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Service Manual
Printed
Apr 2000
Book No.
1810645-02 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:
Contents
1
2.9
2.9.1
2.9.2
2.10
2.10.1
2.10.2
2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
2.3.8
2.3.9
2.3.10
2.4
2.4.1
2.4.2
2.5
2.6
2.7
2.7.1
2.7.2
2.8
2.8.1
Periodic maintenance...................10
Introduction...........................................10
Maintenance intervals ..........................10
Maintenance procedure .......................12
Service kits ...........................................12
Maintenance Logs..........................13
Daily checks .........................................13
Oil change - monthly ............................13
IS - Intermediate Service ......................14
MS - Major Service ...............................15
Check points at
Intermediate Service ....................17
Corrosion ..............................................17
Erosion..................................................19
Cracks ..................................................20
Discharge mechanism .........................21
Bowl hood and sliding bowl bottom .....21
Spindle top cone and bowl body nave 24
Threads of inlet pipe, paring disc ........24
Threads on bowl hood and bowl body.25
Priming of bowl parts............................26
Disc stack pressure..............................27
Check points at
Major Service...................................28
Paring disc height adjustment..............28
Radial wobble of bowl spindle .............29
3-year service ..................................30
Lifting instructions ........................31
Cleaning ............................................32
Cleaning agents ...................................33
Cleaning of bowl discs .........................34
Oil change.........................................35
Oil change procedure ..........................35
Dismantling/Assembly ................... 43
3.1
3.1.1
3.1.2
3.2
3.2.1
3.2.2
3.3
3.3.1
3.3.2
3.4
3.4.1
3.5
3.5.1
3.6
3.7
3.7.1
3.7.2
3.8
3.8.1
1810645-02
Vibration............................................37
Vibration analysis..................................37
Vibration switch (optional) ....................38
General directions .........................39
Ball and roller bearings ........................39
Before shut-downs................................42
4.6.5
4.7
4.7.1
4.7.2
4.7.3
4.7.4
4.8
4.8.1
4.8.2
4.8.3
Cleaning in Place,
Heatpac CBM Heater............... 127
Heatpac EHM
Electric Heater (Optional)..... 130
8.1
8.2
8.2.1
8.2.2
8.2.3
1810645-02
1 SEPARATOR BASICS
1 Separator Basics
1.1 Design and function
1.1.1 Application
The P100 is a high-speed centrifugal separator
intended for marine and land applications. It is
specifically designed for cleaning of mineral oils
from water and solid particles (sludge). The
cleaned oil is discharged continuously, while the
sludge is discharged at intervals.
G0464881
R
DANGE
Disintegration hazards
Use the separator only for the purpose and
parameters (type of liquid, rotational speed,
temperature, density etc.) specified in chapter 4
Technical Reference, page 92 and in the Purchase
Order documents.
Consult your Alfa Laval representative before any
changes outside these parameters are made.
1810645-02
1 SEPARATOR BASICS
1.1.2 Design
The P100 separator comprises a frame consisting
of the frame lower part, the intermediate part
and the frame top part with a frame hood.
The separator bowl (C) is driven by an electric
motor (A) via a flat-belt power transmission (D)
and bowl spindle (B). The motor drive is
equipped with a friction coupling to prevent
overload.
1810645-02
G0739541
Sectional view
Main parts, inlets and outlets
A
B
C
D
E
Electric motor
Bowl spindle
Bowl
Flat belt
Closing water tank
1 SEPARATOR BASICS
G0112361
F
G
H
I
K
L
R
S
T
U
1810645-02
Paring disc
Disc stack
Sludge space
Top disc
Gravity disc
Sludge ports
Bowl body
Bowl hood
Distributor
Paring chamber cover
1 SEPARATOR BASICS
G0112371
Displacement of oil
Gravity disc
1810645-02
Sludge space
Top disc
Gravity disc
Normal interface position
Interface position just before
discharge
1 SEPARATOR BASICS
Clarifier disc
1810645-02
G0112371
1 SEPARATOR BASICS
Bowl opening
Bowl closing
G0112521
1810645-02
1 SEPARATOR BASICS
G0112721
Bowl spindle
Fan
Rubber buffers
Oil pump
Sleeve
Belt drive
G0112821
Friction coupling
G0112911
1810645-02
1 SEPARATOR BASICS
S0 0 0 9 4 1 1
G0548421
1810645-02
1 SEPARATOR BASICS
1.2 Definitions
Back pressure
Clarification
Clarifier disc
Counter pressure
Density
Gravity disc
Interface
Intermediate
Service (IS)
Phase
Purification
Sediment (sludge)
Sludge discharge
Throughput
Viscosity
Water seal
1810645-02
2 SERVICE INSTRUCTIONS
2 Service Instructions
2.1 Periodic maintenance
2.1.1 Introduction
Periodic, preventive maintenance reduces the
risk of unexpected stoppages and breakdowns.
Maintenance logs are shown on the following
pages in order to facilitate periodic maintenance.
R
DANGE
Disintegration hazards
Separator parts that are worn beyond their safe limits
or incorrectly assembled may cause severe damage
or fatal injury.
10
1810645-02
2 SERVICE INSTRUCTIONS
Service schedule
Oil change
Intermediate Service = IS
Major Service = MS
3-year Service
MS
IS
IS
Installation
IS
IS
MS
IS
IS
1st year
IS
IS
MS
IS
2nd year
IS
IS
IS
IS
IS
IS
MS
IS
3-year
Service
Other
1810645-02
11
2 SERVICE INSTRUCTIONS
12
1810645-02
S0 0 2 1 0 3 1
2 SERVICE INSTRUCTIONS
Part
Page
Notes
Connecting housing
Separator bowl
Oil level
Electrical motor
Check for vibration, heat and
noise
See manufacturers instructions
Part
Page
Notes
Belt tension
83
Change
35
1810645-02
13
2 SERVICE INSTRUCTIONS
Local identification:
P100
Manufacture No./Year:
Product No.:
Date:
Signature:
881099-05-01
Renew all parts included in the Intermediate Service kit (IS) and do the following activities.
Main component and activity
Part
Page
24
Paring disc
24
Separator bowl
Clean and inspect
Check
Bowl hood
25
Top disc
34
Bowl discs
34
Distributor
21
21
Discharge mechanism
21
25
24
27
25
17 - 19
Power transmission
Check
83
Change
35
Electrical motor
Lubrication (if nipples are fitted)
14
114
114
1810645-02
Notes
2 SERVICE INSTRUCTIONS
Local identification:
P100
Manufacture No./Year:
Product No.:
Date:
Signature:
881099-05-01
Renew all parts included in the Intermediate and Major Service kits and do the following
activities.
Main component and activity
Part
Page
Notes
24
Paring disc
24
Separator bowl
Clean and inspect
Check
Bowl hood
25
Top disc
34
Bowl discs
34
Distributor
21
21
Discharge mechanism
21
25
24
28
27
25
1810645-02
17 - 19
15
2 SERVICE INSTRUCTIONS
Part
Page
66
Oil pump
66
Water tank
89
Pump sleeve
Bowl spindle
63
63
29
Clean
Oil sump
35
Change
Oil
35
88
Friction coupling
77
Check
Oil sump
Friction coupling
Clean and inspect
Electrical motor
Replace
Bearings1)
1)
16
114
114
1810645-02
Notes
2 SERVICE INSTRUCTIONS
R
DANGE
G0172111
Disintegration hazard
Inspect regularly for corrosion damage. Inspect
frequently if the process liquid is corrosive.
1810645-02
17
2 SERVICE INSTRUCTIONS
Stainless steel
in a crevice,
covered by deposits,
S0020611
R
DANGE
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 the part if corrosion can be suspected of
affecting its strength or function.
18
1810645-02
S0020511
2 SERVICE INSTRUCTIONS
2.3.2 Erosion
Erosion can occur when particles suspended in
the process liquid slide along or strike against a
surface. Erosion can become intensified locally
by flows of higher velocity.
R
DANGE
Disintegration hazard
Inspect regularly for erosion damage. Inspect
frequently if the process liquid is erosive.
G0205221
1810645-02
19
2 SERVICE INSTRUCTIONS
2.3.3 Cracks
Cracks can initiate on the machine after a period
of operation and propagate with time.
R
DANGE
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
20
1810645-02
2 SERVICE INSTRUCTIONS
G0121511
G0071031
1810645-02
21
2 SERVICE INSTRUCTIONS
G0071121
22
1810645-02
2 SERVICE INSTRUCTIONS
G0071231
G0071221
1810645-02
23
2 SERVICE INSTRUCTIONS
G0071611
24
1810645-02
2 SERVICE INSTRUCTIONS
G0071311
Wear
G0578111
(MAX 25 )
R
DANGE
Disintegration hazards
Wear on threads must not exceed safety limit. f mark
on bowl hood must not pass f mark on bowl body by
more than 25.
1810645-02
25
2 SERVICE INSTRUCTIONS
Damage
Contact surfaces to inspect on the bowl
ON
CAUTI
Cut hazard
G0071511
26
1810645-02
G0887731
Before assembly:
2 SERVICE INSTRUCTIONS
If one or more discs have been added recheck the disc stack pressure by repeating
the procedure above.
G0071911
1
2
3
Bowl hood
Bowl body
Disc stack. Number of discs
- below wing insert: 42
- above wing insert: at least 41
NOTE
G0357651
1810645-02
27
2 SERVICE INSTRUCTIONS
28
1810645-02
G00729A1
G0883911
2 SERVICE INSTRUCTIONS
G0172951
G0121211
1810645-02
29
2 SERVICE INSTRUCTIONS
Friction coupling
30
1810645-02
2 SERVICE INSTRUCTIONS
NOTE
Make sure to remove the cap nut fixing the bowl to
the bowl spindle.
G0820621
NOTE
ING
WARN
Crush hazards
Use only the two special lifting eyes (M12) for lifting
the machine. They are to be screwed into the special
threaded holes.
Other holes are not dimensioned for lifting the
machine.
A falling separator can cause accidents resulting in
serious injury and damage.
1810645-02
31
2 SERVICE INSTRUCTIONS
2.7 Cleaning
External cleaning
G0615361
G0613661
32
1810645-02
2 SERVICE INSTRUCTIONS
S0008511
ON
CAUTI
1810645-02
33
2 SERVICE INSTRUCTIONS
Bowl discs
G0065831
Cut hazards
The discs have sharp edges that can cause cuts.
34
1810645-02
2 SERVICE INSTRUCTIONS
Pull out (A) the oil filling device and turn it half
a turn (B).
G0068911
ON
CAUTI
Burn hazards
G0173811
1810645-02
35
2 SERVICE INSTRUCTIONS
G0069211
36
1810645-02
2 SERVICE INSTRUCTIONS
2.9 Vibration
2.9.1 Vibration analysis
A separator normally vibrates and produces a
different sound when passing through its critical
speeds during run-up and run-down.
It also vibrates and sounds to some extent when
running. It is good practice to be acquainted with
these normal conditions.
Excessive vibrations and noise indicate that
something is wrong. Stop the separator and
identify the cause.
Use vibration analysis equipment to periodically
check and record the level of vibration.
G0075251
R
DANGE
Disintegration hazards
When excessive vibration occurs, keep bowl filled
and stop separator.
The cause of the vibration must be identified and
corrected before the separator is restarted.
Excessive vibration can be due to incorrect
assembly or poor cleaning of the bowl.
1810645-02
37
2 SERVICE INSTRUCTIONS
Back-off the setpoint adjusting screw counterclockwise (A) two or three turns. Press the
reset button. If the armature does not remain
in the reset position, turn the adjusting screw
another turn or two until the armature stays in
position when the reset button is pressed.
Back-off the adjusting screw counterclockwise a three-quarter turn. Press the reset
button. If the armature now rocks, turn the
adjusting screw counter-clockwise another
quarter turn and so on until the armature
remains in the reset position.
Refit the cap and fasten with the screws.
NOTE
Further adjustment may become necessary if alarm
occurs due to vibration from surrounding equipment.
38
1810645-02
G0546521
Setpoint adjustment
1. Adjusting screw
2. Pointer
A. Direction of increased checkpoint
(admit higher vibration)
2 SERVICE INSTRUCTIONS
G0587321
1.
2.
3.
4.
Outer race
Ball/roller
Inner race
Cage
NOTE
Using an incorrect bearing can cause a serious
breakdown with injury to personnel and damage to
equipment as a result.
Do not re-fit a used bearing.
Always replace it with a new one.
Dismantling
NOTE
Do not hit with a hammer directly on the bearing.
1810645-02
39
G0587411
2 SERVICE INSTRUCTIONS
G0587511
40
1810645-02
G0587611
2 SERVICE INSTRUCTIONS
G0587711
1810645-02
G0587211
41
2 SERVICE INSTRUCTIONS
G0466851
42
1810645-02
3 DISMANTLING/ASSEMBLY
3 Dismantling/Assembly
References to check points
Check point
S0051011
Tools
Screw driver
6, 7
G0278821
1810645-02
43
3 DISMANTLING/ASSEMBLY
Hammer
44
1810645-02
G0278921
3 DISMANTLING/ASSEMBLY
R
DANGE
1. Safety device
2. Nut
6. Insert
Entrapment hazard
The support ring is removed
from the frame hood top at
paring disc adjustment (Major
Service).
3. Inlet/outlet housing
5. Support ring
7. Height adjusting ring
8. Frame hood
9. Lock ring
G0073751
1810645-02
45
3 DISMANTLING/ASSEMBLY
20. Distributor
G0887711
46
1810645-02
3 DISMANTLING/ASSEMBLY
Left-hand thread
G0074221
1810645-02
47
3 DISMANTLING/ASSEMBLY
R
DANGE
Entrapment hazard
G0819751
G0467361
48
G0821531
Left-hand thread!
1810645-02
3 DISMANTLING/ASSEMBLY
G0070021
Left-hand thread!
G0070131
1810645-02
49
3 DISMANTLING/ASSEMBLY
G0070221
15
G0357411
attached.
50
1810645-02
3 DISMANTLING/ASSEMBLY
11 Lift out the top disc, the bowl discs with wing
G0357521
G0072031
special tool.
Ease the sliding bowl bottom off with the
central screw of the tool. If necessary, knock
on the handle.
G0070631
by jerking, or
by tightening the nuts equally
1810645-02
51
3 DISMANTLING/ASSEMBLY
G0070721
G0070821
52
1810645-02
G0070922
3 DISMANTLING/ASSEMBLY
Check point
2.3.1 Corrosion, page 17,
2.3.2 Erosion, page 19,
2.3.3 Cracks, page 20,
2.3.4 Discharge mechanism, page 21,
2.3.6 Spindle top cone and bowl body nave,
page 24,
2.3.7 Threads of inlet pipe, paring disc, page
24,
2.3.8 Threads on bowl hood and bowl body,
page 25,
2.3.10 Disc stack pressure, page 27,
2.4.1 Paring disc height adjustment, page 28.
1810645-02
53
3 DISMANTLING/ASSEMBLY
Left-hand thread
NOTE
Be sure bowl parts are not
interchanged.
28. Nozzle
54
1810645-02
G0074221
3 DISMANTLING/ASSEMBLY
NOTE
20. Distributor
G0887711
1810645-02
55
3 DISMANTLING/ASSEMBLY
1. Safety device
2. Nut
6. Insert
IS Intermediate service kit
MS Major service kit
3. Inlet/outlet housing
5. Support ring
7. Height adjusting ring
8. Frame hood
9. Lock ring
NOTE
Be sure bowl parts are not
interchanged.
Out of balance vibration
will reduce ball bearing
life.
G0073751
56
1810645-02
Oil
G0071721
3 DISMANTLING/ASSEMBLY
Check point
2.3.6 Spindle top cone and bowl body nave,
page 24 and 2.3.9 Priming of bowl parts, page
26.
G0071831
G0071841
1810645-02
57
3 DISMANTLING/ASSEMBLY
G0378031
a. Drill mark
b. Guide pin
c. Guide pin
G0378111
Left-hand thread!
G0072031
58
1810645-02
3 DISMANTLING/ASSEMBLY
Check point
Before assembling the bowl discs, check the
threads of the bowl hood and bowl body, see
2.3.8 Threads on bowl hood and bowl body,
page 25.
G0357561
Molykote
Paste1000
G0072231
1810645-02
59
3 DISMANTLING/ASSEMBLY
Check point
G0072361
R
DANGE
G0357711
Disintegration hazard
G0072721
60
1810645-02
3 DISMANTLING/ASSEMBLY
G0073341
G0074331
Molykote
paste 1000
Check point
1810645-02
G0073581
61
3 DISMANTLING/ASSEMBLY
G0172951
62
1810645-02
3 DISMANTLING/ASSEMBLY
Check point
2.4.2 Radial wobble of bowl spindle, page 29.
1. Lip seal ring
MS Parts to be renewed at
Major Service
2. Screen
3. Gasket
G0113281
1810645-02
63
3 DISMANTLING/ASSEMBLY
5. Deflector ring
6. Top bearing cover
7. Gasket
MS Parts to be renewed at
Major Service
8. Fan
9. Buffer holder
10. Rubber buffer
20. O-ring
G01131A1
22. O-ring
64
1810645-02
3 DISMANTLING/ASSEMBLY
G0113461
G 0 1 1 3 3 E1
1810645-02
65
3 DISMANTLING/ASSEMBLY
G0113521
G0113621
66
1810645-02
3 DISMANTLING/ASSEMBLY
Screw the cap nut counter-clockwise (lefthand thread) onto the spindle top to protect
the top and bore.
Left-hand thread
G0076132
G0076251
1810645-02
67
3 DISMANTLING/ASSEMBLY
thrust washer.
Puller
G0076321
In case of 3-year-service
G0093791
68
1810645-02
3 DISMANTLING/ASSEMBLY
G0113771
MS Parts to be renewed at
Major Service
2. Screen
3. Gasket
G0113271
1810645-02
69
3 DISMANTLING/ASSEMBLY
5. Deflector ring
G01131B1
Loctite 242
22. O-ring
70
1810645-02
3 DISMANTLING/ASSEMBLY
In case of 3-year-service
G0093781
G0113761
G0076341
1810645-02
71
3 DISMANTLING/ASSEMBLY
Mounting tool
G0113831
Oil
G0113941
72
1810645-02
3 DISMANTLING/ASSEMBLY
G0114341
G0076122
1810645-02
73
3 DISMANTLING/ASSEMBLY
G0114421
G0114521
Silicone grease
(thin layer)
74
1810645-02
3 DISMANTLING/ASSEMBLY
Silicone grease
(thin layer)
G0114661
Silicone grease
(thin layer)
G0114741
1810645-02
75
3 DISMANTLING/ASSEMBLY
Check point
2.4.2 Radial wobble of bowl spindle, page 29.
G01133A1
76
1810645-02
3 DISMANTLING/ASSEMBLY
R
DANGE
Entrapment hazards
Make sure that rotating parts have come to a
complete standstill before starting any dismantling
work.
1. Snap ring
2. Snap ring
5. Belt pulley
3. Ball bearings
5. Belt pulley
6. Coupling hub
7. Friction element
8. Cover
9. Snap ring
10. Washer
11. Spring washer
12. Screw
G0372121
1810645-02
77
3 DISMANTLING/ASSEMBLY
G0113391
G0077331
78
1810645-02
G0170841
3 DISMANTLING/ASSEMBLY
Mounting tool
G0171021
G0171131
1810645-02
79
3 DISMANTLING/ASSEMBLY
Loctite 641
G0171231
NOTE
Do not refit used bearings.
G0171321
Loctite 641
80
1810645-02
3 DISMANTLING/ASSEMBLY
Oil
Mounting tool
G0170921
G0171021
1810645-02
81
3 DISMANTLING/ASSEMBLY
G0077341
82
1810645-02
3 DISMANTLING/ASSEMBLY
R
DANGE
Entrapment hazards
Make sure that rotating parts have come to a
complete standstill before starting any dismantling
work.
G0884721
G0467361
1810645-02
83
3 DISMANTLING/ASSEMBLY
G0076622
G0473911
NOTE
G0885711
G0171531
84
1810645-02
3 DISMANTLING/ASSEMBLY
G0077341
G0489821
G0171661
1810645-02
85
3 DISMANTLING/ASSEMBLY
G0076622
G0477111
G0477211
86
1810645-02
3 DISMANTLING/ASSEMBLY
G0477311
NOTE
Do not start the separator unless the flat belt has
been re-tightened after 30 minutes.
If started, the belt may slip and be damaged.
1810645-02
87
3 DISMANTLING/ASSEMBLY
If plate (8) is to be replaced, wipe the sight glass (7) with a degreasing agent.
Fit the new plate on the outside of the sight glass. The plate is self-adhesive.
Mark the position of the plate relative to the recess in sleeve (1).
G0155811
Assemble the oil filling device and fit it into the frame. Note that the mark on sleeve (1) must be
positioned opposite the mark on the frame. Fill the sump with new oil.
5. Sealing ring
4. Nipple
2. O-ring
1. Sleeve for oil filling
7. Sight glass
88
1810645-02
G0155911
8. Plate
3. O-ring
3 DISMANTLING/ASSEMBLY
G0884711
2. Elbow
1. Water container
2. Elbow
3.7 Brake
3.7.1 Exploded view
5. Split pin
6. Brake handle
G0171731
3. Bracket
4. Cylindrical pin with hole
1810645-02
89
3 DISMANTLING/ASSEMBLY
A = Coupling surface
Molykote 1000 Paste
90
1810645-02
G0171931
Oil
3 DISMANTLING/ASSEMBLY
1810645-02
G0358351
91
4 TECHNICAL REFERENCE
4 Technical Reference
4.1 Technical data
Alfa Laval ref. 561687, rev. 0
Hydraulic capacity
Maximum density
feed
sediment
1100 kg/m3
2631 kg/m3
Operating liquid
Minimum 0 C
Maximum +100 C
Ambient temperature
Minimum +5 C
Maximum +55 C
Motor
Power consumption
idling
0,8 kW
1,8 kW
Bowl speed
9510/9305
3000/3600
Starting time
Stopping time
Running down
With brake
92
1810645-02
4 TECHNICAL REFERENCE
Empty bowl
180 minutes
Filled bowl
180 minutes
Bowl volume
1,5 litre
Discharge volume
Discharge interval
Minimum 2 minutes,
Lubrication
0,5 litre
69 dB(A)
Vibration level
New separator
Separator in use
Max. 9 mm/sec
Motor
Complete bowl
Approx. 35 kg
Weight
Materials
Volume
1,06 m3
Bowl spindle
stainless steel
Frame hood
stainless steel
brass
brass
NOTE
The separator is a component operating in an
integrated system including a monitoring system. If
the technical data in the system description does
not agree with the technical data in this instruction
manual, the data in the system description is the
valid one.
1810645-02
93
4 TECHNICAL REFERENCE
Connection
No.
Description
201
Requirements/limit
Permitted temperature
206
220
Maximum +100 C
minimum 0 C
Fresh water
Instantaneous flow
5,5 litres/minute
Pressure
150-600 kPa
221
No counter pressure
222
372
94
Instantaneous flow
18 litres/minute
Quality requirements
Pressure
150-600 kPa
Time
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Connection
No.
Description
373
Requirements/limit
Instantaneous flow
Quality requirements
Pressure
150-600 kPa
Consumption
377
462
463
701
753
4 TECHNICAL REFERENCE
5%
(10%)
Type
Mechanical switch
5A
12 V DC
2A
24 V DC
1A
48 V DC
0,5 A
120 V DC
7 A 460 V AC 50/60 Hz
Reset coil power supply max 14 W
48 V DC
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95
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G0922911
96
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G0922921
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97
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4.4.1 General
In addition to the 4.2 Connection list, page 94
this document describes limitations and
conditions for safe control, monitoring and
reliable operation.
At the end of the document a function graph and
running limitations are found.
4.4.2 Definitions
Start means:
98
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1810645-02
99
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G0543211
A
B
C
D
E
Stand still
Starting mode
Running mode
Stop mode
Safety stop mode
100
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101
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pH>6
Increased acidity (lower pH) increases the risk
for corrosion; this is accelerated by increased
temperature and high chloride ion content.
NOTE
Alfa Laval accepts no liability for consequences
arising from unsatisfactorily purified operating water
supplied by the customer
102
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4 TECHNICAL REFERENCE
4.6 Lubricants
G0112122
Lubricants
Lubricating oil.
Electric motor.
NOTE
The Lubrication chart, general can be complemented
with more detailed charts, showing the lubrication
points in detail and what type of lubricant to use.
Instructions related to a specific design of the
machine, refer to the general assembly drawings.
Some application processes demand special
lubrication.
If not specified otherwise, follow the suppliers
recommendation about method of application.
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4 TECHNICAL REFERENCE
ON
CAUTI
Check the oil level before start. Top up when
necessary.
Oil volume = see Technical Data.
104
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1810645-02
105
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Manufacturer Designation
Fuchs Lubritech
Gleitmo 805 K
Gleitmo 705 K
Dow Corning
Rocol
Kluber
Wolfracoat C (Paste)
537086-02 (1000 g)
535586-01 (100 g)
535586-02 (50 g)
Bonded coatings
Manufacturer Designation
Fuchs Lubritech
Dow Corning
106
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Manufacturer Designation
Dow Corning
539474-02 (100 g)
539474-03 (25 g)
Fuchs Lubritech
Gleitmo 750
Kluber
Unisilkon L 250 L
Wacker
Silicone P (Paste)
Manufacturer
Designation
BP
Energrease MM-EP2
Energrease LS2
Castrol
APS 2 Grease
EPL 2
Chevron
Elf
Epexa 2
Esso/Exxon
Beacon EP2
Unirex N2
Mobil
Gulf
Gulflex MP2
Q8/Kuwait Petroleum
Rembrandt EP2
Shell
SKF
LGEP2 or LGMT2
Texaco
Multifak AFB 2
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Time in operation
A/150
1500 h
D/220
2000 h
108
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4 TECHNICAL REFERENCE
NOTE
The data in below tables is based on supplier
information in regards to lubrication properties.
Trade names and designations might vary from
country to country, contact your local supplier for
more information.
Brands with Alfa Laval article number are approved
and recommended for use.
150
>95
Manufacturer
Designation
Alfa Laval
546098-80(20 litres)
546098-81(4 litres)
546098-82(208 litres)
546098-83(1 litre )
BP
Bartran 150
Castrol
Alpha ZN 150
Esso/Exxon
Nuto 10
Teresso 150
Terrestic 150
Mobil
Q8/Kuwait Petroleum
Haydn 150
Shell
Morlina 150
Tellus 150
Texaco/Caltex
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NOTE
The data in below tables is based on supplier
information in regards to lubrication properties.
Trade names and designations might vary from
country to country, contact your local supplier for
more information.
Brands with Alfa Laval article number are approved
and recommended for use.
220
>135
Manufacturer
Designation
Alfa Laval
542690-80(20 litres)
542690-81(4 litres)
542690-82(208 litres)
542690-83(1 litre)
BP
Castrol
Alphasyn EP 220
Chevron
Tegra 220
ELF
Epona SA 220
Esso/Exxon
Mobil
SHC 630
Q8/Kuwait Petroleum
Schumann 220
Shell
Paolina 220
110
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4.7 Drawings
4.7.1 Foundation plan
G0645721
A
B
C
D
E
F
Service area
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G0606231
NOTE
The motor bearings are permanent lubricated.
Manufacturer
ABB Motors
Size
90L
Type
M2AA 90L
Weight
16 kg
Poles
Insulation class
Bearings
Method of cooling
Specification
112
Type of mounting
IEC 34-7
Degree of protection
IEC 34-5
IM 1001
IM 3001
IP 55
IM 3011
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IM 3031
4 TECHNICAL REFERENCE
552807-01
2,5
2,2
3460
3435
60
60
Current
A
8,1
Power
Ist / |(1 Termist. Note
factor Cos. j
C(2
0,87
6,6
380Y
220D
4,7
8,0
0,90
5,9
255D
8,1
0,87
6,8
440Y
220D
4,7
8,0
0,90
5,9
255D
8,1
0,87
6,8
552807-02
552807-03
552807-04
552807-05
2,2
2,2
2,2
2,5
2870
2870
2870
3460
50
50
50
60
440Y
415Y
440 Y
200Y
240Y
4,7
4,3
4,1
8,9
4,7
0,87
0,87
0,87
0,87
6,6
6,6
6,6
6,8
Y-ser.
552807-06
2,5
3460
60
220Y
460Y
9,4
4,5
0,87
6,8
Y-par.
Y-ser.
60
50
50
50
50
50
60
60
60
60
60
60
60
60
230Y
575Y
400Y
230D
500Y
660Y
690Y
440Y
460Y
480Y
690Y
230D
220D
200D
380Y
9,0
3,6
4,5
7,8
3,6
2,7
2,6
4,7
4,5
4,3
3,0
9,0
9,4
10,3
5,4
552807-07
552807-09
552807-10
552807-11
552807-12
552807-13
552807-14
552807-15
552807-16
552807-17
552807-18
552807-19
552807-20
552807-21
2,5
2,2
2,2
2,2
2,2
2,2
2,5
2,5
2,5
2,5
2,5
2,5
2,5
2,5
3460
2870
2870
2870
2870
2870
3460
3460
3460
3460
3460
3460
3460
3460
0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87
1)
2)
3)
6,8
6,6
6,6
6,6
6,6
6,6
6,8
6,8
6,8
6,8
6,8
6,8
6,8
6,8
Y-par.
CSA-plated
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G0635131
S0061411
1. Machine plate
Separator
P100
XXXX
Product No
881099-05-01
561313-01
Bowl
561137-01
565390-01
50/60 Hz
1100 kg/m3
2332 kg/m3
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3. Safety label
Text on label:
S0061521
DANGER
Read the instruction manuals before
installation, operation and maintenance.
Consider inspection intervals.
Failure to strictly follow instructions can lead
to fatal injury.
If excessive vibration occurs, stop separator
and keep bowl filled with liquid during
rundown.
Out of balance vibration will become worse if
bowl is not full.
Separator must stop rotating before any
dismantling work is started.
S0063211
4. Name plate
60Hz
S0 0 6 3 1 1 1
50Hz
7. Label
Text on label:
Read the instruction manual before lifting.
A. Space for label indicating
representative
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G0075031
116
Oil temperature, C, F
Throughput, m3/h
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965 kg/m3
at 15 C (60 F)
Separation
temperature
70 C (158 F)
Throughput
1,5 m3/h
Example II in nomogram
Reference in graph: _ _ _ _ _ _ _
Oil density
875 kg/m3
at 15 C (60 F)
Separation
temperature
60 C (140 F)
Throughput
2 m3/h
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Storage
Specification
Upon arrival to the store, check all
components and keep them:
118
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Fixed on a pallet.
G0057111
Fixed on a pallet
G0057211
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Transport
Specification
During transport of the separator, the bowl
must always be removed from the machine
and transported separately.
ING
WARN
Crush hazard
Use correct lifting tools and follow lifting
instructions.
H = minimum 750 mm
120
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4 TECHNICAL REFERENCE
Introduction
G0020611
G0020721
Specification
See the 4.7.1 Foundation plan, page 111 for the
service space required with the separator
installed.
Recommendation
The spanner for the bowl hood should have
sufficient space to make a complete turn without
touching any of the ancillary equipment
surrounding the separator.
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Specification
A minimum height is required to lift the bowl,
bowl parts and the bowl spindle, see the drawing
4.7.1 Foundation plan, page 111.
Recommendation
When two or more separators are installed, the
lifting height may have to be increased to enable
parts from one separator to be lifted and moved
over an adjoining assembled separator.
Specification
The oil filling device must not be blocked by floor
plate arrangement, etc.
Recommendation
It should be possible to place a portable
collecting tray under the oil filling device drain
hole.
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4.8.3 Foundations
NOTE
When lifting a separator it must always be hung
securely. see separate lifting instructions in this
book.
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123
OP-Board
I/O-Board
124
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MT-Board
1810645-02
125
Set Pr 7 = 2.
Push
Reset Pr 7 = 0.
126
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6 CLEANING IN PLACE
6 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.
ING
WARN
Burn hazard
Shut off the oil flow and the heating medium flow
before starting maintenance work.
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127
6 CLEANING IN PLACE
ING
WARN
Corrosion hazard
Pay strict attention to the safety instructions for the
cleaning liquid used.
NOTE
Use only specified cleaning liquids. Other cleaning
agents may corrode the metal surfaces.
Proceed as follows:
After cleaning:
128
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Test pressure
225 C
Medium
Mineral oil
Heating media
8.8 - 9.2
sodium in condensate
Water:pH value
Thermal oil
Fill the heater with hot cleaning liquid (5070 C). Use the type and concentration
required for the deposits present.
1810645-02
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Mineral oil
According to PN 16:
Max. 1.6 MPa (16 bar) up to 150 C
Max. 1.5 MPa (15 bar) up to 160 C
Material:
Heating element
Aluminium
Pressure vessel
Cover
Aluminium
Insulation
20 mm mineral wool
Mounting style
Vertically or horizontally
Voltage supply
Connections
Terminal box
IP 65
Tightening Torques
Flange bolts
M16
240 Nm
Ground screw
M8
21 Nm
Connections on elements
M4
3 Nm
Element nut h = 9
M14
70 Nm
Element nut h = 5
M14
30-50 Nm
Relief valve
G1/2
80 Nm
G1/2
30 Nm
Temperature sensors
130
80 Nm
1810645-02
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G003313A
131
When reassembling:
ON
CAUTI
It is very important that the appropriate heater
element is installed.
132
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G003322A
1810645-02
133
134
1810645-02
G003171A
Voltage (V)
Part load 1
Part load 2
Part load 3
Part load 4
7 kW
400
42
----
----
----
8 kW
440
47
----
----
----
8 kW
480
55
----
----
----
7 kW
690 V
126
----
----
----
14 kW
400
21
----
----
----
16 kW
440
23
----
----
----
16 kW
480
28
----
----
----
14
690
63
----
----
----
22 kW
400
21
42
21
----
24 kW
440
23
47
23
----
24kW
480
28
55
28
----
22
690
63
126
63
----
36 kW
400
21
42
21
----
40 kW
440
23
47
23
----
40 kW
480
23
47
23
----
36
690
63
126
63
----
50 kW
400
21
42
21
21
56 kW
440
23
47
23
23
56
480
28
55
28
28
50
690
63
126
63
63
65 kW
400
21
42
21
11
72 kW
440
23
47
23
12
72kW
480
28
55
28
14
65
690
63
126
63
32
1810645-02
135
Control unit
Contactor box
136
Part load 1
Part load 2
Part load 3
Part load 4
X11:4-5
X11:7-8
X11:10-11
X11:13-14
X11:4-6
X11:8-9
X11:10-12
X11:14-15
X11:5-6
X11:7-9
X11:11-12
X11:13-15
X11:4-5
X11:7-8
----
----
X11:4-6
X11:8-9
----
----
X11:5-6
X11:7-9
----
----
----
----
K21:2-4
K22:2-4
----
----
K21:4-6
K22:4-6
----
----
K21:2-6
K22:2-6
1810645-02
External fuse
Max. 35 A
Overcurrent protection
Max. 23 A
External fuse
Max. 100 A
Overcurrent protection
Fuses, 25 A, 16 A, 25 A, 63 A
Max. 23 A
Control circuits
Control voltage
General
High voltage tested at 2000 V
Max. ambient temperature
55 C
Protection class
IP 65
Material
Steel
Weight
Smaller cabinet
40 kg
Larger cabinet
54 kg
Mains supply
Control signals (48 V AC)
Aux. contact on contactor for pump
Pt 100 temp. sensor (to internal high temp. switch).
Outputs
Power to heater
Safety alarm feedback to control unit
1810645-02
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138
1810645-02
G025651A
A
B
1.
2.
3.
4.
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)
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140
1810645-02
1810645-02
141
142
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