Cleaning unit for coolant · Alfa Laval Tumba AB SE-147 80 Tumba, Sweden Telephone: +46 8 530 650...

Product No.Book No.:

881176-08-01/61271526-02 Rev. 6

Cleaning unit for coolant

Instruction Manual

Published By:Alfa Laval Tumba AB SE-147 80 Tumba, Sweden

Telephone: +46 8 530 650 00 Telefax: +46 8 530 310 40

© Alfa Laval Tumba AB November 2009

This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB.

Contents

3

1 Safety instructions 4

2 Application 6

3 Description of main parts 6

4 Working principle of the cleaning unit 8

5 Operating instructions 10

6 Trouble shooting 13

7 Maintenance 15

8 Technical references 21

9 Spare parts 30

10 Installation 34

Safety instructions

1 Safety instructions

The cleaning unit includes a centrifugal separator that rotates at high speed.

Incorrect operation and maintenance can result in serious damage and/or injury.

The following basic safety instructions therefore apply:

• Use the cleaning unit only for the purpose and parameter range specified by Alfa Laval.

• Note that coolant and sludge should be treated as hazardous. Use gloves and avoid direct contact with skin. Follow local safety instructions.

• Strictly follow the instructions for installation, operation and maintenance.

• Ensure that personnel are competent and have sufficient knowledge of maintenance and operation.

• Use only Alfa Laval genuine spare parts and the special tools supplied.

Study this instruction manual and observe the warnings before installation, operation, service and maintenance.

Not following the instructions can result in serious accidents.

4

Safety instructions

WARNING

Disintegration hazard

• If excessive vibrations occur, stop the separator.

Entrapment hazard

• Make sure that rotating parts inside the separator have come to a complete standstill before moving the cleaning unit or starting any dismantling work.

• To avoid accidental start, remove the power cable from the unit before starting any dismantling work.

Warning labels

A warning label is placed on the cleaning unit.

The interpretation of the label is:

STOP! Read the instruction manual before installation, operation and maintenance. Consider inspection intervals.

Failure to strictly follow instructions can lead to fatal injury.

S01

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ANSI-label for the US market

S01

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ISO-label for other markets

5

Application

2 Application

The alfie 200 unit is restricted to the removal of tramp oil and solids from metal working coolants with a temperature range between +15 and +50 °C.

3 Description of main partsThe alfie 200 unit consists of following parts:

1. Hand control unitFor starting and stopping the cleaning unit.

The green control lamp is lit when the cleaning unit is in operation.

The unit contains a circuit breaker. If the breaker trips, it is automatically reset after about 30 seconds.

2. HandleExcept for lifting the unit, the handle can be used as a stand during e.g. maintenance work.

3. Cleaning unit (separator and motor)Removes tramp oil and solids from the coolant.

4. Outlet hose or pipe for separated tramp oil to collecting vessel

5. Tank for coolant

6. Outlet hoses for cleaned coolantThe three hoses shall be placed in the tank so that the inlet to the cleaning unit is fed by an internal circulation on the tank surface.

7. Suction device (bellows)To keep the bellows and thereby the suction height in correct position the bellows is provided with a floating ring within the top of the bellows.

8. Mounting plateTo the mounting plate (placed on top of tank) are fixed the four housing supports (10) and the cable support (11).

9. HousingThe height of the housing should be adjusted in relations to the max. height of coolant level in the tank, see description in chapter ‘‘10.3 Adjustment of housing’s height in tank” on page 36.

6

Description of main parts

10.Housing supportTo admit the cleaning unit to be placed at suitable height in the tank the four supports are provided with grooves.

11.Cable supportFor security reason keep the length of the power cable between the support and the socket to about 40 cm. The separator motor must not be connected to the power supply in any other place than when fixed in the housing (9).

7

Working principle of the cleaning unit

4 Working principle of the cleaning unit

The cleaning unit shall be placed in a suitable height in the coolant tank (described in chapter ‘‘5 Operating instructions” on page 10).

Dirty coolant continuously flows over the top of the bellows (6) and enters at (A). Three wings (4) in the inlet tube get the liquid to rotate with the same speed as the separator bowl (2). The conical shape of the inlet tube (wider upwards) makes the liquid to rise in the tube by influence of the centrifugal forces. The liquid then enters the bowl via the inlet channels (3) in the bowl bottom.

The bowl spindle (8) is direct driven by the electric motor (7) and the bowl rotates at high speed generating powerful centrifugal forces. As the liquid rotates with the bowl, the coolant (heavy phase) and solid particles moves towards the periphery of the bowl. The particles (1) are deposited on the bowl wall, while the cleaned coolant enters the channels (10) and flows into the frame (11). The coolant finally leaves the cleaning unit at (B). The discs (9) in the bowl improves the cleaning efficiency during the separation process.

The tramp oil (light phase) is forced towards the centre of the bowl and then leaves through the upper side of the bowl at (C) down into a separate collecting tank.

The rotating inlet tube (4) is sealed against the non-rotating frame (11) with a mechanical axial seal (13).

If the top of the bellows is positioned too high (coolant cannot flow into the bellows) it is possible to fit weight adjusting ring(s) à 15 or 30 grams (12) outside the bellows. The ring(s) should be positioned as high up as possible, see the illustration.

A. Coolant inletB. Clean coolant outletC. Tramp oil outlet to collecting tank

1. Particles (sediment)2. Bowl3. Channels from inlet tube to disc

stack4. Wing in inlet tube

5. Surface in tank6. Bellows7. Electric motor8. Bowl spindle9. Conical discs10. Channels from bowl to outlet11. Frame12. Weight adjusting ring(s)13. Axial seal

8

Working principle of the cleaning unit

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Operating instructions

5 Operating instructions

5.1 Before start

1. To obtain max. level in the coolant tank (if wanted) stop the circulation of the coolant.

2. Check that the level in the tank is within the working range of the bellows, see description in ‘‘10.3 Adjustment of housing’s height in tank” on page 36.

3. Check that the bellows (7) can move easily up and down in the liquid.

4. Check that the tramp oil outlet (4) is securely connected to a vessel or similar.

5. Check that the unit is connected to the power supply.

5.2 Start1. Start the cleaning unit by

pressing the black button on the hand control unit.

The green lamp in the control unit is switched on.

WARNING


Some vibrations can occur for short periods during the start phase when the separator passes through the critical speed. This is normal and passes over without danger. If the vibrations become very severe or continue at full speed, stop the separator immediately. See chapter ‘‘6 Trouble shooting” on page 13 for possible causes.

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2. Check the motor for correct direction of rotation (could be necessary if the unit has been removed and/or connected to another power supply). Compare with the arrow fitted on the fan cover on top of motor and/or the motor plate.

3. When the separation has started, check that the top surface of the bellows (floating ring) is located just under the surface of the tank so the surface layer is sucked into the bellows. The setting is normally self-adjusted. If the bellows is lying too high it could be necessary to fit weight adjusting ring(s), see further description on page 8, position No. 12.

4. Check that the flow of cleaned coolant from the cleaning unit do not prevent the surface layer in the tank to be sucked into the bellows. Otherwise move the positions of the outlets of the hoses (6) in the bottom of the tank (5).

Check that all parts of the outlet hoses are positioned below the surface and preferably as near the tank bottom as possible.

1. Hand control unit2. Handle3. Cleaning unit4. Outlet hose or pipe

for tramp oil5. Tank for coolant6. Outlet hoses for

cleaned coolant7. Suction device

(bellows)8. Mounting plate9. Housing10. Housing support11. Cable support

11


5.3 Operation

1. Check the cleaning unit for correct operation (cleaned liquid must flow out through the outlet hoses).

2. Check that the tank level is not below the upper part of the bellows. Otherwise the cleaning unit is operating without flow. If so, see point 3 on page 11.

Note that the liquid height in the tank must be min. 100 mm when the cleaning unit is positioned in its lowest position (the liquid outlets pressing against the tank bottom).

5.4 Stop

1. Stop the cleaning unit by pressing the red button on the hand control unit.

2. Wait until the rotating parts in the separator have come to complete standstill, which will take up to two minutes (can be checked by looking at the fan wheel on top of the motor).

The fluid content in the bowl will then be drained out by gravity back into the coolant tank.

How to clean the unit is described in chapter ‘‘7.1 Cleaning” on page 15.

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Trouble shooting

6 Trouble shooting

6.1 Cleaning unit vibrates

6.2 Cleaning unit does not start

6.3 Only feed through tramp oil outlet

WARNING


If excessive vibrations occur, stop the separator.

Possible cause Action

Bowl out of balance due to:

• Insufficient or incorrect cleaning

• Incorrect assembly

Dismantle and clean the separator bowl. Make sure that the separator is assembled correctly


No/or incorrect power supplied Check the mains switch, fuses, supply line and hand control unit

Incorrect assembly after cleaning. The bowl and motor shaft can not rotate freely

Turn the motor fan wheel with a suitable tool. If resistance, dismantle and check

Defective motor Contact your Alfa Laval representative


Filled sediment space in bowl periphery

Clean separator bowl and disc stack

13

Trouble shooting

6.4 Cleaning unit stops

6.5 No outlet either through cleaned coolant outlet or tramp oil outlet

6.6 Insufficient separation result


Overload due to incorrect assembly Check the bowl assembly

Defective motor Contact your Alfa Laval representative

Motor circuit breaker in the hand control unit tripped due to too high current or short-circuit

Restart the unit. Possible after about 30 seconds if not short-circuit. The reason of too high current could be too low voltage supplied.


Outlet hoses are lying too high in the tank

Place the hoses in a lower position, see description on page 11, point 4

Separator disc stack or inlet tube clogged

Clean separator bowl, disc stack and inlet tube


The suction device (bellows) in coolant tank lays too high or too low

Adjust the height. See description on page 11, point 3.

Separator disc stack or inlet tube clogged

Clean separator bowl, disc stack and inlet tube

Wrong direction of rotation, see page 11, point 2

Connect the electrical connections properly (shift two phases)

14

Maintenance

7 Maintenance

7.1 Cleaning

WARNING

Entrapment hazard

Switch off the power supply and make sure that rotating parts have come to a complete standstill before starting any dismantling work.

NOTE

Never use cleaning agents with a pH below 6 or above 9 as they will damage the metal surfaces.

The separated sediment collected inside the separator bowl and inlet tube must be removed in a manual cleaning procedure. The length of the cleaning interval depends on the coolant flow rate and on the amount of sediment. During the initial period, open and inspect the bowl once a day to determine the necessary cleaning interval. The bowl must be cleaned before the solids layer has become thicker than 10 mm. Otherwise there will be risk of that the clean liquid outlet in the bowl will be clogged by solids.

See ‘‘7.2.2 Cleaning of bowl” on page 17 how to proceed.

G0907411

A. Max. thickness = 10 mm

1. Sediment2. Bowl wall

15

Maintenance

7.2 Dismantling instructions for the cleaning unit

7.2.1 Introduction

The illustrations on the following pages describe step by step how to dismantle, clean, replace and assemble the various parts of the cleaning unit.

The illustrations have only symbols to indicate the actions required. The key to the symbols is given below.

Comments to illustrations on opposite page

Illustration 4:

Before dismantling the separator, wait until the rotating parts have come to a complete standstill. Check through the cover for motor fan.

Illustration 6:

Remove

Screw or turn clockwise

Press or move in the direction of arrow

Clean

Fit, insert

Screw or turn counter-clockwise

Check, make sure Safety

Take care not to damage the sealing surface of the inlet tube.

S-00439-1-1S-00442-1-1 S-00438-1-1 S-00443-1-1

S-00444-1-1 S-00441-1-1 S-00440-1-1 S-00003-1-1

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Maintenance

7.2.2 Cleaning of bowl

Dismantling

See comments on opposite page

17

Maintenance

Comments to illustrations on opposite page

Illustration 16:

Illustration 18:

Only tighten by hand. Never overtighten when assembling parts.

When fitting the bowl wall, press firmly downwards with both hands to overcome the resistance from the O-ring fitted on the bowl bottom. A “clicking” sound will be heard.

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Maintenance

Assembly

See comments on opposite page

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Maintenance

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Technical references

8 Technical references

8.1 Product specificationAlfa Laval ref. 567051, rev. 6

Type designation: alfie 200 – cleaning unit for coolant

Application: Removal of solids and tramp oil from coolants.

Tehnical design: Solid bowl made of aluminium and plastics.

AC motor rotor mounted on the bowl spindle.

Rigidly mounted bearings.

Starting unit included.

Concentrator function.

Designed in accordance with directives and standards:

98/37/EC EN 12547 73/23/EEC

Machinery Directive Centrifuges - Common safety requirements Low voltage Directive

Operational limits: Flow: max. 270 l/h at 50 Hz, max. 310 l/h at 60 Hz

Feed temperature: +15 °C to +50 °C

Ambient temperature: 0 °C to +55 °C

Use is restricted to above mentioned coolants.

Recommended for liquid with pH-values between 6 and 9

Risk for corrosion and erosion have to be investigated in each case by application centre.

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8.2 Technical dataAlfa Laval ref. 567249 rev.2

Line frequency: 50 / 60 Hz

Motor power at 400VAC, 50 Hz / 460VAC, 60HZ: Rated current:

0,25 / 0,30 0,65

kW A

Motor power at 200VAC, 50 Hz / 230VAC, 60HZ: Rated current:

0,25 / 0,30 1,3

kW A

Motor power at 1~120VAC, 60HZ: Rated current:

0,18 3,10

kW A

Motor speed, synchronous 50Hz/60Hz: 3000 / 3600 r/min

Gear ratio: direct drive

Start time, max. 0,5 minutes

Stop time, min. / max.: 1,7 / 2 minutes

Sound power / Uncertainty: 6,9 / 0,3 Bel (A)

Sound pressure / Uncertainty: 55 / 3 dB (A)

Max. vibration level: 10 mm/s (r.m.s)

Max. hydraulic capacity 50Hz / 60 Hz: 0,27 / 0,31 m3/h

Bowl liquid volume: 1,1 litres

Sludge volume, efficient/total: 0,325 / 0,6 litres

Min./Max. feed temperature: 15 / 50 °C

Max. density feed/sediment: 1100/1600 kg/m3

Weight of separator: 14 kg

Bowl weight: 2,9 kg

Jp reduced to motor shaft: 0,009 kgm2

Max. bowl inner diameter: 176 mm

Bowl body material: AL 111 4212-06

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8.3 Connection list (120V)Alfa Laval ref. 569701 rev. 0

No. Description Requirements/limits

201 Inlet for process liquid

220 Outlet for light phase, clarified liquid No counter pressure

221 Outlet for heavy phase

- Counter pressure Max. 1,8 kPa

225 Bowl drain outlet


709 Electrical connection

- The motor is protected against overload by means of a motor ciruit breaker in the staring unit. - Power supply - Fuse - Allowed voltage variation

1~60Hz 120V Max. 10A ± 5%

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8.4 Connection list (400V / 460V)Alfa Laval ref. 567241 rev. 0






225 Bowl drain ooutlet




3~50Hz 400V or 3~60Hz 460V Max. 10A ± 5%

24


8.5 Connection list (200V / 230V)Alfa Laval ref. 569699 rev. 0






225 Bowl drain ooutlet




3~50Hz 200V or 3~60Hz 230V Max. 10A ± 5%

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8.6 Connection diagram, 120 V - 60 Hz

Line

Starter

5-pole connector

Motor

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8.7 Connection diagram, 400/460V - 50/60Hz

Line

Starter

4-pole connector

Motor

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8.8 Connection diagram, 200/230V - 50/60Hz

Line

Starter

4-pole connector

Motor

28


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Spare parts

9 Spare parts9.1 Housing, driving device and starting unitItem Part No. DenominationA-6 – O-ring, see page 32B 566982-02 Axial seal kit B-1 Inlet cone

B-2 Wear ring B-3 Nut B-4 O-ring, FEP coated B-5 Seal ring holder, complete

1 569317-80 569318-80 566444-80

Motor cable set, complete, 400/460V Motor cable set, complete, 200/230V Motor cable set, complete, 120V, single phase

2 569338-01 569390-01

Electric motor 400/460 V and 200/230 V Electric motor 120 V, single phase

554603-08 Motor service kit (bearings, fan etc.)3 566476-01 Screw4 566355-80 Handle, complete5 566212-01 Collecting ring, light phase6 – Bowl, see page 327 566095-01 Screen8 568761-01 O-ring9 566464-80 Flange with studs10 566368-01 Threaded bush11 566693-01 Bracket12 566683-80 Angle knee13 566738-01 Tapping screw14 566156-01 Housing15 567047-01 Weight adjusting ring (30 g), option

567047-02 Weight adjusting ring (15 g), option16 566534-80 Bellows with float ring17 566858-01 Spring18 566296-01 Bottom plate19 566427-80 Outlet flange, complete20 221891-12 Lock nut21 566758-01 Hose coupling22 566447-01

566447-02 569557-01

Starting unit 400 /460V Starting unit 200 /230V Starting unit 120V, single phase

23 567720-01 Collecting cover24 566855-50 Hose kit

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Spare parts

24

24

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Spare parts

9.2 Separator

Item Part No. Denomination

A 566982-01 O-ring kit

A-1 546198-29

A-2 223403-55

A-3 223406-93

A-4 260104-93

A-5 260104-66

A-6 260104-21 (see page 30)

B 554603-03 Disc stack kit

1 553929-02 Lock nut

2 – Inlet cone (see page 30, pos. B1)

3 553982-02 Bowl wall

4 553922-01 Centre screw

5 553914-01 Washer

6 553944-02 Centre rod

7 558677-80 Inlet and outlet cone

8 553921-02 Pin for bowl disc

9 560480-01 Bottom disc

10 553917-82 Bowl bottom, complete

11 223403-29 O-ring

12 553913-01 Deflector ring

13 553911-01 Cylindrical pin

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Spare parts

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Installation

10 Installation

10.1 Pre-installation checks

Before starting the installation of alfie 200 cleaning unit, some measures must be checked as described below:

A. 520 mm (height of separator incl. motor)

B. 750 mm (min. recommended free space above tank top)

C. 200 mm (min. depth of tank)

D. Ø260 - 300 mm (opening in tank top)

E. 360 mm (min. diameter / width of tank)

1. Electric motor

2. Separator

3. Housing

4. Bellows

The illustration shows the outer dimension and the centre distance between the screw holes of the mounting plate.

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Installation

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10.2 Installation of housing

1. Check that the measures given on previous page are fulfilled.

2. Fix the mounting plate (3) to the tank top.

At delivery the angle knees (2) and the supports (1) are fixed to the mounting plate as alt. A (see illustration).

The angle knees must be positioned correctly in order to be able to use the full capacity of the bellows, which is 100 mm. The position of the knees depends on the distance between the tank top and the highest level (5) in the tank. If the distance is less than 90 mm, remove the housing and fit the angle knees as illustrated in B, otherwise as in A.

3. Fit the housing to the knees, see the illustrations on previous and next pages.

For adjusting the height of the housing, see next page.

1. Support2. Angle knee3. Mounting plate4. Tank5. Highest level in tank

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Installation

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10.3 Adjustment of housing’s height in tank

1. Make sure that the level in tank is at maximum that can occur during operation.

2. Move the housing downwards in the coolant.

3. Press down the bellows to admit the coolant to flow into the housing.

4. Adjust the height (H) until the level in the housing corresponds with the notch (A), see the illustration. The height is then 150 mm.

NOTECheck that the surface of the coolant is above the bellows when checking the height (H).

The recommended height of 150 mm is a minimum height. If the measure is less, the top of the bellows will come too far below the surface in the tank.

If the tank is shallow (less than 200 mm), the measure will of course be greater. A greater measure will reduce the capacity (working range) of the bellows, which is 100 mm.

5. Fit the outlet hoses as described in point 6 on pages 6 - 7.

36

Installation

6. Fit the separator and motor as described in ‘‘ Assembly” on page 19, illustrations 19 - 21.

NOTEIf the tank is equipped with a level switch, adjust the height so it corresponds to the lowest level of the bellows top.

Connect the switch in such a way that the separator motor is stopped when the switch is activated and the tank is filled with liquid.

37

Alfa Laval Separation AB

Industrial Separation Divisions. S-147 80 Tumba, SwedenTelephone: +46 8 53 06 50 00. Telefax: +46 8 53 03 95 82

Cleaning unit for coolantInstruction Manual1 Safety instructions2 Application3 Description of main parts4 Working principle of the cleaning unit5 Operating instructions5.1 Before start5.2 Start5.3 Operation5.4 Stop

6 Trouble shooting6.1 Cleaning unit vibrates6.2 Cleaning unit does not start6.3 Only feed through tramp oil outlet6.4 Cleaning unit stops6.5 No outlet either through cleaned coolant outlet or tramp oil outlet6.6 Insufficient separation result

7 Maintenance7.1 Cleaning7.2 Dismantling instructions for the cleaning unit7.2.1 Introduction7.2.2 Cleaning of bowl

8 Technical references8.1 Product specification8.2 Technical data8.3 Connection list (120V)8.4 Connection list (400V / 460V)8.5 Connection list (200V / 230V)8.6 Connection diagram, 120 V - 60 Hz8.7 Connection diagram, 400/460V - 50/60Hz8.8 Connection diagram, 200/230V - 50/60Hz

9 Spare parts9.1 Housing, driving device and starting unit9.2 Separator

10 Installation10.1 Pre-installation checks10.2 Installation of housing10.3 Adjustment of housing’s height in tank

Cleaning unit for coolant · Alfa Laval Tumba AB SE-147 80 Tumba, Sweden Telephone: +46 8 530 650...

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Transcript of Cleaning unit for coolant · Alfa Laval Tumba AB SE-147 80 Tumba, Sweden Telephone: +46 8 530 650...