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Safety 1

SU 865 System Description


Separation
2
System

Operating Instructions
3

P
STO Parameter List
s an
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M anua l r e
n fo
uctio s be
dy Instr warning , service
Stu ve the tion
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insta aintena nts and/ ons are
and
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ri o u s ac the instr 5
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can llowed.
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no t f

Only foreseeable conditions have been taken into


consideration. No warnings are given for
Installation System
situations arising from unintended usage of the Reference 6
system components and tools.

Service Manual
Marine & Diesel Equipment
7

Spare Parts Catalogue


Printed Jan 2003
8
Book No. 1817289-02
Product No. 1010028-01, 1010035-01,
1010035-02
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 & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2003.
S-type Separation System

Safety
Printed Nov 2002
Book No. 1810569-02 V 3
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 & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2002.
S-TYPE SEPARATION SYSTEM SAFETY 1 SAFETY INSTRUCTIONS

1 Safety Instructions

Important – read this!

The centrifugal separator includes parts


that rotate at very high speeds, generating
huge forces. It is therefore essential for the
safe operation of this separator system that
you read and understand this manual,
including the warning signs and safety

P003702A
precautions presented in this manual.
Failure to do so may cause a fatal accident.

1.1 Key Factors for Safe


Operation
The separation system is designed and supplied
for a specific function (type of liquid, rotational
speed, temperature, density, etc.). The system

P0 0 3 6 2 3 A
must be used for this function only, and strictly
within Alfa Laval´s specifications.
Incorrect operation or maintenance may result
in a heavy unbalance, reduction of material
strength, etc. that could lead to serious
breakdown with fatal injury or damage to
property.
For safe operation, strictly follow the
instructions for installation, operation and
maintenance in this manual.

1810569-02 1
1 SAFETY INSTRUCTIONS S-TYPE SEPARATION SYSTEM SAFETY

The following is compulsory for safe


operation:
1 Never start up a separator before the bowl is
completely assembled, and all fastenings
securely tightened.
2 Never discharge a vibrating separator. Always
stop with the emergency stop button.
3 Never begin to disassemble a separator
before it has come to a complete standstill.
4 Always set the discharge intervals according
to instructions in the instruction book.
5 Never ignore alarms. Always eliminate the
cause before resuming operation.
6 Never use the separator for other liquids than
those specified by Alfa Laval.
7 Never operate a separator with a different
power supply frequency than stated on the
machine plate.
8 Clean the operating system regularly to avoid
sludge discharge malfunction.
9 Ensure that personnel are fully trained and
competent in installation, operation,
maintenance, and emergency procedures.
10 Use only Alfa Laval genuine spare parts and
the special tools supplied.

2 1810569-02
S-TYPE SEPARATION SYSTEM SAFETY 1 SAFETY INSTRUCTIONS

1.2 Warning Sign


Definitions
Below are definitions of the warning signs used.

Danger – serious injury or death Example:

This type of safety sign or instruction


R
indicates an imminently hazardous
! DANGE
situation which, if not avoided, will result in
death or serious injury.
Entrapment hazard
Make sure that rotating parts have come to a
complete standstill before starting any
dismantling work.

Warning – serious injury or death Example:

This type of safety sign or instruction indicates


ING
a potentially hazardous situation which, if not WARN
!
avoided, could result in death or serious injury.

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

Caution – minor or moderate injury Example:

This type of safety sign or instruction indicates


ON
a situation which, if not avoided, could result in CAUTI
!
minor or moderate injury.

‘CAUTION’ used without the safety alert Burn hazard


symbol indicates a potentially hazardous Various machine surfaces can be hot and cause
situation which, if not avoided, could result in burns.
equipment damage.

1810569-02 3
1 SAFETY INSTRUCTIONS S-TYPE SEPARATION SYSTEM SAFETY

1.3 Summary of Safety


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

Installation

ING
WARN
!

Crush hazard
When lifting the Separation Unit/Module, use only
the lifting eyes specifically for this purpose. Always
use a lifting beam.

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

ING
WARN
!

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

Continued on next page

4 1810569-02
S-TYPE SEPARATION SYSTEM SAFETY 1 SAFETY INSTRUCTIONS

ING
WARN
!

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

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

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

Breakdown hazard 50 Hz?


60 Hz?
Use the separation system for the purpose, and
within the limits, specified by Alfa Laval. Failure to

P0 0 3 6 0 6 A
do so could cause a violent breakdown.

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

ON
CAUTI
!

If power cable polarity has been reversed, the


separator will rotate in reverse, and vital rotating
parts can loosen.

1810569-02 5
1 SAFETY INSTRUCTIONS S-TYPE SEPARATION SYSTEM SAFETY

Operation

ING
WARN
!

Breakdown hazard
If strong vibration occurs, press the emergency
stop button and evacuate the room.
Never discharge a vibrating separator. Vibration
may then become violent and result in breakdown.

P003606A
N
ING CAUTIO
WARN !
!

Burn hazard
Noise hazard Avoid contact with
Use ear protection if hot surfaces.
noise levels are high. Process pipes,
various machine
surfaces, and
processed liquid can
be hot and cause
burns.
TT
PT
MT
C
B
PT
OP
PT

EPC-50 HEATER

INFO
SEPARAT
ION

STOP

DISCHAR
GE
ENTER
OP ACTIVE

ALARM

N
CAUTIO
!
ING
WARN
!
Slip hazard
Check all connections for
leakage. Breakdown hazard
Oil leakage may make Never reset an alarm without first
the floor slippery. finding and remedying the cause.
P004071A

6 1810569-02
S-TYPE SEPARATION SYSTEM SAFETY 1 SAFETY INSTRUCTIONS

Stop

ON
CAUTI
!

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

Never attempt to clean the bowl by manual discharge


in connection with stop.

Emergency stop

ING
WARN
!

Disintegration hazard

P003606A
If unusually strong vibration occurs, press the
Emergency Stop button and leave the room
Do not enter the room after an emergency stop
while the separator is still rotating.

ING
WARN
!

Disintegration hazard
Do not start the separator after an emergency stop
without first remedying the cause of the
emergency.
Make sure that the bowl is clean before restart.

1810569-02 7
1 SAFETY INSTRUCTIONS S-TYPE SEPARATION SYSTEM SAFETY

Maintenance

R
! DANGE

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

I00293AA
Disintegration hazards
Max. 0,2 mm
Always contact your Alfa Laval representative if
you suspect that the depth of the corrosion damage
exceeds 0.5 mm (0.2 mm for bowl body and bowl
hood) or if cracks have been found. Do not

G0205241
continue to use the separator until it has been
inspected and given clearance for operation by Alfa
Laval.

Disintegration hazard
Pits and spots forming a line may indicate cracks
beneath the surface.
All forms of cracks are a potential danger and are
totally unacceptable.
Replace any part where corrosion can be
suspected of affecting its strength or function.

Disintegration hazard
All forms of cracks are potentially dangerous as
they reduce the strength and functional ability of
components.
Always replace a part if cracks are present.

Disintegration hazard
Erosion damage weakens parts by reducing the
thickness of the material.
Pay special attention to the pillars between the
sludge ports in the bowl wall.
Replace parts if erosion is suspected of affecting
strength or function.

8 1810569-02
S-TYPE SEPARATION SYSTEM SAFETY 1 SAFETY INSTRUCTIONS

ING
WARN
!

Entrapment hazard
To avoid accidental start, switch off and lock power

I002933A
supply before starting any dismantling work.
Make sure that the separator has come to a
complete standstill before starting any dismantling
work.

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

I002935A
Disintegration hazard
Do not weld nor heat parts that are subject to high-
speed rotation.

I0 0 2 9 3 B A
Breakdown hazard
Assemble the separator completely before restart.
All couplings, covers, and guards must be in place
and properly tightened. Non compliance may lead
to breakdown.

P0 0 3 5 9 4 A

1810569-02 9
1 SAFETY INSTRUCTIONS S-TYPE SEPARATION SYSTEM SAFETY

ON
CAUTI
!

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.

10 1810569-02
S-type Separation System

System Description
Printed Nov 2002
Book No. 1810570-02 V 3
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 & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2002.
Contents

1 System Overview ................................. 1


1.1 Oil Flow................................................1
1.2 System Layout .................................2
1.3 Separation Unit Layout .................4
1.4 Separation Unit Options ................5
1.5 Modules ...............................................6
1.5.1 Single Module with Heatpac® CBM
Heater ....................................................6
1.5.2 Single Module with Heatpac® EHS
Heater ....................................................6
1.5.3 Double Module with Heatpac® CBM
Heater, In-Line ........................................7
1.5.4 Double Module with Heatpac® EHS
Heater, In-Line ........................................7

2 The Process............................................. 8
2.1 Principle ..............................................8
2.2 Process Cycle Start.......................10
2.3 Discharge..........................................12
2.4 Increased Water Content ............13

1810570-02
S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION

2 1810570-02
S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION 1 SYSTEM OVERVIEW

1 System Overview
The Separation Unit is designed for cleaning of Cleaned oil leaves the separator through the oil
fuel and lube oils for diesel engines, and fuel oil outlet while separated water and sludge
for gas turbine engines, in marine and power accumulate at the periphery of the rotating
applications. separator bowl.
Heated oil is fed through the separator to clean The control unit supervises the entire
the oil from solid particles and water. operation of the separation system, performing
monitoring, control, and alarm functions.
The basic separation unit comprises:
The process adapts automatically to certain
• A separator.
changes in conditions, such as increased water
• Ancillary equipment including control content in the unprocessed oil, high or low oil
cabinet. feed temperature, etc.
• Optional equipment such as, sludge
removal kit, butterfly valve, vibration sensor,
junction box for free positioning of the
control cabinet, etc.
The unit can be complemented with optional
equipment such as feed pump, heating system,
and flow regulation, in the form of a single or
double module.

1.1 Oil Flow Settling tank Change-over Backpressure


regulating
valve
valve
The unprocessed oil is fed through a heater by a
feed pump, operating at a constant flow.
A change-over valve directs the oil to the
separator. The cleaned oil is pumped from the
separator to either the daily service tank (fuel
oil), or back to the engine (lube oil).
During separator start and stop procedures,
during alarm conditions, or if the oil
temperature is outside the preset range, the oil
is directed by the change-over valve to a return
line back to the engine sump or settling tank. Pump Heater Separator Daily
service tank
P003714A

1810570-02 1
1 SYSTEM OVERVIEW S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION

1.2 System Layout

Heater Temperature Pressure transmitter, Pneumatically controlled Separator


transmitter (TT1, oil (PT1) change-over valve (V1)
Heats unprocessed Cleans the oil by
oil to separation TT2) removing water
Measures the pressure Directs the unprocessed oil to
temperature. Measures the oil in the oil inlet, and the separator, or back to the and solid
temperature and signals the control unit. settling tank (recirculation – particles.
signals the control fuel oil only).
unit.

Feed pump
Feeds
unprocessed oil to the
separator.

Unprocessed oil
inlet

Oil return
Conditioning water

Opening water
Water inlet
Closing water

Solenoid valve block, water Sludge outlet

Distributes separator opening/


Additional equipment closing water, and conditioning water.
not part of the SU

2 1810570-02
S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION 1 SYSTEM OVERVIEW

Control unit Pressure transmitter, oil Water transducer (MT50) Regulating valve (RV4)
(PT4) To manually regulate the
Supervises the separation Measures change in water
system. Measures the pressure in content in the cleaned oil, backpressure in the
the oil outlet, and signals the and signals the control clean oil outlet.
control unit. unit.

Pneumatically controlled
shut-off valve (V4)
Closes the clean oil outlet.

Clean oil outlet


to service tank

Water drain

Pressure transmitter,
water (PT5)
Drain valve (V5)
Measures the pressure in
the water drain outlet, and Opens to drain separated water
signals the control unit. from the separator.

1810570-02 3
1 SYSTEM OVERVIEW S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION

1.3 Separation Unit Layout

Combined regulating
valve (RV4) and shut-off
valve (V4)
Pressure
transmitter, oil
inlet (PT1)

Clean oil outlet


Operating
water
Temperature Operating air
transmitter
(TT1,TT2)
Water transducer
(MT50)
Oil inlet

Pressure transmitter,
oil outlet (PT4)
Oil recirculation
Control unit
EPC50
Change-over
valve (V1)

Pressure
Oil in transmitter,
water (PT5)

Oil out

Water
out Drain valve
(V5)

Sludge
outlet
P0 0 3 7 3 5 A

4 1810570-02
S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION 1 SYSTEM OVERVIEW

1.4 Separation Unit Options

Separation unit with junction


boxes

Separation unit with sludge


removal kit

Basic separation unit

Separation unit with junction boxes


and sludge removal kit
P004204A

1810570-02 5
1 SYSTEM OVERVIEW S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION

1.5 Modules

1.5.1 Single Module with Heatpac® CBM Heater

P0 0 4 1 4 1 A
1.5.2 Single Module with Heatpac® EHS Heater

P004151A

6 1810570-02
S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION 1 SYSTEM OVERVIEW

1.5.3 Double Module with Heatpac® CBM Heater, In-Line

P004161A
1.5.4 Double Module with Heatpac® EHS Heater, In-Line

P0 0 4 1 8 1 A

1810570-02 7
2 THE PROCESS S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION

2 The Process
2.1 Principle
During the separation process, sludge and
water accumulate at the periphery of the
separator bowl. Oil

Sludge and
water

P00356BA
Sludge and water are discharged at preset time
intervals. During discharge, the oil inlet is
closed.

P00356CA
Excessive water can also be drained from the
separator bowl between discharges.

The cleaned oil leaving the separator is tested


for traces of water. Any increase in water is MT
detected by the water transducer. Disc stack
Water
transducer

Water
P00356DA

8 1810570-02
S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION 2 THE PROCESS

The signal from the water transducer is


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

P0 0 3 5 6 EA

1810570-02 9
2 THE PROCESS S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION

2.2 Process Cycle Start

First the oil pump, separator, and heater are


started.
The temperature transmitter (TT) and the
speed transmitter (ST) signal the EPC-50
control unit continuously. When the correct
separator speed and the correct temperature
are reached, a sludge discharge is carried out to

P 0 0 3 5 6 FA
ensure the bowl is empty. The control unit then
starts the process cycle.

1 The change-over valve directs the oil to the


recirculation line. Conditioning water is
added to the separator bowl until the
pressure sensor in the oil outlet senses
pressure and signals the control unit.

P0 0 3 5 6 G A
2 The control unit registers the time taken for
water addition. This water flow reference
value is later used to calculate the correct
amount of conditioning water and
displacement water to be added.

3 The separator discharges.

P00356OA

10 1810570-02
S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION 2 THE PROCESS

4 Using the flow rate calculated in paragraph 2


above, the control unit signals the solenoid
valve to open so that the correct amount of
conditioning water is added to the separator
bowl.

P0 0 3 5 6 N A
5 The change-over valve opens so that oil is
directed to the separator bowl. When
pressure in the oil outlet is sensed, the
pressure sensor (PT) signals the control unit.
The control unit calculates and stores the
time taken to add oil to the bowl.

P00356MA
The cleaning process is now running.
Unprocessed oil is fed to the separator, and clean
oil is pumped from the separator.

1810570-02 11
2 THE PROCESS S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION

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

1 The change-over valve changes to oil


recirculation.

2 Using the flow rate calculated in paragraph 2


under 2.2 Process Cycle Start, page 10, the
control unit signals the solenoid valve to
open so that displacement water is added to
push the oil towards the disc stack.

P0 0 3 5 6 R A
3 After the calculated time for displacement
water addition has elapsed, the separator
discharges.

4 Conditioning water is then added, and a new

P00356JA
separation cycle begins.

12 1810570-02
S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION 2 THE PROCESS

2.4 Increased Water


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

1 The water drain valve (V5) opens for a


number of seconds.

2 The water drain valve closes again, and the


transducer signal is evaluated.
V5

P00356KA
3 If there is still an increase in water content,
the drain valve opens again. If the water
content is still high after the drain valve has
opened five times, a discharge is initiated.

4 If the water content has decreased, the


separation cycle returns to normal.

1810570-02 13
2 THE PROCESS S-TYPE SEPARATION SYSTEM SYSTEM DESCRIPTION

14 1810570-02
S-type Separation System

Operating Instructions
Printed Nov 2002
Book No. 1810571-02 V 5
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 & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2002.
Contents

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

1810571-02
1 OPERATING S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

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

ING
WARN
!

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

ING
WARN
!

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

P0 0 3 5 9 4 A
ING
WARN
!

Breakdown hazard
Check that the power frequency is in agreement with
the machine plate. If incorrect, resulting overspeed 50 Hz?
may cause breakdown. 60 Hz?
P0 0 3 6 0 6 A

ING
WARN
!

Use the separation system for the purpose, and


within the limits, specified by Alfa Laval. Failure to do
so could cause a violent breakdown.

2 1810571-02
S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

2 Check the oil sump level. If necessary,


unscrew the level stick-plug, and top up until
oil starts to run from the oil-filling hole.

NOTE

Too much or too little oil can damage the separator


bearings.

G0868542
Rotation Direction

To check the rotation of the bowl, do a quick


start/stop. The motor fan must rotate in a clockwise
direction.

ON
CAUTI
!

If power cable polarity has been reversed, the


separator will rotate in reverse, and vital rotating
parts can loosen.

NOTE

P0 0 3 5 9 3 A
To make this check, the Mode Selector Switch should
be in the CIP position.

1810571-02 3
1 OPERATING S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

Air Valve Block

Use the pressure gauge situated in the air valve


block to check that the air supply is correct
(500 – 700 kPa or 5 – 7 Bar).
For further information concerning air, see chapter

P003682A
1 Technical Data in the System Reference/
Installation Instructions booklet.

Operating Water Pressure

Check that the operating water pressure is


sufficient (200 – 600 kPa or 2 – 6 Bar).
For further information concerning water, see
chapter 1 Technical Data in the System Reference/
Installation Instructions booklet.

4 1810571-02
S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

1.2 Operators Panel


The operators panel (local) is positioned on the
upper part of the control cabinet. If the unit
contains an optional junction box, the control
cabinet can be positioned at a distance of up to
50 metres cable length from the unit.
A duplicate operators panel (remote) may be
connected for fully functional operation from a
remote location i.e. control room.
By using the REMIND TM software (see the
REMINDTM User’s Manual) it is possible to
operate the control cabinet from a remote
position with the aid of a PC.
For further information concerning
communication alternatives using REMIND TM
and the Remote Operators Panel, see the Remote
Operation Systems chapter in the System
Reference/Installation Instructions booklet.

1810571-02 5
1 OPERATING S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

General principle for changing control


parameters
The ‘Enter’ button is used to:
– enter into a parameter list
– enter into a parameter
– accept/store a new parameter value.
The ‘+’ or the ‘–’ buttons are used to change the
value flashing in the display window.

Process parameters
Set the process parameters to suit the
installation as follows:
1 Push ‘Enter’. Parameter no. 1 in the process
parameter list is shown.
You have now come to the process parameter
list. Go through the list and set parameters.
OP
2 When the parameters have been set, ‘End I/O’ TT PT MT PT

(flashing) shows. Push ‘+’. ‘Standst.’ now HEATER

PT
16 15 10
shows in the display. SEPARATION

STOP
EPC-50
For information on how to set discharge INFO
DISCHARGE

intervals, see chapter 3 Process Parameters in Standst. OP ACTIVE

ENTER

P00361HB
the Paramete list booklet. ALARM

NOTE

Make sure that the operators panel is ‘active’ (LED


green) before operating.

6 1810571-02
S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

1.3 Startup
The control panel mode switch has three
positions: ‘MANUAL’, ‘AUTO’, and ‘CIP’.

The ‘MANUAL’ mode is for use on all Separation


Unit systems. M AN

CIP AUT

G046604A
The ‘AUTO’ mode is for use on systems supplied
for fully automatic control and/or fully automatic M AN

remote control. The following general rules apply


for use of the ‘AUTO’ mode: AUT

• The EPC 50 must have control of the oil feed

G046605A
pump.
• The EPC 50 must have control of the heater.
• The EPC 50 must have control of vibration
monitoring.
• The cover interlock must be fitted.

The ‘CIP’ mode is for use with Cleaning in Place


equipment. See ‘‘Cleaning In Place” on page 19. M AN

CIP
CIP

G046606A

1810571-02 7
1 OPERATING S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1.4 Manual Startup


The first startup must always be carried out
manually.
Before startup make sure that all the main
supply valves for air, oil, and water are open.
Open heating media supply valve if applicable.
Switch on the power supplies. Make sure the
mode selection switch is in the ‘MANUAL’
position.

1 Start the oil feed pump from the pump starter.


The oil flow can be read on the display
(parameter In 32). If applicable, set the
M AN

desired flow using regulating valve RV4. CIP


AUT

G046600A
2 If necessary, vent air from the heater through
OP
the relief valve (if applicable).
Switch on the heater from the operator panel TT PT MT PT

HEATER

(if applicable). 16 15 10
PT
SEPARATION

STOP

EPC-50

NOTE
DISCHARGE
INFO

OP A CTIVE

ENTER
The operators panel must be’ active’ to allow
ALARM
operation.

P0 0 3 6 1 J B
3 Press the ‘SEPARATION’ button to activate the
OP
EPC-50.
TT PT MT PT

HEATER

PT
16 15 10 SEPARATION

STOP

EPC-50
DISCHARGE
INFO

OP A CTIVE

ENTER

ALARM
P00361LB

8 1810571-02
S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

Before the separator can be started, a number of


questions scroll across the display which have to
be answered:

‘Has the bowl been dismantled? + = YES, – = NO’

4 If the bowl has been dismantled press the ‘+’


button.

P0 0 3 6 1 4 A
If no work has been carried out on the bowl, press
the ‘–’ button. The start sequence begins and the
text ‘Start’ appears in the display.

P0 0 3 6 1 3 A
NOTE

If this is the first start, answer ‘YES’.

‘Assembled according to manual? + = YES, – =


NO’

5 If the bowl has been dismantled and

P003614A
assembled according to the instructions in the
Service Manual, press the ‘+’ button.

‘Bowl cleaned? + = YES, – = NO’

6 If the bowl has been cleaned press the ‘+’


button.

P003614A
An automatic calibration of the system is
carried out. See display.
.

7 Push the separator start button.

M AN

CIP
AUT
G046601A

1810571-02 9
1 OPERATING S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

8 Listen and observe.


Vibration may occur during start up, when
passing critical speeds.This is normal and
should pass without danger.
If vibration increases, or continues at full

P003606A
speed, press the emergency stop button and
stand clear until the vibration stops. The
separator and heater are stopped when the
emergency stop button is pushed. The feed
pump stops max. 3 minutes afterwards.
The emergency stop will only reset when the
speed sensor indicates zero speed.
Once the zero speed signal has been
received, the alarm reset button can be
pushed. The message ‘ Switch power on/off.’
will be displayed. This refers to the EPC 50
power indside the control cabinet.
The cause of vibration must be determined
and corrected before starting again!
See the Alarms and Fault Finding booklet.

ING
WARN
!

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

NOTE

If the system is equipped with a vibration sensor, and


has control of heater and feed pump, the Auto Start
can be used.

10 1810571-02
S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

9 The separator speed, and ‘Start.’ are shown


OP
alternately in the display until the separator is
at full speed. If Ti 55 is set to ‘0’, the system TT PT MT PT

HEATER

goes automatically to separation process 16 15 10


PT
SEPARATION

STOP

EPC-50
DISCHARGE
INFO

OP A CTIVE

ENTER

ALARM

10 Check the oil feed temperature by pressing


the ‘+’ button until ‘TT1’ is shown on the
display.

11 Wait until the oil feed temperature is correct:

P00361KB
Heavy fuel mode 98 °C
Lube oil mode 95 °C (trunk engines), or 90 °C
(cross-head engines)
Diesel oil mode 40 °C

12 ‘Standby’ is displayed when the separator has


OP
reached the correct speed, and the oil is at
the correct temperature. The process starts TT PT MT PT

HEATER

automatically. 16 15 10
PT
SEPARATION

STOP

EPC-50
DISCHARGE
INFO

OP A CTIVE

ENTER

ALARM

13 Adjust the backpressure to the normal running


value. Normal running backpressure is
determined at commissioning. See the System
P0 0 3 6 1 L B

Reference/Installation Instructions booklet.

1810571-02 11
1 OPERATING S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1.5 During operation

Operator panel information

Observe the operator panel information:


• Heater operation LED lit (green)
• Separator system operation LED lit (green)
• Activated valve LED lit (green)

During normal operation, the ALCAP trigger


signal is shown on the left of the display, and the
time to next sludge discharge is shown on the
right.
Any alarm is indicated on the display. For
further information see the Alarms and Fault
Finding booklet.

NOTE

Regularly check connections. Tighten if necessary.

12 1810571-02
S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

NOTE OP
TT PT MT PT
The values displayed in the examples below are not HEATER

recommendations. 16 15 10
PT
SEPARATION

STOP

EPC-50
More operational information may be read as INFO
DISCHARGE

required, by pressing the ‘+’ button repeatedly. OP A CTIVE

ENTER

ALARM

To return to normal display, i.e. the trigger


value, and time to next sludge discharge,

P00361MB
continue pressing the ‘+’ button.

• Oil feed temperature. For the correct

P00361RA
separation temperature see the System
Reference/Installation Instructions booklet.
TT1 98 °C
• Oil pressure, oil inlet

P0 0 3 6 1 Q A
PT1 1.4
• Oil pressure, oil outlet

P 0 0 3 6 1 PA
PT4 1.4
• Pressure, water outlet

P0 0 3 6 1 O A
PT5 1.4
• Water transducer value
MT 89
P 0 0 3 6 1 TA

• Speed
P00361UA

Rpm 10300
• Accumulated operating time in hours
P0 0 3 6 2 5 A

Run time 5 hours


1810571-02 13
1 OPERATING S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

ING
CAUTI
ON WARN
! !

Burn hazard Breakdown hazard


Avoid contact with hot surfaces. Process If strong vibration occurs, press the
pipes, various machine surfaces, and emergency stop button and evacuate the
processed liquid can be hot and cause room.
burns. Never discharge a vibrating separator.
Vibration may then become violent and
result in breakdown.

TT
PT
MT
C
B
PT
OP
PT

EPC-50 HEATER

INFO
SEPARAT
ION

STOP

DISCHAR
GE
ENTER
OP ACTIVE

ALARM

ING
CAUTI
ON WARN
! !

Slip hazard Noise hazard


Check all connections for leakage. Use ear protection if noise levels are high
Oil leakage may make the floor
slippery.
P0 0 4 0 7 2 A

14 1810571-02
S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

1.6 Stop

To stop the system:

1 Stop the system by pushing the


‘SEPARATION’ button on the operators panel.
OP
The yellow LED for separator stop sequence TT PT MT PT

HEATER
starts to flash. PT
16 15 10 SEPARATION

A sludge discharge is initiated. STOP

EPC-50
DISCHARGE
The stop sequence LED changes to steady INFO

OP A CTIVE
yellow, and the green LED for separation ENTER

system operation goes out, when the sludge ALARM

discharge is completed.
‘Stop’ is displayed.

P00361SB
If the heater is controlled by the EPC 50, it is
switched off automatically.
When the oil feed temperature has started to
drop, the oil feed pump is switched off
automatically.
The separator comes to a complete standstill
after about 20 – 60 minutes. ‘Standst.’ is then
displayed.

ON
CAUTI
!

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

N
CAUTIO
!

Never attempt to clean the bowl by manual discharge


in connection with stop.

1810571-02 15
1 OPERATING S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

If the system is switched off for reasons other


than high vibration, it is not necessary to wait
for the separator to slow down before restarting
the process. See 1.4 Manual Startup, page 8.

ING
WARN
!

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

1.7 Emergency Stop

If an emergency situation occurs, press the


emergency stop button and evacuate the room.
Do not return until the separator has come to a
complete standstill.

ING
WARN
!

Disintegration hazard

G04659BA
If unusually strong vibration occurs, press the
Emergency Stop button and leave the room
Do not enter the room after an emergency stop
while the separator is still rotating.

NOTE

In order to be able to restart, the system must be at


standstill, and then the EPC power switched off – on.

16 1810571-02
S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

1.8 After Emergency Stop

Separator standstill

Dismantling work must not be started before all


rotating parts have come to a complete
standstill.

R
! DANGE

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

I0 0 2 9 3 A A

1810571-02 17
1 OPERATING S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

Avoid accidental start

ING
WARN
!

Entrapment hazard
To avoid accidental start, switch off and lock power
supply before starting any dismantling work.
Make sure that separator has come to a complete
standstill before starting any dismantling work

Remedy the cause

The cause of the emergency must be remedied


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

ING
WARN
!

Disintegration hazard
Do not start the separator after an emergency stop
without first remedying the cause of the emergency.
Make sure that the bowl is clean before restart.

18 1810571-02
S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

Separator reassembled

The separator must be fully reassembled with all


covers and guards in place and tightened before
unlocking the power supply and starting the
system.

ING
WARN
!

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

P003594A
1.9 Cleaning In Place
The use of Cleaning In Place (CIP) equipment is
recommended for best separation results. For
further information on the CIP equipment, see
the CIP booklet, bookno. 1817261.
Before connecting the CIP equipment to the
Separation Unit, the switch on the control
cabinet must be turned to the CIP position. This
is to avoid accidental pumping of oil when the
pipeline is opened up.
For instructions on how to connect the CIP
equipment to the Separation Unit, see the
Service Manual booklet.
For recommended CIP intervals see chapter 1
Technical Data in the System Reference/
Installation Instructions booklet.

1810571-02 19
1 OPERATING S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1.10 Automatic Operation


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

NOTE

If local control is needed (for example in an


emergency situation), turn the switch to manual
mode. This will automatically override the Pr3
setting.

NOTE

The first startup must always be carried out


manually.
The system can thereafter be run automatically as
long as no changes are made to it between runs.

1 Press the ‘SEPARATION’ button


OP
TT PT MT PT

HEATER

PT
16 15 10 SEPARATION

STOP

EPC-50
DISCHARGE
INFO

OP A CTIVE

ENTER

ALARM

P00361LB
Before the separator can be started, a number of
questions scroll across the display which have to
be answered:

20 1810571-02
S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

‘Has the bowl been dismantled? + = YES, – = NO’

2 If the bowl has been dismantled press the ‘+’


button.

P0 0 3 6 1 4 A
If no work has been carried out on the bowl, press
the ‘–’ button. The start sequence begins and the
text ‘Start’ appears in the display.

P003613A
‘Assembled according to manual? + = YES, – =
NO’

3 If the bowl has been dismantled and

P003614A
assembled according to the instructions in the
Service Manual, press the ‘+’ button.

‘Bowl cleaned? + = YES, – = NO’

4 If the bowl has been cleaned press the ‘+’


button.

P003614A
An automatic calibration of the system is
carried out. See display.

To stop the process, press the ‘SEPARATION’


OP
button (see 1.6 Stop, page 15.)
TT PT MT PT

HEATER

If the system is to be restarted, the system 16 15 10


PT
SEPARATION

valves can remain in operating positions. STOP

EPC-50
DISCHARGE
INFO

OP A CTIVE

ENTER

ALARM
P0 0 3 6 1 L B

1810571-02 21
1 OPERATING S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1.11 Remote Operation

Remind/Remote Operation

NOTE

After maintenance, the system must be started


locally.
If in Remote, and ‘+’ is pushed in answer to the
question ‘Has the bowl been dismantled?’, the
system reverts to local control.

Follow the instructions in chapter 1.10


Automatic Operation, page 20.

22 1810571-02
S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

1.12 Emergency Operation


In the event of a water transducer failure, the
system can still be operated by setting
parameter Pr 4 in the EPC to standby mode (see
the Parameter List booklet). The transducer is
then disabled and the time to discharge
automatically changes to 15 minutes. ‘Nc’ (not
connected) is shown on the display. All Alcap
functions are disabled. Water is removed only
during a discharge. A reminder alarm is
activated after 24 hours.
If the system oil contains plenty of water, and
the oil density is less than 991 kg/m3, emergency
operation as described below is possible.

1.12.1 Manual Operation of the


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

1 Ensure all oil system manual valves are in the


correct position.
2 Set the selection switch on the control unit to
the MANUAL position.
3 Fit a jumper between terminals X9:1, and X9:2
in the EPC.
4 Start the feed pump.
5 Start the separator.
6 Heat the oil to the correct separating
temperature.
Where there is a Heatpac EHM electric
heater, use jumpers in the power unit to
bridge terminals X12.11 – X12.6, X12.11 –
X12.9, and X12.11 – X12.7. Switch on the
heater and use the switch to regulate the
temperature.

NOTE

Remove the jumpers after emergency operation.

1810571-02 23
1 OPERATING S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

7 When the separator is up to speed and the


correct oil flow and temperature are achieved,
close the bowl. Open SV15 for 5 seconds.Wait
15 seconds. Open SV16 for15 seconds. The C
bowl is now closed.

B
8 Temperature, flow, and backpressure must

G065001A
remain constant throughout. A

9 Screw C (see illustration on the right), should


be in the outermost position (12 on the scale).
Screw C is fixed by stop B.
10 Remove the water outlet pipe at D or E.

G065021A

E
G065031A

24 1810571-02
S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

11 Screw in screw A to move the paring tube to


its innermost position.
12 Open SV10 as follows:

Time Amount bowl


(secs.) filled (litre)
SU 200/SU 820/SU 825 40 0.7
A
SU 300/ SU 830/SU 835 40 1,1
SU 400/SU 840/SU 845 70 1.9
SU 500/SU 850/SU 855 30 3.0

G065011A
SU 600/SU 860/SU 865 50 4.5

13 Open SV1 to open oil feed V1.


14 Open SV5. This will open the water outlet
valve V5.
15 Carefully screw out screw A until water starts
to come from D or E.
16 Lock screw A in position.

ING
WARN
!

Breakdown hazard
During operation, SV 16 should be open to ensure
that the bowl remains closed.

1810571-02 25
1 OPERATING S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

Discharge
1 Close oil feed V1 using SV1.
2 Close water outlet V5 using SV5.
3 Open SV10 to add displacement water as
follows:

Time Amount bowl


(secs.) filled (litre)
SU 200/SU 820/SU 825 60 0.9
SU 300/ SU 830/SU 835 49 1.3
SU 400/SU 840/SU 845 79 2.1
SU 500/SU 850/SU 855 44 4.0
SU 600/SU 860/SU 865 59 5.4

4 Open SV15 until a discharge is heard (within 5


seconds).
5 Wait 15 seconds.
6 Open SV16 for 15 seconds.
7 Open SV10 as follows:

Time Amount
(secs.) bowl filled
(litre)
SU 200/SU 820/SU 825 40 0.7
SU 300/ SU 830/SU 835 40 1,1
SU 400/SU 840/SU 845 70 1.9
SU 500/SU 850/SU 855 30 3.0
SU 600/SU 860/SU 865 50 4.5

8 Open V1.
9 Open V5.
10 Maintain backpressure at normal setting
throughout.

ING
WARN
!

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

26 1810571-02
S-type Separation System

Parameter List
Printed Aug 2003
Book No. 1810572-02 V 9
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 & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2003.
Contents

1 Parameter Setting ............................... 2

2 Installation Parameters .................. 5

3 Process Parameters .......................... 8

4 Factory Set Parameters ............... 11

5 Sequence Diagram .......................... 24


5.1 Separation Sequence....................26

1810572-02
1 PARAMETER SETTING S-TYPE SEPARATION SYSTEM PARAMETER LIST

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

There are three parameter types: Installation,


Process, and Factory Set parameters.
The parameters are initially set at installation.
The process parameters can also be set as
required during operation.
Parameters not in use are not displayed.
The parameter list in this booklet is valid for
Separation Units (SU) and SA systems.

General principle
The ‘ENTER’ button is used to:
– enter into a parameter list
– enter into a parameter
– accept/store a new parameter value.
The ‘+’ or the ‘–’ buttons are used to change the
value flashing in the display window.

2 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 1 PARAMETER SETTING

To change parameters, proceed as follows: 4 Push the ‘+’ or ‘–’ button to change the
1 Push the ‘ENTER’ button. parameter value.

‘Time to discharge P1 60’ is shown. ‘P1 is 5 Push the ‘ENTER’ button. The new value is
the parameter, and ‘60’ is the set value. stored.

The ‘1’ of the ‘P1’ is flashing. The parameter number is now flashing.

2 Push the ‘+’ button until the number of the 6 Push the ‘+’ or ‘–’ button to go to the next
parameter you wish to program appears in parameter to be changed.
the display window. 7 To leave the list, push the ‘+’ and the ‘–’
The chosen parameter number is now buttons at the same time. The display shows
flashing. ‘Standst.’ or, when in operation, the trigger
value to the left, and time remaining to
3 Push the ‘ENTER’ button. discharge on the right.
The chosen parameter number is now
shown on the left side in the display. The
parameter value is shown flashing on the
right side of the display.

LED for heater


(green)
Heater on/off
push-button

LED for control


OP program running
(green)
TT PT MT PT
HEATER

PT
16 15 10 SEPARATION
Control program
STOP on/off push-button
EPC-50
DISCHARGE
INFO
Schematic
OP A CTIVE
diagram with LED for stop
ENTER sequence running
position LEDs
(yellow)
ALARM

Sludge
discharge push-
button

Display window – push- + push- Enter Alarm reset LED for common LED showing
button button push- main alarm (red) this panel
button active
P0 0 2 2 1 2 B

1810572-02 3
1 PARAMETER SETTING S-TYPE SEPARATION SYSTEM PARAMETER LIST

The following lists are available for viewing


from a menu in the EPC-50 control unit:
• Install (parameters)
• Factory (parameters)
• Alarms
• Test
For detailed information see each list.
To open the menu and select a list, proceed as
follows:
1 Push the ‘ENTER’ button. The process
parameter list is now open.
2 Push the ‘+’ button until ‘End’ is displayed.
3 Push the ‘ENTER’ button and the ‘+’ button at
the same time. ‘Install’ will show flashing on
the display.
4 Use the ‘+’ button to select a list.
5 Use the ‘Enter’ button to enter into the
selected list.
6 To leave the list, push the ‘+’ and the ‘–’
buttons at the same time.
7 To leave the menu, press the ‘+’ button
repeatedly until ‘Exit’ is displayed. Push the
‘ENTER’ button.

4 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 2 INSTALLATION PARAMETERS

2 Installation Parameters
The installation parameters must be set before
the initial start-up and before process
parameters are set. These parameters rarely
need to be adjusted again. If a new parameter
value is to be stored, it is necessary to go through
the whole list, and confirm at the end.

NOTE

Alfa Laval cannot be held responsible for injuries


and damage caused by usage of parameter values
which are not in proximity to the factory values set
by Alfa Laval.

Parameter Factory set Plant set Range Description


value value
In 1 en en = English Language. All information displayed
de = German on the operators panel is shown in
the selected language.
es = Spanish
fr = French
It = Italian
pt = Portuguese
fi = Finnish
se = Swedish
In 3 Alcap Alcap Separator type
In 4 835 200, 820, 825 Separator size
300, 830, 835 Parameters depending on separator
400, 840, 845 size are set automatically according
to the value in In 4
500, 850, 855
600, 860, 865
700, 870, 875
800. 880, 885
In 5 1 1–9 Separator identity
If more than one EPC on If more than one separator system is
same Sattbus connected to the internal Sattbus
communication, each system must
be given its own identity (1 or 2 or 3
etc.).

1810572-02 5
2 INSTALLATION PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST

Parameter Factory set Plant set Range Description


value value
In 6 Yes No Speed sensor
Yes
In 7 No No Vibration sensor
Yes
In 8 No No OP remote
Yes
In 9 Yes No Water transducer
Yes
In 15 No No Sludge pump used
Yes
In 16 No No I/O expansion board used
Yes
In 17 °C °C Celsius or Fahrenheit
°F
In 18 No No (no heater) Heater type
El. (electrical heater)
Steam (steam heater)
In 19 16 7, 8, 14, 16, 22, 24, 36, 40, El heater size
50, 56, 65, 72, 84, 96, 98, Activated when El. is selected in
100, 110, 112, 126, 128, In 18
130, 144 kw
In 20 120 0 – 999 seconds Steam-valve run time
Activated when Steam is selected in
In 18

6 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 2 INSTALLATION PARAMETERS

Parameter Factory set Plant set Range Description


value value
In 22 15 0 – 30 seconds Alarm delay time
In 23 15 0 – 240 seconds Change-over valve V1 temp. alarm
delay
Prevents false alarm due to any
fluctuations in temperature caused
by valve actions.
In 24 No No Change-over valve V1 action at extra
Yes alarm
When the extra alarm input is used,
action at alarm can be none (No) or
feed off (Yes).
In 25 Yes No Power fail alarm used
Yes If this alarm is not required, set the
parameter to ‘No*.
In 26 No No Type of computer communication
ExtPC = Fieldbus board used

I-Net = Internet
In 27 0 0 – 255 Internet IP address, part 1
In 28 0 0 – 255 Internet IP address, part 2
In 29 0 0 – 255 Internet IP address, part 3
In 30 0 0 – 255 Internet IP address, part 4
In 31 No No Feed pump controlled
Yes Feed pump has to be connected by
EPC when running in auto mode.
In 32 m3/h m3/h Flow rate in m3/h per hour or
USG/h US gallons per hour.
The feed flow measurement, based
on inlet pressure, can be displayed in
one of these ways.

1810572-02 7
3 PROCESS PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST

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

NOTE

Regularly check the condition of the bowl. If there is


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

Parameter Factory set Plant set Range Description


value value
Pr 1 120 1 – 999 minutes Time to discharge
Pr 2 HF380 MDO = Marine Diesel Oil Oil type
GO = Gas Oil
IFxxx = Intermediate Fuel Oil (xxx represents viscosity in Cst at
HFxxx = Heavy Fuel Oil 50 °C)
LO TP = Lubricating Oil for
Trunk Piston Engines
LO CH = Lubricating Oil for
Cross Head Engines
Pr 3 OPloc OPloc = Local OP in control Control location
OPrem = Remote OP OPloc is standard. OPrem, ExtPC
Rmind = Remind using and RemSW are shown only when
Sattbus installed.

ExtPC = Extern Computer


Board
RemSw = Remote switches
Pr 4 On On Alcap On/Standby
Stb. MT-50 function disabled when in
standby (Stb.). Discharge every 15
minutes (overrides Pr1). No
displacement water added.
Pr 5 0.0 0.0 = Not used Countdown service timer
0.1 to 10.0x1000 hours Action is to be taken when the timer
reaches 0.

8 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 3 PROCESS PARAMETERS

Parameter Factory set Plant set Range Description


value value
Pr 6 0 0 = service time elapsed Type of service
1 – 9 = Service text 1...9 When service timer Pr5 reaches 0,
an alarm is given and a message
shown
Pr 7 0 Information Keys to special functions used by
1 = timers shown service engineer

2 = Service mode When Pr7 is set to 1 during normal


operation, the actual timer is
displayed if the ‘+’ button is pressed
once.
Pr 10 3.0 0.0 – 6.0 bar High oil pressure limit
0.0 = oil pressure sensor (cleaned oil outlet)
disabled
Pr 11 1.0 0.0 – 6.0 bar Low oil pressure limit
Pr 12 5.5 0.0 – 6.0 bar High water pressure limit
0.0 = water pressure sensor (water outlet)
disabled
Pr 13 0.2 0.0 – 6.0 bar Low water pressure limit
Pr 14 3.0 0.0 – 6.0 bar High feed pressure limit
0.0 = feed pressure sensor
disabled
Pr 15 0.2 0.0 – 6.0 bar Low feed pressure limit
Low pressure indicates insufficient
flow. The low pressure limit must be
higher than any static pressure and
lower than normal pressure.
Pr 16 105 °C 0 – 115 °C or HFO/LO high temp. limit
0 – 255 °F
0 = Temp sensor disabled
Pr 17 85 °C 0 – 115 °C or HFO/LO low temp. limit
0 – 255 °F

1810572-02 9
3 PROCESS PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST

Parameter Factory set Plant set Range Description


value value
Pr 18 95 °C 0 – 110 °C or HFO/LO setpoint1)
0 – 240 °F Setpoint for feed temperature is valid
0 = Temp sensor disabled only when a temperature controller is
installed in the EPC.
Pr 19 40 °C 0 – 115 °C or DO high temp. limit
0 – 255 °F
Pr 20 20 °C 0 – 115 °C or DO low temp. limit
0 – 255 °F
Pr 21 30 °C 0 – 110 °C or DO setpoint1)
0 – 240 °F Setpoint for feed temperature is valid
only when a temperature controller is
installed in the EPC.
Pr 22 40 10 – 500 % P-constant1)
Preset value based on experience
with Alfa Laval Heatpac heaters.
Pr 23 1.2 0.1 – 10.0 minutes I-constant1)
Preset value based on experience
with Alfa Laval Heatpac heaters.
Pr 24 0 0–9 Heater control location
0 = disabled or heater To be set when more than one EPC
controlled from EPC x temperature controller can be used
for one heater.
Pr 25 2 0 – 240 seconds Sludge tank alarm delay (during
Ti 68)
Pr 40 60 0 – 100 discharges Test of sludge in bowl
Pr 41 15 0 – 100 % Max. decrease of displacement
water
1) Parameter appears only when heater board installed.

10 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS

4 Factory Set Parameters

Parameter Factory set Plant set Range Description


value value
Fa 3 See table on 0.1 – 99.99 litre Conditioning water volume to be fed
page 22 after discharge
Fa 6 0.2 0.0 – 9.9 bar PT4 pressure increase or decrease.
(Test during Ti 59, Ti 64, Ti 70, Ti 71,
Ti 82) Signal that the bowl is filled.
Fa 10 See table on 0 – 14000 rpm High speed
page 22 0 = sensor disabled
Is set depending on
separator size
Fa 11 See table on 0 – 14000 rpm Low speed
page 22 Is set depending on
separator size
Fa 12 300 0 – 2000 rpm Speed decrease during discharge
Fa 16 See table on 0.0 – 2.5 mm Shutdown limit for separator spindle
page 22 0.0 = sensor disabled amplitude

Fa 17 See table on 0.0 – 2.5 mm Vibration alarm prewarning


page 22
Fa 18 0.5 0.0 – 2.5 mm Vibration sensor adjustment zero
point. Zero point should be within 1.5
mm ± Fa 18
Fa 20 3.0 if Pr 2 = fuel 0.01 – 10.0 pF Alcap trigger factor
oil This is the amplification factor for the
0.6 if Pr 2 = lube transducer signal so that the proper
oil trigger range is achieved.
Fa 21 100 0 – 250 % Trigger limit HFO
Fa 22 100 0 – 250 % Trigger limit LO/DO
Fa 23 120 if Pr 2 = fuel 0 – 999.9 pF Alarm limit for high water transducer
oil 0 = water transducer value.
90 if Pr 2 = lube disabled
oil

1810572-02 11
4 FACTORY SET PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST

Parameter Factory set Plant set Range Description


value value
Fa 24 70 0 – 999.9 pF Alarm limit for low water transducer
value
Fa 25 25 0 – 250 seconds Pulse time for open drain valve
Fa 26 5 0 – 30 seconds Drain pause time. With the valve
closed, the system waits for the
result of the draining.
Fa 27 70 0 – 100 % The limit below which the trigger
value must be to interrupt draining.
Fa 28 5 0 – 20 Limit for number of HFO drainings. If
the trigger value has not fallen below
the value of Fa 27 after Fa 28, an
alarm is given.
Fa 29 5 0 – 100 Test of water transducer trigger
0 = disabled signal every x discharge.
(x = 0 – 100)
Fa 30 250 0 – 900 % Trigger level during Ti 64 – Ti 65
Fa 31 2 0–4 Reduction of Ti 72 due to trigger
0 = No reduction signals during Ti 64, Ti 65.

1 = Reduction after every


trigg
2 = Reduction after 2
consecutive triggs
3 = Reduction after 2 triggs
within 3 discharges
4 = Reduction after 2 triggs
within 4 discharges

12 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS

Parameter Factory set Plant set Range Description


value value
Fa 32 1.0 0.0 – 1.0 Reduction of Ti 72 in DO mode.
Timer Ti 72 is reduced by Fa 32
Fa 33 2 0 – 10 Limit for number of LO drainings. If a
higher no. of drainings than Fa 33
takes place within one separation
period (Ti 68), an alarm will be given.
Fa 34 +0.00 -2.00 – +2.00 HFO temperature adjustment, MT 50
0 = -2.00 Temperature compensation for the
200 = 0.00 water transducer, HFO mode.1)

400 = +2.00
Fa 35 +0.00 -2.00 – +2.00 LO temperature adjustment, MT 50
0 = -2.00 Temperature compensation for the
200 = 0.00 water transducer, LO mode.1)

400 = +2.00
Fa 36 +0.00 -2.00 – +2.00 DO temperature adjustment, MT 50
0 = -2.00 Temperature compensation for the
200 = 0.00 water transducer, DO mode.1)

400 = +2.00
Fa 37 20 0 – 100 Flush water every x disch.
Fa 41 5 1 – 30 minutes Closing water pulse time
Time between closing water pulses

1)
The transducer value can be influenced by temperature variations. This can be compensated for by using this
parameter. Proceed as follows:
Note the transducer value. N.B. The transducer value must be steady (no water in oil) in order to do this test.
At normal stable running temperature, decrease the temperature by 10 °C.
At stable new temperature, read the temperature and transducer value.
Example:
Temperature decrease = 10 °C
Transducer value change = + 1 (from 82.6 to 83.6)
Since the transducer value increased, this must be compensated by making Fa34 negative.
Fa 34 = (1.0 x 10) /10 °C = – 1.0

1810572-02 13
4 FACTORY SET PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST

Parameter Factory set Plant set Range Description


value value
Fa 42 No No V4 activated in Ti 64
Yes To get a faster pressure response
when oil feed fills the bowl (see
Ti 64) valve V4 could be closed =
Yes.
Fa 44 See table on 0 – 15 seconds Delay for close of V4 at leak test.
page 22 Automatically adjusted during test.
(Ti 66)
Fa 45 See table on 0 – 15 seconds Delay of PT4 pressure reference
page 22 value registration during the
automatic adjustment of pressure
range for leakage test (see Ti 66).
Fa 46 1.0 0 – 4 bar Acceptable PT4 decrease during
leakage test
Alarm for leaking bowl if the pressure
decreases more than Fa 46 during
leakage test.
Fa 47 3.0 0 – 4 bar PT4 high limit during leakage test
Fa 48 1.0 0 – 4 bar PT4 low limit during leakage test
Fa 49 5 0 – 10 Max. no. of leakage tests to establish
the test pressure within high-low
limits.

NOTE

For parameters Fa 90 – Fa 95, see page 21.

14 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS

Timer Sequence Parameters (separation


start, sludge discharge, stop)
Parameters for timers are listed under Factory,
but are called ‘Ti’.
When expected feedback from a timer is given,
the timer is interrupted and the next timer
starts.
If feedback is not received within the preset
time, an alarm is given.
Timers for start are 50 - 59.
Timers for operation are 60 - 69.
Timers for discharge are 70 - 79.
Timers for stop are 80 - 89.
Timers 50, 51, 52 and 87 are intended for the
‘fully automatic’ system (Auto mode) with pump
and heater controlled by EPC 50.
If pump and heater are started independent of
EPC and Alfa Laval starter, X6:4 - X40 must be
connected to a free closing contact at the
external pump contactor. Increasing
temperature is the only process condition needed
for timers 51 and 52. The program skips directly
to timer 55 when not ‘fully automatic’.

1810572-02 15
4 FACTORY SET PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST

Parameter Factory set Plant set Range Description


value value
Ti 50 60 2 – 300 seconds Feed pump on
Ti 51 15 0 – 30 seconds Feed pressure feedback
Ti 52 4 0 – 60 minutes Separator start-up (Speed feedback)
Speed above low limit (Fa 11)
expected. Condition of belt, coupling,
motor bearings, height adjustment,
and speed sensor supervised.
Ti 53 15 0 – 60 minutes Heater on (temp. feedback)
Temperature above low limit (Pr 17,
Pr 20) expected to confirm that the
heater works normally.
Ti 55 0 0 – 30 minutes Max. time for ‘Standby’ mode. During
0 = no standby ‘Standby’ mode, the system is
waiting for an order to start the
process sequence. The process
sequence is started with a push of
the start button.
When Ti 55 = 0 the process starts
without delay.
Ti 56 3.0 0.1 – 5.0 seconds Discharge if Ti 59 has expired after
alarm.
Ti 57 15 0 – 30 seconds Pause = Draining of operating
system
Ti 58 See table on 0 – 60 seconds Close bowl
page 22

16 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS

Parameter Factory set Plant set Range Description


value value
Ti 59 170 0 – 300 seconds Water flow rate calibration
At start three questions are
displayed:
• Bowl dismantled?
• Assembled according to manual?
• Bowl cleaned?
When the answer to the third
question is Yes, calibration of the
water flow rate through SV 10 takes
place. SV 10 is open until pressure in
the water outlet increases (Fa 6).
The water volume is defined for each
separator size. Based on this and the
time taken to fill the bowl, the EPC
calculates the water flowrate.
When the answer is No, this means
that stored calibration data will be
used and consequently the program
performs Ti 63.
Ti 60 See table on 0.1 – 5.0 seconds Discharge
page 22 – when starting, the operating
system needs some extra water to
support the operating slide before
closing the bowl. (This is not a
proper discharge, since the bowl is
empty.),
– after a power failure to prevent a
period between discharges greater
than Pr 1.
Ti 61 15 0 – 30 seconds Pause = Draining of operating
system
Ti 62 See table on 0 – 30 seconds Close bowl
page 22

1810572-02 17
4 FACTORY SET PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST

Parameter Factory set Plant set Range Description


value value
Ti 63 120 Seconds, calculated Conditioning water added
Based on the calibration of the water
flow rate, the EPC calculates the
time to which Ti 63 is set, so that the
correct volume of conditioning water
is added to the bowl. Data
concerning the bowl is activated
when size of separator is choosen
(In 4). The preset value is just for
start. After the calculation, the
correct value for Ti 63 is set
automatically.
Ti 64 60 0 – 60 seconds Oil feed on. Max 60 secs.
Ti 65 15 0 – 30 seconds Water transducer pulse control time
Test of the signal from the water
transducer. If this shows water in the
oil, the displacement time prior to
next discharge will be reduced.
Ti 66 See table on 0 – 30 seconds Bowl leakage check
page 22 (See also Fa 44 – 49)
Ti 67 60 0 – 300 seconds Time for stabilisation of the
transducer signal. When the time
has elapsed the EPC stores the
actual transducer value as a
reference for changes in water
content.

18 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS

Parameter Factory set Plant set Range Description


value value
Ti 68 120 ( = Pr1) 0 – 300 minutes Time between discharges. This is the
same as Pr 1. If one is changed, the
other one is automatically changed.
During Ti 68 the water transducer
supervises changes of the water
content in the clean oil. If the trigger
value is greater than 100, the drain
valve (V5)opens. For details see Fa
25–28.
Ti 70 15 0 – 30 seconds Oil feed off. Oil outlet pressure below
low limit (Pr 11) expected.
Ti 71 15 0 – 120 seconds Displacement of oil. During Ti 71, V4
is closed until increasing pressure is
sensed, indicating displacement
water has entered the bowl.
Ti 72 150 Seconds, calculated (max. Displacement water (SV 10)
300 seconds) continues for the calculated time.
Ti 73 10 0 – 30 seconds Opening of the drain valve to wash
out any oil from the paring tube and
piping.
Ti 74 3.0 0.1 – 5.0 seconds Discharge

1810572-02 19
4 FACTORY SET PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST

Parameter Factory set Plant set Range Description


value value
Ti 75 15 0 – 30 seconds Pause = Draining of operating
system
Discharge feedback (as shown by
decreased speed, Fa 11).
If the speed sensor is out of order/
disabled, feedback is automatically
taken over by timer Ti 64. (If time
close to 0 there was no discharge).
Draining of operating system takes
place during Ti 75.
After Ti 75, the program returns to
Ti 62, provided stop is not ordered.
If however any value or timer
influencing the water calibration has
been changed, the program returns
to Ti 58.
When stop is ordered the discharge
precedes the stop sequence.
Ti 81 See table on 0 – 30 seconds Close bowl
page 22
Ti 82 150 0 – 300 seconds Heater off.
Addition of water until 80% of bowl
volume, or increased pressure is
sensed in the oil outlet (Fa 6). This is
to keep the bowl filled during stop
sequence.
Ti 83 10 0 – 30 seconds Opening of the drain valve to wash
out any oil from the paring tube and
the pipe.
Ti 85 5 0 – 30 minutes Temperature decrease
The EPC switches the separator
motor off.
Decreasing oil feed temperature
greater than 5 °C expected.
If Ti 85 = 0, no temperature control.

20 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS

Parameter Factory set Plant set Range Description


value value
Ti 86 3 0 – 30 minutes Decreasing speed expected (Fa11).
Ti 87 60 0 – 300 seconds Pump off
In Auto mode, the EPC switches the
feed pump off. By doing so after
switching off the separator, further oil
is fed to the heater (which is already
switched off) to help cooling.
Ti 89 30 30 – 60 minutes The EPC is waiting for zero speed.
As long as the separator is rotating
at a speed greater than 6 revs/min.
(1 puls/ rev.), the speed is displayed
alternating with ‘Stop.’ Speed less
than 6 revs/min. is displayed as 0.
When speed 0 has been displayed
for 1 minute (alternating with ‘Stop’),
‘Standst.’ will be displayed.
Fa 90 --- 0 – 9999 days Set runtime. See chapter 4 Change
of Circuit Board in the Alarms and
Fault Finding booklet.
Fa 91 50 0 – 99 °C Break point, cold start.
0 – 210 °F The temperature up to which gain
factor Fa92 is active. Above this
temperature normal gain (Pr 22) is
active.
Fa 92 40 1 – 100 % Gain factor, cold start
This factor is used to increase the
normal P-band (Pr 22) when
temperature is below that defined in
Fa 91.
Ex. Normal P-band = 30, Fa 92 = 40
gives an actual P-band below Fa 91
of 0.40 x 30 = 12.

1810572-02 21
4 FACTORY SET PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST

Parameter Factory set Plant set Range Description


value value
Fa 93 SBSU SBSU (Sattbus on RS232) Communication type
ASCII (ASCII protocol)
PRINT (Printer output)
Fa 94 9.6 1.2, 2.4, 4.8, 9.6, 19.2, or Serial communication Baudrate
38.4 channel A
(4.8 = 4800)
Fa 95 No No Communication parity channel A
Odd
Even
Fa 96 3.0 if Pr 2 = fuel 0.1 – 10.0 pF Alcap trigger range during discharge
oil
0.6 if Pr 2 = lube
oil

Parameters depending on separator size


Separator Fa3 Fa10 Fa11 Fa16 Fa17 Fa44 Fa45
size
S 200 0.16 13.300 11.000 0.3 0.2 2 5
S 820/825 0.3 11.000 9.900 0.3 0.2 2 5
S 300/S 830/835 0.3 11.000 9.900 0.3 0.2 2 5
S 400/S 840/845 0.4 9.600 8.600 0.5 0.3 4 10
S 500/S 850/855 0.7 8.300 7.400 0.5 0.3 6 10
S 600/S 860/865 0.9 7.800 6.400 0.5 0.3 8 10
S 700/S 870/875 1.5 6.700 5.500 0.5 0.3 10 10
S 800/S 880/885 2.5 5.800 4.700 0.5 0.3 10 10

Separator Ti58 Ti60 Ti62 Ti66 Ti81


size
S 200 15 5 15 10 15
S 820/825 15 5 15 10 15
S 300/S 830/835 15 5 15 10 15
S 400/S 840/845 15 5 15 20 15
S 500/S 850/855 15 5 15 20 15
S 600/S 860/865 25 15 25 25 25
S 700/S 870/875 35 25 35 30 35
S 800/S 880/885 60 25 60 30 60

22 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS

1810572-02 23
5 SEQUENCE DIAGRAM S-TYPE SEPARATION SYSTEM PARAMETER LIST

5 Sequence Diagram

Autostart Start Separation


Ti50 Ti51 Ti52 Ti53 Ti55 Ti56 Ti57 Ti58 Ti59 Ti60 Ti61 Ti62 Ti63 Ti64 Ti65 Ti66 Ti67 Ti68
60s 15s 4m 15m 30m 3s 15s 15s 170s 5s 15s 15s Calc 60s 15s 10s 60s 60m
Activity
1)
Feed pump
motor on
Flow stabilized
1)
Separator
motor on
1) )
Heater on
temp. increase
1)
Heater max.
start time
Discharge,
SV15
Drain of
operating water
Closing water, 2)
SV16
Calibration of 1)
water flow rate
SV 10
Conditioning
water SV 10
Feed on V1

Oil outlet 1)
closed, V4
Leak test

Ref. time

Separation

Drain of water; 3)
V5
Feed off
Displacement
water
SV 10
Water
SV10
11) 10)
Optional
sludge pump

1) Interrupted by feedback signal


5) Interrupted by decreasing speed 9) 1 sec. pulse at 4000 rpm
2) Pulse 1 sec. every 5 min. 6) Interrupted by pump off feedback 10) 5 sec. every 30 minutes
3) Activated when needed 7) Interrupted by 0-speed during 1 min. 11) 15 sec. only
4) Interrupted by decreasing temperature 8) Interrupted by calculated time
or trigger signal

NOTE

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

24 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 5 SEQUENCE DIAGRAM

Discharge Stop
Ti70 Ti71 Ti72 Ti73 Ti74 Ti75 Ti62 Ti63 Ti64 Ti65 Ti66 Ti67 Ti81 Ti82 Ti83 Ti85 Ti86 Ti87 Ti89
15s 15s Calc 10s 3s 15s 15s Calc 60s 15s 10s 60s 15s 150s 10s 5m 3m 60s 30m
Activity
4) 5) 6) 7) Feed pump
motor on
Flow stabilized

Separator
motor on
Heater on
temp. increase
Heater max.
start time
Discharge,
SV15
Drain of
operating
water
9)
Closing water,
SV16
Calibration of
water flow rate
SV 10
Conditioning
water SV 10
Feed on V1
1) 1) 1)
Oil outlet
closed, V4
Leak test

Ref. time

Separation
Drain of water;
V5
1) Feed off
1) 8) Displacement
water
SV 10
1) Water
SV10
11) If ‘Stop’ after Ti62 skip to Optional
Ti81 sludge pump

Flow rates for Flow rates for Flow rates for Flow rates for Flow rates for
S 200 S 820/S 825 S 500/S 850/S 855 S 700/S 870/S 875 S 800/S 880/S 885
S 300/S 830/S 835 S 600/S 860/S 865
S 400/S 840/S 845
SV10: 0.9 l/m SV10: 1.6 l/m SV10: 5.5 l/m SV10: 11 l/m SV10: 15 l/m
SV15: 11.0 l/m SV15: 11 l/m SV15: 11 l/m SV15: 11 l/m SV15: 11 l/m
SV16: 2.8 l/m SV16: 2.8 l/m SV16: 2.8 l/m SV16: 2.8 l/m SV16: 2.8 l/m

1810572-02 25
5 SEQUENCE DIAGRAM S-TYPE SEPARATION SYSTEM PARAMETER LIST

5.1 Separation Sequence


Timer Action Alarms

Ti 56 = 3 sec. Discharge
Start

SV 15 To ensure that the operating system gets sufficient


water before closing.

Ti 57 = 15 sec. Draining of operating water

Ti 58 = See table Bowl closing


chapter 4.
SV 16

Ti 59 = calculated Calibration of water flow ‘NO PT4 PRESSURE


FEEDBACK DURING Ti 59’
V 4, SV 10 Bowl filled with water until pressure is indicated in the
oil outlet (Parameter Fa6 = 0.2 bar). Flow rate is Ti 59 has a max. value of 170
calculated based on the known bowl volume and time sec. Alarm is given if no
taken to fill with water. pressure response within this
time.

Ti 60 = See table Discharge


chapter 4.
Normal start begins here. There are two reasons for
SV 15 this:
1. To ensure that the operating system gets sufficient
water before closing.
2. To empty the bowl before start after power failure.

Ti 61 = 15 sec. Pause
During this timer, water is drained from the operating
system.

Ti 62 = See table Bowl closing


chapter 4.
SV 16

Ti 63 = calculated Filling of conditioning water


SV 10 The time (volume) is based on the calibrated flow rate Max. 120 sec.
and bowl volume.

26 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 5 SEQUENCE DIAGRAM

Timer Action Alarms

Ti 64 = 60 sec. Feed on to separator ‘Oil backpressure PT4 – LOW’


Separation

V 1, (V 4 automatic Alarm is given if no pressure


selection) response in oil outlet within
Ti 64.

Ti 65 = 15 sec. Test of water content in oil outlet


V1 If traces of water are detected in the oil outlet, the time
for displacement (Ti 72) will be reduced before next
discharge.
After calibration start, the oil outlet pipe is filled with oil
and the system now skips to Ti 70 to perform a
discharge. Ti 72 max 90 sec interrupted by
transducer response.

Ti 66 = See table Bowl leaking test ‘OIL LEAKING FROM BOWL’


chapter 4.
With the feed off and the oil outlet closed, a Alarm is given if the pressure
V4 decreasing pressure indicates that the bowl is falls by more than 1.0 bar.
leaking.
In order to find a suitable pressure range (1 – 2 bar)
for test, Ti 65 and Ti 66 may be repeated (see Fa 49).

Ti 67 = 60 sec. Reference time


V1 After the process has stabilized, the transducer
(MT 50) reference value is stored.

Ti 68 = 120 min. Separation. ‘Water drain - INSUFFICIENT’


V1 (V5) When necessary, the drain valve (V5) in the water During separation all necessary
outlet opens for a short while. The trigger value is then functions are supervised.
checked during a few seconds. Draining stops when Alarm given if more than 5
the trigger value is lower than 70. Draining can openings and trigger value not
continue max. 5 openings. After 5 openings, skip to less than 70.
Ti 74.

1810572-02 27
5 SEQUENCE DIAGRAM S-TYPE SEPARATION SYSTEM PARAMETER LIST

Timer Action Alarms

Ti 70 = 15 sec. Feed off. ‘OIL PRESSURE PT4 HIGH


Discharge

DURING Ti70’.
Oil outlet pressure decreases.
Alarm given if no pressure
feedback.

Ti 71 = 15 sec. Displacement water. ‘NO PT4 PRESSURE


FEEDBACK DURING Ti71’.
V4, SV10 Oil outlet pressure increase more than 0.5 bar
indicates that water is fed. The timer is then Alarm given if no pressure
interrupted. feedback.
Max. 15 sec.

Ti 72 = 0 – 150 sec. Displacement water.


SV10 Max. to calibrated value.

Ti 73 = 10 sec Water pumped out through the water outlet to wash


out any remaining oil.
V5
Sludge pump in operation.

Ti 74 = 3 sec. Discharge.
SV15

Ti 75 = 15 sec. Discharge feedback and draining of operating ‘Discharge feedback –


system ERROR’.
After’bowl cleaned’ at start, the program continues Alarm is given if bowl speed
with Ti 58 – 68. Once Ti 68 has elapsed, the program after discharge is not below
skips from Ti 75 to Ti 62 after every discharge, or to Fa 11 minus Fa 12.
Ti 81 if stop is ordered.

Ti 62 to 67
repeated.

or Ti 81

28 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 5 SEQUENCE DIAGRAM

Timer Action Alarms

Ti 81 = See table Bowl closing


Stop

chapter 4.
SV16

Ti 82 = 150 sec. Water to the bowl.


V4, SV10 Timer interrupted when 80% of bowl volume is filled, Max. 300 sec.
Heater off or when pressure in oil outlet is increased by more
than 0.2 bar.

Ti 83 = 10 sec Water pumped out through the water outlet to wash


out any remaining oil from the paring tube and pipes.
V5

Ti 85 = 5 min. Waiting for oil feed temp. decrease. ‘Temperature - NOT


DECREASING’
Separator motor off Timer is interrupted when temp. decrease below low
limit. If temp. not decreased within Ti
85.

Ti 86 = 3 min. Waiting for speed decrease. ‘Bowl speed – HIGH xxxxx’


Time for cooling of heater If speed not decreased within
timer.

Ti 87 = 60 sec. Timer is interrupted by pump off feedback.


Feed pump off

Ti 89 = 30 – 60 min. Waiting for zero speed


When speed = 0, timer is interrupted and ‘Standst’ is Max. 60 min.
indicated.

1810572-02 29
5 SEQUENCE DIAGRAM S-TYPE SEPARATION SYSTEM PARAMETER LIST

Process Start Start With Calibration


Ti58 Bowl Closing
Push
Ti50-54 Feed,
‘Separation’
speed, and Ti 57 Pause
temp check
Ti59 Water
calibration
TI 56
Bowl No
Ti55 Standby. Discharge
dismantled?
Push
‘Separation’ to
Max. time Yes
continue Alarm
expired?
Yes
Ti 60 Discharge
No

Assembled No Ti60 Discharge


according to Standst.
manual? Ti 61 Pause

Ti61 Pause
Yes Ti62 Bowl
closing
Ti62 Bowl
closing
No Go to Start
Bowl Ti64 Feed on
cleaned? Without
Calibration Ti63 Conditioning
water

Ti65 Stabilizing
Yes
Ti64 Feed on
Go to Start With
Calibration
Ti70 Feed off Ti65 Mt 50
signal test

Ti71 Displ. Ti66 Leak test


Repeated at start
water check

Ti67 MT50
reference
Ti 72
Displacement
Yes
Ti68 Time to No
discharge Stop?
Ti 73 Water
outlet flushing.
No

Ti74 Discharge Ti68 No


elapsed? Man.
discharge?

Ti75 Pause and Yes


discharge Yes
feedback
Discharge

30 1810572-02
S-TYPE SEPARATION SYSTEM PARAMETER LIST 5 SEQUENCE DIAGRAM

Start Without Discharge Stop


Calibration
Ti50-54 Feed, Ti70 Feed off Ti81 Bowl
speed, and temp closing
check

Ti82 Water into


bowl.Heater off
Ti55 Standby. Ti68 Yes
Push ‘Separation’ interrupted by
to continue draining ?
Ti83 Water outlet
flushing

Ti 60 Discharge
No
Ti85 Sep. motor
Ti71 Displ. off. Check
water check decreasing temp
Ti 61 Pause

Ti 72
Ti62 Bowl closing Displacement Ti86 Heater
cooling. Check
decreasing speed

Ti63 Conditioning Ti 73 Water


water outlet flushing.
Ti87 Pump off

Ti64 Feed on Ti74 Discharge


Ti89 Waiting for
0-speed
Ti65 Mt 50
Ti75 Pause and
signal test
discharge
feedback
Standst.
Ti66 Leak test Repeated at start

Ti67 MT50
reference No
Stop? Ti62

No Yes
Ti68 Time to
discharge Stop?
Yes

No
Stop
Ti68 No Man.
elapsed? discharge?

Yes
Yes

Discharge

1810572-02 31
5 SEQUENCE DIAGRAM S-TYPE SEPARATION SYSTEM PARAMETER LIST

32 1810572-02
S-type Separation System

Alarms and Fault Finding


Printed Aug 2003
Book No. 1810573-02 V 8
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 & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2003.
Contents

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

2 Display Alarms and Actions ......... 5

3 Alarm Tests .......................................... 19

1810573-02
1 ALARMS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

1 Alarms
1.1 Alarm Functions
The alarm system is designed to ensure a safe
separation system.
All alarms are shown on the operator panel
display, and most of them are complemented by
light emitting diodes (LEDs).
The alarms are displayed in order of occurrence.

1.2 Reading Alarm History


List
To read the stored list of alarms, do as follows:
• Push ‘Enter’.
• Push ‘+’ until ‘End’ is shown on the display.
• Push ‘Enter’ and ‘+’ at the same time.
• Push ‘+’ repeatedly until ‘AL list’ shows on the
display.
• Push ‘Enter’.
• Go through the list using the ‘+’ pushbutton
until ‘End’ shows on the display.
• Push ‘Enter’.
• Push ‘+’ repeatedly until ‘Exit’ shows on the
display.
• Push ‘Enter’ to return to normal display.

NOTE

The texts ‘Alcap Pr4 = On/ Standby’, and ‘Discharge


Repeated’ are reminders to the operator, and not
alarms.

2 1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 1 ALARMS

1.2.1 Alarm message explanation:


The display shows:

Alarm no. 5 Alarm number


Feed pressure low Type of alarm
0:13 This alarm occured 13 minutes ago.
P1 60 Parameter Pr 1 was set to 60 minutes.
00:02:13 The alarm was reset after 2 minutes 13 seconds.

1.3 Alarm Reset

ING
WARN
!

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

1 Acknowledge the alarm signal by pressing the


alarm pushbutton.
The flashing LED then changes to steady
shine.

G001648A
ALARM
2 Remedy the cause.

3 Reset the alarm function by pressing the


alarm pushbutton a second time.
The LED will go out.

G001649A
ALARM

It is possible to reset the system without


remedying the cause, but the alarm signal will
be repeated.

NOTE

The STOP sequence is automatically initiated if an


alarm is not remedied within 30 minutes.

1810573-02 3
1 ALARMS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

ON
CAUTI
!

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

1.4 Abnormalities not


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

Why? What to do

Smell • Normal occurrence during start None.


while the friction blocks are
slipping.

• Oil level in oil sump too low. Check oil level and add oil if
necessary.

Noise • Height position of paring disc is Stop the separator, measure and
incorrect. adjust the height.

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

• Improper bowl assembly Check and reassemble.

Unsatisfactory separation result • Incorrect separation Adjust.


temperature.

• Throughput too high. Adjust.

• Disc stack is clogged. Clean disc stack.

• Sludge space in bowl is filled. Clean and reduce the time


between sludge discharges.

• Bowl speed too low. Examine the motor and power


transmission for correct frequency
parts.
Check belt and coupling pads.

• Bowl rotates in wrong direction Check the electrical connections


to the motor.

4 1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 2 DISPLAY ALARMS AND ACTIONS

2 Display Alarms and Actions

on page on page
The display The display
shows shows

17 IO expansion board - ERROR 18


Alcap in standby - MORE THAN 24 HOURS

18 Local OP in control 17
xxxxx board - ERROR

11 Lockswitch - FAILURE 7
Bowl speed - HIGH xxxxx

12 NO PT5 DRAIN FEEDBACK DURING Tixx 17


Bowl speed - LOW xxxxx

13 NO PT4 PRESSURE FEEDBACK DURING Tixx 15


Bowl speed sensor - ERROR

18 NO SIGNAL FROM EXTRA INPUT X6:8 16


Communication - ERROR xxxxx

18 Oil backpressure PT4 - HIGH 13


Computer communication board - ERROR

17 Oil backpressure PT4 - LOW 14


Discharge feedback - ERROR

9 Oil feed temperature - HIGHxxxxx 9


Emergency stop - BUTTON PUSHED

11 Oil feed temperature - LOWxxxxx 10


Feed flow PT1 - ERROR DURING Tixx

15 OIL LEAKING FROM BOWL 13


Feed pressure PT1 - HIGH

15 OIL PRESSURE PT4 HIGH DURING Ti70 15


Feed pressure PT1 - LOW

15 Oil pressure sensor PT4 - ERROR 14


Feed pressure sensor PT1 - ERROR

16 Parameter xx:xx - ILLEGAL 18


Heater - FAULT

18 POWER FAILURE 17
Heater board - ERROR

18 Pressure in water outlet PT5 - HIGH 15


Heater connection - ERROR

7 Pressure in water outlet PT5 - LOW 15


High vibration - SHUTDOWN

8 Pump starter - FAILURE 15


High vibration - WARNING

16 Separator motor - FAILURE 13


HIGH WATER CONTENT

17 Separator run-up time - TOO LONG 16


HIGH WATER CONTENT IN OIL

1810573-02 5
2 DISPLAY ALARMS AND ACTIONS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

on page
The display
shows

SLUDGE IN BOWL 13

Sludge tank level - HIGH 13

Temperature increase - TOO SLOW 18

Temperature - NOT DECREASING 18

Temperature alarm sensor - ERROR 10

Temperature control sensor - ERROR 11

Transducer - NO RESPONSE 17

MT 50 board - ERROR 16

Transducer value - HIGH 16

Transducer value - LOW 16

Vibration board - ERROR 18

Vibration sensor - ERROR 8

Water drain pressure - HIGH 17

Water pressure sensor PT5 - ERROR 15

6 1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 2 DISPLAY ALARMS AND ACTIONS

The display Why? What to do


shows

Lockswitch - FAILURE • Separator not mounted as Mount the separator according to


described in the Service Manual the instructions in the Service
booklet. Manual booklet.

NOTE

The cause of this alarm must


be remedied within 30
minutes. If not, the STOP
sequence will begin.

High vibration - SHUTDOWN • Sludge remaining in part of the Dismantle, clean and check the
bowl bowl before restart. See Service
Manual.
ING
WARN
!
ING
WARN
!
Disintegration hazards
If excessive vibration occurs, stop Disintegration hazard
separator and keep bowl filled with
The separator bowl must be
liquid during rundown.
manually cleaned before starting
The cause of the vibration must be
identified and corrected before the up again.
separator is restarted.

• Bowl wrongly mounted Check assembly. See Service


• Disc stack compression incorrect Manual.
• Bowl assembled with parts from
other separators

• Height position of paring disc is Stop the separator, measure and if


incorrect. necessary adjust the height.

• Bowl spindle bent. Renew the bowl spindle.

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

• The frame feet are worn out. Renew the frame feet.

• Spindle top bearing spring Renew all springs.


broken.

1810573-02 7
2 DISPLAY ALARMS AND ACTIONS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

The display Why? What to do


shows

High vibration - WARNING • Sludge remaining in part of the Dismantle, clean and check the
bowl bowl before restart.

ING
WARN
!

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

• Bowl wrongly mounted Check assembly. See Service


• Disc stack compression incorrect Manual.
• Bowl assembled with parts from
other separators

• Height position of paring disc is Stop the separator, measure and if


incorrect. necessary adjust the height.

• Bowl spindle bent. Renew the bowl spindle.

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

• The frame feet are worn out. Renew the frame feet.

• Spindle top bearing spring Renew all springs.


broken.

Vibration sensor - ERROR • Sensor or cable damaged Replace sensor. If no spare sensor
available, set parameter Fa 16 =
0.0 to be able to run the system.
Note that it is not possible to run
in AUTO mode.

8 1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 2 DISPLAY ALARMS AND ACTIONS

The display Why? What to do


shows

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

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

• Faulty triac module(s) in the If relay K11 is on:


power unit or faulty controller in
Disconnect X12:10.
the control unit. (electric heater)
If the temperature is falling,
replace the control module in the
control unit.
If the temperature is not falling,
replace the triac module(s).
If relay K11 is off, but contactor
K12, K16, or K17 is on, and the
temperature is not falling:
Check if power is supplied from
the control unit to the contactor
which is on (X12:6 – X12:12, X12:7
– X12:12 , X12:9 – X12:12). If it is,
replace the control module in the
control unit.

• Broken wiring or defective heater Check adjustment of P and I


resistance, or faulty controller in functions in the control unit.
the control unit.
If contactor sequence correct:
Check wiring and heater
resistance of each block or heater
element. See EHM heater
component booklet.
If contactor sequence not correct:
Replace the control module in the
control unit.

1810573-02 9
2 DISPLAY ALARMS AND ACTIONS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

The display Why? What to do


shows

Oil feed temperature - LOWxxxxx • Heater clogged Investigate cause and remedy.
• Steam supply insufficient
• Steam trap faulty
• Steam supply valve faulty

• Faulty fuses or burned Check and renew broken fuses.


contactors Reset overcurrent protection
(electric heater) (applicable for 8/7 – 24/22 kW
power unit).
Check wiring and contactor coils.

• Broken wiring or defective heater Check wiring and heater


resistance resistance of each block or heater
(electric heater) element. See the Service Manual
booklet.

Temperature alarm sensor - ERROR • Short circuit / broken sensor or Disconnect cable at sensor.
cable. Measure resistance between 1-3.
Resistance shall be within 100-142
ohms = 0-110 C / 32-230 F.
Test of EPC 50 input: disconnect
cables from sensor, (terminal X
5:1-2-3) and move jumpers Xj1 and
Xj2 upwards. Indication within 50-
60 C when OK. If no spare sensor
available set parameter Pr 16 = 0,
or if control sensor free, move
connection to that one.

10 1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 2 DISPLAY ALARMS AND ACTIONS

The display Why? What to do


shows

Temperature control sensor - ERROR • Short circuit / broken sensor or Disconnect cable at sensor.
cable. Measure resistance between 1-3.
Resistance shall be within 100-142
ohms = 0-110 C / 32-230 F. If no
spare sensor available set
parameter Pr 18 = 0. Heater is then
out of function.

Feed flow PT1 - ERROR DURING Tixx • Pump not working Check pump.
• Pressure in feed line too low Check feed line.

Bowl speed - HIGH xxxxx • High power (net) frequency Check power supply before
restart.

• Incorrect transmission parts


(50 Hz belt pulley and belt for ING
60 Hz power supply). WARN
!

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

1810573-02 11
2 DISPLAY ALARMS AND ACTIONS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

The display Why? What to do


shows

Bowl speed - LOW xxxxx • Slipping belt Change belt.

• Worn coupling pads Check / change pads.

• Bowl not properly closed Check closing water supply (valve


SV 16).
Check bowl operating system for
leakage.
Check nozzle.

• Bowl not properly assembled Check that the lock ring is in


place.

• Low power net frequency Check power.

• Motor failure. Repair the motor.

• Bearing(s) damaged. Renew all bearings.

• Incorrect transmission parts (60


Hz belt pulley and belt for 50 Hz ING
power supply). WARN
!

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

12 1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 2 DISPLAY ALARMS AND ACTIONS

The display Why? What to do


shows

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

Separator motor - FAILURE • Feedback signal from contactor Check the contactor function.
K 2 missing Input terminal
X 6:5 in EPC 50.

OIL LEAKING FROM BOWL • Bowl periphery sealing Change seal ring in bowl hood.
damaged
Check/change rubber rings and
valve plugs.

• Leakage somewhere in oil outlet Check for leakage.

• Closing water leaking Check/change sealings and plugs.

SLUDGE IN BOWL • Too much sludge in bowl This alarm cannot be


acknowledged. The separator will
come to a stop. Wait until EPC
comes to ‘Standstill’. Investigate
cause and remedy.

Sludge tank level - HIGH • Pump has not drained the tank Check the pump function.

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

• Regulating valve too restricted Adjust valve

1810573-02 13
2 DISPLAY ALARMS AND ACTIONS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

The display Why? What to do


shows

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

• Regulating valve open too much Adjust valve

• Change over valve V1 in Check air pressure, solenoid valve


recirculation position SV1 and output from EPC 50
terminal X 8:1-X 41.

Bowl opens unintentionally during


operation because:

• Strainer in the operating water Clean the strainer.


supply is clogged.

• No water in the operating water Check the operating water system


system. and make sure any supply valves
are open.

• Hoses between the supply Fit correctly.


valves and separator are
incorrectly fitted.

• Nozzle in bowl body clogged Clean the nozzle.

• Rectangular ring in discharge Renew the rectangular ring.


slide is defective.

• Valve plugs are defective. Renew all plugs.

• Supply valve SV15 for opening Rectify the leak.


water is leaking.

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

14 1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 2 DISPLAY ALARMS AND ACTIONS

The display Why? What to do


shows

OIL PRESSURE PT4 HIGH DURING Ti70 • No decrease in oil pressure Check function of change-over
during this timer. valve V1.

NO PT4 PRESSURE FEEDBACK DURING • No increase in oil pressure Check supply of displacement
during this timer. water. Valve SV 10.

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

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

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

Replace sensor. If no spare sensor


available set parameter Pr 12=0.0
to be able to run the system.

Feed pressure PT1 - HIGH • Pipe restricted Check recirculation for restriction

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

Check heater for fouling.

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

Replace sensor. If no spare sensor


available set parameter Pr 14=0.0
to be able to run the system.

Pump starter - FAILURE • Feedback signal from contactor Check the contactor function.
K 3 missing
Check input terminal X 9:1 in the
EPC.

1810573-02 15
2 DISPLAY ALARMS AND ACTIONS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

The display Why? What to do


shows

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

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

• Belt slipping Check the belt.

• Height position of paring disc is Stop. Check and adjust the height.
incorrect.

• Motor failure Repair the motor.

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

• Separator start button not Push start button.


pushed.

Heater - FAULT • 0V in cable heater X 12:3 to EPC Check the power supply to the
50 X 51:4 heater.
(electric heater)

• High temp. switch released Check temp. setpoint in the


(electric heater) control unit.
Check the heater and clean if
necessary.
Reset temp. switch in power unit.
Restart heater.

MT 50 board - ERROR • Faulty board Change MT50 Board (see Change


of Circuit Board in the Service
Manual booklet).

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

• Fouling in the monitor MT 50 Dismantle and clean with


detergent.

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

HIGH WATER CONTENT For HFO and DO

• Too much water in oil Investigate cause and remedy.

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

• Paring tube not moving properly Check that movement is not


impeded by friction.

16 1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 2 DISPLAY ALARMS AND ACTIONS

The display Why? What to do


shows

HIGH WATER CONTENT IN OIL For LO

• Too much water in oil Investigate cause and remedy.

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

• Paring tube not moving properly Check that movement is not


impeded by friction.

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

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

NO PT5 DRAIN FEEDBACK DURING Tixx • Restriction in water outlet Clean the outlet pipe.
causing no reduction in pressure

Transducer - NO RESPONSE • Expected increase of trigger Check water supply. Valve SV 10.
signal during Ti 64 and Ti 65
failed

Discharge feedback - ERROR Speed not decreased as discharge


feedback (below Fa12) caused by:

• Strainer in the operating water Clean the strainer.


supply is clogged.

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


flow = 11 l/min.

• Hoses between the supply Correct.


valves and separator are
incorrectly fitted.

• Rectangular ring in the operating Renew the rectangular ring.


slide is defective.

Local OP in control • Attempt to operate remote OP Not legal when local OP is active.

POWER FAILURE • Black-out has occurred with EPC Check plant conditions and
in operation restart.

1810573-02 17
2 DISPLAY ALARMS AND ACTIONS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

The display Why? What to do


shows

Parameter xx:xx - ILLEGAL • If parameters are changed Switch EPC50 power off. Move X
automatically by "thunderstorm" 34 on I/O board to position right.
type influence, alarm is given to Switch power on. Parameters are
indicate out of range. now all set to default values. Move
X 34 back to original position.
Adjust all parameter settings to
correct value.
Switch power off and on again.

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

xxxxx board - ERROR • Transducer board, operator Check cables to board or replace
panel board, or I/O board in EPC the board (see Change of Circuit
not working Board in the Service Manual
booklet).

Computer communication board - ERROR • Bad connection Check connection

• Board faulty Replace the board

Communication - ERROR xxxxx • Cable errors Check cables to board or replace


the board (see Change of Circuit
Board in the Service Manual
booklet).

Heater board - ERROR • Optional heater board in EPC not Check cables to board or replace
working the board (see Change of Circuit
Board in the Service Manual
booklet).

Vibration board - ERROR • Optional vibration board in EPC Check cables to board or replace
not working the board (see Change of Circuit
Board in the Service Manual
booklet).

Heater connection - ERROR • System cross-connection heater Check parameters and cable.
communication error

Temperature increase - TOO SLOW • Insufficient heating during start Check heater function.
(Ti 53)

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

• Recirculating oil not cooling Reset alarm to continue.

18 1810573-02
S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING 3 ALARM TESTS

3 Alarm Tests

NOTE

If any parameter value is changed to activate an


alarm, do not forget to reset to the original value
before operation.

Alarm message Red Sequence Method Termin Reaction


diode al
Standard functions
Bowl speed sensor - ERROR Standst. Start separator with sensor X6:1
disconnected.
POWER FAILURE Start Switch power off / on during
operation
Feed pressure PT1 - HIGH PT1 Start Decrease limit (Pr14)
Feed pressure PT1 - LOW PT1 Start Increase limit (Pr15)
Feed pressure sensor PT1 - PT1 Start Disconnect sensor X5:4
ERROR
Pump starter - FAILURE Pump Start Switch pump off
Oil feed - TEMPERATURE HIGH TT Start Decrease limit (Pr16/Pr19) V1 off.
Heating off.
Oil feed - TEMPERATURE LOW TT Start Increase limit (Pr17/Pr20) or . V1 off
decrease Ti 53
Temperature alarm sensor - TT Start Disconnect sensor X5:2 V1 off
ERROR Heating off.
Bowl speed - HIGH Separation Decrease limit (Fa10) Stop
sequence.
Bowl speed - LOW Separation Increase limit (Fa11) Stop
sequence.
Oil backpressure PT4 - HIGH PT4 Separation Increase backpressure V1 off
Oil backpressure PT4 - LOW PT4 Separation Decrease backpressure V1 off
NO PT4 PRESSURE Timer Ti 71 Disconnect V4 X8:3
FEEDBACK DURING Tixx
Oil pressure sensor PT4 - PT4 Separation Disconnect sensor X5:6
ERROR

1810573-02 19
3 ALARM TESTS S-TYPE SEPARATION SYSTEM ALARMS AND FAULT FINDING

Alarm message Red Sequence Method Termin Reaction


diode al
Pressure in water outlet PT5 - PT5 Separation Force the paring tube
HIGH outwards or decrease limit
(Pr12)
Pressure in water outlet PT5 - PT5 Separation Force the paring tube
LOW inwards or increase limit
(Pr13)
Water pressure sensor PT5 - PT5 Separation Disconnect sensor X5:8
ERROR
Transducer value - HIGH MT Separation Decrease limit (Fa23) V1 off
Transducer value - LOW MT Separation Increase limit (Fa24) V1 off
Transducer - ERROR MT Separation Disconnect X2 cable plug
HIGH WATER CONTENT IN Separation Add much water to the feed V1 off
OIL and wait for 5 draining
actions. Discharge. After
another 5 drainings alarm is
given.
Discharge feedback - ERROR Discharge Disconnect SV15 X8:5 A second
attempt to
discharge will
take place
before alarm
and stop.
Emergency stop - BUTTON Separation Push the button Sep.motor off,
PUSHED heater off, feed
on for max.3
minutes. Feed
stops when
pressure
reaches Pr11.
Optional functions
Temperature control sensor - TT Start Disconnect X51:3
ERROR
Heater - FAULT Heater Start Disconnect X51:4
Sludge tank level - HIGH Tank Start Disconnect X201
Separator run-up - TOO LONG Start Decrease Ti 52 to 1. Start Sep. motor off.
the separator.
Temperature increase - TOO TT Start Start separator and EPC but
SLOW not heater, or start system
with Ti 53 set to 1.

20 1810573-02
Separation Unit 855/865

Installation System Reference


Printed Jan 2003
Book No. 1810818-02 V 2
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 & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2003.
Contents
1 Technical Data ...................................... 1 2.6.13 Transmitters Interconnection
Diagram ...............................................29
1.1 Demand Specifications Water .....1
2.6.14 Optional Equipment Interconnection
1.2 Demand Specifications Air ...........1
Diagram ...............................................30
1.3 System Data .....................................2
2.6.15 Power Circuits, Separator and Feed
Pump Circuit Diagram .........................31
2 Drawings .................................................... 6
2.6.16 Remote Start Interlock Circuit
2.1 General Flow Chart..........................6
Diagram (Optional) ..............................32
2.2 Separation Unit Flow Chart ..........7
2.6.17 Junction Box EPC Signal Cables
2.3 Separation Unit with Junction Interconnection Diagram
Boxes Flow Chart .............................8 (Optional)..............................................33
2.4 Dimension Drawings, Unit .............9 2.6.18 Junction Box EPC Signal Cables
2.4.1 Separation Unit SU 855 ..........................9 Interconnection Diagram
2.4.2 Separation Unit SU 865 ........................10 (Optional)..............................................34
2.4.3 Separation Unit SU 855 with Junction 2.6.19 Electric Heater Interconnection
Boxes ...................................................11 Diagram (Optional) ..............................35
2.4.4 Separation Unit SU 865 with Junction 2.6.20 Power Unit Circuit Diagram 0 – 24 kW
Boxes....................................................12 (Optional) .............................................36
2.4.5 Control Cabinet ...................................13 2.6.21 Power Unit Circuit Diagram 0 – 24 kW
cont. (Optional) ....................................37
2.4.6 Control Cabinet Cable Drawing ...........14
2.6.22 Power Unit Circuit Diagram
2.4.7 Junction Box Starter Connections .......15
72/380 – 415 kW – 440 V
2.4.8 Junction Box EPC Connections ...........16 (Optional)..............................................38
2.5 Electrical System Layout ...........17 2.6.23 Power Unit Circuit Diagram
2.6 Electrical Diagrams .......................18 72/380 – 415 kW – 440 V cont.
2.6.1 Starter Basic Design Cable List ..........18 (Optional)..............................................39
2.6.2 Starter Optional Equipment Cable 2.6.24 Electrical System Layout
List ........................................................19 CBM Heater ..........................................40
2.6.3 Starter and Feed Pump 2.6.25 Steam Heater Interconnection
Interconnection Diagram .....................20 Diagram (Optional) ..............................41
2.6.4 Starter and Feed Pump Circuit 2.6.26 Electric Heating System Cable List
Diagram ...............................................21 (Optional)..............................................42
2.6.5 Junction Box Starter Interconnection 2.6.27 Electrical System Layout, EHS-62 ........44
Diagram (Optional) ...............................22 2.6.28 Heatpac 7/8 kW, 14/16 kW
2.6.6 Sludge Handling Interconnection Interconnection Diagram ......................45
Diagram (Optional) ..............................23 2.6.29 Heatpac 22/24 kW Interconnection
2.6.7 Sludge Handling Circuit Diagram Diagram ................................................46
(Optional) .............................................24 2.6.30 Heatpac 36/40 kW Interconnection
2.6.8 Space Heating and Heat Tracing Diagram ................................................47
Interconnection Diagram 2.6.31 Heatpac 50/56 kW, 65/72 kW
(Optional)..............................................25 Interconnection Diagram ......................48
2.6.9 Space Heating and Heat Tracing 2.7 Single Module Flow Chart ..........49
Circuit Diagram (Optional) ...................26 2.8 Double Module, Parallel,
2.6.10 Control Cabinet Basic Design Standby, and Heater Cross
Cable List ............................................27 Connection Flow Chart ................50
2.6.11 Control Cabinet Optional Equipment 2.9 Dimension Drawings,
Cable List (as ordered).........................27 Modules .............................................51
2.6.12 Solenoid Valves Interconnection 2.9.1 Single Module (S, T, H) ........................51
Diagram ...............................................28 2.9.2 Single Module (E) ................................52

1810818-02
2.9.3 Double Module SL, TL, HL, 4.9 Sludge Tank..................................... 77
with Pipe Rack ..................................... 53 4.10 Sludge Piping .................................. 79
2.9.4 Double Module SL, TL, HL,
without Pipe Rack ................................ 54 5 Commissioning and Initial
2.9.5 Double Module EL .............................. 55 Start ...........................................................81
2.10 Assembly Drawings, Modules ... 56 5.1 Completion Check List ................ 81
2.10.1 Single Module S, T, H Assembly 5.2 Initial Start-up................................. 83
Drawing ............................................... 56 5.2.1 Calculating Operating Pressure .......... 85
2.10.2 Single Module S, T, H with Feed
Pump 038, Assembly Drawing ............ 57 6 Shut-down and Storage ................86
2.10.3 Single Module S, T, H with Feed 6.1 Shut-down after Use ..................... 86
Pump 045/045, Assembly Drawing ..... 58 6.2 Protection and Storage ............... 87
2.10.4 Single Module E, Assembly 6.3 Reassembly and Start up ............ 89
Drawing ............................................... 59
2.10.5 Single Module E with Feed Pump,
Assembly Drawing............................... 60
2.10.6 Double Module SL, TL, HL, with
Pipe Rack Assembly Drawing ............. 61
2.10.7 Double Module SL, TL, HL, without
Pipe Rack Assembly Drawing ............. 62
2.10.8 Double Module EL, Assembly
Drawing ............................................... 63

3 Remote Operation
Systems ................................................... 64

4 Specifications/
Recommendations ........................... 67
4.1 Lifting Instructions ....................... 67
4.1.1 Lifting the Separation Unit ................... 67
4.1.2 Lifting the Single Module (S, T, H) ...... 68
4.1.3 Lifting the Single Module (S, T, H)
with fork lift........................................... 68
4.1.4 Lifting the Single Module (E) ............... 69
4.1.5 Lifting the Single Module (E)
with fork lift........................................... 69
4.1.6 Lifting the Double Module
(SL, TL, HL) ......................................... 70
4.1.7 Lifting the Double Module (EL) ........... 70
4.2 Cables ............................................... 71
4.3 Cable Routing ................................. 72
4.4 Oil, Water, Steam, and
Condensate Piping ........................ 72
4.5 Ambient Temperature
Limitation ......................................... 73
4.6 Heat Tracing and Insulation
of Fuel Oil, Sludge, and
Steam Pipes .................................... 73
4.7 Sludge Removal Kit ...................... 74
4.8 More than one Oil Tank ............... 76

1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 1 TECHNICAL DATA

1 Technical Data
1.1 Demand Specifications Water

Specific requirements regarding the quality 5 pH > 6


of water Increased acidity (lower pH) increases the
Operating water is used in the separator for risk for corrosion; this is accelerated by
several different functions: e.g to operate the increased temperatures and high chloride
discharge-mechanism, to lubricate and cool ion content.
mechanical seals, etc. 6 Water pressure 200 – 600 kPa (2 – 6 bar).
Alfa Laval accepts no liability for consequences
If the operating water is of poor quality, it
arising from unsatisfactorily purified operating
may with time cause erosion, corrosion
water supplied by the customer.
and/or operating problems in the separator
and must therefore be treated to meet
certain demands

The following requirements are of


1.2 Demand
fundamental importance. Specifications Air
1 Clear water, solids content < 0,001% of Specific requirements regarding the quality
volume. Deposits must not be allowed to of air
form in certain areas in the separator.
1 Pressure 500 – 700 kPa (5 – 7 bar).
2 Max. particle size 50 µm.
2 Free from oil.
3 Total hardness ≤180 mg CaCo3 per litre,
3 Dry, with dew point min. 10 °C below
which corresponds to 10 °dH or 12,5 °E.
ambient temperature.
Hard water may with time form deposits in
the operating mechanism. The precipitation
rate is accelerated with increased operating
temperature and low discharge frequency.
These effects become more severe the
harder the water is. NOTE

4 Chloride content ≤100 ppm NaCl (equivalent Electrical interconnections must be made by
qualified electricians.
to 60mg Cl/l). Chloride ions contribute to
Mechanical interconnections must be made by
corrosion on the separator surfaces in qualified mechanical technicians.
contact with the operating water, including
the spindle. Corrosion is a process that is
accelerated by increased separating
temperature, low pH, and high chloride ion
concentration. A chloride concentration
above 60 mg/l is not recommended.

1810818-02 1
1 TECHNICAL DATA SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

1.3 System Data


Media Fuel oil and lube oils for diesel engines
Feed density, max. 1010 kg/m³ at 15 °C
Viscosity, max. 55 cSt at 100 °C (700 cSt at 50 °C)
Pressure:
oil inlet Max. 2 bar at separator inlet
oil outlet Max. delivery head 2.5 bar
sludge outlet from separator open outlet
sludge outlet from sludge pump Max. 5 bar at 6 bar air pressure
separated water Max. 4 bar
Feed temperature, max. 98 °C ± 2 °C
Ambient temperature Min. +5 °C, max. +55 °C
Sludge production (including displacement water) max
SU 855 7.2 litre/discharge
SU 865 10.0 litre/discharge
Operating water pressure Min 2 bar, max. 6 bar
Operating water temp. Min. +5 °C, max. +55 °C (unheated water)
Operating water consumption
SU 855 8.5 litre/discharge
SU 865 11.5 litre/discharge
Make up water 1.7 litre/hour
Operating water flow from SV10:5.5 l/m
from SV 15:11.0 l/m
from SV 16:2.8 l/m
Air quality Instrument air
Air pressure Min. 5 bar, max. 7 bar
Drip tray volume Max. 60 litre
Drain connection size 2x1” (internally threaded)
Mains supply voltage 3x400/440/480/575/690 V ± 10%
Power consumption
SU 855 Max. 17.5 kW, 50 A (including feed pump)
SU 865 Max. 24.0 kW, 50 A (including feed pump)
Power supply voltage EPC, Electric heat tracing 230 V /110V/115 V/100V ± 10%, max. fuse 10 A
Power consumption, EPC 230 VA
Power consumption, electric heat tracing 600 VA
Control voltage, operating 24 V AC
Frequency 50 or 60 Hz ± max. 5%
Enclosure class Min. IP 54
Control cabinet max. distance from unit 50 m
Storage time before use (with bowl removed) 6 months
Storage temp. Min. +0 °C, max. +70 °C
Storage humidity Relative humidity (RH) 10% – 95 % Non Condensing

2 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 1 TECHNICAL DATA

Weight, Units and Modules complete:


SU 855 1060 kg
SU 865 1200 kg
SU 855 S, T, H 1380 kg
SU 865 S, T, H 1520 kg
SU 855 E 1610 kg
SU 865 E 1750 kg
SU 855 SL, TL, H L 3100 kg
SU 865 SL, TL, H L 3380 kg
SU 855 EL 3550 kg
SU 865 EL 3830 kg
Service intervals: Note! Regularly check connections. Tighten if necessary.
Unit Overhaul every 3 years operation
Sludge Removal Kit Inspection every 4000 hours or 6 months operation
Overhaul every 12000 hours or 18 months operation
CBM heater CIP when needed
EHM heater Cleaning:
New heater – after max. three months
LO – Every 3 months if the elements are heavily soiled on
latest inspection; every 6 months if they are only slightly
soiled
HFO/DO – Every 12 months
Separator Inspection every 4000 hours or 6 months operation
Overhaul every 12000 hours or 18 months operation
Note! Cleaning In Place (CIP) is recommended to avoid Prior to inspection and overhaul
manual internal cleaning of the bowl. The following intervals HFO 1 – 2 months depending on oil quality
are recommended:
LO (Cross-head engines) 1 – 2 months depending on oil
quality and engine condition.
LO (Trunk engines) 1 month

1810818-02 3
1 TECHNICAL DATA SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

Separation Unit Planned Maintenance Kits


Hours Period Separator Unit Sludge Feed Control El. CIP CBM
pump pump cabinet heater
1000
2000
4000 6 months Inspection

12000 18 months Overhaul Overhaul

24000 3 years Overhaul Overhaul Overhaul Overhaul

As necessary Repair Repair CIP


(components)

With delivery Inspection


Tools
Backup Support Support

4 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 1 TECHNICAL DATA

1810818-02 5
6
ALFA LAVAL HEATING
SYSTEMS
2 DRAWINGS

Ref. 569368 Rev. 0


CBM-steam
Control unit
Drain

To sludge
pump Starter

Circuit board
–Vibration CBM-hot water – thermal oil
–Communication
2 Drawings

–Heater control
–Remote alarms
2.1 General Flow Chart

EHM-electric

POWER
UNIT

201 Oil inlet

1810818-02
206 Water for water seal and
displacement

209 Oil Recirculation to tank


Lo-application Alt
220 Clean oil outlet
Alt 221 Water outlet
MCFR FC
Flow Control Flow Control Alt 222 Sludge discharge outlet
Sludge tank 371 Operating water

375 Opening/closing water

463 Drain

501 Operating air

Heating system
Optional Alfa
Laval delivery
Feed pump
Block mounted

Unit
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X017733A
Ref. 569365 Rev. 0
Drain
Control unit
To sludge
pump

Starter

Circuit board
–Vibration 201 Oil inlet
–Communication
–Heater control 206 Water for water seal and
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

–Remote alarms displacement

209 Oil Recirculation to tank

220 Clean oil outlet

1810818-02
2.2 Separation Unit Flow Chart

221 Water outlet

222 Sludge discharge outlet

371 Operating water

375 Opening/closing water

463 Drain

501 Operating air

Optional Alfa
Laval delivery
Alt
Block mounted
Lo-application
Unit

Alt
Sludge tank

7
2 DRAWINGS

X0 1 7 7 3 5 A
8
2 DRAWINGS

Ref. 569366 Rev. 0


Control unit
Drain

To sludge
pump
Starter

Circuit board
–Vibration
–Communication
–Heater control

Junction boxes
–Remote alarms

1810818-02
201 Oil inlet

206 Water for water seal and


displacement

209 Oil Recirculation to tank

220 Clean oil outlet

221 Water outlet

222 Sludge discharge outlet

371 Operating water


Alt 375 Opening/closing water

Lo-application 463 Drain

501 Operating air

Alt 540 Ventilation


Sludge tank
2.3 Separation Unit with Junction Boxes Flow Chart
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X0 1 7 9 6 3 A
201 Oil inlet

209 Oil Recirculation to tank


When lifting bowl parts over adjoining separator
220 Clean Oil outlet

221 Water outlet

222 Sludge discharge outlet

371 Operating water pH value not


below 6pH. Pressure 200-600
kPa (2-6 bar). Salinity max
60ppm Cl
(equivalent to 100 ppm NaCl ).
Temp. min +5°C, max. +55°C.

463 Drain

501 Operating air. Instrument air,


pressure 500-700 kPa (5-7
bar).

Ref. DIN 570328 Rev. 0, JIS 570330 Rev. 0


709 Mains supply 3x400/440/480/
2.4.1 Separation Unit SU 855

575/690V

791 Earthing of unit


Alternative
connection 799 EPC 50 supply voltage, 230V,
110/115V or 100V.

* Optional

* Optional
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

(Flange conn.) Connections


A DIN Flange DN40-PN16-
2.4 Dimension Drawings, Unit

DIN2633
JIS Flange 40A-16K-JIS

1810818-02
B2223

B DIN Flange DN25-PN16-


DIN2543
JIS Flange 25A-16K-JIS
B2223

C DIN Flange DN100-PN16-


DIN2543
-Fastening: JIS Flange 100A-10K-JIS
Bolting 4xM16 B2222
Tightening
torque 222 Nm D ISO G 1/4
-Welding E ISO G 1/2

F ISO G 1

Foundation plan, view Weight: 1060 kg


from top
Center of gravity

* Sludge removal kit optional

Control cabinet and frame for


components to be supported if necessary
using existing screws.

9
2 DRAWINGS

X018531B
10
201 Oil inlet

209 Oil Recirculation to tank


2 DRAWINGS

220 Clean Oil outlet


When lifting bowl parts over adjoining separator
221 Water outlet

222 Sludge discharge outlet

371 Operating water pH value not


below 6pH. Pressure 200-600
kPa (2-6 bar). Salinity max
60ppm Cl
(equivalent to 100 ppm NaCl ).
Temp. min +5°C, max. +55°C.

463 Drain

501 Operating air. Instrument air,

Ref. DIN 570336 Rev. 0, JIS 570337 Rev. 0


pressure 500-700 kPa (5-7
bar).
2.4.2 Separation Unit SU 865

709 Mains supply 3x400/440/480/


575/690V

791 Earthing of unit

799 EPC 50 supply voltage, 230V,


110/115V or 100V.
Alternative
connection

* Optional

* Optional
Connections
(Flange conn.) 65 A DIN Flange DN40-PN16-

1810818-02
DIN2633
JIS Flange 40A-16K-JIS
B2223

B DIN Flange DN25-PN16-


DIN2543
JIS Flange 25A-16K-JIS
B2223

C DIN Flange DN125-PN16-


DIN2543
JIS Flange 125A-10K-JIS
B2222
-Fastening:
Bolting 4xM16 D ISO G 1/4
Tightening
torque 222 Nm E ISO G 1/2
-Welding F ISO G 1

Weight: 1200 kg

Center of gravity

Foundation plan, view * Sludge removal kit optional


from top
Control cabinet and frame for
components to be supported if necessary
using existing screws.
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X018532B
201 Oil inlet

209 Oil Recirculation to tank

When lifting bowl parts over adjoining separator 220 Clean Oil outlet

221 Water outlet

222 Sludge discharge outlet


371 Operating water pH value not
below 6pH. Pressure 200-600
kPa (2-6 bar). Salinity max
60ppm Cl
(equivalent to 100 ppm NaCl ).
Temp. min +5°C, max. +55°C.

463 Drain
501 Operating air. Instrument air,
pressure 500-700 kPa (5-7 bar).

Ref. DIN 570329 Rev. 0, JIS 570331 Rev. 0


709 Mains supply 3x400/440V/480/
575/690V
791 Earthing of unit

799 EPC 50 supply voltage, 230V,


View F – F 110/115V or 100V.
Alternative
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

connection

* Optional

* Optional
Connections

(Flange conn.) A DIN Flange DN40-PN16-


DIN2633

1810818-02
JIS Flange 40A-16K-JIS B2223

B DIN Flange DN25-PN16-


DIN2543
JIS Flange 25A-16K-JIS B2223

C DIN Flange DN100-PN16-


DIN2543
2.4.3 Separation Unit SU 855 with Junction Boxes

JIS Flange 100A-10K-JIS


B2222

D ISO G 1/4
-Fastening:
Bolting 4xM16 E ISO G 1/2
Tightening torque
222 Nm F ISO G 1
-Welding Weight: 1020 kg + 60 kg

Center of gravity
Foundation plan, view
from top * Sludge removal kit optional

Control cabinet and frame for


components to be supported if necessary
using existing screws.

11
2 DRAWINGS

X018541B
12
201 Oil inlet

209 Oil Recirculation to tank


2 DRAWINGS

220 Clean Oil outlet

221 Water outlet

222 Sludge discharge outlet


When lifting bowl parts over adjoining separator
371 Operating water pH value not
below 6pH. Pressure 200-600
kPa (2-6 bar). Salinity max
60ppm Cl
(equivalent to 100 ppm NaCl ).
Temp. min +5°C, max. +55°C.

463 Drain

501 Operating air. Instrument air,

Ref. DIN 570338 Rev. 0, JIS 570339 Rev. 0


pressure 500-700 kPa (5-7 bar).

709 Mains supply 3x400/440V/480/


575/690V

791 Earthing of unit

799 EPC 50 supply voltage, 230V,


110/115V or 100V.

Connections

View F – F A DIN Flange DN40-PN16-


Alternative DIN2633

1810818-02
connection JIS Flange 40A-16K-JIS B2223

* Optional
* Optional
B DIN Flange DN25-PN16-
(Flange conn.) DIN2543
JIS Flange 25A-16K-JIS B2223

C DIN Flange DN125-PN16-


DIN2543
2.4.4 Separation Unit SU 865 with Junction Boxes

JIS Flange 125A-10K-JIS


B2222

D ISO G 1/4

E ISO G 1/2

F ISO G 1
-Fastening: Weight: 1160 kg + 60 kg
Bolting 4xM16
Tightening torque Center of gravity
222 Nm
* Sludge removal kit optional
-Welding

Control cabinet and frame for


Foundation plan, view components to be supported if necessary
from top using existing screws.
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X0 1 8 5 4 2 B
Ref. 1765860 Rev. 2
On/off, heat tracing (optional)
On/off, sludge pump (optional EPC cabinet section
2.4.5 Control Cabinet

On/off, feed pump


PC connection
On/off, Separator

Selector switch, CIP, MAN, AUTO


Operator panel
Emergency stop, separator
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

Sludge valve interlock


indication (optional) Amperemeter, separator

1810818-02
Starter
cabinet
Main switch
Separator interlock indication section
(optional)

Nut for grounding screw (M8)

13
2 DRAWINGS

X0 1 7 7 6 3 A
14
2 DRAWINGS

Ref. 1765865 Rev. 3


Cable 39 (opt. **)
Separator current over Separator current up
25 A to 25 A Cable 41 (opt. *) Cable 38
(opt. **)
Cable 44 (opt. *) Cable 34
(opt. **)
(Cable 13)
Cable 32
(Cable 12) (opt. **)
EPC 50 EPC 50
I/O I/O Cable 31
EPC 50 Cable 11
(opt. **)
OP Cable 16 Cable 22 (**)

Cable 15 (Cable 19)

EPC cabinet section


(EMC)
Cable 14 Cable 18
(Cable 20) (EMC)
(Cable 21)
Cable 40 (opt. *) Cable 17
2.4.6 Control Cabinet Cable Drawing

Cable 3 Spare, M20

Cable 4 (opt. *) Cable 23

1810818-02
Spare, M25
Cable 74 (opt.)

Cable 71 (opt.)
Cable 72 (opt. *)
Cable 73 (opt.)

Starter cabinet section


Cable 45 (opt.)
Cable 35 (opt.)

Cable 37 (opt.)
Cable 36 (opt.)
Spare, M20

opt. = Optional as per order


* = Module mounted or customer supplied
** = Customer supplied

= Screw plug (May be replaced by optional gland)

Cable glands without mounted cables are sealed with plastic inserts
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X0 1 7 7 7 3 B
Cable gland M25 for
cable 11-17 mm Cable gland M25 for
cable 11-17 mm
Reducing
Reducing

Ref. 1765917 Rev.1


fitting M40/
M25 fitting M40/
M25

Cable gland
M25 for cable
11-17 mm
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

Terminals
Cable gland
2.4.7 Junction Box Starter Connections

M20 for cable

1810818-02
8-13 mm

Terminal support

Cabinet

Earth pin M8
Earthing braid

15
2 DRAWINGS

X0 1 8 2 1 2 A
16
Cable gland M25 for Cable gland M20 for
cable 11-17 mm cable 8-13 mm
Tower stack light
2 DRAWINGS

Gland M 20

Ref. 1765917 Rev. 1


Gland M 25

Terminal
support

Terminals
2.4.8 Junction Box EPC Connections

Cabinet

1810818-02
Earth pin M8 Top view
Earthing braid
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X0 1 8 2 2 2 A
Ref. 1765898 Rev. 2
Data
Comm.
System

Temp. Al.

SUM
Remote
OP unit
Remote
Alarm
Emergency

Junc. Control unit


box

Circuit board
–Vibration
–Communication
–Heater control
–Remote alarms
Heat tracing system
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

Junc. Starter
box
2.5 Electrical System Layout

1810818-02
Mains supply
Power supply
Heating system
See also 1765867 for Control unit EPC
electric heater; 1765868
SRK
for steam heater
Interconnection diagrams for:
Sludge tank Sludge Starter: 1765834, 1765835, 1765836
Feed pump pump Control unit EPC: 1765837, 1765838,
1765839

Cable lists:
Starter: 1765797
Control unit EPC: 1765876
Optional Alfa Laval
delivery
Block mounted

Unit

17
2 DRAWINGS

X017784A
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6 Electrical Diagrams

2.6.1 Starter Basic Design Cable List


No. Type Connection point Instruction Connection point Remarks
A B
Basic design (currents according to order)
1 MPRXCX 3x4 Mains supply Starter Fuse 20 A1)
1 MPRXCX 3x10 Mains supply Starter Fuse 35 A1)
1 MPRXCX 3x16 Mains supply Starter Fuse 50A1)
1 MPRXCX 3x25 Mains supply Starter Fuse 63 A1)
1 MPRXCX 3x35 Mains supply Starter Fuse 80 A1)

2 MPRXCX 2x1.5 Power supply 2 Starter Fuse 10 A1)

3 MPRXCX 3x1.5 Starter Marked 3A Separator motor 4 – 6.3 A


3 MPRXCX 3x2.5 Starter Marked 3B Separator motor 6.3 – 16 A
3 MPRXCX 3x4 Starter Marked 3C Separator motor 16 – 20 A
3 MPRXCX 3x6 Starter Marked 3D Separator motor 20 – 25 A
3 MPRXCX 3x10 Starter Marked 3E Separator motor 25 – 32 A
3 MPRXCX 3x16 Starter Marked 3F Separator motor 32 – 45 A
3 MPRXCX 3x25 Starter Marked 3G Separator motor 45 – 63 A
1)
Cable not included in Alfa Laval delivery.
2) Not used in version ‘single supply’.
Ref. 1765797 Rev.3

18 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.6.2 Starter Optional Equipment Cable List


No. Type Connection point Instruction Connection point Remarks
A B
Feed pump, optional or customer owned (as ordered)
1)
4 MPRXCX 3x2.5 Starter Drawing Feed pump
1766655
Sludge handling (as ordered)
35 RFE-HF 1x4x0.75 Starter GS, Valve switch
36 RFE-HF 1x2x0.75 Starter LS, Sludge level
37 RFE-HF 1x2x0.75 Starter SV6, Solenoid valve For pneumatic
sludge pump

73 2x0.75 Starter Heatpac on tank Included in


heater element
Space heating (as ordered)
71 MPRXCX 2x1.5 Starter Separator motor
72 MPRXCX 2x1.5 Starter Feed pump 1)

Heat tracing (as ordered)


74 MPRXCX 4x1.5 Starter Thermostat
75 3x1.5 Starter Drawing Heating cable
7060227
1)
Cable not included in Alfa Laval delivery except when feed pump ordered as part of a Module including
Pumping and Heating Unit.
Ref. 1765797 Rev. 3

1810818-02 19
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.3 Starter and Feed Pump Interconnection Diagram

*Replaces jumper in terminals ** Internal connections *** 1765838

Mains suppy
3x400, 440, 480, 575 or 690 V AC, 50/60 Hz
(Cable not included in Alfa Laval delivery)

Separator motor

Feed pump motor


Optional

Contactor response, separator


Potential free contacts, max. 250 V, 0.5 A

Contactor response, feed pump


Potential free contacts, max. 250 V, 0.5 A

Emergency shut-down (ESD) signal (optional)


(Replaces ‘Systems Emergency Stop’ when used.
See also drawing 1765837. Cable not included in Alfa Laval
delivery).
Separator emergency stop

STARTER
(Optional, external)
(Cable not included in Alfa Laval
delivery)

Sludge valve interlock switch


Optional

Feed pump Remote stop


Remote start
(Cable not included in Alfa Laval delivery)

Tripped motor circuit breakers (optional)


Potential free NC contacts, max. 250 V, 0.5 A
(Cable not included in Alfa Laval delivery)
Power supply for EPC 50
100, 110/115 or 230 V AC, 50/60 Hz
Max. fuse: 10 A. (Cable not included in Alfa Laval delivery)
X0 1 7 7 9 4 B

Ref. 1765834 Rev. 3

20 1810818-02
Ref. 1765856 Rev. 3
EMERGENCY STOP

START SEPARATOR
CONTACTOR,
SEPARATOR

AUTO MODE (Optional)


SLUDGE PILOT LAMP,
VALVE SEPARATOR
INTERLOCK
SWITCH
(Optional)
SEPARATOR FEEDBACK

(Remote indication)
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

SLUDGE VALVE INDICATION


Optional

CONTACTOR, FEED
PUMP

1810818-02
START FEED PUMP EPC 50, OP
(Internal) PILOT LAMP, FEED
2.6.4 Starter and Feed Pump Circuit Diagram

PUMP

(Heater interlock)
FEED PUMP FEEDBACK

(Remote indication)

* = 1765854/1767264
** = 1765858/1767265
*** = 1765871
Conector in panel front 5-
pole, RS232C

21
2 DRAWINGS

X017862B
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.5 Junction Box Starter Interconnection Diagram (Optional)

To Unit To Starter
Junction Box

optional

optional

optional

optional

optional

optional

optional

Cables between Junction Box and


For cable information, see Cable
Starter are not included in the Alfa
X018232A

List 1765797
Laval delivery.

Ref. 1765886 Rev. 1

22 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.6.6 Sludge Handling Interconnection Diagram (Optional)

LS
Level switch,
Sludge tank

STARTER
SV6
Solenoid valve
for control of
pneumatic
sludge pump

X0 1 7 8 0 3 A
Ref. 1765835 Rev. 1

1810818-02 23
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.7 Sludge Handling Circuit Diagram (Optional)

PNEUMATIC SLUDGE PUMP


SOLENOID VALVE FOR

SLUDGE PUMP ON
(MOMENTARY OP.)

LEVEL SWITCH,
SLUDGE TANK
SV6

LS
S4
SLUDGE PUMP CONTROL

SLUDGE LEVEL

X017902A

Ref. 1765857 Rev. 1

24 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.6.8 Space Heating and Heat Tracing Interconnection Diagram (Optional)

Space heater,
Separator motor
230 V AC

STARTER
Space heater,
Feed pump
motor
230 V AC

Heat tracing system

Thermostat (S61)
(24 V AC)

Heating cable
(230 V AC)
STARTER

Heating of SRK
(230 V AC)
X017813B

Ref. 1765836 Rev. 2

1810818-02 25
26
2 DRAWINGS

Ref. 1765858 Rev. 2


Heat tracing
pipes
from
1765854

Heat tracing
Heating of SRK

1810818-02
AC 230 V AC 230 V AC 230 V AC 230 V
SPACE HEATER SPACE HEATER HEAT TRACING HEAT TRACING
SEPARATOR FEED PUMP PIPES TANK IN SRK
SPACE HEATING OPTION MOTOR MOTOR
2.6.9 Space Heating and Heat Tracing Circuit Diagram (Optional)
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X017913A
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.6.10 Control Cabinet Basic Design Cable List


No. Type Connection point Instruction Connection point Remarks
A B
Basic design
11 RFE–HF 1x2x0.75 EPC 50 SV1
12 RFE–HF 1x2x0.75 EPC 50 SV4
13 RFE–HF 1x2x0.75 EPC 50 SV5
14 RFE–HF 1x2x0.75 EPC 50 SV10
15 RFE–HF 1x2x0.75 EPC 50 SV15
16 RFE–HF 1x2x0.75 EPC 50 SV16
17 RFE–HF 1x2x0.75. EPC 50 SSC PT1
18 RFE–HF 1x2x0.75 EPC 50 SSC PT4
19 RFE–HF 1x4x0.75 EPC 50 SSC + EMC MT
20 RFE–HF 4x2x0.50 EPC 50 EMI protection ST, (YT, SS)
21 RFE–HF 1x2x0.75 EPC 50 SSC PT5
1)
22 RFE–HF 1x2x0.75 EPC 50 SUM Alarm
23 RFE–HF 4x2x0.75 EPC 50 SSC TT1/TT2
1)
Cable not included in Alfa Laval delivery.

2.6.11 Control Cabinet Optional Equipment Cable List (as ordered)


No. Type Connection point Instruction Connection point Remarks
A B
31 RFE-HF 1x4x0.75 EPC 50 SSC + EMC Remote OP unit 1)

1)
32 RFE-HF 1x4x0.75 EPC 50 Remote temp.
1) 2)
34 RFE-HF 1x4x0.75 EPC 50 SSC + EMC Comm. module
38 MPRXCX 4X1.5 EPC 50 Syst. emergency 1)

1)
39 RFE-HF 1x2x0.75 EPC 50 Junction box (EPC)
Electric Heater (as ordered)
40 RFE-HF 4x2x0.75 EPC 50 Power unit
45 RFE-HF 1x2x0.75 Starter Power unit
Steam Heater (as ordered)
41 RFE-HF 1x4x0.75 EPC 50 Steam regulating valve
44 RFE-HF 1x2x0.75 EPC 50 Shut-off valve
1)
Cable not included in Alfa Laval delivery.
2)
Cable must be less than 25 metres long to avoid drop in voltage.
Ref. 1765876 Rev. 2

1810818-02 27
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.12 Solenoid Valves Interconnection Diagram

Jumper at 110/115 V AC
Jumper at 100 V AC

Jumper at 230 V AC
alternative voltages
Connections for

ESD relay option


Systems emergency stop (Control
voltage off)
Note! ESD relay option replaces this
when used.
(Cable not included in Alfa Laval
delivery)

Signal to alarm panel.


Pot. free contact, opens at alarm

Max. 50 V AC/DC, 1.0 A


(Cable not included in Alfa Laval delivery)

connection to
Present
internal

CONTROL UNIT EPC 50


S1
SV1
Oil feed

SV4
Oil outlet

SV5
Water outlet

SV10
Water seal

SV15
Opening water

SV16
Closing water
X0 1 7 8 2 3 A

* Replaces jumper in terminals.

Ref. 1765837 Rev. 1

28 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.6.13 Transmitters Interconnection Diagram

* Termination jumper.
Only at sattbus end
units

** 1765839
*** 1765834, 1767266

PT1

PT4

PT5

Temp. sensor,

CONTROL UNIT EPC 50


2xPT 100
TT 1 (Alarm)

Heater board
TT 2 (Control)

Optional
Speed transmitter
(Cable included in
separator delivery)
Internal connections

Vibration transmitter
(Factory mounted
when used)

Note!
Separator interlock
switch (Optional)
connections
Internal

MT
Water transducer
X0 1 7 8 3 3 B

Ref. 1765838 Rev. 3

1810818-02 29
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.14 Optional Equipment Interconnection Diagram

** = 1765838

VIBR. BOARD
Remote OP unit
* Termination jumper.
(Only at sattbus end
units)

Standstill indication
In Junction Box for
signal cables

Remote alarms ind.

CONTROL UNIT EPC 50


High temp. indication

Low temp. indication


Pot. free contacts.
Max. 50 V AC/DC, 1.0 A
Contacts close at
alarm.

I/O – EXPANSION BOARD


Remote operation
Remote mode selected
(output 24 VAC)
Sep. status indication
(output 24 VAC)

Separation Start/Stop
Note!
Jumper X71:1 to X71:3 to avoid
false alarm when not used.
COMM. BOARD

Data communication
PROFIBUS
X017843B

(Cables not included in Alfa Laval delivery)

Ref. 1765839 Rev. 3

30 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.6.15 Power Circuits, Separator and Feed Pump Circuit Diagram

CONT.

Feed pump
(Optional)
Separator
Alt. over 25A

Mains supply
1765858
to Q8 on
EPC 50 I/O module

Power supply for


EPC 50

X017853A

Ref. 1765854 Rev. 2

1810818-02 31
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.16 Remote Start Interlock Circuit Diagram (Optional)

SEPARATOR INTERLOCK
AUX. RELAY

AUX. RELAY

INDICATION
Separator interlock switch
(optional)

VIBRATION
BOARD

X0 1 7 8 7 3 A

Ref. 1765871 Rev. 2

32 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.6.17 Junction Box EPC Signal Cables Interconnection Diagram (Optional)

Junction Box
To Unit To EPC-50

For cable information, see Cable Cables between Junction


List 1765876 Box and EPC are not
included in the Alfa Laval
X0 1 8 2 4 2 A

delivery.

Ref. 1765887 Sheet 1 Rev. 1

1810818-02 33
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.18 Junction Box EPC Signal Cables Interconnection Diagram (Optional)

For cable information, see Cable Cables between


List 1765876 Junction Box and EPC
are not included in the
Alfa Laval delivery.

Optional

Optional

Optional

To Unit To EPC-50
Junction Box
X0 1 8 2 5 2 A

Ref. 1765887 Sheet 2 Rev. 1

34 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.6.19 Electric Heater Interconnection Diagram (Optional)

Heatpac
power unit

See also
interconnection
diagram for
selected heater

CONTROL UNIT EPC 50


HEATER BOARD

Temp. sensor
2xPt 100

TT 1 (Alarm)

TT 2 (Control)
X017881A

Ref. 1765878 Rev. 0

1810818-02 35
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.20 Power Unit Circuit Diagram 0 – 24 kW (Optional)

ON
OFF

MAINS INPUT HEATER BLOCK 1 HEATER BLOCK 2


15 kW 7.5 kW
X018261A

Ref. 31830-635-80 Sheet 1 Rev. 1

36 1810818-02
Triac module phase L1
Triac phase L1
Triac pulse

Ref. 31830-635-80 Sheet 2 Rev. 1


Triac module phase L3

Triac phase L3

Heater contactor triac


Contactor
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

for pump

1810818-02
Step 1 Heater contactor step 1

Fault

Hold Auxillary relay


2.6.21 Power Unit Circuit Diagram 0 – 24 kW cont. (Optional)

Temp. switch

37
2 DRAWINGS

X0 1 8 4 5 1 A
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.22 Power Unit Circuit Diagram 72/380 – 415 kW – 440 V (Optional)

HEATER BLOCK 4
STEP 3, 32 kW
HEATER BLOCK 3
STEP 2, 16 kW
HEATER BLOCK 2
STEP 1, 8 kW
HEATER BLOCK 1
TRIAC, 16 kW
OFF
ON

MAINS INPUT

X0 1 8 2 8 1 A

Ref. 31830-640-80 Sheet 1 Rev. 0

38 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.6.23 Power Unit Circuit Diagram 72/380 – 415 kW – 440 V cont. (Optional)

Triac pulse Triac phase L1

Triac phase L3

Heater contactor triac


(16 kW)
Contactor
for pump

Step 1 Heater contactor step 1


(8 kW)

Step 2 Heater contactor step 2


(16 kW)

Step 3 Heater contactor step


3 (32 kW)

Fault

Hold Auxillary relay

Temp. switch
X018291A

Ref. 31830-640-80 Sheet 2 Rev. 0

1810818-02 39
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.24 Electrical System Layout CBM Heater

Interconnection diagram: 1765879


Cable list: 1765876

From EPC

Steam To separator

Condensate From feed pump

CBM Heater

From EPC

To separator
Hot oil or water Shut-off valve

From feed pump

CBM Heater
X0 1 7 8 9 3 A

Ref. 1765868 Rev. 0

40 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.6.25 Steam Heater Interconnection Diagram (Optional)

SR1
Steam reg. valve
(24 VAC motor,
max. 1.6 A)

HEATER BOARD
Steam shut-off

CONTROL UNIT EPC 50


(Output, 24 V AC)

Temp. sensor
2xPt 100

TT1 (Alarm)

TT2 (Control)
X0 1 7 8 9 1 A

Ref. 1765879 Rev. 0

1810818-02 41
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.26 Electric Heating System Cable List (Optional)


No. Type Connection point Instruction Connection point Remarks
A B
Basic design
Control cables
40 RFE – HF 7x2x0.75 Power Unit SSC EPC–50
45 RFE – HF 1x2x0.75 Power Unit Starter
46 RFE – HF 1x2x0.75 Power Unit Temp. sensor TT

Power Cables
Electric Heater size 7 – 24 kW, 400 V, 440 V, or 480 V
6 MPRXCX 3x6 Mains supply Fuse: 35 A Power Unit 1)

7 MPRXCX 3x6 Power Unit Heater


8 MPRXCX 3x2.5 Power Unit Heater
Electric Heater size 36 – 72 kW, 400 V, 440 V, or 480 V
6 MPRXCX 3x16 Mains supply Fuse: 63 A Power Unit (36/40 kW)1)
6 MPRXCX 3x25 Mains supply Fuse: 80 A Power Unit (50/56 kW)1)
6 MPRXCX 3x35 Mains supply Fuse: 100 Power Unit (65/72 kW)1)

7 MPRXCX 3x6 Power Unit Heater (fuse 25 A)2)


8 MPRXCX 3x2.5 Power Unit Heater (fuse 16 A)2)
9 MPRXCX 3x6 Power Unit Heater (fuse 25 A)2)
10 MPRXCX 3x16 Power Unit Heater (fuse 63A)2)
1)
Cable not included in Alfa Laval delivery.
2)
Internal fuses included in standard delivery.
For size 36/40 kW, cable 10 is not used.
For size 50/56 kW, cable 10 may be 3x6 if 25 A fuses are used.
Ref. 1765866 Rev. 1

42 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

Other equivalent and approved cables may be


used.
Cable areas are calculated with correction
factor 0.7.
Cables used are Shipboard Cables, designed
according to IEC 92-3.
Flame retardant according to IEC 332-3/A.
Halogen-free according to IEC 754-1
Code designations for cables obtainable
through cable producers Helkama, Finland,
and Acatel, France.
Where SSC is indicated it should be a Signal
Shielded Cable with the shield properly
connected to earth as shown in the electrical
drawings.
For other connections, an armoured cable may
be used provided the armour is connected to
earth, as shown in the electrical drawings, and
gives sufficient EMI protection. Copper wire
armouring is normally used.

1810818-02 43
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.27 Electrical System Layout, EHS-62

Interconnection diagram for Power Unit:


7/8 kW 1765869
14/16 kW 1765870
22/24 kW 1765872
36/40 kW 1765873
50/56 kW 1765874
65/72 kW 1765875

Interconnection diagram for Control Cabinet:


All sizes 1765878

Cable list: 1765866

HEATPAC
Power Unit

From EPC

From starter

Mains supply

To separator From feed pump


X0 1 7 8 9 4 A

Ref. 1765867 Rev. 0

44 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.6.28 Heatpac 7/8 kW, 14/16 kW Interconnection Diagram

Mains suppy
(Cable not included in Alfa Laval delivery)

Voltage 3x400, 440 or 480 V AC, 50/60 Hz


Power Unit 31830-6356-1 Max. fuse 35 A

Heater
0–7/8 kW,
0–14/16 kW

HEATPAC POWER UNIT


From Control Unit EPC-50

TT
High temp. sensor
on heater

Aux. contact on
contactor for pump
X0 1 7 8 9 5 A

Ref. 1765869 Rev. 0, 1765870 Rev. 0

1810818-02 45
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.29 Heatpac 22/24 kW Interconnection Diagram

Mains suppy
(Cable not included in Alfa Laval delivery)

Voltage 3x400, 440 or 480 V AC, 50/60 Hz


Power Unit 31830-6356-1 Max. fuse 35 A

Heater
0–14/16 kW

7/8 kW

From Control Unit EPC-50


HEATPAC POWER UNIT

TT
High temp. sensor
on heater

Aux. contact on
contactor for pump
X0 1 7 8 9 6 A

Ref. 1765872 Rev. 0

46 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.6.30 Heatpac 36/40 kW Interconnection Diagram

Mains suppy
(Cable not included in Alfa Laval delivery)

Voltage 3x400, 440 or 480 V AC, 50/60 Hz


Max. fuse 100 A

Heater
0–14/16 kW

7/8 kW

14/16 kW

HEATPAC POWER UNIT


From Control Unit EPC-50

TT
High temp. sensor
on heater

Aux. contact on
contactor for pump
X017897A

Ref. 1765873 Rev. 0

1810818-02 47
2 DRAWINGS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

2.6.31 Heatpac 50/56 kW, 65/72 kW Interconnection Diagram

Mains suppy
(Cable not included in Alfa Laval delivery)

Voltage 3x400, 440 or 480 V AC, 50/60 Hz


Max. fuse 100 A

Heater
0–14/16 kW

7/8 kW

14/16 kW

14/16 kW,

HEATPAC POWER UNIT


28/32 kW

From Control Unit EPC-50

TT
High temp. sensor
on heater

Aux. contact on
contactor for pump
X0 1 7 8 9 8 A

Ref. 1765874 Rev. 0, 1765875 Rev. 0

48 1810818-02
HEATING SYSTEMS

Ref. 569332 Rev. 0


Control unit CBM-steam
Drain

To sludge
pump Starter

Circuit boards: CBM-hot water – thermal oil


–Vibration
–Communication
–Heater control
–Remote alarms

EHM-electric

POWER
UNIT
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

201 Oil inlet


2.7 Single Module Flow Chart

1810818-02
206 Water for water seal and dis-
placement
SEPARATION UNIT 209 Oil Recirculation to tank

220 Clean oil outlet


Alt. HFO-
application 221 Water outlet
Alt. LO-application ALT.
222 Sludge discharge outlet

371 Operating water

375 Opening/closing water


ALT.
Sludge tank 463 Drain
Flow HEATING UNIT
control 501 Operating air

540 Ventilation

Optional Alfa
Laval delivery

Heating system
Block mounted

Unit

49
2 DRAWINGS

X017923A
50
HEATING SYSTEMS
2 DRAWINGS

Ref. 569331 Rev. 0


Drain Control unit
CBM-steam

To sludge
pump
Starter

Circuit board SEPARATION UNIT 2


–Vibration CBM-hot water – thermal oil
–Communication
–Heater control
–Remote alarms

EHM-electric
SEPARATION UNIT 1
POWER
UNIT

ALT.
Connection Flow Chart

Alt. LO-application
Alt. LO-application 201 Oil inlet
ALT. 206 Water for water seal and dis-
Sludge tank Sludge tank placement

1810818-02
209 Oil Recirculation to tank

220 Clean oil outlet

221 Water outlet

222 Sludge discharge outlet

371 Operating water


Flow
control
HEATING UNIT 1 HEATING UNIT 2 375 Opening/closing water

463 Drain

501 Operating air

540 Ventilation

Heating system
Heating system

Optional Alfa
Laval delivery

Block mounted

Unit
2.8 Double Module, Parallel, Standby, and Heater Cross
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X017933A
201 Oil inlet

209 Oil Recirculation to tank

220 Clean Oil outlet


When lifting bowl parts over adjoining separator
221 Water outlet

Ref. 570527 Rev. 0


222 Sludge discharge outlet

371 Operating water pH value not be-


low 6pH. Pressure 200-600 kPa (2-
6 bar). Salinity max 60ppm Cl
(equivalent to 100 ppm NaCl ).
Temp. min +5°C, max. +55°C.
451 Steam inlet (or T, H)
*) Optional
456 Condensate outlet (not for T or H)

463 Drain
2.9.1 Single Module (S, T, H)

501 Operating air. Instrument air, pres-


sure 500-700 kPa (5-7 bar).
*) Optional
709 Mains supply 3x400/440/480/575/
690 V
**) With CBM 26
791 Earthing of module
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

799 EPC 50 supply voltage, 230V, 110/


115V or 100 V.

1810818-02
Alternative Connections
connection
Foundation plan View A Flange DN40-PN16-DIN
from top
2.9 Dimension Drawings, Modules

B Flange DN65-PN16-DIN

C Flange DN25-PN16-DIN

D SU 855: Flange DN100-PN16-DIN


SU 865: Flange DN125-PN16-DIN

E Flange DN15-PN16-DIN
Flange DN20-PN16-DIN
Flange DN25-PN16-DIN
-Bolting 4xM16. F ISO G 1/4
Tightening torque:
222Nm. G ISO G 1/2
-Welding
H ISO G 1

J Flange DN65-PN6-DIN

For JIS application, counter flanges type


Weight, SU 855 S, T, H: 1380 kg *) Sludge removal kit ‘slip-on’ will be supplied.
Weight, SU 865 S, T, H: 1520 kg (optional)

Control cabinet and frame for components S (Steam)


Centre of gravity to be supported if necessary by using T (Thermal oil)
existing screws. H (Hot water)

51
2 DRAWINGS

X018611B
52
201 Oil inlet

209 Oil Recirculation to tank


When lifting bowl parts over adjoining separator
2 DRAWINGS

220 Clean Oil outlet

221 Water outlet

Ref. 570541 Rev. 0


222 Sludge discharge outlet
371 Operating water pH value not be-
low 6pH. Pressure 200-600 kPa (2-
6 bar). Salinity max 60ppm Cl
(equivalent to 100 ppm NaCl ).
*) optional Temp. min +5°C, max. +55°C.

463 Drain
2.9.2 Single Module (E)

501 Operating air. Instrument air, pres-


sure 500-700 kPa (5-7 bar).
*) optional
709 Mains supply 3x400/440/480/575/
690 V

791 Earthing of module

799 EPC 50 supply voltage, 230V, 110/


115V or 100 V.

Alternative Connections
connection
Foundation plan View A Flange DN40-PN16-DIN

1810818-02
from top
B Flange DN65-PN16-DIN

C Flange DN25-PN6-DIN

D SU 855: Flange DN100-PN16-DIN


SU 865: Flange DN125-PN16-DIN

E ISO G 1/4

F ISO G 1/2

G ISO G 1
-Bolting 4xM16.
Tightening torque: For JIS application, counter flanges type
222 Nm. ‘slip-on’ will be supplied.
-Welding

*) Sludge removal kit (optional)

Weight, SU 855 E: 1610 kg Control cabinet and frame for


Weight, SU 865 E: 1750 kg components to be supported if
necessary by using existing screws.
Centre of gravity
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X0 1 8 5 7 1 B
When lifting bowl parts over adjoining separator
**) With CBM 26

Ref. 570533 Rev. 0


Alt.

*)Optional Alt.

201 Oil inlet Drain


SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

463
209 Oil Recirculation to tank 501 Operating air. Instrument air, pres-
sure 500-700 kPa (5-7 bar).
220 Clean Oil outlet
709 Mains supply 3x400/440/480/575/

1810818-02
221 Water outlet 690 V

222 Sludge discharge outlet 791 Earthing of module

371 Operating water pH value not be- 799 EPC 50 supply voltage, 230V, 110/
2.9.3 Double Module SL, TL, HL, with Pipe Rack

low 6pH. Pressure 200-600 kPa (2- 115V or 100 V.


6 bar). Salinity max 60ppm Cl
Foundation plan View from (equivalent to 100 ppm NaCl ). Connections
top Temp. min +5°C, max. +55°C.
A Flange DN40-PN16-DIN
451 Steam inlet (or T, H)
B Flange DN65-PN16-DIN
456 Condensate outlet (not for T or H)
C Flange DN25-PN16-DIN

D SU 855: Flange DN100-PN16-DIN


SU 865: Flange DN125-PN16-DIN

-Bolting 6xM16. E Flange DN15-PN16-DIN


Tightening torque: 222 Flange DN20-PN16-DIN
Nm. Flange DN25-PN16-DIN
-Welding
F ISO G 1/4

G ISO G 1/2

Weight, SU 855 SL, TL, HL: 3100 kg Control cabinet and frame for SL (Steam in line) *) Sludge removal kit H ISO G 1
Weight, SU 865 SL, TL, HL: 3380 kg components to be supported if TL (Thermal oil in line) (optional)
necessary by using existing screws. HL (Hot water in line) J Flanges DN65-PN6-DIN
Centre of gravity
For JIS application, counter flanges type ‘slip-
on’ will be supplied.

53
2 DRAWINGS

X018631B
54
When lifting bowl parts over adjoining separator
2 DRAWINGS

**) With CBM 26

Ref. 570534 Rev. 0


*)Optional

*)Opt.
Alt.
Alt.

201 Oil inlet 463 Drain

209 Oil Recirculation to tank 501 Operating air. Instrument air, pres-
sure 500-700 kPa (5-7 bar).
220 Clean Oil outlet
709 Mains supply 3x400/440/480/575/

1810818-02
221 Water outlet 690 V

222 Sludge discharge outlet 791 Earthing of module

371 Operating water pH value not be- 799 EPC 50 supply voltage, 230V, 110/
low 6pH. Pressure 200-600 kPa (2- 115V or 100 V.
6 bar). Salinity max 60ppm Cl
Foundation plan View from (equivalent to 100 ppm NaCl ). Connections
top Temp. min +5°C, max. +55°C.
2.9.4 Double Module SL, TL, HL, without Pipe Rack

A Flange DN40-PN16-DIN
451 Steam inlet (or T, H)
B Flange DN65-PN16-DIN
456 Condensate outlet (not for T or H)
C Flange DN25-PN16-DIN

D SU 855: Flange DN100-PN16-DIN


SU 865: Flange DN125-PN16-DIN
-Bolting 6xM16. E Flange DN15-PN16-DIN
Tightening torque: 222 Flange DN20-PN16-DIN
Nm. Flange DN25-PN16-DIN
-Welding
F ISO G 1/4

G ISO G 1/2

Weight, SU 855 SL, TL, HL: 3100 kg Control cabinet and frame for SL (Steam in line) *) Sludge removal kit H ISO G 1
Weight, SU 865 SL, TL, HL: 3380 kg components to be supported if TL (Thermal oil in line) (optional)
necessary by using existing screws. HL (Hot water in line) I Flanges DN65-PN6-DIN
Centre of gravity
For JIS application, counter flanges type ‘slip-
on’ will be supplied.
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X0 1 8 6 3 1 E
When lifting bowl parts over adjoining separator

*) Optional *) Optional

Ref. 570546 Rev. 0


2.9.5 Double Module EL

Alt.

*) Optional
Alt.
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

201 Oil inlet Connections

209 Oil Recirculation to tank A Flange DN40-PN16-DIN

220 Clean Oil outlet B Flange DN65-PN16-DIN

1810818-02
221 Water outlet C Flange DN25-PN16-DIN

222 Sludge discharge outlet D SU 855: Flange DN100-


PN16-DIN
Foundation plan View
from top 371 Operating water pH value not be- SU 865: Flange DN125-
low 6pH. Pressure 200-600 kPa (2- PN16-DIN
6 bar). Salinity max 60ppm Cl
(equivalent to 100 ppm NaCl ). E ISO G 1/4
Temp. min +5°C, max. +55°C.
F ISO G 1/2
463 Drain
G ISO G 1
501 Operating air. Instrument air, pres-
H Flange DN65- PN6-DIN
sure 500-700 kPa (5-7 bar).
For JIS application, counter flanges
709 Mains supply 3x400/440/480/575/
690 V type ‘slip-on’ will be supplied.

-Bolting 6xM16. 791 Earthing of module *) Sludge removal kit (optional)


Tightening
torque: 222 Nm. 799 EPC 50 supply voltage, 230V, 110/
-Welding 115V or 100 V.

Weight, SU 855 EL: 3550 kg Control cabinet and frame for


Weight, SU 865 EL: 3830 kg components to be supported if
necessary by using existing screws.
EL (Electric in line)
Centre of gravity

55
2 DRAWINGS

X0 1 8 6 5 1 B
56
2 DRAWINGS

HFO-application

Ref. 570486 Rev. 0


Steam regulating valve Heater Separation unit
kit
Safety valve

Steam trap
kit (not
*) optional
incl. in T/H
design) *) optional

Frame
Alternative
connection

201 Oil inlet


LO-application,
(optional) 209 Oil Recirculation to tank
Base

1810818-02
220 Clean Oil outlet

221 Water outlet


2.10 Assembly Drawings, Modules

2.10.1 Single Module S, T, H Assembly Drawing

222 Sludge discharge outlet

Checker plate 371 Operating water


*) optional
451 Steam inlet (or T; H)
Drain conn. from base to SU base *) optional
456 Condensate outlet (not for T or H)

463 Drain

501 Operating air

Alternative 540 Ventilation


Flow regulation kit connection
(optional) Sealed with Locktite
*) Sludge removal kit (optional)

View A
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X018581B
HFO-application

Ref. 570529 Rev. 0


Steam regulating valve Heater Separation unit
kit

Safety valve

Steam trap *) optional


kit (not
*) optional
incl. in T/H
design)

Frame
Alternative
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

connection
Pump
LO-application,
201 Oil inlet
(optional)

1810818-02
209 Oil Recirculation to tank

Base 220 Clean Oil outlet

221 Water outlet

222 Sludge discharge outlet

371 Operating water

*) optional 451 Steam inlet (or T; H)

*) optional 456 Condensate outlet (not for T or


Drain conn. from base to SU base H)

463 Drain

501 Operating air


Checker plate
540 Ventilation
Flow regulation kit Alternative
(optional) connection
*) Sludge removal kit (optional)

Sealed with Locktite


2.10.2 Single Module S, T, H with Feed Pump 038, Assembly Drawing

View A

57
2 DRAWINGS

X018591B
58
HFO-application
2 DRAWINGS

Steam regulating valve Heater Separation unit

Ref. 570530 Rev. 0


kit

Safety valve

Steam trap *) optional


kit (not
*) optional
incl. in T/H
design)

Frame
Alternative
connection
Pump
LO-application,
201 Oil inlet
(optional)
209 Oil Recirculation to tank

1810818-02
Base 220 Clean Oil outlet

221 Water outlet

222 Sludge discharge outlet

371 Operating water


*) optional
451 Steam inlet (or T; H)
*) optional 456 Condensate outlet (not for T or
Drain conn. from base to SU base H)

463 Drain

501 Operating air


Checker plate
540 Ventilation
Flow regulation kit Alternative
connection *) Sludge removal kit (optional)
(optional)
Sealed with Locktite

View A
2.10.3 Single Module S, T, H with Feed Pump 045/045, Assembly Drawing
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X0 1 8 6 0 1 B
Separation unit
HFO-application

Ref. 570497 Rev. 1


*) optional

*) optional

Alternative connection

LO-application
(optional)
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

Frame
*) optional

1810818-02
2.10.4 Single Module E, Assembly Drawing

*) optional
Heater

Base 201 Oil inlet


Alternative connection
Drain conn. from base to SU base 209 Oil Recirculation to tank

Bracket 220 Clean Oil outlet

221 Water outlet

222 Sludge discharge outlet

371 Operating water


Flow regulation kit Sealed with Locktite 463 Drain
(optional)
View A 501 Operating air

540 Ventilation

*) Sludge removal kit (Optional)

59
2 DRAWINGS

X0 1 8 5 5 1 B
60
Separation unit
HFO-application
2 DRAWINGS

Ref. 570499 Rev. 0


*) optional

*) optional

Alternative connection

LO-application
(optional)

Frame
*) optional

1810818-02
*) optional
Heater

Base
Alternative connection
Drain conn. from base to SU base 201 Oil inlet

Bracket 209 Oil Recirculation to tank

220 Clean Oil outlet

221 Water outlet


2.10.5 Single Module E with Feed Pump, Assembly Drawing

222 Sludge discharge outlet


Flow regulation kit
Sealed with Locktite 371 Operating water
(optional)
463 Drain
View A
501 Operating air

540 Ventilation

*) Sludge removal kit (Optional)


SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X0 1 8 5 6 1 B
Ref. 570492 Rev. 0
Single Module

*) Optional

Pipe arrangement

Alternative
connection
Alternative connection
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

*) Optional

1810818-02
Checker plate
201 Oil inlet

209 Oil Recirculation to tank

220 Clean Oil outlet


Base 221 Water outlet

222 Sludge discharge outlet

371 Operating water

Checker plate 451 Steam inlet (or T; H)

456 Condensate outlet (not for T or H)

463 Drain

501 Operating air


2.10.6 Double Module SL, TL, HL, with Pipe Rack Assembly Drawing

540 Ventilation

*) Sludge removal kit (Optional)

61
2 DRAWINGS

X0 1 8 6 2 1 B
62
2 DRAWINGS

Ref. 570496 Rev. 0


Single Module
*) Optional

*) Optional

*) Optional

Alternative Alternative
connection connection

1810818-02
Checker plate
201 Oil inlet

209 Oil Recirculation to tank

220 Clean Oil outlet


Base 221 Water outlet

222 Sludge discharge outlet

371 Operating water


Checker plate 451 Steam inlet (or T; H)

456 Condensate outlet (not for T or H)

463 Drain

501 Operating air

540 Ventilation

*) Sludge removal kit (Optional)


2.10.7 Double Module SL, TL, HL, without Pipe Rack Assembly Drawing
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

X018621C
Ref. 570493 Rev. 0
*) Optional

Single Module

*) Optional

Alternative
connection
Alternative connection
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

*) Optional

1810818-02
Checker plate
2.10.8 Double Module EL, Assembly Drawing

201 Oil inlet


Frame 209 Oil Recirculation to tank

220 Clean Oil outlet

221 Water outlet


Checker plate
222 Sludge discharge outlet

371 Operating water

463 Drain

501 Operating air

540 Ventilation

Pipe arrangement *) Sludge removal kit (Optional)

63
2 DRAWINGS

X018641B
3 REMOTE OPERATION SYSTEMS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

3 Remote Operation Systems

ING
WARN
!

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

PC connection with REMINDTM


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

64 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 3 REMOTE OPERATION SYSTEMS

PC connection with REMINDTM via SATTBUS


and SATTBUS card for supervision and
remote control (art. no. 1766468-80)
Up to 9 EPC 50 control cabinets can be
connected together via SATTBUS and then
further connected to a PC. In such cases, the
PC must have a SATTBUS card which is
placed in a free card space in the PC.

PC connection with REMINDTM via SATTBUS


and SATTBUS converter SBSU232 for
supervision and remote control (art. no.
1766469-80)
Up to 9 EPC 50 control cabinets can be
connected together via SATTBUS as described
above. In this case, however, there is no place
for a SATTBUS card in the PC. A SATTBUS
converter must be connected to the PC COM
gate. This transforms the SATTBUS signal to
RS232.

Connection to PC or steering system via


PROFIBUS (art. no. 1766470-80)
PROFIBUS is a standardized communications
protocol which can be used in an EPC 50
control cabinet for connection to steering
systems where SATTBUS communication
cannot be used. The EPC 50 control cabinet
uses a PROFIBUS DP. Every node, or EPC 50
control cabinet, on the bus has a unique
address, and can use 200 bytes for data
exchange. An interface card, EPC 50
PROFIBUS board, is needed to connect an EPC
50 control cabinet to PROFIBUS. This is
mounted on the I/O card.
PROFIBUS for EPC 50 control cabinet is for
use in those cases where the user wants access
to data and operation information from the
control cabinet, and supervision and/or remote
control from his own steering system.
REMINDTM via PROFIBUS is not available. If
a PROFIBUS user wants to have a REMINDTM
window on his monitor, a programme is needed
to make the PROFIBUS information
accessable in REMINDTM.

1810818-02 65
3 REMOTE OPERATION SYSTEMS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

Alternative REMINDTM EPC REMINDTM REMINDTM PROFIBUS


50 Basic (via Network (via Network (via
31830-6559-1
RS232) Sattbus) Sattbus)

31830-6409-1 31830-6410-1 31830-6411-1


TM TM
User interface REMIND REMIND REMINDTM .
installation discs
included in SU delivery.
Cable Part no. 31830-6415-1 Pair-twisted Sattbus Pair-twisted Sattbus Cable for PROFIBUS
included in SU delivery. cable. Aquired and cable. Aquired and aquired and installed
installed by the installed by the by customer.
customer. customer.
PC card for Part no. 492720202
Sattbus
PROFIBUS card Part no. 31830-4585-1
SATTBUS SBSU232
converter converter,part no.
492829701 included in
SU delivery.

66 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS/RECOMMENDATIONS

4 Specifications/Recommendations
4.1 Lifting Instructions
• Only qualified personnel are allowed to work
with lifting of the unit/module. ING
WARN
!
• Use only the lifting eyes as shown in the
illustrations.
Crush hazard
• Slings or wires used for lifting the Unit/Single When lifting the Separator Unit/Module, use only
the lifting eyes specifically for this purpose.
Module must be adjusted so that the beam
Always use a lifting beam.
is located above the centre of gravity.
• Slings or wires used for lifting the Double
Module must be of the same length to avoid
instability.
• For information on how to lift the separator,
see the Service Manual booklet.

4.1.1 Lifting the Separation Unit

Weight SU 855 = max. 1060 kg


Secure to unit to prevent Weight SU 865 = max. 1200 kg
tipping

}
X = 470 Centre of
Y = 275 gravity
Z = 575
Extension piece for lifting,
factory mounted
P004221A

1810818-02 67
4 SPECIFICATIONS/RECOMMENDATIONS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

4.1.2 Lifting the Single Module (S, T, H)

Weight SU 855 = max. 1380kg


Weight SU 865 = max. 1520 kg

Secure to module to
prevent tipping

}
X = 1080 Centre of
Y = 355 gravity
Z = 590

P004234A
4.1.3 Lifting the Single Module (S, T, H) with fork lift

Weight SU 855 = max. 1380kg


Weight SU 865 = max. 1520 kg

To prevent tipping, make


sure that the forks are
longer than the width of the
module.

}
X = 1080 Centre of
Y = 355 gravity
Z = 590
P0 0 4 2 3 6 A

68 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS/RECOMMENDATIONS

4.1.4 Lifting the Single Module (E)

Weight SU 855 = max. 1610kg


Weight SU 865 = max. 1750 kg

Secure to module to
prevent tipping

}
X = 1140 Centre of
Y = 565 gravity
Z = 340

P004301A
4.1.5 Lifting the Single Module (E) with fork lift

Weight SU 855 = max. 1610kg


Weight SU 865 = max. 1750 kg

To prevent tipping, make


sure that the forks are
longer than the width of the
module.

}
X = 1140 Centre of
Y = 565 gravity
Z = 340
P0 0 4 2 8 1 A

1810818-02 69
4 SPECIFICATIONS/RECOMMENDATIONS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

4.1.6 Lifting the Double Module (SL, TL, HL)

Secure to module to
prevent tipping

}
X = 2230 Centre of
Y = 600 gravity Weight SU 855 = max. 3100kg
Z = 665 Weight SU 865 = max. 3380 kg

P004235A
4.1.7 Lifting the Double Module (EL)

Secure to module to
prevent tipping

X = 2400
Y = 575
Z = 645
} Centre of
gravity Weight SU 855 = max. 3550kg
Weight SU 865 = max. 3830kg
P004291A

70 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS/RECOMMENDATIONS

4.2 Cables

Cable Identification
All cables are marked to simplify identification
and fault finding.

Specifications
The following specifications apply to cables
connected to and from Alfa Laval equipment.
Follow the instructions given in the cable list.
Examples of cable types that can be used:
• Steel armoured cable.

G032224A
• Copper armoured cable with a separate earth
core.

G032244A
• Steel armoured and shielded signal cable;
pair twisted or parallel.

G032214A

• Shielded signal cable; pair twisted or


parallel.
G032234A

1810818-02 71
4 SPECIFICATIONS/RECOMMENDATIONS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

4.3 Cable Routing


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

S0 0 2 8 9 1 A
reduces electrical noise transfer.
Examples of recommended routing of various
cable types.
Power Signal
• Power cables and signal cables routed on a Cables Cable
cable rack should be separated.
• Sattbus cables should be routed away from

G032273A
power cables.
If the space is limited, cables can be routed in
tubes.

4.4 Oil, Water, Steam, and Condensate Piping


For piping to and from Alfa Laval equipment,
see the specifications below.

Specifications
• The correct pipe size must be used in the oil
system.
• The number of bends in the oil pipes must
be minimized.
• The suction height must be as low as
possible.
• The oil feed pump must be of positive
displacement type.
• The pump must be positioned close to the
oil tank.
• The heater must be installed close to the
separation unit to maintain correct feed oil
temperature.
• The recirculation line should be connected
either directly to the settling tank (HFO) or to
the oil outlet line from the separator (LO).
• The oil outlet line from the separator must be
connected to the system tank for lube oil, or
the service tank for fuel oil.

72 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS/RECOMMENDATIONS

4.5 Ambient Temperature Limitation

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

G032197A
4.6 Heat Tracing and Insulation of Fuel Oil, Sludge, and
Steam Pipes
The Separation Unit will not be heat traced
or insulated due to short pipes and limited
space. Hot pipes are however painted in a
different colour.
Alfa Laval Tumba AB can, on request, supply
Modules which are heat traced and insulated,
as optional equipment.

1810818-02 73
4 SPECIFICATIONS/RECOMMENDATIONS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

4.7 Sludge Removal Kit


The Sludge Removal Kit must be connected to a
ventilation pipe.

ING
WARN
!

Health Risk
Oil mist and vaporized oil constituents from hot oily
sludge may be dangerous to health and must not be
inhaled.

A PN6 DIN flange which is connected from the


tank to the frame side of the unit/module is
provided for this purpose. A counter flange of
‘slip on’ type is supplied to simplify connection to
other standards.
A pipe or hose must be drawn from the flange to
the nearest oil tank ventilation pipe.
The pipe /hose must have the same diameter as
the flange opening.
The pipe/hose must be as straight as possible,
with a steady upward incline.
The connection to the oil tank ventilation pipe
must point upwards as shown.

NOTE Oil tank ventilation


pipe

For HFO separation, it is not recommended to make


the connection to the separator room ventilation Unit frame
system.
For LO separation, connection to the separator room
ventilation system should be made only if the
separator room ventilation is adequate. Use the
optional connection hose (part no. 568023-80, -81, or
~ 5 mm
-82) for this purpose. This hose is designed to entrap
P0 0 0 0 6 3 A

oil drops in the vent hose, and lead the oil back to the
Sludge Removal Kit tank.

74 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS/RECOMMENDATIONS

NOTE

Impurities gather in the Sludge Removal Kit tank.


Regularly check the tank and level switch. See
instructions below.

Proceed as follows:
• From the Control Panel, run the sludge pump
manually for a few seconds.
• Undo the four screws at the top of the sludge
tank and remove the sludge pump.
• If necessary, clean the level switch and the
inside of the tank using diesel oil.
• Check the seals and gaskets, and change if
necessary.
• Loosen the hose clip and check the inside of
the ventilation hose. Clean if necessary.
To avoid breakdown of the Sludge Removal
system, the sludge pump must be regularly
overhauled as follows using spare parts kit
1766702-81.
• Replace the diaphragms and the o-rings with
those delivered in the spare parts kit.
• Perform a 4000 hour Inspection Service.
For Service and Overhaul intervals, see ‘‘1.3
System Data” on page 2.

1810818-02 75
4 SPECIFICATIONS/RECOMMENDATIONS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

4.8 More than one Oil Tank

Recommendation Unprocessed Clean oil


When one separator serves more than one oil oil
tank, both the suction and the outlet lines should Change-
be fitted with change-over valves. To avoid oil over
valve
transfer from one tank to another, these valves
must be interlinked.
Change
-over
valve
Inter-
link

P0 0 0 0 6 2 A

76 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS/RECOMMENDATIONS

4.9 Sludge Tank


It is not necessary to have a sludge tank together Ventilation pipe
with a Separation Unit with sludge removal kit
(for lube oil). If a sludge tank is required, follow
the recommendations below: Sludge pipe
connection

Recommendations
• Sludge tank volume per Separation Unit
should cover approximately up to 2 days
Min. height
storage at a discharge interval of 2 hours (for Sludge outlet 400 mm
pump connection
discharge volumes see technical data).

G004273A
• A manhole should be installed for inspection Min. slope 15°
and cleaning.
• The tank should be fitted with a sounding
pipe.
• The tank floor, or most of it, should have a
slope (B) of minimum 15°. Bowl casing drain Manhole Water drain High level
connection connection alarm
• The sludge outlet pump connection should be switch

positioned in the lowest part of the tank.


• A high level alarm switch, connected to the Heating
sludge pump, should be installed. coil

• A heating coil should be used to keep the


sludge warm and fluid while being pumped

G004270A
out.
• Tank ventilation must follow the classification
rules for evacuation of gases.
• There should be a ventilation pipe to fresh air.
• The ventilation pipe should be straight. If this
is not possible, any bends must be gradual.
• The ventilation pipe must not extend below the
tank top.
• A sludge tank with partition walls must have
ventilation pipes in all compartments, or
cutouts in the upper edge, to allow vapours to
travel through the tank.

1810818-02 77
4 SPECIFICATIONS/RECOMMENDATIONS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

In retrofit applications, where an Alfa Laval


Separation Unit will share a common
separator sludge tank with existing separators,
it is recommended to install a Separation Unit
with Sludge Removal Kit.
The number of ventilation pipes, and their
minimum dimension, depend on the size and
number of separators connected to the same
tank. See table below.

Type 1 unit 2 units

SU 200/SU 820/SU 825 1 x ∅75mm 1 x ∅75mm


SU 300/SU 830/SU 835
SU 400/SU 840/SU 845

SU 500/ SU 850/SU 855 1 x ∅100mm 1 x ∅100mm


SU 600/SU 860/SU 865

SU 700/SU 870/SU 875 1 x ∅100mm 1 x ∅125mm


SU 800/SU 880/SU 885

The Separation Unit generates almost no air


during operation. At any discharge, the
maximum volume of air produced is the same
as the bowl volume (see technical data).

78 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS/RECOMMENDATIONS

4.10 Sludge Piping

Specification
• The sludge pipe from the separator to the
sludge tank should be vertical.
If a vertical pipe is not possible, the deviation (A)
from the vertical line must not exceed 30°.

G004401A
• The sludge pipe must not extend below the
tank top.

NOTE

An extended sludge pipe will obstruct ventilation and


create back pressure that could cause separator
problems.

G004316A

1810818-02 79
4 SPECIFICATIONS/RECOMMENDATIONS SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

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

NOTE

If a butterfly valve is not used, the bowl and the


operating system may be affected.

• If a butterfly valve is used, it should be


equipped with an interlocking switch
(connected to the separator starter) to prevent
the separator from being started when the
valve is not fully open.

G004411A

80 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 5 COMMISSIONING AND INITIAL START

5 Commissioning and Initial Start


5.1 Completion Check List
It is essential before starting up the separation
system that all units are in good operating
condition and that all pipelines and control
equipment are properly connected to assure
correct operation.
Use this check list as a guide for completing the
system installation:

ING
WARN
!

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

1 Check that transport seals are removed from


all pipes.
2 Use flushing filters to prevent pipe work debris
from being pumped into the separation unit.

NOTE

The flushing filters must be removed after initial


flushing.

3 Check that all separators are in proper


working condition. Follow the manufacturer’s
instructions.
4 Make sure that separators are lubricated in
accordance with instructions.
5 Separators are delivered without oil in the oil
sump. For information on oil filling and oil type,
see the Service Manual booklet.

NOTE

Too much, or too little oil may result in damage the


separator bearings.
Neglecting an oil change may result in damage to
separator bearings.

1810818-02 81
5 COMMISSIONING AND INITIAL START SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

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

G046606A
ON
CAUTI
!

If power cables have been installed incorrectly, the


separator will rotate in reverse, and vital rotating
parts can unscrew.

8 Check the pump function and direction.

82 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 5 COMMISSIONING AND INITIAL START

5.2 Initial Start-up


Use this check list for initial system start up:
1 Check that there is oil in the feed oil tank.
2 Check water and air supply. See 1.3 System
Data.
3 Check power supplies to the control unit and
that the voltage is in accordance with data in
1.3 System Data.
4 Check all parameter settings in the control
unit. See Installation Parameters in the
Parameter List booklet.
5 Check the separator.

NOTE

Always lubricate the bearings before start-up.

NOTE

The Separation Unit is supplied with standard


configuration parameters. You may have to make
some changes to suit your installation.

6 Start the separation system as described in


the Operating Instructions booklet.
7 Start up step by step, checking that the
machine and units function properly.
8 Establish system pressures.
The delivery height pressure is the pressure in
the oil pipe work down stream from the
separation unit, due to the pipe bends and the
height (head) to the cleaned oil tank. If the
cleaned oil tank is below the separation unit
the delivery height pressure may be very low.
The oil paring disc pressure will have to be
greater than the delivery height pressure for
any oil to flow.
Proceed as follows:
• Ensure the valves in the oil system are in the
correct positions.
• The oil should be at separation temperature.
Cont.

1810818-02 83
5 COMMISSIONING AND INITIAL START SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

• The adjustment screw for the water paring


tube should be in the outer position. The
paring tube should be able to move freely.
• Ensure that V5 is closed.
• Fully open the back pressure regulating valve
RV4.
• The shut off valve V4 should be open.
• Open SV15 for 3 seconds to prime the
operating slide.
• Open SV16 for 15 seconds to close the bowl.
• Open SV10 for 1 minute to put water into the
bowl.
• Feed oil to the separator at the normal flow
rate by opening SV1.
• Note the pressure in the oil outlet PT4, both on
the pressure gauge and in the EPC50 display.
This pressure is P min.
• Gradually close the back pressure regulating
valve RV4. The pressure on PT4 will increase.
The water pressure (PT5) decreases slightly
as the paring tube moves inwards. The water
pressure will suddenly drop when oil passes
from the oil paring chamber to the water
paring chamber. Note the pressure of PT4
both on the pressure gauge and in the EPC50
display. This pressure is P max.
• Open RV4.
• Stop the oil feed to the separator and note the
pressure in the oil outlet. This is the delivery
height pressure P del.
• Stop the heater.
• Stop the separator.
• Stop the feed pump when the heater has
cooled.

84 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 5 COMMISSIONING AND INITIAL START

5.2.1 Calculating Operating Pressure


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

Pmin + Pmax
= Pnormal
2

• Calculate the value for low pressure alarm


setting (Pr 11) as follows:

Pmin + Pnormal
= Plow press.
2

• Calculate the value for high pressure alarm


(Pr 10) as follows:

Pnormal + Pmax
= Phigh press.
2

Adjust the back pressure to Pnormal


Set Pr 11 to give alarm at pressure decreasing
below the Plow press. value.
Set Pr 10 to give alarm at pressure increasing
above the Phigh press. value.

1810818-02 85
6 SHUT-DOWN AND STORAGE SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

6 Shut-down and Storage


Storage before Installation
If the separation unit is stored before
installation, the following safeguards must be
taken:

Storage period 3 – 6 months > 6 months See


Action
Protect from dust, dirt, x x This chapter
water, etc.
Protect with anti-rust x This chapter
oil
Inspection x x Service manual
Overhaul x Service manual

NOTE

Always lubricate the bearings before start-up.

6.1 Shut-down after Use


If the separation system is going to be shut down
for a period of time, the following safeguards
must be taken:

Shut-down period 1 – 3 months 6 – 18 months > 18 months See

(stand-by)
Action
Remove bowl x x x Dismantling and
Assembly in the
Service Manual
Protect from dust, dirt, x x x This chapter
water, etc.
Protect with anti-rust oil x x This chapter

Inspection x x Service manual


Overhaul x Service manual

NOTE

Always lubricate the bearings before start-up.

86 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 6 SHUT-DOWN AND STORAGE

6.2 Protection and Storage


All system equipment, both the separator and
the ancillary equipment, must be stored indoors
at 5 – 55°C, if not delivered in water-resistant
box for outdoor storage.
If there is a risk for condensation of water, the
equipment must be protected by ventilation and
heating above dew point.
The following protection products are
recommended:
• Anti-rust oil with long lasting effective
treatment for external surfaces. The oil should
prevent corrosion attacks and give a waxy
surface.
• Anti-rust oil (Dinitrol 40 or equivalent) thin and
lubricating for inside protection. It gives a
lubricating transparent oil film.
• Solvent, e.g. white spirit, to remove the anti-
rust oil after the shut-down.
• If the storage time exceeds 12 months, the
equipment must be inspected every 6 months
and, if necessary, the protection be renewed.

Units/Modules
• Clean unpainted steel parts with solvent and
treat with anti-rust oil (type 112).
• If necessary, clean other equipment on the
module with solvent.
• Treat the equipment with anti-rust oil by
following the description above accordingly.
• Bolts, nuts and other steel components should
be treated with anti-rust oil (type 112).

1810818-02 87
6 SHUT-DOWN AND STORAGE SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

Rubber Parts
• Gaskets, O-rings and other rubber parts
should not be stored for more than two years.
After this time, they should be replaced.

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

Valves, Pipes and Similar Equipment


• Components like valves need to be cleaned
with solvent and treated with anti-rust oil (type
112).
• Water pipes should be drained and treated
with anti-rust oil (type 112).
• Articles made of rubber or plastics (e.g. seals)
must not be treated with anti-rust oil.

Electric Heater
• Fill the heater with a non-corrosive lubricating
oil.
• Place a number of bags of silica gel inside the
connection box to absorb humidity.

Steam Heater
• Drain the condensed water from the steam
valve and the steam trap.
• Drain all condensed water from the heater.
• Fill the oil part of the heater with a
non-corrosive lubricating oil.

88 1810818-02
SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE 6 SHUT-DOWN AND STORAGE

Pump
• Clean the pump housing outside from oil and
grease with solvent.
• Protect the pump by filling it with non-
corrosive lubricating oil.
• Apply anti-rust oil on the pump housing
outside.

6.3 Reassembly and


Start up
• Clean away the anti-rust oil with white spirit.
• Remove the silica gel bags from all units.
• Follow all relevant instructions in this booklet
and in the Service Manual.
• Before operating the heater:
– Check by lifting the safety valve handle that
it functions correctly.
– Follow the start-up check list for the heater
in the manufacturer’s instructions.
– For plate heat exchangers: check the bolt
connections to ensure that all gaskets are
tight.

1810818-02 89
6 SHUT-DOWN AND STORAGE SEPARATION UNIT 855/865 INSTALLATION SYSTEM REFERENCE

90 1810818-02
Separation Unit 865

Service Manual
Printed Dec 2002
Book No. 1810833-02 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 & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2002.
Contents
1 Separator Design ................................. 1 3.4 Actions Before Assembly ............74
1.1 Overview .............................................1 3.4.1 Cleaning .............................................74
1.2 The Drive Section.............................3 3.4.2 Inspection for corrosion ......................75
1.3 The Process Section .......................4 3.4.3 Inspection for cracks ..........................76
1.4 Sensors................................................8 3.4.4 Inspection for erosion .........................77
1.5 Separating Function ........................9 3.4.5 Exchange of frame feet ........................79
1.5.1 The liquid balance in the bowl ...............9 3.4.6 Lubrication of bowl parts ......................80
1.5.2 Liquid flow ............................................10 3.5 Assembly...........................................81
1.5.3 Discharge of sludge and water ............10 3.5.1 Centrifugal clutch .................................81
1.5.4 ALCAPTM concept................................11 3.5.2 Driving device.......................................85
3.5.3 Bowl ......................................................97
2 Technical Reference ...................... 13 3.5.4 Frame hood ........................................110
2.1 Technical Data ................................13 3.5.5 Unbalance sensor (option) .................114
2.2 Connection List...............................15 3.6 Actions After Assembly..............116
2.3 Interface Description ....................17 3.6.1 Control of machine plates and safety
2.3.1 Scope ...................................................17 labels .................................................116
2.3.2 References ...........................................17 3.7 Oil Change ......................................118
2.3.3 Definitions .............................................18 3.7.1 Lubricating oil .....................................118
2.3.4 Goal ......................................................18 3.7.2 Check oil level ....................................119
2.3.5 Description of separator modes ...........19 3.7.3 Oil change procedure.........................119
2.3.6 Remote start .........................................20 3.7.4 Lubrication chart.................................120
2.3.7 Handling of connection interfaces .......20 3.7.5 Recommended lubricants ..................121
2.4 Drawings ...........................................27 3.7.6 Lubricating oils ...................................123
2.4.1 Basic size drawing ...............................27 3.8 Lifting instructions ......................124
2.4.2 Foundation drawing..............................28 3.8.1 Lifting the separator............................124
2.4.3 Interconnection diagram ......................29 3.8.2 Lifting the bowl ...................................125
2.4.4 Electric motor .......................................30
4 Change of Circuit Board ............ 126
2.5 Nomogram paring tube.................32
4.1 Circuit Board Temperatures .....128
3 Separator Service,
5 Cleaning in Place ........................... 129
Dismantling, Assembly ................. 35
5.1 Cleaning in Place, Separator....129
3.1 Periodic Maintenance ...................35
5.2 Cleaning in Place, Heatpac®
3.1.1 Maintenance intervals ..........................35
CBM Heater ....................................130
3.1.2 Maintenance procedures .....................36
5.3 Cleaning in Place, Separator
3.1.3 Tightening of screws ............................37 and Heater ......................................132
3.1.4 Service kits ...........................................37
3.1.5 Cleaning ...............................................38 6 Heatpac® CBM Heater
3.2 Maintenance Log ............................39 (Optional) ............................................. 133
3.3 Dismantling ......................................41 6.1 Technical Data .............................133
3.3.1 Introduction...........................................41 6.1.1 Manual Cleaning.................................133
3.3.2 Tools .....................................................42
7 Heatpac® EHM Electric
3.3.3 Frame hood ..........................................44
Heater (Optional) ........................... 135
3.3.4 Bowl......................................................46
7.1 Technical Data .............................135
3.3.5 Driving device ......................................56
7.2 Dismantling and Cleaning..........136
3.3.6 Centrifugal clutch .................................68
7.2.1 Replacing Heater Element..................137

1810833-02
7.2.2 Insulation Resistance Megger Test ... 138
7.2.3 Measuring of Heater Block
Resistance ........................................ 140

8 Heatpac® Power Unit


(Optional) ............................................. 143
8.1 Technical Data ............................ 143
8.2 Working principle ........................ 144
8.3 Electric Heater Function ......... 144
8.4 Heating Performance
Principle ........................................ 145
8.5 Load Control and Functions..... 146
8.5.1 Variable Part Load ............................ 146
8.5.2 Fixed Part Load ................................ 146
8.5.3 External Safety Stop ......................... 147
8.5.4 Start and Reset Functions ................ 147

1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 1 SEPARATOR DESIGN

1 Separator Design

Process section
The feed inlet and outlets
are situated at the top of Electric motor
the separator. 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
The separator is monitored
by a speed sensor. An The rotating separator
unbalance sensor and a bowl is driven by a flat
interlocking switch is belt transmission.
optional.

Frame feet
Sludge outlet
The separator rests
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 sump for lubrication of spindle bearings.

1810833-02 1
1 SEPARATOR DESIGN SEPARATION UNIT 865 SERVICE MANUAL

The frame hood contains the processing parts of


the separator; the inlets, outlets and piping.
The process liquid is cleaned in the separator
bowl. The bowl is fitted on the upper part of a
vertical spindle and rotates at high speed inside
the frame hood. The bowl also contains the
discharge mechanism which empties the sludge
during operation.
A speed sensor and an unbalance sensor (option)
are part of the equipment for monitoring the
separator functions.

2 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 1 SEPARATOR DESIGN

1.2 The Drive Section


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

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

To reduce bearing wear and the


transmission of bowl vibrations to The centrifugal clutch ensures a
the frame and foundation, the top gentle start and smooth acceleration,
bearing of the bowl spindle is and at the same time prevents
mounted in a spring dampened overloading of the belt and motor.
bearing seat.

The bearings on the spindle are


lubricated by the oil spray produced
by an oil pump mounted on the
lower end of the spindle.
G0870741

1810833-02 3
1 SEPARATOR DESIGN SEPARATION UNIT 865 SERVICE MANUAL

1.3 The Process Section


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

Inlet and outlet


The inlet and outlet unit consists of the
following parts:
A connection house for pipe connections.
A pipe with a paring disc and a paring tube is
located inside the connection house. The pipe
has channels for incoming and outgoing
process liquid.
The paring disc and paring tube pump the
cleaned oil and water respectively out of the
bowl.
The paring tube can move radially. During
separation it surfs on the liquid surface. It is
balanced by a spring.
Under certain operating conditions, the paring
tube radial position can be locked in place by
two adjustable screws on the connection house.
The paring disc and tube are located inside and
at the top of the separator bowl.
The inlet and outlet device is held together
against the frame hood by a nut on the end of
the inlet pipe.
Height adjusting rings determine the height
position of the paring disc and paring tube
relative to the bowl.

4 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 1 SEPARATOR DESIGN

Pipe

Spring

Uncleaned oil

Cleaned oil

Water

Arm

Paring tube
Paring disc

Connection house

G0886141

1810833-02 5
1 SEPARATOR DESIGN SEPARATION UNIT 865 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 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 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 1 SEPARATOR DESIGN

Water paring chamber


Bowl hood

Top disc
Oil paring chamber
Bowl body
Disc stack
Lock ring

Seal ring

Discharge
slide

Operating slide

Sludge space

Nozzle
G0886951

Holder Operating water ring

1810833-02 7
1 SEPARATOR DESIGN SEPARATION UNIT 865 SERVICE MANUAL

1.4 Sensors
The separator is equipped with a speed
sensor. As an option, an unbalance sensor
can be fitted.

Speed sensor Unbalance sensor (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 equipped with a sensor monitoring the radial position of
results and for reasons of safety. Refer to name plate for the bowl spindle.
speed particulars.
Cover interlocking switch (option)
When the cover is closed the interlocking circuit in the control
system is closed which makes it possible to start the
separator.

Cover interlocking switch

Unbalance sensor

Speed sensor
G0873471

8 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 1 SEPARATOR DESIGN

1.5 Separating Function


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

1.5.1 The liquid balance in the bowl


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

SEPARATOR BOWL TURNED 90°

Unseparated oil

Separated oil
Water

G
R
Top disc
A Distributor
V Oil/water interface
I
T
Y Unseparated oil
Separated oil
Water

SETTLING TANK
G0886431

1810833-02 9
1 SEPARATOR DESIGN SEPARATION UNIT 865 SERVICE MANUAL

1.5.2 Liquid flow


Unseparated oil is fed into the bowl through the
inlet pipe and travels via the distributor towards
the periphery of the bowl.
When the oil reaches slots in the distributor, it
rises through the channels formed by the disc
stack, where it is evenly distributed.
The oil is continuously cleaned as it travels
towards the centre of the bowl. When the cleaned
oil leaves the disc stack, it flows through a
number of holes in the distributor and enters the
oil paring chamber. From here it is pumped by
the oil paring disc, and leaves the bowl through
the oil outlet. Separated water, sludge and solid
particles, which are heavier than the oil, are
forced towards the periphery of the bowl and
collect in the sludge space.
The space between the bowl hood and top disc, as
well as the water paring chamber, is filled with
oil, which is distributed over the entire
circumference via the grooves in the top disc.
During normal operation, the water drain valve
in the water outlet is closed.

1.5.3 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:
• The water drain valve opens and the water
leaves the bowl through the water outlet.
• Through the sludge ports at sludge
discharge.
Which way is decided by the process control
system.

10 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 1 SEPARATOR DESIGN

1.5.4 ALCAPTM 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.

1810833-02 11
1 SEPARATOR DESIGN SEPARATION UNIT 865 SERVICE MANUAL

DISCHARGE OF WATER THROUGH WATER OUTLET

Unseparated oil

Bowl hood
Separated oil

Oil paring disc Water

Water paring tube


Water paring chamber
Oil paring chamber
Holes in distributor

Top disc

Sludge
space

Oil/water interface
Uncleaned oil

Cleaned oil

Water
G0886231

12 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 2 TECHNICAL REFERENCE

2 Technical Reference
2.1 Technical Data
Alfa Laval ref. 569170, rev. 0, 569224, rev. 0

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.

Product number: 881205-02-01


Separator type: S 865
Application: Cleaning of fuel and lube oil.
Technical design: Intended for marine- and land
installations.
Total discharge.
Designed in accordance with standards:

89/392EEC The Council Directive of the European Communities except for


91/368EEC the instruction manuals (i.e. CE-marking not possible).

93/44EEC

EN 292-2 Safety of machines. Use of the machine in applications subject to


hygienic demands requires a well adapted cleaning program.

Operational limits:
Feed temperature: 0°C to +100°C
Ambient temperature +5°C to +55°C
Discharge intervals: min. 2 minutes max. 2 hours.
Maximum allowed density of operating liquid: 1000
kg/m3.
Viscosity max. 700 cSt at 50°C.
Not to be used for liquids with flashpoint below
60°C.
Remote restart allowed under certain conditions,
see Interface description.

1810833-02 13
2 TECHNICAL REFERENCE SEPARATION UNIT 865 SERVICE MANUAL

Subject Value Unit


General technical data:
Motor power 18,5 kW
Gear ratio 251,5 / 106 50Hz
Gear ratio 209 / 106 60Hz
Alarm levels for vibration monitor
connection 752, 1st/2nd 0,3/0,45 mm
Bowl max. inner diameter 373 mm
Discharge interval, min./max. 2/120 minutes
Max. density of operating liquid, max. 1000 kg/m³
Max. density of feed/sediment 1100 / 2057 kg/m³
Feed temperature, min./max. 0 / 100 °C
Max. running time without flow,
- empty bowl 30 minutes
- filled bowl 30 minutes
Bowl body material AL 111 2377-02
Operating data:
Bowl speed, synchronous 7118/7115 r/min 50Hz/60Hz
Motor speed synchronous 3000 / 3600 r/min 50Hz/60Hz
Power consumption at start-up, max. 24 kW
Power consumption idling/max.
capacity: 4,7 / 16,3 kW
Starting time, min./max. 120 / 130 seconds
Stopping time min./max. 37 / 43 minutes
Stopping time without brake, average <30 minutes
Sound power 9,7 Bel(A)
Sound pressure 80 dB(A)
Volume and capacity data:
Max. hydraulic capacity, bowl 19,5 m³/h (water at 3,5 bar)
Bowl liquid volume 10,9 litres
Fixed discharge volume 10,1 litres
Sludge volume, efficient/total 1,8 / 4,7 litres
Lubricating oil volume 4,6 litres
Weight information:
Motor drive 135 kg
Bowl 154 kg
Separator total 773 kg

14 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 2 TECHNICAL REFERENCE

2.2 Connection List


Alfa Laval ref. 563538 rev. 1

No. Description Requirements/limits

201 Inlet for process liquid


• Allowed temperature Min. 0 °C, max. 100 °C
• Max allowed density See ‘‘Technical Data” on page 13
• Allowed flow Max 16,8 m3/h

206 Inlet for conditioning and displacement liquid Fresh water


• Instantaneous flow 5,5 litres/minute

220 Outlet for light phase, clarified liquid


• Counter pressure 0 - 250 kPa

221 Outlet for heavy phase No counter pressure.

222 Outlet for solid phase


• Small discharge
• Large discharge Total discharge
• Discharge frequency Max 24 discharge/h.
The outlet from the cyclone must always be
arranged to prevent the cyclone from being
filled up with sludge. Solids are discharged
by gravity.

1810833-02 15
2 TECHNICAL REFERENCE SEPARATION UNIT 865 SERVICE MANUAL

375 Inlet for discharge and make-up liquid


• Quality requirements See ‘Technical Data’ in the Installation
System Reference.

• Max density Max. 1000 kg/m3

• Pressure min. 150 kPa

Make-up liquid
• Flow (momentary) 2,8 litres/minute

• Consumption 1,7 litre/hour

• Interval 5 minutes

• Time 3 seconds

Discharge liquid
• Flow 11 litres/minute

• Consumption 0,55 litre/discharge

• Time 3 seconds

Closing liquid
• Flow 2,8 litres/minute

• Consumption 0,7 litre/discharge

• Time 15 seconds

Start up closing liquid


• Flow 11 litres/minute

• Time 5 seconds

462 Drain of frame top section, lower

701 Motor for separator


Allowed frequency variation: ± 5%
(momentarily during 5 seconds) ± 10%
740 Speed sensor for bowl spindle See page 21.
• Type Inductive promixly switch
• Supply voltage, nominal 8V
• With sensor activated (near metal) Less or equal to 1 mA.
• With sensor not activated (far from metal) More or equal to 3 mA.
• Number of pulses per revolution 1

752 Position transducer for bearing holder See page 22.


• Type Inductive analogue sensor
• Supply voltage 18 to 30 V DC
• Operation range (mild steel) 0,5 to 2,5 mm
• Output voltage within sensing range 4 to 20 mA
• Load resistance, RL 400 Ohm

760 Cover interlocking switch


• Type Mechanical limit switch
• Switch rating, resistive load max. 3 A (at 48 V DC)
1 A (at 220 V AC)

16 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 2 TECHNICAL REFERENCE

2.3 Interface Description


Alfa Laval ref. 564834 rev. 2

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

2.3.2 References
This Interface Description is one complementary
document to the separator. Other such
documents that contain necessary information
and are referred to here are:
• Interconnection Diagram
• Connection List
• Technical Data

Standards referred to are:


• EN 418 Safety of machinery - Emergency stop
equipment, functional aspects - Principles of
design
• EN 1037 Safety of machinery - Prevention of
unexpected start-up
• EN 954-1 Safety of machinery - Safety related
parts of control systems - Part 1 General
principles for design.

1810833-02 17
2 TECHNICAL REFERENCE SEPARATION UNIT 865 SERVICE MANUAL

2.3.3 Definitions
For the purpose of this document, the following
definitions apply:
• Synchronous speed: The speed the machine
will attain when it is driven by a three phase
squirrel-cage induction motor and there is no
slip in the motor and the drive system.
• Full speed: The synchronous speed minus
normal slip.

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

Situation Effect

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 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 1810833-02
SEPARATION UNIT 865 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:
• The separator is correctly assembled.
• All connections are made according to
Connection List, Interconnection Diagram and
Interface Description.
• The separator control system is activated.
If above conditions are not fulfilled the separator
will be in SERVICE mode.

Stand still means:


• The power to the separator motor is off
• The bowl is not rotating.

Starting means:
• The power to the separator motor is on.
• The bowl is rotating and accelerating

Running means:
• The power to the separator motor is on.
• The bowl is rotating at full speed.
• RUNNING is a collective denomination for a
number of sub modes which e.g. can be:
– STAND BY: Separator is in a waiting mode
and not producing.
– PRODUCTION: Separator is fed with
product and producing.
– CLEANING: Separator is fed with cleaning
liquids with the intention to clean the
separator.

1810833-02 19
2 TECHNICAL REFERENCE SEPARATION UNIT 865 SERVICE MANUAL

Stopping means:
• The power to the separator motor is off.
• The bowl is rotating and decelerating.
• 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;
• First start after any kind of service or manual
cleaning must be supervised locally in order
to ensure that no mistakes has been made
during assembly.
• The unbalance sensor is mandatory for
remote start.
• The installation must include equipment to
prevent unintentional start-up from remote
location when the machine is disassembled.
• The installation must include equipment to
prevent unintentional start of process flow
from remote location when the machine is not
properly connected to the piping.

2.3.7 Handling of connection


interfaces

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

20 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 2 TECHNICAL REFERENCE

There shall be an emergency stop circuit


designed according to EN 418 and a power
isolation device according to EN 1037.
There shall be a start button close to the
separator that shall be used for first start after
assembly of the separator.
There should be a counter to count number of
running hours.
There should be a current transformer to give an
analogue signal to the control unit about the
motor current.

740 Speed sensor


A proximity sensor of inductive type according to
DIN 19234 (Namur) standard is giving a number
of pulses per revolution of the bowl (see
Connection List).
Signal processing in STARTING:
• The separator should be stopped
automatically according to NORMAL STOP
procedure and an 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 checking that
pulses are coming). In case of failure
indication the separator shall be stopped
automatically by NORMAL STOP with a timer
controlled stop sequence and an alarm for
speed monitoring system failure shall be
given.
• The acceleration should be supervised to
ensure that a certain speed (e.g 250r/min.)
has been reached within a certain time (e.g 30
seconds).

1810833-02 21
2 TECHNICAL REFERENCE SEPARATION UNIT 865 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 speed 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 DISCHARGE.
compared to the measured speed
immediately before, should be between 3-8%
which will indicate a proper discharge.
Signal processing in STOPPING:
• STAND STILL shall be indicated when no
pulses are detected within 30 seconds.
• Stopping the separator when alarm for speed
monitoring system failure is active, shall cause
a timer controlled stop. (See “Stop time” in
Technical Data.)

752 Unbalance sensor (option).


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

22 1810833-02
SEPARATION UNIT 865 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 initiated.
Signal processing in RUNNING:
• 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.
• If vibrations exceed the second alarm level
the separator shall be stopped automatically
by SAFETY STOP.
• If the self check system triggers, an alarm
shall be given.
Signal processing in STOPPING:
• If the self check system triggers, an alarm
shall be given.
Signal processing in NORMAL STOP:
• If vibrations exceed the second level the
system shall turn over automatically to
SAFETY STOP.

1810833-02 23
2 TECHNICAL REFERENCE SEPARATION UNIT 865 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:


• The circuit is closed when the cover of the
separator is mounted.
• 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:
• If the circuit is broken the separator should be
stopped automatically by NORMAL STOP.
This is to minimise the risk of having access to
moving parts.

Fluid connections
Complementary information is given in the
document Connection List.
201 Inlet
Processing in STAND STILL:
• Shall be closed.
Processing in STARTING:
• Should be closed. Bowl will be open and
empty or closed and filled depending on if
start is done from STAND STILL or STOPPING.
Processing in RUNNING:
• Could be closed or open.
Processing in CLEANING:
• A sequence of cleaning liquids should be fed
to the separator. The flow rate should be as
high as possible and preferably not less than
the production flow rate.
Processing in NORMAL STOP or EMERGENCY
STOP:

24 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 2 TECHNICAL REFERENCE

• Could be closed or open but the bowl should


be filled unless the stop is initiated in
STARTING.
Processing in SAFETY STOP:
• Could be closed or open but the bowl shall be
filled unless the stop is initiated in STARTING.
206 Inlet for conditioning and displacement
liquid
• According to process

220, 221 and 222 Outlets


Processing in STAND STILL:
• Could be closed or open.

Processing in other modes:


• Shall be open.

375 Inlet for discharge and make-up liquid


Processing in all modes:
• It is recommendable to supervise the supply
pressure. If pressure is too low (see
Connection List), start should be interlocked
and if it happens in PRODUCTION or
CLEANING turn over to STAND BY should
take place.
Signal processing in STARTING:
• Below 85 % of synchronous bowl speed no
water supply may be made.
• When coming from PRODUCTION a
discharge shall be initiated to remove
sediments from bowl to avoid problems due to
solidification, see Connection List.
Signal processing in PRODUCTION:
• Automatic discharges shall be initiated by
timer or ALCAP system.
Signal processing in CLEANING:
• Automatic discharges shall be initiated by
timer or CIP-control system.
Signal processing in NORMAL STOP:

1810833-02 25
2 TECHNICAL REFERENCE SEPARATION UNIT 865 SERVICE MANUAL

• Discharges should not be made.


Signal processing in SAFETY STOP and
EMERGENCY STOP:
• Discharges should not be made.

26 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 2 TECHNICAL REFERENCE

2.4 Drawings

2.4.1 Basic size drawing


Alfa Laval ref. 563510 rev. 1

E
A D

G0867661
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 2 holes M10, depth 30
E ø38, depth 55
F ø22, depth 42
G 4 holes M12

1810833-02 27
2 TECHNICAL REFERENCE SEPARATION UNIT 865 SERVICE MANUAL

2.4.2 Foundation drawing


Alfa Laval ref. 563761 rev. 1

F
E

I
J

A K
G
L
M
H

B C

G0977631
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.
Foundation turnable 360o
I Recommended free floor space for unloading when doing
service.
J No fixed installation within this area.
K Centre of gravity (complete machine).
L Vertical force not exceeding 18 kN/foot.
M Horizontal force not exceeding 18 kN/foot.

28 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 2 TECHNICAL REFERENCE

2.4.3 Interconnection diagram


Alfa Laval ref. 561786 rev.4

Interlocking switch (frame top part)

Unbalance sensor (position trans.


for bearing holder).

Speed sensor (bowl speed).

Junction box

Wiring of connector “X”: Wire colour codes:

RD=A BK=Black
BU=B BN=Brown
GN=C BU=Blue
YW=D RD=Red
WT=E GN=Green
BK=F PU=Purple
BN=G YW=Yellow
PU=H WT=White
G0867541

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

1810833-02 29
2 TECHNICAL REFERENCE SEPARATION UNIT 865 SERVICE MANUAL

2.4.4 Electric motor


Alfa Laval ref. 563396 rev.2

Knockout openings for cable glands


on both sides.
4 holes M12x24R5

External earthing Casted lifting lugs


bolt

The rotor balanced with


half key. Max. vibration
velocity 2,8 mm/s (rms) Note: The motor
acc. to IEC 34-14 bearings have
permanent
lubrication

G0977521
Manufacturer ABB Motors Type of mounting Degree of
Manuf. drawing Cat. BA/Marine mot./GB 96-10 protection

Standards IEC 34-series, 72, 79 and 85 IEC 34-7 IEC 34-5


Size 160 L
IM 2101 IP 55
Type M2AA 160 L

Weight 94 kg

Poles 2 IM 2111 IP 55

Insulation class F

Bearings D-end 6209-2Z/C3 IM 2131 IP 55


N-end 6209-2Z/C3

Method of cooling IC 411 (IEC 34-6)

Spec. Totally enclosed three-phase


motor for marine service 2)
Motor with feet and small flange.

30 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 2 TECHNICAL REFERENCE

Article Output Speed Freq Voltage Current Pow.fac | st / |1) Note


No. kW rpm Hz V A cos j

563396-17 21 3510 60 690D 21,4 0,92 6,3

563396-16 21 3510 60 380D 39 0,92 6,3

563396-15 21 3520 60 230 D 63 0,91 7 -

563396-14 21 3510 60 220 D 67 0,92 6,3

563396-13 21 3510 60 575D 25,5 0,92 6,3 CSA- plated

563396-12 21 3510 60 480D 30,5 0,92 6,3 -

563396-11 21 3520 60 460D 31,5 0,91 7 -

563396-10 21 3510 60 440 D 33,5 0,92 6,3 -

563396-9 18,5 2920 50 230 D 55 0,91 7 -

563396-8 18,5 2910 50 220 D 58 0,92 6,3 -

563396-7 18,5 2920 50 690 D 18,5 0,91 6,3 -

563396-6 18,5 2910 50 660D 19,3 0,92 6,3 -

563396-5 18,5 2910 50 500 D 25,5 0,92 6,3 -

563396-4 18,5 2910 50 440 D 29 0,92 6,3 -

563396-3 18,5 2910 50 415 D 30,5 0,92 6,3 -

563396-2 18,5 2920 50 400 D 32 0,91 7 -

563396-1 18,5 2910 50 380 D 33,5 0,92 6,3 -

1) lst /l=starting current /rated current at direction line starting.

2) 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.

1810833-02 31
2 TECHNICAL REFERENCE SEPARATION UNIT 865 SERVICE MANUAL

2.5 Nomogram paring tube


Alfa Laval ref. 566511, rev. 0

Calculated level ring ø 100

G0938041

A Density ratio

32 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 2 TECHNICAL REFERENCE

G0938141

A Paring radius
B Position of adjusting screw

1810833-02 33
2 TECHNICAL REFERENCE SEPARATION UNIT 865 SERVICE MANUAL

34 1810833-02
SEPARATION UNIT 865 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
maintenance.

3.1.1 Maintenance intervals


The following directions for periodic
maintenance give a brief description of parts to
be cleaned, checked and renewed at different
maintenance intervals.
The maintenance log for each maintenance
interval on page 39 gives a detailed list of actions
to be performed.

Inspection i i
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 o
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.

1810833-02 35
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 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 the maintenance log and
description in 3.4 Actions Before Assembly,
page 74.
3 Fit all the parts delivered in the service kit
while assembling the separator as described
in chapter 3.5 Assembly, page 81.
4 When the separator is assembled, make final
checks described in 3.6 Actions After
Assembly, page 116.

R
! DANGE

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

ON
CAUTI
!

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 i i and/or o in
the assembly instructions.

36 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

Example:
a Fit the O-ring ii .

When dismantling and assembling between the


service periods, some procedures do not have to
be carried out. These procedures are marked
i i and/or o .
Example:
5 Renew the valve plugs on the operating slide
ii .
All symbols used in the instructions refer to
activities mentioned in the maintenance logs.

3.1.3 Tightening of screws


Tightening all screws with the correct torque
value is important.
These figures apply unless otherwise stated:

Torque

Metric Stainless steel Carbon steel


thread
Nm kpm Ib.ft Nm kpm Ib.ft

M6 7 0,7 5 8 0,8 5,9

M8 17 1,7 13 20 2 14,7

M10 33 3,4 24 39 3,9 28,7

M12 57 5,8 42 68 6,9 50

M16 140 14 100 155 15,8 114

M20 270 28 200 325 33 239

M24 470 48 340 570 58 420

The figures apply to lubricated screws tightened


with a torque wrench.

3.1.4 Service kits


Special service kits are available for Inspection
and Overhaul.

1810833-02 37
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

For other services, a Support kit is available.


Spare parts not included in the Support kit have
to be ordered separately.
Note that the parts for Inspection are included
in the Overhaul kit.
The contents of the kits are described in the
Spare Parts Catalogue.

NOTE

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.

ING
WARN
!

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 CIP together
with repeated discharges can be used.
Some CIP liquids can be corrosive to brass- and
aluminium alloy parts which are included in the
separator.

N
CAUTIO
!

Use only Alfa Laval recommended CIP liquids.

38 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3.2 Maintenance Log

Name of ship/plant: Local identification:

Separator: S 865 Manufacture No./Year:

Total running hours: Product No.: 881205-02-01

Date: Inspection Signature:

Overhaul

Check

Part i o Action Page Note


Frame hood
- All parts x x Clean 74
- All parts x x Check for corrosion 75
- All parts x x Check for cracks 76
- Connecting housing x x Check for erosion damages 77
- Frame hood x x Renew O-ring 110
x Control measure of paring disc height 111
x Check height adjusting rings 111
Bowl
- All parts x x Clean 74
- All parts x x Check for corrosion 75
- All parts x x Check for cracks 76
- All parts x x Check for erosion damages 77
- Bowl body x x Check for impact marks and corrosion 97
x x Renew rectangular ring 98
x x Renew O-rings 99, 102
- Operating slide x x Renew rectangular ring 98
x x Renew valve plugs 97
- Discharge slide x x Renew rectangular ring 102
- In and outlet pipe x x Renew O-rings 105
- Paring tube x x Renew O-ring 105
- Bowl hood x x Renew seal ring 107
x x Renew O-ring 107
Frame
- Frame feet Renew frame feet (including washers 79 Has to be ordered
and screws) separately
- Drain and oil filling holes x x Renew washers 96
- Oil pin x x Renew O-ring 96

1810833-02 39
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

Inspection

Overhaul

Check
Part i o Action Page Note
Driving device
- All parts x Clean 74
- All parts x Check for corrosion 75
- All parts x Check for cracks 76
- Bottom bearing housing x Renew O-ring 85
- Labyrinth ring holder x Renew labyrinth ring 86
x Renew O-ring 86
- Top bearing housing x Renew springs 88
- Flat belt x Renew flat belt 92
- Bowl spindle x Pre-lubricate and renew ball bearing 87
x Pre-lubricate and renew self-aligning
roller bearing 89
x Lubricate the spindle
x Measure the radial wobble 95
- Neck bearing cover x Renew O-ring 94
- Deflector ring x Renew O-ring 94
- Water inlet pipe x Renew O-ring 95
- Operating water cover x Renew seal ring and O-ring 95
- Fan x Renew the O-ring 91
Coupling
- All parts x Clean 74
- All parts x Check for corrosion 75
- All parts x Check for cracks 76
- Coupling hub x Renew single row ball bearings
- Friction blocks x Renew friction pads (if they are worn) 81
or clean the pads if they are oily
Electrical motor
- Electrical motor x Lubricate if nipples are fitted. See sign ---
on motor
Signs and labels on separator
- Machine plate x Check attachment and legibility 116
- Power supply frequency x Check attachment and legibility 116
- Lifting instructions x Check attachment and legibility 116
- Safety labels x Check attachment and legibility 116
- Name plate x Check attachment and legibility 116
- Representative label x Check attachment and legibility 116

40 1810833-02
SEPARATION UNIT 865 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 table to avoid oil draining from the
hoses.

The frame hood and heavy bowl parts must


be lifted by means of a hoist. Position the
hoist exactly above the bowl centre. Use a
lifting sling and lifting hooks with safety
catches.

The parts must be handled carefully. Don’t


place parts directly on the floor, but on a
clean rubber mat, fibreboard or a suitable
pallet.

NOTE

For safety reasons, it is essential that all personnel


who work with the separator read this manual
thoroughly and completely.
Do not allow personnel to clean, assemble, operate
or maintain the separator until they have read and
fully understood this manual.
Ensure that all personnel who operate and service
the separator are well-trained and knowledgeable
concerning the separator and the work to be carried
out.

1810833-02 41
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 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.

ING
WARN
!

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 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

Standard Tools

5
4
3
1
2 6

7 12
9 11
10
8
13

14

G0911641
1 Screwdriver
2 Torque wrench (capacity 0-200 Nm)
3 Drift ( Ø 4 mm)
4 Dial indicator with magnetic base
5 Spanner for clutch (55 mm)
6 Heating equipment for bearings
7 Sliding calliper
8 Hammers (standard and soft-faced)
9 Pliers for internal snap rings
10 Pliers for external snap rings
11 T-handle with extension rod, sockets
(13, 16, 17, 18, 19, 27, 30 mm)
12 Spanners (various sizes)
13 Adjustable spanner
14 Shackle

1810833-02 43
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

3.3.3 Frame hood


Lock nut
Washer

Connecting
housing
Spring

Screw

Arm

G0863331
Screws

G0860531
1

1 Hook spanner (lock nut)


Frame hood

ING
WARN O-ring
!
Height adjusting
rings
Entrapment hazard
To avoid accidental start, switch off and lock-out the Support ring

G0863471
power supply before starting any dismantling work.

Make sure that machine has come to a complete


standstill before starting any dismantling work
(after about 45 minutes from switch off).

1 Removing the connecting housing.

a Remove the lock nut using the


hook spanner.
NOTE

ING Remove connections before


WARN starting dismantling.
!

The nut must not be b Press the pipe down to loosen


removed before the the connecting housing.
separator has stopped.

Remove the washer


c Remove the connecting housing
NOTE
.

Right hand thread.


G0863531

44 1810833-02
SEPARATION UNIT 865 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 screw


from the arm.

c Remove the arm


together with the
spring.

d Turn the paring tube so that the frame hood can be


removed upwards.

NOTE

To avoid the paring tube from being damaged


and preventing the inlet pipe from sticking to
the frame hood when lifting the hood, always
turn the paring tube towards the pipe before
lifting.

G08636B1
Paring tube

3 Removing the frame hood.

a Remove the screws holding


the frame hood. c Lift off the frame
hood.

NOTE
b Loosen the hood
Do not place
by bending with
the hood
a screwdriver in upside down.
all grooves in the
hood.
G0863671

1810833-02 45
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

3.3.4 Bowl Lock ring

Bowl hood

Seal ring

O-ring

Top disc

O-rings

G0861621
Inlet and outlet
pipe

Paring tube

Axial support.
1
Splash sealing

Bowl disc
(without caulks)
Bowl discs
2

Distributor

Cap nut
6

4 Nut
3 7 Discharge slide

Rectangular ring
5 O-ring
8
9
Bowl body
10
G0860571

11 Rectangular ring

O-ring
1 Compressing tool (lock ring). Valve plugs
2 Lifting eyes.
3 Bowl hood puller. Operating slide
4 Spanner for nut (nut/discharge slide).
5 Puller (discharge slide). Rectangular ring
6 Lifting tool (distributor, spindle).
O-ring
7 Puller (Bowl body)
8 Screw (lock ring) (M5) Holder
9 Hexagon head key Nozzle
G08626C1

10 Chisel (seal ring) Operating water ring


11 Pin (distributor/lifting tool)
Ring

46 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

1 Removing the lock ring.

a Fit the compressing tool. c Compress the disc stack by


alternately tightening the
b Screw in the screws to screws on the compressing
stop. tool a maximum of 40 Nm at a
time.
NOTE

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.

f Remove the
dismantling screws.
G0862761

1810833-02 47
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

2 Removing the bowl hood.

a Loosen the screws on the b Fit the puller.


compressing tool.
Remove the tool.
Remove the lock ring.

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.

ING
WARN
!

Crush hazard
The top disc can adhere to the bowl
hood when lifting. Be careful not to
accidentally drop it.
G0862881

48 1810833-02
SEPARATION UNIT 865 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.

NOTE

It is very important not to


Seal ring damage the bottom of the
groove!

ING
WARN
!

Risk for eye injury from flying seal ring parts


The seal ring breaks when removed from the bowl
hood.

G0862441
4 Removing the inlet/outlet pipe and top disc.

a Lift out the in- and outlet pipe together with the top disc.

ING
WARN
!

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.
G0862961

1810833-02 49
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

5 Removing the paring tube.

a Remove the top disc from


the inlet and outlet pipe.

NOTE

To avoid damaging the paring


tube, turn it towards the
centre of the pipe.

b Remove the splash sealing.

c Remove the screws


and the axial support

d Lift up and remove the


paring tube.

Turn the paring tube


upwards.
NOTE

If the paring tube sticks, use a drift


to carefully tap it out from the pipe.
Be careful not to damage the
paring tube.
G0863091

50 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

6 Removing the disc stack and distributor.

c Carefully lift off the


a Assemble the lifting tool with the pin. disc stack assembly.

b Fit the assembled tool into the


distributor and ease off the disc stack
using a spanner or wrench.

N
CAUTIO
!

Cut hazard
Sharp edges on the separator
discs may cause cuts

G0863171
7 Removing the nut

a To prevent the bowl body from rotating


when removing the nut;
Fit the compression tool to the bowl
b Use the spanner body and fit a screw together with a
for nut to remove socket into the frame, as shown in the
the nut. illustration.

Nut

Compressing tool

Screw

Socket (or similar)


G0923831

1810833-02 51
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

8 Removing the discharge slide.

a Fit the lifting tool by


pressing the puller rods
towards each other and
position them into the
two slots on the bowl b Ease off the discharge slide
bottom. by turning the central screw.
Slide metal ring down
over bowl nave.

NOTE

If discharge slide is
difficult to remove,
tap lightly on outside
edge with a soft
faced hammer.

Ring on tool
Puller rod

Discharge slide

Bowl body

c Lift out the discharge slide.

ING
WARN
!

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.
G0863251

52 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

9 Removing the cap nut.

a Remove the cap nut

NOTE

Left-hand thread!

b Remove the compressing tool.

G0860651
10 Removing the bowl body

a Fit the lifting tool to the bowl body.

b Raise the bowl body off the spindle taper


by turning the lifting eye clock-wise.

c Lift off the bowl body


G0860731

1810833-02 53
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

11 Turn the bowl body upside down.

ING
WARN
!

Crush hazard

G0860821
Support the bowl body when turning to prevent it from rolling.

12 Removing the holder.

a Remove the screws.

b Lift off the holder.

NOTE

If the ring sticks, use two M8


screws in threaded holes to raise
the operating slide holder up and
away from the bowl body.
G0860921

54 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

13 Removing the operating slide.

a Lift off the operating slide.

NOTE

If the ring sticks, use two M8 screws in


threaded holes to raise the operating
slide holder up and away from the bowl
body.

G0861021
14 Removing the operating water ring.
a Loosen and remove the screws .

b Lift off the ring.

NOTE

If the ring sticks, use two M8


screws in threaded holes to raise
the operating slide holder up and
NOTE
away from the bowl body.
The discoloration on the ring is oxide
protection. Do not clean with abrasives.
G0861121

1810833-02 55
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

3.3.5 Driving device 1 3 4 5

G0857971
G0857821
7

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).

Seal ring
Air deflector
Operating water cover

O-ring
O-rings Spindle pulley
Deflector ring

Seal ring
Neck bearing cover Belt

O-ring

O-rings
Self-aligning roller
Fan bearing
Lubrication oil orifice
Snap ring
O-ring
Oil pump
Bowl spindle
Labyrinth ring holder

O-ring
Ball bearing Labyrinth ring

Top bearing seat Wing insert


Springs
O-ring
Top bearing housing Bottom bearing
holder
Composite springs Screw

O-ring
Plugs
G0858061

Strainer

56 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

1 Removing the clutch cover.

a Remove the screws.

b Remove the clutch cover.

G0858131
2 Empty the oil sump.

Unscrew the oil plug and


empty the oil sump.
G0868571

1810833-02 57
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 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. Motor
Do not loosen more than shown in the illustration.
Separator frame
Nut

Screw

b Loosen the two upper screws a little bit more so


that the motor can be tilted. Do not loosen more
than shown in the illustration.

ING
WARN
!

Crush hazard
c Remove the flat belt from the motor pulley. The motor will come off if the screws are

G 0 8 5 8 8 A1
unscrewed.

58 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

4 Removing the operating water cover.

a Remove the screws.

b Lift off the operating water cover.

NOTE

If the cover sticks, fit two


M10 screws to the threaded
holes and tighten.

G0858931
5 Removing the neck bearing cover and deflector ring.

d Lift off the neck bearing cover


together with the deflector ring.

a Attach the tools.

b Fasten the tool to


c Ease off the the cover.
cover by
tightening
the screw.

Cover
Frame
G0859051

1810833-02 59
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

6 Prepare for removal of spindle assembly.

NOTE

a To facilitate later removal of


plugs, loosen (do not remove)
the plugs on the bearing
housing.

b Remove the screws

NOTE

If the cover sticks, fit two


M10 screws to the threaded
holes and tighten.

G0859151

60 1810833-02
SEPARATION UNIT 865 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.

ING
WARN
!

Crush hazard
Do not rotate the spindle assembly
during lifting. The spindle assembly
may otherwise come loose from the
lifting tool.

G0907831

1810833-02 61
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

8 Place the spindle assembly upside down on a support.

Make a support

~210 mm

~170 mm
~3,0 mm
free space

G0859211
9 Removing the air deflector.

Remove the screws and the air


deflector.
G0859221

62 1810833-02
SEPARATION UNIT 865 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.

NOTE
Key-grip
Left-hand thread!

G0923921
11 Removing the bottom bearing assembly.
a Turn the spindle assembly up-side down and
Puller tool
remove the oil pump by using spanners.

b Pull off the belt pulley and the


self-aligning roller bearing using
the puller tool.

NOTE

Always discard a used


bearing.

Lubrication oil orifice c Cover the the oil orifice and blow compressed
air through the bottom hole of the oil pump and
slowly ease out the lubrication oil orifice.
G0865981

Compressed air

1810833-02 63
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

12 Removing the top bearing housing.


a Turn the spindle
Composite b Remove the plugs
assembly over.
springs and the composite
springs.

c Carefully remove the spindle


from the top bearing seat.
Plug
NOTE

Be careful not to damage


d Collect the
the vibration indicator.
axial springs.

G0858221

64 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

13 Removing the ball bearing.

a Remove the snap ring.

ING
WARN
!

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.

NOTE

Do not damage threads on


spindle. NOTE

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.

NOTE

Always discard
d Place the top bearing seat on a support to used bearings.
protect the vibration indicator.
Remove the bearing. Use a drift in the two
holes.
G0858331

1810833-02 65
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

14 Removing the labyrinth ring holder.

a Remove the screws.

NOTE

If the holder sticks, fit two screws M8


to the threaded holes and tighten.

G08586B1

66 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

15 Removing the bottom bearing holder.

a Fit the tool into the bottom bearing holder and attach the
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.


G08586D1

1810833-02 67
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

3.3.6 Centrifugal clutch


Snap rings

Ball bearings
Spacing ring

Belt pulley

G0864711 Coupling
ING hub
WARN
!

Parallel pin
Entrapment hazard
To avoid accidental start, switch off and lock-out
power supply before starting any dismantling work.
Friction blocks
(5=50 Hz)
Make sure that machine has come to a complete
standstill before starting any dismantling work Sleeve
(takes about 30 minutes from switch off).

Fan

G0865161
NOTE

50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks

The illustration shows 50 Hz

2
G0865021

1 Mounting /dismantling tool (centrifugal clutch).


2 Mounting /dismantling tool (ball bearing).

68 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

1 Removing the clutch cover.

a Loosen and remove the screws.

b Remove the clutch cover.

G0858131
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. Motor
Do not loosen more than shown in the illustration.
Separator frame
Nut

Screw

b Loosen the two upper screws a little bit more so


that the motor can be tilted. Do not loosen more
than shown in the illustration.

ING
WARN
!

Crush hazard
c Remove the flat belt from the motor pulley. The motor will come off if the screws are
G08588A1

unscrewed.

1810833-02 69
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

3 Removing the motor.

a Disconnect the electrical cables.

ING
WARN
!

Electrical hazard
If the cables are not disconnected during lifting procedures,
they may become damaged.

b Fit a sling to the c Tense the lifting sling to support the motor and
motor using a remove the screws. Lift the motor while supported.
shackle on the upper
part.
ING
Weight of motor with WARN
coupling: approx. !
115 kg.
Crush hazard
If not supported, the motor with coupling
will drop when removing the screws.

G0864641
d Lower the motor onto a suitable pallet.

4 Removing the friction blocks.

a Remove the fan and friction


blocks.

Friction blocks
(5=50 Hz)
Sleeve and screw

Fan

NOTE

50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks
G0865241

70 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

5 Checking the condition of the friction blocks o .

If the blocks are worn:


Fit new friction blocks.

NOTE

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.

NOTE

Make sure that there is no oil on the pads.

b If only friction block service is to be done,


proceed to ‘‘Assembly of friction blocks” on page
83.

G0865341

1810833-02 71
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 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

Screw

NOTE

Use a spanner (55 mm) on the


coupling hub to prevent rotation
during dismantling.

b Check that the brass plug is mounted


Flat areas for spanner (55 mm). on the puller tool.
Fit the tool to the friction clutch.

c Ease off the friction coupling.

ING
WARN
!

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).


G0865471

72 1810833-02
SEPARATION UNIT 865 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.

NOTE

Always discard used bearings.


G0865511

1810833-02 73
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

3.4 Actions Before Assembly

3.4.1 Cleaning i o
Clean the separator parts according to the
diagram below. Afterwards, protect all cleaned
carbon steel parts against corrosion by oiling.

Part Procedure Cleaning agents

Frame and The external cleaning of the frame and motor should be Water and de-greasing agent.
motor restricted to brushing, sponging or wiping while the motor is
running or still is hot.

ING
WARN
!

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.

Bowl Cleaning of bowl discs A chemical cleaning agent must


Inlet/ outlet Handle the bowl discs carefully in order to avoid damage to dissolve the deposits quickly without
the surfaces during cleaning attacking the material of the separator
parts.
1 Remove the bowl discs from the distributor and place them
individually in the cleaning agent. Fuel oil sludge mainly consists of
complex organic substances such as
2 Allow the discs to remain in the cleaning agent until the asphaltenes. The most important
deposits have been dissolved. This will normally take property of a cleaning liquid for the
between two and four hours. removal of fuel oil sludge is the ability to
3 Lastly, clean the discs with a soft brush. dissolve these asphaltenes.

ON
Cleaning of holder for operating slide, operating water CAUTI
ring and operating slide with nozzle. !

Use 10% acetic acid solution to dissolve lime deposits. The


acid should be heated to 80 °C. Cut hazard
Clean the nozzle on the operating slide using a soft iron wire Sharp edges on the separator
discs may cause cuts.
or a similar object.

Driving device Use a sponge or a soft brush. White spirit, cleaning-grade kerosene
or diesel oil.

Centrifugal Use a sponge or a soft brush. White spirit, cleaning-grade kerosene


clutch or diesel oil.

Belt pulley Use a a steel brush. Solvent

74 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3.4.2 Inspection for corrosion i o


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

! D
ANGER

G0205241
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.

Material Type of corrosive Appearance Measure


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
Chloride corrosion begins as small grain emery cloth. This may prevent
dark spots that can be difficult to further damage.
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.

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

1810833-02 75
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

3.4.3 Inspection for cracks i 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.

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.

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.

R
! DANGE

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 for other
parts).
Do not continue to use the separator until it has
been inspected and given clearance for operation by
Alfa Laval.

76 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3.4.4 Inspection for erosion i o


Erosion may occur when particles suspended
in the process liquid slide along or strike
against a surface.

Erosion is characterised by:


Surfaces particularly subjected to erosion are:
1 Burnished traces in the
material.
2 Dents and pits having a
granular and shiny surface.

The sealing edge of the


discharge slide.
Paring disc and paring tube

Lock ring
Bowl body and holder.

Pillars between the


Holder and operating slide. sludge ports in the
bowl wall

The sealing edge of the discharge


slide for the seal ring in the bowl
hood
The underside of the distributor in the vicinity of the

G0911831
distribution holes and wings

1 Inspect the bowl and inlet/outlet parts for


erosion damages.

NOTE

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.

1810833-02 77
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

2 Replace parts if erosion is suspected.

R
! DANGE

Disintegration hazard
Erosion damage weakens parts by reducing the
thickness of the material.
Pay special attention to the pillars between the
sludge ports in the bowl wall.
Replace parts if erosion is suspected of affecting
strength or function.

78 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3.4.5 Exchange of frame feet


The frame feet have to be changed
occasionally due to rubber deterioration from
age.

When replacing the frame feet, the separator


must be lifted. Follow 3.8.1 Lifting the
separator, page 124.

NOTE

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 124

c Remove the existing frame feet.

d Fit the new feet, screws and washers. Tightening


torque: 160 Nm.

e Place the separator in its original position and


fasten the mounting bolts.
G0874421

1810833-02 79
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

3.4.6 Lubrication of bowl parts

a Apply Molykote 1000, or equivalent lubrication, on the


following contact surfaces. Also apply D321 on the
operating slide and the bowl body guide pin.

Nut

Discharge slide

Bowl body
(also apply D321 on guide pin)

Operating slide
(also apply D321)

Holder

Operating water ring


G0911741

80 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

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.

ING
WARN
!

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=251,5 mm 50 Hz
d=209,5 mm 60 Hz NOTE

Remove rust from the


belt pulley using a steel
brush.

b Apply a thin film of oil onto the


external and internal surfaces of the
ball bearings o .

Mounting tool

c Press the ball bearings down one at a time into the coupling
hub, preferably using a hydraulic press. Place the spacing
ring between them.

NOTE

Never re-fit used ball bearings.


The ball bearings must not be heated as they are
packed with grease and sealed with plastic
membranes.

d Fit the snap rings.


G0865621

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3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

2 Fitting the coupling to the motor.

a Clean the motor shaft and apply a


thin oil film.

NOTE

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.
G0865431

82 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

Assembly of friction blocks

3 Fitting the friction blocks.

Guide pin

a Fit the friction blocks onto the


guide pins

NOTE

Be sure that the pins on the


back of the blocks project into
the grooves in the clutch hub.

NOTE

50 Hz = 5 Friction blocks
60 Hz = 3 Friction blocks

b Place the fan in position and secure it with the


screws.

Sleeve and screw

Fan

Screws
G0865461

1810833-02 83
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 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. 135 kg.

ING
WARN
!
b Lower the motor (while
supported) on to the
separator frame. Crush hazard
It will set on the ledge. If not supported, the motor with
coupling may drop when lifted.

c Fit the screws.


Do not tighten until the
belt has been mounted.

d Connect the electrical cables.

G0864641
5 Fitting the flat belt.

a Fit the flat belt to the motor belt pulley.

b Tighten the two upper screws.

c Tighten all motor attachment


screws.

ING
WARN
!

Crush hazard
The motor will come off if the
screws are unscrewed.
G0858851

84 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3.5.2 Driving device

1 Fitting the bottom bearing holder.

a Fit the wing insert, O-rings


and strainer. NOTE

Clean the strainer before fitting.

b Secure the wing insert


with the screw secured d Thread the bottom bearing
with Loctite 243 holder into the frame and fit
c To secure the bottom
the tool into the bottom
bearing holder into the
bearing housing.
frame, apply Loctite
222 on the surfaces
directly above and
below the upper O-
ring.

Socket

Tool

Bottom bearing holder

e Tighten the holder to a torque of 200 Nm.


G0866191

1810833-02 85
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

2 Fitting the labyrinth ring holder.

a Fit the O-ring using


silicone grease o .

b Lubricate and fit the


labyrinth ring o .

c Fit and seal the holder with Loctite 222. Fit


and tighten the screws.

G0866361

86 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3 Fitting the ball bearing and top bearing seat o to the spindle.

a Heat the top bearing seat in oil to b Fit the ball bearing.
maximum 125 °C.
ING
WARN NOTE
!
Always fit a new bearing.
Burn hazard Pre-lubricate before fitting.
Use protective
gloves when
handling any heated
parts.

c Fit the snap ring.

ING
WARN
!

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 °C.
Sleeve

e Wipe off the spindle


and fit the top bearing
seat to the spindle
using the sleeve and
puller.

NOTE

Make sure to fit the bearing seat


correctly or it might get stuck!
G0984831

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3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

4 Fitting the top bearing housing.

a Fit the axial springs o 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.

c Lubricate the threads before


assembly.

d Fit the composite springs o and


plugs to the top bearing housing.
Do not tighten the plugs.
Make sure that the springs enter the
recesses in the top bearing seat.
The plugs should be tightened when
the spindle assembly is mounted into
the frame.
G0866621

88 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

5 Fitting the spindle pulley.

a Turn the spindle assembly


upside down.

b Wipe off the spindle pulley c Fit the spindle pulley


seat on the spindle and nave firmly on the bowl
bore in the spindle pulley with spindle.
a dry cloth.

NOTE

At least 1mm free space between


support and spindle assembly to
protect the bearing.

Mount the cap nut to protect the


threads and support the spindle.

G0866731
6 Fitting the self-aligning roller bearing o .

a Heat the bearing in oil to maximum


125 °C.
b Lower the bearing
NOTE onto the spindle
and press down
Always fit a new bearing. onto the spindle
Pre-lubricate before fitting. pulley using the
special drift tool.

ING
WARN
!

Burn hazard
Use protective gloves when
handling the heated bearing.
G0866841

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7 Fitting the oil pump.

a Fit O-ring onto lubrication oil orifice. Spread oil film on c Lubricate all threads before
O-ring. assembly.
b Push lubrication oil orifice into oil pump. Be sure to
line up tabs on orifice with slots in pump.

d Fit the oil pump (125 + 5 Nm) using


spanners.

NOTE

Clean the oil pump and make


sure that the bottom hole is not
clogged.

G0866961

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SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

8 Fitting the fan

a Turn the spindle assembly up-side down.

NOTE

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 o into the fan.

NOTE

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.

Key-grip

G0924061
9 Fitting the air deflector.

a Turn the spindle assembly up-side


down and fit the air deflector.
G0859231

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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.

ING
WARN
!

Crush hazard
Do not rotate the spindle assembly during lifting. The spindle
assembly may otherwise come loose from the lifting tool.

NOTE

Check that the hole at the bottom of the oil pump is clean before
lowering the assembly down.

Carefully blow
compressed air
b Position the flat belt o so
through the hole in
the bearing housing. that the spindle assembly can
pass through when lowering.
Check the bottom hole. See note below.

c Carefully lower the spindle assembly and position


the bolt holes over the threaded frame holes.
Make sure that the bottom bearing, enters the
bottom bearing holder correctly. Do not use force.

ING
WARN
!
Space

Cut hazard
Do not put fingers between the frame and air
deflector while lowering the assembly.

d Fit and tighten the screws.

NOTE

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.
G0867971

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11 Fitting the flat belt.

a Lift up the belt to the middle (centre) of the


spindle pulley.

NOTE

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.

NOTE

Do not turn the spindle until the


motor is tightened properly to the
frame.

G08588B1

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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 o

b Fit the neck bearing cover.

NOTE 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.

G0868051

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SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

13 Fitting the operating water cover.

O-ring

a Lubricate with oil and fit the seal


ring and O-ring o into the
operating water cover.

Renew the O-ring o


b Fit the operating water cover. Fit washers
and tighten the screws.

NOTE

The water pipe in the frame should


enter the hole in the cover.

G0868141
14 Measuring the radial wobble of the bowl spindle.

a Fit a dial indicator in a support


and fasten it in position as
illustrated. Use the flat belt to NOTE
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
G0858711

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15 Fitting the clutch cover.

b Tighten the screws.

a Fit the clutch cover.

G0858141
16 Fill oil in the oil sump.

NOTE

The separator should be level and at


standstill when oil is filled.

a Remove the oil pin, plug and washer.

b Fit new washer i and refit the drain


plug.
c Fill with new oil until oil flows out from
the filler hole.
The oil volume should be 4,3 litres
d Fit new O-ring i onto the oil pin. when filled.
e Refit the plug with new washer i
NOTE
G0868781

f Fit the oil pin.


For grade and quality of oil see
3.7.6 Lubricating oils, page 123

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SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3.5.3 Bowl

1 Check for impact marks and corrosion in bowl


body nave and on spindle taper i o .

a Remove any impact marks using


N
CAUTIO 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.

G0874611
2 Fitting new valve plugs on the operating slide i i .

a Remove the valve plugs using b Carefully tap in new valve plugs, using a
a drift. clean, soft-faced hammer.

Drift NOTE

Make sure that the plugs are fitted as


described in the illustration.
G0874841

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3 Fitting the operating slide.

a Apply a thin layer of silicone grease and fit the


rectangular ring on the operating slide and the b Fit the operating slide.
rectangular ring and O-ring on the bowl body.
i o . NOTE

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 243

Alignment hole

Operating slide

Bowl body

Guide pin

G0861241
4 Fitting the operating slide holder.

a Fit the holder over the


operating slide.
b Apply a thin layer of molykote grease
and fit and tighten the screws to a
torque of min.15 Nm and max. 20 Nm.

G0861331

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SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

5 Fitting the operating water ring.

NOTE
a Fit the ring i
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 i o

c Fit the operating water ring.

NOTE

The drilled assembly mark on the water ring should


face the corresponding mark on the bowl body.

c Grease, fit and tighten the screws to a torque of


33 Nm.

G0861441

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6 Lifting the bowl body onto the spindle taper.

a Put a drop of oil on the spindle taper.

b Wipe off the spindle taper and


nave bore with a dry cloth.

c Turn the bowl body over.

ING
WARN
!

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.


G0861731

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SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

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 to a
illustration. torque of 50 Nm.

NOTE

Left-hand thread!

Compressing tool

Screw

Socket (or similar)

G0861851
Cap nut

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3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

8 Fitting the discharge slide.

a Apply a thin layer of silicone grease and


fit the rectangular ring i o .

O-ring

b Apply a thin layer of silicone grease


and fit the O-ring i o

ING
WARN
!
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


G0861951

spanner for nut.

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SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

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
ING
positioning of the bowl discs. Always end with WARN
!
the disc without caulks.

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 109

N
CAUTIO
!

Cut hazard
Sharp edges on the bowl discs may cause
cuts.

Recess on bowl disc

Guide rib on distributor


G0862051

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3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

10 Fitting the disc stack assembly to the bowl body.

a Fit the lifting tool into the


distributor.

b Lower the disc stack into the bowl.

Guide pin on bowl


NOTE body

The guide pin on the bowl body should face


the drill mark on the distributor.

The guide ribs inside the distributor then


enter the recesses on the bowl body nave.

Drill mark on
distributor

Guide ribs inside the distributor.

Recesses on the bowl body nave.


G0862181

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SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

11 Assembling the paring tube i .

a Fit the O-rings i bearings


i to the paring tube.

G0984951
12 Mounting the paring tube and fitting the inlet and outlet pipe.

b Mount the splash sealing


a Insert the
paring tube
and mount
the axial
support to c Apply a thin layer of
the inlet and silicone grease and fit
d Carefully lower the inlet and outlet
outlet pipe. the O-rings i o
pipe assembly into the top of the
distributor.

G08622C1

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13 Fitting the top disc.

a Move the paring tube


to the centre.

b Lower the top disc.

The guide rib on the


distributor should enter
one of the two larger
recesses on the top disc.
NOTE

To avoid damaging
the paring tube, turn
it towards the centre
of the pipe.

G0862361

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SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

14 Fitting the bowl hood.

a Apply a thin layer of silicone grease and fit the


O-ring i o

b Fit the seal ring i o Press


the ring down evenly until two
bulges appear.

c Carefully tap down the bulges alternately 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


G0862451

e Remove the lifting tool.

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3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

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.

NOTE

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 NOTE
the lock ring fits into the bowl
body. The lock ring is correctly Check that the lock ring is
fitted when the lock ring ends are correctly positioned all way
facing each other. around!

For correct disc stack pressure


see page 109

c Release the pressure on the


compressing tool and remove it.

Lock ring

NOTE
Bowl hood

Never remove any material


Bowl body from the lock ring. A
hazardous situation could
result.
G0862541

Before compressing Lock ring in position

108 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

16 Checking the disc stack pressure i i .

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.
NOTE
NOTE

Always refit the disc


Do not use more power than
without caulks on top
40 Nm/screw at a time,
of the disc stack!
alternately.

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.
G0874961

1810833-02 109
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3.5.4 Frame hood

1 Fitting the frame hood i o .

a Turn the paring tube so that the frame hood can


pass the paring tube. NOTE

Paring tube. Make sure that the frame


b Apply a thin layer of silicone grease and hood is mounted in its
fit the O-ring onto the frame hood correct position
according to the piping
i o
arrangement.

c Lower the frame hood.

d Fit and tighten the


screws.

NOTE

G08637C1
Make sure to fit the frame hood
groove and the projection of the
pipe.

110 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2 Control measurement of paring disc height o .

a Remove the guide screw (A).

D Quantity height
b Measure the distance D. adjusting rings
mm
Assemble the correct
number of height 33 ± 0,5 5
adjusting rings (B)
according to the table. Guide screw 32 ± 0,5 4

31 ± 0,5 3

30 ± 0,5 2

c Refit the guide screw (A) 29 ± 0,5 1

Support ring Frame hood

Height adjusting rings Guide screw

Distributor Paring disc


Bowl hood
9115F1

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3 Fitting the spring and arm.

Screw
Spring
a Fit the spring on the arm
and fit the arm to the top
of the paring tube end
with the screw.

Arm
Pin Paring tube

b Fit the spring to the pin


on the frame hood and
make sure that it is
properly attached on
both ends.

G08637D1

112 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

4 Fitting the connection housing.

a Fit the connection housing over


the inlet/outlet pipe.

NOTE

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.

G0863941

1810833-02 113
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

3.5.5 Unbalance sensor (option)

1 Fitting the unbalance sensor holder.

a Remove the cover.

Sensor holder.

Sensor arm Frame

Screw M8 b Fit the O-ring on the holder.


Fit the screw into the holder and
M10 mount the holder into the
separator frame.

Sensor
holder

O-ring NOTE

If removing the sensor holder;


use a M10 screw as a puller.

NOTE

See next page for fitting and


correct adjustment of the sensor.
G0873481

114 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2 Adjusting the unbalance sensor

a Measure the distance (A) from the sensor


arm (inside the frame) to the edge of the
holder, using a sliding calliper.

b Measure the length (B) of the sensor.

A
Holder edge

Sensor arm

c Fit the sensor into the holder. Do not forget the nut.

C d Adjust the sensor so that the distance (C) is B - A + 1,5 mm.

1,5 mm
Nut
Sensor

Nut.
+ = brown or red

J = black or white 24 V DC

0V = blue

e When correct distance is achieved tighten the nut Adjustment value (approx. distance 1,5 mm) for the sensor
is; 12 mA ± 1mA.
against the holder. For more details see 2.2 Connection List, page 15 and 752
Fit the cover (see previous page). Unbalance sensor (option)., page 22
G0873461

1810833-02 115
3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

3.6 Actions After Assembly

3.6.1 Control of machine plates and


safety labels o
Alfa Laval ref. 561498 rev. 2

1 Check that the following signs are attached.

Machine plate

Lifting instructions

Space for label indicating representative.

Safety label.

Space for additional label as specified.

S0 0 5 0 1 A 1

Indicating direction of rotation of horizontal driving device.

116 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

2 Check legibility. Following texts should be read on the labels.

Separator S 865
Manufacturing serial No. / Year
Product No. 881205-02-01
In and outlet device 562939-01
Bowl 562565-01
Machine bottom part 562708-01
Max. speed (bowl) 7118 r/minute (50 Hz)
7081 r/minute (60 Hz)
Direction of rotation (bowl) ←
Speed motor shaft 3000 r/min (50 Hz),3600 r/min (60 Hz)
El. current frequency 50/60 Hz
Recommended motor power 18,5 kW
Max. density of feed 1100 kg/m3
Max. density of sediment 2057 kg/m3
Max. density of operating liquid 1000 kg/m3
Process temperature min./max. 0/100 ° C

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.

Read instruction manual before lifting.

1810833-02 117
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3.7 Oil Change


The separator should be level and at
standstill when oil is filled or the oil level is
checked.

3.7.1 Lubricating oil


Do not mix different oil brands.
Always use clean vessels when handling lubricating oil.
Great attention must be paid not to contaminate the lubricating oil. Of
particular importance is to avoid mixing of different types of oil. Even a
few drops of motor oil mixed into a synthetic oil may result in severe
foaming.
Any presence of black deposits in a mineral type oil is an indication that
the oil base has deteriorated seriously or that some of the oil additives
have precipitated. Always investigate why black deposits occurs.
If changing from one oil brand to another it is recommended to do this
in connection with an overhaul of the separator. Clean the gear housing
and the spindle parts thoroughly and remove all deposits before filling
the new oil.

NOTE

Always clean and dry parts (also tools) before lubricants are applied.

ON
CAUTI
!

Check the oil level before start. Top up when necessary.


Oil volume = see “Technical Data”.
It is of utmost importance to use the lubricants recommended in our
documentation.
This does not exclude, however, the use of other brands, provided they
have equivalently high quality properties as the brands recommended.
The use of oilbrands and other lubricants than recommended, is done
on the exclusive responsibility of the user or oil supplier.

Applying, handling and storing of lubricants


Always be sure to follow lubricants manufacturer's instructions.

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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


1 Remove the oil pin, plug and washer.
2 Remove the drain plug.

ON
CAUTI
!

Burn hazard
The lubricating oil and various machine surfaces Oil fill
can be sufficiently hot to cause burns.
Oil drain

3 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.

G0868771
NOTE

See 3.7.6 Lubricating oils, page 123.


NOTE

For Intermediate service procedures; See


6 Fit the washer and the oil filling plug. Tighten “Fill oil in the oil sump.” on page 96.
the plug.
7 Fit the oil pin.

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3.7.4 Lubrication chart


Alfa Laval ref. 567329-01, rev. 0

Bowl (3), Rubber seal rings (4)

Electric motor (6)


Bowl spindle taper (2)

Buffers (3)

Bowl spindle and bearings (1)


Friction clutch bearings (5)

G0875441
Lubricating points Type of lubricant Interval
1 The oil bath. Bowl spindle bearings See 3.7.6 Lubricating oils, 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 At assembling.


of lock nut and cap nut. Recommended lubricants, page 121
4 Rubber seal rings. Grease as specified in 3.7.5 At assembling
Recommended lubricants, page 121
5 Friction clutch bearings. The bearings are pre-lubricated with No need for extra lubrication.
grease.

6 Electric motor. Follow the manufacturer’s instructions. Follow the manufacturer’s instructions.

NOTE ON
CAUTI
!
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 start.
If not otherwise specified, follow the suppliers Top up when necessary.
instructions about applying, handling and storing of Do not overfill.
lubricants.

120 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3.7.5 Recommended lubricants


Alfa Laval ref. 553217-01 rev. 7

Pastes for non-food applications:

NOTE

The data in below tables is based on supplier


information in regards to lubrication properties.
Trade names and designations might vary from
country to country, contact your local supplier for
more information.

Brands with Alfa Laval article numbers are approved


and recommended for use.

Manufacturer 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)

Rocol Antiscuffing (ASP) (Paste)

Kluber Wolfracoat C (Paste)

Bonded coatings

Manufacturer Designation Alfa Laval No.

Fuchs Lubritech Gleitmo 900 (Varnish or


spray)

Dow Corning Molykote D321R (Spray) 535586-01 (300 ml)


Molykote D321R (Varnish) 535586-02 (60 ml)

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3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY SEPARATION UNIT 865 SERVICE MANUAL

Silicone grease for rubber rings

Manufacturer Designation Alfa Laval No.

Dow Corning Molykote 111 (Compound) 539474-02 (100 g)


Molykote 111 (Compound) 539474-03 (25 g)

Fuchs Lubritech Gleitmo 750

Kluber Unisilkon L 250 L

Wacker Silicone P (Paste)

Greases for ball and roller bearings:

NOTE

Always follow the specific recommendation for


lubrication as advised by the manufacturer.

Manufacturer Designation

BP Energrease MM-EP2
Energrease LS2

Castrol APS 2 Grease


EPL 2

Chevron Duralith grease EP2

Elf Epexa 2

Esso/Exxon Beacon EP2


Unirex N2

Mobil Mobilith SHC 460


Mobilux EP2

Gulf Gulflex MP2

Q8/Kuwait Petroleum Rembrandt EP2

Shell Albida Grease EP2


Alvania EP Grease 2

SKF LGEP2 or LGMT2

Texaco Multifak AFB 2

122 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

3.7.6 Lubricating oils


Alfa Laval ref. 567330-02, rev. 0

Paraffinic mineral lubricating oil, category


(ISO-L-) HM 100.
Viscosity grade (ISO-3448/3104) VG 100.
The oil shall follow the requirements in one of
the standards below.

Standard Designation

DIN 51524 part 2 (German standard) DIN 51524-HLP 100

ISO 11158 (International standard) ISO-L-HM 100

The following is the list of recommended oil


brands. Trade names and designations might
vary from country to country. Please contact your
local oil supplier for more information.

Manufacturer Designation

Alfa Laval 567335-01 1 litre


567335-02 4 litres

BP Bartran 100

Castrol Hyspin AWS 100

Chevron Hydraulic oil AW 100


Mechanism LPS hydraulic oil 100

Esso / Exxon Nuto H 100

Mobil DTE 27 (ISO VG 100)

Shell Tellus Oil 100 / S 100

Statoil HydraWay HMA 100

The list of recommended oil brands is not


complete. Other oil brands may be used as long
as the follow the above standards and have
equivalent high quality as the brands
recommended. The use of other lubricants than
recommended is done on the exclusive
responsibility of the user or oil supplier.

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3.8 Lifting instructions

3.8.1 Lifting the separator

Weight to lift 480 kg

Sling length: Min. 750 mm

Fasten all four bolts. Tightening


torque 35 - 45 Nm

G0868451
1 Remove the inlet and outlet device, the frame
hood and the bowl according to the
instructions in 3.3 Dismantling, page 41.

NOTE

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.

124 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 3 SEPARATOR SERVICE, DISMANTLING, ASSEMBLY

6 When lifting and moving the separator, follow


normal safety precautions for lifting large
heavy objects.

ING
WARN
!

Crush hazards
A falling separator can cause accidents resulting
in serious injury and damage.
Never lift the separator by any other method than
described in this manual.

NOTE

When lifting parts without weight specifications,


always use lifting straps with the capacity of at
least 500 kg.

3.8.2 Lifting the bowl

When lifting and moving an assembled bowl, Weight to lift 160 kg


always follow these instructions.

1 Fit the lifting tool with lifting eyes to the bowl


assembly.
2 Check that the lock ring is mounted correctly Tightening torque 35 - 45 Nm
before lifting the complete bowl.
3 Lift the bowl using a sling with the proper
rating.
Lock ring

NOTE
Make sure that
Never try to lift the bowl while it is still in the frame. lock ring is fitted.
G0868441

The bowl body is fastened to the frame with the


cap nut.

1810833-02 125
4 CHANGE OF CIRCUIT BOARD SEPARATION UNIT 865 SERVICE MANUAL

4 Change of Circuit Board


If a circuit board has to be changed, proceed as
follows:
Note down the run time (days only) as shown in
the function list of the EPC 50.
Change the board according to the instructions
below.
Go to parameter Fa 90, and insert the run time.

OP-Board
• Switch power off.
• Remove the snap-in transparent cover.
• Disconnect the two cable plugs (do not
remove the cables from the plugs).
• Disconnect the flatcable connector at the top.
• Unscrew the five hexagon nuts.
• Mount the new board, and connect in reverse
order.

I/O-Board
• Switch power off.
If there is no optional board installed:
• Disconnect all the cable plugs on the large
board (do not remove the cables from the
plugs).
• Unscrew the hexagon nuts. Take care to note
where the special nuts for optional board(s)
are located.
• Mount the new board, and connect in reverse
order.

126 1810833-02
SEPARATION UNIT 865 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.

1810833-02 127
4 CHANGE OF CIRCUIT BOARD SEPARATION UNIT 865 SERVICE MANUAL

4.1 Circuit Board


Temperatures
Circuit board temperature information can be
read as follows:
• Set Pr 7 = 2.
• Push ‘+’ and ‘–’ at the same time (‘Standst.’
now shows on the display).
• Push ‘–’
The actual temperature, max. temperature, and
the number of times the temperature has been
above 70 °C for the transducer scrolls across the
display.
• For further circuit board temperatures, push
the ‘–’ button.
• To leave the list push the ‘+’ and the ‘–’ buttons
at the same time.
• Reset Pr 7 = 0.

128 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 5 CLEANING IN PLACE

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

Before connecting the CIP equipment to the


Separation Unit, the switch on the control
cabinet must be turned to the CIP position.
This is so that oil is not accidentally pumped
when the pipeline is opened up.

5.1 Cleaning in Place,


Separator
1 Remove the pipe connecting plate with pipes
from the separator.
2 Attach the CIP equipment as shown in the
illustration.

NOTE

The top outlet on the CIP unit should be connected to


the top inlet on the separator.

G065054A
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.

1810833-02 129
5 CLEANING IN PLACE SEPARATION UNIT 865 SERVICE MANUAL

5.2 Cleaning in Place,


Heatpac® CBM Heater
For systems including a Heatpac® CBM heater,
cleaning in place of the heater should be carried
out circa every 6 months, or according to
experience. Cleaning in place of the heater
should also be carried out in the event of a
pressure drop increase greater than 0.3 – 0.5 bar
(which indicates that the heater is beginning to
clog).
We recommend that you use Alfa Laval cleaning
liquids. These are specially suitable for the
materials used in the Heatpac® CBM heater.
Liquids that are corrosive to copper or stainless
steel, for example hydrochloric acid, phosphoric
acid, or nitric acid, must not be used.

ING
WARN
!

Burn hazard
Shut off the oil flow and the heating medium flow
before starting maintenance work.

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.

130 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 5 CLEANING IN PLACE

Proceed as follows:

1 Close the valves before and after the heater.


2 Open the heater drain valve until oil remaining
in the heater has drained.
3 Close the drain valve.
4 Loosen the turnable connections before and
after the heater. Turn the connections 90 ° so
that the special CIP connections can be
connected.
5 Connect the CIP equipment. The top inlet on
the CIP unit should be connected to the oil

G065053A
outlet on the heater. The hose from the heater
inlet should be inserted into the tank and
secured with the help of the cover.

NOTE

The middle and lower CIP unit outlets must be


closed.

6 Clean with CIP fluid.


7 Flush with water.

After cleaning:
1 Open the heater drain valve until the flushing
water has drained.
2 Close the drain valve.
3 Remove the CIP connections.
4 Return the turnable connections to their
former positions and re-tighten.
5 Re-open the valves before and after the
heater.

1810833-02 131
5 CLEANING IN PLACE SEPARATION UNIT 865 SERVICE MANUAL

5.3 Cleaning in Place,


Separator and Heater

Connect the CIP equipment as shown in the


illustration. Proceed with cleaning as described Oil outlet Water outlet
above.

G065062A

132 1810833-02
SEPARATION UNIT 865 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 < 0.01 mg/l
Water:pH value Shall be neutral to minimize corrosion risk
Thermal oil The thermal oil must be highly resistant to oxidation 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.
2 Drain the heater.
3 Flush the heater through with fresh water.
4 Drain the heater from water.
5 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.

NOTE

Take care to reinstall the heater the right way up.

1810833-02 133
6 HEATPAC® CBM HEATER (OPTIONAL) SEPARATION UNIT 865 SERVICE MANUAL

134 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 7 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL)

7 Heatpac® EHM Electric Heater


(Optional)
7.1 Technical Data
Media Mineral oil
Max. testing pressure 2.4 MPa (24 bar)
Operating pressure and media temp 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 Pressure vessel steel
Cover Aluminium
Insulation 20 mm mineral wool
Mounting style Vertically or horizontally
Voltage supply 230, 400, 440, 460/480/500, 690 V AC, 50/60 Hz
Connections Acc. to DIN standard 2633 or JIS standard B2213
Terminal box IP 65
Elements; resistance, surface load, output 400 V: 63 Ω, 1.3 W/cm2, 2.5 kW
440 V: 70 Ω, 1.4 W/cm2, 2.8 kW
460 V: 83 Ω, 1.3 W/cm2, 2.5 kW
480 V: 83 Ω, 1.4 W/cm2, 2.8 kW
500 V: 83 Ω, 1.5 W/cm2, 3.0 kW
690 V see 400 V (= Y-connected 400 V elements)

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

Spring pocket for Pt 100 and safety guard G1/2 30 Nm

Temperature sensors 80 Nm

1810833-02 135
7 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL) SEPARATION UNIT 865 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:

1 Lift off the junction box cover.


2 Loosen the cable nipples.
3 Mark the signal wires, disconnect them and
pull out the cables.
4 Remove the flange bolts.
5 Remove the earth connections between the
flanges and the junction box.
6 Lift off the heater insert. If cold heavy fuel has
stiffened the heater insert, a couple of
screwdrivers may be used to ease off the
insert. Avoid using a sling.
7 Clean 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.
8 Assemble the heater in reverse order.
9 Measure the heater block resistance and the
insulation resistance to ground before
G003313A

reconnecting the wires.

136 1810833-02
SEPARATION UNIT 865 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.
4 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:
9 Use a new copper packing.
10 Screw fast the elements in the top counter
flange.
11 Before refitting the junction box, change the
O-rings.

For tightening torques, see page 135.

ON
CAUTI
!

It is very important that the appropriate heater


element is installed.

1810833-02 137
7 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL) SEPARATION UNIT 865 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


• 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 ≥1 MΩ.

G003322A

138 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 7 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL)

Action to Increase Insulation Resistance


If the insulation resistance is between 100 kΩ
and 1 MΩ, 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 can 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 kΩ 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 kΩ
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 MΩ, a new megger test should be carried
out after 14 days operation. The elements should
now have a resistance of over 1 MΩ. If this is not
the case, any element still below 1 MΩ should be
replaced.

1810833-02 139
7 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL) SEPARATION UNIT 865 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.

G003171A
Resistances of available heater sizes and
applicable voltage supply are given in the
following table:
.

Heater Block Resistance (Ω)


Size 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

140 1810833-02
SEPARATION UNIT 865 SERVICE MANUAL 7 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL)

Terminals for Block Resistance Measuring


Power unit 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
Control unit X11:4-5 X11:7-8 ---- ----
X11:4-6 X11:8-9 ---- ----
X11:5-6 X11:7-9 ---- ----
Contactor box ---- ---- K21:2-4 K22:2-4
---- ---- K21:4-6 K22:4-6
---- ---- K21:2-6 K22:2-6

1810833-02 141
7 HEATPAC® EHM ELECTRIC HEATER (OPTIONAL) SEPARATION UNIT 865 SERVICE MANUAL

142 1810833-02
SEPARATION UNIT 865 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) 400, 440, 460/480/500 V AC +10% /-15% ,
50/60 Hz ±5%
External fuse Max. 35 A
Overcurrent protection Thermal relays, 16-23 A/8.5-12.5 A
Triac circuit current Max. 23 A
Power circuits. 36 kW to 72 kW (larger cabinet )
31830-6407-1
Mains supply (3 phase) 400, 440, 460/480/500 V AC +10% /-15% ,
50/60 Hz ±5%
External fuse Max. 100 A
Overcurrent protection Fuses, 25 A, 16 A, 25 A, 63 A
Triac circuit current Max. 23 A

Control circuits
Control voltage 24 V AC +10% /-15% , 50/60 Hz ±5% (from external
control unit)
Power consumption (inrush/hold) 31830-6356-1 Max. 120 VA/30 VA
31830-6407-1 Max. 200 VA/55 VA
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
External inputs and outputs
Inputs Mains supply
Control signals (24 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

1810833-02 143
8 HEATPAC® POWER UNIT (OPTIONAL) SEPARATION UNIT 865 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 K11 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 A2. 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-K17, 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.

144 1810833-02
SEPARATION UNIT 865 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.
The fixed power is fed in steps as a constant part
load. The variable load operates on top of the
fixed part load for fine tuning of temperature.
Sequential switching of the fixed part load and
regulation of the variable part load are
automatically controlled by the control unit, and
results in an overall smooth operation.

G025651A
A Load (kW)
B Size (kW)
1. Part load #1 (variable 0 –16 kW)
2. Part load #2 (fixed 8 kW)
3. Part load #3 (fixed 16kW)
4. Part load #4 (fixed 32kW)

Heating Performance Principle for 440 V

1810833-02 145
8 HEATPAC® POWER UNIT (OPTIONAL) SEPARATION UNIT 865 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 A1 and A2.
Contactor K11 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 System
Reference/Installation Instructions). The triac
modules are controlled 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 (F11).

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, K14) in the case of
excessive temperature or low oil flow (pump
interlocking).

146 1810833-02
SEPARATION UNIT 865 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 K14. Contactor K14 is interlocked by
the temperature switch.
• If 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.

1810833-02 147
8 HEATPAC® POWER UNIT (OPTIONAL) SEPARATION UNIT 865 SERVICE MANUAL

148 1810833-02
Separation Unit 865
Spare Parts Catalogue

Product No. 1010028-01, 1010035-01, 1010035-02


Book No. 1810845-02 V 2
Separator Part No. 881205-02-01
Printed Jan 2003

Spare Parts Catalogue Catalogo parti di ricambio


Reservdelskatalog Catalogo de pecas
Ersatzteilkatalog sobressalentes

Catalogue de piéces de Varaosaluettelo


rechange Êáôáëïãïó
Catalogue de piezas de áíôáëëáêôéêùí
recambio Reserveonderdelen-
catalogus
Êàòàëîã çàïàñíûõ
÷àñòåè Reservedelskatalog
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 & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2003.
Contents
1 Separator................................................ 18 2.18.6 Control cabinet, kit for feed pump
0.4–0.63A..............................................64
1.1 Machine bottom part.....................18
2.18.7 Control cabinet, kit for feed pump
1.2 Driving device vertical .................20
0.63–1.0A..............................................64
1.3 Separator bowl................................22
2.18.8 Control cabinet, kit for feed pump
1.4 In- and outlet device .....................24 1.0–1.6A................................................64
1.5 Belt driving device .........................26 2.18.9 Control cabinet, kit for feed pump
1.6 Centrifugal clutch ..........................28 1.6–2.5A................................................64
1.7 Set of plates.....................................30 2.18.10Control cabinet, kit for feed pump
1.8 Monitoring kit ..................................32 2.5–4.0A................................................65
1.9 Set of tools .......................................34 2.18.11Control cabinet, kit for feed pump
4.0–6.3A................................................65
1.10 Inspection kit ..................................36
2.18.12Control cabinet, kit for feed pump
1.11 Overhaul kit......................................38
6.3–10A.................................................65
1.12 Lifting tool ........................................40
2.18.13Control cabinet, kit for feed pump
1.13 Support kit ........................................42 10–16A..................................................65
1.14 Cover interlocking kit ...................44 2.18.14Remote start interlock ..........................65
2 Ancillary Equipment ....................... 46 2.18.15Sludge valve interlock..........................66
2.18.16Sludge handling ..................................66
2.1 General .............................................46
2.18.17Electric heat tracing ............................66
2.2 Frame assembly .............................46
2.18.18Space heating .....................................66
2.3 Valve block oil ...............................48
2.18.19Space heating, Single Supply .............66
2.4 Water transducer MT50, DN40...50
2.19 Heatpac EHM® heater, 400 V
2.5 Valve assembly ..............................50
(24 V Operation)..............................68
2.6 Pneumatic change-over valve ..50
2.20 Heatpac EHM® heater, 440 V
2.7 Valve block water .........................52 (24 V Operation)..............................68
2.8 Valve block air ...............................52 2.21 Heatpac EHM® heater,
2.9 Sludge removal kit ........................54 460/480/500 V
2.10 Sludge pump ...................................56 (24 V Operation)..............................69
2.11 Butterfly valve, SU 855 ................56 2.22 Heatpac EHM® heater, 690 V
(24 V Operation)..............................70
2.12 Butterfly valve, SU 865 ................56
2.23 Heatpac® Power unit 0–24 kW,
2.13 Connection kit, water/air .............56
400 V, 440 V,
2.14 Connection kit, oil..........................58 and 480 V .........................................72
2.15 Sludge outlet, DIN .........................58 2.24 Heatpac® Power unit, 72 kW,
2.16 Sludge outlet, JIS .........................58 400 V, 440 V,
2.17 Unit overhaul kit.............................60 and 480 V ..........................................74
2.18 Control cabinet ...............................62 2.25 Heatpac® CBM heat
2.18.1 Control cabinet, kit for separator exchanger .........................................76
10–16A .................................................63 2.26 ACP Pump 032, 038 .......................78
2.18.2 Control cabinet, kit for separator 2.26.1 ACP 032 Inspection kit (optional) ........78
16–20A .................................................63 2.26.2 ACP Pump 032 Overhaul kit
2.18.3 Control cabinet, kit for separator (optional)...............................................78
20–25A .................................................63 2.26.3 ACP 032L Repair kit (optional) ............79
2.18.4 Control cabinet, kit for separator 2.26.4 ACP 032N Repair kit (optional) ............79
25–32A .................................................63 2.26.5 Ball bearing kit for el. motor M2AA 90
2.18.5 Control cabinet, kit for separator (optional) ..............................................79
32–45A .................................................64 2.26.6 ACP Pump 038 Overhaul kit
(optional)...............................................80

1810845-02
2.26.7 ACP 038 Inspection kit (optional) ....... 80
2.26.8 ACP 038K Repair kit (optional) ........... 80
2.26.9 ACP 038N Repair kit (optional) ........... 80
2.27 ACP Pump 045 ............................... 82
2.27.1 ACP 045 Inspection kit (optional) ....... 82
2.27.2 ACP Pump 045 Overhaul kit
(optional).............................................. 82
2.27.3 ACP 045K Repair kit (optional) ........... 83
2.27.4 ACP 045N Repair kit (optional) ........... 83
2.27.5 Ball bearing kit for el. motor M100
(optional) ............................................. 83
2.27.6 Ball bearing kit for el. motor M112M
(optional) ............................................. 83
2.28 ACP Pump 052 ............................... 83
2.28.1 ACP 052 Inspection kit (optional) ....... 84
2.28.2 ACP Pump 052 Overhaul kit
(optional).............................................. 84
2.28.3 ACP 052K Repair kit (optional) ........... 84
2.28.4 ACP 052N Repair kit (optional) ........... 84
2.28.5 Ball bearing kit for el. motor M100
(optional) ............................................. 84
2.28.6 Ball bearing kit for el. motor M112M
(optional) ............................................. 84

3 Index .......................................................... 86

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The name plate - the guide for finding the correct spare part numbers.
See also Warnings in chapter ‘‘1.1 General information” on page 7.
Maskinskylten - en guide till det rätta reservdelsnumret.
Se även Varningar i kapitel “1.1 Allmän information” på sidan 8.
Das Typenschild - ein Hinweis zur korrekten Ersatzteilnummer.
Siehe auch Warnhinweise in Kapitel “1.1 Allgemeine Informationen” auf Seite 9.
La plaque de la machine - un guide pour trouver le numéro de piéce de rechange correct.
Voir à ce propos les mises en garde du chapitre “1.1 Informations générales ” en page 10.
La placa-marca de la máquina - guía del número correcto del repuesto. Consulte también las
Advertencias del capítulo “1.1 Información General” en la página 11.
Ôèðìåííàÿ òàáëè÷êà ìàøèíû — óêàçàòåëü ïðàâèëíîãî íîìåðà çàïàñíîé ÷àñòè.
Ñì. òàêæå ïðåäóïðåæäåíèÿ â ãëàâå “1.1 Îáùèå ñâåäåíèÿ” íà ñòðàíèöå 12.
La targhetta della macchina - guida al corretto numero dei ricambi.
Vedere anche le Avvertenze nel capitolo “1.1 Informazioni generali” a pagina 13.
A placa do fabricante da máquina - um guia do número correto das partes sobressalentes.
Consultar também os Avisos no capítulo “Informação Geral 1.1” da página 14.
Konekilpi - opastin oikeaan varaosanumeroon.
Katso myös kappaleessa 1.1 sivulla 15 olevaa kohtaa “Yleiset tiedot ”.
Ç ðéíáêßäá ôçò ìç÷áíÞò åßíáé ï ïäçãüò ôïõ óùóôïý áíôáëëáêôéêïý. Äåßôå åðßóçò ôéò
ðñïåéäïðïéÞóåéò ôïõ êåöáëáßïõ "1.1 ÃÅÍÉÊÅÓ ÐËÇÑÏÖÏÑÉÅÓ", óôç óåëßäá 16.
Het gegevensplaatje - een wegwijzer naar het juiste onderdeelnummer.
Zie ook Waarschuwingen in hoofdstuk “1.1 Algemene informatie”, op blz. 17.
Typeskiltet - en guide til det rette reservedelsnummer.
Se også under Advarsler i kapitel “1.1 Generelle oplysninger” på side 18.

5
6
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1.1 General information

Safeguard your commitment to quality by always using genuine


Alfa Laval spare parts.
Remember, Alfa Laval cannot accept responsibility for the failure of a
separator equipped with non-original spare parts. We guarantee the
quality and reliability of our products.

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WARNING B

When changing certain parts in the separator bowl assembly, the


vibration level may increase. This can result in shorter life time of
components like rolling bearings and gears. If severe unbalance
occurs, the rotating bowl assembly can come into contact with the
frame causing damage to equipment and injuries to personnel.
It is strongly recommended that the exchange of parts is
supervised by an Alfa Laval service engineer. Alfa Laval
assumes no liability for damage to property or injury to personnel
resulting from unauthorized installation of those parts.

WARNING C

Certain bowl parts carry milling marks from the balancing of the
complete separator bowl. These parts must not be replaced
without rebalancing the complete bowl. The rebalancing should
be made by an Alfa Laval service shop.

7
Följ ditt kvalitetstänkande genom att endast använda Alfa Laval
originalreservdelar.
Kom ihåg att Alfa Laval inte tar något ansvar för fel på en separator
som innehåller icke-originaldelar. Vi garanterar kvaliteten och
driftsäkerheten hos våra egna produkter.

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VARNING B

Om vissa delar i separatorkulan byts ut, kan vibrationsnivån


komma att öka. Detta kan i sin tur leda till förkortad livslängd på
t.ex. lager och växlar. Om kraftiga vibrationer uppstår, kan den
roterande kulan komma att slå i stativets delar, vilket kan medföra
allvarlig maskin- och personskada. Det är därför av stor vikt att
utbyte av kulans delar övervakas av en serviceingenjör från
Alfa Laval. Alfa Laval tar inget ansvar för maskin- eller
personskador som kan uppkomma på grund av att delar bytts ut
av icke auktoriserad personal.

VARNING C

Vissa av separatorkulans delar har urfrästa spår som resultat av


balansering av hela kulan. Dessa delar kan inte bytas ut utan att
en ombalansering av kulan görs. För att bästa resultat ska
uppnås, ska den kompletta kulan sändas till en Alfa Laval
serviceverkstad för ombalansering.

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Sichern Sie sich Ihren Anspruch auf Qualität durch ausschließliche


Verwendung von original Alfa Laval Ersatzteilen.
Beachten Sie bitte, daß Alfa Laval keine Verantwortung für den Ausfall
eines Separators übernimmt, der mit Nicht-Originalteilen ausgestattet
ist. Wir garantieren für die Qualität und Zuverlässigkeit unserer

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Produkte.

WARNUNG B

Durch den Austausch bestimmter Teile in der Separatortrommel-


Baugruppe, kann ihr Schwingungspegel steigen. Dies kann zu
einer kürzeren Lebensdauer von Teilen, wie z.B. Wälzlagern und
Getrieben, führen. Bei einer schweren Unwucht kann die
rotierende Trommelbaugruppe in Kontakt mit dem Gestell kom-
men, was zu Beschädigungen der Ausrüstung oder Personenver-
letzungen führen kann. Es wird dringend empfohlen, den
Austausch von einem Alfa Laval Service-Ingenieur beauf-
sichtigen zu lassen. Alfa Laval übernimmt keine Haftung für
eine Gerätebeschädigung oder Personenverletzung aufgrund
einer ungenehmigten Montage dieser Teile.

WARNUNG C

Bestimmte Trommelteile haben Fräsmarken vom Auswuchten der


kompletten Separatortrommel. Diese Teile dürfen nicht ohne eine
Neuauswuchtung der kompletten Trommel ausgetauscht werden.
Die Neuauswuchtung sollte in einer Alfa Laval Service-werkstatt
erfolgen.

9
Respectez votre engagement de qualité en utilisant toujours des
pièces de rechange d’origine Alfa Laval.
Attention, Alfa Laval décline toute responsabilité en cas de panne d’un
séparateur équipé de pièces de rechange qui ne sont pas d’origine.
Nous garantissons la qualité et la fiabilité de nos produits.

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AVERTISSEMENT B

Le remplacement de certaines pièces du bol du séparateur


risque d’augmenter le niveau de vibrations, et donc de réduire la
durée de vie des composants tels que les paliers à roulements et
les engrenages. En cas de déséquilibre trop important, le bol en
rotation risque d’entrer en contact avec des pièces du bâti,
provoquant ainsi des détériorations de l’équipement et des
blessures du personnel. Nous vous incitons fortement à faire
réaliser le remplacement sous la surveillance d’un technicien
de maintenance Alfa Laval. Alfa Laval n’assume aucune
responsabilité en cas de détérioration du matériel ou de blessure
du personnel résultant d’une installation non approuvée de ces
pièces.

AVERTISSEMENT C

Certaines pièces du bol présentent des marques de repérage


effectuées lors de l’équilibrage du bol du séparateur. Il ne faut pas
remplacer ces pièces sans avoir au préalable procédé à un
nouvel équilibrage de l’ensemble du bol. Cet équilibrage doit être
réalisé dans un atelier de réparation Alfa Laval.

10
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Proteja su compromiso con la calidad utilizando siempre repuestos


originales Alfa Laval.
Recuerde que Alfa Laval no acepta ninguna responsabilidad por el
fallo de una separadora equipada con repuestos no originales.
Alfa Laval garantiza la calidad y la fiabilidad de sus productos.

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ADVERTENCIA B

Cuando se cambian ciertas piezas del conjunto del rotor de la


separadora, puede que se produzca un aumento del nivel de
vibraciones, lo que puede provocar un desgaste de algunos com-
ponentes, como los rodamientos de rodillos y los engranajes. Si
se produce un desequilibrado importante, el conjunto del rotor en
movimiento puede rozar con el bastidor, causando serios daños
al equipo y al personal. Se recomienda encarecidamente que el
cambio sea supervisado por un técnico de mantenimiento de
Alfa Laval. Alfa Laval no se hace responsable de los daños
materiales o daños personales provocados por la instalación no
autorizada de esas piezas.

ADVERTENCIA C

Algunas piezas del rotor llevan marcas estampadas para el


equilibrado del rotor completo de la separadora. Siempre que se
cambien estas piezas se debe equilibrar de nuevo todo el rotor,
operación que debe ser realizada por un experto de un centro de
servicio Alfa Laval.

11
Äëÿ îáåñïå÷åíèÿ êà÷åñòâà ðàáîòû âàøåãî îáîðóäîâàíèÿ
èñïîëüçóéòå òîëüêî ïîäëèííûå çàïàñíûå äåòàëè êîìïàíèè
Alfa Laval.
Ïîìíèòå: êîìïàíèÿ Alfa Laval íå íåñåò îòâåòñòâåííîñòü çà
íàðóøåíèÿ ðàáîòû ñåïàðàòîðà, íà êîòîðîì óñòàíîâëåíû íå

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ïîäëèííûå çàïàñíûå äåòàëè. Ìû ãàðàíòèðóåì êà÷åñòâî è
íàäåæíîñòü íàøåé ïðîäóêöèè.

ÏÐÅÄÓÏÐÅÆÄÅÍÈÅ B

 ñëó÷àå çàìåíû íåêîòîðûõ ÷àñòåé óñòðîéñòâà áàðàáàíà


ñåïàðàòîðà ìîæåò ïîâûñèòüñÿ óðîâåíü âèáðàöèè.Ýòî ìîæåò
ïðèâåñòè ê ñîêðàùåíèþ ñðîêà ñëóæáû êîìïîíåíòîâ, òàêèõ
êàê ïîäøèïíèêè è ïðèâîä.  ñëó÷àå çíà÷èòåëüíîãî
äèñáàëàíñà, óñòðîéñòâî âðàùàþùåãîñÿ áàðàáàíà ìîæåò
âîéòè â êîíòàêò ñî ñòàíèíîé, ÷òî ïðèâåäåò ê ñåðüåçíîìó
ïîâðåæäåíèþ îáîðóäîâàíèÿ è òðàâìàì îáñëóæèâàþùåãî
ïåðñîíàëà. Íàñòîÿòåëüíî ðåêîìåíäóåòñÿ, ÷òîáû çàìåíà
áûëà ïðîêîíòðîëèðîâàíà èíæåíåðîì ïî îáñëóæèâàíèþ
êîìïàíèè Alfa Laval. Êîìïàíèÿ Àlfa Laval íå íåñåò íèêàêîé
îòâåòñòâåííîñòè çà ïîâðåæäåíèÿ ñîáñòâåííîñòè èëè
òðàâìû ïåðñîíàëà â ðåçóëüòàòå íåðàçðåøåííîé óñòàíîâêè
ýòèõ äåòàëåé.

ÏÐÅÄÓÏÐÅÆÄÅÍÈÅ C

Íà íåêîòîðûõ ÷àñòÿõ áàðàáàíà ïîñòàâëåíû îòìåòêè ïîñëå


áàëàíñèðîâêè áàðàáàíà ñåïàðàòîðà ïîëíîñòüþ. Ýòè ÷àñòè
íå ìîãóò áûòü çàìåíåíû áåç ïîâòîðíîé áàëàíñèðîâêè âñåãî
óñòðîéñòâà áàðàáàíà ñåïàðàòîðà. Ïîâòîðíàÿ áàëàíñèðîâêà
äîëæíà áûòü ïðîèçâåäåíà â ðåìîíòíîì öåíòðå Alfa Laval.

12
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Salvaguardate la qualità del vostro separatore utilizzando sempre


ricambi originali Alfa Laval.
Ricordate che la Alfa Laval non accetta alcuna responsabilità in caso
di difetti al separatore dovuti all’utilizzo di ricambi non originali. La
Alfa Laval garantisce la qualità e l’affidabilità esclusivamente dei

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propri prodotti.

AVVERTENZA B

In seguito alla sostituzione di alcune parti del tamburo del separa-


tore, il livello di vibrazioni può aumentare. Questo può comportare
la riduzione della vita utile di componenti quali cuscinetti a rulli ed
ingranaggi. In caso di elevato spostamento, il tamburo può
entrare a contatto con le parti del telaio provocando seri danni
all’attrezzatura e lesioni alle persone. Si raccomanda caldamente
di far controllare la sostituzione da un tecnico di assistenza
Alfa Laval. La Alfa Laval non assume alcuna responsabilità per
danni alle cose o lesioni al personale dovuti all’installazione non
autorizzata delle suddette parti.

AVVERTENZA C

Alcune parti del tamburo dipendono dal bilanciamento comples-


sivo del tamburo del separatore. Le suddette parti non possono
essere sostituite senza procedere ad un nuovo bilanciamento.
Per ottenere i migliori risultati, rivolgersi ad un centro assistenza
Alfa Laval per il ribilanciamento dell’intero gruppo.

13
Preserve o seu compromisso com a qualidade utilizando sempre
peças originais Alfa Laval.
Não se esqueça de que a Alfa Laval não assume quaisquer
responsabilidades pela avaria dum separador que não esteja
equipado com peças originais. Por isso, asseguramos a garantia da

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qualidade e fiabilidade dos nossos produtos.

AVISO B

Ao mudar determinadas peças no conjunto do rotor da separa-


dora, poderá provocar um aumento da vibração. Tal poderá origi-
nar a redução do tempo de duração dos componentes, tais como
rolamentos de roletes e engrenagens. Caso se verifique um
desequilíbrio acentuado, o conjunto do rotor giratório poderá
entrar em contacto com a estrutura, vindo a provocar danos no
equipamento e ferimentos pessoais. Recomenda-se vivamente
que a substituição de peças seja vistoriada por um técncico de
serviço da Alfa Laval. A Alfa Laval não assume qualquer
responsabilidade por danos em bens ou ferimentos pessoais
resultantes da instalação não autorizada daquelas peças.

AVISO C

Determinadas partes do rotor contêm marcas de atrito do bal-


anceamento do rotor do separador completo. Estas peças não
devem ser substituídas sem reequilibrar o rotor completo.
O reequilibro deve ser executado por uma centro de assistência
Alfa Laval.

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Varmista käyttämiesi tuotteiden laatu käyttämällä aina aitoja ja


alkuperäisiä Alfa Laval -varaosia.
Muista, ettei Alfa Laval voi vastata sellaisen separaattorin
toimintahäiriöstä, jossa on käytetty muita kuin alkuperäisiä varaosia.
Me takaamme omien tuotteidemme laadun ja luotettavuuden.

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VAROITUS B