Alfalaval Alfie User manual

Book No.: 9017117-02 Rev. 8
Alfa Laval Alfie
Cleaning system for liquids
Product No.: 9016086-80, -81
9016092-80, -81
Instruction Manual

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 Separator 16
4.3 Pump 16
4.4 Control unit 16
4.5 Collecting tank 17
5 Working principle of the separator 19
6 Control Cabinet 21
6.1 Operator panel 21
6.2 Connection for correct voltage 27
6.3 Alarm light pattern 28
6.4 Alarm table 29
7 Operating instructions 31
7.1 Before first start 31
7.2 Before normal start 31
7.3 Start 31
7.4 Operation 35
7.5 Standby 35
7.6 Stop 35
8 Trouble shooting 37
8.1 Cleaning system/separator does not
start or stops shortly after start 37
3

8.2 Pump does not start 37
8.3 Pump stops 37
8.4 Separator stops 38
8.5 Noise 38
8.6 Separator vibrates 39
8.7 No flow from pump 39
8.8 Flow too low 40
8.9 No flow either through clean oil outlet
or through drain to collecting tank 40
8.10 Some liquid escaping through drain
outlet to collecting tank 41
8.11 Oil flow through drain outlet to
collecting tank only 41
8.12 Oil leakage through drain outlet to
collecting tank when separator is not
running 41
8.13 Collecting tank overflowing but pump
does not stop 41
8.14 Insuficient separation result 42
9 Maintenance 43
9.1 Cleaning 43
9.1.1 Strainer 43
9.1.2 Separator 43
9.2 Once per month 44
9.2.1 Pump 44
9.3 Once per year 44
9.3.1 Separator 44
9.4 Every second year 45
9.4.1 Separator 45
9.5 Dismantling - assembly instructions for
separator 45
9.5.1 Introduction 45
9.5.2 Cleaning of bowl 46
9.5.3 Replacement of O-rings 50
9.5.4 Replacement of motor bearings 52
9.6 Replacing the impeller and mechanical
seal for pump 55
10 Technical data 57
10.1 Technical data, system 57
4

10.2 Declaration 58
11 Lifting instruction 59
11.1 Cleaning unit 59
12 Diagrams 61
12.1 Electrical system 61
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 Alfie 500 cleaning system is
restricted to the removal of solids and oil from
liquids with a temperature range between +15
and +70 °C.
!WARNING
Disintegration hazard
The cleaning system must not be operated in an
explosion environment.
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
1
2
G1101911
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 Alfie 500 cleaning system
consists of the following parts (numbered in
process order):
1. Suction device
Feed inlet with adjustable height setting. For
tanks with a depth min. 100 mm.
2. Hoses
For in- and outlet of feed between the cleaning
unit and the liquid tank.
3. Strainer
Greater particles are removed here before the
feed enters the separator.
4. Pump
Feed pump for the liquid. The pump speed is
raised until the counter pressure in the outlet
line passes 50 kPa.
5. Separator
Removes oil and solids from the liquid.
The separator has a bowl hood interlock(•) over
the hood and connection housing. A magnetic
switch indicates if the interlock is in correct
position. If not, the control system prohibits the
unit from starting.
6. 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.
13

4 Description of main parts
7. Motorised regulating valve
For maintaining the correct counter
pressure in the outlet line (ca. 100 - 180
kPa). The valve is regulated by the control
unit (9).
8. Collecting tank (20 litres)
Collects the oil separated out from the liquid.
The tank stands on a support under the
separator which is held in its upper position by a
spring with adjustable tension (••). This spring
is adjusted by the handle 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 (9) which stops the pump (4).
An alarm alerts the operator.
9. Control cabinet(further described in
chapter 6 Control Cabinet on page 21).
The control system supervises the starting
and stopping of the cleaning unit. It also
supervises system functions such 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
(10) 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 28
14

4 Description of main parts
1
2
87
6
5
4
3
9
∗
∗∗
10
G1102011
A suction device of bellows type can preferably be used in shallow tanks
(55-100 mm).
15

4 Description of main parts
4.2 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
4.3 Pump
The flow is controlled by the VFD in the control
cabinet, see chapter 6 Control Cabinet.
4.4 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
16

4 Description of main parts
4.5 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
17

4 Description of main parts

5 Working principle of the
separator
Dirty liquid continuously enters at (A) and flows into the bowl (1). The bowl rotates at high speed
generating powerful centrifugal forces. As the liquid rotates with the bowl, the liquid (heavy phase)
and solid particles moves towards the periphery of the bowl. The particles (2) are deposited on the
bowl wall, while the cleaned liquid enters the channels (3) and leaves the bowl (B) at a constant
pressure. The discs (4) in the bowl improves the cleaning efficiency during the separation process.
The oil (light phase) is forced towards the centre of the bowl and then leaves through the underside
of the bowl at (C) down into the collecting tank.
The speed of the electric motor (6) driving the bowl spindle (5) is regulated by a frequency converter,
which by that eliminates any use of a transmission such as a gear or a belt. The converter also acts
as a brake when the separator is stopped.
The bowl (1) and motor (6) are suspended on vibration dampers (7).
A. Liquid inlet
B. Clean liquid outlet
C. Oil outlet to collecting tank
1. Bowl
2. Particles (sediment)
3. Channels from bowl to outlet B
4. Conical discs
5. Bowl spindle
6. Electric motor
7. Vibration dampers
G0450581
G0519231
19

5 Working principle of the separator