Mechanical Separation
Division
Instruction Manual
No.: 2325-9001-020
Edition: 0806
2 Westfalia Separator AG
©
All rights reserved. No part of this document may be reproduced in any form – by graphic, electronic or me-
chanical means including all types of photocopying or any other means of duplication – without our prior written
consent.
The transmission of originals and reproductions to third parties is prohibited without our prior consent.
2325-9001-020 / 0806
Westfalia Separator AG 3
1 Introduction 7
2 Lubrication 17
3 Motor connection 21
4 Bowl 29
5 Technical information 65
2325-9001-020 / 0806
4 Westfalia Separator AG
6 Operation 75
7 Cleaning 95
7.1 Cleaning-in-place...................................................................................96
7.2 Bowl .......................................................................................................99
7.3 Frame...................................................................................................100
7.4 Operating water feeding device...........................................................100
7.5 Cleaning the lube-oil vessel .....................................................................100
7.6 Prior to a long-term shut-down ............................................................101
7.7 Note on cleaning work on hoods .........................................................102
7.8 Note on cleaning work on disks...........................................................102
8 Drive 103
8.1 Drive.....................................................................................................104
8.1.1 Special risks of a separator .................................................................105
8.1.2 Safety precautions for maintenance and repair...................................108
8.2 Fitting and removing the motor............................................................112
8.2.1 Removing the motor ............................................................................112
8.2.2 Installing the motor ..............................................................................113
8.3 Removing spindle assembly, supporting disk......................................114
8.4 Dismantling the spindle assembly .......................................................116
8.5 Assembling the spindle unit .................................................................118
8.6 Replacing the rubber-metal bushes and the rubber cushions.............121
8.7 Installing the spindle assembly............................................................123
8.8 Adjusting the proximity switch .............................................................124
2325-9001-020 / 0806
Westfalia Separator AG 5
2325-9001-020 / 0806
6 Westfalia Separator AG
2325-9001-020 / 0806
Westfalia Separator AG 7
1 Introduction
2325-9001-020 / 0806
8 Westfalia Separator AG
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
2325-9001-020 / 0806
Westfalia Separator AG 9
This booklet must be kept for further use and be available at all times in
the vicinity of the separator for all persons who work with or on the sepa-
rator.
NOTE
At the beginning of this manual, you will find the schematic of the separa-
tor and the nameplate. The nameplate must be filled in by the operator.
Enter the data from the nameplate on the separator. Dangers of later con-
NOTE fusion are thus avoided.
2325-9001-020 / 0806
10 Westfalia Separator AG
2325-9001-020 / 0806
Westfalia Separator AG 11
2325-9001-020 / 0806
12 Westfalia Separator AG
2325-9001-020 / 0806
Westfalia Separator AG 13
This symbol indicates potential risks for machine, material and environ-
ment.
Attention!
This symbol draws attention to the fact that at this point additional manu-
als must be read and observed.
Instruction manual
This symbol does not indicate safety precautions but rather information
for a better understanding of the machine.
NOTE
2325-9001-020 / 0806
14 Westfalia Separator AG
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
2325-9001-020 / 0806
Westfalia Separator AG 15
Westfalia Separator
…………….GmbH
D-59302 Oelde ( Germany)
Type Serial-No.
Model
2325-9001-020 / 0806
16 Westfalia Separator AG
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
2325-9001-020 / 0806
Westfalia Separator AG 17
2 Lubrication
2325-9001-020 / 0806
18 Westfalia Separator AG
Fig. 1
The drive bearings are supplied with oil by the oil circulation lubrication system
(external oil lubrication unit). The oil feed is under pressure, the lube oil return is
under gravity or under pressure, as illustrated above.
For the electrical connection of the external oil lubrication unit, bear in mind that
it has to be switched on when the separator reaches a certain bowl speed dur-
ing start up and that it must be switched off during shut-down.
The specific bowl speeds are listed in the datasheet.
NOTE
For more in-depth information concerning the external oil lubrication unit,
refer to the instruction manual supplied with the oil lubication unit.
Instruction manual
2325-9001-020 / 0806
Westfalia Separator AG 19
NOTE
2.1.2 Oil quantity
Before starting the separator for the
first time fill the oil vessel of the exter-
nal oil lubrication unit with oil until the
oil level reaches the upper mark of the
oil level indicator.
Minimum oil level:
slightly above the lower mark of the oil
level indicator
Maximum oil level:
slightly below the upper mark of the oil
level indicator
Fig. 2
During operation, the oil level in the vessel of the oil lubrication unit must
never be below minimum level; do not fail to re-fill in time (see chapter
“Lubrication and maintenance”, section “Maintenance schedule”).
IMPORTANT
The quantity of oil needed for filling the vessel is indicated in the instruction
manual of the oil lubrication unit.
NOTE
The operating hours up to the first oil change and the subsequent oil change
intervals are specified in the “Maintenance Schedule”.
Change the oil at the latest as specified in the “maintenance schedule” even if
the operating hours specified for an oil change have not been reached.
NOTE
Whenever changing the oil, clean the lubricating oil chamber thoroughly with
thin-bodied oil.
Do not use fluffy cleaning rags or cotton waste!
Clean sight glass.
2325-9001-020 / 0806
20 Westfalia Separator AG
Do not bring gaskets made from the special material EPDM (ethylene-
propylene-diene-caoutchouc) in contact with mineral oils and greases.
Consequence in the event of contact: Swelling of the gaskets
Attention!
2325-9001-020 / 0806
Westfalia Separator AG 21
3 Motor connection
2325-9001-020 / 0806
22 Westfalia Separator AG
Gear drive
– with fluid or centrifugal clutch
– with frequency converter
Belt drive
– with controlled torque motor
– with frequency converter
– with clutch
The technical specifications on the motor supplied are given in the data-
sheets supplied with the documentation, the motor nameplate and / or the
documentation of the motor manufacturer.
NOTE The switching devices must be rated for the starting current of the motor.
Starting currents
Depending on the different drive and motor types, different starting currents are
required for starting a separator.
Motor protection
If the motor is equipped with a PTC thermistor, it must be connected to the
corresponding tripping device.
Lay the measuring circuit line (tripping device-motor) as a separate control
line.
Lubrication
If the motor is equipped with a re-lubricating device, it must be re-
lubricated at regular intervals in accordance with the specifications of the
Attention! motor manufacturer on the motor nameplate.
2325-9001-020 / 0806
Westfalia Separator AG 23
2325-9001-020 / 0806
24 Westfalia Separator AG
Fig. 3
2325-9001-020 / 0806
Westfalia Separator AG 25
The bowl must rotate in clockwise direction when looked at from above.
CAUTION!
If the direction of rotation is wrong, the wiring of the motor power supply lead
must be checked for conformity with the circuit diagram and changed accord-
ingly. This may only be carried out by an authorized specialist.
The bowl speed has been defined to suit the process as a function of the densi-
ties of the centrifugally dry solids and the clarified liquid.
All components have been constructionally rated for this speed (operating
speed) taking into account all safety-relevant factors.
The operating speed (bowl speed) and other important process data are speci-
fied on the separator nameplate. Alterations to the process data may also ne-
cessitate a change in operating speed.
The bowl speed may not be changed by the operator without appropriate
consultation.
The bowl speed stated on the separator nameplate must not be exceeded!
Fig. 4
The spindle speed must be checked before the first start-up and before
fitting the bowl.
NOTE
2325-9001-020 / 0806
26 Westfalia Separator AG
Specifications on the starting time of the bowl are given in the enclosed
data sheets.
NOTE
Make sure that the bowl reaches its rated speed within the starting time and
that this speed is maintained during operation.
The run-down time specified in the data sheet refers to the rated speed (see
separator nameplate) with free run-down and at atmospheric pressure.
NOTE
In addition to mechanical or electric brakes, the run-down time of the separator
can be influenced by various process factors.
The run-down time specified in the data sheet specifies the maximum time
span required until the separator bowl has stopped rotating.
2325-9001-020 / 0806
Westfalia Separator AG 27
2325-9001-020 / 0806
28 Westfalia Separator AG
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
2325-9001-020 / 0806
Westfalia Separator AG 29
4 Bowl
2325-9001-020 / 0806
30 Westfalia Separator AG
2325-9001-020 / 0806
Westfalia Separator AG 31
Switch off the separator before carrying out maintenance or repair work.
Wait, observe and check that all rotating parts are at a standstill.
Do not reach into the rotating drive section or bowl!
Do not loosen any part before the bowl has come to a standstill!
CAUTION!
Risk of injury and danger to life through rotating parts.
Standstill should not be checked using only one source of information (e.g.
speed indicator) but must be backed up by at least one further checking device.
It must always be reckoned with that the first used standstill indication will pro-
vide false information because, for example, the electronics have failed or the
belt or gearbox in the drive is defective.
The following options are available for checking standstill on separators depend-
ing on the version:
Electric speed indicator
Revolution indicator or sight glass on the gear cover of gear separators
Optical speed check of the drive motor
Noise check
Vibration check
If you are not sure whether the machine is at a standstill, you must wait for the
run-down time specified in the separator documentation. A subsequent check is
carried out when you are sure that the machine is at a standstill.
Visual speed check by opening the inspection ports on hood and frame
Removing the inspection port in the separator hood enables you to look directly
on to the bowl. In addition, checking is also possible by removing the gearbox
cover or opening the port in the frame.
Only when you are convinced that the separator is at a standstill can the
following checks be carried out for additional security.
NOTE
2325-9001-020 / 0806
32 Westfalia Separator AG
Fig. 5
Fig. 6
Fig. 7
2325-9001-020 / 0806
Westfalia Separator AG 33
Observing the motor fan is not a reliable method of checking standstill because
the motor or fan can already be at a standstill when the separator bowl is still
rotating.
NOTE
During cleaning programs (steam sterilization and CIP), very high temperatures
are reached on the surfaces of the separator and piping.
During cleaning programs, the surfaces of the separator and pipes are
very hot.
When the cooling is switched on, the surfaces of the separator and pipes
can get very cold.
CAUTION!
Danger of hearing damage!
During all maintenance and repair work on the separator, the fittings and
pipelines, there is the risk of injury due to spurting liquids, e.g. hot or
caustic liquids can spurt out under pressure.
2325-9001-020 / 0806
34 Westfalia Separator AG
Observing the maintenance intervals and user information is decisive for the
service life and permanent operating readiness of the separator.
The maintenance intervals depend on the operating conditions. Especially
highly stressed parts of the separator must be regularly checked. Reduce the
maintenance intervals to adapt to the operating conditions!
Timely maintenance of the separator is essential for safe operation.
Fig. 8
Fig. 9
Repairs to the separator may only be carried out by service technicians from
Westfalia Separator or personnel trained and certified by Westfalia Separator.
2325-9001-020 / 0806
Westfalia Separator AG 35
Fig. 10
Make sure that the rotating parts of the separator (drive, bowl) are at a stand-
still before carrying out maintenance and repair work.
When the machine is defective, a warning sign must be attached and the
separator must be secured against unauthorized starting.
Fig. 11
2325-9001-020 / 0806
36 Westfalia Separator AG
Fig. 12
Fig. 13
Fig. 14
2325-9001-020 / 0806
Westfalia Separator AG 37
Fig. 15
2325-9001-020 / 0806
38 Westfalia Separator AG
Lock ring
Gasket
Centripetal pump
Chamber cover
Separating disk
Centripetal pump
Chamber cover
Gasket Gasket
Upper centripe-
tal pump Distance sleeve
Centripetal pump
Gasket
Chamber cover
Gasket
Disk
Gasket
Centripetal pump
Chamber cover
Gasket
Gasket
Distance sleeve
Gasket
Distributor
Feed tube
Gasket
Spindle screw
Gasket
* Lock ring
Gasket
Gasket
* Bowl top
Bowl bottom
Gasket
Gasket
Fig. 16
*) Attention: After replacing this part, the complete bowl must be re-balanced!
2325-9001-020 / 0806
Westfalia Separator AG 39
Caution!
To prevent accidents, do NOT loosen any part before the bowl has
stopped completely!
Caution
Standstill of the bowl is indicated by
– LED "bowl standstill" or
– the speed indicator in the control unit or in the motor control or
– revolution indicator or
– gear standstill, visible through the sight glass on the frame.
Replace worn gaskets immediately.
For tools, see separate order-specific parts list.
Stop compressed-air supply.
Disconnect electrical connection 1
and compressed-air supply 2.
Note:
This has to be done before remov-
ing the guards - danger of crush-
ing!
Caution
Fig. 17
Fig. 18
2325-9001-020 / 0806
40 Westfalia Separator AG
Fig. 19
Fig. 20
Fig. 21
Fig. 22
2325-9001-020 / 0806
Westfalia Separator AG 41
Fig. 23
2325-9001-020 / 0806
42 Westfalia Separator AG
Fig. 24
Fig. 25
Remove cover 1.
Fig. 26
Fig. 27
2325-9001-020 / 0806
Westfalia Separator AG 43
Fig. 28
Fig. 29
Fig. 30
Fig. 31
2325-9001-020 / 0806
44 Westfalia Separator AG
Fig. 32
Fig. 33
2325-9001-020 / 0806
Westfalia Separator AG 45
Fig. 34
Fig. 35
2325-9001-020 / 0806
46 Westfalia Separator AG
Fig. 36
Fig. 37
Fig. 38
Fig. 39
2325-9001-020 / 0806
Westfalia Separator AG 47
Fig. 40
Fig. 41
2325-9001-020 / 0806
48 Westfalia Separator AG
Fig. 43
Fig. 44
Fig. 45
2325-9001-020 / 0806
Westfalia Separator AG 49
Fig. 46
Make sure that the sealing lip B of the sliding piston does not get dam-
aged.
Attention!
After inserting the sliding piston take out pressure piece A.
Turn distributor through 180o.
Install lower distributor 1 so that the
cams in the lower distributor and
distributor
– are aligned,
Secure lower distributor 1 against
falling out by screwing in cylindrical
pin 2.
Turn around distributor again.
Fig. 48
2325-9001-020 / 0806
50 Westfalia Separator AG
Fig. 49
Fig. 50
Fig. 51
Fig. 52
2325-9001-020 / 0806
Westfalia Separator AG 51
Fig. 53
Fig. 55
Fig. 56
2325-9001-020 / 0806
52 Westfalia Separator AG
Fig. 57
Fig. 58
2325-9001-020 / 0806
Westfalia Separator AG 53
If the maximum pressure is not attained and grease flows out of the stroke limit-
ing hole, bolt 1 has not been screwed far enough into the bowl bottom.
The compressing device is not ready for use again until bolt 1 and threaded ring
2 have been brought back into the position as described above.
When compressing the disc stack, make sure that the arresting piece of the
bowl bottom snaps into the groove of the bowl top and that the bowl top does
not become twisted when lowered.
Hit wrench handle with the mallet to
obtain "O" mark alignment (left-
hand thread).
Fig. 60
If the lock ring can be tightened by hand up to the “O” mark at maximum disk
compression, add a spare disk or compensating disk.
In the case of newly fitted disk stacks, the pressure in the disk stack can
slacken due to settling of the disks. For this reason, check the pressure in the
disk stack several times using the procedure described above.
At least once a month in the first 3 months.
Dismantling the compressing de-
vice:
Move pump lever of compressing
device down as far as it will go to
prevent it from jumping back. Only
then undo pressure relief screw 5.
Unscrew threaded ring 2 (left-hand
thread).
Remove hydraulic unit 3 and disk 4.
Fig. 61
Fig. 62
2325-9001-020 / 0806
54 Westfalia Separator AG
Fig. 63
Fig. 64
Fig. 65
Fig. 66
2325-9001-020 / 0806
Westfalia Separator AG 55
Fig. 67
Fig. 68
Fig. 69
2325-9001-020 / 0806
56 Westfalia Separator AG
Fig. 70
Fig. 71
Fig. 72
2325-9001-020 / 0806
Westfalia Separator AG 57
Fig. 73
2325-9001-020 / 0806
58 Westfalia Separator AG
Fig. 74
Fig. 75
Fig. 76
2325-9001-020 / 0806
Westfalia Separator AG 59
Fig. 78
Fig. 79
Caution
Fig. 80
2325-9001-020 / 0806
60 Westfalia Separator AG
Fig. 81
Fitting
Insert the gasket in the cleaned
groove of the bowl top (with the nar-
row side towards the bowl top).
Drive the gasket evenly into the
groove.
If the diameter of the gasket is too
small, place it in a water bath of 70 -
80 oC for about 5 minutes. The gas-
ket will then assume its original di-
mensions.
Fig. 82
Fig. 83
2325-9001-020 / 0806
Westfalia Separator AG 61
Fig. 84
Fig. 85
Fig. 86
At the same time, check the gaskets and replace them if necessary.
2325-9001-020 / 0806
62 Westfalia Separator AG
Use the tools stated in the parts list to fit the gaskets.
Fig. 87
Fig. 88
2325-9001-020 / 0806
Westfalia Separator AG 63
1 Filling device
2 Clamping piece
3 Grease cartridge
4 Pumpenkopf
5 Non-return valve
6 Pressure chamber
7 Hydraulic cylinder
8 Piston
9 Bolt
10 Disc
11 Hydraulic part
12 Threaded ring
13 Stroke-limiting hole
14 Venting screw
15 Pressure gauge (0-600 bar)
16 Pressure relief screw
Fig. 89
Operating principles
The pump presses grease at a high pressure into pressure chamber 6.
The increase in pressure in the pressure chamber displaces piston 8 in relation
to hydraulic cylinder 7.
The hydraulic part 11 (piston, hydraulic cylinder) is bolted securely to the bowl
bottom by means of bolt 9 and threaded ring 12.
When the pressure increases in pressure chamber 6, piston 8 is forced down-
wards.
The force produced is transferred via disk 10 on to the bowl top. The disc stack
is compressed.
Pump
The pump produces a pressure of max. 400 bar. It consists of:
pump head
grease cartridge
filling device
non-return valve
2325-9001-020 / 0806
64 Westfalia Separator AG
7 Hydraulic cylinder
8 Annular piston
9 Bolt
16 Pressure relief screw
Fig. 90
If grease oozes out through the stroke limiting hole 13, bolt 9 and threaded
ring 12 have not been screwed into their final position, and the stroke is too
long.
2325-9001-020 / 0806
Westfalia Separator AG 65
5 Technical information
2325-9001-020 / 0806
66 Westfalia Separator AG
Fig. 91
Self-cleaning bowl:
– The bowl can be emptied during operation by means of a hydraulically ac-
tuated sliding piston 17.
Closed feed and discharge of the product phases:
– The product is fed into the machine through a closed line system.
– For product observation illuminated sight glasses are fitted in feed 3, clean
oil discharge 4 and heavy phase discharge 2.
– A pressure switch monitors the discharge pressure of the light phase.
– Soap or gums are discharged through a closed discharge pipe.
"Fine Tuner":
– With the aid of "Fine Tuner" 6 the separating zone in the disk stack can be
altered while the separator is running. By this means, the separator can be
optimally adapted to changes in the product (e.g. different oil types).
During start-up and bowl ejections the separating zone can temporarily be
displaced to the centre to prevent oil carry-over at the separating disk outer
diameter.
Hydrohermetic feed:
– The product is fed into the bowl gently and with slight overpressure through
hydrohermetic feed 10.
"Steam seal":
– A hydrohermetic seal 9 prevents clouding of the oil due to vapours from the
inlet chamber.
2325-9001-020 / 0806
Westfalia Separator AG 67
"Bowl Flush":
– Liquid can be fed into the outer solids space via a separate channel 5.
By this means, surplus lye or acid can be flushed out or a high-viscous
phase can be diluted and conveyed more easily out of the bowl.
–
The separator is also equipped with a
direct drive (without belt and gear)
three-phase AC motor for FC operation
external lubricating oil unit for oil circulation lubrication
2325-9001-020 / 0806
68 Westfalia Separator AG
Fig. 92
2325-9001-020 / 0806
Westfalia Separator AG 69
2325-9001-020 / 0806
70 Westfalia Separator AG
Fig. 93
Fig. 94
2325-9001-020 / 0806
Westfalia Separator AG 71
Fig. 95
2325-9001-020 / 0806
72 Westfalia Separator AG
Note:
Prior to a partial ejection there is a
brief water pressure increase in the
operating water connection. This can
be read off on pressure gauge 2.
Adjust the air pressure for the meter-
ing unit so that the heightened water
pressure is lower than the maximum
pressure marked on solenoid valve 1.
Fig. 96
2325-9001-020 / 0806
Westfalia Separator AG 73
2325-9001-020 / 0806
74 Westfalia Separator AG
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
2325-9001-020 / 0806
Westfalia Separator AG 75
6 Operation
2325-9001-020 / 0806
76 Westfalia Separator AG
2325-9001-020 / 0806
Westfalia Separator AG 77
6.2 Start-up
Press the "Separator ON" button.
– Signal lamp "Start" lights up.
LED "Bowl standstill" on the mimic display of control unit goes out as soon as
the drive rotates.
Together with the main motor the external fan is switched on automatically.
The bowl speed can be read off from the speed indicator.
The power consumption of the main drive motor is indicated by the ammeter.
After approx. 4 minutes start-up and reaching half the bowl speed, switch-
over to run-up takes place speed-dependently.
– Signal lamp "Run-up" lights up.
After a further 8 minutes, switch-over to operation takes place speed-
dependently.
– Signal lamp "Operation" lights up.
The operating speed is reached (see separator nameplate).
The ammeter indicates the no-load current of the machine.
The lubricating oil unit is started at a certain bowl speed (see data sheet).
– The oil circulation is monitored by a pressure switch. If the pressure in the
oil line drops below the minimum value, the fault is signalled. The separator
is switched off after a pre-set delay time.
If severe vibrations occur during start-up, stop the separator immediately via
"Emergency-Off" and check when the bowl is at rest whether the bowl is cor-
rectly assembled and thoroughly cleaned.
Separators equipped with a vibration monitoring system are continuously
monitored for unduly high mechanical vibrations and automatically stopped
upon exceeding the limit value stage 2.
2325-9001-020 / 0806
78 Westfalia Separator AG
2325-9001-020 / 0806
Westfalia Separator AG 79
Fig. 97
Program sequence
Refer also to section 6.4.2.
After the program time "Separation - Partial Ejection" has elapsed, a partial
ejection is initiated automatically which is then repeated at identical intervals.
Before each partial ejection the solenoid valve C "Hood flush water" opens for
approx. 10 seconds. This time can be preset as the program time "Pre-flushing".
Water is sprayed into the hood to prevent the solids to be ejected from sticking
to the walls.
For solids ejection the solenoid valves B "Closing water" and D "Opening water"
open for 1 second. This time can be preset as the program time "Partial ejec-
tion".
The solenoid valve B "Closing water" remains open for a further 5 seconds after
the ejection. The time is set via "Closing". At the same time the hood flush water
valve stays open for the time "Post-flushing".
The "Separation" program can be interrupted by pressing the "Partial ejection"
button. A partial ejection is then triggered. After termination of this forced partial
ejection the control program automatically switches back to "Separation".
Before each partial ejection the "Fine Tuner" is contracted to a small centripetal
pump diameter (see 6.4.2-"Ta").
After each ejection the centripetal pump is extended to the large centripetal
pump diameter after time (see 6.4.2 - "Tb").
These times are adjustable.
2325-9001-020 / 0806
80 Westfalia Separator AG
2325-9001-020 / 0806
Westfalia Separator AG 81
Program times
Fig. 98
2325-9001-020 / 0806
82 Westfalia Separator AG
Never initiate a total bowl ejection when the machine is vibrating severely
(bowl unbalance).
Attention!
To trigger a total ejection, press function key "Total ejection".
If the installation is correctly set up (see connection diagram of control unit), the
feed pump is automatically switched off by pressing push button "total ejection"
and automatically re-started approx. 1 min. after completion of the total ejection.
The interruption of the feed to the bowl by switching off the feed pump is neces-
sary for the bowl speed to recover, which drops slightly during total ejections.
Once the bowl has been filled again (observe increasing discharge pressure of
centrifuge), a further total ejection can be carried out by again pressing push
button "total ejection".
Should the feed pump fail to stop automatically during a total ejection, it must be
switched off manually and re-started 1 min. after total ejection.
Fig. 99
2325-9001-020 / 0806
Westfalia Separator AG 83
2325-9001-020 / 0806
84 Westfalia Separator AG
! heavy phase (D separating zone ² - D heavy phase ²) " ! oil (D separating zone ² - D oil ²)
! oil
D heavy phase " D separating zone ² # $ ( D separating zone ² # D oil#centripe ² )
! heavy zone
Whether the correct diameter for the "Fine Tuner" has been selected can be es-
tablished by checking the position of the separation zone which forms between
the light and heavy phase in the bowl. The middle of the separating zone is the
separating line; it is almost always visible on the underside of the disks after
opening the bowl. It is sufficient to check a few of the uppermost disks.
The separating line should be situated in the outer third of the rising channels.
2325-9001-020 / 0806
Westfalia Separator AG 85
Fig. 100
The values shown in the diagram are based on measuremens with turbine oil
and water. They should be considered as reference only. When treating other
products, the range of operation might be different.
Determine feed capacity.
Determine feed pressure from the above diagram.
Adjust the determined feed pressure by throttling the light-phase (oil) dis-
charge.
Note:
– If the feed pressure exceeds the permissible value Pmax, there will be an
overflow into the heavy phase.
– if the pressure falls below Pmin, the system is not sufficiently filled, the hy-
drohermetic feed does not work.
2325-9001-020 / 0806
86 Westfalia Separator AG
- The light phase contains part ය Increase the diameter of the ”Fine
of the heavy phase. Tuner”.
- The heavy phase contains part ය Reduce the diameter of the ”Fine Tuner”
of the light phase. or check the discharge pressure to make
sure that no overflow from light to heavy
phase has occurred.
Note:
The light phase centripetal pump is only needed for adjusting the hy-
drohermetic feed.
Attention!
– The hydrohermetic feed is throughput-dependent, i.e. it has to be read-
justed when the throughput changes.
The "Fine Tuner" is intended for setting the separating zone.
2325-9001-020 / 0806
Westfalia Separator AG 87
The throughput capacity of the separator (i.e. supplied liquid volume per
unit of time) depends on
– the viscosity,
– the temperature,
– the difference in densities of the components to be separated,
– the nature of the heavy component to be separated,
– the desired degree of purity of the light component.
In the case of longer interruptions in operation, e.g. due to no product supply,
we recommend carrying out one or two partial ejections by pressing the „Par-
tial ejection" key to avoid compacting of the heavy phase in the bowl.
The bowl is not allowed to run without liquid supply for more than 15
minutes, as otherwise it would result in overheating of the bowl mate-
Attention!
rial.
The separation program including the partial ejections is carried out automati-
cally by the control unit.
The running program can be interrupted by pressing the „Partial ejection" key
which triggers a bowl ejection immediately.
The function diagram shows the program sequence for partial and total ejec-
tions.
The program sequence is indicated in the mimic diagram of the control unit by
means of LEDs.
2325-9001-020 / 0806
88 Westfalia Separator AG
Do NOT loosen any part of the separator before the bowl is at a standstill!
At bowl standstill
– Run-down water valve closed.
– Signal "bowl standstill".
Do NOT loosen any part of the separator before the bowl is at a standstill!
2325-9001-020 / 0806
Westfalia Separator AG 89
Do NOT loosen any part of the separator before the bowl is at a standstill!
2325-9001-020 / 0806
90 Westfalia Separator AG
Do not loosen any part of the separator before the bowl is at a standstill!
Caution
2325-9001-020 / 0806
Westfalia Separator AG 91
Observe ammeter.
If motor current is too high,
check drive.
Let motor idle and check after
approx. 15 minutes if the signal
can be acknowledged by
pressing the ”reset” button.
2325-9001-020 / 0806
92 Westfalia Separator AG
Lubrication FAL Lube oil flow interrupted. Visual and audible alarm. After Check lubrication system.
Lube oil level too low. 5 minutes: Check monitoring system.
Main motor OFF.
Separation program OFF.
Product valve closes or product
pump off.
Total ejection
Operating–water Water pressure <Pmin or water Visual and audible alarm. Check water supply system.
t >5 sec supply failure. Separation program OFF. Clean filter in pressure reducer.
Product valve closes or product If the water pressure drops so
pump off. far that the required water
pressure does not build up
within the max. possible sepa-
rating time and no ejection is
possible, the separator must be
shut down and the bowl
cleaned by hand. (If the per-
missible retention time of the
solids in the bowl is exceeded
– product–dependent – the
solids will harden and be
ejected unevenly from the
bowl. The result is severe
unbalance during ejection).
Speed min. RUN Bowl leaks. Visual and audible alarm. Carry out the following
Slippage of flat Separation program OFF. checks at operating speed:
belt. Starting time longer 12 Product valve closes or product
minutes. pump off. – bowl for watertightness
Water brake is in operation. – speed measuring device
Drive defective. – limit value setting on
speed indicator
– solenoid valve for water
brake
at standstill:
– drive
– flat belt, replace when nec-
essary
2325-9001-020 / 0806
Westfalia Separator AG 93
2325-9001-020 / 0806
94 Westfalia Separator AG
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
2325-9001-020 / 0806
Westfalia Separator AG 95
7 Cleaning
7.1 Cleaning-in-place...................................................................................96
7.2 Bowl .......................................................................................................99
7.3 Frame...................................................................................................100
7.4 Operating water feeding device...........................................................100
7.5 Cleaning the lube-oil vessel .....................................................................100
7.6 Prior to a long-term shut-down ............................................................101
7.7 Note on cleaning work on hoods .........................................................102
7.8 Note on cleaning work on disks...........................................................102
2325-9001-020 / 0806
96 Westfalia Separator AG
7.1 Cleaning-in-place
After use, the separator must be cleaned in place.
During CIP, cleaning solution is circulated through the separator and the con-
nected system.
Attention:
Make sure that the cleaning solution emerging from the discharge lines of the
separator cannot enter the product lines.
Set changeover valves, if provided, accordingly.
If no changeover valves are provided, the plant has to be modified accord-
ingly.
To prevent corrosion damage, only approved detergents should be used.
Example: Henkel - 2 % lye (P3 Super LA)
Bayer - 2 % caustic (Trosilin M alkaline)
- Acid solution 0.5% (Trosilin M acid)
2325-9001-020 / 0806
Westfalia Separator AG 97
2. Caustic flushing
temperature: 70 - 80 oC
Feed rate: approx 5 m3/h
2 percent caustic solution (NaOH) (caustic
soda free of chloride)
Dislodging residual dirt 20 minutes
Purging the piping with water
Overflow
3. Intermediate flushing
temperature: 70 - 80 oC
Feed rate: approx. 5 m3/h
hot water 2 -5 minutes
total ejection
4. Neutralizing
Temperature: 65oC
Feed rate: approx. 5 m3/h
Neutralizing with 0.5 % HNO3 solution 20 minutes
Purging the piping with water
Total ejection
5. Post-flushing
Temperature: 70 - 80 oC
Feed rate: approx. 5 m3/h
Flushing out the HNO3 solution with water 5 minutes
Total ejection approx. 30 seconds
2325-9001-020 / 0806
98 Westfalia Separator AG
Feed
Pressure mea-
surement
Fig. 101
To obtain perfect cleaning of the bowl, the system has to be connected as fol-
lows:
The CIP solution is fed into the feed.
The liquid emerging from the heavy-phase discharge is diverted into the oil
discharge unthrottled. Thus, an internal circuit is formed whose throughput
rate is greater than the feed rate. The volume that is fed flows off through the
light-phase discharge.
The oil discharge towards the tank is throttled (V3) as far as the motor current
allows, or until overflow of the bowl occurs (Inom of drive motor - see name-
plate).
The volume of circulating liquid is set only by means of the oil valve V3.
To prevent overload of the motor, the rated current (Inom) must not be ex-
ceeded.
Attention!
2325-9001-020 / 0806
Westfalia Separator AG 99
7.2 Bowl
Cleaning of the bowls after separation is only required when the nature of the
separated solids necessitates it.
Experience will show how often the bowl has to be cleaned.
The following points should be kept in mind:
During the first few months of operation, the lock rings should be removed
approximately every two weeks for greasing the threads to prevent seizing.
Later on, the greasing intervals may be extended.
However, the bowl should be dismantled at least every two months for thorough
cleaning of the inner bowl parts.
Never use metal scrapers or metal brushes for cleaning the discs and bowl
parts.
IMPORTANT
All bowl parts have fine tolerances; it is therefore important that all parts are
cleaned thoroughly and are free from burrs.
Remove the gaskets from the bowl parts.
Clean grooves and gaskets to prevent corrosion.
Replace damaged or very swollen gaskets immediately.
Swollen gaskets should be left to dry in a warm place so that they can regain
their original dimensions and can be re-used.
Carefully clean the small holes in bowl bottom and the two bowl valves for the
supply and discharge of the operating-water to ensure trouble-free perform-
ance of the solids ejections.
Clean and wipe dry guide surfaces and threads of bowl parts and grease
them.
Spindle cone and inside of bowl hub should be oiled and then wiped clean
and dry with a smooth rag.
The solids catcher and solids collector bottom should also be cleaned every
time.
Re-assemble bowl immediately after cleaning.
Otherwise the bowl parts must be protected against dust and dirt.
2325-9001-020 / 0806
100 Westfalia Separator AG
7.3 Frame
When cleaning the frame:
Never expose the machine to a direct water jet. It must be cleaned by hand,
with a sponge or cloth.
This applies especially to the motor, even if it is enclosed.
For more instructions for cleaning the lube oil vessel, refer to the instruc-
tion manual of the external lube oil unit.
Instruction manual
2325-9001-020 / 0806
Westfalia Separator AG 101
2325-9001-020 / 0806
102 Westfalia Separator AG
Fig. 102
When mounting the disks, they are centrically guided over the distributor neck.
If disks are dismantled in connection with servicing / manual cleaning and are
stacked on one another outside the distributor, it must be ensured that the oni-
cal disk surfaces do not slide into each other.
To avoid damage, the disks should also be stacked centrically.
2325-9001-020 / 0806
Westfalia Separator AG 103
8 Drive
8.1 Drive.....................................................................................................104
8.1.1 Special risks of a separator .................................................................105
8.1.2 Safety precautions for maintenance and repair...................................108
8.2 Fitting and removing the motor............................................................112
8.2.1 Removing the motor ............................................................................112
8.2.2 Installing the motor ..............................................................................113
8.3 Removing spindle assembly, supporting disk......................................114
8.4 Dismantling the spindle assembly .......................................................116
8.5 Assembling the spindle unit .................................................................118
8.6 Replacing the rubber-metal bushes and the rubber cushions.............121
8.7 Installing the spindle assembly............................................................123
8.8 Adjusting the proximity switch .............................................................124
2325-9001-020 / 0806
104 Westfalia Separator AG
8.1 Drive
All work on the drive may only be carried out by specialists authorized by
Westfalia Separator.
Before carrying out maintenance or
repair work on the motor, bear in
mind that there may still be residual
voltage.
For this purpose,
– read the operating instructions
given by the manufacturer of the
frequency converter,
Caution
– have the appropriate measures
taken by specially trained staff.
Fig. 103
During all work on the drive, disconnect the power to the separator and
secure against re-starting!
Replace damaged gaskets immediately!
Caution
Before removing separator parts, their fitting position must be marked. This
eliminates later problems caused by fitting the part in the wrong position.
Before fitting, the grease must be removed from all contact surfaces of the slide-
ring packings.
Since slide-ring packings are easily destructible, they may only be fitted
by specially trained personnel.
Attention!
Safety risks can arise from the use of non-genuine spare parts. In addition, the
durability of such parts is frequently significantly lower which leads to a higher
maintenance requirement and lower availability!
2325-9001-020 / 0806
Westfalia Separator AG 105
Switch off the separator before carrying out maintenance or repair work.
Wait, observe and check that all rotating parts are at a standstill.
Do not reach into the rotating drive section or bowl!
Do not loosen any part before the bowl has come to a standstill!
CAUTION!
Risk of injury and danger to life through rotating parts.
Standstill should not be checked using only one source of information (e.g.
speed indicator) but must be backed up by at least one further checking device.
It must always be reckoned with that the first used standstill indication will pro-
vide false information because, for example, the electronics have failed or the
belt or gearbox in the drive is defective.
The following options are available for checking standstill on separators depend-
ing on the version:
Electric speed indicator
Revolution indicator or sight glass on the gear cover of gear separators
Optical speed check of the drive motor
Noise check
Vibration check
If you are not sure whether the machine is at a standstill, you must wait for the
run-down time specified in the separator documentation. A subsequent check is
carried out when you are sure that the machine is at a standstill.
Visual speed check by opening the inspection ports on hood and frame
Removing the inspection port in the separator hood enables you to look directly
on to the bowl. In addition, checking is also possible by removing the gearbox
cover or opening the port in the frame.
Only when you are convinced that the separator is at a standstill can the
following checks be carried out for additional security.
NOTE
2325-9001-020 / 0806
106 Westfalia Separator AG
Fig. 104
Fig. 105
Fig. 106
2325-9001-020 / 0806
Westfalia Separator AG 107
Observing the motor fan is not a reliable method of checking standstill because
the motor or fan can already be at a standstill when the separator bowl is still
rotating.
NOTE
During cleaning programs (steam sterilization and CIP), very high temperatures
are reached on the surfaces of the separator and piping.
During cleaning programs, the surfaces of the separator and pipes are
very hot.
When the cooling is switched on, the surfaces of the separator and pipes
can get very cold.
CAUTION!
Danger of hearing damage!
During all maintenance and repair work on the separator, the fittings and
pipelines, there is the risk of injury due to spurting liquids, e.g. hot or
caustic liquids can spurt out under pressure.
2325-9001-020 / 0806
108 Westfalia Separator AG
Observing the maintenance intervals and user information is decisive for the
service life and permanent operating readiness of the separator.
The maintenance intervals depend on the operating conditions. Especially
highly stressed parts of the separator must be regularly checked. Reduce the
maintenance intervals to adapt to the operating conditions!
Timely maintenance of the separator is essential for safe operation.
Fig. 107
Fig. 108
Repairs to the separator may only be carried out by service technicians from
Westfalia Separator or personnel trained and certified by Westfalia Separator.
2325-9001-020 / 0806
Westfalia Separator AG 109
Fig. 109
Make sure that the rotating parts of the separator (drive, bowl) are at a stand-
still before carrying out maintenance and repair work.
When the machine is defective, a warning sign must be attached and the
separator must be secured against unauthorized starting.
Fig. 110
2325-9001-020 / 0806
110 Westfalia Separator AG
Fig. 111
Fig. 112
Fig. 113
2325-9001-020 / 0806
Westfalia Separator AG 111
Fig. 114
2325-9001-020 / 0806
112 Westfalia Separator AG
Fig. 115
2325-9001-020 / 0806
Westfalia Separator AG 113
Fig. 116
Fig. 117
2325-9001-020 / 0806
114 Westfalia Separator AG
Fig. 118
Fig. 119
Fig. 120
Fig. 121
2325-9001-020 / 0806
Westfalia Separator AG 115
Fig. 122
Fig. 123
Fig. 124
2325-9001-020 / 0806
116 Westfalia Separator AG
Fig. 125
Fig. 126
Fig. 127
Fig. 128
2325-9001-020 / 0806
Westfalia Separator AG 117
Fig. 129
Fig. 130
Fig. 131
2325-9001-020 / 0806
118 Westfalia Separator AG
Attention!
The angular contact ball bearings may be loaded in one direction only.
Install the bearings as shown in Fig. 132 .
Prepare the spindle:
Clean holes.
Slip in oil guide ring 1 as far as it will
go.
Warm up angular contact ball bear-
ing 2 in oil to about 80 °C and slip it
on the spindle.
Watch for correct position!
Slip on the distance sleeve 3.
Warm up grooved ball bearing 4 in
oil to about 80 °C and slip it on the
spindle.
Insert gasket 5.
Insert key 6.
Fig. 132
2325-9001-020 / 0806
Westfalia Separator AG 119
Fig. 133
Fig. 134
Fig. 135
Before mounting the oil collector housing, oil the spindle seat and wipe clean
and dry using a cloth.
Clean the inner bore of the oil collector housing to ensure a good fit.
NOTE
2325-9001-020 / 0806
120 Westfalia Separator AG
Fig. 136
Fig. 137
2325-9001-020 / 0806
Westfalia Separator AG 121
Fig. 138
Fig. 139
Fig. 140
Fig. 141
2325-9001-020 / 0806
122 Westfalia Separator AG
Fig. 142
Fig. 143
Fig. 144
Fig. 145
2325-9001-020 / 0806
Westfalia Separator AG 123
Fig. 146
Fig. 148
Fig. 149
2325-9001-020 / 0806
124 Westfalia Separator AG
Fig. 150
Fig. 151
2325-9001-020 / 0806
Westfalia Separator AG 125
9 Trouble shooting
2325-9001-020 / 0806
126 Westfalia Separator AG
The bowl does not come up to Motor is incorrectly connected. Check connection
rated speed or takes too long to
do so (see chapter "Motor con-
nection").
Clutch ring defective or insufficiently Replace clutch ring or check its fas-
fastened. tening arrangement.
Oil collector housing slides on the Check fastening of oil collector hous-
spindle. ing (see chapter “Drive”).
The bowl speed drops during Motor speed drops during operation. Check motor and line voltage.
operation.
Bowl leaks (current consumption is Check the gaskets in the sliding pis-
too high). ton, bowl top and bowl bottom.
2325-9001-020 / 0806
Westfalia Separator AG 127
2325-9001-020 / 0806
128 Westfalia Separator AG
Uneven run of the separator. Rubber-metal cushions in drive Change the rubber-metal cush-
(Cont’d) are fatigued. ions (see chapter “Drive“).
Discharging operating water is The ejected solids are too con- Perform several successive total
dirty. centrated with the result that ejections manually on the con-
they cannot discharge from the trol unit to flush free the solids
solids catcher into the discharge catcher. Shorten the ejection
pipe. intervals.
Solids rise in the catcher and Increase the ejection volume.
flow over into the frame to the
operating water discharge.
Current consumption too high. Bowl leaks. Check the gaskets in the bowl
top, sliding piston and bowl bot-
tom.
2325-9001-020 / 0806
Westfalia Separator AG 129
Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note
2325-9001-020 / 0806
130 Westfalia Separator AG
Fig. 152
2325-9001-020 / 0806
Westfalia Separator AG 131
Ejected solids contain too much Ejection volume too large. Reduce ejection volume.
process liquid.
2325-9001-020 / 0806
132 Westfalia Separator AG
Fig. 153
2325-9001-020 / 0806
Westfalia Separator AG 133
2325-9001-020 / 0806
134 Westfalia Separator AG
The bowl opens during separa- Solenoid valve B is defective. Check solenoid valve.
tion.
2325-9001-020 / 0806
Westfalia Separator AG 135
2325-9001-020 / 0806
136 Westfalia Separator AG
2325-9001-020 / 0806
Westfalia Separator AG 137
LUBRICATION SCHEDULE
Check oil level and circulation. D
D Oil change and thorough cleaning of the lube oil vessel (see also D
manual of external lubricating oil unit)*
D Grease manually-operated parts (brake bolt, valves, etc) D
whenever dismantling Grease threads, contact and guide surfaces of bowl parts (quan- whenever dismantling
tity approx. 50 g).
as per manufacturer specs on Grease motor ball bearings. as per manufacturer specs on
motor nameplate motor nameplate
MAINTENANCE SCHEDULE
Cleaning
Refer to manual of lubricat- D Clean the lubricating oil vessel of the external lube oil unit. D
ing oil unit.
D Clean bowl valves.
D Clean outlet bores of operating-water feeding device. D
D Remove bowl. D
Clean inner walls of frame solids catcher.
as required Clean strainer in pressure reducer in operating-water line. as required
product–dependent Dismantle and thoroughly clean the bowl. Be sure also to clean product–dependent
the bores and chambers of the hydraulic system.
Check
D Check starting time and rated speed. D
D Check bowl gaskets. D
Check the gasket grooves for corrosion.
D Check spindle bearings. D
whenever dismantling Check the flexible coupling packages. whenever dismantling
– wear
D Bowl inspection. D
Check all bowl parts and threads of lock rings for erosion and
corrosion.
product–dependent Check material between solids ejection ports. product–dependent
after each bowl unbalance Check all screwed unions. D
Replacement
D Replace all gaskets and seals. D
D Replace oil filter of low pressure filter. D
D Replace ball bearings of spindle. D
D Replace rubber-metal cushions and vibration absorbers. D
as required Replace the flexible coupling packages. as required
as per manufacturer specs on Replace motor bearing. as per manufacturer specs on
motor nameplate motor nameplate
* Keep to maintenance intervals even if the operating hours have not been reached.
2325-9001-020 / 0806
138 Westfalia Separator AG
Rapid and correct supply of spare parts can only be guaranteed if your order
includes the following information:
Information only required when ordering spares for pump and pump connec-
tion parts.:
2325-9001-020 / 0806
Westfalia Separator AG 139
Fig. 154
If a safety risk arises, this may have legal consequences for the responsi-
ble persons.
In this case, Westfalia Separator shall assume no liability or warranty.
NOTE
2325-9001-020 / 0806
Westfalia Separator AG
Take the Best – Separate the Rest
http://www.westfalia-separator.com/ mailto:info@gea-westfalia.de