Instruction Manual

Westfalia Separator AG Mechanical Separation Division

Instruction Manual No.:

2325-9001-020

Edition:

0806

2

Westfalia Separator AG

© All rights reserved. No part of this document may be reproduced in any form – by graphic, electronic or mechanical means including all types of photocopying or any other means of duplication – without our prior written consent. The transmission of originals and reproductions to third parties is prohibited without our prior consent.

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1

3

Introduction 1.1 1.2 1.3 1.4 1.5

2

3

5

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29 Important hints .......................................................................................30 Special risks of a separator ...................................................................31 Safety precautions for maintenance and repair..................................... 34 Removing the feed and discharge connections .................................... 39 Dismantling the bowl..............................................................................42 Assembling the bowl..............................................................................48 Fitting the centripetal pump ................................................................... 55 Installing the swivel-type actuator..........................................................57 Assembling the feed and discharge connections .................................. 58 Replacing the main bowl gasket (bowl top) ...........................................60 Bowl valves............................................................................................61 Disk stack compressing device .............................................................63

Technical information 5.1 5.2 5.3 5.3.1

21

Three-phase AC motor ..........................................................................22 Direction of rotation of the bowl .............................................................25 Bowl speed ............................................................................................25 Starting time of the bowl ........................................................................26 Run-down time of the bowl ....................................................................26 Speed measuring device .......................................................................27 Electronic vibration monitoring ..............................................................27

Bowl 4.1 4.1.1 4.1.2 4.2 4.3 4.4 4.4.1 4.4.2 4.5 4.6 4.7 4.8

17

Lubricating system.................................................................................18 Oil quality ...............................................................................................19 Oil quantity.............................................................................................19 Oil change..............................................................................................19 Bowl parts ..............................................................................................20 Motor bearings.......................................................................................20

Motor connection 3.1 3.2 3.3 3.4 3.5 3.6 3.7

4

About this manual ....................................................................................9 It is imperative to observe the following instructions to assure safe operation of the separator......................................................................10 For your safety.......................................................................................12 Note on the symbols used in the documentation ..................................13 Old symbols: ..........................................................................................13

Lubrication 2.1 2.1.1 2.1.2 2.1.3 2.2 2.3

7

65

Constructional features.......................................................................... 66 Operating principles of the bowl ............................................................ 68 Operating principles of the hydraulic system of the bowl ...................... 70 Bowl ejection..........................................................................................71


4 5.4 5.4.1 5.5

6

Operation 6.1 6.2 6.3 6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.5 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12

7

7.5

7.6 7.7 7.8

Drive 8.1 8.1.1 8.1.2 8.2 8.2.1 8.2.2 8.3 8.4 8.5 8.6 8.7 8.8

75

Before start-up ....................................................................................... 76 Start-up ..................................................................................................77 Closing of bowl: .....................................................................................77 Water run after start-up..........................................................................78 Program control .....................................................................................78 Function diagram of partial ejection.......................................................81 Total ejection .........................................................................................82 Bowl ejection (manual) ..........................................................................82 Adjusting the separation efficiency ........................................................83 Adjusting the "Fine Tuner" .....................................................................83 Calculation of the "Fine Tuner" diameter...............................................84 Presetting separation.............................................................................84 Adjusting the hydrohermetic feed ..........................................................85 Final adjustment of separating efficiency ..............................................86 Product mode ........................................................................................86 Shut-down (Normal Off).........................................................................88 Shut-down (Emergency-Off) ..................................................................88 Run-down (overspeed) ..........................................................................89 After shut-down......................................................................................89 Prior to a long-term shut-down .............................................................. 89 Trouble shooting ....................................................................................90

Cleaning 7.1 7.2 7.3 7.4

8

Operating water connection...................................................................72 Solenoid valves......................................................................................73 Swivel-type actuator for control of the centripetal pump ....................... 73

95

Cleaning-in-place...................................................................................96 Bowl .......................................................................................................99 Frame...................................................................................................100 Operating water feeding device...........................................................100 Cleaning the lube-oil vessel .....................................................................100 Prior to a long-term shut-down ............................................................101 Note on cleaning work on hoods .........................................................102 Note on cleaning work on disks...........................................................102

103 Drive.....................................................................................................104 Special risks of a separator .................................................................105 Safety precautions for maintenance and repair...................................108 Fitting and removing the motor............................................................112 Removing the motor ............................................................................112 Installing the motor ..............................................................................113 Removing spindle assembly, supporting disk......................................114 Dismantling the spindle assembly .......................................................116 Assembling the spindle unit .................................................................118 Replacing the rubber-metal bushes and the rubber cushions.............121 Installing the spindle assembly............................................................123 Adjusting the proximity switch .............................................................124

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Westfalia Separator AG 9

5

Trouble shooting 9.1 9.2

10

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Mechanical function .............................................................................126 Clarifying function ................................................................................130

Lubrication and maintenance 10.1 10.2 10.2.1 10.2.2

125

135

Lubrication schedule............................................................................136 Maintenance schedule.........................................................................137 Guide to ordering spare parts..............................................................138 Use of non-genuine spare parts ..........................................................139

6


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1

7

Introduction 1.1 1.2 1.3 1.4 1.5

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About this manual ....................................................................................9 It is imperative to observe the following instructions to assure safe operation of the separator......................................................................10 For your safety.......................................................................................12 Note on the symbols used in the documentation ..................................13 Old symbols: ..........................................................................................13


8

Note Notes Notizen Anotaciones Notizen Notes Note

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Westfalia Separator AG 1.1

9

About this manual This manual is part of the documentation supplied with the separator. Everyone who works with or on this machine must have read and understood this manual and also the brochure “Safety precautions for separators”. In order to make available to you the latest safety precautions, they have been set out in a separate brochure “Safety precautions for separators”. They reflect the state of the art and are furnished with the separator documentation.

In the interest of your personal safety and a better understanding of the machine, please first read the brochure “Safety precautions for separaSafety precautions tors” and then this manual.

NOTE

This booklet must be kept for further use and be available at all times in the vicinity of the separator for all persons who work with or on the separator.

The documentation contains important information for all persons who work with or on the separator. Non-compliance with the instructions in the documentation can not only result in danger for machines, material and Caution environment but also endanger persons who work on or in the environment of the separator. (danger to life, risk of injury) At the beginning of this manual, you will find the schematic of the separator and the nameplate. The nameplate must be filled in by the operator. Enter the data from the nameplate on the separator. Dangers of later conNOTE fusion are thus avoided.

If this machine is used in an explosion-hazarded zone, please first read the brochure “Separators in explosion-hazarded areas” and then this manual in the interest of your own safety and for better understanding of NOTE the machine.

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1.2

It is imperative to observe the following instructions to assure safe operation of the separator. 1. Assign only adequately trained and competent personnel with operation, maintenance and repair of the separator. 2. Before every start-up, ensure that all parts are fitted, completely mounted and that all connections on and around the separator are secure and tight. 3. Never use the separator for a purpose other than the intended and correct purpose! 4. Never operate the separator at a speed higher than that specified on the nameplate (rating plate)! 5. Never ignore or acknowledge an alarm without first eliminating the cause! 6. Never start-up or shut-down a partially filled bowl. Danger of imbalance! 7. Never loosen any part before the separator has come to a complete standstill. Before carrying out maintenance and repair work, switch off the separator, wait until it has come to standstill and check that all rotating parts have really come to rest. Then switch off the main switch and lock the machine to prevent it from accidentally being switched back on. 8. When unusual noises and / or vibrations occur, shut down the separator via “Emergency Off” and evacuate the room. Never perform an ejection! 9. Never heat the bowl and bowl parts with a naked flame during dismantling! Welding on the bowl and bowl parts are likewise strictly prohibited. 10. Shut down the separator immediately when damage caused by corrosion or erosion is detected on the bowl. 11. The hood and solids catchers of steam-sterilizable separators are pressure vessels. It is prohibited to weld or machine them! 12. Adjust the disk pressure as specified in the documentation. An incorrect disk pressure can lead to severe imbalance. 13. Have the separator checked by competent, qualified personnel at least once a year in operating state and at least every 3 years in dismantled state. 14. Do not carry out conversions or modifications to the separator. 15. When working on the separator or with dangerous operating materials, always wear the necessary protective gear. 16. Operating the separator with hot products leads to hot surfaces of hood, solids catcher and surrounding piping. Danger of burns!

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17. Always flush the separator after chemical cleaning (CIP). 18. Regularly check the separator, paying particular attention to its nozzles and ejection system to avoid malfunctions. Where necessary, regularly check concentrate nozzles for damage to nozzle stones and soldered joints. Replace damaged nozzles immediately! 19. Use only genuine spare parts from Westfalia Separator. 20. Ensure that the personnel has access to the documentation and that, in particular the safety precautions and instructions have been read and understood before commissioning and working on the separator.

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1.3

For your safety Observe accident prevention regulations.

The local safety and accident prevention regulations apply unconditionally to the operation of the separator. Refer to the documentation supplied.

Proceed only in accordance with the documentation supplied. Operate the separator only in accordance with agreed process and operating parameters. Maintain the separator as described in the documentation supplied. Carry out safety checks on the separator,

as described in the documentation supplied. Liability for the function of the machine passes to the owner. Liability for the function of the machine passes unconditionally to the owner or operator irrespective of existing warranty periods in so far as the machine is improperly maintained or serviced by persons other than Westfalia Separator personnel or if the machine is not applied in accordance with the intended use. Westfalia Separator AG shall not be liable for damage which occurs as a result of non-compliance with the above. Warranty and liability conditions in the Conditions of Sale and Delivery of Westfalia Separator AG are not extended by the above.

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13

Note on the symbols used in the documentation Below is an explanation of the meaning of the symbols used in the documentation. Special attention must be paid to all passages in the documentation marked with safety symbols. The operation described after such a symbol must be carried out with utmost care.

This symbol indicates potential danger to persons. (danger to life, risk of injury) Caution

This symbol indicates potential risks for machine, material and environment. Attention!

This symbol draws attention to the fact that at this point additional manuals must be read and observed. Instruction manual

This symbol does not indicate safety precautions but rather information for a better understanding of the machine. NOTE

1.5

Old symbols: Strictly adhere to instructions marked with this symbol. This avoids damage or destruction of the separator and other equipment. Take special care when carrying out operations marked with this symbol otherwise danger to life.

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Westfalia Separator …………….GmbH D-59302 Oelde ( Germany)

Type

Serial-No.

Model Max. admissible rated bowl speed in min-1 Max. admissible density in kg/dm3 of product Heavy liquid kg/dm3 min/max throughput m3/h min./max. temperature of product in °C min/max housing pressure range in bar

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Solids kg/dm3


16


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2

17

Lubrication 2.1 2.1.1 2.1.2 2.1.3 2.2 2.3

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Lubricating system.................................................................................18 Oil quality ...............................................................................................19 Oil quantity.............................................................................................19 Oil change..............................................................................................19 Bowl parts ..............................................................................................20 Motor bearings.......................................................................................20


18

2.1

Lubricating system

1

Fig. 1

1 External oil lubrication unit

The drive bearings are supplied with oil by the oil circulation lubrication system (external oil lubrication unit). The oil feed is under pressure, the lube oil return is under gravity or under pressure, as illustrated above.

For the electrical connection of the external oil lubrication unit, bear in mind that it has to be switched on when the separator reaches a certain bowl speed during start up and that it must be switched off during shut-down. The specific bowl speeds are listed in the datasheet. NOTE

Instruction manual

For more in-depth information concerning the external oil lubrication unit, refer to the instruction manual supplied with the oil lubication unit.

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19

2.1.1 Oil quality As lube oil use only gear oils with the WS part number stated in the parts list or on the data sheet.

Do NOT use motor vehicle gearbox or engine oils. NOTE 2.1.2

Oil quantity Before starting the separator for the first time fill the oil vessel of the external oil lubrication unit with oil until the oil level reaches the upper mark of the oil level indicator. Minimum oil level: slightly above the lower mark of the oil level indicator Maximum oil level: slightly below the upper mark of the oil level indicator Fig. 2

During operation, the oil level in the vessel of the oil lubrication unit must never be below minimum level; do not fail to re-fill in time (see chapter “Lubrication and maintenance”, section “Maintenance schedule”). IMPORTANT

The quantity of oil needed for filling the vessel is indicated in the instruction manual of the oil lubrication unit. NOTE

2.1.3 Oil change The operating hours up to the first oil change and the subsequent oil change intervals are specified in the “Maintenance Schedule”. Change the oil at the latest as specified in the “maintenance schedule” even if the operating hours specified for an oil change have not been reached. NOTE Whenever changing the oil, clean the lubricating oil chamber thoroughly with thin-bodied oil. Do not use fluffy cleaning rags or cotton waste! Clean sight glass.

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2.2

Bowl parts Before assembling the bowl, coat the threads, guide and contact surfaces on bowl parts such as: – Bowl bottom, – sliding piston, – bowl top, – lock rings, etc. with the lubricating pastes or greases specified in the parts list.

NOTE

Use only lubricants tested by Westfalia Separator for use on separators. The use of non-genuine parts leads to: – safety risks, – less durability of these parts, – reduced availability of the separator, – increased maintenance requirement. In this case, Westfalia Separator shall assume no liability or warranty.

During assembly, note:

Attention!

Do not bring gaskets made from the special material EPDM (ethylenepropylene-diene-caoutchouc) in contact with mineral oils and greases. Consequence in the event of contact: Swelling of the gaskets EPDM-compatible silicon greases can be used for these gaskets to facilitate assembly. The greased surfaces must be free from sand and filings. Otherwise the surfaces can become scored. When cleaning, check the threads, contact and guide surfaces for impact marks. Impact marks will result in scoring.

2.3

Motor bearings

For lubrication of the motor bearings, refer to the instructions of the manufacturer (see motor plate). Instruction manual

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3

21

Motor connection 3.1 3.2 3.3 3.4 3.5 3.6 3.7

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Three-phase AC motor ..........................................................................22 Direction of rotation of the bowl .............................................................25 Bowl speed ............................................................................................25 Starting time of the bowl ........................................................................26 Run-down time of the bowl ....................................................................26 Speed measuring device .......................................................................27 Electronic vibration monitoring ..............................................................27


22

3.1

Three-phase AC motor All separators are driven by three-phase motors. Depending on the construction, the following drive variants are available: Direct drive – with frequency converter Gear drive – with fluid or centrifugal clutch – with frequency converter Belt drive – with controlled torque motor – with frequency converter – with clutch

The technical specifications on the motor supplied are given in the datasheets supplied with the documentation, the motor nameplate and / or the documentation of the motor manufacturer. NOTE The switching devices must be rated for the starting current of the motor.

Starting currents Depending on the different drive and motor types, different starting currents are required for starting a separator. – with frequency converter approx. rated current – with fluid or centrifugal clutch approx. 1.5 – 2 times rated current – with controlled torque approx. 2 – 3 times rated current

Motor protection If the motor is equipped with a PTC thermistor, it must be connected to the corresponding tripping device. Lay the measuring circuit line (tripping device-motor) as a separate control line.

Lubrication If the motor is equipped with a re-lubricating device, it must be relubricated at regular intervals in accordance with the specifications of the Attention! motor manufacturer on the motor nameplate.

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Motor with frequency converter (FC) Pay attention to the following when operating the separator with frequency converter:

The separator must never be started without frequency converter. Attention!

The frequency on the frequency converter must be selected so that the maximum admissible bowl speed is not exceeded. The admissible bowl speed is indicated on the nameplate of the separator. The frequency converter is equipped with a frequency limiter to prevent the admissible bowl speed from being exceeded. Additionally, a speed sensor is installed on the separator. The latter transmits the pulses for bowl speed monitoring to the control system. The control system switches off the separator when the ceiling speed is exceeded. NOTE The separator may be operated only with this auxiliary device. The ceiling speed must be set to 5% above rated speed (see separator nameplate). Important measures to take during commissioning: Check the correct setting of the monitoring devices in accordance with the circuit diagram and setting instructions. Check the speed of the drive spindle. Test the safety circuit. Attach the following safety stickers and check that they are properly attached and in good condition.

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Frequency converter operation The admissible maximum bowl speed must not be exceeded.

Fig. 3

Before carrying out maintenance or repair work on the motor, bear in mind that there may still be residual voltage. CAUTION!

In this connection, refer to the documentation of the frequency converter manufacturer and have safety measures implemented by suitable personnel.

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25 Direction of rotation of the bowl

The bowl must rotate in clockwise direction when looked at from above. CAUTION! If the direction of rotation is wrong, the wiring of the motor power supply lead must be checked for conformity with the circuit diagram and changed accordingly. This may only be carried out by an authorized specialist.

3.3

Bowl speed The bowl speed has been defined to suit the process as a function of the densities of the centrifugally dry solids and the clarified liquid. All components have been constructionally rated for this speed (operating speed) taking into account all safety-relevant factors. The operating speed (bowl speed) and other important process data are specified on the separator nameplate. Alterations to the process data may also necessitate a change in operating speed. The bowl speed may not be changed by the operator without appropriate consultation. The bowl speed stated on the separator nameplate must not be exceeded! The manufacturer must be contacted before changing process data.

CAUTION! If this instruction is not observed, there is danger to life and limb of the

persons working on the separator by machine parts flying around.

Always check the spindle speed when drive parts have been replaced. Also pay attention to the direction of rotation of the spindle and bowl. It must rotate clockwise (see arrow on frame). If this is not the case, an electrician must alter the connection at the motor.

Fig. 4

The spindle speed must be checked before the first start-up and before fitting the bowl. NOTE

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26 3.4

Starting time of the bowl

Specifications on the starting time of the bowl are given in the enclosed data sheets. NOTE

Make sure that the bowl reaches its rated speed within the starting time and that this speed is maintained during operation.

Separators with a motor controlled by frequency converter can be re-started any time. The following applies for separators with controlled torque motors: Re-starting after the motor has reached a constant operating temperature is permitted only after 60 minutes. IMPORTANT

Non-observance of this instruction can lead to overheating of the clutch or motor.

3.5

Run-down time of the bowl The run-down time of the separator bowl, from switching off to shutdown, is specified in the data sheet.

The run-down time specified in the data sheet refers to the rated speed (see separator nameplate) with free run-down and at atmospheric pressure. NOTE In addition to mechanical or electric brakes, the run-down time of the separator can be influenced by various process factors. The run-down time specified in the data sheet specifies the maximum time span required until the separator bowl has stopped rotating. After the run-down time and before working on the separator: Check that the separator is at a standstill. CAUTION!

Otherwise, there is a danger of injury through rotating bowl parts or discharging liquids.

Pay attention to the safety precautions relating to “checking standstill”.

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27 Speed measuring device When the separator is equipped with a speed measuring device, detailed explanations are given in the documentation furnished with the separator control.

3.7

Electronic vibration monitoring Electronic vibration monitoring systems protect the separator against inadmissibly high vibration levels. If certain preset limit values are exceeded, an alarm is given and follow-up measures are initiated.

Vibration monitoring of the bowl spindle On some separators, a further proximity switch for additional vibration monitoring of the bowl spindle is fitted. When bowl imbalance occurs (= vibratory motion of the spindle), this information is transmitted to a downstream evaluating unit and/or indicator and the necessary follow-up measures are initiated.

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4

29

Bowl 4.1 4.1.1 4.1.2 4.2 4.3 4.4 4.4.1 4.4.2 4.5 4.6 4.7 4.8

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Important hints .......................................................................................30 Special risks of a separator ...................................................................31 Safety precautions for maintenance and repair..................................... 34 Removing the feed and discharge connections .................................... 39 Dismantling the bowl..............................................................................42 Assembling the bowl..............................................................................48 Fitting the centripetal pump ................................................................... 55 Installing the swivel-type actuator..........................................................57 Assembling the feed and discharge connections .................................. 58 Replacing the main bowl gasket (bowl top) ...........................................60 Bowl valves............................................................................................61 Disk stack compressing device .............................................................63


30

4.1

Important hints The separator bowl rotates at a very high speed. Hence, forces are produced which can endanger the operating safety of the machine in case of – incorrect assembly or – inadequate cleaning of the bowl. The instructions for assembly must therefore be followed exactly. The following points should also be observed:

Before fitting the bowl parts thoroughly clean, grease or lubricate: Attention!

– Guide and contact surfaces – Lock ring When fitting the bowl parts, make sure that the "O" marks on all parts are in line with each other. (Only then will the parts fit correctly over arresting pins and guide ribs). Avoid damage to bowl parts during assembly and dismantling by – exact positioning. – avoiding diagonal pull. – selecting the lower lifting speed of the hoist. Only use correctly rated, fully functional hoists. Caution

Do not use force to fit or remove parts. Before fitting gaskets, check the gaskets and gasket grooves for cleanness and wear. After fitting, check that the gaskets – are not twisted. – fit evenly into their grooves. All bowl parts – must be handled gently – and placed on a rubber mat or wooden pallet. In the case of a plant with several separators: Do not interchange parts of different bowls (danger of imbalance).

Caution The bowl parts are marked with the serial number of the machine or the last three digits of the serial number.

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4.1.1 Special risks of a separator The separator is equipped with a high-speed rotating metal bowl which represents a danger potential not to be underestimated on account of the rotational energy which can pose a danger for the installation and persons working in the installation when not properly handled.

Switch off the separator before carrying out maintenance or repair work. Wait, observe and check that all rotating parts are at a standstill. Do not reach into the rotating drive section or bowl! Do not loosen any part before the bowl has come to a standstill! CAUTION! Risk of injury and danger to life through rotating parts.

Standstill should not be checked using only one source of information (e.g. speed indicator) but must be backed up by at least one further checking device. It must always be reckoned with that the first used standstill indication will provide false information because, for example, the electronics have failed or the belt or gearbox in the drive is defective.

The following options are available for checking standstill on separators depending on the version: Electric speed indicator Revolution indicator or sight glass on the gear cover of gear separators Optical speed check of the drive motor Noise check Vibration check If you are not sure whether the machine is at a standstill, you must wait for the run-down time specified in the separator documentation. A subsequent check is carried out when you are sure that the machine is at a standstill. Visual speed check by opening the inspection ports on hood and frame Removing the inspection port in the separator hood enables you to look directly on to the bowl. In addition, checking is also possible by removing the gearbox cover or opening the port in the frame.

Only when you are convinced that the separator is at a standstill can the following checks be carried out for additional security. NOTE

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Revolution visual check on machines with belt drive. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out design modifications.

Fig. 5

Revolution visual check on machines with gearbox. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out design modifications.

Fig. 6

Revolution visual check on machines with direct drive. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out design modifications.

Fig. 7

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Observing the motor fan is not a reliable method of checking standstill because the motor or fan can already be at a standstill when the separator bowl is still rotating. NOTE

During cleaning programs (steam sterilization and CIP), very high temperatures are reached on the surfaces of the separator and piping. During cleaning programs, the surfaces of the separator and pipes are very hot. CAUTION! Danger of burns! With some products, the separator has to be cooled. As a result, temperatures of up to minus 30 °C are reached on the surfaces of the separator and pipes.

When the cooling is switched on, the surfaces of the separator and pipes can get very cold. CAUTION! Danger of frostbite!

Depending on type and installation site, hazards in the form of noise emission from the separator may occur. Therefore, always wear protective gear in accordance with the national regulations. CAUTION! Danger of hearing damage!

During all maintenance and repair work on the separator, the fittings and pipelines, there is the risk of injury due to spurting liquids, e.g. hot or caustic liquids can spurt out under pressure. CAUTION! Danger of causticization of skin and eyes!

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4.1.2 Safety precautions for maintenance and repair Observing the maintenance intervals and user information is decisive for the service life and permanent operating readiness of the separator. The maintenance intervals depend on the operating conditions. Especially highly stressed parts of the separator must be regularly checked. Reduce the maintenance intervals to adapt to the operating conditions! Timely maintenance of the separator is essential for safe operation.

Especially highly stressed parts of the separator such as – Bowl lock ring, – Bowl bottom, – Bowl top must be regularly checked (at least once a year) as specified in the maintenance schedule to assure safe and efficient operation.

Fig. 8

When carrying out maintenance and repair work:

Do not climb onto or stand on the machine or parts of the machine! Danger of injury through slipping or falling down!

Fig. 9

Repairs to the separator may only be carried out by service technicians from Westfalia Separator or personnel trained and certified by Westfalia Separator.

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35 During maintenance and repair work, make sure that the main switches are switched off and secured against restarting. Make sure that other persons do not have the possibility to start the machine before the maintenance or repair work is finished.

Fig. 10

Make sure that the rotating parts of the separator (drive, bowl) are at a standstill before carrying out maintenance and repair work. When the machine is defective, a warning sign must be attached and the separator must be secured against unauthorized starting.

Do not heat bowl parts with a naked flame to facilitate dismantling work. Structural changes in the material of the bowl parts which affect the operating safety of the machine may result!

Do not weld bowl parts.

Fig. 11

Do not weld hood and solids catcher parts of steam-sterilizable separators.

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36

Place the dismantled separator parts on suitable surfaces (rubber, wood etc.). Take appropriate steps to prevent machine parts from overturning and rolling away.

Fig. 12

When carrying out assembly work on several separators, be careful not to interchange parts of different bowls! Each bowl must be balanced with its respective components.

The parts are marked with the serialnumber of the machine or with the last three digits of the serial number.

Fig. 13

Some bowl parts must be arranged in fixed positions relative to one another. Locking devices and alignment marks must be in perfect condition. The separator may not be operated when locking devices and marks on the bowl parts are damaged.

Fig. 14

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37 After fitting certain new bowl parts (e.g. bowl bottom, bowl top) the bowl must be re-balanced. Bowl balancing may be carried out only by specialists from Westfalia Separator or specialist workshops authorized by Westfalia Separator! If in doubt, consult the service department of Westfalia Separator. Fig. 15

Unqualified balancing can lead to dangerous operating states and to destruction of the separator with danger to life and limb of the personnel. CAUTION!

Do not manipulate speed-altering devices such as frequency converters so that the maximum admissible bowl speed (see nameplate or “technical data” in the instruction manual) is not exceeded. Ensure that monitoring devices (e.g. overspeed monitors etc.) are not manipulated or damaged and check their function in accordance with the instructions in chapter “Maintenance and repair – maintenance schedule”. After maintenance and repair work on the separator, refit all protective devices. When carrying out maintenance and repair work, carry out a visual check of the separator components. Have the components checked for damage through corrosion and erosion by authorized specialists and proceed in accordance with the instructions in chapter “Maintenance and repair – inspections”.

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Lock ring

Gasket Centripetal pump Chamber cover

Separating disk Gasket Upper centripetal pump Gasket

Disk

Centripetal pump Chamber cover Gasket Distance sleeve Centripetal pump Chamber cover Gasket Gasket Centripetal pump Chamber cover Gasket Gasket Distance sleeve Gasket

Distributor Sleeve

Lower distributor Feed tube

Gasket

Sliding piston

Spindle screw Gasket

Gasket * Lock ring

Gasket

Gasket * Bowl top

Bowl bottom

Gasket

Gasket

Fig. 16

*) Attention: After replacing this part, the complete bowl must be re-balanced!

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39 Removing the feed and discharge connections Switch off and lock the main switch.

Caution

Caution! To prevent accidents, do NOT loosen any part before the bowl has stopped completely! Standstill of the bowl is indicated by – LED "bowl standstill" or – the speed indicator in the control unit or in the motor control or – revolution indicator or – gear standstill, visible through the sight glass on the frame. Replace worn gaskets immediately. For tools, see separate order-specific parts list. Stop compressed-air supply. Disconnect electrical connection 1 and compressed-air supply 2. Note: This has to be done before removing the guards - danger of crushing!

Caution

Fig. 17

Disconnect the following lines: – Cooling lines of the hood cooling, – flush water line, – supply line to hood flushing. Disconnect the feed and discharge lines. Cut off the electrical connection to the contact pressure gauge and sight glass illumination. Unscrew vent line 2. Unscrew connection piece 1. Lift off the connection housing.

Fig. 18

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40

Unscrew hex head screws 3. Remove protecting-case halves 1 and 2.

Fig. 19

Remove toothed segment 3.

Fig. 20

Unscrew hexagon nuts 5. Thread two eye bolts 1 into the tapholes. Lift off ring 2 together with swiveltype actuator. For the transport, use lifting device, if required (correct application is shown on (Fig. 23 ).

Fig. 21

Screw two ring nuts opposite each other onto the studs of the hood.

Fig. 22

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41 Unscrew the screws for fastening the hood. Shorten the chains of the lifting device. Hang the shortened lifting device into the lifting-eye nuts and lift off the hood.

Fig. 23

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42

4.3

Dismantling the bowl Unscrew centripetal pump chamber lock ring by lightly hammering against the handle of the annular wrench (left-hand thread). Lift off the centripetal pump lock ring.

Fig. 24

Lift off centripetal pump chamber cover using lifting tongs 1.

Fig. 25

Remove cover 1.

Fig. 26

Pull off the distance sleeve 1 with upper centripetal pump.

Fig. 27

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43

Remove upper centripetal pump 1.

Fig. 28

Lift off centripetal pump chamber cover 1.

Fig. 29

Pull off lower centripetal pump 1.

Fig. 30

Force off centripetal pump chamber cover 1 by screwing in hex head screws 2. Lift off centripetal pump chamber cover 1. Unscrew hex head screws 2. Pull off disk 3.

Fig. 31

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44

Lift out feed tube 1 with lower distributor 2.

Fig. 32

Unscrew spindle screw with the wrench (left-hand thread).

Fig. 33

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45

Mounting the compressing device: Screw threaded rod 1 as far as it will go into the bowl bottom (left-hand thread). Insert hydraulic part 3 into the centering recess of the disc 4. Screw on threaded ring 2 until its upper edge is flush with end thread of bolt 1 (left-hand thread).

Fig. 34

To prevent damage to threads:

Screw in threaded bolt completely. Attention!

Screw on threaded ring down to thread end. If the threaded ring cannot be screwed down completely, then the piston and the cylinder of the compressing device are too far apart. In this case: Bring piston and cylinder into initial position: – Loosen pressure relief screw 5 by two turns. – Press the pump lever down as far as it will go. – Screw on threaded ring down to thread end. Tighten screw connections of the compressing device. Close pressure relief screw 5. Compress the disk stack to facilitate loosening of the bowl lock ring. Compression: See data sheet. Loosen the bowl lock ring by hammering against the handle of the wrench with a mallet (left-hand thread).

Fig. 35

If the lock ring is jammed tight, loosening can be considerably facilitated by heating the upper part of the bowl bottom with steam or hot water. Do not use any other sources of heat, e.g. blow torch or welding torch.

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46

Dismantling the compressing device: Move pump lever of compressing device down as far as it will go to prevent it from jumping back. Loosen pressure relief screw 5. Unscrew threaded ring 2 (left-hand thread). Remove hydraulic unit 3 and disk 4. Unscrew bolt 1 (left-hand thread). Fig. 36

Unscrew bowl lock ring completely and lift it out using device 1 and eye bolt 2.

Fig. 37

Insert disk 1 in the distributor neck. Screw lifting device 2 onto the bowl top. Force off the bowl top by turning the spindle clockwise and lift it out. Take disk 1 out of the distributor neck.

Fig. 38

Screw lifting device 1 into the distributor. Force off the distributor together with the disc stack by turning jackscrew clockwise. Lift out distributor with disk stack.

Fig. 39

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47

Place pressure piece A of the lifting device (sliding piston) on the hub of the bowl bottom. Grease outer surface of the pressure piece.

Fig. 40

Screw lifting device 1 onto the sliding piston (left-hand thread).. Force sliding piston off the bowl bottom by turning threaded spindle 2 clockwise. Lift off sliding piston. Make sure that the sealing lip of the sliding piston does not get damaged.

Fig. 41

Pressing off the bowl bottom: Screw pressure piece 7 into threaded bolt 4. Screw eye bolt 3 into the upper bolt end 4. Screw the entire device into the thread of the bowl bottom as far as it will go (left-hand thread). Force the bowl bottom off the spindle cone using the wrench which is placed over the hexagon at the upper threaded bolt end. Fig. 42

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48

4.4

Assembling the bowl Handle bowl parts with care. Assemble the bowl on a rubber mat or wooden pallet. Grease threads and guide surfaces of the bowl parts. Replace worn gaskets. For tools, see order-specific parts list. Transport the bowl bottom using the threaded spindle.

Fig. 43

Thoroughly clean gasket groove in the sliding piston and apply a thin film of grease. Insert gasket into the groove of the sliding piston.

Fig. 44

Insert the gaskets in the grooves in the bowl bottom.

Fig. 45

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49 Place pressure piece 1 of lifting device for sliding piston onto hub of bowl bottom.

Fig. 46

Grease guide surfaces of the sliding piston and bowl bottom. Insert the sliding piston using the lifting device so that the "O" marks are perfectly aligned. Lower the sliding piston slowly by turning the jackscrew counterclockwise until the arresting pins of the bowl bottom catch into the holes of the sliding piston. If necessary, jolt the piston until it snaps into position. Fig. 47

Make sure that the sealing lip B of the sliding piston does not get damaged. Attention!

After inserting the sliding piston take out pressure piece A. Turn distributor through 180o. Install lower distributor 1 so that the cams in the lower distributor and distributor – are aligned, Secure lower distributor 1 against falling out by screwing in cylindrical pin 2. Turn around distributor again.

Fig. 48

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50

Stack the disks onto the neck of the distributor in numerical order, beginning with number 1.

Fig. 49

Grease contact surfaces. Install distributor together with disks in the bowl bottom. The "O" marks on the bowl bottom and distributor must be aligned; the grooves in the bowl bottom will then catch into the locking devices of the distributor.

Fig. 50

Install separating disk with inserted gaskets. The "O" marks on the separating disk and bowl bottom must be aligned.

Fig. 51

Clean and grease guide surfaces and threads of the bowl bottom. Insert disc 1 of the lifting device (bowl top) into the distributor neck as a support for the lifting device.

Fig. 52

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51 Insert the gaskets in the grooves of the bowl top. If the main bowl gasket has to be replaced, see chapter “Replacing main gasket”. Clean and grease guide surfaces of the bowl top.

Fig. 53

Place bowl top on bowl bottom with the aid of the lifting device A. Slowly lower the bowl top by turning the threaded spindle B counterclockwise. Make sure that the arresting piece of the bowl bottom catches into the groove of the bowl top. The "O" marks on both parts must be aligned. Unscrew disk from the distributor neck. Fig. 54

Check and grease threads as well as contact and guide surfaces (see arrows).

Fig. 55

Place bowl lock ring on the bowl bottom using lifting device 1 and eye bolt 2. First screw in the bowl lock ring using the pin spanner by hand (lefthand thread).

Fig. 56

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52

Take disk 1 of the lifting device out of the distributor neck.

Fig. 57

Mounting the compressing device: Place disc 4 on the bowl top. Screw bolt 1 as far as it will go into the bowl bottom (left-hand thread). Insert hydraulic part 3 into the centering recess of the disc. Screw on threaded ring 2 until its upper edge is flush with end thread of bolt 1 (left-hand thread).

Fig. 58

To prevent damage to threads: Screw in threaded bolt completely. Screw on threaded ring down to thread end. Attention!

If the threaded ring cannot be screwed down completely, then the piston and the cylinder of the compressing device are too far apart. In this case: Bring piston and cylinder into initial position: – Loosen pressure relief screw 5 by two turns. – Press the pump lever down as far as it will go. – Screw on threaded ring down to thread end. Tighten screw connections of the compressing device. Close pressure relief screw 5. Compressing the disk stack: Pressure must be gradually applied to the disk stack until the max. disk compression is attained, see data sheet. Each pressure increase should be approx. 50 bar. After each pressure increase, tighten bowl lock ring further. When the max. disk compression of (see data sheet) has been reached, the "O" mark on the bowl lock ring must be approx. 1 -2 cm apart from the "O" mark on the bowl bottom. Fig. 59

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53

If the maximum pressure is not attained and grease flows out of the stroke limiting hole, bolt 1 has not been screwed far enough into the bowl bottom. The compressing device is not ready for use again until bolt 1 and threaded ring 2 have been brought back into the position as described above. When compressing the disc stack, make sure that the arresting piece of the bowl bottom snaps into the groove of the bowl top and that the bowl top does not become twisted when lowered. Hit wrench handle with the mallet to obtain "O" mark alignment (lefthand thread).

Fig. 60

If the lock ring can be tightened by hand up to the “O” mark at maximum disk compression, add a spare disk or compensating disk. In the case of newly fitted disk stacks, the pressure in the disk stack can slacken due to settling of the disks. For this reason, check the pressure in the disk stack several times using the procedure described above. At least once a month in the first 3 months. Dismantling the compressing device: Move pump lever of compressing device down as far as it will go to prevent it from jumping back. Only then undo pressure relief screw 5. Unscrew threaded ring 2 (left-hand thread). Remove hydraulic unit 3 and disk 4.

Fig. 61

Unscrew the hex head screws of the pin spanner and remove it. Unscrew the eye bolt. Screw hex head screws with fitted gasket into the lock ring.

Fig. 62

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54

Before placing the bowl on the spindle, oil the upper part of the spindle (thread and cone). Clean and dry the conical part of the spindle and the inside of the bowl hub with a cloth to ensure proper fitting.

Fig. 63

Screw the eye threaded rod.

bolt

onto

the

Fig. 64

Lower the bowl on the spindle. Dismantle the device.

Fig. 65

Screw spindle screw (with inserted gasket) firmly into the spindle (lefthand thread).

Fig. 66

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55

4.4.1 Fitting the centripetal pump Introduce feed tube 1 with gasket 2 into the bowl. Fit lower distributor 3 with inserted gasket 4. Pay attention to correct positioning! Put spacer 5 and gasket 6 on the feed tube. Place on centripetal pump chamber cover 7 with inserted gasket 8. Pay attention to correct positioning! Install lower centripetal pump 9 with gasket 10. Mount centripetal pump chamber cover 11 with gasket 12. Mount distance sleeve 13 with gasket 14. Install upper centripetal pump 15 with gasket 16.

Fig. 67

Pay attention to correct positioning; check assembly of centripetal pump components.

Fig. 68

Clean and grease threads on bowl top and in the lock ring. Install upper centripetal pump 1 with fitted gaskets and tilt towards the bowl centre.

Fig. 69

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56

Mount centripetal pump chamber cover pos. 1.

Fig. 70

Place on centripetal pump chamber cover with inserted gasket. Pay attention to correct positioning! The "O" marks must be aligned.

Fig. 71

Clean and grease threads on bowl top and in the lock ring. Screw on the lock ring by hand and tighten it by hammering against the handle of the annular wrench (lefthand thread).

Fig. 72

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57

4.4.2 Installing the swivel-type actuator

Fig. 73

Exploded view of the swivel-type actuator The swivel-type actuator need not be dismantled when the bowl is to be removed. If, however, the swivel-type actuator has to be dismantled in order to replace a defective component, the bowl has to be removed and reinstalled as shown in Fig. Fig. 73. Also keep in mind the following points: The pointer indicating the angle of setting must be on "0". Place on the drive pinion as shown in Fig. Fig. 73.

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58 4.5

Assembling the feed and discharge connections Screw two ring nuts opposite each other onto the studs of the hood.

Fig. 74

Shorten the chains of the lifting device. The chain link must be put crosswise on hook A (see adjacent small figure)! Hang the shortened lifting device into the lifting-eye nuts and place the hood on the solids catcher. Bolt hood and solids catcher together using hex head screws.

Fig. 75

Thread two eye bolts 1 into ring 2. Insert gasket 3. Place on ring 2 together with the swivel-type actuator. Fasten ring 2 by means of hex head screws 5 with installed lock washers 4.

Fig. 76

Fig. 77

The pointer must be on "0" (see arrow). Place toothed segment 3 on centripetal pump 2 (watch for "O" mark alignment). Insert toothed segment 3 so that the marks of the teeth of segment 3 and of the drive pinion are placed opposite to each other (see arrows). For this purpose, the centripetal pump has to be turned while the toothed segment is held in a slightly inclined position.

2325-9001-020 / 0806


59 Place on protecting-case halves 1 and 2, and fasten them with hex head screws 3.

Fig. 78

Install the discharge. Connect the feed and discharge lines. Connect vent line 2. Screw tight connection piece 1 with inserted gasket.

Fig. 79

Connect the following lines: – Cooling lines of the hood cooling, – flush water line, – supply line to hood flushing. Make electrical connections to the contact pressure gauge. Fit sight glass illumination. Connect current supply 1 and compressed-air supply 2. Note: The protecting cases must be in place - danger of crushing!

Caution

Fig. 80

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60

4.6

Replacing the main bowl gasket (bowl top) Removal Screw wooden screw 1 into the gasket. Lever out the gasket with screwdriver 2.

Fig. 81

Fitting Insert the gasket in the cleaned groove of the bowl top (with the narrow side towards the bowl top). Drive the gasket evenly into the groove. If the diameter of the gasket is too small, place it in a water bath of 70 80 oC for about 5 minutes. The gasket will then assume its original dimensions. Fig. 82

Drive the gasket into the groove so far that the sealing area of the gasket does not protrude above surface "A" of the bowl top by more than 1 mm.

Fig. 83

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61

Bowl valves Remove and clean the bowl valves once a month. Screw wrench 1 (bowl valve) into the bowl valve.

Fig. 84

Push sleeve a of the wrench together with the pins into the holes of the bowl valve. Tighten collar nut b. Unscrew bowl valve from bowl bottom using socket wrench 1.

Fig. 85

If the valve piston 2 remains stuck in the bowl bottom while pulling out the valve: Screw wrench 3 (for valve piston) into the valve piston. Pull the valve piston out of the bowl bottom by means of the wrench.

Fig. 86

At the same time, check the gaskets and replace them if necessary.

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62

Use the tools stated in the parts list to fit the gaskets. Stretch the gasket 3 over the expanding mandrel 4 and fit in piston valve 1.

Fig. 87

Stretch gaskets 3 and 5 over expanding mandrel 2 and 4 and fit in piston 1.

Fig. 88

For installation proceed in opposite order of removal. Pay special attention to the following: Moisten gaskets. Grease threads. Screw in valve as far as it will go, but not too tightly . The front face of the valve housing must be flush with the outer wall of the bowl bottom.

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63 Disk stack compressing device

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Filling device Clamping piece Grease cartridge Pumpenkopf Non-return valve Pressure chamber Hydraulic cylinder Piston Bolt Disc Hydraulic part Threaded ring Stroke-limiting hole Venting screw Pressure gauge (0-600 bar) Pressure relief screw

Fig. 89

Operating principles The pump presses grease at a high pressure into pressure chamber 6. The increase in pressure in the pressure chamber displaces piston 8 in relation to hydraulic cylinder 7. The hydraulic part 11 (piston, hydraulic cylinder) is bolted securely to the bowl bottom by means of bolt 9 and threaded ring 12. When the pressure increases in pressure chamber 6, piston 8 is forced downwards. The force produced is transferred via disk 10 on to the bowl top. The disc stack is compressed. Required compression:

see datasheet

maximum pressure:

see datasheet

Pump The pump produces a pressure of max. 400 bar. It consists of: pump head grease cartridge filling device non-return valve

2325-9001-020 / 0806


64

Filling the grease cartridge Cartridge filling: 450 g special grease K2R The grease cartridge of the compressing device is filled with special grease before shipment. Actuate clamp piece 2 and pull the filling device 1 upwards. Unscrew grease cartridge 3 from pump head 4. Fill in grease, approx. 450 g. Screw grease cartridge 3 into pump head 4. Actuate clamp piece 2 and push filling device 1 into grease cartridge 3. Fill the grease cartridge only with WS special grease K2R. If there is no build-up of pressure, the following must be checked: Is the pressure relief screw 16 screwed in tightly? Is there enough K2R grease in the grease cartridge? Has piston 8 travelled too far out of hydraulic cylinder 7? If yes: Unscrew pressure relief screw 16 a little way. Press piston 8 back into hydraulic cylinder 7. This must be done in the absence of pump pressure. Re-tighten pressure relief screw 16. 7 Hydraulic cylinder 8 Annular piston 9 Bolt 16 Pressure relief screw

Fig. 90

If grease oozes out through the stroke limiting hole 13, bolt 9 and threaded ring 12 have not been screwed into their final position, and the stroke is too long.

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5

65

Technical information 5.1 5.2 5.3 5.3.1 5.4 5.4.1 5.5

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Constructional features.......................................................................... 66 Operating principles of the bowl ............................................................ 68 Operating principles of the hydraulic system of the bowl ...................... 70 Bowl ejection..........................................................................................71 Operating water connection...................................................................72 Solenoid valves......................................................................................73 Swivel-type actuator for control of the centripetal pump ....................... 73


66

5.1

Constructional features

Fig. 91

Self-cleaning bowl: – The bowl can be emptied during operation by means of a hydraulically actuated sliding piston 17. Closed feed and discharge of the product phases: – The product is fed into the machine through a closed line system. – For product observation illuminated sight glasses are fitted in feed 3, clean oil discharge 4 and heavy phase discharge 2. – A pressure switch monitors the discharge pressure of the light phase. – Soap or gums are discharged through a closed discharge pipe. "Fine Tuner": – With the aid of "Fine Tuner" 6 the separating zone in the disk stack can be altered while the separator is running. By this means, the separator can be optimally adapted to changes in the product (e.g. different oil types). During start-up and bowl ejections the separating zone can temporarily be displaced to the centre to prevent oil carry-over at the separating disk outer diameter. Hydrohermetic feed: – The product is fed into the bowl gently and with slight overpressure through hydrohermetic feed 10. "Steam seal": – A hydrohermetic seal 9 prevents clouding of the oil due to vapours from the inlet chamber.

2325-9001-020 / 0806


67

"Bowl Flush": – Liquid can be fed into the outer solids space via a separate channel 5. By this means, surplus lye or acid can be flushed out or a high-viscous phase can be diluted and conveyed more easily out of the bowl. – The separator is also equipped with a direct drive (without belt and gear) three-phase AC motor for FC operation external lubricating oil unit for oil circulation lubrication

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68

5.2

Operating principles of the bowl

Fig. 92 Control unit

1 2 3 4 5 6

Heavy phase discharge Feed Discharge (light phase) Flush water channel (”Bowl Flush”)

7 8 9 10 11 12 13

Centripetal pump – heavy component (”Fine Tuner”) Centripetal pump – light component Distributor ”Steam seal” Hydrohermetic feed Disk stack Rising channels

14 15 16 17 18 19

Flush water channel (”Bowl Flush”)

20 21 22 23 24 25

Opening water

Solids holding space Solids ejection ports Sliding piston Closing chamber Piston valve

Closing–water Metering piston Control air Filling water / opening–water Cooling medium

Separating disk channels

The bowl is used to separate mixtures that consist of – a liquid (oil) and – pasty substances (soapstock or gums) with simultaneous removal of the solids contained in the mixture. The product flows through feed 3 into the bowl, and is separated in disk stack 11. The disk stack consists of a large number of conical disks placed on top of one another. Due to the narrow interspaces between these disks the liquid is split up into thin layers and the settling path is minimized.

2325-9001-020 / 0806


69

The light component flows to the bowl center, then flows to the centripetal pump chamber, is discharged under pressure by centripetal pump 7, and led off through discharge pipe 4. The heavy component flows out of the disk stack to the periphery, flows over the separating disk to the centripetal pump chamber, is discharged under pressure by centripetal pump 6, and is led off under gravity through a discharge pipe. The solids particles are flung against the underside of the disk above, slide outwards into the solids holding space 15, are periodically discharged through solids ejection ports 16. Solids ejection is initiated by control unit 1.

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70

5.3

Operating principles of the hydraulic system of the bowl Closing the bowl When the bowl has reached its rated speed, solenoid valve 12 for closing water is opened briefly several times. The closing water flows into the closing chamber 3 beneath the sliding piston 4. Due to the rotation, pressure builds up in the closing chamber. This pressure creates force in axial direction which presses the sliding piston against gasket 9 of bowl top, thus closing the solids holding space 11 during the separation process. Closing chamber 3 is sealed by valve piston 7 which is pressed through centrifugal force against gasket 8 and thus closes discharge hole 10. In order to compensate for closing water losses, closing water and filling water are supplied every 5 mins for 1sec via an interval switching arrangement.

Fig. 93

Opening the bowl (ejection) To empty the solids holding space opening water 13 is added which flows from injection chamber 2 through feed hole 5 to piston valve 6. Due to hydraulic opening of the valve the water discharges from the closing chamber through hole 10: for partial ejection the closing chamber empties partially, for total ejection it empties completely. As the liquid level recedes the closing pressure acting on the underside of the sliding piston decreases quickly. As soon as it is smaller than the opening pressure acting on the upper side of the piston, the sliding piston is pressed downwards, thus opening the ejection ports in the bowl bottom: the solids are then ejected instantaneously through the ejection ports 14 of the bowl.

Once the ejection has taken place, – opening-water valve 13 closes – closing-water valve 12 opens. Piston valve 6 re-seals discharge hole 10 and the closing chamber fills with water again. The sliding piston is forced back into closed position. Fig. 94

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71

5.3.1 Bowl ejection When to empty the bowl? The intervals at which solids ejections have to take place depend on the solids content and on the nature of the process liquid. If possible, the solids holding space should not be filled to the brim. As soon as the separation or separation efficiency starts to deteriorate, either a total ejection or partial ejection must be carried out. During a total ejection the whole bowl contents are ejected, during a partial ejection only part of the bowl contents. Whether partial or total ejections or a combination of both are carried out depends on the mechanical behaviour of the solids during bowl ejection. Partial ejection Partial ejection is a term used to denote partial emptying of the solids holding space of the bowl. The product feed is not interrupted during partial ejections. The amount to be ejected can be adjusted externally during operation between 5 - 30 l. For partial ejection, opening water is fed to the hydraulic system via the metering device E. The amount of solids to be ejected is primarily determined by the opening water volume. The opening water volume is adjusted on the metering device. Adjusting the amount to be ejected Adjusting by means of the adjusting screw of the metering device. Reduce ejection volume. Turn adjusting screw clockwise Increase ejection volume: Turn adjusting screw anti-clockwise

Fig. 95

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72

5.4

Operating water connection The operating water connection is equipped with solenoid valves, pressure reducer and pressure switch. The function of the pressure switch is to monitor the operating water pressure. If the pressure drops below a preset minimum value, an alarm is given and the separation program interrupted. Operating water connection:

1¼

in

Operating-water pressure: (with open closing water valve)

Pmin. Pmax.

= =

2,0 bar 2,5 bar

=

min. 4000 l/h

Pmin.

=

4,0 bar

Pmax.

=

6,0 bar

Operating water capacity: Air pressure for metering unit:

Note: Prior to a partial ejection there is a brief water pressure increase in the operating water connection. This can be read off on pressure gauge 2. Adjust the air pressure for the metering unit so that the heightened water pressure is lower than the maximum pressure marked on solenoid valve 1.

Fig. 96

If the setting is wrong no partial ejection is possible.

Standard operating water values: D Suspended matter in operating water: max 10 mg/l D Particle size: max. 50 µm D Hardness:

12 odH separating temperature up to 55oC 6 odH at separating temperatures above 55 oC To convert the hardness values stated use the following equation: 1odH = 1.79ofH = 1.25oeH = 17.9 ppm CaCO3

D Chloride content: D pH value:

100 mg/l 6.5 – 7.5

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73

5.4.1 Solenoid valves The solenoid valves incorporated in the operating-water system are 2/2-way straight-way diaphragm valves with internal piloting. The solenoid coil is entirely embedded in epoxy resin which ensures protection against moisture, good dissipation of heat, and perfect electrical insulation. The valves are fully tropicalized. Maintanance The solenoid valves do not require special maintenance. Electrical faults Shut off main valve for operating-water. Fault Cause Valve does not func- Control unit defective. tion. Connecting terminal on terminal strip is loose. Coupler socket loose or leaks.

Remedies Contact servicing staff. Tighten screw of connecting terminal.

Tighten coupler socket and replace gasket, if necessary. Solenoid coil defec- Replace complete tive. solenoid head.

5.5

Swivel-type actuator for control of the centripetal pump The swivel-type actuator is controlled by means of an electric unit signal. As auxiliary anergy, instrument air (dry and free of dust) is required. Air pressure: Flow rate:

Pmin

= 4bar

Pmax

= 6 bar

approx. 93 Nl/min

! The centripetal–pump diameters required a) for operation (" large diameter) and b) for start–up / partial ejection (" small diameter) are entered on the control unit. The values entered are transformed to a certain electric signal. This signal causes the centripetal pump to enter into the desired position. The actual position can be read from the separator.

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74


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6

75

Operation 6.1 6.2 6.3 6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.5 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12

2325-9001-020 / 0806

Before start-up ....................................................................................... 76 Start-up ..................................................................................................77 Closing of bowl: .....................................................................................77 Water run after start-up..........................................................................78 Program control .....................................................................................78 Function diagram of partial ejection.......................................................81 Total ejection .........................................................................................82 Bowl ejection (manual) ..........................................................................82 Adjusting the separation efficiency ........................................................83 Adjusting the "Fine Tuner" .....................................................................83 Calculation of the "Fine Tuner" diameter...............................................84 Presetting separation.............................................................................84 Adjusting the hydrohermetic feed ..........................................................85 Final adjustment of separating efficiency ..............................................86 Product mode ........................................................................................86 Shut-down (Normal Off).........................................................................88 Shut-down (Emergency-Off) ..................................................................88 Run-down (overspeed) ..........................................................................89 After shut-down......................................................................................89 Prior to a long-term shut-down .............................................................. 89 Trouble shooting ....................................................................................90


76

6.1

Before start-up Note: – Instructions in the brochures: “Separators in explosion-hazarded zones”, “Machine controls for separators”, “Safety precautions on the separator”. – Process dependent modifications reserved – refer to the project-related documentation. – Only feed product which conforms to the specifications on the nameplate. Check that – the machine has been correctly assembled, – the bowl is fitted, – the bowl lock rings have been tightened securely, – the screws for fastening the hood and the feed and discharge housing are tightened securely, – the centripetal pump with connection piece is tight, – the frame drains are open, – enough oil has been filled in (see manual of external lubricating oil unit), Open shut-off valves in supply lines for – operating water, – cooling water – hood flush water, – control air Press "Release" button. Check that – the specified pressures are indicated on the respective pressure gauges for – operating water, – braking water – control air Fill the siphon (when cooling medium does not discharge via siphon).

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77 Start-up Press the "Separator ON" button. – Signal lamp "Start" lights up. LED "Bowl standstill" on the mimic display of control unit goes out as soon as the drive rotates. Together with the main motor the external fan is switched on automatically. The bowl speed can be read off from the speed indicator. The power consumption of the main drive motor is indicated by the ammeter. After approx. 4 minutes start-up and reaching half the bowl speed, switchover to run-up takes place speed-dependently. – Signal lamp "Run-up" lights up. After a further 8 minutes, switch-over to operation takes place speeddependently. – Signal lamp "Operation" lights up. The operating speed is reached (see separator nameplate). The ammeter indicates the no-load current of the machine. The lubricating oil unit is started at a certain bowl speed (see data sheet). – The oil circulation is monitored by a pressure switch. If the pressure in the oil line drops below the minimum value, the fault is signalled. The separator is switched off after a pre-set delay time. If severe vibrations occur during start-up, stop the separator immediately via "Emergency-Off" and check when the bowl is at rest whether the bowl is correctly assembled and thoroughly cleaned. Separators equipped with a vibration monitoring system are continuously monitored for unduly high mechanical vibrations and automatically stopped upon exceeding the limit value stage 2.

Attention!

6.3

Never initiate a total ejection when the separator is vibrating severely. Strong unbalance of the separator may result. Damage of dame to assets and persons due to machines flying round.

Closing of bowl: After having switched over from acceleration to operation, two total ejections are carried out automatically in order to close the bowl. Unless this program has been activated, the two total ejections have to be initiated manually by pressing the corresponding function key. To prevent water losses, closing water is injected every 5 minutes for one second. All program time settings are variable. Closing-water injection is indicated by an LED in the separator symbol on the timing unit.

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78

6.4

Water run after start-up Check that – metering device on the operating water connection is correctly adjusted. – program times are set on the control unit to suit the operating conditions. Feed separator with water. Check that the bowl is watertight. – Bowl leakage is indicated by a higher reading on the ammeter. – When bowl leakage is detected, terminate the water run, press "total ejection" button. – Refill the bowl with water and check that it does not leak. – If the bowl cannot be made watertight after several attempts. Press "total ejection" button. Warm up the bowl for max. 15 minutes without water. The polyamide ring adapts to the sealing surface of the sliding piston. – Refill the bowl with water and check that it does not leak. – If bowl leakage persists, shut down the separator via "Normal Off". Dismantle and check the bowl after standstill (polyamide gasket, gaskets of bowl hydraulic system etc.). Ejection progress is shown by LEDs in the valve symbols.

6.4.1 Program control A PLC unit is used for automatic program control of the separator. Consult the control unit manual for further information.

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79 Function of the metering device The metering device E is filled with water via filling valve A after every ejection. For partial ejection chamber F is supplied with compressed air. Through actuating the opening water valve D the adjusted water volume is displaced by air pressure and fed to the hydraulic system of the bowl. A B C D E F P

Solenoid valve filling water Solenoid valve closing water Solenoid valve hood flush water Solenoid valve opening water Metering device Air chamber Solenoid valve cooling water

Fig. 97

Program sequence Refer also to section 6.4.2. After the program time "Separation - Partial Ejection" has elapsed, a partial ejection is initiated automatically which is then repeated at identical intervals. Before each partial ejection the solenoid valve C "Hood flush water" opens for approx. 10 seconds. This time can be preset as the program time "Pre-flushing". Water is sprayed into the hood to prevent the solids to be ejected from sticking to the walls. For solids ejection the solenoid valves B "Closing water" and D "Opening water" open for 1 second. This time can be preset as the program time "Partial ejection". The solenoid valve B "Closing water" remains open for a further 5 seconds after the ejection. The time is set via "Closing". At the same time the hood flush water valve stays open for the time "Post-flushing". The "Separation" program can be interrupted by pressing the "Partial ejection" button. A partial ejection is then triggered. After termination of this forced partial ejection the control program automatically switches back to "Separation". Before each partial ejection the "Fine Tuner" is contracted to a small centripetal pump diameter (see 6.4.2-"Ta"). After each ejection the centripetal pump is extended to the large centripetal pump diameter after time (see 6.4.2 - "Tb"). These times are adjustable.

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80

Setting the program times: Program times... sec are process-related and must be set before start-up. Program time Pre–flushing

approx. 10 secs Pre–flushing hood/solids collector.

Partial ejection

1 sec This determines the opening time of the opening–water valve. This time must be longer than the displacement time of the opening water from the metering unit. The ejected solids volume depends on the preset volume in the metering unit.

Secondary flushing

approx. 20 secs Flushing the hood and solids collector after an ejection.

Closing

5 sec Closing water addition after an ejection.

Metering device

3 secs Continued control of air for metering device after partial ejection.

Filling water

2 secs Delayed filling water supply after partial ejection.

Total ejection

10 secs (not variable) Addition of opening water during total ejection.

Waiting

approx. 60 secs Waiting time after total ejection for speed recovery of bowl.

Delay ejection after con- Capacity–dependent 1) tracting centripetal pump Displacement of the separating zone to the centre to enable more heavy phase (Ta) to enter the bowl. Delay centripetal pump Capacity–dependent 1) travel–out after ejection Filling the bowl with heavy phase. (Tb) Centripetal pump travel–out Capacity–dependent 1) When product is first fed into the bowl, delay (Tc) the bowl must be filled with heavy phase to the extent that there is no carry–over when the centripetal pump is extended.

1) The higher the capacity, the shorter the time.

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81

6.4.2 Function diagram of partial ejection Program times

Fig. 98

Setting the program times: See control unit manual

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1)

When the waiting period for resuming the bowl speed has elapsed, no automatic switch–over to ”separation” will take place.

2)

These functions are provided in the control unit and can be adjusted if an automatic water valve has been installed.

Ta

Delay of ejection after contracting the centripetal pump)

Tb

Delay in extending the centripetal pump after ejection

Tc

Delay in extension of centripetal pump (after starting with product).


82

6.4.3 Total ejection During cleaning-in-place total ejections can only be initiated manually with the control unit. (Automatic cleaning-in-place requires a separate CIP unit, see relevant brochure.) During a total ejection the whole bowl contents are ejected. Never initiate a total bowl ejection when the machine is vibrating severely (bowl unbalance). Attention!

To trigger a total ejection, press function key "Total ejection". If the installation is correctly set up (see connection diagram of control unit), the feed pump is automatically switched off by pressing push button "total ejection" and automatically re-started approx. 1 min. after completion of the total ejection. The interruption of the feed to the bowl by switching off the feed pump is necessary for the bowl speed to recover, which drops slightly during total ejections. Once the bowl has been filled again (observe increasing discharge pressure of centrifuge), a further total ejection can be carried out by again pressing push button "total ejection". Should the feed pump fail to stop automatically during a total ejection, it must be switched off manually and re-started 1 min. after total ejection.

6.4.4 Bowl ejection (manual) In the case of control unit failure or defective solenoid valves the separator can be controlled manually: Partial ejection Open closing water valve B and filling valve A with the hand actuated lever. Open opening-water valve D briefly (approx. 1 sec). After the partial ejection leave closingwater valve B open. Total ejection Switch off the product pump. Open closing water valve B and filling valve A with the hand actuated lever. Open opening-water valve D with the hand actuated lever until the ejection noise has died down. Close opening water valve D and filling valve A; leave closing water valve B open. Switch on the product pump again 1 minute after the total ejection.

Fig. 99

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83

Adjusting the separation efficiency To achieve perfect separation of the liquid mixture, the bowl must be adjusted to the different densities. To do this, – first adjust the "Fine Tuner" (6.5.1) – and then the hydrohermetic feed system (6.5.4). – Then carry out final adjustment of the "Fine Tuning" (6.5.5).

6.5.1 Adjusting the "Fine Tuner" The bowl is adjusted to the different densities of the mixture by altering the diameter of the "Fine Tuner". The required diameter of the "Fine Tuner" can be determined using the formula below. The general rule of thumb is: Small "Fine Tuner" diameter with a low density difference, Large "Fine Tuner" diameter with a large density difference. When separating pasty substances, the diameter of the "Fine Tuner" not only depends on the densities of the two components but also on the flow characteristics of the heavy component. In almost all cases a larger diameter of the "Fine Tuner" should be selected than is actually required by the difference in densities of the light liquid and the heavy pasty component.

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84

6.5.2 Calculation of the "Fine Tuner" diameter The diameter of the "Fine Tuner" can be determined with the aid of the formula below. It should be noted that the densities are dependent on the temperature. To determine the "Fine Tuner" diameter, those densities must be entered that correspond to the separating temperature. gheavy phase

= 1.0484 kg/dm3

Doil – centripetal = 120 mm (immersed)

pump

goil

3

= 0.88 kg/dm

Dseparating zone

= 426 mm (centre rising channel)

! heavy phase (D separating zone ² - D heavy phase ²) " ! oil (D separating zone ² - D oil ²) Dheavy phase = D"Fine Tuner":

D heavy phase " D separating zone ² #

! oil ! heavy zone

$ ( D separating zone ² # D oil#centripe ² )

Whether the correct diameter for the "Fine Tuner" has been selected can be established by checking the position of the separation zone which forms between the light and heavy phase in the bowl. The middle of the separating zone is the separating line; it is almost always visible on the underside of the disks after opening the bowl. It is sufficient to check a few of the uppermost disks. The separating line should be situated in the outer third of the rising channels.

6.5.3 Presetting separation Setting the separation on the machine is done by entering the desired centripetal pump diameter on the control unit. The selected centripetal pump diameter should initially be slightly smaller than needed. This procedure provides less risk of carry-over when the hydrohermetic feed is adjusted in the next step. Setting possibilities: Input of the large centripetal pump diameter: max 245 mm – The working diameter of the "Fine Tuner" is adjusted (calculated from 6.5.2), i.e. separation takes place in this position. Input of the small centripetal pump diameter: min. 172 mm – The position is defined to which the "Fine Tuner" travels during start-up and solids ejection. The standard value is a diameter of approx. 185 mm.

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85

6.5.4 Adjusting the hydrohermetic feed

Fig. 100

The values shown in the diagram are based on measuremens with turbine oil and water. They should be considered as reference only. When treating other products, the range of operation might be different. Determine feed capacity. Determine feed pressure from the above diagram. Adjust the determined feed pressure by throttling the light-phase (oil) discharge. Note: – If the feed pressure exceeds the permissible value Pmax, there will be an overflow into the heavy phase. – if the pressure falls below Pmin, the system is not sufficiently filled, the hydrohermetic feed does not work.

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86

6.5.5 Final adjustment of separating efficiency After having finally adjusted the hydrohermetic feed, carry out final adjustment of the "Fine Tuner". Set the optimum separating efficiency by entering the large centripetal pump diameter. - The light phase contains part of the heavy phase.

ය Increase the diameter of the ”Fine Tuner”.

- The heavy phase contains part ය Reduce the diameter of the ”Fine Tuner” of the light phase. or check the discharge pressure to make sure that no overflow from light to heavy phase has occurred.

Note: The light phase centripetal pump is only needed for adjusting the hydrohermetic feed. Attention!

– The hydrohermetic feed is throughput-dependent, i.e. it has to be readjusted when the throughput changes. The "Fine Tuner" is intended for setting the separating zone.

6.6

Product mode Prior to feeding oil, supply cold or hot water to the bowl, depending on the process, until the separating temperature is reached (this is of particular importance when treating oils that tend to emulsify easily). Then stop the process water supply. The water forms a water seal in the bowl which prevents the oil from discharging through the water outlet. Open the hand shut-off valve in the product feed line, if provided. Press „Product ON" key: – Switch on the separation program. – Oil metering pump on or product valve open. Adjust the throughput capacity. – The "Fine Tuner" is positioned for a small centripetal pump diameter. Carryover is thus prevented. As soon as enough heavy phase has formed inside the bowl, the centripetal pump is positioned for a large diameter. The period to be provided for this step can be preset (see 6.4.2). Throttle the pressure in the oil discharge line so that the hydrohermetic feed works. Carry out final adjustment of the "Fine tuner" (6.5.5). After the pressure switch on the clean oil side has responded the LED „PAL" goes out. Monitoring of the clean oil discharge is disabled for the program time „delay discharge pressure". The program time starts with „Separation". If the pressure switch responds during separation, the product feed valve closes automatically or the oil metering pump is switched off and the separation program is interrupted. The LED „PAL" flashes. Be sure to feed process water again before restarting with product.

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87 The throughput capacity of the separator (i.e. supplied liquid volume per unit of time) depends on – the viscosity, – the temperature, – the difference in densities of the components to be separated, – the nature of the heavy component to be separated, – the desired degree of purity of the light component. In the case of longer interruptions in operation, e.g. due to no product supply, we recommend carrying out one or two partial ejections by pressing the „Partial ejection" key to avoid compacting of the heavy phase in the bowl.

Attention!

The bowl is not allowed to run without liquid supply for more than 15 minutes, as otherwise it would result in overheating of the bowl material. The separation program including the partial ejections is carried out automatically by the control unit. The running program can be interrupted by pressing the „Partial ejection" key which triggers a bowl ejection immediately. The function diagram shows the program sequence for partial and total ejections. The program sequence is indicated in the mimic diagram of the control unit by means of LEDs.

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88

6.7

Shut-down (Normal Off) Press function key "Separator 0". Product feed pump off. – Product feed valve closes. – Braked run-down of separator through frequency converter with feedback facility. – Signal "operation" goes out. – Total ejection takes place. – Valves in the separator discharges are opened (control air bled from constant pressure valves). – The lubricating oil unit switches off at a certain bowl speed (see data sheet). – Signal "bowl standstill".

Do NOT loosen any part of the separator before the bowl is at a standstill! CAUTION!

6.8

Danger of injury to persons through rotating bowl parts.

Shut-down (Emergency-Off) Shut-down (Emergency-Off) can be initiated: by vibration stage 2, by vibration stage 1 after 5 minutes, manually.

Do not supply opening water! – Product feed valve closes. – Braked run-down of separator through frequency converter with feedback facility. – Run-down water valve open (max. 20 m3/h). – Switch-over in the separator discharge from product path to sewer. – Valve in separator discharge is open (control air bled from constant pressure valve). – Separation program off. – The lubricating oil unit switches off at a certain bowl speed (see data sheet). At bowl standstill – Run-down water valve closed. – Signal "bowl standstill".


Danger of injury to persons through rotating bowl parts. When shut-down (Emergency-Off) is caused by vibration, Open and clean bowl before re-starting.

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89 Check if bowl is correctly assembled and check drive. Observe safety precautions when carrying out maintenance work!

6.9

Run-down (overspeed) – Product feed valve closes. – Main motor off. – Switch-over in the separator discharges from product path to sewer. – Valves in the separator discharges are opened (control air bled from constant pressure valves). – Separation program off. – The lubricating oil unit switches off at a certain bowl speed (see data sheet). At bowl standstill – Signal "bowl standstill".


Danger of injury to persons through rotating bowl parts. After shut-down through overspeed before renewed start-up – Open and clean the bowl. – check programmed output frequency on the frequency converter, – check transmission ratio of the drive, – Check speed limit value setting on the operator panel, – Check control electronics on the frequency converter.

6.10

After shut-down Close hand shut-off valves in the feed and discharge of the separator. Close manual shut-off valves in supply lines for – operating water, – control air, – cooling liquid, – hood flush water, When the machine is shut down for prolonged periods, follow the instructions in the chapter “Cleaning”!

6.11

Prior to a long-term shut-down If the separator is not operated for a prolonged period, a number of basic points must be observed. Only in this way can it be ensured that no damage occurs to the separator when it is later put back into operation. The exact procedure for preparing a separator for a prolonged shut-down is described in the chapter cleaning.

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90

6.12

Trouble shooting Short-term mains failure Product feed valve closes. Main motor OFF. Separation program OFF. Automatic valves close. When power returns Press "reset" function key. Press "Separator I" function key. After switching to "Operation" two total ejections are carried out automatically. Note: The machine is shut down (Emergency Off) before pressing the Reset" key. Long-term mains failure with bowl standstill Product feed valve closes. Main motor OFF. Separation program OFF. Automatic valves close.

Do not loosen any part of the separator before the bowl is at a standstill! Caution Open and clean bowl before re-starting. Note safety precautions when carrying out maintenance work!

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Westfalia Separator AG Faults Motor temp. stage 1 C (160 o ) TAH

91 Causes

Motor overloaded. Motor defective. Ejection intervals too short. Ambient temperature too high. No or insufficient motor cooling.

Automatic responses Visual and audible alarm.

Remedies Extend ejection intervals, reduce throughput capacity. Check that bowl is tight, water and mechanical brakes are serviceable. Check motor current: Observe ammeter. If motor current is too high, check drive. Let motor idle and check after approx. 15 minutes if the signal can be acknowledged by pressing the ”reset” button. If that is the case, the motor temperature has dropped. Then perform a total ejection and check if motor fan system is dirty. If necessary, shut down the Separator and clean external fan.

Motor temp. stage 2 C (180 o ) TAH

No remedial action was taken after fault indication Stage I”. Motor overloaded. Drive defective. Motor defective.

Visual and audible alarm. Main motor OFF. Separation program OFF. Product valve closes or product pump off. Total ejection

Check drive. Check motor.

Overcurrent IAH

Bowl leaks. Bowl rotates in solids. Water brake is in operation .Drive defective. Motor overloaded. Single phase run .Motor defective.

Visual and audible alarm. Main motor OFF. Separation program OFF. Product valve closes or product pump off. Total ejection

Check if – bowl is tight, – solids discharge is blocked, – bowl rotates in solids. Clean solids collector and frame Check that water brake is serviceable (solenoid valve for brake water leaks). Check motor. Check drive.

Vibration stage 1 22,5 % = 4,5 mm/s t > 10 sec NAH

Unbalance of bowl due to uneven solids ejection or due to incorrect assembly of bowl. Drive defective (bearings or vibration absorbers)

Total ejection Visual and audible alarm.

While the bowl is filled perform several partial ejections by pressing the respective button.

A 5 minute delay time starts simultaneously. If unbalance cannot be eliminated during this time, separator is shut down via ”emergency off”.

Vibration stage 2 35 % = 7 mm/s t >5 sec NAH

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Visual and audible alarm. Shut–down ”Emergency Off”.

Open and clean the bowl. If bowl is not dirty and is correctly assembled, check drive (bearings and vibration absorbers).


92 Faults

Causes

Automatic responses

Remedies

Fan [IMG,0,20,3,2]FL

Fan motor defective. Fan motor overloaded. Single phase run.

Visual and audible alarm. Main motor OFF. Separation program OFF. Fan motor off. Product valve closes or product pump off. Total ejection

Lubrication FAL

Lube oil flow interrupted. Lube oil level too low.

Visual and audible alarm. After Check lubrication system. Check monitoring system. 5 minutes: Main motor OFF. Separation program OFF. Product valve closes or product pump off. Total ejection

Operating–water t >5 sec

Water pressure
Visual and audible alarm. Separation program OFF. Product valve closes or product pump off.

Speed min. RUN

Bowl leaks. Slippage of flat belt. Starting time longer 12 minutes. Water brake is in operation. Drive defective.

Visual and audible alarm. Carry out the following Separation program OFF. checks at operating speed: Product valve closes or product pump off. – bowl for watertightness – speed measuring device – limit value setting on speed indicator – solenoid valve for water brake

Check fan motor. Clean fan.

Check water supply system. Clean filter in pressure reducer. If the water pressure drops so far that the required water pressure does not build up within the max. possible separating time and no ejection is possible, the separator must be shut down and the bowl cleaned by hand. (If the permissible retention time of the solids in the bowl is exceeded – product–dependent – the solids will harden and be ejected unevenly from the bowl. The result is severe unbalance during ejection).

at standstill: – drive – flat belt, replace when necessary

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93

Faults

Causes

Ejection monitoring (The signal is activated when there is no current increase when an ejection is initiated. The speed drops during ejections. Increased current consumption brings the bowl back up to operating speed.)

Water pressure too low. Water filter blocked. Operating–water line leaks. Nozzles in the operating–water feed are blocked. Bowl hydraulic system is defective. Operating–water valves defective. Opening time too short. Air supply to metering device not operational: – pressure reducer – 3/2–way pilot valve

Automatic responses Visual and audible alarm. Separation program OFF. Product valve closes or product pump off.

Remedies Initiate a solids ejection by pressing the ”Total ejection” key and observe the ammeter. Check water pressure. Clean filter in operating–water line. Check operating–water line for leakage. Clean nozzles and bores in operating–water feed. Check operating–water valves. Check air supply to metering device.

If still no success, shut down separator! Check bowl hydraulic system and renew gaskets if necessary.

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94


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7

95

Cleaning 7.1 7.2 7.3 7.4 7.5

7.6 7.7 7.8

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Cleaning-in-place...................................................................................96 Bowl .......................................................................................................99 Frame...................................................................................................100 Operating water feeding device...........................................................100 Cleaning the lube-oil vessel .....................................................................100 Prior to a long-term shut-down ............................................................101 Note on cleaning work on hoods .........................................................102 Note on cleaning work on disks...........................................................102


96

7.1

Cleaning-in-place After use, the separator must be cleaned in place. During CIP, cleaning solution is circulated through the separator and the connected system. Attention: Make sure that the cleaning solution emerging from the discharge lines of the separator cannot enter the product lines. Set changeover valves, if provided, accordingly. If no changeover valves are provided, the plant has to be modified accordingly. To prevent corrosion damage, only approved detergents should be used. Example:

Henkel

- 2 % lye (P3 Super LA)

Bayer

- 2 % caustic (Trosilin M alkaline) - Acid solution 0.5% (Trosilin M acid)

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97

The following cleaning program is recommended: Program sequence

1.

Pre–flushing Feed rate: approx. 5 m3/h Displacing the product with hot water

2.

Caustic flushing temperature: 70 - 80 oC Feed rate: approx 5 m3/h 2 percent caustic solution (NaOH) (caustic soda free of chloride) Dislodging residual dirt Purging the piping with water Overflow

3.

4.

5.

Intermediate flushing temperature: 70 - 80 oC Feed rate: approx. 5 m3/h hot water total ejection Neutralizing Temperature: 65oC Feed rate: approx. 5 m3/h Neutralizing with 0.5 % HNO3 solution Purging the piping with water Total ejection Post-flushing Temperature: 70 - 80 oC Feed rate: approx. 5 m3/h Flushing out the HNO3 solution with water Total ejection

Duration of the individual program steps 2 - 5 minutes

20 minutes

2 -5 minutes

20 minutes

5 minutes approx. 30 seconds

The total ejections must be initiated by pressing a button. The commands “Total ejection" can be automatically triggered from an external CIP control unit.

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98

Feed

Light phase discharge Heavy phase discharge

Pressure measurement

Fig. 101

To obtain perfect cleaning of the bowl, the system has to be connected as follows: The CIP solution is fed into the feed. The liquid emerging from the heavy-phase discharge is diverted into the oil discharge unthrottled. Thus, an internal circuit is formed whose throughput rate is greater than the feed rate. The volume that is fed flows off through the light-phase discharge. The oil discharge towards the tank is throttled (V3) as far as the motor current allows, or until overflow of the bowl occurs (Inom of drive motor - see nameplate). The volume of circulating liquid is set only by means of the oil valve V3. To prevent overload of the motor, the rated current (Inom) must not be exceeded. Attention!

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99 Bowl Cleaning of the bowls after separation is only required when the nature of the separated solids necessitates it. Experience will show how often the bowl has to be cleaned. The following points should be kept in mind: During the first few months of operation, the lock rings should be removed approximately every two weeks for greasing the threads to prevent seizing. Later on, the greasing intervals may be extended. However, the bowl should be dismantled at least every two months for thorough cleaning of the inner bowl parts.

Never use metal scrapers or metal brushes for cleaning the discs and bowl parts. IMPORTANT

All bowl parts have fine tolerances; it is therefore important that all parts are cleaned thoroughly and are free from burrs. Remove the gaskets from the bowl parts. Clean grooves and gaskets to prevent corrosion. Replace damaged or very swollen gaskets immediately. Swollen gaskets should be left to dry in a warm place so that they can regain their original dimensions and can be re-used. Carefully clean the small holes in bowl bottom and the two bowl valves for the supply and discharge of the operating-water to ensure trouble-free performance of the solids ejections. Clean and wipe dry guide surfaces and threads of bowl parts and grease them. Spindle cone and inside of bowl hub should be oiled and then wiped clean and dry with a smooth rag. The solids catcher and solids collector bottom should also be cleaned every time. Re-assemble bowl immediately after cleaning. Otherwise the bowl parts must be protected against dust and dirt.

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100

7.3

Frame When cleaning the frame: Never expose the machine to a direct water jet. It must be cleaned by hand, with a sponge or cloth. This applies especially to the motor, even if it is enclosed.

7.4

Operating water feeding device The strainer in the water pressure reducer and the small holes in the operating water feeding device should be cleaned when necessary.

7.5

Cleaning the lube-oil vessel

The lube oil vessel on the external lube oil unit has to be cleaned at regular intervals and after several oil changes, but after the number of operating hours stated in the “maintenance schedule” at the latest when the oil has to be changed because water or dirt has seeped into the drive, when the oil circulation decreases (pressure drop in the oil circulation line In this, case, the oil lines and channels in the drive have to be cleaned as well. Procedure: – Loosen the lube oil advance and return lines.

For more instructions for cleaning the lube oil vessel, refer to the instruction manual of the external lube oil unit. Instruction manual

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101 Prior to a long-term shut-down Thoroughly clean the separator bowl and frame (see chapter “Cleaning”) Preserving the separator: Drain the lubricating oil. Fill the oil pan with a slushing oil, e.g. SHELL Ensis Fluid E or equivalent up to middle of sight glass. In the case of separators with an external lubricating oil unit, fill the lubricating oil vessel in accordance with the instructions in the “external lubricating unit manual”. Let the separator run with bowl until all the drive parts are coated with slushing oil. (Observe start-up instructions!) Remove the bowl from the spindle (see chapter “Bowl”). Oil the upper end of the spindle by hand. Permanent corrosion protection for separator drive parts with the specified slushing oil can be guaranteed for a maximum of 1 year. After this time, the bearings must be replaced as specified in the maintenance schedule. Wipe dry and grease all bowl parts and all unvarnished machine parts. The clean, grease-coated bowl should be kept in a dry place until it is used again. Remove all the gaskets and the drive belt and keep them in a cool, dry room, protected from dust and light, to prevent them from getting brittle. Check water shut-off devices for leakage. If necessary, disconnect water supply lines to avoid damage caused by drip water. Switch off the operating water supply (if fitted) at the mains to prevent inrush of water caused by inadvertent opening of the shut-off valve. Before re-starting: Drain the slushing oil. Fill the oil pan with lubricating oil (see chapter “Lubrication”). In the case of separators with an external lubricating oil unit, fill the lubricating oil vessel in accordance with the instructions in the “external lubricating unit manual”.

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102 7.7

Note on cleaning work on hoods The following instructions must be followed during cleaning and maintenance work on hoods.

Caution

Load suspension devices such as lifting devices for bowl or hood may only be used correctly and properly and for the intended purpose only. This means that work must be carried out as described in the separator manual. Do not use damaged or incomplete load carrying equipment. Special safety precaution when turning over the hood: Unintended swinging or overturning of the hood must be prevented. Use the carrying straps as illustrated. The minimum lifting capacity of the carrying strap must be double as high as the weight of the hood even under consideration of the application conditions. Fig. 102

7.8

Note on cleaning work on disks When mounting the disks, they are centrically guided over the distributor neck. If disks are dismantled in connection with servicing / manual cleaning and are stacked on one another outside the distributor, it must be ensured that the onical disk surfaces do not slide into each other. To avoid damage, the disks should also be stacked centrically.

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8

103

Drive 8.1 8.1.1 8.1.2 8.2 8.2.1 8.2.2 8.3 8.4 8.5 8.6 8.7 8.8

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Drive.....................................................................................................104 Special risks of a separator .................................................................105 Safety precautions for maintenance and repair...................................108 Fitting and removing the motor............................................................112 Removing the motor ............................................................................112 Installing the motor ..............................................................................113 Removing spindle assembly, supporting disk......................................114 Dismantling the spindle assembly .......................................................116 Assembling the spindle unit .................................................................118 Replacing the rubber-metal bushes and the rubber cushions.............121 Installing the spindle assembly............................................................123 Adjusting the proximity switch .............................................................124


104

8.1

Drive All work on the drive may only be carried out by specialists authorized by Westfalia Separator. Before carrying out maintenance or repair work on the motor, bear in mind that there may still be residual voltage. For this purpose, – read the operating instructions given by the manufacturer of the frequency converter, – have the appropriate measures taken by specially trained staff.

Caution

Fig. 103

Caution

During all work on the drive, disconnect the power to the separator and secure against re-starting! Replace damaged gaskets immediately! Before removing separator parts, their fitting position must be marked. This eliminates later problems caused by fitting the part in the wrong position. Before fitting, the grease must be removed from all contact surfaces of the slidering packings. Since slide-ring packings are easily destructible, they may only be fitted by specially trained personnel.

Attention! Safety risks can arise from the use of non-genuine spare parts. In addition, the durability of such parts is frequently significantly lower which leads to a higher maintenance requirement and lower availability!

Therefore, only genuine original spare parts may be used! Attention!

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105

8.1.1 Special risks of a separator The separator is equipped with a high-speed rotating metal bowl which represents a danger potential not to be underestimated on account of the rotational energy which can pose a danger for the installation and persons working in the installation when not properly handled.

Switch off the separator before carrying out maintenance or repair work. Wait, observe and check that all rotating parts are at a standstill. Do not reach into the rotating drive section or bowl! Do not loosen any part before the bowl has come to a standstill! CAUTION! Risk of injury and danger to life through rotating parts.

Standstill should not be checked using only one source of information (e.g. speed indicator) but must be backed up by at least one further checking device. It must always be reckoned with that the first used standstill indication will provide false information because, for example, the electronics have failed or the belt or gearbox in the drive is defective.

The following options are available for checking standstill on separators depending on the version: Electric speed indicator Revolution indicator or sight glass on the gear cover of gear separators Optical speed check of the drive motor Noise check Vibration check If you are not sure whether the machine is at a standstill, you must wait for the run-down time specified in the separator documentation. A subsequent check is carried out when you are sure that the machine is at a standstill. Visual speed check by opening the inspection ports on hood and frame Removing the inspection port in the separator hood enables you to look directly on to the bowl. In addition, checking is also possible by removing the gearbox cover or opening the port in the frame.

Only when you are convinced that the separator is at a standstill can the following checks be carried out for additional security. NOTE

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106

Revolution visual check on machines with belt drive. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out design modifications.

Fig. 104

Revolution visual check on machines with gearbox. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out design modifications.

Fig. 105

Revolution visual check on machines with direct drive. You can observe whether the machine is at a standstill at the points marked with the arrows. We reserve the right to carry out design modifications.

Fig. 106

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107

Observing the motor fan is not a reliable method of checking standstill because the motor or fan can already be at a standstill when the separator bowl is still rotating. NOTE

During cleaning programs (steam sterilization and CIP), very high temperatures are reached on the surfaces of the separator and piping. During cleaning programs, the surfaces of the separator and pipes are very hot. CAUTION! Danger of burns! With some products, the separator has to be cooled. As a result, temperatures of up to minus 30 °C are reached on the surfaces of the separator and pipes.

When the cooling is switched on, the surfaces of the separator and pipes can get very cold. CAUTION! Danger of frostbite!

Depending on type and installation site, hazards in the form of noise emission from the separator may occur. Therefore, always wear protective gear in accordance with the national regulations. CAUTION! Danger of hearing damage!

During all maintenance and repair work on the separator, the fittings and pipelines, there is the risk of injury due to spurting liquids, e.g. hot or caustic liquids can spurt out under pressure. CAUTION! Danger of causticization of skin and eyes!

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108

8.1.2 Safety precautions for maintenance and repair Observing the maintenance intervals and user information is decisive for the service life and permanent operating readiness of the separator. The maintenance intervals depend on the operating conditions. Especially highly stressed parts of the separator must be regularly checked. Reduce the maintenance intervals to adapt to the operating conditions! Timely maintenance of the separator is essential for safe operation.

Especially highly stressed parts of the separator such as – Bowl lock ring, – Bowl bottom, – Bowl top must be regularly checked (at least once a year) as specified in the maintenance schedule to assure safe and efficient operation.

Fig. 107

When carrying out maintenance and repair work:

Do not climb onto or stand on the machine or parts of the machine! Danger of injury through slipping or falling down!

Fig. 108

Repairs to the separator may only be carried out by service technicians from Westfalia Separator or personnel trained and certified by Westfalia Separator.

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109 During maintenance and repair work, make sure that the main switches are switched off and secured against restarting. Make sure that other persons do not have the possibility to start the machine before the maintenance or repair work is finished.

Fig. 109

Make sure that the rotating parts of the separator (drive, bowl) are at a standstill before carrying out maintenance and repair work. When the machine is defective, a warning sign must be attached and the separator must be secured against unauthorized starting.

Do not heat bowl parts with a naked flame to facilitate dismantling work. Structural changes in the material of the bowl parts which affect the operating safety of the machine may result!

Do not weld bowl parts.

Fig. 110

Do not weld hood and solids catcher parts of steam-sterilizable separators.

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110

Place the dismantled separator parts on suitable surfaces (rubber, wood etc.). Take appropriate steps to prevent machine parts from overturning and rolling away.

Fig. 111

When carrying out assembly work on several separators, be careful not to interchange parts of different bowls! Each bowl must be balanced with its respective components.

The parts are marked with the serialnumber of the machine or with the last three digits of the serial number.

Fig. 112

Some bowl parts must be arranged in fixed positions relative to one another. Locking devices and alignment marks must be in perfect condition. The separator may not be operated when locking devices and marks on the bowl parts are damaged.

Fig. 113

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111 After fitting certain new bowl parts (e.g. bowl bottom, bowl top) the bowl must be re-balanced. Bowl balancing may be carried out only by specialists from Westfalia Separator or specialist workshops authorized by Westfalia Separator! If in doubt, consult the service department of Westfalia Separator. Fig. 114

Unqualified balancing can lead to dangerous operating states and to destruction of the separator with danger to life and limb of the personnel. CAUTION!

Do not manipulate speed-altering devices such as frequency converters so that the maximum admissible bowl speed (see nameplate or “technical data” in the instruction manual) is not exceeded. Ensure that monitoring devices (e.g. overspeed monitors etc.) are not manipulated or damaged and check their function in accordance with the instructions in chapter “Maintenance and repair – maintenance schedule”. After maintenance and repair work on the separator, refit all protective devices. When carrying out maintenance and repair work, carry out a visual check of the separator components. Have the components checked for damage through corrosion and erosion by authorized specialists and proceed in accordance with the instructions in chapter “Maintenance and repair – inspections”.

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112

8.2

Fitting and removing the motor Danger of injury through running machine! Before carrying out work on drive and drive components:

Caution

– Set the main switch of the separator to "OFF”. – Disconnect power to the motor control and – secure both against switching back on!

8.2.1 Removing the motor Take adequate measures to prevent the motor from overturning. Support it with a hoist (e.g. using a fork stacker and a pallet as shown in figure). The fan housing is designed to hold this type of load. Unscrew hexagon nuts 1. Carefully let the motor touch down with the hoist.

Fig. 115

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113

8.2.2 Installing the motor Slip clutch element 1 onto the motor shaft as described in the manual for the clutch. Adjust the axial clearance S (gap dimension); refer to the manual for the clutch. Locate the clutch on the motor shaft by means of the adjusting screw. Tighten screws of the clutch with torque (greased screws) M = 37 Nm. Fig. 116

Take adequate measures to prevent the motor from overturning. Lift it with a hoist (e.g. using a fork stacker and a pallet as shown in figure). Turn the clutch elements so that the clutch ring (cam element) catches into clutch element 1 (see Fig. 116 ). Lift the motor with the aid of the hoist. Make sure that the bolts for fastening the motor catch into the holes of the motor flange. Screw on hexagon nuts 1 with inserted lock washer and tighten firmly. Check width of gap (see Fig. 116 ) and adjust if necessary. For this purpose remove the motor as described under “Removing the motor”.

Fig. 117

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114

8.3

Removing spindle assembly, supporting disk Removing the spindle assembly Pull ring 1 with gasket by hand upwards off the spindle. Remove cap nuts 2 with inserted gaskets. Lift out protective cover 3. Disconnect hose connection 5 for the spraying device.

Fig. 118

If the solids catcher has to be dismantled: Unscrew the screws for fastening the solids catcher. Screw the eye bolts 1 into the solids catcher. Lift off solids collector 2 together with the chains.

Fig. 119

Disconnect hoses 1 and 2 from the connections. Loosen connector 3 of the connecting cable towards the proximity switch. The proximity switch can be left in position. Loosen the coupling nut 4 of the bearing condition monitoring system (optional).

Fig. 120

Remove hex head screws 1 (fastening rubber-metal bush) and hex head screw 2 (fastening rubber cushion). Thread hex head screws 3 (M12x90) into the four puller holes of the bearing housing and force off the bearing housing by altenately tightening the screws.

Fig. 121

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115 Screw spindle lifter 1 into the threaded hole of spindle 2 and lift out the spindle unit.

Fig. 122

Remove hex head screws 1 from the supporting disk. Thread 4 hex head screws into the tapholes and force the supporting disk from the frame.

Fig. 123

Screw in 4 eye bolts 1 and lift off the supporting disk with the hoist.

Fig. 124

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116

8.4

Dismantling the spindle assembly Undo Allen screws 1 on the oil collector housing and lift off cover 3 and clutch ring 2.

Fig. 125

Remove securing ring 1. Pull the oil collector housing 2 off the spindle with the tool provided. While doing so, slightly tilt the oil collector housing because of the protruding oil centripetal pump.

Fig. 126

Dismantle feather key. Unscrew cylindrical screws 1 and cams 2 (oil centripetal pump).

Fig. 127

Unscrew threaded pin 1. Pull off sleeve 2 upwards. Remove the gasket from the sleeve.

Fig. 128

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117 Unscrew Allen screws 1. Screw two hex head screws 2 into the tapholes of the housing 3. Force off housing 3 by evenly tightening the hex head screws 2.

Fig. 129

Carefully drive out the spindle together with the bearings by hitting with a hammer. Place a wooden block against the shaft collar at the bottom of the spindle. Drive out the spindle until the angular contact ball bearings have become dislodged from their seats. Remove the spindle. Fig. 130

Mount pressure disk to protect the spindle 1. Pull cylindrical roller bearing 2, distance sleeve 3, angular contact ball bearing 4 and oil guide ring 5 off the spindle using a commercially available puller.

Fig. 131

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118

8.5

Assembling the spindle unit Each time before installing the bearings, make sure: Use only bearings as specified in the Parts List. Replace angular contact ball bearings and grooved ball bearings when they show the slightest sign of damage, but at the latest in accordance with the operating hours specified in the maintenance schedule . The two angular contact ball bearings must always be replaced together.

Faulty mounting will inevitably result in irreparable damage to the bearing! Attention!

The angular contact ball bearings may be loaded in one direction only. Install the bearings as shown in Fig. 132 . Prepare the spindle: Clean holes. Slip in oil guide ring 1 as far as it will go. Warm up angular contact ball bearing 2 in oil to about 80 °C and slip it on the spindle. Watch for correct position! Slip on the distance sleeve 3. Warm up grooved ball bearing 4 in oil to about 80 °C and slip it on the spindle. Insert gasket 5. Insert key 6.

Fig. 132

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119 Carefully fit spindle 1 with bearing as far as it will go into bearing housing 2. Mount cam 3 (oil centripetal pump) on the bearing housing with cylindrical screws 4.

Fig. 133

Insert gasket 1 in housing 2. Install housing 2 and fasten with Allen screws 3.

Fig. 134

Insert gasket 2 in sleeve 1. Mount sleeve 1. The bore of the sleeve must be placed above the arresting hole of the spindle. Fasten sleeve 1 with Allen screws 3 and secure with Loctite 245.

Fig. 135

For installation, adjusting or maintenance work on the clutch, refer to the instructions given in the clutch manual. Instruction manual

Before mounting the oil collector housing, oil the spindle seat and wipe clean and dry using a cloth. Clean the inner bore of the oil collector housing to ensure a good fit. NOTE

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120

Slip on the oil collector housing. While doing so, slightly tilt the oil collector housing because of the protruding oil centripetal pump. Install the oil collector housing together with the securing ring.

Fig. 136

Fasten clutch ring 2 and ring 3 on the oil collector housing with Allen screws 1. (Torque 37 Nm)

Fig. 137

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121

Replacing the rubber-metal bushes and the rubber cushions Removing the rubber-metal bushes: Place bolt 1 on ring 2. Press of rubber-metal bush 3 together with bolt 5 out of the supporting disk.

Fig. 138

With the aid of puller withdraw rubber-metal bush over ring 4.

Fig. 139

Apply tube pliers only at the lower metal support of the rubber cushion. Remove rubber cushions 1.

Fig. 140

Replace vibration absorbers. Insert ring 1. Place bolt 2 on the outer ring of the rubber-metal bush. Press rubber-metal bush 3 into the supporting disk.

Fig. 141

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122

Place ring 1 on bolt 3. Insert disc 2 between inner ring of the rubber-metal bush and the base. Press bolt 3 with bolt 4 into the rubber metal bush.

Fig. 142

Apply tube pliers only at the lower metal support of the rubber cushion! Install rubber cushions 1 with the tube pliers.

Fig. 143

Screw eye bolts 1 into the supporting disc. Insert supporting disc into the frame using the hoist. Remove eye bolts 1 from the supporting disk.

Fig. 144

Fasten the supporting disk in the frame with hex head screws 1.

Fig. 145

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123

Installing the spindle assembly Screw spindle lifter 1 into the spindle. Install spindle assembly 2 in the lower part of the frame with a suitable hoist. Unscrew spindle lifter 1.

Fig. 146

Fasten the spindle assembly to the rubber metal bushes with Allen screws 1 and to the rubber cushions with Allen screws 2. Connect hoses 3 to the respective connections. Insert connector 4 of the connecting cable into the proximity switch (optional). Connect vibration pickup 5 (optional) for the bearing condition monitoring system. Fig. 147

3

Place the operating water feeding device 2 on the spindle. Pay attention to correct positioning. Screw in and tighten hex head screws 1. Introduce and screw tight the hoses for the operating water feeding device 2 at the connections 3.

Fig. 148

Screw the eye bolts 1 into the solids catcher. Place solids catcher 2 on the frame. Fasten to the frame using the hex head screws.

Fig. 149

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124

Mount protective hood 7 and fasten with cap nuts 1 and hex head screws 3 with gaskets 2 and 4. Fit ring 6 with gasket and fasten with hex head screws 5. Slide the clutch onto the spindle from below and secure against slipping with the retaining ring.

Fig. 150

8.8

Adjusting the proximity switch If necessary, adjust switching distance A 1 mm ± 0.2 as follows: Screw the proximity switch 1 (M 14x1) as far as it will go onto spindle cap 2, then screw back by a complete turn and lock with a hexagon nut. This ensures the correct switching distance.

Fig. 151

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9

125

Trouble shooting 9.1 9.2

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Mechanical function .............................................................................126 Clarifying function ................................................................................130


126

9.1

Mechanical function

Fault The bowl does not come up to rated speed or takes too long to do so (see chapter "Motor connection").

Possible causes

Remedies

Motor is incorrectly connected.

Check connection

Water brake in operation

Check brake water valve.

Check the operating water discharge, The frame drain is blocked. Liquid or dirt has accumulated in the liquid must run off freely. Clean the frame pot, thereby braking the bowl. frame beneath the bowl. Clutch ring defective or insufficiently Replace clutch ring or check its fasfastened. tening arrangement.

The bowl speed drops during operation.

Oil collector housing slides on the spindle.

Check fastening of oil collector housing (see chapter “Drive”).

Product feed is open.

Close product feed.

Motor speed drops during operation. Check motor and line voltage.

Bowl leaks (current consumption is too high).

Check the gaskets in the sliding piston, bowl top and bowl bottom.

Clutch defective.

Replace the clutch ring (see chapter “Drive”, section “Removing the motor” and “Assembling the spindle unit”).

Main bowl gasket in bowl top is damaged.

Replace gasket (see 4.6).

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Fault Uneven run of the separator.

127

Possible causes Bowl is out of balance.

Remedies For pos. 1 - 4: Stop the separator immediately. Open the water feed. The bowl may not be emptied as otherwise the vibrations occurring during rundown would intensify.

Causes: 1. Solids have deposited unevenly in the bowl and are partially not ejected because D solids structure is too firm, D solids are fibrous or contain coarse impurities, D solids are earthy or sandy or cake together, D Ejection intervals are too long. 2. Bowl is not correctly assembled or parts of different bowls have been interchanged. 3. Tension of disc stack has slackened.

4.

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The bowl is damaged and, therefore, out of balance.

Clean the bowl (4.7). Pre-strain the product.

Readjust on control unit. Shorter ejection intervals. Assemble bowl properly (see chapter 4.4).

Make sure bowl lock ring is screwed on tightly (see 4.4). A loose lock ring can endanger life. Check number of disks. If necessary, add spare disk or compensating disk. Send the bowl to the factory for repair. Do not make your own repairs. Do not weld or solder as this would weaken the bowl material – danger to life!


128

Fault Uneven run of the separator. (Cont’d)

Possible causes

Remedies

Rubber-metal cushions in drive are fatigued.

Change the rubber-metal cushions (see chapter “Drive“).

Rubber-metal cushions in drive are fatigued.

Replace rubber-metal cushions (see chapter “Drive”).

Angular contact ball bearings or cylindrical roller bearings are worn.

Replace damaged bearings. CAUTION: Use only bearings as specified in the Parts List.

Angular contact ball bearings or cylindrical roller bearings are damaged due to inadequate lubrication because the suction pipe in the spindle is clogged.

Replace damaged bearings. Clean the lubrication system (see chapter “Cleaning”)

Discharging operating water is dirty.

The ejected solids are too concentrated with the result that they cannot discharge from the solids catcher into the discharge pipe. Solids rise in the catcher and flow over into the frame to the operating water discharge.

Perform several successive total ejections manually on the control unit to flush free the solids catcher. Shorten the ejection intervals. Increase the ejection volume.

Current consumption too high.

Bowl leaks.

Check the gaskets in the bowl top, sliding piston and bowl bottom.

Solenoid valve for closing water defective.

Check solenoid valve.

Oil level is too low.

Top up oil.

Lube oil bores of spindle assembly or hoses clogged or defective.

Remove the spindle assembly (see chapter “Drive”), clean the holes in the drive spindle and hoses. Check hoses for leakage and replace, if necessary.

Oil filter clogged.

Check the lubricating oil unit and clean according to the instructions in the instruction manual.

Oil monitoring alarm

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129


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130

9.2

Clarifying function

Fig. 152

1

Sliding piston

A

Solenoid valve filling water

2

Closing chamber

B

Solenoid valve closing water

3

Bowl valve

C

Solenoid valve hood flush water

4

Bowl bottom

D

Solenoid valve opening water

5

Gasket (sliding piston)

E

Metering device

6

Gasket (bowl top)

F

Non-return valve

7

Main bowl gasket

G

Water pressure reducer

8

Sealing rim (sliding piston)

M

Pressure gauge (opening water)

N

Pressure gauge closing water

10

Gaskets (bowl bottom)

11

Operating water feeding device

12

Gasket (operating water)

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Fault

131

Possible causes

Remedies

Ejected solids contain too much Ejection volume too large. process liquid.

Reduce ejection volume.

Bowl leaks. The

bowl

does

not

See following sections.

close. Not enough operating water is supplied because

CAUTION: Water pressure in the line to the Check line pressure. operating water connection is In this case close the product too low. The pressure with open valves feed and interrupt the separation must be min. 2 bar. program. Water discharge holes in top of Clean holes. operating water feed are partially blocked by scale.

Strainer in water pressure re- Clean strainer. ducer G of operating–water line is clogged.

Operating water feed 11 is leak- Check lines, screw couplings and gaskets. ing.

Operating–water feeding system Clean operating–water feeding system. 11 is blocked. Gasket 12 is damaged or has Replace damaged gasket or fit not been inserted. gasket. Gaskets or gasket valves 3 defective.

in

bowl Remove valves (see 4.7). Replace damaged gaskets or gasket.

damaged gasket. Gasket 5 in the sliding piston is Replace damaged or it is frayed at the edges (due to the up and down If only the edges of the gasket motion of the piston). are frayed and the gasket is otherwise in good condition, grind off the edges on an emery wheel and re–use it.

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132

Fig. 153

1

Sliding piston

A

Solenoid valve filling water

2

Closing chamber

B

Solenoid valve closing water

3

Bowl valve

C

Solenoid valve hood flush water

4

Bowl bottom

D

Solenoid valve opening water

5

Gasket (sliding piston)

E

Metering device

6

Gasket (bowl top)

F

Non-return valve

7

Main bowl gasket

G

Water pressure reducer

8

Sealing rim (sliding piston)

M

Pressure gauge (opening water)

N

Pressure gauge closing water

10

Gaskets (bowl bottom)

11

Operating water feeding device

12

Gasket (operating water)

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Fault

133

Possible causes

Remedies

The bowl does not close and The gasket 5 has not settled Stretch the gasket if the pre– open properly. against the outer sealing sur- tension is too high. faces in the sliding piston. Lightly grease the groove in the sliding piston before inserting the gasket. Gasket 7 in the bowl top is dam- Replace gasket (see 4.6). aged. Gaskets 10 in the bowl bottom Fit or replace gaskets. have not been fitted or are damaged. Gasket 5 in the sliding piston is Fit correctly dimensioned gasnot accurate in height. ket. The differences in height of a gasket must not be more than 0,25 mm. The sealing rim 8 of the sliding Replace sliding piston. piston is damaged. Bowl does not open at all or not Dry dirt or rubber shreds have Clean bowl parts. completely. deposited between the guides of sliding piston 1 and bowl bottom Round off edges of gaskets. 4. Replace damaged gaskets; grease guides with the special lubricating paste. Closing chamber 2 between Remove sliding piston 1 and bowl bottom and sliding piston is clean the closing chamber. dirty. The holes in bowl valves 3 are Remove valves blocked. Clean holes.

(see

4.7).

No or not enough opening water is fed to the bowl (master pressure gauge M does not deflect) for the following reasons: The non–return valve F is dirty Clean or replace the non–return valve. or defective. Solenoid valve A or D is defec- Replace solenoid valve. tive Air pressure for metering device Increase air pressure to 4 bar. E too low. Opening times of the solenoid Check program times on control valves are incorrectly set. unit (see function diagram).

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134

Fault

Possible causes

The bowl opens during separa- Solenoid valve B is defective. tion. No closing water pulses.

Remedies Check solenoid valve.

Check control unit and closing– water valve. Check control unit and closing–water valve.

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10

135

Lubrication and maintenance 10.1 10.2 10.2.1 10.2.2

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Lubrication schedule............................................................................136 Maintenance schedule.........................................................................137 Guide to ordering spare parts..............................................................138 Use of non-genuine spare parts ..........................................................139


136

10.1 Lubricant

Lubrication schedule Lubrication interval

Lubricant qty.

Lubrication point

Lubricant KSB 8 / WSF

as required

apply thin coat

All threads, fittings and contact surfaces as well as manually operated parts like brake bolts, valves, tools etc.

Ceramic paste

as required

apply thin coat

Bowl lock ring

Lubricant KSB 8 / WSF

as required

apply thin coat

Gaskets

Silicon grease Paraliq GTE-703

as required

apply thin coat

All EPDM gaskets (If applicable)

accord. to manufact. instruct.

Accord. to manufact. instruct.

See maintenance schedule

See data sheet

With oil pan or external lubricating oil unit depending on design

as required

apply thin coat

Neck bearing springs, spring pistons and pressure surface of the clutch shoe backup. (If applicable)

See maintenance schedule

In accordance with specs in the documentation

Güsol-Anti-Seize (If supplied)

as per manufacturer specs on motor nameplate Gear oil see Parts List, Roller bearing grease K3K

Steam turbine oil TDL 32

NOTE

Motor bearings

Fluid clutch (If applicable)

Use only lubricants tested by Westfalia Separator for use on separators. The use of non-genuine parts leads to: – safety risks, – less durability of these parts, – reduced availability of the separator, – increased maintenance requirement. In this case, Westfalia Separator shall assume no liability or warranty.

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137 Maintenance schedule every

after operating hours

OPERATIONS 250

1000

2000

4000

8000

day

3 6 1 mont mont year hs hs

2 year s

LUBRICATION SCHEDULE Check oil level and circulation.

D D

Grease threads, contact and guide surfaces of bowl parts (quantity approx. 50 g).

as per manufacturer specs on motor nameplate

D

Oil change and thorough cleaning of the lube oil vessel (see also manual of external lubricating oil unit)* Grease manually-operated parts (brake bolt, valves, etc)

whenever dismantling

D

Grease motor ball bearings.

D whenever dismantling as per manufacturer specs on motor nameplate

MAINTENANCE SCHEDULE Cleaning Refer to manual of lubricating oil unit.

D

D

Clean the lubricating oil vessel of the external lube oil unit. Clean bowl valves.

D

D

D D

Clean outlet bores of operating-water feeding device. Remove bowl. Clean inner walls of frame solids catcher.

D as required

Clean strainer in pressure reducer in operating-water line.

product–dependent

Dismantle and thoroughly clean the bowl. Be sure also to clean the bores and chambers of the hydraulic system.

as required product–dependent

Check D D

Check starting time and rated speed.

D

Check spindle bearings.

Check bowl gaskets. Check the gasket grooves for corrosion.

whenever dismantling

D product–dependent

Check the flexible coupling packages. – wear Bowl inspection. Check all bowl parts and threads of lock rings for erosion and corrosion. Check material between solids ejection ports.

after each bowl unbalance

D D D whenever dismantling

D product–dependent

D

Check all screwed unions.

Replacement D D D D as required as per manufacturer specs on motor nameplate

Replace oil filter of low pressure filter. Replace ball bearings of spindle. Replace rubber-metal cushions and vibration absorbers. Replace the flexible coupling packages. Replace motor bearing.

* Keep to maintenance intervals even if the operating hours have not been reached.

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D D D D

Replace all gaskets and seals.

as required as per manufacturer specs on motor nameplate


138

10.2.1 Guide to ordering spare parts Rapid and correct supply of spare parts can only be guaranteed if your order includes the following information:

Separator model

see separator nameplate e.g. MSD 200-01-076

Serial-No.

see separator nameplate e.g. 1724-035

Designation

see order-specific parts catalogue

Part-No.

see order-specific parts catalogue

The following information is required only when ordering bowl parts: Bowl S/N

since it may be different from the serial number of the machine. It can be found on the bowl lock ring, bowl bottom and bowl top.

Information only required when ordering spares for pump and pump connection parts.: Type and number of pump

see pump nameplate

The information must be complete in order to avoid incorrect deliveries.

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139

10.2.2 Use of non-genuine spare parts Use only genuine spare parts from Westfalia Separator. The use of non-genuine parts leads to: – safety risks – less durability of these parts – reduced availability of the separator – increased maintenance requirement. Fig. 154

If a safety risk arises, this may have legal consequences for the responsible persons. In this case, Westfalia Separator shall assume no liability or warranty. NOTE

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Westfalia Separator AG Take the Best – Separate the Rest A company of GEA Group Westfalia Separator AG Tel.: +49 (0) 25 22 / 77-0

Werner-Habig-Straße 1 D-59302 Oelde (Germany) Fax: +49 (0) 25 22 / 77-24 88

http://www.westfalia-separator.com/ mailto:[email protected]

Instruction Manual

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