Alfalaval IFB 403X-73 User manual

IFB 403X-73
Instruction book
High speed separator
Product No. 881176-09-01/1
Book No. 576956-02 Rev. 6

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: [phone]
Telefax: [phone]
© Alfa Laval Tumba AB 18 February 2020
The original instructions are in English
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of
Alfa Laval Tumba AB.

Contents
3
1 Safety Instructions 7
1.1 Warning signs in text 10
1.2 Recycling Information 11
1.3 Requirements of personnel 12
1.4 Remote start 12
2 Separator basics 15
2.1 Application 15
2.2 Description of main parts 16
2.2.1 Overview 16
2.2.2 Detailed description 17
2.2.3 Paring disc 18
2.3 Working principle 18
2.3.1 Concentrator mode 18
3 Operating instructions 19
3.1 Operating routine 19
3.1.1 Introduction 19
3.1.2 Before start 19
3.1.3 Start 20
3.1.4 Operation 21
3.1.5 Manual stop 22
3.1.6 Automatic stop 23
4 Trouble shooting 25
4.1 The separator does not start 25
4.2 The separator stops 26
4.3 The separator vibrates 26
4.4 Noise 27
4.5 Low outlet flow 27
4.6 Insufficient separation result 27
4.7 Some coolant is escaping through oil outlet 28

4
4.8 Coolant flows through oil outlet only 28
4.9 No outlet flow either through clean coolant 
outlet or oil drain 28
4.10 Coolant leakage through oil outlet when
separator is not running 28
5 Maintenance 29
5.1 Cleaning 29
5.2 Once per year 30
5.3 Every second year 30
5.3.1 Disc stack replacement 30
5.3.2 Vibration damper replacement 30
5.4 Dismantling - assembly instructions 31
5.4.1 Introduction 31
5.4.2 Cleaning of bowl 32
5.4.3 Replacement of O-rings 36
5.4.4 Replacement of motor bearings 38
5.4.5 Replacement of connection housing 41
6 Technical references 43
6.1 Product description 43
6.1.1 Declaration 44
6.2 Technical data 46
6.3 Basic size drawing 47
6.4 Connection list 48
6.5 Interface description 49
6.5.1 Scope 49
6.5.2 References 49
6.5.3 Definitions 50
6.5.4 Goal 50
6.5.5 Description of separator modes 51
6.5.6 Handling of connection interfaces 52
6.5.7 Fluid connections 54
6.6 Foundation drawing 55
6.7 Plate location drawing 56

5
Read and understand instruction manuals
and observe the warnings before installation,
operation, service and maintenance.
Not following the instructions can result in
serious accidents.
In order to make the information clear only foreseeable conditions
have been considered. No warnings are given, therefore, for
situations arising from the unintended usage of the machine and its
tools.

6

7
1 Safety Instructions
The centrifuge includes parts that rotate at high
speed. This means that:
Kinetic energy is high
Great forces are generated
Stopping time is long
Manufacturing tolerances are extremely fine.
Rotating parts are carefully balanced to reduce
undesired vibrations that can cause a breakdown.
Material properties have been considered
carefully during design to withstand stress and
fatigue.
The separator is designed and supplied for a
specific separation duty (type of liquid, rotational
speed, temperature, density etc.) and must not be
used for any other purpose.
Incorrect operation and maintenance can result in
unbalance due to build-up of sediment, reduction
of material strength, etc., that subsequently could
lead to serious damage and/or injury.
The following basic safety instructions therefore
apply:
Use the separator only for the purpose
and parameter range specified by
Alfa Laval. Applies not only to the process
but also to cleaning and service liquids.
Strictly follow the instructions for
installation, operation and maintenance.
Ensure that personnel are competent and
have sufficient knowledge of maintenance
and operation, especially concerning
emergency stopping procedures.
Use only Alfa Laval genuine spare parts
and the special tools supplied.
G0010421
S0151211

1 Safety Instructions
8
Disintegration hazards
If excessive vibration occurs, stop
separator.
Use the separator only for the purpose
and parameter range specified by
Alfa Laval.
Welding or heating of parts that rotate
can seriously affect material strength.
Inspect regularly for corrosion and
erosion damage. Inspect frequently if
process or cleaning liquid is corrosive or
erosive.
Entrapment hazards
Make sure that rotating parts have come
to a complete standstill before
accessing parts inside the machine or
starting any dismantling work.

If there is no braking function the run
down time can exceed two hours.

To avoid accidental start, switch off and
lock power supply before starting any
dismantling work.

Assemble the machine completely
before start. All covers, connections and
guards must be in place.








S0151241
S01512H1
S01512O1
S0151261

9
1 Safety Instructions
Electrical hazard
Follow local regulations for electrical
installation and earthing (grounding).
Only qualified electricians are allowed to
install and maintain the drive.
Make sure the intermediate circuit
capacitors discharge before you start
working on the drive, motor or motor
cable. After disconnecting the input
power, always wait in accordance with
the documentation for the frequency
converter.
Skin irritation hazards
When using chemical cleaning agents,
make sure you follow the general rules
and suppliers recommendation
regarding ventilation, personnel
protection etc.
Use of lubricants in various situations.
Flying objects
Risk for accidental release of snap rings
and springs when dismantling and
assembly. Wear safety goggles.
S0151271
S01512D1
S01512C1

1 Safety Instructions
10
1.1 Warning signs in text
Pay attention to the safety instructions in this
manual. Below are definitions of the three grades
of warning signs used in the text where there is a
risk for injury to personnel.
DANGER
Type of hazard
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
Type of hazard
WARNING indicates a potentially
hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
Type of hazard
CAUTION indicates a potentially
hazardous situation which, if not avoided,
may result in minor or moderate injury.
NOTE
NOTE indicates a potentially hazardous
situation which, if not avoided, may result
in property damage.

11
1 Safety Instructions
1.2 Recycling Information
Unpacking
Packing material consists of wood, plastics,
cardboard boxes and in some cases metal straps.
Wood and cardboard boxes can be reused,
recycled or used for energy recovery.
Plastics should be recycled or burnt at a
licensed waste incineration plant.
Metal straps should be sent for material
recycling.
Maintenance
During maintenance oil and wear parts in the
machine are replaced.
Oil must be taken care of in agreement with
local regulations.
Rubber and plastics should be burnt at a
licensed waste incineration plant. If not
available they should be disposed to a
suitable licensed land fill site.
Bearings and other metal parts should be
sent to a licensed handler for material
recycling.
Seal rings and friction linings should be
disposed to a licensed land fill site. Check
your local regulations.
Worn out or defected electronic parts should
be sent to a licensed handler for material
recycling.
Scrapping
At the end of use, the equipment must be
recycled according to relevant local regulations.
Besides the equipment itself, any hazardous
residues from the process liquid must be taken
into consideration and dealt with in a proper
manner. When in doubt, or in the absence of local
regulations, please contact your local Alfa Laval
sales company.

1 Safety Instructions
12
1.3 Requirements of
personnel
Only skilled or instructed persons are allowed to
operate the machine, e.g. operating and
maintenance staff.
Skilled person: A person with technical
knowledge or sufficient experience to enable
him or her to perceive risks and to avoid
hazards which electricity/mechanics can
create.
Instructed person: A person adequately
advised or supervised by a skilled person to
enable him or her to perceive risks and to
avoid hazards which electricity/mechanics
can create.
In some cases special skilled personnel may
need to be hired, like electricians and others. In
some of these cases the personnel has to be
certified according to local regulations with
experience of similar types of work.
1.4 Remote start
If the separator is operated from a remote
position where the separator cannot be seen or
heard the power isolation device shall be
equipped with an interlock device to prevent that a
remote start command could result in liquid being
fed to the separator when it is shut down for
service.
The first start after the separator has been taken
apart or been standing still for a long time shall
always be manually supervised locally.

13
1 Safety Instructions 1.4 Remote start

1.4 Remote start 1 Safety Instructions
14

15
2 Separator basics
2.1 Application
The separator is a small, solid-walled bowl, disc-
stack centrifugal separator. It separates two
insoluble liquids, where the heavy one (coolant)
has the major volume.
Its use is restricted to the removal of solids and
tramp oil from coolants.
Liquid type: Coolant
Separating
temperature:

Min. +15 °C, max. +70 °C
NOTE
Maximum permissible separation
temperature is +70 °C.
WARNING
Disintegration hazard
Do not use the separator for separating any
liquids other than those specified above.

2.2 Description of main parts 2 Separator basics
16
2.2 Description of main
parts
2.2.1 Overview
A general view of the separator is shown in the
illustration beside.
The dirty liquid is fed to the inlet (A) and down to
the rotating bowl (1) where separation takes
place. The cleaned liquid leaves the separator at
(B). The separated oil runs down the collecting
channel (4) to the outlet (C).
The bowl (1) and motor (3) are suspended on
three vibration dampers (2).
G0450591
Separator
A. Dirty liquid inlet
B. Clean liquid outlet
C. Oil outlet.

When the separator is stopped the bowl is
drained via this outlet.
1. Bowl
2. Vibration dampers
3. Electric motor
4. Water collecting channel
More details are shown in the illustration on next
page.

17
2 Separator basics 2.2 Description of main parts
2.2.2 Detailed description
Separation takes place in the bowl (6) which is
mounted directly on the motor shaft. The bowl
contains a set of conical discs (7) between which
the separation process takes place.
The bowl wall (6) and the paring chamber cover
(2) are held in place by the lock nut (5).
The paring disc (3) is stationary, held by the
paring disc knob (1). Below the paring disc a level
ring (4) is fitted.
The motor flange rests on three rubber cushions
(16) in the frame (8). An inclined channel in the
motor flange directs the oil that has been
separated from the liquid to the outlet (10).
The motor (9) is powered via an electronic
frequency converter, which converts the incoming
mains to an output frequency of 125 Hz. This
gives the motor and bowl an operating speed of
7500 r/min. When the current is switched off the
converter acts as a brake quickly reducing the
speed to below 1000 r/min. within 25 seconds.
The separator is equipped with the following
safety devices:
A safety yoke (12) over the hood (13) and the
connection housing (11) has a magnet (14) which
operates a magnetic safety switch (15), so that
power can only be supplied to the motor when the
yoke is in its upright position. The yoke can be
raised to this position only when both the
mounting screws of the hood and the paring disc
knob (1) have been tightened.
NOTE
The lock nut has a conventional right-hand
thread contrary to most Alfa Laval separators
that have left-hand threaded lock rings.
G0406251
Separator main parts
1. Paring disc knob
2. Paring chamber cover
3. Paring disc (see separate description on page 18)
4. Level ring
5. Lock nut
6. Bowl
7. Disc stack
8. Frame
9. Motor
10. Oil outlet
11. Connection housing
12. Safety yoke
13. Hood
14. Magnet
15. Magnetic safety switch
16. Rubber cushions
Not shown: Frequency converter, located in Control unit.

2.3 Working principle 2 Separator basics
18
2.2.3 Paring disc
The paring disc serves as a stationary pump
wheel mounted in a chamber in the rotating bowl
neck. The paring disc dips radial into the rotating
liquid ring and pares out the liquid (coolant). The
paring disc is used as a discharge pump.
2.3 Working principle
2.3.1 Concentrator mode
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
at (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).
G0631061
The liquid and all bowl parts (except the stationary
paring disc) rotate in direction illustrated by arrow (A)
G0519231
Concentrator bowl

19
3 Operating instructions
3.1 Operating routine
3.1.1 Introduction
These operating instructions describe routine
procedures to follow before and during the start,
running and stopping sequences of the separator.
3.1.2 Before start
Make sure that the separator is correct
assembled according to the instructions given
in chapter ‘‘5 Maintenance” on page 29.
Make sure that the three hood screws (3) and
the paring disc knob (1) are firmly tightened
and that the safety yoke (2) is in its closed
(vertical) position.
Make sure the bowl is free from solids before
restarting.
NOTE
If there is a System Manual, always follow
the operating instructions given therein. If
there is no System Manual the instructions
below are to be followed.
WARNING
Disintegration hazard
Unevenly spaced sludge cake will result in
heavy vibration and damage can be caused.
G0908821
1. Paring disc knob
2. Safety yoke
3. Hood screw (3 pcs)

3.1 Operating routine 3 Operating instructions
20
3.1.3 Start
1. Make sure that the outlet valve (if any) for
cleaned coolant is open.
2. Start the separator (keep the button pressed
3 - 4 seconds).
3. After 20 seconds (when the separator has
gained full speed), turn on the liquid feed to
the separator.
Max. recommended flow is 525 litres/hour.
4. Regulate the counter pressure in the oil outlet
line to 100 - 200 kPa.
5. After 1 minute, check that coolant is not
discharging from the separator. Check as
illustrated (1) using a torch or check through
the oil outlet at the bottom of the separator.
If coolant escapes through the oil outlet, stop
the liquid feed and follow the instructions
given in ‘‘4.7 Some coolant is escaping
through oil outlet” on page 28 or ‘‘4.8 Coolant
flows through oil outlet only” on page 28.
WARNING
Disintegration hazard
Some vibrations can occur for short periods
during the start phase when the separator
passes through the critical speed. This is
normal and passes over without danger. If
the vibrations become very severe or
continue at full speed, stop the separator
immediately. See chapter ‘‘4.3 The
separator vibrates” on page 26 for possible
causes.
G0907591
Check if coolant escapes through the oil outlet (1)