Alfalaval Emmie User manual

Instruction Manual
Book No.: 9017368-02 V7
Product no.: 9016161-80, -81, -82, -83
9016162-80, -81, -82, -83
X
X
Alfa Laval Emmie
Mobile hydraulic oil cleaning system

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: [phone]
Telefax: [phone]
© Alfa Laval Tumba AB 05-2016
Original instruction
This publication or any part there of may not
be reproduced or transmitted by any process
or means without prior written permission of
AlfaLavalTumbaAB.

Contents
1 Safety instructions 7
2 Application 9
3 Machine plates 11
4 Description of main parts 13
4.1 System overview 13
4.2 Hoses 16
4.3 Separator 17
4.4 Pump 17
4.5 Control unit 17
4.6 Collecting tank 18
5 Working principle of the separator 19
5.1 Introduction 19
5.2 Clarifier operation 21
5.3 Purifier operation 21
5.4 Changing operation mode 22
6 Control Cabinet 25
6.1 Operator panel 25
6.2 Connection for correct voltage 31
6.3 Alarm light pattern 32
6.4 Alarm table 33
7 Operating instructions 35
7.1 Separation time 35
7.2 Separation mode 35
7.3 Before start 37
7.4 Start 40
7.5 Operation 44
3

7.6 Standby 44
7.7 Stop 45
7.8 How to drain hoses 46
8 Trouble shooting 47
8.1 Cleaning system/separator does not
start or stops shortly after start 47
8.2 Pump does not start 47
8.3 Pump stops 47
8.4 Separator stops 48
8.5 Noise 48
8.6 Separator vibrates 49
8.7 Insufficient separation result 49
8.8 No flow from pump 49
8.9 Flow too low 50
8.10 No flow either through clean oil outlet
or through drain to collecting tank 50
8.11 Some liquid escaping through drain
outlet to collecting tank 51
8.12 Oil flow through drain outlet to
collecting tank only 51
8.13 Oil leakage through drain outlet to
collecting tank when separator is not
running 51
8.14 Collecting tank overflowing but pump
does not stop 51
8.15 Separation temperature too low 52
9 Maintenance 53
9.1 Cleaning 53
9.1.1 Separator 53
9.1.2 Strainer 54
9.2 Once per year 54
9.2.1 Separator 54
9.3 Every second year 55
9.3.1 Separator 55
9.4 Dismantling - assembly instructions for
separator 55
9.4.1 Introduction 55
9.4.2 Cleaning of bowl 56
9.4.3 Replacement of O-rings in purifier bowl 60
4

9.4.4 Replacement of O-rings in clarifier bowl 62
9.4.5 Replacement of motor bearings 64
10 Technical data 67
10.1 Technical data, system 67
10.2 Declaration 68
11 Installation 69
11.1 Installation alternatives 69
11.1.1 Replacement of filler cap 69
11.1.2 Connection to drain hole in tank 70
11.1.3 Using separate suction and return pipes 70
12 Lifting instruction 71
12.1 Cleaning unit 71
13 Diagrams 73
13.1 Electrical system 73
5

1 Safety instructions
Study this instruction manual
and observe the warnings
before installation, operation,
service and maintenance.
Not following the instructions
can result in serious accidents.
The centrifugal separator, which is the major
part of the cleaning unit, includes parts that
rotate at high speed.
Incorrect operation and maintenance of the
cleaning unit can result in serious damage
and/or injury.
The following basic safety instructions therefore
apply:
•Use the cleaning unit only for the
purpose and parameter range specified
by Alfa Laval.
•Only use the cleaning unit in
non-explosion environment.
•Strictly follow the instructions for
installation, operation and maintenance.
•Ensure that personnel are competent
and have sufficient knowledge of
maintenance and operation.
•Use only Alfa Laval genuine spare parts
and the special tools supplied.
D
!ANGER
Electrocution risk
Switch off the power supply and remove the
electric cable from the socket before opening the
starter/control unit.
7

1 Safety instructions
!WARNING
Disintegration hazard
The separator is supplied with a safety yoke and a
magnetic safety switch. Modifications to the machine
which put the safety devices out of operation can lead
to serious injury or damage.
If excessive vibrations occur, stop the separator.
!WARNING
Entrapment hazard
Make sure that rotating parts inside the separator have
come to a complete standstill before moving the
cleaning unit or starting any dismantling work.
To avoid accidental start, switch off the power supply
and remove the electric cable from the socket before
starting any dismantling work.
Warning label located on
separator hood
Warning labels
A warning label is placed on the
separator hood.
The interpretation of the label is:
STOP! Read the instruction
manual before installation,
operation and maintenance.
Consider inspection intervals.
Another warning label is placed on
the door for the heater control unit.
The interpretation of the label is:
Switch off the power before
opening the cover.
8

2 Application
The Alfa Laval Emmie oil cleaning module
is here included in the Alfa Laval Emmie oil
cleaning system. The module can be bought
separately and included in a similar system to
the one described in this book.
The Alfa Laval Emmie hydraulic oil cleaning
system is restricted to the removal of solids
and water from mineral hydraulic, gear and
sterntube lube oils with a maximum temperature
of +65 °C and with a maximum viscosity (VG) of
150cStat40°C
!WARNING
Disintegration hazard
The cleaning system must not be operated in an
explosion environment.
NOTE
Never use Alfa Laval Emmie on engine lube oils as
any small amount of remaining engine lube oil in the
system can seriously affect and change the properties
of the hydraulic oil if mixed.
NOTE
Never connect Alfa Laval Emmie to a pressurized
system with the same or higher pressure than the
pressure switch set point (50 kPa). Otherwise the
safety function of the switch will be overridden, which
means that the pump and heater can operate without
flow.
9

2 Application

3 Machine plates
The cleaning unit has two different machine
plates.
1. One for the separator only
2. One for the complete unit
2
X
X
1
G1113011
NOTE
When ordering spare parts for the
cleaning unit (except the separator)
please specify the article and serial
numbers stamped on the machine
plate (1) for the complete unit.
NOTE
When ordering spare parts for the
separator itself, please specify the
type, product and serial numbers
stamped on the machine plate (2) for
the separator.
11

3 Machine plates
A
C
E
G
H
B
D
F
I
G1114211
Example of machine plate (separator only)
A. Type:
B. Product No.:
C. Speed:
D. Direction of rotation:
E. Supply voltage:
F. Rated current: (for separation)
G. Manufacturer:
H. Serial No.:
I. Enclosure:
Article No.
Serial No./Year
Manufacturer
Alfa Laval - Krakow
Service enquiries www.alfalaval.com
ABC
G1102721
Example of machine plate (complete unit)
A. Article No.
B. Serial No.
C. Manufacturing Year
Note that the illustrations are examples of
a machine plates. Values shown on the
illustrations are not valid for all machines.
12

4 Description of main parts
4.1 System overview
The Alfa Laval Emmie unit consists of the
following parts (numbered in process order):
Parts marked with *) are further described on
pages 16 to 18.
Please turn over.
13

4 Description of main parts
1. Coupling device fitted in oil tank
2. Inlet hose (1/2”) from tank to pump *)
3. Feed pump for the oil *)
4. Hose (1/2”) from pump to inlet*)
5. Bleeding valve
Manually evacuates air at start and at emptying the system.
6. Check-valve before separator
The valve is spring loaded and keeps tight in both directions at stand still.
7. Separator *)
Removes water and sludge from the oil.
8. Pressure sensor at separator outlet
If the counter pressure after the separator does not reach at least 50 kPa within 35 seconds
after start the pump is stopped.
9. Motorised regulating valve
For setting the correct counter pressure in the outlet line (circa 60 - 90 kPa).
The setting is supervised by the starter / control unit (9).
10. Hose (3/8”) from separator to tank *)
11. Collecting tank (20 litres) *)
Collects the bowl drain oil and the water separated out from the oil (at purification).
12. Starter/control unit
For starting, stopping and supervising the cleaning unit. The main part in the control unit
is the PLC (Programmable Logic Computer) which supervises the starting and stopping of
the cleaning unit. It also supervises system functions as:frequency converters, one for the
separator and one for the pump.
motor load
bowl hood interlock
amount of liquid in the collecting tank
counter pressure at outlet
The red alarm light on top of the Control cabinet
(13) indicates if there is any problem with the
supervised functions. Detailed information of
the problem is presented on the operator panel.
See 6.3 Alarm light pattern on page 32.
14

4 Description of main parts
X
X
1
2
3
8
12
9
10
*
7
6
5
4
11
13
G1115011
15

4 Description of main parts
4.2 Hoses
The hose from the tank to the cleaning unit (cold
side) is 1/2” and the hose from the cleaning unit
back to the tank (warm side) is 3/8”.
NOTE
When the two coupling halves are fitted into each other,
remember to secure the coupling by turning the locking
ring until it engages.
G0906711
A. Locking ring in unlocked position
B. Locking ring in locked position
NOTE
When the coupling halves are disengaged, the
protective caps must be fitted to protect the couplings
and the oil from impurities.
G0906911
When removing the left protecting cap, first pull
back the outer ring
16

4 Description of main parts
4.3 Separator
The separator has a bowl hood interlock (3)
over the hood (2) and connection housing (1).
A magnet (4) in contact with a safety switch
indicates if the yoke is in correct position. If
not, no power is supplied to the motor. For a
description of the separator function, see 5
Working principle of the separator on page 19.
G0907931
4.4 Pump
The flow is controlled by the VFD in the control
cabinet, see chapter 6 Control Cabinet.
4.5 Control unit
The Control unit consist of following main parts:
1. Power supply, 24 V DC
2. PLC kit
3. Frequency converter, separator
4. Frequency converter, feed pump
5. Mini terminal
6. Contactor
See chapter 6 Control Cabinet.
1
5
6
G1115311
17

4 Description of main parts
4.6 Collecting tank
The tank stands on a support under the separator
which is held in its upper position by a spring with
adjustable tension. The spring can be adjusted
by the handle (1) on the underside of the support.
When the collecting tank is nearly full the weight
will overcome the spring tension and a limit switch
is actuated. The signal goes to the control unit
which stops the pump. The lamp on the control
unit lights up.
1
G1113211
18

5 Working principle of the
separator
5.1 Introduction
Separation takes place in a bowl (1), which
rotates at high speed generating powerful
centrifugal forces.
The speed of the electric motor (6) driving the
bowl spindle (3) is controlled by a frequency
converter in the control cabinet. The converter
also acts as brake when the separator is
stopped.
The bowl (1) and motor (6) are suspended on
three vibration dampers (5).
If the unseparated oil contains water the
separator should be operated as a purifier,
otherwise clarifier operation is recommended.
G04505b1
Figure text also valid for illustrations on page 21
1. Bowl
2. Particles (sludge)
3. Bowl spindle
4. Conical discs
5. Vibration dampers
6. Electric motor
A. Dirty oil inlet
B. Clean oil outlet
C. Water outlet to collecting tank (purifier
operation).
When the separator is stopped the bowl is
drained via this outlet.
19

5 Working principle of the separator
NOTE
The separator can be operated either as a clarifier or
as a purifier.
Choose clarifier operation when no or only traces
of water in the oil.
At delivery the separator is assembled for clarifier
operation.
Choose purifier operation when the oil contains
much water. The differences between the two
modes are further described on next page.
20