Cleaning unit for coolant :_decftez`_>r_fr] Book No.: 1271526-02 V2
Alfa Laval Separation AB Separator Manuals, dept. SKEL S-147 80 Tumba, Sweden Telephone: +46 8 53 06 50 00 Telefax: +46 8 53 03 10 40 Printed in Sweden, 00-10 Alfa Laval Separation AB 2000 This publication or any part thereof may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Separation AB.
Contents 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 data 20 9 Spare parts 22 10 Installation 26 3
Safety instructions 1 Safety instructions Study this instruction manual and observe the warnings before installation, operation, service and maintenance. Not following the instructions can result in serious accidents. 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. 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. ANSI-label for the US market S0147811 S0147911 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 parts The alfie 200 unit consists of following parts: 1. Hand control unit For 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. Handle Except 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 coolant The 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 plate To the mounting plate (placed on top of tank) are fixed the four housing supports (10) and the cable support (11). 9. Housing The 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 28. 6
Description of main parts 10.Housing support To admit the cleaning unit to be placed at suitable height in the tank the four supports are provided with grooves. 11.Cable support For 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 inlet B. Clean coolant outlet C. Tramp oil outlet to collecting tank 1. Particles (sediment) 2. Bowl 3. Channels from inlet tube to disc stack 4. Wing in inlet tube 5. Surface in tank 6. Bellows 7. Electric motor 8. Bowl spindle 9. Conical discs 10. Channels from bowl to outlet 11. Frame 12. Weight adjusting ring(s) 13. Axial seal 8
Working principle of the cleaning unit G0925761 9
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 28. 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 Start 1. Start the cleaning unit by pressing the black button on the hand control unit. The green lamp in the control unit is switched on. G0925831 WARNING Disintegration hazard 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. 10
Operating instructions 1. Hand control unit 2. Handle 3. Cleaning unit 4. Outlet hose or pipe for tramp oil 5. Tank for coolant 6. Outlet hoses for cleaned coolant 7. Suction device (bellows) 8. Housing 9. Support 10. Cable support 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. G0935721 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 prevents 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. 11
Operating instructions 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. G0925841 How to clean the unit is described in chapter 7.1 Cleaning on page 15. 12
Trouble shooting 6 Trouble shooting 6.1 Cleaning unit vibrates WARNING Disintegration hazard If excessive vibrations occur, stop the separator Possible cause Bowl out of balance due to: Insufficient or incorrect cleaning Incorrect assembly Action Dismantle and clean the separator bowl. Make sure that the separator is assembled correctly 6.2 Cleaning unit does not start Possible cause No power supplied Incorrect assembly after cleaning. The bowl and motor shaft can not rotate freely Defective motor Action Check the mains switch, fuses and supply line Turn the motor fan wheel with a suitable tool. If resistance, dismantle and check Contact your Alfa Laval representative 6.3 Only feed through tramp oil outlet Possible cause Filled sediment space in bowl periphery Action Clean separator bowl and disc stack 13
Trouble shooting 6.4 Cleaning unit stops Possible cause Overload due to incorrect assembly Defective motor Motor circuit breaker in the hand control unit tripped due to too high current or short-circuit Action Check the bowl assembly Contact your Alfa Laval representative Restart the unit. Possible after about 30 seconds if not short-circuit. The reason of too high current could be too low voltage supplied. 6.5 No outlet either through cleaned coolant outlet or tramp oil outlet Possible cause Outlet hoses are lying too high in the tank Separator disc stack or inlet tube clogged Action Place the hoses in a lower position, see description on page 11, point 4 Clean separator bowl, disc stack and inlet tube 6.6 Insufficient separation result Possible cause The suction device (bellows) in coolant tank lays too high or too low Separator disc stack or inlet tube clogged Wrong direction of rotation, see page 11, point 2 Action Adjust the height. See description on page 11, point 3. Clean separator bowl, disc stack and inlet tube Connect the electrical connections properly (swop two phases) 14
Maintenance 7 Maintenance 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. 7.1 Cleaning 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 covered by solids. See 7.2.2 Cleaning of bowl on page 17 how to proceed. A. Max. thickness = 10 mm 1. Sediment 2. Bowl wall G0907411 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. S-00439-1-1 Remove Screw or turn clockwise Press or move in the direction of arrow S-00442-1-1 S-00438-1-1 S-00443-1-1 Clean Fit, insert Screw or turn counterclockwise Check, make sure S-00444-1-1 S-00441-1-1 S-00440-1-1 S-00003-1-1 Safety 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: Take care not to damage the sealing surface of the inlet tube. G0928021 16
Maintenance 7.2.2 Cleaning of bowl Dismantling See comments on opposite page 17
Maintenance Comments to illustrations on opposite page Illustration 16: 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. G0912131 Illustration 18: Only tighten by hand. Never overtighten when assembling parts. 18
Maintenance Assembly G04491B1 See comments on opposite page 19
Technical data 8 Technical data 8.1 Cleaning unit Type designation: Application: Throughput capacity - max.: - average: alfie 200 cleaning unit for coolant Use is restricted to removal of tramp oil and solids from water-based coolant with the following specifications: Process media: Coolant ph value: 6-9 Separation temperature: +15 +50 C 280 litres/hour 230 litres/hour Max. ambient temperature: +55 C Motor data: 3 ~ 50 Hz, 400 V ±5%, 0.20 kw, 0.6 A, 2 800 r/min 3 ~ 60 Hz, 460 V ±5%, 0.23 kw, 0.6 A, 3 400 r/min Recommended fuse: 10 A Working range (height) of bellows: 100 mm Weight, complete unit: to lift: 14 kg (excl. hand control unit and hoses) 10 kg (when cleaning the separator bowl etc.) Dimensions: See chapter 10 Installation on page 26. 8.2 Separator Sludge space in bowl: 0.6 litre Speed: 2 800 / 3 400 r/min (50 / 60 Hz) Running up time: Max. 30 seconds Stopping time: 100-120 seconds Enclosure class, motor: IP 54 20
Technical data 8.3 Connection diagram Line G0925911 Starter Motor 4-pole connector 21
Spare parts 9 Spare parts 9.1 Housing Item Part No. Denomination A-6 O-ring, see page 24 B 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 566444-80 Motor cable set, complete 2 566431-80 Electric motor incl. flange 554603-06 Motor service kit (bearings, fan etc.) 3 566476-01 Screw 4 566355-80 Handle, complete 5 566212-01 Collecting ring, light phase 6 Bowl, see page 24 7 566095-01 Screen 8 223406-98 O-ring 9 566464-80 Flange with studs 10 566368-01 Threaded bush 11 566693-01 Bracket 12 566683-80 Angle knee 13 566738-01 Tapping screw 14 566156-01 Housing 15 567047-01 Weight adjusting ring (30 g), option 567047-02 Weight adjusting ring (15 g), option 16 566534-80 Bellows with float ring 17 566858-01 Spring 18 566296-01 Bottom plate 19 566427-80 Outlet flange, complete 20 221891-12 Lock nut 21 566758-01 Hose coupling 22 566447-01 Starting unit 22
Spare parts G0936111 23
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 223406-99 (see page 22) B 554603-03 Disc stack kit 1 553929-02 Lock nut 2 Inlet cone (see page 22, 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 553917-81 Bowl bottom, complete 11 223403-29 O-ring 12 553913-01 Deflector ring 13 553911-01 Cylindrical pin 24
Spare parts G0935911 25
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 G0927521 The illustration shows the outer dimension and the centre distance between the screw holes of the mounting plate. G0935811 26
Installation 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. Support 2. Angle knee 3. Mounting plate 4. Tank 5. Highest level in tank G0927431 27
Installation 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. NOTE Check 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. G0927741 5. Fit the outlet hoses as described in point 6 on pages 6-7. 28
Installation 6. Fit the separator and motor as described in Assembly on page 19, illustrations 19-21. NOTE If 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. 29
Alfa Laval Separation AB Industrial Separation Divisions. S-147 80 Tumba, Sweden Telephone: +46 8 53 06 50 00. Telefax: +46 8 53 03 95 82 Internet: www.alfalaval.com e-mail: sengineering.info@alfalaval.com