to person who accidentally touches these parts Insufficient cleaning of separator Unsatisfactory product quality Bowl leakage 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
72. now be compared with a settling tank SEPARATOR BOWL TURNED 90 _ __ li Unseparated oil lt D Separated oil Ji a T water rh G R Top disc A Distributor V Oil water interface T y lt lt Unseparated oil Separated oil J Water SETTLING TANK 1810828 02 9 G0886431 1 SEPARATOR DESIGN SEPARATION UNIT 840 SERVICE MANUAL 1 5 2 Liquid flow U nseparated 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 norm
73. ntrolled from the control unit The required electric power is then supplied to the heater in accordance with the present load Contactor K11 is furnished with a variable overload protection relay F 11 8 5 2 Fixed Part Load Power to the fixed part loads 2 4 is fed via contactors K12 K16 and K17 and controlled from the control unit as on off functions in accordance with the present load The contactors are switched off by the heater safety switch function TS K 14 in the case of excessive temperature or low oil flow pump interlocking 152 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 8 HEATPAC POWER UNIT OPTIONAL 8 5 3 External Safety Stop The contactor circuits for switching power on off to the different part loads are interlocked by means of the external safety stop switch which iS connected in series to the internal temperature switch TS to prevent the electric heater from overheating The contactors K11 K12 K16 and K17 in the power unit are connected in series to the internal temperature switch TS Excessive temperature or no oil flow pump stopped will deactivate the contactors thus switching off the heater Overload relays fuses F11 F12 F16 and F17 in the power unit are used for overload protection 8 5 4 Start and Reset Functions During normal operation the contactors in the power unit are activated from the Control Unit and interlocked by the pump starter and contactor
74. o vs om a mens os as wm amo mr om a sesso os as o amo me om ee 7 _sezsse os ass wm emo oy om oe sears os ass s eo er om a ss os as s smo ee om ee mna os ass s woo sa om ee mna os ass s aso ver om a mne os ass s wo a7 om oe mr os ass s oo vs os aa Ist l starting current rated current at direction line starting The 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 ZC Indian Register of Shipping IRS Maritime Register of Shipping IRS Required classification society must always be specified when ordering Factory test certificate to be enclosed at the delivery Rated output kW valid for temp rise max 90 C The motors can be provided with space heaters for 110 V or 220 V 25 W as option 1810828 02 31 2 TECHNICAL REFERENCE SEPARATION UNIT 840 SERVICE MANUAL 2 5 Nomogram paring tube Alfa Laval ref 566504 rev O Calculated level ring o 80 1 000 41 5 0 950 42 5
75. or 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 4 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 1 SEPARATOR DESIGN 1810828 02 Pipe Spring Uncleaned oil EZ Cleaned oil mp Water Arm Paring tube Paring disc Connection house G0886141 1 SEPARATOR DESIGN SEPARATION UNIT 840 SERVICE MANUAL 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
76. ots that can be difficult to detect and goes on to local damage If damage exceeds 0 5 mm 0 2 such as pitting grooves or cracks mm for bowl body and bowl hood contact Alfa Laval Other metal parts Aggressive Possible corrosion damage can be If damage exceeds 0 5 mm contact environment in the form of pits and or cracks 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 76 1810828 02 G0205241 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 3 4 3 Inspection for cracks i 2 o 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 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 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 Disintegration hazards 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 fo
77. ported 4 Removing the friction blocks 70 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 Crush hazard If not supported the motor with coupling will drop when removing the screws d Lower the motor onto a suitable pallet a Remove the snap ring cover and friction blocks vacuum or a damp cloth 50 Hz 5 Friction blocks 60 Hz 3 Friction blocks 1810828 02 Friction blocks 3 60 Hz Cover G0864641 G0865231 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 5 Checking the condition of the friction blocks Ee 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 blocks 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 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 1810828 02 71 G0865331 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARA
78. r other parts Do not continue to use the separator until it has been inspected and given clearance for operation by Alfa Laval 1810828 02 17 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 4 4 Inspection for erosion Hite LL 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 Erosion is characterised by 1 Burnished traces in the material 2 Dents and pits having a granular and shiny surface Bowl body and holder Holder and operating N Paring disc and paring tube Lock ring Pillars between the sludge ports in the bowl wall The underside of the distributor in the vicinity of the distribution holes and wings 1 Inspect the bowl and inlet outlet parts for erosion damages 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 78 1810828 02 The sealing edge of the discharge slide for the seal ring in the bowl hood G0911831 SEPARATION UNIT 840
79. rs The separator is equipped with a speed sensor As options an unbalance sensor and an interlocking kit can befitted Speed sensor Monitoring kit option A speed sensor indicates the speed of the separator The For indication of any abnormal unbalance the separator can correct speed is needed to achieve the best separating be eq uipped with a sensor monitoring the radial position of results and for reasons of safety Refer to name plate for the bowl spindle speed particulars i i i i 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 a Speed sensor 8 1810828 02 G0873471 SEPARATION UNIT 840 SERVICE MANUAL 1 SEPARATOR DESIGN 1 5 Separating Function The separator separates water and solids from the und eaned 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
80. rt Top up when necessary Do not overfill If not otherwise specified follow the suppliers instructions about applying handling and storing of lubricants 1810828 02 125 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 7 5 Lubricants Alfa Laval ref 553217 01 rev 7 Pastes for non food applications 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 Designation Alfa Laval No Fuchs Lubritech Gleitmo 805 K Gleitmo 705 K Dow Corning Molykote 1000 Paste 537086 02 1000 g Molykote 1000 Paste 535586 01 100 g Molykote G rapid plus 535586 02 50 g Paste Bonded coatings Fuchs Lubritech Gleitmo 900 Varnish or spray Dow Corning Molykote D321R Spray 535586 01 300 ml Molykote D321R Varnish 535586 02 60 ml 126 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY Silicone grease for rubber rings Manufacturer Designation Alfa Laval No Dow Corning Molykote 111 Compound 539474 02 100g Molykote 111 Compound 539474 03 25 g Fuchs Lubritech Gleitmo 750 SS Greases for ball and roller bearings Always follow the specific recommendation
81. s on the separator Clean the nozzle on the operating slide using a soft iron wire discs may cause cuts or a similar object Driving device Use a sponge or a soft brush and clean the oil orifice bearing White spirit cleaning grade kerosene holder and oil pump thoroughly or diesel oil Centrifugal Use a sponge or a soft brush White spirit cleaning grade kerosene clutch or diesel oil 1810828 02 75 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 4 2 Inspection for corrosion gt 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 v Disintegration hazards 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 Type of corrosive Appearance environment Non stainless steel Water or dampness Rust If damage exceeds 0 5 mm contact and cast iron parts Alfa Laval Stainless steel Chlorides or acidic Acidic solutions cause general Polish dark coloured spots and solutions corrosion other corrosion marks with a fine grain emery cloth This may prevent Chloride corrosion begins as small further damage dark sp
82. t the springs enter the recesses in the top bearing seat The plugs should be tightened when the spindle assembly is mounted into the frame 1810828 02 93 0866621 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 5 Fitting the spindle pulley a Turn the spindle assembly upside down b Wipe off the spindle pulley c Fitthe spindle pulley seat on the spindle and nave firmly on the bowl bore in the spindle pulley with spindle a dry cloth i KA At least 1mm free space between support and spindle assembiy to protect the bearing Wo D Mount the cap nut to protect the se threads and support the spindle 6 Fitting the self aligning roller bearing E gt a Heat the bearing in oil to maximum 125 Always fit a new bearing Pre lubricate before fitting T A QS nr a gt S Burn hazard Use protective gloves when handling the heated bearing b Lower the bearing onto the spindle and press down onto the spindle pulley using the special mounting tool 94 1810828 02 G0866841 G0866731 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 7 Fitting the oil pump a Fit O ring onto lubrication oil orifice Spread oil film on c Lubricate all threads with a few O ring drops of oil before assembl
83. tch hub b Place the cover in position and secure it with the snap ring P Snap ring 0 wl Cover 1810828 02 G0865451 SEPARATOR SERVICE DISMANTLING ASSEMBLY O SEPARATION UNIT 840 SERVICE MANUAL 4 Fitting the motor a Fit a lifting sling to the 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 Crush hazard lt will set on the ledge If not supported the motor with coupling may drop when lifted c Fit the screws eo Se Do not tighten until the gt belt has been mounted d Connect the electrical cables If carrying out change of friction blocks only continue with steps 5 to 6 If carrying out a complete machine assembly continue with the driving device instructions on page 90 1810828 02 87 G0864641 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 5 Fitting the flat belt 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 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 Do not turn the spindle un
84. ternal and internal surfaces of the ball bearings ED Mounting tool c Press the ball bearings down one at atime into the coupling hub preferably using a hydraulic press Place the spacing ring between them Never re fit used ball bearings The ball bearings must not be heated as they are packed with grease and sealed with plastic wl membranes D d Fitthe snap rings 84 1810828 02 G0865621 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 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 b Apply lubricating paste to the tool the motor shaft threads keep lubricated c 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 1810828 02 85 G08654D1 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL Assembly of friction blocks 86 3 Fitting the friction blocks Guide pin a Fit the friction blocks onto the guide pins 50 Hz 5 Friction blocks 60 Hz 3 Friction blocks Be sure that the pins on the back of the blocks project into the grooves in the clu
85. 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 6 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 1 SEPARATOR DESIGN lt gt Sloe Ku Zi I Water paring chamber S Bowl hood Top disc Bowl body Oil paring chamber Disc stack Lock ring Seal ring Discharge slide Operating slide Sludge space SENA Nozzle DZ Holder Operating water ring 1810828 02 G0886951 1 SEPARATOR DESIGN SEPARATION UNIT 840 SERVICE MANUAL 1 4 Senso
86. the maintenance log and description in 3 4 Actions Before Assembly page 4 3 Fit all the parts delivered in the service kit while assembling the separator as described in chapter 3 5 Assembly page 54 4 When the separator is assembled make final checks described in 3 6 Actions After Assembly page 121 Disintegration Hazards Separator parts that are either missing worn beyond their safe limits or incorrectly assembled may cause severe damage or fatal injury Burn 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 service symbols in the dismantling assembly instructions Parts that have to be renewed from the service kits see below are marked j and or in the assembly instructions 36 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY Example a Fit the O ring ni When dismantling and assembling between the service periods some procedures do not have to be carried out These procedures are marked DH and or ED 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 Metric Stainless steel Carbon steel thread HL i
87. til the motor is tightened properly to the frame 88 1810828 02 G08588D1 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 6 Fitting the clutch cover 0 b Tighten the screws G0858141 a Fit the clutch cover 1810828 02 89 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 5 2 Driving device 1 Fitting the bottom bearing holder a Fit the wing insert O rings and strainer lt gt Clean the strainer and bearing Ug holder thoroughly before fitting Ss be b Secure the wing insert l with the screw secured d Thread the bottom bearing with Loctite 222 holder into the frame and fit the tool into the bottom bearing housing c To secure the bottom AN bearing holder into the frame apply Loctite al 222 on the surfaces directly above and below the upper O ring Socket Tool TSS fi Bottom bearing holder e Tighten the holder to a torque of 200 Nm 90 1810828 02 G0866191 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 2 Fitting the labyrinth ring holder a Fit the O ring using silicone grease ED b Lubricate and fit the labyrinth ring ED c Fit and seal the holder with Loctite 222 Fit and tighten the screws
88. tion and thermal desintegration It must also have good corrosion protection properties 6 1 1 Manual Cleaning Manual cleaning is carried out as follows 1 Disconnect the heater Drain the heater Flush the heater through with fresh water Drain the heater from water ul A W N Fill the heater with hot cleaning liquid 50 70 C Use the type and concentration required for the deposits present 6 Let the liquid stay in the heater for at least 60 minutes If possible let the cleaning liquid circulate in the heater 7 Drain the cleaning liquid 8 Flush through with clean water 9 Reconnect the heater using new gaskets Take care to reinstall the heater the right way up 1810828 02 139 6 HEATPAC CBM HEATER OPTIONAL SEPARATION UNIT 840 SERVICE MANUAL 140 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 7 HEATPAC EHM ELECTRIC HEATER OPTIONAL 7 Heatpac EHM Electric Heater Optional 7 1 Technical Data Media Max testing pressure Operating pressure and media temp Material Heating element Pressure vessel Cover Insulation Mounting style Voltage supply Connections Terminal box Elements resistance surface load output Tightening Torques Flange bolts Mineral oil 2 4 MPa 24 bar According to PN 16 Max 1 6 MPa 16 bar up to 150 C Max 1 5 MPa 15 bar up to 160 C Aluminium Pressure vessel steel Aluminium 20 mm mineral wool Vertically or horizont
89. tool c Compress the disc stack by alternately tightening the screws on the compressing tool a maximum of 40 Nm ata time b Screw in the screws to stop Be sure not to cover the threaded holes d Fit the dismantling screws to the bowl body and press out the lock ring by tightening the screws successively going counter clockwise Start with the screw nearest the lock ring end the one without the guide pin The lock ring can be removed when it has passed the edge of the groove e Remove the lock ring from the groove 7 eae 4 f Remove the Wg ly dismantling screws A Ss ZA D b 1810828 02 47 G0862751 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 48 2 Removing the bowl hood a Loosen the screws on the compressing tool Remove the tool Remove the lock ring b Fit the puller c Fit the compressing tool Loosen the screws de compress on the compressing tool Pull the bowl hood off by continuing to unscrew the screws d Remove the compressing tool and attach the lifting eyes to the puller and lift off the bowl hood Crush hazard The top disc can adhere to the bowl hood when lifting Be careful not to accidental
90. tor for pump Pt 100 temp sensor to internal high temp switch Power to heater Safety alarm feedback to control unit 1810828 02 149 8 HEATPAC POWER UNIT OPTIONAL SEPARATION UNIT 840 SERVICE MANUAL 8 2 Working principle Power for the electric heater is supplied from an external power source via the main switch and the different contactors The contactor K 11 supplies power to a variable heater load of 0 7 8 kW or 0 14 16 kW which is controlled from the triac modules A1 and AZ This contactor is activated at all times once the heater is started and as long as the control unit signals no function fault The remaining contactors K12 and K16 K 17 if applicable supply power to fixed heater loads as on off functions in accordance with the size of the heater By combining the variable load and the fixed loads an overall stepless heater is achieved 8 3 Electric Heater Function By using the proportional and integral PI functions in the EPC it is possible to activate the power unit load functions to feed the electric heater with variable and fixed power The power unit is equipped with the necessary contactors fuses and terminals The power unit also holds two triac modules A1 and A2 for regulating the variable load The electric heater requires an extra temperature sensor on the heater connected to a temperature switch in the power unit to prevent overheating 150 1810828 02 SEPARATION UNIT 84
91. 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 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 2 TECHNICAL REFERENCE 2 3 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 e The separator is correctly assembled e All connections are made according to Connection List Interconnection Diagram and Interface Description e The separator control system is activated If above conditions are not fulfilled the separator will be in SERVICE mode Stand still means e The power to the separator motor is off e The bowl is not rotating Starting means e The power to the separator motor is on e The bowl is rotating and accelerating Running means e The power to the separator motor is on e The bowl is rotating at full speed e RUNNING is a collective denomination for a number of sub modes which e g can be STAND BY Separator is in a waiting mod
92. ue to solidification see Connection List Signal processing in PRODUCTION e Automatic discharges shall be initiated by timer or ALCAP system 1810828 02 25 2 TECHNICAL REFERENCE SEPARATION UNIT 840 SERVICE MANUAL Signal processing in CLEANING e Automatic discharges shall be initiated by timer or CIP control system Signal processing in NORMAL STOP e Discharges should not be made Signal processing in SAFETY STOP and EMERGENCY STOP e Discharges should not be made 26 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 2 TECHNICAL REFERENCE 2 4 Drawings 2 4 1 Basic size drawing Alfa Laval ref 562557 rev 3 a n A pes Z me ZAN gt ep i imma pan K a NI SS Bt 375 Z ISO G 1 2 J 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 2 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 M10 E M10 depth 30 F g28 depth 45 G g22 depth 45 1810828 02 27 GO8676D1 2 TECHNICAL REFERENCE SEPARATION UNIT 840 SERVICE MANUAL 2 4
93. vel 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 1810828 02 123 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 3 7 2 Check oil level 1 Remove the oil pin and make sure that the oil level is above the lower end of the pin 3 7 3 Oil change procedure i Remove the oil pin plug and washer 2 Remove the drain plug Burn hazard The lubricating oil and various machine surfaces can be sufficiently hot to cause burns Collect the oil in a vessel 4 Fit and tighten the drain plug 5 Fill with new oil until oil flows out of oil filler hole See 3 7 6 Lubricating oils page 128 6 Fit the washer and the oil filling plug Tighten the plug 7 Fit the oil pin Oil drain plug For Inspection service procedures See Fill oil in the oil sump on page 101 124 1810828 02 G08687C1 SEPARATION UNIT
94. x 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 1810828 02 13 2 TECHNICAL REFERENCE SEPARATION UNIT 840 SERVICE MANUAL Alfa Laval ref 562576 rev 3 Subject Value Une General technical data Motor power Gear ratio Gear ratio Alarm levels for vibration monitor connection 752 1st 2nd Bowl max inner diameter Discharge interval min max Max 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 Max power consumption Power consumption Starting time min max Stopping time min max Sound power Sound pressure Vibration level max Volume and capacity data Max hydraulic capacity bowl Bowl liquid volume Fixed discharge volume Sludge volume efficient total Lubricating oil volume Weight information Motor drive Bowl Separator total 14 9 5 292 82 243 82 0 3 0 45 279 2 240 1000 1100 2425 0 100 60 60 AL 111 2377 02 9220 9220 3000 3600 12 3 7 5 1 7 2 3 25 30 9 1 76 5 6 9 1 12 4 3 4 0 65 1 8 2 84 74 kW 50Hz 60Hz mm s mm minutes kg m kg m C minutes minutes r min 50Hz 60Hz r min 50Hz2 60Hz kW at starting up 50H
95. y b Push lubrication oil orifice into oil pump Be sure to line up tabs on orifice with slots in pump A Li j i O d Fit the oil pump 65 5 Nm using Ez zn spanners Clean the oil pump and make sure that the bottom hole is not clogged 1810828 02 95 G0866961 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY SEPARATION UNIT 840 SERVICE MANUAL 8 Fitting the fan Key grip a Turn the spindle assembly up side down Ensure that the spindle is seated against the inner ring of the ball bearing b Apply a thin layer of silicone grease and fit the O rings into the fan Make 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 the air deflector a Turn the spindle assembly up side down and fit the air deflector 96 1810828 02 G0924061 G0859231 SEPARATION UNIT 840 SERVICE MANUAL 3 SEPARATOR SERVICE DISMANTLING ASSEMBLY 10 Lowering the spindle assembly into the frame a Remove the cap nut from the spindle Fit the lifting tool to the spindle assembly and lift it Crush hazard Do not rotate the spindle assembly during lifting The spindle assembly may otherwise come loose from the lifting tool Check that the
96. z 60 Hz kW idling at max capacity minutes minutes Bel A dB A mm sec new sep sep in use m3 h litres litres litres litres kg kg kg 1810828 02 SEPARATION UNIT 840 SERVICE MANUAL 2 TECHNICAL REFERENCE 2 2 Connection List Alfa Laval ref 562527 rev 2 ection Roemer Inlet for process liquid Min 0 C max 100 C See demand specification e Allowed temperature e Max allowed density e Allowed flow Max 9 m h Inlet for conditioning and displacement liquid e Instantaneous flow 1 6 litres minute 220 Outlet for light phase clarified liquid e Counter pressure 0 250 kPa 222 Outlet for solid phase e Small discharge Total discharge e Large discharge Max 24 discharge h e Discharge frequency The outlet from the cyclone must always be arranged to prevent the cyclone from being filled up with sludge Solids are discharged by gravity Inlet for discharge and make up liquid e Quality requirements See Technical Data in the nstallation System Reference Max 1000 kg m min 150 kPa e Max density e Pressure Make up liquid e Flow momentary 2 8 litres minute 1 7 litres hour e Consumption e Interval 5 minutes Tine 3 seconds Discharge liquid Flow 11 litres minute e Consumption 0 55 litres discharge Tim 3 seconds Closing liquid e Flow 2 8 litres minute e Consumption 0 7 litres discharge Time 15 seconds 181

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