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Mechanical Separation Division Instruction Manual Westfalia Separator AG No.: 2325-9001-020 Edition: 0 8 0 6

Mechanical Separation Division

Instruction Manual

Westfalia Separator AG

No.:

2325-9001-020

Edition:

0806

No.: 2325-9001-020 Edition: 0 8 0 6

2

Westfalia Separator AG

©

All rights reserved. No part of this document may be reproduced in any form – by graphic, electronic or me- chanical 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.

Westfalia Separator AG

3

1 Introduction

7

1.1 About this manual

9

1.2 It is imperative to observe the following instructions to assure safe operation of the separator

10

1.3 For your safety

12

1.4 Note on the symbols used in the documentation

13

1.5 Old symbols:

13

2 Lubrication

17

2.1

Lubricating system

18

2.1.1

Oil

quality

19

2.1.2

Oil

quantity

19

2.1.3

Oil

change

19

2.2

Bowl parts

20

2.3

Motor bearings

20

3 Motor connection

21

3.1 Three-phase AC motor

22

3.2 Direction of rotation of the bowl

25

3.3 Bowl speed

25

3.4 Starting time of the bowl

26

3.5 Run-down time of the bowl

26

3.6 Speed measuring device

27

3.7 Electronic vibration monitoring

27

4 Bowl

29

4.1

Important hints

30

4.1.1

Special risks of a separator

31

4.1.2

Safety precautions for maintenance and repair

34

4.2

Removing the feed and discharge connections

39

4.3

Dismantling the

bowl

42

4.4

Assembling the bowl

48

4.4.1

Fitting the centripetal pump

55

4.4.2

Installing the swivel-type actuator

57

4.5

Assembling the feed and discharge connections

58

4.6

Replacing the main bowl gasket (bowl top)

60

4.7

Bowl valves

61

4.8

Disk stack compressing device

63

5 Technical information

65

5.1

Constructional features

66

5.2

Operating principles of the bowl

68

5.3

Operating principles of the hydraulic system of the bowl

70

5.3.1

Bowl ejection

71

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5.4

Operating water connection

72

5.4.1

Solenoid valves

73

5.5

Swivel-type actuator for control of the centripetal pump

73

6 Operation

75

6.1

Before start-up

76

6.2

Start-up

77

6.3

Closing of bowl:

77

6.4

Water run after start-up

78

6.4.1

Program

control

78

6.4.2

Function diagram of partial ejection

81

6.4.3

Total

ejection

82

6.4.4

Bowl ejection (manual)

82

6.5

Adjusting

the

separation efficiency

83

6.5.1

Adjusting the "Fine Tuner"

83

6.5.2

Calculation of the "Fine Tuner" diameter

84

6.5.3

Presetting separation

84

6.5.4

Adjusting the hydrohermetic feed

85

6.5.5

Final adjustment of separating efficiency

86

6.6

Product mode

86

6.7

Shut-down

(Normal Off)

88

6.8

Shut-down

(Emergency-Off)

88

6.9

Run-down (overspeed)

89

6.10

After

shut-down

89

6.11

Prior to a long-term shut-down

89

6.12

Trouble shooting

90

7 Cleaning

95

7.1 Cleaning-in-place

 

96

7.2 Bowl

99

7.3 Frame

 

100

7.4 Operating water feeding device

100

7.5

Cleaning the lube-oil vessel

 

100

7.6 Prior to a long-term shut-down

101

7.7 Note

on

cleaning

work

on

hoods

102

7.8 Note on cleaning work on disks

102

8 Drive

103

8.1

Drive

104

8.1.1

Special risks of a separator

105

8.1.2

Safety precautions for maintenance and repair

108

8.2

Fitting and removing the motor

112

8.2.1

Removing the motor

112

8.2.2

Installing the motor

113

8.3

Removing spindle assembly, supporting disk

114

8.4

Dismantling the spindle assembly

116

8.5

Assembling the spindle unit

118

8.6

Replacing the rubber-metal bushes and the rubber cushions

121

8.7

Installing the spindle assembly

123

8.8

Adjusting the proximity switch

124

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5

9 Trouble shooting

125

9.1 Mechanical function

126

9.2 Clarifying function

130

10 Lubrication and maintenance

135

10.1

Lubrication schedule

136

10.2

Maintenance schedule

137

10.2.1

Guide to ordering spare parts

138

10.2.2

Use of non-genuine spare parts

139

6

Westfalia Separator AG

Westfalia Separator AG

7

1

Introduction

1.1 About this manual

9

1.2 It is imperative to observe the following instructions to assure safe operation of the separator

10

1.3 For your safety

12

1.4 Note on the symbols used in the documentation

13

1.5 Old symbols:

13

8

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Note

Notes

Notizen

Anotaciones

Notizen

Notes

Note

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9

1.1 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 documenta- tion.

art and are furnished with the separator documenta- tion. Safety precautions In the interest of your

Safety precautions

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

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 sepa- rator.precautions for separa- tors” and then this manual. NOTE Caution NOTE NOTE The documentation contains important

NOTE

for all persons who work with or on the sepa- rator. NOTE Caution NOTE NOTE The

Caution

persons who work with or on the sepa- rator. NOTE Caution NOTE NOTE The documentation contains

NOTE

who work with or on the sepa- rator. NOTE Caution NOTE NOTE The documentation contains important

NOTE

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 environment but also endanger persons who work on or in the environ- ment of the separator. (danger to life, risk of injury)

At the beginning of this manual, you will find the schematic of the separa- tor and the nameplate. The nameplate must be filled in by the operator. Enter the data from the nameplate on the separator. Dangers of later con- 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 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, al-

ways wear the necessary protective gear.

16. Operating the separator with hot products leads to hot surfaces of hood, sol-

ids catcher and surrounding piping. Danger of burns!

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11

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 con- centrate 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 par-

ticular the safety precautions and instructions have been read and understood before commissioning and working on the separator.

12

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1.3 For your safety

Observe accident prevention regulations.

The local safety and accident prevention regulations apply uncondi- tionally 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 ap- plied 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 Sepa- rator AG are not extended by the above.

Westfalia Separator AG

13

1.4 Note on the symbols used in the documentation

Below is an explanation of the meaning of the symbols used in the documenta- tion.

Special attention must be paid to all passages in the documentation marked with safety symbols. The operation described after such a symbol must be car- ried out with utmost care.

This symbol indicates potential danger to persons. (danger to life, risk of injury)after such a symbol must be car- ried out with utmost care. Caution This symbol indicates

Caution

This symbol indicates potential risks for machine, material and environ- ment.danger to persons. (danger to life, risk of injury) Caution Attention! This symbol draws attention to

Attention!

This symbol draws attention to the fact that at this point additional manu- als must be read and observed.risks for machine, material and environ- ment. Attention! Instruction manual This symbol does not indicate safety

Instruction manual

This symbol does not indicate safety precautions but rather information for a better understanding of the machine.manu- als must be read and observed. Instruction manual NOTE 1.5 Old symbols: Strictly adhere to

NOTE

1.5 Old symbols:

Strictly adhere to instructions marked with this symbol.

Strictly adhere to instructions marked with this symbol.

 

This avoids damage or destruction of the separator and other equip- ment.

Take special care when carrying out operations marked with this symbol

Take special care when carrying out operations marked with this symbol

otherwise danger to life.

14

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Note

Notes

Notizen

Anotaciones

Notizen

Notes

Note

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15

Westfalia Separator AG 15 Westfalia Separator …………….GmbH D-59302 Oelde ( Germany) Type Serial-No. Model
Westfalia Separator …………….GmbH D-59302 Oelde ( Germany) Type Serial-No. Model Max. admissible rated bowl
Westfalia Separator
…………….GmbH
D-59302 Oelde ( Germany)
Type
Serial-No.
Model
Max. admissible rated bowl speed in min -1
Max. admissible density in kg/dm 3 of product
Heavy liquid kg/dm 3
Solids kg/dm 3
min/max throughput m 3 /h
min./max. temperature of product in °C
min/max housing pressure range in bar

16

Westfalia Separator AG

Note

Notes

Notizen

Anotaciones

Notizen

Notes

Note

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17

2

Lubrication

2.1

Lubricating system

18

2.1.1

Oil

quality

19

2.1.2

Oil

quantity

19

2.1.3

Oil

change

19

2.2

Bowl parts

20

2.3

Motor bearings

20

18

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2.1 Lubricating system

1
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 dur- ing start up and that it must be switched off during shut-down. The specific bowl speeds are listed in the datasheet . datasheet.

NOTE

For more in-depth information concerning the external oil lubrication unit, refer to the instruction manual supplied with the oil lubication unit.during shut-down. The specific bowl speeds are listed in the datasheet . NOTE Instruction manual 2325-9001-020

Instruction manual

Westfalia Separator AG

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.part number stated in the parts list or on the data sheet. NOTE 2.1.2 Oil quantity

NOTE 2.1.2 Oil quantity
NOTE
2.1.2
Oil quantity

Fig. 2

Before starting the separator for the first time fill the oil vessel of the exter- nal 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

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”).slightly below the upper mark of the oil level indicator IMPORTANT NOTE The quantity of oil

IMPORTANT

section “Maintenance schedule”). IMPORTANT NOTE The quantity of oil needed for filling the vessel is

NOTE

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

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”.

intervals are specified in the “Maintenance Schedule”. NOTE Change the oil at the latest as specified

NOTE

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.

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.

20

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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.

lubricating pastes or greases specified in the parts list. NOTE Use only lubricants tested by Westfalia

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.

Westfalia Separator shall assume no liability or warranty. Attention! During assembly, note: Do not bring gaskets

Attention!

During assembly, note:

Do not bring gaskets made from the special material EPDM (ethylene- propylene-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 sur- faces 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

Impact marks will result in scoring. 2.3 Motor bearings Instruction manual For lubrication of the motor

Instruction manual

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

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21

3 Motor connection

3.1 Three-phase AC motor

22

3.2 Direction of rotation of the bowl

25

3.3 Bowl speed

25

3.4 Starting time of the bowl

26

3.5 Run-down time of the bowl

26

3.6 Speed measuring device

27

3.7 Electronic vibration monitoring

27

22

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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

the following drive variants are available: Direct drive NOTE – with frequency converter Gear drive –

NOTE

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 data- sheets supplied with the documentation, the motor nameplate and / or the documentation of the motor manufacturer. 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.

line (tripping device-motor) as a separate control line. Attention! Lubrication If the motor is equipped with

Attention!

Lubrication

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

Westfalia Separator AG

23

Motor with frequency converter (FC)

Pay attention to the following when operating the separator with frequency con- verter:

The separator must never be started without 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.

bowl speed is indicated on the nameplate of the separator. NOTE The frequency converter is equipped

NOTE

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 ex- ceeded. 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 cir- cuit 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.

24

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24 Westfalia Separator AG CAUTION! Fig. 3 Frequency converter operation The speed must not be exceeded.

CAUTION!

24 Westfalia Separator AG CAUTION! Fig. 3 Frequency converter operation The speed must not be exceeded.

Fig. 3

Frequency converter operation

The

speed must not be exceeded.

admissible

maximum

bowl

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

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

Westfalia Separator AG

25

3.2 Direction of rotation of the bowl

The bowl must rotate in clockwise direction when looked at from above.Separator AG 25 3.2 Direction of rotation of the bowl CAUTION! If the direction of rotation

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 accord- ingly. 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 densi- ties 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 speci- fied on the separator nameplate. Alterations to the process data may also ne- cessitate a change in operating speed.

data may also ne- cessitate a change in operating speed. CAUTION! NOTE The bowl speed may

CAUTION!

may also ne- cessitate a change in operating speed. CAUTION! NOTE The bowl speed may not

NOTE

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. 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.

working on the separator by machine parts flying around. Fig. 4 speed re- placed. Also pay

Fig. 4

speed

re-

placed. 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.

Always

check

drive

the

spindle

have

when

parts

been

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

26

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3.4 Starting time of the bowl

26 Westfalia Separator AG 3.4 Starting time of the bowl NOTE Specifications on the starting time

NOTE

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

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.

by frequency converter can be re-started any time. IMPORTANT The following applies for separators with

IMPORTANT

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.

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

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.

switching off to shutdown, is specified in the data sheet. NOTE The run-down time specified in

NOTE

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.

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.

required until the separator bowl has stopped rotating. CAUTION! After the run-down time and before working

CAUTION!

After the run-down time and before working on the separator:

Check that the separator is at a standstill.

Otherwise, there is a danger of injury through rotating bowl parts or dis- charging liquids.

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

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27

3.6 Speed measuring device

When the separator is equipped with a speed measuring device, detailed expla- nations are given in the documentation furnished with the separator control.

3.7 Electronic vibration monitoring

Electronic vibration monitoring systems protect the separator against inadmis- sibly 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 monitor- ing 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.

28

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Note

Notes

Notizen

Anotaciones

Notizen

Notes

Note

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29

4

Bowl

4.1

Important hints

 

30

4.1.1

Special risks of a separator

31

4.1.2

Safety precautions for maintenance and repair

34

4.2

Removing the feed and discharge connections

39

4.3

Dismantling

the

bowl

42

4.4

Assembling the bowl

48

4.4.1

Fitting the centripetal pump

55

4.4.2

Installing the swivel-type actuator

57

4.5

Assembling the feed and discharge connections

58

4.6

Replacing the main bowl gasket (bowl top)

60

4.7

Bowl valves

61

4.8

Disk stack compressing device

63

30

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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:

exactly. The following points should also be observed: Attention! Before fitting the bowl parts thoroughly clean,

Attention!

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

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.

pull. – selecting the lower lifting speed of the hoist. Caution Only use correctly rated, fully

Caution

Only use correctly rated, fully functional hoists.

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.

gently – and placed on a rubber mat or wooden pallet. Caution In the case of

Caution

In the case of a plant with several separators:

Do not interchange parts of different bowls (danger of imbalance).

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

Westfalia Separator AG

31

4.1.1 Special risks of a separator

The separator is equipped with a high-speed rotating metal bowl which repre- sents 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!working in the installation when not properly handled. CAUTION! Risk of injury and danger to life

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 pro- vide 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 depend- ing 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.checking is also possible by removing the gearbox cover or opening the port in the frame.

NOTE

32

Westfalia Separator AG

32 Westfalia Separator AG Fig. 5 Fig. 6 Fig. 7 Revolution visual check on ma- chines

Fig. 5

32 Westfalia Separator AG Fig. 5 Fig. 6 Fig. 7 Revolution visual check on ma- chines

Fig. 6

32 Westfalia Separator AG Fig. 5 Fig. 6 Fig. 7 Revolution visual check on ma- chines

Fig. 7

Revolution visual check on ma- chines 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 de- sign modifications.

Revolution visual check on ma- chines 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 de- sign modifications.

Revolution visual check on ma- chines 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 de- sign modifications.

Westfalia Separator AG

33

Westfalia Separator AG 33 NOTE Observing the motor fan is not a reliable method of checking

NOTE

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.

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.are reached on the surfaces of the separator and piping. CAUTION! Danger of burns! With some

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.

°C are reached on the surfaces of the separator and pipes. CAUTION! CAUTION! CAUTION! When the

CAUTION!

reached on the surfaces of the separator and pipes. CAUTION! CAUTION! CAUTION! When the cooling is

CAUTION!

the surfaces of the separator and pipes. CAUTION! CAUTION! CAUTION! When the cooling is switched on,

CAUTION!

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

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.

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.

Danger of causticization of skin and eyes!

34

Westfalia Separator AG

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.

of the separator is essential for safe operation. Fig. 8 Fig. 9 Especially highly stressed parts

Fig. 8

of the separator is essential for safe operation. Fig. 8 Fig. 9 Especially highly stressed parts

Fig. 9

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 main-

tenance schedule to assure safe and efficient operation.

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!

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

Westfalia Separator AG

35

Westfalia Separator AG 35 Fig. 10 During maintenance and repair work, make sure that the main

Fig. 10

During maintenance and repair work, make sure that the main switches are switched off and se- cured against restarting. Make sure that other persons do not have the possibility to start the ma- chine before the maintenance or re- pair work is finished.

Make sure that the rotating parts of the separator (drive, bowl) are at a stand- still 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.

the separator must be secured against unauthorized starting. Fig. 11 Do not heat bowl parts with

Fig. 11

Do not heat bowl parts with a naked flame to facilitate disman- tling work. Structural changes in the material of the bowl parts which affect the operat- ing safety of the machine may result!

Do not weld bowl parts.

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

36

Westfalia Separator AG

36 Westfalia Separator AG Fig. 12 Fig. 13 Fig. 14 Place the dismantled separator parts on

Fig. 12

36 Westfalia Separator AG Fig. 12 Fig. 13 Fig. 14 Place the dismantled separator parts on

Fig. 13

36 Westfalia Separator AG Fig. 12 Fig. 13 Fig. 14 Place the dismantled separator parts on

Fig. 14

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

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 serial- number of the machine or with the last three digits of the serial number.

Some bowl parts must be arranged in fixed positions relative to one an- other. 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.

Westfalia Separator AG

37

Westfalia Separator AG 37 CAUTION! Fig. 15 After fitting certain new bowl parts (e.g. bowl bottom,

CAUTION!

Westfalia Separator AG 37 CAUTION! Fig. 15 After fitting certain new bowl parts (e.g. bowl bottom,

Fig. 15

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 de- partment of Westfalia Separator.

Unqualified balancing can lead to dangerous operating states and to de- struction of the separator with danger to life and limb of the personnel.

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 ma- nipulated or damaged and check their function in accordance with the instruc- tions in chapter “Maintenance and repair – maintenance schedule”.

After maintenance and repair work on the separator, refit all protective de- vices.

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 – in- spections”.

38

Westfalia Separator AG

Lock ring Gasket Centripetal pump Chamber cover Separating disk Centripetal pump Chamber cover Gasket Gasket
Lock ring
Gasket
Centripetal pump
Chamber cover
Separating disk
Centripetal pump
Chamber cover
Gasket
Gasket
Upper centripe-
Distance sleeve
tal pump
Centripetal pump
Gasket
Chamber cover
Gasket
Disk
Gasket
Centripetal pump
Chamber cover
Gasket
Gasket
Distance sleeve
Gasket
Distributor
Lower distributor
Sleeve
Feed tube
Gasket
Spindle screw
Sliding piston
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!

Westfalia Separator AG

39

4.2 Removing the feed and discharge connections

AG 39 4.2 Removing the feed and discharge connections Caution Switch off and lock the main

Caution

Switch off and lock the main switch.

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.

order-specific parts list. Stop compressed-air supply. Caution Fig. 17 Disconnect the following lines: Disconnect

Caution

parts list. Stop compressed-air supply. Caution Fig. 17 Disconnect the following lines: Disconnect

Fig. 17

Disconnect the following lines:

Disconnect electrical connection 1 and compressed-air supply 2. Note:

This has to be done before remov- ing the guards - danger of crush- ing!

Cooling lines of the hood cooling,

flush water line,

supply line to hood flushing.

– flush water line, – supply line to hood flushing. Fig. 18 Disconnect the feed and

Fig. 18

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.

40

Westfalia Separator AG

40 Westfalia Separator AG Fig. 19 Fig. 20 Fig. 21 Fig. 22 Unscrew hex head screws

Fig. 19

40 Westfalia Separator AG Fig. 19 Fig. 20 Fig. 21 Fig. 22 Unscrew hex head screws

Fig. 20

40 Westfalia Separator AG Fig. 19 Fig. 20 Fig. 21 Fig. 22 Unscrew hex head screws

Fig. 21

40 Westfalia Separator AG Fig. 19 Fig. 20 Fig. 21 Fig. 22 Unscrew hex head screws

Fig. 22

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

Remove toothed segment 3.

Unscrew hexagon nuts 5. Thread two eye bolts 1 into the ta- pholes. Lift off ring 2 together with swivel- type actuator. For the transport, use lifting device, if required (correct ap- plication is shown on (Fig. 23 ).

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

Westfalia Separator AG

41

Westfalia Separator AG 41 Fig. 23 Unscrew the screws for fastening the hood. Shorten the chains

Fig. 23

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

42

Westfalia Separator AG

4.3 Dismantling the bowl

42 Westfalia Separator AG 4.3 Dismantling the bowl Fig. 24 Fig. 25 Fig. 26 Fig. 27

Fig. 24

42 Westfalia Separator AG 4.3 Dismantling the bowl Fig. 24 Fig. 25 Fig. 26 Fig. 27

Fig. 25

Separator AG 4.3 Dismantling the bowl Fig. 24 Fig. 25 Fig. 26 Fig. 27 Unscrew centripetal

Fig. 26

AG 4.3 Dismantling the bowl Fig. 24 Fig. 25 Fig. 26 Fig. 27 Unscrew centripetal pump

Fig. 27

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.

Lift off centripetal pump chamber cover using lifting tongs 1.

Remove cover 1.

Pull off the distance sleeve 1 with upper centripetal pump.

Westfalia Separator AG

43

Westfalia Separator AG 43 Fig. 28 Fig. 29 Fig. 30 Fig. 31 Remove upper centripetal pump

Fig. 28

Westfalia Separator AG 43 Fig. 28 Fig. 29 Fig. 30 Fig. 31 Remove upper centripetal pump

Fig. 29

Westfalia Separator AG 43 Fig. 28 Fig. 29 Fig. 30 Fig. 31 Remove upper centripetal pump

Fig. 30

Westfalia Separator AG 43 Fig. 28 Fig. 29 Fig. 30 Fig. 31 Remove upper centripetal pump

Fig. 31

Remove upper centripetal pump 1.

Lift off centripetal pump chamber cover 1.

Pull off lower centripetal pump 1.

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.

44

Westfalia Separator AG

44 Westfalia Separator AG Fig. 32 Fig. 33 Lift out feed tube 1 with lower dis-

Fig. 32

44 Westfalia Separator AG Fig. 32 Fig. 33 Lift out feed tube 1 with lower dis-

Fig. 33

Lift out feed tube 1 with lower dis- tributor 2.

Unscrew spindle screw wrench (left-hand thread).

with the

Westfalia Separator AG

45

Westfalia Separator AG 45 Fig. 34 To prevent damage to threads: Attention! Screw in threaded bolt

Fig. 34

To prevent damage to threads:

Separator AG 45 Fig. 34 To prevent damage to threads: Attention! Screw in threaded bolt completely.

Attention!

Screw in threaded bolt completely.

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 cen- tering 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).

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.

of the compressing device. Close pressure relief screw 5. Fig. 35 Compress the disk stack to

Fig. 35

Compress the disk stack to facilitate loosening of the bowl lock ring. Compression: See data sheet. Loosen the bowl lock ring by ham- mering against the handle of the wrench with a mallet (left-hand thread).

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.

46

Westfalia Separator AG

46 Westfalia Separator AG Fig. 36 Fig. 37 Fig. 38 Fig. 39 Dismantling the compressing de-

Fig. 36

46 Westfalia Separator AG Fig. 36 Fig. 37 Fig. 38 Fig. 39 Dismantling the compressing de-

Fig. 37

46 Westfalia Separator AG Fig. 36 Fig. 37 Fig. 38 Fig. 39 Dismantling the compressing de-

Fig. 38

46 Westfalia Separator AG Fig. 36 Fig. 37 Fig. 38 Fig. 39 Dismantling the compressing de-

Fig. 39

Dismantling

the

compressing

de-

vice:

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).

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

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.

the distributor

Take disk neck.

1

out

of

Screw lifting device 1 into the dis- tributor. Force off the distributor together with the disc stack by turning jack- screw clockwise. Lift out distributor with disk stack.

Westfalia Separator AG

47

Westfalia Separator AG 47 Fig. 40 Fig. 41 Fig. 42 Place pressure piece A of the

Fig. 40

Westfalia Separator AG 47 Fig. 40 Fig. 41 Fig. 42 Place pressure piece A of the

Fig. 41

Westfalia Separator AG 47 Fig. 40 Fig. 41 Fig. 42 Place pressure piece A of the

Fig. 42

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

Screw lifting device 1 onto the slid- ing 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 dam- aged.

Pressing off the bowl bottom:

Screw

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 spin- dle cone using the wrench which is placed over the hexagon at the up- per threaded bolt end.

into

pressure

piece

7

48

Westfalia Separator AG

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.

worn gaskets. For tools, see order-specific parts list. Fig. 43 Fig. 44 Fig. 45 Transport the

Fig. 43

gaskets. For tools, see order-specific parts list. Fig. 43 Fig. 44 Fig. 45 Transport the bowl

Fig. 44

For tools, see order-specific parts list. Fig. 43 Fig. 44 Fig. 45 Transport the bowl bottom

Fig. 45

Transport the bowl bottom using the threaded spindle.

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

Insert gasket into the groove of the sliding piston.

Insert the gaskets in the grooves in the bowl bottom.

Westfalia Separator AG

49

Westfalia Separator AG 49 Attention! Fig. 46 Fig. 47 Place pressure piece 1 of lifting device

Attention!

Westfalia Separator AG 49 Attention! Fig. 46 Fig. 47 Place pressure piece 1 of lifting device

Fig. 46

Westfalia Separator AG 49 Attention! Fig. 46 Fig. 47 Place pressure piece 1 of lifting device

Fig. 47

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

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 counter- clockwise 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 posi- tion.

Make sure that the sealing lip B of the sliding piston does not get dam- aged.

After inserting the sliding piston take out pressure piece A.

inserting the sliding piston take out pressure piece A. Fig. 48 Turn distributor through 180 o

Fig. 48

Turn distributor through 180 o .

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.

50

Westfalia Separator AG

50 Westfalia Separator AG Fig. 49 Fig. 50 Fig. 51 Fig. 52 Stack the disks onto

Fig. 49

50 Westfalia Separator AG Fig. 49 Fig. 50 Fig. 51 Fig. 52 Stack the disks onto

Fig. 50

50 Westfalia Separator AG Fig. 49 Fig. 50 Fig. 51 Fig. 52 Stack the disks onto

Fig. 51

50 Westfalia Separator AG Fig. 49 Fig. 50 Fig. 51 Fig. 52 Stack the disks onto

Fig. 52

Stack the disks onto the neck of the distributor in numerical order, be- ginning with number 1.

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.

Install separating disk with inserted gaskets.

The "O" marks on the separating disk and bowl bottom must be aligned.

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.

Westfalia Separator AG

51

Westfalia Separator AG 51 Fig. 53 Fig. 54 Fig. 55 Fig. 56 Insert the gaskets in

Fig. 53

Westfalia Separator AG 51 Fig. 53 Fig. 54 Fig. 55 Fig. 56 Insert the gaskets in

Fig. 54

Westfalia Separator AG 51 Fig. 53 Fig. 54 Fig. 55 Fig. 56 Insert the gaskets in

Fig. 55

Westfalia Separator AG 51 Fig. 53 Fig. 54 Fig. 55 Fig. 56 Insert the gaskets in

Fig. 56

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.

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 counterclock- wise. 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.

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

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 (left- hand thread).

52

Westfalia Separator AG

52 Westfalia Separator AG Attention! Fig. 57 Fig. 58 To prevent damage to threads: Take disk

Attention!

52 Westfalia Separator AG Attention! Fig. 57 Fig. 58 To prevent damage to threads: Take disk

Fig. 57

52 Westfalia Separator AG Attention! Fig. 57 Fig. 58 To prevent damage to threads: Take disk

Fig. 58

To prevent damage to threads:

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

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 cen- tering recess of the disc. Screw on threaded ring 2 until its upper edge is flush with end thread of bolt 1 (left-hand thread).

Screw in threaded bolt completely. 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.

of the compressing device. Close pressure relief screw 5. Fig. 59 Compressing the disk stack: Pressure

Fig. 59

Compressing the disk stack:

Pressure must be gradually applied to the disk stack until the max. disk com- pression 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.

Westfalia Separator AG

53

If the maximum pressure is not attained and grease flows out of the stroke limit- ing 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.

and that the bowl top does not become twisted when lowered. Fig. 60 Hit wrench handle

Fig. 60

Hit wrench handle with the mallet to obtain "O" mark alignment (left- hand thread).

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.

above. At least once a month in the first 3 months. Fig. 61 Fig. 62 Dismantling

Fig. 61

above. At least once a month in the first 3 months. Fig. 61 Fig. 62 Dismantling

Fig. 62

Dismantling the compressing de- vice:

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.

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.

54

Westfalia Separator AG

54 Westfalia Separator AG Fig. 63 Fig. 64 Fig. 65 Fig. 66 Before placing the bowl

Fig. 63

54 Westfalia Separator AG Fig. 63 Fig. 64 Fig. 65 Fig. 66 Before placing the bowl

Fig. 64

54 Westfalia Separator AG Fig. 63 Fig. 64 Fig. 65 Fig. 66 Before placing the bowl

Fig. 65

54 Westfalia Separator AG Fig. 63 Fig. 64 Fig. 65 Fig. 66 Before placing the bowl

Fig. 66

Before placing the bowl on the spin- dle, 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.

Screw

the

eye

threaded rod.

bolt

onto

the

Lower the bowl on the spindle.

Dismantle the device.

Screw spindle screw (with inserted gasket) firmly into the spindle (left- hand thread).

Westfalia Separator AG

55

4.4.1 Fitting the centripetal pump

Separator AG 55 4.4.1 Fitting the centripetal pump Fig. 67 Fig. 68 Fig. 69 Introduce feed

Fig. 67

AG 55 4.4.1 Fitting the centripetal pump Fig. 67 Fig. 68 Fig. 69 Introduce feed tube

Fig. 68

AG 55 4.4.1 Fitting the centripetal pump Fig. 67 Fig. 68 Fig. 69 Introduce feed tube

Fig. 69

Introduce feed tube 1 with gasket 2 into the bowl.

Fit lower distributor 3 with inserted

4.

gasket

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

cover 11 with gasket 12. Mount distance sleeve 13 with gas- ket 14. Install upper centripetal pump 15 with gasket 16.

chamber

centripetal

pump

Pay attention to correct position- ing; check assembly of centripe- tal pump components.

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.

56

Westfalia Separator AG

56 Westfalia Separator AG Fig. 70 Fig. 71 Fig. 72 Mount centripetal cover pos. 1. pump

Fig. 70

56 Westfalia Separator AG Fig. 70 Fig. 71 Fig. 72 Mount centripetal cover pos. 1. pump

Fig. 71

56 Westfalia Separator AG Fig. 70 Fig. 71 Fig. 72 Mount centripetal cover pos. 1. pump

Fig. 72

Mount

centripetal

cover pos. 1.

pump

chamber

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

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 (left- hand thread).

Westfalia Separator AG

57

4.4.2 Installing the swivel-type actuator

Separator AG 57 4.4.2 Installing the swivel-type actuator Fig. 73 Exploded view of 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 re- moved. If, however, the swivel-type actuator has to be dismantled in order to re- place 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.

58

Westfalia Separator AG

4.5 Assembling the feed and discharge connections

AG 4.5 Assembling the feed and discharge connections Fig. 74 Fig. 75 Fig. 76 Fig. 77

Fig. 74

AG 4.5 Assembling the feed and discharge connections Fig. 74 Fig. 75 Fig. 76 Fig. 77

Fig. 75

the feed and discharge connections Fig. 74 Fig. 75 Fig. 76 Fig. 77 Screw two ring

Fig. 76

the feed and discharge connections Fig. 74 Fig. 75 Fig. 76 Fig. 77 Screw two ring

Fig. 77

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

Shorten the chains of the lifting de- vice. The chain link must be put cross- wise 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.

to-

Bolt

hood

and

solids

catcher

gether using hex head screws.

Thread two eye bolts 1 into ring 2. Insert gasket 3.

Place

swivel-type actuator. Fasten ring 2 by means of hex head

2 together with the

on ring

screws 5 with installed lock washers

4.

The

arrow). Place toothed segment 3 on cen- tripetal 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 oppo- site 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.

(see

pointer must be

on

"0"

Westfalia Separator AG

59

Westfalia Separator AG 59 Fig. 78 Fig. 79 Connect the following lines: Place on protecting-case halves

Fig. 78

Westfalia Separator AG 59 Fig. 78 Fig. 79 Connect the following lines: Place on protecting-case halves

Fig. 79

Connect the following lines:

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

Install the discharge.

feed

lines. Connect vent line 2. Screw tight connection piece 1 with inserted gasket.

discharge

Connect

the

and

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.

to the contact pressure gauge. Fit sight glass illumination. Caution Fig. 80 Connect current supply 1

Caution

pressure gauge. Fit sight glass illumination. Caution Fig. 80 Connect current supply 1 and com- pressed-air

Fig. 80

Connect current supply 1 and com- pressed-air supply 2. Note:

The protecting cases must be in place - danger of crushing!

60

Westfalia Separator AG

4.6

Replacing the main bowl gasket (bowl top) Removal Screw

gasket.

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

wooden

screw

1

into

the

Lever out the gasket with screw- driver 2.

Fig. 81

into the Lever out the gasket with screw- driver 2. Fig. 81 Fig. 82 Fig. 83

Fig. 82

Lever out the gasket with screw- driver 2. Fig. 81 Fig. 82 Fig. 83 Fitting Insert

Fig. 83

Fitting Insert the gasket in the cleaned groove of the bowl top (with the nar- row side towards the bowl top).

the

Drive

the

gasket

evenly

into

groove.

If the diameter of the gasket is too small, place it in a water bath of 70 - 80 o C for about 5 minutes. The gas- ket will then assume its original di-

mensions.

Drive the gasket into the groove so

far that the sealing area of the gas- ket does not protrude above surface "A" of the bowl top by more than 1

mm.

Westfalia Separator AG

61

4.7 Bowl valves

Remove and clean the bowl valves once a month.

Bowl valves Remove and clean the bowl valves once a month . Fig. 84 Fig. 85

Fig. 84

Remove and clean the bowl valves once a month . Fig. 84 Fig. 85 Screw wrench

Fig. 85

and clean the bowl valves once a month . Fig. 84 Fig. 85 Screw wrench 1

Screw wrench 1 (bowl valve) into the bowl valve.

Push sleeve a of the wrench to- gether with the pins into the holes of the bowl valve. Tighten collar nut b. Unscrew bowl valve from bowl bot- tom using socket wrench 1.

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.

62

Westfalia Separator AG

Use the tools stated in the parts list to fit the gaskets.

Use the tools stated in the parts list to fit the gaskets. Fig. 87 Fig. 88

Fig. 87

tools stated in the parts list to fit the gaskets. Fig. 87 Fig. 88 Stretch the

Fig. 88

Stretch the gasket 3 over the ex- panding mandrel 4 and fit in piston valve 1.

Stretch

3

panding mandrel 2 and 4 and fit in

ex-

gaskets

and

5 over

piston 1.

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.

Westfalia Separator AG

63

4.8 Disk stack compressing device

1 Filling device 2 Clamping piece 3 Grease cartridge 4 Pumpenkopf 5 Non-return valve 6
1 Filling device
2 Clamping piece
3 Grease cartridge
4 Pumpenkopf
5 Non-return valve
6 Pressure chamber
7 Hydraulic cylinder
8 Piston
9 Bolt
10 Disc
11 Hydraulic part
12 Threaded ring
13 Stroke-limiting hole
14 Venting screw
15 Pressure gauge (0-600 bar)
16 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 down- wards.

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

64

Westfalia Separator AG

Filling the grease cartridge

Cartridge filling: 450 g special grease K2R

The grease cartridge of the compressing device is filled with special grease be- fore 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?

Has piston 8 travelled too far out of hydraulic cylinder 7? Fig. 90 If yes: Unscrew

Fig. 90

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

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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65

5 Technical information

5.1

Constructional features

66

5.2

Operating principles of the bowl

68

5.3

Operating principles of the hydraulic system of the bowl

70

5.3.1

Bowl ejection

71

5.4

Operating water connection

72

5.4.1

Solenoid valves

73

5.5

Swivel-type actuator for control of the centripetal pump

73

66

Westfalia Separator AG

5.1 Constructional features

66 Westfalia Separator AG 5.1 Constructional features Fig. 91 Self-cleaning bowl: – The bowl can be

Fig. 91

Self-cleaning bowl:

The bowl can be emptied during operation by means of a hydraulically ac- tuated 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.

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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

68

Westfalia Separator AG

5.2 Operating principles of the bowl

Westfalia Separator AG 5.2 Operating principles of the bowl Fig. 92 1 Control unit 2 Heavy

Fig. 92

1 Control unit

2 Heavy phase discharge

3

Feed

4 Discharge (light phase)

5 Flush water channel (”Bowl Flush”)

6 Centripetal pump – heavy compo-

nent (”Fine Tuner”)

14

15

16

17

18

Flush water channel (”Bowl Flush”)

Solids holding space

Solids ejection ports

Sliding piston

Closing chamber

19 Piston valve

7 Centripetal pump – light component 20

8

9

Distributor

”Steam seal”

10 Hydrohermetic feed

11 Disk stack

12

Rising channels

21

22

23

24

25

Opening water

Closing–water

Metering piston

Control air

Filling water / opening–water

Cooling medium

13 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.

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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.

70

Westfalia Separator AG

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 clos- ing 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 gas- ket 9 of bowl top, thus closing the sol- ids holding space 11 during the sepa-

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 ar- rangement.

5 mins for 1sec via an interval switching ar- rangement. ration Fig. 93 Fig. 94 Opening

ration

Fig. 93

1sec via an interval switching ar- rangement. ration Fig. 93 Fig. 94 Opening the bowl (ejection)

Fig. 94

Opening the bowl (ejection)

To empty the solids holding space opening water 13 is added which flows from injec- tion 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

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 instan- taneously through the ejection ports 14 of the bowl.

empties

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.

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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 ejec- tion only part of the bowl contents.

Whether partial or total ejections or a combination of both are carried out de- pends 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 meter- ing 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.

The opening water volume is adjusted on the metering device. Fig. 95 Adjusting the amount to

Fig. 95

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

72

Westfalia Separator AG

5.4 Operating water connection

The operating water connection is equipped with solenoid valves, pressure re- ducer 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:

Operating-water pressure:

(with open closing water valve)

Operating water capacity:

Air pressure for metering unit:

Operating water capacity: Air pressure for metering unit: Fig. 96 1 ¼ in P min. =

Fig. 96

1 ¼

in

P

min.

=

P

max.

=

 

=

P

min.

=

P

max.

=

Note:

2,0 bar

2,5 bar

min. 4000

4,0

6,0

bar

bar

l/h

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 meter- ing unit so that the heightened water pressure is lower than the maximum pressure marked on solenoid valve 1.

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

Hard-

12 o dH separating temperature up to 55 o C

ness:

6 o dH at separating temperatures above 55 o C

To convert the hardness values stated use the follow- ing equation:

1 o dH = 1.79 o fH = 1.25 o eH = 17.9 ppm CaCO 3

D

Chloride content:

100 mg/l

D

pH value:

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

Remedies

 

Valve does not func- tion.

Control unit defective.

Contact

servicing

staff.

 

Connecting terminal

Tighten screw of con- necting terminal.

on

terminal

strip

is

loose.

   

Coupler socket loose or leaks.

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 au- xiliary anergy, instrument air (dry and free of dust) is required.

Air pressure:

Flow rate:

P min

P max

= 4bar

= 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.