Page 1 Instruction manual Designation Mineral oil centrifuge with self-cleaning bowl Type OSE 20-0136-067 2064-9001-001 Edition 1010 GEA Mechanical Equipment / GEA Westfalia Separator Group...
Page 2 The authors are always grateful for comments and suggestions for improving the documentation. They can be addressed to: GEA Mechanical Equipment GEA Westfalia Separator Group GmbH Werner-Habig-Str. 1, 59302 Oelde (Germany) Phone +49 2522 77-0, Fax +49 2522 77-2488 ws.info@geagroup.com, www.westfalia-separator.com ®...
Page 3 2064-9001-001 / 1010 GEA Westfalia Separator Group GmbH 59302 Oelde, Germany Type S/N: Year of manufacture Max. admissible rated bowl speed in min Max. admissible density in kg/dm of product Heavy Solids kg/dm liquid kg/dm Min/max throughput m Min/max temp. of product in °C Min/max housing pressure range in bar This nameplate must be filled in by the operator.
Page 4 2064-9001-001 / 1010 For your safety • Take special care when carrying out operations marked with this symbol - otherwise danger to life! • Strictly adhere to instructions marked with this symbol. This avoids damage to the separator and other equipment. •...
Page 5 GEA Westfalia Separator shall not be liable for damage which occurs as a result of non-observance of the above. Warranty and liability con- ditions in the Conditions of Sale and Delivery of GEA Westfalia Sepa- rator are not extended by the above.
Page 6: Table Of Contents
2064-9001-001 / 1010 Safety precautions Correct usage ..................10 Non-compliance with the intended use ..........11 Safety markings ..................12 1.3.1 Safety markings and their meaning ............13 Basic operating principles ..............17 Operations on the separator ..............18 1.5.1 Demands on the operating and maintenance personnel .......
Page 7 Lubrication Chart ................. 116 4.3.5 Table of lubricating oils ................ 118 4.3.6 Comments on table of lubricating oils for separators from GEA Westfalia Separator ..............119 Bowl ..................... 120 4.4.1 Dismantling the bowl ................122 4.4.2 Cleaning the bowl ................138 4.4.3...
Page 8 2064-9001-001 / 1010 Before a long-term shut-down of the separator ........200 4.9.1 Preserving the separator ..............200 4.9.2 Preserving the motor ................201 4.10 Storage ....................202 4.10.1 After delivery ..................202 4.10.2 Separator ..................... 202 4.10.3 Control system ..................202 4.11 Before restarting ..................
Page 9: Safety Precautions
2064-9001-001 / 1010 Safety precautions Correct usage ..................10 Non-compliance with the intended use ..........11 Safety markings ..................12 1.3.1 Safety markings and their meaning ............13 Basic operating principles ..............17 Operations on the separator ..............18 1.5.1 Demands on the operating and maintenance personnel .......
Page 10: Correct Usage
Only products conforming to the specifications on the nameplate may be processed. • in accordance with the method of application of the separator agreed with GEA Westfalia Separator. Refer to the data sheet and contractually agree- ments. • in accordance with the admissible utilities (cleaning agents, lubricants, operat- ing liquids etc.) specified in the documentation or on the data sheet.
Page 11: Non-Compliance With The Intended Use
– the required safety and/or protective covers have not been installed. • by persons who are not adequately trained. • when the separator is operated with spare parts which do not come from GEA Westfalia Separator. Non-compliance with intended use can result in severe damage to prop- erty and persons! ®...
Page 12: Safety Markings
2064-9001-001 / 1010 Safety markings The safety markings (adhesive and metal plates) are attached to all separators on the hood and frame of the respective separator in such a way that they are clearly visible. All safety markings on the separator, control system and plant components must always be in perfect condition.
Page 13: Safety Markings And Their Meaning
2064-9001-001 / 1010 1.3.1 Safety markings and their meaning The following safety markings must be attached to the separator as adhesive labels. Fig. 2 Refer to the machine documen- tation! • Every person who is assigned the task of installing, operating, main- taining and repairing the machine must have read and understood the documentation.
Page 14 2064-9001-001 / 1010 Before carrying out work, dis- connect power to all compo- nents of the monitoring system! Risk of injury due to electrical voltage and unintended start-up of the separa- tor! Before carrying out work on the separator and electrical plant com- ponents: •...
Page 15 2064-9001-001 / 1010 Frequency converter operation! • When setting the frequency con- verter, do not exceed the admissible bowl speed (see nameplate) Note: This adhesive plate is only used for frequency converter operation. Fig. 7 Warning extreme surface temperatures! The surfaces of the separator and plant components can be hot! Note: This adhesive plate is only used for hot...
Page 16 Fig. 11 Example 2 No te : Orange coloured leads are fitted as standard at GEA Westfalia Separator. Different colour leads can be fitted if requested by the customer! ® Westfalia Separator...
Page 17: Basic Operating Principles
2064-9001-001 / 1010 Potential equalisation (protec- tive-earth terminal) The grounding protection is a measure which, in the case of a malfunction, leads off the touch voltage into the earth. Fig. 12 Basic operating principles Separators are used for the separation of liquid mixtures or for the separation of solids out of liquids or liquid mixtures.
Page 18: Operations On The Separator
GEA Westfalia Separator accepts no liability for damage caused by un- qualified or unauthorized personnel! For operation, maintenance and repair work, personnel may only be deployed •...
Page 19: Spare Part Requirements
2064-9001-001 / 1010 GEA Westfalia Separator offers an extensive range of training and advanced training courses. You can obtain further information from GEA Westfalia Sepa- rator or from one of the authorized representatives. 1.5.2 Spare part requirements • Use only genuine spare parts from GEA Westfalia Separator.
Page 20 – Lock ring – Bowl top – Distributor – Bowl bottom – Water chamber bottom GEA Westfalia Separator must be consulted. These parts – are marked with a footnote in the separator manual (see section “Bowl”).
Page 21 2064-9001-001 / 1010 • When assembling the bowl, be sure to strictly adhere to the assembly in- structions in order to avoid undue imbalance. • Before starting the bowl, be sure to fit all parts. Fig. 22 • Tighten the bowl lock ring securely: the "O"...
Page 22: Electrical Installation
• The governing accident prevention regulations apply for the electrical appliances and installations. • Special attention must be paid to the installation guidelines of GEA West- falia Separator. • The frequency and voltage of the power supply must correspond to the machine specifications.
Page 23: Before Start-Up
2064-9001-001 / 1010 1.5.5 Before start-up • Check that the bowl lock ring has been firmly tightened. • The "O" marks on bowl bottom or bowl top and on the lock ring must be aligned. Fig. 29 • The bowl must rotate in clockwise direction (see arrow on frame or sol- ids collector).
Page 24 2064-9001-001 / 1010 • Check that the lubrication and cool- ing systems are serviceable. Fig. 32 • Check whether supervisory equipment is operational and the correct limit values are adjusted. • When hoods, concentrate collectors and vessels are pressurized, e.g. by –...
Page 25: Start-Up
2064-9001-001 / 1010 1.5.6 Start-up • Refer to chapter “operation”. • Note nameplate. The values for – bowl speed, – density of the heavy liquid, – density of the solids (centrifugally dry) are maximum values and must not be exceeded. Fig.
Page 26 2064-9001-001 / 1010 • Do not feed product which is catego- rised as explosive. • The separator must not be used in areas where explosion protection is required. Fig. 38 • When processing products harmful to persons, observe the pertinent safety regulations.
Page 27: Shut-Down And "Emergency-Off
2064-9001-001 / 1010 • The bowl is not allowed to run with- out liquid supply for more than 15 – 30 minutes, as otherwise it would result in overheating of the bowl ma- terial. Fig. 42 1.5.7 Shut-down and “Emergency-Off" •...
Page 28: Voltage Cutoff During Operation
2064-9001-001 / 1010 1.5.8 Voltage cutoff during operation When the voltage is cut off for longer than one second during operation, the control system switches off automatically and the separating process is aborted. Important: – The bowl is not emptied. Product and solids remain in the bowl. –...
Page 29: Maintenance And Repair
2064-9001-001 / 1010 1.5.9 Maintenance and repair Unfavourable operating conditions may require shorter maintenance intervals. The factors listed below are unfavourable because they either attack the sepa- rator material directly or impair the lubrication/cooling system: • Aggressive product (chemical or physical) •...
Page 30 2064-9001-001 / 1010 Before carrying out work on the separator and electrical plant com- ponents: • Make sure the separator is at a standstill. • Switch off all electrical appliances via the main switch. • Lock the installation to prevent it from being accidentally switched on.
Page 31 2064-9001-001 / 1010 • Do not heat bowl parts with the naked flame. • Bowl parts must never be welded. This also applies for hood and solids catcher parts of steam- sterilizable separators. • Even during cleaning the bowl parts the temperature must not exceed 100 °C (212 °F).
Page 32 2064-9001-001 / 1010 • Collect dripping oil to prevent danger of slipping or product infection. • When handling waste oils note: – They can be injurious to health, depending on their chemical com- position. – Waste oil must be disposed of in accordance with local regulations.
Page 33: Corrosion
2064-9001-001 / 1010 Corrosion Corrosion can also affect bowl parts made of stainless steel. This corrosion can be flat-spread or pit- or crack-shaped and merits special attention. Corrosion on stainless steel bowl material should be examined thoroughly and documented. Flat-spread corrosion can usually be measured (reduction of wall thickness) Pit- or crack-shaped corrosion cannot be measured without the risk of damage.
Page 34: Erosion
2064-9001-001 / 1010 Erosion Erosion is caused by solid particles in the process liquid. These solid particles grind marks into the surfaces with which they come into contact. The following factors favour the occurrence of erosion: • hard solids particles •...
Page 35 2064-9001-001 / 1010 Signs of erosion which you should immediately report to your nearest Westfalia Separator representative: • The bottom of the erosion mark has a radius smaller than 1 mm (large notch effect). • The depth of erosion mark exceeds 1 mm (0.04 inch) at the deepest point.
Page 36: The Health Hazards Involved When Handling Heavy Oils And Lube Oils
2064-9001-001 / 1010 The health hazards involved when handling heavy oils and lube oils As a result of the deterioration in quality of fuel oils, the danger has arisen that the heavy oils used on board contain greater amounts of substances injurious to health. These include: - polycyclic aromatic hydrocarbons, - lead compounds, - chemical residues.
Page 37: Machine Description
2064-9001-001 / 1010 Machine description Standard dimensioned drawing of the separator ........38 Section through separator ..............40 General ....................41 OSE ...-0136-..................41 2.4.1 Separator with water content and sludge space monitoring system (WMS and SMS) for fuel oil treatment ........... 42 Main components of the separator ............
Page 38: Standard Dimensioned Drawing Of The Separator
2064-9001-001 / 1010 Standard dimensioned drawing of the separator • Refer to the installation guidelines for further information. Minimum lifting capacity hoist: 100 kg For repair and maintenance bowl, motor The complete bowl can then be transported over adjacent separators of identical type. Centre of gravity Water discharge/ Opera- ting water discharge...
Page 39 2064-9001-001 / 1010 Pressure transmitter (product discharge) Pressure transmitter („self-thinker“ system) 2/2-way solenoid valve (water discharge) 2/2-way solenoid valve (circuit) Water detector Centre of gravity Socket: Product discharge Discharge by the centripetal pump built into the separator Product feed Filling, displacement and operating water feed Terminal box Solids discharge Solenoid valve block...
Page 40: Section Through Separator
2064-9001-001 / 1010 Section through separator Fig. 59 ® Westfalia Separator...
Page 41: General
2064-9001-001 / 1010 General The machine described in this manual is a high-speed centrifugal separator with self-cleaning bowl. "Separation" means the separation of liquid mixtures which consist of two liq- uids, with simultaneous removal of the solids contained in the liquids. "Clarification"...
Page 42: Separator With Water Content And Sludge Space Monitoring System (Wms And Sms) For Fuel Oil Treatment
2064-9001-001 / 1010 2.4.1 Separator with water content and sludge space monitoring system (WMS and SMS) for fuel oil treatment The simultaneous water content and sludge space monitoring systems (WMS and SMS) are used for the continuous purification of fuel oil. Fig.
Page 43: Main Components Of The Separator
2064-9001-001 / 1010 Main components of the separator Fig. 61 Pos. Designation Function • connects centripetal pump and hood. Handle connection • holds the filling and displacement water supply piece line. Centripetal pump See section 2.5.1 Sensing liquid pump • covers the rotating bowl. Hood •...
Page 44 2064-9001-001 / 1010 Pos. Designation Function Sight glass allows checking the oil level. Sight glass for checking the drive belt. Solenoid valve block See section 2.5.5 Drive See section 2.5.4 • accelerates the separator to the required Motor speed. • is protected against overload during operation. ®...
Page 45: Centripetal Pump
2064-9001-001 / 1010 2.5.1 Centripetal pump Fig. 62 Pos. Designation Function • discharges the purified liquid under pressure. Centripetal pump • is firmly connected to hood 2 of the separator. • The disk provided with channels dips into the liquid rotating with the bowl.
Page 46: Bowl
2064-9001-001 / 1010 2.5.2 Bowl Fig. 63 Pos. Designation Function Bowl produces high centrifugal forces through rotation making possible separation and clarification. Distributor accelerates the product fed in through feed A to the rotational velocity of the bowl and then con- veys it into the disk stack.
Page 47: Bowl Hydraulics
2064-9001-001 / 1010 2.5.3 Bowl hydraulics Fig. 64 Separation – Bowl closed Ejection – Bowl open Pos. Designation Function Operating liquid In the rotating bowl the incoming, rotating oper- (usually water) ating liquid generates a high centrifugal pres- sure. This pressure is utilised for actuating the annular piston and sliding piston which closes and opens the bowl.
Page 48 2064-9001-001 / 1010 Closing the bowl (separation) Fig. 65 Separation – Bowl closed Ejection – Bowl open After starting the separator the solenoid valve for operating liquid is actuated with the aid of the control unit, and the bowl is closed as follows: Pos.
Page 49 2064-9001-001 / 1010 Opening the bowl (ejection) Fig. 66 Separation – Bowl closed Ejection – Bowl open The solenoid valve for operating liquid is opened with the aid of the control unit, and the ejection cycle is triggered as follows: Pos.
Page 50: Drive
2064-9001-001 / 1010 2.5.4 Drive Fig. 67 Pos. Designation Function Drive motor drives the separator. Power transmission to the bowl spindle is via the centrifugal clutch to the motor belt pulley and via the drive belt. • ensures power transmission between motor, Centrifugal clutch drive belt and spindle.
Page 51: Solenoid Valve Block
2064-9001-001 / 1010 2.5.5 Solenoid valve block The solenoid valve block for operating, filling and displacement water consists of two 2/2-way solenoid valves with servo control. They are equipped with a man- ual override for testing purposes. Fig. 68 10 Pressure controller 90 Diaphragm 20 Sleeve-type ball valve 100 Magnet core...
Page 52 2064-9001-001 / 1010 Adjusting the pressure setpoint - pressure controller 10 If necessary: • Correct the pressure setpoint by turning the setpoint screw 1 (jaw span 7). Pressure setpoint correction • Open the operating water valve using the manual override (see Fig. 69).
Page 53 2064-9001-001 / 1010 Technical data ATTENTION: • Note the specifications on the nameplate of the solenoid valve block and • the installation guidelines. Part-No. see parts list Operating principles 2/2-way solenoid valve Material: Gasket EPDM Housing CuZn Solenoid Coil size 32 mm valves: Nominal diameter...
Page 54 2064-9001-001 / 1010 Problem Cause Action Solenoid valve does Control unit is defective. Contact service backup not function. support. Wire break in the connect- Replace wire. ing terminal. Connecting terminal on the Tighten the screw of the connector block is loose. connecting terminal.
Page 55: Supervisory Equipment
2064-9001-001 / 1010 Supervisory equipment The separating process is monitored and controlled by an automatic control unit. For further details, refer to the control unit manual. 2.6.1 Pressuretransmitter Pressure transmitters PT1 and PT2 (Pressure Transmitter) – are included in the standard scope of supply, –...
Page 56: Water Detector
2064-9001-001 / 1010 Technical data Voltage 24 V DC Range 0 – 16 bar Output signal 4 – 20 mA Pressure connection G 1/4in outer (O-ring seal) Tightening torque Pressure connection max. 25 Nm Connector plug M 12 x 1; 5-pole Cable PUR-2 core, 1.5 m Cable box M 12 x 1;...
Page 57 2064-9001-001 / 1010 Technical data Switching hysteresis Depending on the process HFO/LO Ambient temperature -30 to +125 °C (-22 to +257 °F) (LED: -30 to 100 °C / -22 to 212 °F ) Temperature drift dependent on medium Enclosure (according to IEC 60529) Terminal strip: IP 54 Probe: IP 68 –...
Page 58: Solenoid Valve
2064-9001-001 / 1010 2.6.3 Solenoid valve The solenoid valve is a 2/2-way diaph- ragm straight-way valve with internal piloting. Main components: 1 Diaphragm 2 Emergency locking manual override A Operating mode B Emergency manual override Fig. 73 The emergency manual override (2) Note: –...
Page 59 2064-9001-001 / 1010 Problem Cause Action Valve does not Control unit is defective. Contact service backup function. support. Wire break in the connect- Replace wire. ing terminal. Connecting terminal on the Tighten the screw of the connector block is loose. connecting terminal.
Page 60: Vibration Monitoring (Option)
2064-9001-001 / 1010 2.6.4 Vibration monitoring (Option) The separator is protected against inadmissibly high vibrations by means of an electronic vibration monitoring system. Fig. 74 Installation example Pos. Designation Function • is installed at the upper part of the frame. Vibration pick-up •...
Page 61: Speed Monitoring
2064-9001-001 / 1010 2.6.5 Speed monitoring Speed monitoring device • displays bowl speed. Speed deviations of up to 5 % are permissible. • monitors speed drop as well as excess of speed and starting time. Fig. 75 Pos. Designation Function •...
Page 62: Product Feed Line And Product Discharge Line
2064-9001-001 / 1010 Product feed line and product discharge line Fig. 76 The separator is adapted to local conditions for throughput capacity and line pressure by means of orifice plates installed in product feed line A and product discharge line B (see section 4.2). 2.7.1 Throughput monitoring (product feed line A) The effective throughput capacity of the separator is stated on the project de- pendent data sheet.
Page 63: Throughput Determination (Product Feed Line A) - Only For Control D10
2064-9001-001 / 1010 When using an E10 control unit The effective throughput capacity is displaced on the control unit via the pres- sure transmitter 5. Throughput values deviating between the actual value and the setpoint value can be adapted in the control unit. 2.7.2 Throughput determination (product feed line A) - only for control Fig.
Page 64: Pressure Monitoring (Product Discharge Line B)
2064-9001-001 / 1010 3/2-way valve with flow indicator 4 Procedure: • Read the value on the scale of flowmeter 4 (see Fig. 76). e.g. 3 • From the value read from the scale (e.g. 3) draw a line up to the curve of the inner diameter of the built-in orifice plate A (e.g.
Page 65: Technical Data
2064-9001-001 / 1010 Technical data Subject to modification! The order-specific process data are given on the operating data sheet in- cluded in the documentation. Bowl Solids holding space (total) 1.5 dm –1 Speed 12 000 min – for densities of the product up to (see name-plate) 1.01 kg/dm (at 15...
Page 66 2064-9001-001 / 1010 Normal separating temperature of the product 20 °C (68 °F) 40 °C (104 °F) 90 °C (194 °F) LO HD 95 °C (203 °F) 98 °C (208 °F) Due to the large number of products to be treated, it is not possible to specify an exact separating temperature of the product in this manual.
Page 67: Operation
2064-9001-001 / 1010 Operation Technical information ................68 3.1.1 Separating with the unitrolplus system ..........68 3.1.2 General information on bowl ejection ............ 68 Before start-up ..................70 3.2.1 Before the first start-up – after maintenance and repair ......70 3.2.2 Before every start-up ................
Page 68: Technical Information
2064-9001-001 / 1010 Technical information Take note of the following sections: 3.1.1 Separating with the unitrolplus system The separator with unitrol plus-System has two built-in monitoring functions: – water content monitoring system - WMS – sludge space monitoring system - SMS Procedure: •...
Page 69 2064-9001-001 / 1010 • If the displacement time is too long, water will discharge through the light liq- uid outlet. • If the displacement time is too short, part of the product remains in the bowl and is lost during desludging. Flush ejection If the solids cant be completely ejected, –...
Page 70: Before Start-Up
2064-9001-001 / 1010 Before start-up Note: • Safety precautions in chapter 1. • Instruction manual of the corresponding control unit. • Instructions “Settings and malfunctions” • Instruction manuals for other auxiliary equipment • Process-related deviations are possible (refer to the order-specific operating data sheet!) 3.2.1 Before the first start-up –...
Page 71 2064-9001-001 / 1010 • the feed and discharge lines are connected (see 4.5). • the supervisory equipment is complete, mechanically and electrically func- tional. • the product and supply lines are ready-for-operation. – Pay attention to the air and water pressures (see order-specific operating data sheet).
Page 72: Before Every Start-Up
2064-9001-001 / 1010 3.2.2 Before every start-up Ensure that • the sight glass in the frame for observing the drive belt is clean. • the sight glass in the frame for observing the oil level is clean. • the drive chamber is filled with oil in accordance with section 4.3.3. •...
Page 73: Starting The Separator
2064-9001-001 / 1010 Starting the separator • See section 3.2.1 or 3.2.2 • Switch on the control unit. • Switch on the separator motor. Compare the starting current and starting time with the diagram (section 4.1.3) until the bowl reaches the speed specified on the separator nameplate. Note: The run-up phase of the separator motor is signalled by slow flashing of the LED in the “Status Separator”...
Page 74: Monitoring Of Operation
2064-9001-001 / 1010 • Open the shut-off flap in the solids discharge (option). 1 Shut-off flap 2 Solids tank 3 Solids discharge Fig. 79 • Start the program. P re -c o n d itio n s : – Continuous lighting of the LED in the “Status Separator” button. –...
Page 75 2064-9001-001 / 1010 • Inspection We, therefore, recommend in your own interest to have your separator in- spected by our service engineers once a year. These checks help to – maintain the operating safety of the machine and – avoid unscheduled downtime. Im p o rta n t! •...
Page 76: Setting The Separation Time
2064-9001-001 / 1010 Setting the separation time When using time-dependent automatic control programs, accurate setting of the separation time (time between ejection cycles) is only possible if the throughput capacity and solids loading in the feed remain constant. If this is not the case, it may be necessary to correct the settings during operation.
Page 77: Ejecting The Bowl
2064-9001-001 / 1010 Ejecting the bowl Automatic operation • Initiate ejection program by pressing the key ”Process START”: – Product feed is closed. – Displacement – Bowl ejection – Speed recovery – Filling water (process-dependent) • The product valve opens again. Manual operation (in the case of unscheduled shut–down) •...
Page 78: Shutting Down The Separator
2064-9001-001 / 1010 Shutting down the separator Automatic operation • End the separation program with the key "Process STOP”. – Two total ejections are performed automatically. Manual operation (in the case of unscheduled shut–down) • Switch off the preheater (option). –...
Page 79 2064-9001-001 / 1010 Standstill of drive belt • Shine a torch through the frame sight glass. • Visually check that the drive belt is no longer moving. Fig. 80 When the sight glass is turbid: • Unscrew the sight glass, •...
Page 80: Shut-Down "Emergency-Off
2064-9001-001 / 1010 CAUTION: Danger of injury through very hot separator parts! When carrying out maintenance work, there is a danger of injury through hot separator parts (separating temperatures of 70 to 100 C (158 – 212 3.7.1 Shut-down “Emergency-Off" In a hazardous situation (unusual noises or vibrations) or in the case of damage to the separator or plant components (e.g.
Page 81 2064-9001-001 / 1010 Д л я з а п и с е й Д л я з а п и с е й Σ η μ ε ι ώ σ ε ι ς Σ η μ ε ι ώ σ ε...
Page 82: Trouble Shooting
2064-9001-001 / 1010 Trouble shooting The following tables are an aid for locating and eliminating faults. If assembly operations have to be carried out refer to the section "Maintenance and Repair". 3.8.1 Trouble shooting Failure Possible causes Action • Clean belt contact surface of the The bowl does not come up Oil has run down the spindle onto the spindle and clutch pulley.
Page 83 2064-9001-001 / 1010 Failure Possible causes Action Uneven run of the centrifuge. Bowl is out of balance for the following For pos. 1 - 4: reasons: • Shut down separator. • Close the product feed and dis- charge. CAUTION: • Bowl must not be emptied as otherwise the vibrations occurring during shut-down will intensify.
Page 84: Bowl Faults
2064-9001-001 / 1010 3.8.2 Bowl faults Fig. 85 Bowl and operating water feeding system 1 Gasket (bowl top) Operating water feeding system 2 Gasket (bowl top) Injection chamber 3 Gasket (sliding piston) Closing chamber bottom 4 Gasket (annular piston) Bowl bottom 5 Gasket (closing chamber bottom) Drain hole 6 Gasket (annular piston)
Page 85 2064-9001-001 / 1010 Failure Possible causes Action Operating water The bowl does not close. • Check the control unit. Control unit is defective or ATTENTION: • Check or reset program parameters. Motor is not correctly set. – Product flows out of the (See control unit documentation.) solids discharge.
Page 86 2064-9001-001 / 1010 Fig. 86 Bowl and operating water feeding system 1 Gasket (bowl top) Operating water feeding system 2 Gasket (bowl top) Injection chamber 3 Gasket (sliding piston) Closing chamber bottom 4 Gasket (annular piston) Bowl bottom 5 Gasket (closing chamber bottom) Drain hole 6 Gasket (annular piston) Annular piston...
Page 87 2064-9001-001 / 1010 Failure Possible causes Action Operating water The bowl does not open or not properly • Check the control unit. Control unit is defective or • Check or reset program parameters. Motor is not correctly set. (See control unit documentation.) •...
Page 88 2064-9001-001 / 1010 Fig. 87 Bowl and operating water feeding system 1 Gasket (bowl top) Operating water feeding system 2 Gasket (bowl top) Injection chamber 3 Gasket (sliding piston) Closing chamber bottom 4 Gasket (annular piston) Bowl bottom 5 Gasket (closing chamber bottom) Drain hole 6 Gasket (annular piston) Annular piston...
Page 89 2064-9001-001 / 1010 Failure Possible causes Action • Check line pressure, increase if The bowl does not empty The operating water capacity is too completely. Solids remain in low. necessary. the bowl. Operating water data: – Pressure 2 – 3 bar (with open valve) –...
Page 90 2064-9001-001 / 1010 Д л я з а п и с е й Д л я з а п и с е й Σ η μ ε ι ώ σ ε ι ς Σ η μ ε ι ώ σ ε...
Page 91: Installation - Maintenance - Repair
Lubrication Chart ................. 116 4.3.5 Table of lubricating oils ................ 118 4.3.6 Comments on table of lubricating oils for separators from GEA Westfalia Separator ..............119 Bowl ..................... 120 4.4.1 Dismantling the bowl ................122 4.4.2 Cleaning the bowl ................138 4.4.3...
Page 92: Installation Of The Separator
2064-9001-001 / 1010 Installation of the separator • Refer to the installation guidelines for further information. Minimum lifting capacity hoist: 100 kg For repair and maintenance bowl, motor The complete bowl can then be transported over adjacent separators of identical type. Centre of gravity Water discharge/ Opera- ting water discharge...
Page 93 2064-9001-001 / 1010 Pressure transmitter (product discharge) Pressure transmitter („self-thinker“ system) 2/2-way solenoid valve (water discharge) 2/2-way solenoid valve (circuit) Water detector Centre of gravity Socket: Product discharge Discharge by the centripetal pump built into the separator Product feed Filling, displacement and operating water feed Terminal box Solids discharge Solenoid valve block...
Page 94: Transporting The Separator
2064-9001-001 / 1010 4.1.1 Transporting the separator • CAUTION: Use appropriate lifting devices to prevent accidents! – Be sure to use suitably rated, intact hoists for transport and installation. • CAUTION: Danger to life under hoists! – Do NOT step under hanging load. •...
Page 95 2064-9001-001 / 1010 • CAUTION! Do not use the eye bolt of the motor to suspend the sepa- rator. • ATTENTION: Do not damage any machine attachment parts when fas- tening the ropes. • Attach the transport ropes – to the machine A as illustrated, –...
Page 96: Installing The Separator
2064-9001-001 / 1010 4.1.2 Installing the separator • Before installing the separator make sure that – sufficient space is available for operating and dismantling the machine. – the foundation is not connected to foundations of other vibrating units to avoid the transfer of vibrations. •...
Page 97: Motor
2064-9001-001 / 1010 4.1.3 Motor Fig. 96 Start-up diagram (current and speed characteristics) – example Enclo- 50 Hz 60 Hz 50 Hz 60 Hz sign sure IP 55 see name- approx. 2 – IM V ISO- 3 000 3 600 plate class * WS standard...
Page 98 2064-9001-001 / 1010 – is protected against overheating by thermal overload releases or a PTC thermistor as sole protection. (As WS standard, the motor is protected against overheating by three PTC thermistors). – can be equipped with a frequency converter if requested by the customer. When using thermal overload releases, the motor has to be protected as fol- lows: –...
Page 99 2064-9001-001 / 1010 Star switching (example) Fig. 98 Delta switching (example) Fig. 99 IMPORTANT: • In the case of additional electrical components, PTC thermistors or space heaters, refer to the motor manual. Shipboard operation • When operating the machine on board of ship, pay attention to the installation guidelines issued by the respective classification societies.
Page 100: Direction Of Rotation Of The Bowl
2064-9001-001 / 1010 4.1.4 Direction of rotation of the bowl Provided that: – The drive chamber is filled with oil up to the half way mark on the sight glass. • Switch on motor. Fig. 100 The bowl must rotate in clockwise direction when looked at from above. The direction of rotation of the bowl is correct when the drive belt rotates clockwise (check through the sight...
Page 101: Speed And Starting Time Of The Bowl
2064-9001-001 / 1010 4.1.5 Speed and starting time of the bowl Speed see name-plate – for densities of the product up to max. 1.01 kg/dm – for densities of the separated solids up to max. 1.4 kg/dm Starting time approx. 2 – 4 min The bowl speed has been rated so as to ensure the operating safety of the separator.
Page 102 2064-9001-001 / 1010 In case of frequency converter operation: The frequency converter is equipped with a reliable frequency limitation to pre- vent operation at inadmissibly high bowl speeds. CAUTION! • Operate the separator with fre- quency converter, speed monitor- device hardware- controlled speed shut-off device.
Page 103: Fitting Orifice Plates, Flow Indicator, Pressure Transmitter
2064-9001-001 / 1010 Fitting orifice plates, flow indicator, pressure transmitter A set of orifice plates (with different inner diameters) and a set of commissioning parts are supplied with the separator. – The set of orifice plates is fastened to the separator hood. –...
Page 104: Installing The Orifice Plates
2064-9001-001 / 1010 Pressure transmitter 5 (option – for control E40) • Remove the plug from the corresponding hole of 3/2-way valve 6. • Fit pressure transmitter 5 in the 3/2-way valve 6 and connect to the control unit in accordance with the order-specific circuit diagram. The circuit diagram is kept inside the control cabinet.
Page 105: Maintenance And Lubrication
2064-9001-001 / 1010 Maintenance and lubrication • Special care must be taken when performing maintenance and lubrication operations. Conscientiously performed maintenance and lubrication operations improve the service life of the separator. • In the case of accessories (motor, product pump, preheater, solenoid valve block etc.) the manufacturer’s maintenance and lubrication instructions must be observed.
Page 106 2064-9001-001 / 1010 Set of spare parts "bowl/hood“ (operation: 1 year or 8000 hours) Fig. 108 ® Westfalia Separator...
Page 107 2064-9001-001 / 1010 Commissioning date: (to be filled in by user) Maintenance work Remark – After 4000 operating hours – after 6 months at the latest – After 12,000 operating hours – after 1 ½ years at the latest – After 20,000 operating hours – after 2 ½ years at the latest –...
Page 108 2064-9001-001 / 1010 Set of spare parts "bowl/hood“ (operation: 1 year or 8000 hours) Fig. 109 ® Westfalia Separator...
Page 109 2064-9001-001 / 1010 Remark Maintenance work – After 8000 operating hours – after 1 year at the latest – After 24,000 operating hours – after 3 years at the latest – After 40,000 operating hours – after 5 years at the latest •...
Page 110 2064-9001-001 / 1010 Set of spare parts "bowl/hood“ (operation: 1 year or 8000 hours) Fig. 110 ® Westfalia Separator...
Page 111 2064-9001-001 / 1010 Remark Maintenance work – After 16,000 operating hours – after 2 years at the latest – After 32,000 operating hours – after 4 years at the latest – After 48,000 operating hours – after 6 years at the latest •...
Page 112: Hoses And Hose Pipes
2064-9001-001 / 1010 Maintenance work – After 48,000 operating hours – after 6 years at the latest Equip the separator with new vibration isolators. We recommend having the separator checked by a WS service engineer. 4.3.2 Hoses and hose pipes Replace hose pipes when an inspection reveals one or more of the following de- fects: •...
Page 113: Lubrication
2064-9001-001 / 1010 4.3.3 Lubrication The spindle bearings are splash-lubricated from a central oil bath. MOTOR BEARINGS For re-greasing the motor bearings, refer to the instructions of the motor manu- facturer. OIL QUALITY (mineral oil) The mineral gear oil tested by Westfalia Separator with the designation "Separa- tor lube oil CLP 100"...
Page 114 2064-9001-001 / 1010 OIL QUANTITY IMPORTANT: Do not forget to top up the oil in good time! Filling in oil Fill the drive with oil before commis- sioning the separator. • Unscrew the screw plug and • fill in oil through the charge hole. Filling quantity approx.
Page 115 2064-9001-001 / 1010 Д л я з а п и с е й Д л я з а п и с е й Σ η μ ε ι ώ σ ε ι ς Σ η μ ε ι ώ σ ε...
Page 116: Lubrication Chart
2064-9001-001 / 1010 4.3.4 Lubrication Chart Fig. 114 Lubrication schedule ® Westfalia Separator...
Page 117 2064-9001-001 / 1010 Lubricant Lubrication frequency Lubricat- Amount of Lubrication point after ing point lubricant Designation Designation operating per year hours Lube oil DIN 51502 4 000 2 500 cm Drive chamber (mineral) CC 100 ISO 3498 Lube oil ISO VG 68 8 000 2 500 cm Drive chamber...
Page 118: Table Of Lubricating Oils
2064-9001-001 / 1010 4.3.5 Table of lubricating oils Lubricating oil sorts suggested by some firms Viscosity Manufac- Designation at 40 °C (104 °F) turer /s (cSt) Lubricating oil table BLASIA 100 for separators in onshore and shipboard opera- tion RADULA 100 DIESEL GAMMA 30 Separator Lube oil...
Page 119: Comments On Table Of Lubricating Oils For Separators From Gea Westfalia Separator
For the lubrication of our separators we recommend to use the oils specified by us since continuous qual- ity checks are performed by GEA Westfalia Separator. Oils proposed from some firms are not subjected to these tests.
Page 120: Bowl
2064-9001-001 / 1010 Bowl Fig. 115 Exploded view of the bowl and centripetal pump ® Westfalia Separator...
Page 121 2064-9001-001 / 1010 Pos. Designation Dimensions Bowl bottom, compl. Gasket Piston guide ring Water chamber bottom Gasket Gasket Allen screw ISO 4762 – M 8 x 16 – A4-80 Annular piston Gasket Gasket Closing chamber bottom Gasket Gasket Gasket Sliding piston Gasket Distributor Disk stack, complete...
Page 122: Dismantling The Bowl
2064-9001-001 / 1010 4.4.1 Dismantling the bowl • Switch off the main switch and lock it. CAUTION: Danger to life through high-speed rotating separator parts! • Do not loosen any part of the separator before the bowl has come to a stand- still.
Page 123 2064-9001-001 / 1010 • Avoid damage to bowl parts when fitting and removing by – precise positioning, – no diagonal pull! – selecting the low lifting speed of the hoist. CAUTION: Use appropriate lifting devices to prevent accidents! • Use suitably rated, intact hoists. CAUTION: Danger to life when transporting heavy parts! •...
Page 124 2064-9001-001 / 1010 Hinging up the hood • Unscrew filling and displacement water line 1. Fig. 118 • Unscrew handle connection piece 1 by lightly hammering with a mallet (left-hand thread); at the same time • hold the centripetal pump with offset screwdriver 2.
Page 125 2064-9001-001 / 1010 • Unscrew three hex head screws with their washers. Fig. 121 • Hinge up the hood. CAUTION: Danger of injury by in- correct hinging up of the hood! • The stirrup must register properly. Fig. 122 If necessary (see section 4.3.1): •...
Page 126 2064-9001-001 / 1010 Removing the centripetal pump Required special tool – Double hook wrench • Loosen the centripetal pump cham- ber lock ring using the double hook wrench (left-hand thread) and re- move it. Fig. 124 • Screw handle connection piece into centripetal pump (left-hand...
Page 127 2064-9001-001 / 1010 • Remove the following parts if nec- essary: – centripetal pump chamber cover – sensing liquid pump 2 with in- serted gaskets, – centripetal pump chamber cover 4 with gaskets 3 and 5, – centripetal pump 6 with inserted gasket.
Page 128 2064-9001-001 / 1010 • Unscrew hexagon nut 2. • Screw eye bolt 1 into the bowl bot- tom. • Press off the bowl from the spindle cone by at least 10 mm. Fig. 130 • CAUTION: Danger to life when transporting heavy parts! –...
Page 129 2064-9001-001 / 1010 • Compress the disk stack firmly. – Screw tight hexagon nut 1. Fig. 133 Lifting off the bowl top • Unscrew two threaded pins out of the bowl top with a screwdriver. Fig. 134 Required special tool –...
Page 130 2064-9001-001 / 1010 Important: • The O-marks of the bowl top and of the bowl bottom must be visible. – Do NOT hide them under ring spanner 1! • The arrow and the "open" mark must show upwards. • Bolt ring spanner 1 to the bowl top. •...
Page 131 2064-9001-001 / 1010 Removing the separating disk • Remove the Separating disk from the distributor neck. Fig. 140 Removing the disk stack and the distributor • Remove the disks out of the distribu- tor, one by one or group-wise. Fig. 141 •...
Page 132 2064-9001-001 / 1010 Removing the sliding piston • Insert the spindle screw into the hub. Fig. 143 Required special tools – Eye bolt 1 – Bell-shaped piece 2 • Unscrew hexagon nut 3 Fig. 144 • Assemble eye bolt 1 and bell- shaped piece 2: –...
Page 133 2064-9001-001 / 1010 • Grease the thread of sliding piston 1 (see chapter 4.3.4). • Screw the bell-shaped piece with fitted eye bolt into the thread of the sliding piston. Fig. 146 Required special tool – Socket wrench 1 • Press off the sliding piston from the bowl bottom by turning the socket wrench clockwise.
Page 134 2064-9001-001 / 1010 Removing the annular piston and the closing chamber bottom Required special tool – Socket wrench 1 • Unscrew the Allen screws holding the bowl bottom and the closing- chamber bottom together. Fig. 149 Required special tools – Eye bolt 1 –...
Page 135 2064-9001-001 / 1010 • Place the bell-shaped piece with fitted eye bolt into the bowl bottom. • Fit assembling device 3 onto the bell-shaped piece. • Loosen three Allen screws 4 using the ratchet wrench (with extension and socket). • Slip three disks 5 of the assembling device towards the periphery, under the rim of annular piston 6.
Page 136 2064-9001-001 / 1010 • Unscrew spindle screw 1. Fig. 156 If necessary: • Remove gasket 1 and piston guide ring 2. Fig. 157 ® Westfalia Separator...
Page 137 2064-9001-001 / 1010 Removing the water chamber bottom Required special tool – Socket wrench 1 • Turn bow bottom through 180 (up- side down). • Unscrew four Allen screws 2 from water chamber bottom 3. Fig. 158 • Force off water chamber bottom 1 with a screwdriver and remove it with inserted gaskets.
Page 138: Cleaning The Bowl
2064-9001-001 / 1010 4.4.2 Cleaning the bowl It is generally not necessary to dismantle self-cleaning bowls for cleaning after separation unless – the nature of the product makes it necessary, – the separator is to be shut down for a lengthy period (see section 4.9). •...
Page 139: Cleaning The Frame
2064-9001-001 / 1010 4.4.3 Cleaning the frame CAUTION: Danger to life through electrical components! • Never rinse off the motor with a direct water jet. • Use only a cleaning agent that is approved for the field of application! ATTENTION! •...
Page 140: Cleaning The Motor
2064-9001-001 / 1010 • Undo screw 1 (jaw span 22) with fitted gasket 2. • Remove filter element 3. • Clean or replace filter element 3. – Use citric acid in case of furring. – Thoroughly clean the parts with water.
Page 141: Important Instructions For Assembling The Bowl
2064-9001-001 / 1010 4.4.6 Important instructions for assembling the bowl CAUTION: Danger of imbalance! When the bowl has not been correctly assembled or is inadequately cleaned, forces can be produced in the high-speed rotating bowl which endanger the operating safety of the separator! Therefore, the cleaning instructions (section 4.4.2) and assembling instructions (section 4.4.7) must be exactly followed.
Page 142 2064-9001-001 / 1010 CAUTION: Avoid accidents by using undamaged, complete tools! • Use tools only for their intended use! – For special tools, see section 4.14 or spare parts catalog. – For standard tools, see section 4.13. • Do not use force when removing or fitting parts. CAUTION: Danger of imbalance! •...
Page 143: Assembling The Bowl
2064-9001-001 / 1010 4.4.7 Assembling the bowl • Pay special attention to sections “Safety”, 4.4.2 and 4.4.6 • For dimensions of the parts see 4.4 - exploded view. Installing the water chamber bottom Required special tool – Socket wrench 4 •...
Page 144 2064-9001-001 / 1010 • For replacing the polyamide gasket 1 see section 4.4.9. • Place gasket 2 into the groove of the annular piston and press in evenly and firmly. • Grease guide surfaces as specified in the lubrication schedule (see 4.3.4).
Page 145 2064-9001-001 / 1010 • Press the annular piston 1 into the bowl bottom by turning hexagon nut 2 clockwise with the wrench. • Remove special tools and sliding piston. Fig. 174 • Insert gaskets 1 and 3 in the grooves of the closing chamber bot- tom.
Page 146 2064-9001-001 / 1010 Required special tool – Socket wrench 1 • Screw tight the Allen screws holding the closing chamber bottom and the bowl bottom together. Torque: 25 Nm Fig. 178 • Make sure that piston guide ring 1 is firmly located in the groove.
Page 147 2064-9001-001 / 1010 Required special tools Compressing device – Eye bolt 1 – Bell-shaped piece 2 • Unscrew hexagon nut 3 Fig. 181 Bolt unit 1 comprises ring nut, hexagon nuts, and bolt. CAUTION: Avoid accidents by using undamaged and complete tools! –...
Page 148 2064-9001-001 / 1010 Installing the distributor and the disk stack • Insert the distributor into the sliding piston. – Pay attention to correct position- ing. – The "O" marks must be aligned. Fig. 184 ATTENTION: Pay attention for cor- rect total number of disks! It is marked on the blind disk, e.g.
Page 149 2064-9001-001 / 1010 Fitting the separating disk • Mount the separating disk. – Pay attention to correct position- ing! – The "O" marks must be aligned. Fig. 187 • Slightly compress the disk stack with the bell-shaped piece and the eye bolt.
Page 150 2064-9001-001 / 1010 ATTENTION: Prevent seizing threads! • The following parts must be carefully cleaned, wiped dry and greased in accordance with lubrication schedule (see 4.3.4). – threads and guide surfaces of bowl bottom and bowl top – contact surfaces of bowl top and sliding piston Fig.
Page 151 2064-9001-001 / 1010 Compressing the disk stack • Compress the disk stack firmly. – Screw tight hexagon nut 1. Fig. 193 • Compress the disk stack again and • Screw in the bowl top using the ring spanner (left-hand thread). Fig.
Page 152 2064-9001-001 / 1010 • Remove eye bolt, bell-shaped piece, and ring spanner. Fig. 196 • Screw in two threaded pins using a screwdriver. Fig. 197 Installing the complete bowl and the centripetal pump • Clean and wipe dry the spindle cone with a suitable cloth.
Page 153 2064-9001-001 / 1010 Required special tool – Eye bolt 1 • Unscrew hexagon nut 2 • Screw eye bolt 1 into the bowl bot- tom. Fig. 199 • Turn bowl through 90 (opposite the fitting position). • Clean the bowl hub with a suitable cloth.
Page 154 2064-9001-001 / 1010 CAUTION: A loose spindle screw can endanger life! • Tighten spindle screw. Torque: 50 Nm Fig. 203 • Check that the spindle and bowl are centric. The control dimension B – is 4 ±1.5 mm – between the bowl and the upper section of the frame.
Page 155 2064-9001-001 / 1010 • Mount the centripetal pump chamber cover with fitted gaskets. – The “O” marks of the centripetal pump chamber cover and the bowl top must be aligned. Fig. 207 • Insert gaskets 1 and 2 in the sensing liquid pump grooves.
Page 156 2064-9001-001 / 1010 • Insert gaskets 1 and 2 in spacer ring. • Grease the guide surfaces of the centripetal pump as specified in the lubrication schedule (see 4.3.4). • Fit spacer ring. Fig. 211 • Pay attention to section 4.7.1. ®...
Page 157: Replacing The Polyamide Gasket (Bowl Top)
2064-9001-001 / 1010 4.4.8 Replacing the polyamide gasket (bowl top) • For standard tools, see section 4.13. REMOVAL ATTENTION: Sensitive bowl part! – Do NOT damage the bowl top groove when drilling! • Drill through the damaged polyam- ide gasket twice centrically and vertically.
Page 158 2064-9001-001 / 1010 • Assemble the bowl and centripetal pump and fit in the separator (see section 4.4.7 "Assembling the bowl". • Close the hood (see section 4.5 “Closing the hood”). • Start the separator (see section 3.3 “Starting the separator”). ATTENTION! Do not start the program! Only after a running time of 30 minutes •...
Page 159: Replacing The Polyamide Gasket (Bowl Top)
2064-9001-001 / 1010 4.4.9 Replacing the polyamide gasket (bowl top) Important: Time-consuming installation! Change the polyamide gasket only when it is damaged. • For standard tools, see section 4.13. REMOVAL ATTENTION: Sensitive bowl part! – Do NOT damage the ring piston groove when drilling! •...
Page 160 2064-9001-001 / 1010 FITTING • Thoroughly clean groove. • Heat the new polyamide gasket in approx. 80 C (176 °F) water for 5 minutes. • Wipe the gasket dry and press it evenly and firmly into the groove, at four opposite points Fig.
Page 161 2064-9001-001 / 1010 • Turn sliding piston 3 through 180 (upside down). • Place sliding piston 3, bell-shaped piece 2 and eye bolt 1 on the annu- lar piston. Fig. 220 • Press the annular piston 1 into the bowl bottom by turning hexagon nut 2 clockwise with the wrench.
Page 162 2064-9001-001 / 1010 • Insert closing chamber bottom 1 into the annular piston. – The O marks of the closing cham- ber bottom and the bowl bottom must be aligned. Fig. 224 • Fasten closing chamber bottom 1 onto the bowl bottom by tightening Allen screws 2 crosswise.
Page 163 2064-9001-001 / 1010 • Unscrew the Allen screws holding the bowl bottom and the closing- chamber bottom together. Fig. 228 Required special tools – Eye bolt 1 – Bell-shaped piece 2 – Assembling device 3 • Unscrew hexagon nut 4. Fig.
Page 164 2064-9001-001 / 1010 • Force off closing chamber bottom 3 together with annular piston 4 by turning wrench 5 clockwise. Fig. 232 • Remove closing chamber bottom 3 and annular piston 4 (with fitted gas- kets) with the bell-shaped piece and the eye bolt.
Page 165 2064-9001-001 / 1010 • Unscrew the spindle screw. Fig. 235 • By carrying out several measure- ments around the entire circumfer- ence of the annular piston, check that the polyamide gasket is seated parallel in the groove. Fig. 236 ® Westfalia Separator...
Page 166: Reworking The Sliding Piston
2064-9001-001 / 1010 4.4.10 Reworking the sliding piston The bowl seal consists of • the sealing surface A of the sliding piston ( Fig. 237) (Sealing surface A as de- livered 2 mm high) and • the polyamide gasket B of the bowl top ( Fig. 239). When worn, the sealing surface A of the sliding piston can be remachined up to max.
Page 167: Closing The Hood
2064-9001-001 / 1010 Closing the hood If the gasket has been removed to keep to the service intervals: • insert a new gasket 1 in the groove of the upper part of the frame. Fig. 240 CAUTION: Danger of injury! •...
Page 168 2064-9001-001 / 1010 If the gaskets 2 have been removed to keep to the service intervals: • Provide handle connection piece 1 with new gaskets 2. • Apply a thin coat of grease to the guide surfaces and threads of the handle connection piece as speci- fied in the lubrication schedule (see 4.3.4).
Page 169 2064-9001-001 / 1010 Д л я з а п и с е й Д л я з а п и с е й Σ η μ ε ι ώ σ ε ι ς Σ η μ ε ι ώ σ ε...
Page 170: Drive
2064-9001-001 / 1010 Drive Fig. 247 Exploded view of the drive ® Westfalia Separator...
Page 171 2064-9001-001 / 1010 Pos. Designation Dimensions Retaining ring 95 x 3 Retaining ring 60 x 2 Clutch pulley Grooved ball bearing Spacer bush Grooved ball bearing Retaining ring 95 x 3 Clutch driver Clutch shoe Washer 13 x 33 x 3 Hex head screw M 11 x 60 Washer...
Page 172: Important Instructions For Fitting And Removing The Drive
2064-9001-001 / 1010 4.6.1 Important instructions for fitting and removing the drive • Switch off the main switch and lock it. CAUTION: Danger to life through high-speed rotating separator parts! • Do not loosen any part of the separator before the bowl has come to a stand- still.
Page 173 2064-9001-001 / 1010 • Avoid damage to drive parts when fitting and removing by – precise positioning, – no diagonal pull! – selecting the low lifting speed of the hoist. CAUTION: Use appropriate lifting devices to prevent accidents! • Use suitably rated, intact hoists. CAUTION: Danger to life when transporting heavy parts! •...
Page 174: Removing The Drive Belt And Spindle Assembly
2064-9001-001 / 1010 4.6.2 Removing the drive belt and spindle assembly • Pay special attention to section 4.6.1. • Undo the oil drain screw and • Drain the oil into an oil pan (approx. 2.5 l). Fig. 249 • Undo three hex head screws 1. •...
Page 175 2064-9001-001 / 1010 • Pull the motor out of the flange guide by means of the hoist (approx. 5 mm). – Drive belt is slackened! ATTENTION! • Pull the drive belt off the clutch pul- ley (centrifugal clutch) downwards. Fig. 252 •...
Page 176 2064-9001-001 / 1010 • Unscrew four hex head screws 1. • Remove ring 2 and protective cap 3 with inserted gasket 4. Fig. 256 Removing the speed monitoring device: • Unscrew hex head screw 1. • Take off speed monitoring device 2 and lay it down in the lower section of frame.
Page 177 2064-9001-001 / 1010 • Remove from the lower part of frame: – Gasket 1 – Rubber-metal cushion 2 Fig. 260 If necessary: • Undo three hex head screws 1. • remove bearing cover 2 with sealed hex head screws, disk and cup springs 3 from the lower part of the frame.
Page 178: Dismantling The Spindle Assembly
2064-9001-001 / 1010 4.6.3 Dismantling the spindle assembly Spindle assembly Required tools: – Pulling device – Open ended wrench – Pliers with outer snap jaws Fig. 263 • Detach the bearing sleeve 1 from the spindle. Fig. 264 ® Westfalia Separator...
Page 179 2064-9001-001 / 1010 • Pull off from the spindle: – Angular contact ball bearing 2: – Ball bearing protection ring 3 Fig. 265 • Remove the retaining ring. Fig. 266 • Pull off from the spindle: – Grooved ball bearing 1 –...
Page 180: Dismantling The Centrifugal Clutch
2064-9001-001 / 1010 4.6.4 Dismantling the centrifugal clutch • Pay special attention to section 4.6.1. • Undo three hex head screws 1. • Take off cover 2. Fig. 268 • Unscrew four hex head screws 1. Fig. 269 • Pull the motor out of the flange guide by means of the hoist (approx.
Page 181 2064-9001-001 / 1010 • CAUTION: Danger to life when transporting heavy parts! – Do NOT step under hanging load. • Lift the motor with fluid clutch out of the lower section of the frame. Fig. 271 • Turn the motor together with the centrifugal clutch 90 (upside down) with the aid of the hoist.
Page 182 2064-9001-001 / 1010 • Arrest the clutch driver 1 with an open-ended wrench. • Unscrew hex head screw 2 from the motor shaft end. • Take off disk 3. Fig. 275 Required special tool: – Threaded pin 2 = M 12 x 40 •...
Page 183 2064-9001-001 / 1010 • CAUTION: Danger to life when transporting heavy parts! – Do NOT step under hanging load. • Place the clutch pulley and clutch driver on a wooden base using transport ropes and hoist. • CAUTION: Secure from rolling away and overturning using suit- able aids! •...
Page 184: Fitting The Spindle Assembly
2064-9001-001 / 1010 4.6.5 Fitting the spindle assembly • Pay special attention to section 4.6.1. • For dimensions of the parts see 4.6 - exploded view. If necessary: • Insert gasket 1 in the groove in the lower section of frame. Fig.
Page 185 2064-9001-001 / 1010 • Turn spindle through 180 (upside down). ATTENTION: Pay attention to the correct fitting position of the bear- ing cover! • Mount bearing covers 1 and 2. • Heat grooved ball bearing 3 in oil up to 100 C (212 F) and slip it onto the spindle.
Page 186: Fitting The Centrifugal Clutch
2064-9001-001 / 1010 4.6.6 Fitting the centrifugal clutch • Pay special attention to section 4.6.1. • For dimensions of the parts see 4.6 - exploded view. • Clean the clutch pulley. • Insert retaining ring 1 in the lower groove. •...
Page 187 2064-9001-001 / 1010 ATTENTION: Bearing damage is caused by incorrect fitting! – Distance bush 1 may only contact the inner ring of grooved ball bear- ing 2! • Place distance bush on the ball bearing inner ring. Fig. 292 ATTENTION: Bearing damage is caused by incorrect fitting! –...
Page 188 2064-9001-001 / 1010 Required tool: – Disk 1 (Ø 61 – 69 mm) • CAUTION: Danger to life when transporting heavy parts! – Do NOT step under hanging load. • Turn clutch pulley with fitted grooved ball bearings through 180 Fig.
Page 189 2064-9001-001 / 1010 • Turn the clutch pulley through 180 • Fit the retaining ring in the groove of the clutch driver. Fig. 298 • CAUTION: Danger to life when transporting heavy parts! – Do NOT step under hanging load. •...
Page 190 2064-9001-001 / 1010 • Pull the centrifugal clutch onto the motor shaft end as far as it will go, by turning hexagon nut 4 with a sec- ond open-ended wrench. Fig. 301 • Undo hex head screw 3 together with hexagon nut 4 and •...
Page 191 2064-9001-001 / 1010 • Insert disk 2. • Fit the retaining ring 1 in the groove of the clutch driver. Fig. 305 ® Westfalia Separator...
Page 192: Fitting The Motor
2064-9001-001 / 1010 4.6.7 Fitting the motor • Pay special attention to section 4.6.1. • Carefully place the motor with pre- assembled centrifugal clutch on lower section of frame by means of a hoist. – Do not yet let the motor flange lock into the frame opening.
Page 193 2064-9001-001 / 1010 • Screw hex head screw 1 (M 10 x 200) with hexagon nut 2 and washer 3 through the frame bore into the ta- phole of the centrifugal clutch. • ATTENTION: To avoid damage to the grooved ball bearing: –...
Page 194 2064-9001-001 / 1010 • Check – that the spindle 1 can be turned easily. – whether the spindle 3 has been pulled into the centric axis by tensioning the drive belt 3 (see Fig. 204). Fig. 312 Installing the speed monitoring de- vice: •...
Page 195 2064-9001-001 / 1010 • Place spindle cap 1 with fitted gasket on the spindle. – Pay attention to correct position- ing! Fig. 316 Fitting the operating water feeding device in the upper section of frame: • Slide nut 2 over pipe 3. •...
Page 196 2064-9001-001 / 1010 Danger to life and limb through electric current! • Have the motor connected by an authorized electrician! ® Westfalia Separator...
Page 197: Height Adjustment
2064-9001-001 / 1010 Height adjustment For reasons of operating reliability, adjustment of • bowl height • and centripetal pump play must be performed with particular care. 4.7.1 Bowl height ATTENTION: The bowl height must not be adjusted on this separator! The bowl height may only be measured with fitted and tightened drive belt! A bowl height check is necessary, e.g.
Page 198: Centripetal Pump Clearance
2064-9001-001 / 1010 4.7.2 Centripetal pump clearance • Move the centripetal pump axially to and fro in the centripetal pump chamber. • Measure the total clearance (approx. 10 Mm). • Close the hood. • Check: – Is the hood correctly seated on the frame rim? –...
Page 199 2064-9001-001 / 1010 • Raise the handle connection piece to its maximum. • Measure the axial clearance. = 4 – 6 mm Fig. 325 ® Westfalia Separator...
Page 200: Final Checks After Assembling The Separator
2064-9001-001 / 1010 Final checks after assembling the separator Before starting the separator Perform the following checks after assembling and before starting the separator depending on the scope of the repair work: Checks Section 1. Bowl height 4.7.1 2. Oil level in drive chamber 4.3.3 3.
Page 201: Preserving The Motor
2064-9001-001 / 1010 CAUTION! Risk of injury through rotating separator parts. • Keep a safe distance away from the rotating spindle. • After switching off the separator, wait until the spindle has stopped rotating. • Take off the drive belt. 4.9.2 Preserving the motor •...
Page 202: Storage
2064-9001-001 / 1010 4.10 Storage ATTENTION! Improper and incorrect storage of the separator and control unit can dam- age or destroy their components. Store accessories like spare parts, tools, lubricants properly! Note: Gaskets, hoses and hosepipes, for example, change their physical properties in unfavourable storage conditions.
Page 203: Before Restarting
2064-9001-001 / 1010 Recommended storage temperature: + 5 to + 45 °C (41 – 113 °F) 4.11 Before restarting Before re-starting, the operator must ensure • that all separators and plant components have been function-checked by competent personnel (qualified specialists). •...
Page 204: Disposal
2064-9001-001 / 1010 4.12 Disposal When the equipment is no more useful or the separator has reached the end of its service life, the operator is responsible for appropriate, environmentally friendly disposal of its components and materials such as – metal, –...
Page 205: Cleaning Liquids
2064-9001-001 / 1010 4.12.2 Cleaning liquids Only those cleaning agents may be used that are specified in the overall docu- mentation (see data sheet). CAUTION: Danger of chemical burns! The cleaning agents can be acids and caustics which, if used carelessly, can cause severe damage to persons.
Page 206: Standard Tools
2064-9001-001 / 1010 4.13 Standard tools are commercially available tools to be supplied by the customer. Fig. 327 ® Westfalia Separator...
Page 207 2064-9001-001 / 1010 Pos. Designation Screwdriver Torque wrench (0 - 100 Nm) with inserts and extension Caliper gauge Electric oil heater for ball bearings Ratchet with inserts and extension Standard hammer and mallet Inner snap pliers with offset jaws (Ø 40 mm) Outer snap pliers (Ø...
Page 208: Special Tools
2064-9001-001 / 1010 4.14 Special tools Fig. 328 ® Westfalia Separator...
Page 209 2064-9001-001 / 1010 • Special tools are provided by the manufacturer. • For the delivery of special tools, the packing list supplied with the sepa- rator is applicable. Pos. Designation Mallet Complete socket wrench (spindle screw) Offset screwdriver (centripetal pump) Double hook wrench (centripetal pump chamber lock ring) Hexagon nut M 10 (centrifugal clutch) Hex head screw M 10 x 200 (centrifugal clutch)
Page 210 2064-9001-001 / 1010 Д л я з а п и с е й Д л я з а п и с е й Σ η μ ε ι ώ σ ε ι ς Σ η μ ε ι ώ σ ε...
Page 211: Spare Parts
2064-9001-001 / 1010 Spare parts Spare part requirements ..............212 Guide to ordering spare parts .............. 212 ® Westfalia Separator...
Page 212: Spare Part Requirements
2064-9001-001 / 1010 Spare part requirements • Use only genuine spare parts from GEA Westfalia Separator. The original spare parts are listed in the spare parts catalog. The use of non-genuine parts leads to: – safety risks, – reduced durability of these parts, –...
Page 213 2064-9001-001 / 1010 Д л я з а п и с е й Д л я з а п и с е й Σ η μ ε ι ώ σ ε ι ς Σ η μ ε ι ώ σ ε...
Page 214 2064-9001-001 / 1010 Д л я з а п и с е й Д л я з а п и с е й Σ η μ ε ι ώ σ ε ι ς Σ η μ ε ι ώ σ ε...
Page 215 2064-9001-001 / 1010 ® Westfalia Separator...
Page 216 GEA Mechanical Equipment GEA Westfalia Separator Group GmbH Werner-Habig-Str. 1, 59302 Oelde (Germany) Phone +49 2522 77-0, Fax +49 2522 77-2488 ws.info@geagroup.com, www.westfalia-separator.com...

GEA OSE 20-0136-067 Instruction Manual

1 Safety Precautions

2 Machine Description

3 Operation

4 Installation - Maintenance - Repair

5 Spare Parts

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